Description
This article explains "Removal, Disassembly, Installation, Inspection and Adjustment" and "Trouble Diagnoses".
Note. Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing.
- Before performing trouble diagnoses, read the "Preliminary Check", the "Symptom Chart" or the "Work Flow".
- After repairs, re-check that the problem has been completely eliminated.
- Refer to Component Parts and Harness Connector Location for the Systems described in each article for identification/location of components and harness connectors.
- Refer to the Circuit Diagram for quick pinpoint check. If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to «WIRING DIAGRAM»(ref-375700-S32880622182010102800000) in each individual article and «HARNESS LAYOUT»(ref-375701-S25046587452010102800000) in appropriate article for identification of harness connectors.
- When checking circuit continuity, ignition switch should be OFF.
- Before checking voltage at connectors, check battery voltage.
- After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were.
Scheme 2
- Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed test groups.
- Questions and required results Questions and required results are indicated in bold type in test group. The meaning of are as follows: a. Battery voltage --> 11 - 14V or approximately 12V b. Voltage: Approximately 0V --> Less than 1V
- Symbol used in illustration Symbols included in illustrations refer to «MEASUREMENTS OR PROCEDURES»(ref-375700-S32669090872010102800000) . Before diagnosing a problem, familiarize yourself with each symbol. Refer to " «CONNECTOR SYMBOLS»(ref-375700-S05519806782010102800000) " in General Information article and " «KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES»(ref-375700-S32669090872010102800000) " below.
- Action items Next action for each test group is indicated based on result of each question. Test group number is shown in the left upper portion of each test group.
| Number | Item | Description | |
|---|---|---|---|
| 1 | Power condition | This shows the condition when the system receives battery positive voltage (can be operated). | |
| 2 | Fusible link | The double line shows that this is a fusible link. The open circle shows current flow in, and the shaded circle shows current flow out. | |
| 3 | Fusible link/fuse location | This shows the location of the fusible link or fuse in the fusible link or fuse box. For arrangement, refer to " POWER SUPPLY DIAGRAM ". | |
| 4 | Fuse | The single line shows that this is a fuse. The open circle shows current flow in, and the shaded circle shows current flow out. | |
| 5 | Current rating | This shows the current rating of the fusible link or fuse. | |
| 6 | Connectors | This shows that connector E3 is female and connector M1 is male. The G/R wire is located in the 1A terminal of both connectors. Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is SMJ connector. Refer to WIRING SYSTEMS , SMJ (SUPER MULTIPLE JUNCTION). | |
| 7 | Optional splice | The open circle shows that the splice is optional depending on vehicle application. | |
| 8 | Splice | The shaded circle shows that the splice is always on the vehicle. | |
| 9 | Illustration crossing | This arrow shows that the circuit continues to an adjacent illustration. The A will match with the A on the preceding or next illustration. | |
| 10 | Common connector | The dotted lines between terminals show that these terminals are part of the same connector. | |
| 11 | Option abbreviation | This shows that the circuit is optional depending on vehicle application. | |
| 12 | Relay | This shows an internal representation of the relay. For details, refer to STANDARDIZED RELAY: DESCRIPTION . | |
| 13 | Connectors | This shows that the connector is connected to the body or a terminal with bolt or nut. | |
| 14 | Wire color | This shows a code for the color of the wire. | |
| B = Black W = White R = Red G = Green L = Blue Y = Yellow | LG = Light Green BR = Brown OR or O = Orange P = Pink PU or V (Violet) = Purple GY or GR = Gray SB = Sky Blue CH = Dark Brown DG = Dark Green | ||
| When the wire color is striped, the base color is given first, followed by the stripe color as shown below: Example: L/W = Blue with White Stripe | |||
| 15 | Option description | This shows a description of the option abbreviation used in the illustration. | |
| 16 | Switch | This shows that continuity exists between terminals 1 and 2 when the switch is in the A position. Continuity exists between terminals 1 and 3 when the switch is in the B position. | |
| 17 | Assembly parts | Connector terminal in component shows that it is a harness incorporated assembly. | |
