Suzuki Liana (RH413-RH416) - Multilanguage Service Manual, Repair Manual

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SUZUKI LIANA (RH413-RH416) - SERVICE MANUAL

- Multilanguage (English, Español, Deutsch and Français) Service Manual, to Suzuki Liana (RH413-RH416).


CONTENTS/CONTENIDOS:

SERVICE MANUAL

IMPORTANT
- WARNING/CAUTION/NOTE

FOREWORD
TABLE OF CONTENTS

SECTION 0A
- How To Use This Manual
- Precautions
- Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
- Diagnosis
- Servicing and handling
- General Precautions
- Precautions for Catalytic Converter
- Precaution for Installing Mobile Communication Equipment
- Precaution for Vehicle Tie-Down Hooks
- Precaution in Servicing Full-Time 4WD Vehicle
- Precautions for Electrical Circuit Service
- Electrical Circuit Inspection Procedure
- Open circuit check
- Short circuit check (wire harness to ground)
- Intermittent and Poor Connection
- Identification Information
- Vehicle Identification Number
- Engine Identification Number
- Transmission Identification Number
- Warning, Caution and Information Labels
- Vehicle Lifting Points
- Abbreviations and Symbols May Be Used in This Manual
- Fastener Information
- Metric Fasteners
- Fastener Strength Identification
- Standard Tightening Torque

SECTION 0B
- Maintenance Schedule
- Maintenance Schedule Under Normal Driving Conditions
- Maintenance Recommended under Severe Driving Conditions
- Maintenance Service
- Engine
- Drive belt
- Valve lash (clearance)
- Engine oil and oil filter
- Engine coolant
- Exhaust system
- Ignition System
- Spark plugs
- Fuel System
- Air cleaner filter
- Fuel lines and connections
- Fuel filter
- Fuel tank
- Emission Control System
- PCV valve
- Fuel evaporative emission control system
- Brake
- Brake discs and pads (front)
- Brake drums and shoes (rear)
- Brake hoses and pipes
- Brake fluid
- Brake lever and cable
- Chassis and Body
- Clutch
- Tires / Wheels
- Suspension system
- Steering system
- Drive shaft (axle) boots / Propeller shafts (4WD)
- Manual transaxle oil
- Automatic transaxle fluid
- Transfer oil (4WD A/T) and rear differential oil (4WD)
- All latches, hinges and locks
- Power steering (P/S) system (if equipped)
- Final Inspection
- Recommended Fluids and Lubricants

SECTION 1A
- General Description
- Wiring Circuit
- Diagnosis
- Diagnosis Table
- On-Vehicle Service
- Blower Unit
- Blower Motor
- Blower Motor Resistor
- Heater Unit
- Heater Controller
- Air Inlet Actuator
- Blower Motor and Blower Motor High Relays
- Center Ventilation Louver
- Side Ventilation Louver

SECTION 1B
- General Description
- Sub-cool System
- A/C Evaporator Inlet Air Temperature Sensor and A/C Evaporator Outlet Air Temperature Sensor
- Refrigerant Type
- Major Components and Location
- Diagnosis
- General Diagnosis Table
- Abnormal Noise Diagnosis
- Quickly Checking of Refrigerant Charge
- Performance Diagnosis
- Performance diagnosis table
- Detail diagnosis table (ambient temperature at 30°C (86°F))
- Electrical Diagnosis
- A/C System Inspection of ECM and Its Circuits
- Wiring diagram
- Voltage check
- Refrigerant Recovery, Evacuating and Charging
- Operation Procedure for Refrigerant Charging
- Recovery
- Replenishing Compressor Oil
- Evacuating
- Evacuating procedure
- Checking system for pressure leaks
- Charging
- Charging procedure
- Replacement of refrigerant container in charging procedure
- Leak Test
- Liquid leak detectors
- On-vehicle Service
- Service Precaution
- Handling refrigerant HFC-134a (R-134a)
- Refrigerant Line
- Condenser Assembly
- Desiccant
- Condenser Cooling Fan
- Heater and Cooling Unit
- A/C Evaporator
- A/C Evaporator Inlet and Outlet Air Temperature Sensors
- Expansion Valve
- A/C Refrigerant Pressure Switch
- A/C Switch and Defroster Switch in Heater Controller
- Compressor Relay and Condenser Cooling Fan Relay
- Compressor
- Compressor Drive Belt
- Magnet Clutch
- Required Service Material
- Special Tool

