dizel.pdf

IMPORTANT

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions

carefully. To emphasize special information, the words

WARNING , CAUTION and NOTE have special mean-

ings. Pay special attention to the messages high-

lighted by these signal words.

WARNING:

For vehicles equipped with Supplemental

Restraint (Air Bag) System:

Service on or around the air bag system

components or wiring must be performed

only by an authorized SUZUKI dealer.

Refer to “Air Bag System Components

and Wiring Location View” under “Gener-

al Description” in air bag system section

in order to confirm whether you are per-

forming service on or near the air bag sys-

tem components or wiring. Please

observe all WARNINGS and “Precau-

tions” in air bag system section before

performing service on or around the air

bag system components or wiring. Failure

to follow WARNINGS could result in

unintentional activation of the system or

could render the system inoperative. Ei-

ther of these two conditions may result in

serve injury.

WARNING:

Indicates a potential hazard that could result

in death or injury.

CAUTION:

Indicates a potential hazard that could result

in vehicle damage.

NOTE:

Indicates special information to make mainte-

nance easier or instructions clearer.

If the air bag system and another vehicle

system both need repair, SUZUKI recom-

mends that the air bag system be repaired

first, to help avoid unintentional air bag

system activation.

WARNING:

This service manual is intended for autho-

rized SUZUKI dealers and qualified service

mechanics only. Inexperienced mechanics

or mechanics without the proper tools and

equipment may not be able to properly per-

form the services described in this manual.

Improper repair may result in injury to the

mechanic and may render the vehicle un-

safe for the driver and passengers.

Do not modify the steering wheel, instru-

ment panel or any other air bag system

component ( on or around air bag system

components or wiring). Modifications can

adversely affect air bag system perfor-

mance and lead to injury.

If the vehicle will be exposed to tempera-

tures over 93

F) (for example, dur-

ing a paint baking process), remove the

air bag system components air bag (infla-

tor) modules, sensing and diagnostic

module (SDM), seat belt pretensioner (if

equipped) beforehand to avoid compo-

nent damage or unintended activation.

C (200

FOREWORD

This manual contains procedures for diagnosis, maintenance, adjustments, minor service operations, replace-

ment of components (service) and for disassembly and assembly of major components (Units Repair-Overhaul).

Applicable model: SY419 on and after the following VIN No.

SEDAN

JSAEGC51S00300001

WAGON

JSAEGC51W00300001

Whenever servicing the above applicable model, consult this manual.

And for any section, item or descripton not found in this manual, refer to the related manuals mentioned below.

The contents are classified into sections each of which is given a section number as indicated in the Table of Con-

tents on the next page. And on the first page of each individual section is an index of that section.

This manual should be kept in a handy place for ready reference of the service work.

Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.

When replacing parts or servicing by diassembling, it is recommnded to use SUZUKI genuine parts, tools and ser-

vice materials (lubricant, sealants, etc.) as specified in each description.

All information, illustrations and specifications contained in this literature are based on the latest product informa-

tion available at the time of publication approval. And used as the main subject of description is the vehicle of stan-

dard specifications among others.

Therefore, note that illustrations may differ from the vehicle being actually serviced.

The right is reserved to make changes at any time without notice.

RELATED MANUALS

Manual Name

Manual No.

SY413/SY416/SY418 Service Manual

99500-60G20-01E

SY413/SY416/SY418/SY419 Wiring Diagram Manual

99512-60G60-015

All Models Deisel Diagnosis Manual

99501-66G10-01E (967-GB-04/97)

Overhaul Checking Tuning Manual

99501-66G21-01E (9608GB 15/06/2000)

OVERSEAS SERVICE DEPARTMENT

TABLE OF CONTENTS

SECTION

GENERAL INFORMATION

General Information

Maintenance and Lubrication

HEATING AND AIR CONDITIONING

Heater and Ventilation

Air Conditioning

STEERING, SUSPENSION, WHEELS AND TIRES

Steering, Suspension, Wheels and Tires

Front End Alignment

Power Steering (P/S) System

Steering Wheel and Column

Front Suspension

Rear Suspension

Wheel and Tires

DRIVE SHAFT

Front Drive Shaft

BRAKE SYSTEM

Brakes

Antilock Brake System (ABS)

ENGINE

Engine General Information and Diagnosis

Engine (XUD9 BSD Engine)

Engine Cooling

Engine Fuel

Engine and Emission Control System (XUD9 BSD Engine)

Cranking System

Charging System

Exhaust System

TRANSMISSION AND CLUTCH

Manual Transmission

Clutch (Hydraulic Type)

BODY ELECTRICAL SERVICE

IMMOBILIZER CONTROL SYSTEM

WIRING DIAGRAM

BODY SERVICE

AIR BAG SYSTEM

3B1

3C1

6A4

6G3

6G4

7C1

NOTE:

The screen toned sections are included in “SY413/SY416/SY418 SERVICE MANUAL”.

6E3

GENERAL INFORMATION 0A-1

SECTION 0A

GENERAL INFORMATION

NOTE:

For the descriptions (items) not found in this section, refer to the same section of the Service Manual men-

tioned in FOREWORD of this manual.

CONTENTS

IDENTIFICATION INFORMATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0A-1

Engine Identification Number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0A-1

WARNING, CAUTION AND INFORMATION LABELS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0A-2

FASTENER INFORMATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0A-3

Metric Fasteners

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0A-3

IDENTIFICATION INFORMATION

ENGINE IDENTIFICATION NUMBER

The number is punched on cylinder block.

0A-2 GENERAL INFORMATION

WARNING, CAUTION AND INFORMATION LABELS

The figure below shows main labels among others that are attached to vehicle component parts. When servicing

and handling parts, refer to WARNING / CAUTION instructions printed on labels.

If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.

NOTE:

Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.

1. Air bag caution label

2. Smoke level label

3. Tire information placard

4. Child lock caution label

5. Seat belt pretensioner warning label (if equipped)

6. Fuel limitation label

7. Coolant degassing tank cap (radiator cap) warning label

8. Engine cooling fan warning label

9. Air bag warning label on driver air bag (inflator) module

10. Air bag warning label on combination switch and contact coil assembly

11. Air bag caution label on steering column

12. Air bag warning label on passenger air bag (inflator) module

13. Air bag warning label on SDM

14. Child seat warning label (if equipped)

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