| 18 | Cell code | This identifies each article of the wiring diagram by location, system and wiring diagram number. | |
| 19 | Current flow arrow | Arrow indicates electric current flow, especially where the direction of standard flow (vertically downward or horizontally from left to right) is difficult to follow. A double arrow shows that current can flow in either direction depending on circuit operation. | |
| 20 | System branch | This shows that the system branches to another system identified by cell code (article and system). | |
| 21 | Illustration crossing | This arrow shows that the circuit continues to another illustration identified by cell code. The C will match with the C on another illustration within the system other than the next or preceding illustrations. | |
| 22 | Shielded line | The line enclosed by broken line circle shows shield wire. | |
| 23 | Component box in wave line | This shows that another part of the component is also shown on another page (indicated by wave line) within the system. | |
| 24 | Component name | This shows the name of a component. | |
| 25 | Connector number | This shows the connector number. The letter shows which harness the connector is located in. Example: M : main harness. For detail and to locate the connector, refer to HARNESS LAYOUT . A coordinate grid is included for complex harnesses to aid in locating connectors. | |
| 26 | Ground (GND) | The line spliced and grounded under wire color shows that ground line is spliced at the grounded connector. | |
| 27 | Ground (GND) | This shows the ground connection. For detailed ground distribution information, refer to GROUND DISTRIBUTION . | |
| 28 | Connector views | This area shows the connector faces of the components in the wiring diagram on the illustration. | |
| 29 | Common component | Connectors enclosed in broken line show that these connectors belong to the same component. | |
| 30 | Connector color | This shows a code for the color of the connector. For code meaning, refer to wire color codes, Number 14 of this chart. | |
| 31 | Fusible link and fuse box | This shows the arrangement of fusible link(s) and fuse(s), used for connector views of " POWER SUPPLY DIAGRAM ". The open square shows current flow in, and the shaded square shows current flow out. | |
| 32 | Reference area | This shows that more information on the Super Multiple Junction (SMJ) and Joint Connectors (J/C) exists. Refer to " REFERENCE AREA " for details. | |
ITEM DESCRIPTION CHART
Scheme 3
- Letter designations next to test meter probe indicate harness (connector) wire color.
- Connector numbers in a single circle M33 indicate harness connectors.
Note. Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing.
- Before performing trouble diagnoses, read the "Work Flow" in each article.
- After repairs, re-check that the problem has been completely eliminated.
- Refer to Component Parts and Harness Connector Location for the Systems described in each article for identification/location of components and harness connectors.
- When checking circuit continuity, ignition switch should be OFF.
- Refer to the Circuit Diagram for quick pinpoint check. If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to «WIRING DIAGRAM»(ref-375700-S32880622182010102800000) in each individual article and «HARNESS LAYOUT»(ref-375701-S25046587452010102800000) for identification of harness connectors.
- Before checking voltage at connectors, check battery voltage.
- After accomplishing the Diagnosis Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were.
Scheme 4
- Test group number and test group title Test group number and test group title are shown in the upper portion of each test group.
- Work and diagnosis procedure Start to diagnose a problem using procedures indicated in enclosed test groups.
- Questions and results Questions and required results are indicated in test group.
- Action Next action for each test group is indicated based on result of each question.
Scheme 5
Scheme 6
| Number | Item | Description | |
|---|---|---|---|
| 1 | Power supply | This means the power supply of fusible link or fuse. | |
| 2 | Fusible link | "X" means the fusible link. | |
| 3 | Number of fusible link/fuse | This means the number of fusible link or fuse location. | |
| 4 | Fuse | "/" means the fuse. | |
| 5 | Current rating of fusible link/fuse | This means the current rating of the fusible link or fuse. | |
| 6 | Optional splice | The open circle shows that the splice is optional depending on vehicle application. | |
| 7 | Connector number | The letter shows which harness the connector is located in. Example "M": main harness. For detail and to locate the connector, refer to ELECTRICAL UNITS LOCATION , HARNESS LAYOUT | |