SECTION 3
- CONTENTS
- Diagnosis
- General Diagnosis
- Diagnosis Table
- Specifications
- On-Vehicle Service
- Front Wheel Alignment
- Preliminary checks prior to adjustment front wheel alignment
- Toe inspection and adjustment
- Steering angle check and adjustment
- Reference information
- Rear Wheel Alignment

- Toe inspection and adjustment
- Reference information
- General Description
- P/S System Description
- Specifications
- Specification and Service Data
- Diagnosis
- Diagnosis Table
- Steering Wheel Play Check
- Steering Force Check
- Power Steering Fluid Level Check
- Power Steering Belt Check
- Power Steering Belt Tension Adjustment
- Idle Up System Check
- Fluid Leakage Check
- Hydraulic Pressure in P/S Circuit Check
- Steering Rack Boot Check
- Tie Rod End Boot Check
- Steering Shaft Joint Check
- Air Bleeding Procedure
- On-vehicle Service
- Power Steering Belt
- Tie Rod End
- Power Steering Gear Box
- Tie Rod/Rack Boot
- Power Steering Pump
- Tightening Torque Specification
- Required Service Material
- Special Tool
- General Description
- Steering Column
- Steering Wheel and Driver Air Bag (Inflator) Module
- Diagnosis
- Inspection and Repair Required after Accident
- On-Vehicle Service
- Service Precautions
- Service and diagnosis
- Disabling air bag system
- Enabling air bag system
- Handling and storage
- Disposal
- Driver Air Bag (Inflator) Module
- Steering Wheel
- Centering Contact Coil
- Contact Coil and Combination Switch Assembly
- Steering Column Assembly
- Steering Lock Assembly (Ignition Switch)
- Steering Lower Shaft
- Checking Steering Column Assembly and Lower Shaft for Accident Damage
- Special Tool
- General Description
- Construction
- Diagnosis
- Diagnosis Table
- Stabilizer Bar and/or Bushing Check
- Strut Assembly Check
- Suspension Control Arm/Steering Knuckle Check
- Suspension Control Arm Bushing Check
- Suspension Control Arm Joint Check
- Front Suspension Frame Check
- Front Suspension Fasteners Check
- Wheel Disc, Nut and Bearing Check
- On-vehicle Service
- Strut Assembly
- Stabilizer Bar and/or Bushings
- Wheel Hub and Steering Knuckle
- Suspension Control Arm/Bushing
- Front Suspension Frame
- Required Service Material
- Special Tool
- General Description
- Construction
- Diagnosis
- Strut Assembly Check
- Stabilizer Bar, Bushing and/or Joint Check
- Suspension Knuckle Check
- Control Rod Check
- Trailing Rod Check
- Suspension Frame, Bushing and Pad Check
- Rear Suspension Fasteners
- Wheel Disc, Nut and Bearing Check
- On-vehicle Service
- Rear Strut Assembly
- Stabilizer Bar and/or Bushings
- Control Rod
- Trailing Rod
- Suspension Frame
- Wheel Hub, Wheel Bearing and Wheel Stud
- Knuckle
- Tightening Torque Specifications
- Required Service Material
- Special Tool
- General Description
- Construction
- On-vehicle Service
- Rear Suspension Frame
- Wheel Hub, Wheel Stud/Wheel Bearing Outside Inner Race
- Knuckle, Wheel Bearing/Oil Seal
- Tightening Torque Specifications
- Required Service Material
- Special Tool
- General Description
- Tires
- Tire placard
- Inflation of tires
- Matched tires and wheels (steel type)
- Replacement tires
- Wheels
- Wheel maintenance
- Replacement wheels
- How to measure wheel runout
- Metric lug nuts and wheel studs
- Specifications
- Diagnosis
- Diagnosis Table
- Irregular and/or Premature Wear
- Wear Indicators
- Radial Tire Waddle
- Radial Tire Lead/Pull
- Balancing Wheels
- General Balance Procedures
- On-Vehicle Service
- Wheel
- Tire

