2003-2005 Suzuki Ignis Service & Repair Manual

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 meanings. Pay special attention to the messages highlighted by these signal words. 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 maintenance easier or instructions clearer. WARNING: This service manual is intended for authorized Suzuki dealers and qualified service mechanics only. Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the driver and passengers. WARNING: For vehicles equipped with a Supplemental Restraint (Air Bag) System: • Service on and 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 “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser- vice Precautions” under “On-Vehicle Service” 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. Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation. • Do not modify the steering wheel, instrument panel or any other air bag system component (on or around air bag system components or wiring). Modifications can adversely affect air bag system performance and lead to injury. • If the vehicle will be exposed to temperatures over 93°C (200°F) (for example, during a paint baking process), remove the air bag system components (air bag (inflator) modules, SDM and/or seat belt with pretensioner) beforehand to avoid component damage or unintended activation.

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 (Unit Repair-Overhaul). Applicable model: RG413 The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following 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 disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description. All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. And used as the main subject of description is the vehicle of standard 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 Manual © COPYRIGHT SUZUKI MOTOR CORPORATION 2000 Manual Name Manual No. RG413 Wiring Diagram Manual 99512-80G00-015

TABLE OF CONTENTS GENERAL INFORMATION ENGINE 0A 6 General Information 0A General Information and Diagnosis 6 0B 6A1 Maintenance and Lubrication 0B Engine Mechanical 6A1 6B HEATING AND AIR CONDITIONING Engine Cooling 6B 1A 6C Heater and Ventilation 1A Engine Fuel 6C 1B 6E1 Air Conditioning 1B Engine and Emission Control System 6E1 6F1 STEERING, SUSPENSION, WHEELS AND TIRES Ignition System 6F1 3 6G Cranking System 6G 3A 6H Steering, Suspension, Wheels and Tires 3 Charging System 6H 3B 6K Front End Alignment 3A Exhaust System 6K 3B1 6B Manual Rack and Pinion 3B TRANSMISSION, CLUTCH AND DIFFERENTIAL 3C 7A Power Steering System 3B1 3D 7B Steering Wheel and Column 3C Manual Transmission 7A 3E 7C Front Suspension 3D Automatic Transmission 7B 3F 7D Rear Suspension 3E Clutch 7C 7F Wheels and Tires 3F Transfer 7D 4A DRIVE SHAFT AND PROPELLER SHAFT Differential (Rear)(4WD) 7F 4B 8 Front Drive Shaft 4A ELECTRICAL SYSTEM 8A Propeller Shaft 4B Body Electrical System 8 5 8G BRAKE SYSTEM Wiring Diagram 8A 5E Brakes 5 Immobilizer Control System (if equipped) 8G 9 Antilock Brake System 5E BODY SERVICE 9 RESTRAINT SYSTEM 10 Restraint System 10 10B Air Bag System (if equipped) 10B NOTE: The screen toned Section 8A is in Wiring Diagram Manual mentioned in FOREWORD of this manual.

GENERAL INFORMATION 0A-1 0A 6F2 6G 6H 6K 7A 7A1 7B1 7C1 7D 7E 7F 8A 8B 8C 8D 8E 9 10 10A 10B SECTION 0A GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL .........................0A-2 PRECAUTIONS ................................................ 0A-3 PRECAUTION FOR VEHICLES EQUIPPED WITH A SUPPLEMENTAL RESTRAINT (AIR BAG) SYSTEM ..................................... 0A-3 DIAGNOSIS .............................................. 0A-3 SERVICING AND HANDLING .................. 0A-4 GENERAL PRECAUTIONS .......................... 0A-6 PRECAUTIONS FOR CATALYTIC CONVERTER................................................ 0A-9 PRECAUTION FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT ................. 0A-9 PRECAUTION IN SERVICING FULL-TIME 4WD VEHICLE ............................................ 0A-10 PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE ..................................... 0A-11 ELECTRICAL CIRCUIT INSPECTION PROCEDURE ............................................. 0A-13 OPEN CIRCUIT CHECK ......................... 0A-13 CONTINUITY CHECK ............................. 0A-14 VOLTAGE CHECK .................................. 0A-15 SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND)....................... 0A-16 INTERMITTENT AND POOR CONNECTION ............................................ 0A-16 IDENTIFICATION INFORMATION ................. 0A-18 VEHICLE IDENTIFICATION NUMBER ...... 0A-18 ENGINE IDENTIFICATION NUMBER ........ 0A-18 TRANSMISSION IDENTIFICATION NUMBER .................................................... 0A-18 WARNING, CAUTION AND INFORMATION LABELS.......................................................... 0A-19 VEHICLE LIFTING POINTS ........................... 0A-20 ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL.......................... 0A-22 FASTENER INFORMATION .......................... 0A-25 METRIC FASTENERS................................ 0A-25 FASTENER STRENGTH IDENTIFICATION ....................................... 0A-25 STANDARD TIGHTENING TORQUE......... 0A-25

0A-2 GENERAL INFORMATION HOW TO USE THIS MANUAL 1) There is a “TABLE OF CONTENTS” on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of each section, where the main items in that section are listed. 2) Each section of this manual has its own pagination. It is indicated at the top of each page along with the Sec- tion name. 3) The special tool usage and torque specification are given as shown in the figure. 4) A number of abbreviations and symbols are used in the text.For their full explanations, refer to “ABBREVIA- TIONS AND SYMBOLS MAY BE USED IN THIS MANUAL” in this section. 5) The SI, metric and foot-pound systems are used as units in this manual. 6) “DIAGNOSIS” are included in each section as necessary. 7) At the end of each section, there are descriptions of “SPECIAL TOOL”, “REQUIRED SERVICE MATERIAL” and “TIGHTENING TORQUE SPECIFICATION” that should be used for the servicing work described in that section.

2003-2005 Suzuki Ignis Service & Repair Manual

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