| 8 | Splice | The shaded circle "•" means the splice. | |
| 9 | Illustration crossing | This circuit continues to an adjacent Illustration. | |
| 10 | Option abbreviation | This means the vehicle specifications which layouts the circuit between "o". | |
| 11 | Relay | This shows an internal representation of the relay. | |
| 12 | Option description | This shows a description of the option abbreviation used on the page. | |
| 13 | Switch | This shows that continuity exists between terminals 1 and 2 when the switch is in the A position. Continuity exists between terminals 1 and 3 when the switch is in the B position. | |
| 14 | Circuit (Wiring) | This means the wiring. | |
| 15 | System branch | This shows that the circuit is branched to other systems. | |
| 16 | Shielded line | The line enclosed by broken line circle shows shield wire. | |
| 17 | Component name | This shows the name of a component. | |
| 18 | Ground (GND) | This shows the ground connection. | |
| 19 | Connector | This means the connector information. This unit-side is described by the connector symbols. | |
| 20 | Connectors | This means that a transmission line bypasses two connectors or more. | |
| 21 | Wire color | This shows a code for the color of the wire. | |
| B = Black W = White R = Red G = Green L = Blue Y = Yellow LG = Light Green | BR = Brown OR or O = Orange P = Pink PU or V (Violet) = Purple GY or GR = Gray SB = Sky Blue CH = Dark Brown DG = Dark Green | ||
| When the wire color is striped, the base color is given first, followed by the stripe color as shown below: Example: L/W = Blue with White Stripe | |||
| 22 | Terminal number | This means the terminal number of a connector. | |
ITEM DESCRIPTION CHART
Abbreviations
The following ABBREVIATIONS are used
| ABBREVIATION | DESCRIPTION |
|---|---|
| A/C | Air Conditioner |
| A/T | Automatic Transaxle/Transmission |
| ATF | Automatic Transmission Fluid |
| AWD | All wheel drive |
| D 1 | Drive range 1st gear |
| D 2 | Drive range 2nd gear |
| D 3 | Drive range 3rd gear |
| D 4 | Drive range 4th gear |
| ESP® | Electronic Stability Program |
| FR, RR | Front, Rear |
| LH, RH | Left-Hand, Right-Hand |
| OD | Overdrive |
| P/S | Power Steering |
| SAE | Society of Automotive Engineers, Inc. |
| SDS | Service Data and Specifications |
| SST | Special Service Tools |
| 2WD | 2-Wheel Drive |
| 2 2 | 2nd range 2nd gear |
| 2 1 | 2nd range 1st gear |
| 1 2 | 1st range 2nd gear |
| 1 1 | 1st range 1st gear |
ABBREVIATIONS CHART
Note. ESP® is a registered trademark of Daimler Chrysler AG.
Identification Information: Model Variation
| Position | Character | Qualifier | Definition |
|---|---|---|---|
| 1 | B | Body type | B: King Cab |
| C: Crew Cab | |||
| 2 | LK | Engine | LK: VQ40DE |
| 3 | DB: QR25DE | ||
| 4 | A | Axle | A: 2WD |
| N: 4WD | |||
| G: Long Bed 2WD | |||
| U: Long Bed 4WD | |||
| 5 | L | Drive | L: LH |
| 6 | R | Grade | R: XE |
| T: SE | |||
| V: LE | |||
| U: Pro-4X | |||
| 7 | N | Transmission | F: 5-speed manual transmission |
| N: 5-speed automatic transmission | |||
| Y: 6-speed manual transmission | |||
| 8 | S54 | Model | S54 Equator |
| 9 | |||
| 10 | |||
| 11 | E | Intake | E: EGI |
| 12 | U | Zone | N: Canada |
| U: Federal | |||
| 13 | O | Equipment | |
| 14 | XXXXX | Option Codes | Option Codes |
| 15 | |||
| 16 | |||
| 17 | |||
| 18 |
IDENTIFICATION INFORMATION - MODEL VARIATION
Scheme 7
VEHICLE IDENTIFICATION NUMBER ARRANGEMENT
| Position | Character | Qualifier | Definition |
|---|---|---|---|
| 1 | 5Z6 | Manufacturer | 5Z6: USA produced multi-purpose vehicle |
| 2 | |||
| 3 | |||
| 4 | A | Engine type | A: VQ40DE |
| B: QR25DE | |||
| 5 | D | Model code | D0: S-D40 SUZUKI EQUATOR |
| 6 | 0 | ||
| 7 | 6 | Body type | 6: King Cab |
| 7: Crew Cab | |||
| 9: Crew cab extra long | |||
| 8 | U | Gross vehicle weight rating | U: 2WD, 4-wheel ABS, Class D |
| W: 4WD, 4-wheel ABS, Class D | |||
| T: 2WD, 4-wheel ABS, Class C | |||
| 9 | * | Check digit | (0 to 9 or X) The code for the check digit is determined by a mathematical computation. |
| 10 | 9 | Model year | 2009 |
| 11 | C | Manufacturing plant | C: Smyrna, Tennessee |
| 12 | XXXXXX | Vehicle serial number | Chassis number |
| 13 | |||
| 14 | |||
| 15 | |||
| 16 | |||
| 17 |
VEHICLE IDENTIFICATION NUMBER ARRANGEMENT
Scheme 8
Scheme 9
Scheme 10
Scheme 11
Scheme 12
Sometimes the symptom is not present when the vehicle is brought in for service. If possible, recreate the conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The following information illustrates ways to simulate the conditions/environment under which the owner experiences an electrical incident.