SECTION 4A
- General Description
- Component
- Diagnosis
- Diagnosis Table
- Drive Shaft Boot Check
- On-Vehicle Service
- Drive Shaft Assembly
- Tightening Torque Specification
- Required Service Material
- Special Tool

SECTION 4B
- General Description
- On-Vehicle Service
- Propeller Shafts
- Tightening Torque Specification

SECTION 4C
- General Description
- On-Vehicle Service
- Tightening Torque Specifications
- Required Service Material

SECTION 5
- General Description
- Diagnosis
- Road Testing Brakes
- Brake Fluid Leaks
- Substandard or Contaminated Brake Fluid
- Diagnosis Table
- Brake Pedal Free Height Inspection
- Brake Pedal Play Inspection
- Stop Light Switch Adjustment
- Excessive Pedal Travel Inspection
- Front Brake Pad Inspection
- Brake Disc Inspection
- Parking Brake Inspection and Adjustment
- Booster Operation Inspection
- Fluid Pressure Test (If Equipped with LSPV)
- Master Cylinder and Brake Fluid Level Inspection
- Brake Hose and Pipe Inspection
- On-Vehicle Service
- Air Bleeding of Brake System
- Front Brake
- Brake pad
- Caliper assembly
- Brake disc
- Rear Brake
- Brake drum
- Brake shoe
- Wheel cylinder
- Brake back plate
- Master Cylinder
- Master cylinder reservoir
- Master cylinder assembly
- Brake Booster
- Brake Hose/Pipe
- Front brake hose/pipe
- Rear brake hose/pipe
- Parking brake cable
- LSPV (Load Sensing Proportioning Valve) Assembly (If Equipped)
- Required Service Material
- Special Tool

SECTION 5B
- General Description
- Components/Parts Location and Brake Hose/Pipe Routing
- System Schematic
- ABS Hydraulic Unit/Control Module Assembly
- Self-diagnosis function
- Fail-safe function
- System Circuit
- Diagnosis
- Precaution in Diagnosing Troubles
- ABS Diagnostic Flow Table
- ABS Warning Lamp Check
- EBD Warning Lamp (Brake Warning Lamp) Check
- Table-A ABS Warning Lamp Circuit Check – Lamp Does Not Come “ON” at Ignition Switch ON
- Table-B ABS Warning Lamp Circuit Check – Lamp Comes “ON” Steady
- Table-C ABS Warning Lamp Circuit Check – The Lamp Flashes Continuously While Ignition Switch Is ON
- Table-D Code (DTC) Is Not Outputted Even with Diagnosis Switch Terminal Connected to Ground
- Table-E EBD Warning Lamp (Brake Warning Lamp) Check – Lamp Comes “On” Steady
- Diagnostic Trouble Code (DTC) Check (Using ABS Warning Lamp)
- Diagnostic Trouble Code (DTC) Check
- (Using SUZUKI Scan Tool)
- Diagnostic Trouble Code (DTC) Clearance
- Diagnostic Trouble Code (DTC) Table
- DTC C1013 (DTC 13) – System Specifications Different From ABS Control Module Specifications
- DTC C1015 (DTC 15) -G Sensor Circuit
- DTC C1021 (DTC 21), DTC C1022 (DTC 22) – Right-front Wheel Speed Sensor Circuit or Sensor Ring
- DTC C1025 (DTC 25), DTC C1026 (DTC 26) – Left-front Wheel Speed Sensor Circuit or Sensor Ring
- DTC C1031 (DTC 31), DTC C1032 (DTC 32) – Right-rear Wheel Speed Sensor Circuit or Sensor Ring
- DTC C1035 (DTC 35), DTC C1036 (DTC 36) – Left-rear Wheel Speed Sensor Circuit or Sensor Ring
- DTC C1041 (DTC 41) – Right-front Inlet Solenoid Circuit
- DTC C1045 (DTC 45) – Left-front Inlet Solenoid Circuit
- DTC C1051 (DTC 51) – Right-rear Inlet Solenoid Circuit
- DTC C1055 (DTC 55) – Left-rear Inlet Solenoid Circuit
- DTC C1042 (DTC 42) – Right-front Outlet Solenoid Circuit
- DTC C1046 (DTC 46) – Left-front Outlet Solenoid Circuit
- DTC C1052 (DTC 52) – Right-rear Outlet Solenoid Circuit
- DTC C1056 (DTC 56) – Left-rear Outlet Solenoid Circuit
- DTC C1057 (DTC 57) – Power Source Circuit
- DTC C1061 (DTC 61) – ABS Pump Motor Circuit
- DTC C1063 (DTC 63) – ABS Fail-safe Relay Circuit
- DTC C1071 (DTC 71) – ABS Control Module
- ON-Vehicle Service
- Precautions
- ABS Hydraulic Unit Operation Check
- (Using SUZUKI Scan Tool)
- ABS Hydraulic Unit Operation Check
- (Not Using SUZUKI Scan Tool)
- ABS Hydraulic Unit/Control Module Assembly
- Front Wheel Speed Sensor
- Front Wheel Speed Sensor Ring
- Rear Wheel Speed Sensor
- Rear Wheel Speed Sensor Ring
- G Sensor (For 4WD Vehicle Only)
- Special Tool

SECTION 6
- General Information
- Statement on Cleanliness and Care
- General Information on Engine Service
- Precaution on fuel system service
- Fuel pressure relief procedure
- Fuel leakage check procedure
- Engine Diagnosis
- General Description
- On-Board Diagnostic System (Vehicle with Immobilizer Indicator Lamp)
- On-Board Diagnostic System (Vehicle without Immobilizer Indicator Lamp)
- Precaution in Diagnosing Trouble
- Engine Diagnostic Flow Table
- Customer problem inspection form (example)
- Malfunction indicator lamp (MIL) check
- Diagnostic trouble code (DTC) check
- Diagnostic Trouble Code (DTC) Clearance
- Diagnostic trouble code (DTC) table
- Fail-safe table
- Visual inspection
- Engine basic inspection
- Engine diagnosis table
- Scan Tool Data
- Inspection of ECM and Its Circuits
- Component Location
- Table A-1 Malfunction Indicator Lamp Circuit Check - Lamp Does Not Come “ON” at Ignition Switch O...
- Table A-2 Malfunction Indicator Lamp Circuit Check - Lamp Remains “ON” after Engine Starts
- Table A-3 MIL Check - MIL Flashes at Ignition Switch ON (Vehicle without Immobilizer Indicator Lamp)
- Table A-4 MIL Check - MIL Does Not Flash or Just Remains ON Even with Grounding Diagnosis Switch ...
- Table A-5 ECM Power and Ground Circuit Check - MIL Does Not Light at Ignition Switch ON and Engin...
- DTC P0105 (DTC No.11) Manifold Absolute Pressure (MAP) Circuit Malfunction
- DTC P0110 (DTC No.18) Intake Air Temp. (IAT) Circuit Malfunction
- DTC P0115 (DTC No.19) Engine Coolant Temperature (ECT) Circuit Malfunction
- DTC P0120 (DTC No.13) Throttle Position Circuit Malfunction
- DTC P0121 Throttle Position Circuit Range/Performance Problem
- DTC P0130 (DTC No.14) Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-1)
- DTC P0133 Heated Oxygen Sensor (HO2S) Circuit Slow Response (Sensor-1)
- DTC P0134 Heated Oxygen Sensor (HO2S) Circuit No Activity Detected (Sensor-1)
- DTC P0135 (DTC No.14) Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-1)
- DTC P0136 Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-2)
- DTC P0141 Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-2)
- DTC P0171 Fuel System Too Lean
- DTC P0172 Fuel System Too Rich
- DTC P0300 Random Misfire Detected (Misfire Detected at 2 or More Cylinders)
- DTC P0301 Cylinder 1 Misfire Detected
- DTC P0302 Cylinder 2 Misfire Detected
- DTC P0303 Cylinder 3 Misfire Detected