The information is broken into the six following topics
- Vehicle vibration
- Heat sensitive
- Freezing
- Water intrusion
- Electrical load
- Cold or hot start up
Get a thorough description of the incident from the customer. It is important for simulating the conditions of the problem.
- In general, testing electrical circuits is an easy task if it is approached in a logical and organized method. Before beginning it is important to have all available information on the system to be tested. Also, get a thorough understanding of system operation. Then you will be able to use the appropriate equipment and follow the correct test procedure.
- You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring harness or electrical component to do this.
| OPEN | A circuit is open when there is no continuity through a section of the circuit. | |
|---|---|---|
| SHORT | There are two types of shorts. | |
| SHORT CIRCUIT | When a circuit contacts another circuit and causes the normal resistance to change. | |
| SHORT TO GROUND | When a circuit contacts a ground source and grounds the circuit. | |
SERVICE INFORMATION
Note. Refer to SERVICE INFORMATION FOR ELECTRICAL INCIDENT: HOW TO CHECK TERMINAL to probe or check terminal.
Identification Information: Dimensions
| Unit: mm (in) | |||||
|---|---|---|---|---|---|
| Drive type | 2WD | 4WD | |||
| Overall length | 5220 (205.5) (Short Wheel Base) | ||||
| 5574 (219.4) (Long Wheel Base) | |||||
| Overall width | 1850 (72.8) | ||||
| Overall height | King Cab (1) | XE | 235/75R15 | 1745 (68.7) | |
| 265/70R16 | 1748 (68.8) | 1758 (69.2) | |||
| SE | 265/70R16 | 1748 (68.8) | 1758 (69.2) | ||
| Pro-4X | 265/75R16 | 1758 (69.2) | 1770 (69.7) | ||
| LE | 265/65R18 | 1748 (68.8) | 1758 (69.2) | ||
| Crew Cab (1) | SE | 265/70R16 | 1760 (69.3) | 1775 (69.9) | |
| Pro-4X | 265/75R16 | 1773 (69.8) | 1780 (70.1) | ||
| LE | 265/65R18 | 1760 (69.3) | 1775 (69.9) | ||
| Crew Cab (2) | SE | 265/70R16 | 1780 (70.1) | 1780 (70.1) | |
| Pro-4X | 265/75R16 | 1780 (70.1) | 1780 (70.1) | ||
| LE | 265/65R18 | 1780 (70.1) | 1780 (70.1) | ||
| Front tread width | 1570 (61.8) | ||||
| Rear tread width | 1570 (61.8) | ||||
| Wheelbase | 3200 (125.9) (Short Wheel Base) | ||||
| 3554 (139.9) (Long Wheel Base) | |||||
| Minimum Running Ground Clearance (with standard tires) | King Cab | XE | 235/75R15 | 193.4 (7.6) | |
| 265/70R16 | 218.2 (8.6) | 226.1 (8.9) | |||
| SE | 265/70R16 | 218.2 (8.6) | 226.1 (8.9) | ||
| Pro-4X | 265/75R16 | 218.2 (8.6) | 226.1 (8.9) | ||
| LE | 265/65R18 | 218.2 (8.6) | 226.1 (8.9) | ||
| Crew Cab | SE | 265/70R16 | 218.2 (8.6) | 226.1 (8.9) | |
| Pro-4X | 265/75R16 | 218.2 (8.6) | 226.1 (8.9) | ||
| LE | 265/65R18 | 218.2 (8.6) | 226.1 (8.9) | ||
| (1) Without roof rack (2) With roof rack | |||||
| (1) | Without roof rack |
| (2) | With roof rack |
IDENTIFICATION INFORMATION - DIMENSIONS
Identification Information: Wheels & Tires
| Drive Type | Grade | Road wheel | Tire | Spare tire size |
|---|---|---|---|---|
| All | XE | 15 X 7J Styled Steel | P235/75R15 | P235/75R15 |
| 16 X 7J Designed Steel | P265/70R16 | P265/70R16 | ||
| SE | 16 X 7J Designed Steel | P265/70R16 | P265/70R16 | |
| 16 X 7J Aluminum Alloy | ||||
| Pro-4X | 16 X 7J Aluminum Alloy | P265/75R16 | P265/75R16 | |
| LE | 18 X 7J Aluminum Alloy | P265/65R18 | P265/65R18 |
IDENTIFICATION INFORMATION - WHEELS & TIRES