- DTC P0304 Cylinder 4 Misfire Detected
- DTC P0325 (DTC No.17) Knock Sensor Circuit Malfunction
- DTC P0335 (DTC No.23) Crankshaft Position (CKP) Sensor Circuit Malfunction
- DTC P0340 (DTC No.15) Camshaft Position (CMP) Sensor Circuit Malfunction
- DTC P0400 Exhaust Gas Recirculation Flow Malfunction
- DTC P0420 Catalyst System Efficiency below Threshold
- DTC P0443 Purge Control Valve Circuit Malfunction
- DTC P0480 Radiator Cooling Fan Control System Malfunction
- DTC P0500 (DTC No.16) Vehicle Speed Sensor (VSS) Malfunction
- DTC P0505 (DTC No.26) Idle Control System Malfunction
- DTC P1450 Barometric Pressure Sensor Low/High Input
- DTC P1451 Barometric Pressure Sensor Performance Problem
- DTC P1500 Engine Starter Signal Circuit Malfunction
- DTC P1510 ECM Back-Up Power Supply Malfunction
- DTC P1600 Serial Communication Problem Between ECM and TCM
- DTC P1717 A/T Drive Range (Park/Neutral Position) Signal Circuit Malfunction
- Table B-1 Fuel Injector Circuit Check
- Table B-2 Fuel Pump and Its Circuit Check
- Table B-3 Fuel Pressure Check
- Table B-4 Idle Air Control System Check
- Table B-5 A/C Signal Circuits Check (Vehicle with A/C)
- Table B-6 Electric Load Signal Circuit Check
- TAble B-7 Radiator Fan Control System Check
- Table B-8 Power Steering Pressure (PSP) Switch Signal Circuit Check (If equipped)
- Table B-9 Generator Control Signal Circuit Check
- Special Tool

SECTION 6A1
- General Description
- Engine
- Engine Lubrication
- Diagnosis
- Diagnosis Table
- Compression Check
- Engine Vacuum Check
- Oil Pressure Check
- Valve Lash (Clearance)
- On-Vehicle Service
- Air Cleaner Element
- Knock Sensor
- Cylinder Head Cover
- Throttle Body and Intake Manifold
- Exhaust Manifold
- Oil Pan and Oil Pump Strainer
- Engine Mountings
- Unit Repair Overhaul
- Engine Assembly
- Timing Chain Cover
- Oil Pump
- Timing Chain and Chain Tensioner
- Camshaft, Tappet and Shim
- Valves and Cylinder Head
- Pistons, Piston Rings, Connecting Rods and Cylinders
- Main Bearings, Crankshaft and Cylinder Block
- Required Service Material
- Tightening Torque Specification
- Special Tool

SECTION 6B
- General Description
- Cooling System Circulation
- Coolant
- Diagnosis
- Diagnosis Table
- System Circuit
- System Circuit Inspection
- Maintenance
- Coolant Level Check
- Engine Cooling System Inspection and Service
- Cooling System Flush and Refill
- Water Pump/Generator Drive Belt Tension Inspection and Adjustment
- On-Vehicle Service
- System Components
- Cooling Water Pipes or Hoses
- Thermostat
- Radiator
- Radiator Cooling Fan
- Radiator Cooling Fan Relay
- Water Pump/Generator Drive Belt
- Water Pump
- ECT Sensor
- Required Service Material
- Tightening Torque Specification

SECTION 6C
- General Description
- On-Vehicle Service
- Components
- Precautions
- Fuel Lines
- Fuel Pipe
- Fuel Filler Cap
- Fuel Tank
- Fuel Tank Inlet Valve
- Fuel Pump Assembly
- Special Tool
- Tightening Torque Specification

SECTION 6E1
- General Description
- Air Intake System
- Fuel Delivery System
- Fuel pump
- Electronic Control System
- Engine & emission control input/output table
- On-vehicle Service
- Accelerator cable adjustment
- Idle speed/idle air control (IAC) duty inspection
- Idle mixture inspection / adjustment (vehicle without heated oxygen sensor)
- Air Intake System
- Throttle body
- Idle air control valve (IAC valve)
- Fuel Delivery System
- Fuel pressure inspection
- Fuel pump
- Fuel pressure regulator
- Fuel injector
- Electronic Control System
- Engine control module (ECM)
- Manifold absolute pressure sensor (MAP sensor)
- Throttle position sensor (TP sensor)
- Intake air temperature sensor (IAT sensor)
- Engine coolant temperature sensor (ECT sensor)
- Heated oxygen sensor (HO2S-1 and HO2S-2)
- Camshaft position sensor
- Crankshaft position sensor
- Vehicle speed sensor (VSS)
- Fuel level sensor (gauge)
- Knock sensor (if equipped)
- Main relay, fuel pump relay, A/C compressor relay and A/C condenser fan relay
- Fuel cut operation
- Radiator fan control system
- Radiator fan relay No. 1, No. 2 and No.3
- Output signals of throttle valve opening and engine coolant temp. (vehicle with A/T only)
- Emission Control System
- EGR system
- Evaporative emission control system
- PCV system
- Special Tool
- Tightening Torque Specification

SECTION 6F1
- General Description
- System Components
- System Wiring Diagram
- Diagnosis
- On-vehicle Service
- Ignition Spark Test
- High-tension Cords
- Spark Plugs
- Ignition Coil Assembly (Including Igniter)
- Crankshaft Position Sensor (CKP Sensor)
- Ignition Timing
- Special Tool

SECTION 6G
- Specification
- 1.0 kW type
- 1.2 kW type
- 1.4 kW type
- Required Service Material
- General Description
- Cranking Circuit
- Diagnosis
- Diagnosis Table
- Performance Test
- Pull-in test
- Hold-in test
- Plunger and pinion return test
- No-load performance test
- ON-Vehicle Service
- Starting Motor
- Dismounting
- Remounting
- Disassembly and reassembly
- Inspection

SECTION 6H
- General Description
- Battery
- Carrier and hold-down
- Electrolyte freezing
- Sulfation
- Built-in indicator (if equipped)
- Care of battery
- Generator
- Diagnosis
- Battery
- Visual inspection
- Hydrometer test
- Generator
- Charging indicator lamp operation
- Undercharged battery
- Overcharged battery
- On-Vehicle Service
- Battery
- Jump starting in case of emergency
- Dismounting
- Handling
- Remounting
- Generator
- Generator belt
- Dismounting and remounting
- Disassembly and reassembly
- Inspection
- Specification
- Battery
- Generator
- Tightening Torque Specification

SECTION 6K
- General Description
- On-Vehicle Service
- Exhaust Manifold
- Exhaust Pipe


MANUAL DE SERVICIO


IMPORTANTE
- ADVERTENCIA/PRECAUCIÓN/NOTA
PREFACIO
ÍNDICE GENERAL

SECCIÓN 0A
- Cómo emplear este manual
- Precauciones
- Precauciones para los vehículos equipados con un Sistema Suplementario de Sujeción
- Diagnóstico
- Servicio y manipulación
- Precauciones generales
- Precauciones para el convertidor catalítico
- Precauciones para la instalación de equipo móvil de comunicaciones
- Precauciones para los ganchos de amarre del vehículo
- Precauciones para el servicio del vehículo con tracción continua 4WD
- Precauciones para el servicio de circuitos eléctricos
- Procedimiento de comprobación de circuitos eléctricos
- Comprobación de circuito abierto
- Comprobación de cortocircuito (mazo de cables a masa)
- Malfuncionamiento intermitente y conexión mala
- Información de identificación
- Número de identificación del vehículo
- Número de identificación del motor
- Número de identificación de la transmisión
- Etiquetas de advertencia, precaución e información
- Puntos de levantamiento del vehículo
- Abreviaturas y símbolos empleados en este manual
- Información sobre los elementos de fijación
- Fijadores métricos
- Identificación de la resistencia del elemento de fijación
- Par de apriete estándar

AND MORE....