Servicing - A/t: Other Suzuki X-90 I

Esteem

Manufacturer recommends replacing transaxle oil cooler hoses at 45,000 mile intervals. Replace transaxle fluid every 100,000 miles under normal driving conditions. Change fluid every 12,000 miles under severe operating conditions. Severe conditions are same as listed for Sidekick and X90. See SIDEKICK & X90.

Sidekick & X90

1. Manufacturer recommends replacing transmission oil cooler hoses at 45,000 mile intervals. Under normal driving conditions, replace transmission fluid every 100,000 miles. Replace transfer case fluid at 30,000 mile intervals.
2. Under severe driving conditions, replace transmission fluid every 15,000 miles or 15 months (4-speed), or every 52,500 miles or 52 1/2 months (3-speed). Replace transfer case fluid at 7500 miles, and then every 15,000 miles or 15 months thereafter. Severe driving conditions are any of the following: Driving Mostly In Stop-And-Go Traffic Delivery Service Towing Average Trip Less Than 4 Miles Average Trip Less Than 10 Miles With Outside Temperature Below Freezing Driving In Dusty Conditions Swift

Manufacturer recommends replacing transaxle oil cooler hoses at 45,000 mile intervals. Replace transaxle fluid every 100,000 miles under normal driving conditions. Change fluid every 15,000 miles or 15 months under severe driving conditions. Severe conditions are same as listed for Sidekick and X90. See SIDEKICK & X90.

Transaxle & Transmission (Except Esteem)

1. Engine must be at normal operating temperature. Park vehicle on level surface and apply parking brake. Place selector lever in Park.
2. Start engine and allow to idle. Apply brakes, shift through all gears and return selector lever to Park.
3. Remove dipstick. Fluid level should be in HOT or FULL HOT range. Add fluid (if necessary) and recheck. DO NOT overfill.

Transaxle (Esteem)

1. Engine must be at normal operating temperature. Park vehicle on level surface and apply parking brake. Place selector lever in Park.
2. Start engine and allow to idle. Apply brakes, shift through all gears and return selector lever to Park.
3. Remove dipstick. Fluid level should be between FULL HOT and LOW HOT. If level is below LOW HOT add fluid until level is at FULL HOT.

Transfer Case (Sidekick & X90)

Remove transfer case fill plug (upper plug) from rear of transfer case. Fill plug is located near speedometer gear housing. Fluid level must be at bottom of fill plug hole. Install fill plug and tighten to specification. See TORQUE SPECIFICATIONS .

Transaxle & Transmission

All models use Dexron-III ATF.

Use SAE 75W-90 or 80W-90 gear oil with GL-4 rating.

Esteem (Transaxle)

Raise vehicle. With engine cool, remove drain plug from oil pan and drain ATF. Install drain plug. Lower vehicle and fill with Dexron-III. Check fluid level. See CHECKING FLUID LEVEL under LUBRICATION.

Sidekick & X90 (Transmission)

1. On 3-speed model, raise and support vehicle. Disconnect front drive shaft from front differential flange. Remove all oil pan bolts except 3 bolts on rear of oil pan. Loosen remaining 3 bolts, allowing pan to tip downward so fluid will drain.
2. Once fluid is drained, remove remaining oil pan bolts, oil pan and gasket. Remove filter screen and gasket. Install NEW filter screen and gasket. Install oil pan gasket and oil pan. Tighten oil pan bolts to specification. See «TORQUE SPECIFICATIONS»(ref-91659-S33941689262001032600000) .
3. Install drive shaft. Tighten drive shaft flange bolts to specification. See «TORQUE SPECIFICATIONS»(ref-91659-S33941689262001032600000) . Fill transmission with 3 qts. (2.8L) of Dexron-III. Check fluid level. See CHECKING FLUID LEVEL under «LUBRICATION»(ref-91659-S08549724272001032600000) .
4. On 4-speed model, raise and support vehicle. Ensure engine is cool and remove oil pan drain plug. Once fluid is drained, install drain plug and tighten to 13-20 ft. lbs. (18-27 N.m). Lower vehicle and fill transmission with 2.6 qts. (2.5L) of Dexron-III. Check fluid level. See «CHECKING FLUID LEVEL»(ref-91659-S29387538162001032600000) under LUBRICATION.

Sidekick & X90 (Transfer Case)

1. Raise and support vehicle. Remove drain plug from back of transfer case, below speedometer gear housing and drain fluid. Install drain plug and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-91659-S33941689262001032600000) .
2. Remove transfer case fill plug (upper plug) from rear of transfer case. Fill plug is located near speedometer gear housing.
3. Fill transfer case with SAE 75W-90 or 80W-90 gear oil with a GL-4 rating until fluid level is at bottom of fill plug hole. Install fill plug and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-91659-S33941689262001032600000) .

Scheme 58

1. Remove drain plug from bottom of oil pan and drain fluid. If removing filter screen, note position of cross-grooved oil pan bolts. (Scheme 58) Remove oil pan bolts, oil pan, gasket, filter screen bolts and filter screen.
2. Install filter screen. Install oil pan with NEW gasket. Apply thread sealant to threads of cross-grooved bolts. Tighten oil pan bolts to specification. Tighten drain plug to specification. See «TORQUE SPECIFICATIONS»(ref-91659-S33941689262001032600000).
3. Add 1.6 qts. (1.5L) of Dexron-III through dipstick tube. Check fluid level. See «CHECKING FLUID LEVEL»(ref-91659-S29387538162001032600000) under LUBRICATION.

Shift Lock Solenoid (Esteem & Swift)

Remove parking brake cover and console box to access solenoid. Ensure detent pin is locked in PARK position by lock plate. (Scheme 59) Ensure lock plate is pulled in when ignition is turned to ON position and brake pedal is depressed (this allows voltage to energize solenoid). This allows detent pin to be pushed down.

Interlock Cable (Esteem & Swift)

1. Disconnect negative battery cable. Disable air bag system. Remove covers to access upper steering column. Ensure interlock cable clamp screw is tight and cable is attached to release shaft. (Scheme 60)
2. Loosen cable bracket nut at gear selector cable. Place gear selector lever in Park and manually move solenoid lock plate towards front of vehicle, push gear selector lever lock knob. Insert Special Alignment Tool (09925-78210) into holes in gear selector key release cam and selector lever.
3. Ensure cable is connected to key release cam and tighten cable bracket nut to 114 INCH lbs. (13 N.m). Remove special tool. Manually hold solenoid shift lock plate toward front of vehicle and ensure key release cam moves smoothly when gear selector button is pushed.
4. With selector lever in Park, turn ignition key to ACC position. Ensure when knob is released, ignition key can be turned from ACC to LOCK position. Replace components removed for service.

Scheme 59

Scheme 60

Note. Shift Interlock system will not allow gearshift to move from Park unless ignition is on. It also prevents ignition key removal unless gearshift is in Park.

Shift Lock Solenoid (Sidekick & X90)

Remove parking brake cover and console box to access solenoid. Ensure detent pin is locked in PARK position by lock plate. Ensure lock plate is pulled in when ignition is turned to ON position and brake pedal is depressed (this allows voltage to energize solenoid). This allows detent pin to be pushed down.

Interlock Cable (Sidekick & X90)

1. Remove console covers. Cable is adjusted at bracket, located near gearshift. Place ignition in ACC position. Ensure cable is attached to key interlock lever.
2. Loosen cable bracket nut. (Scheme 61)and (Scheme 62). Position release cam and insert Special Alignment Tool (09925-78210) into holes in gear selector key release cam and selector lever.
3. Ensure cable is connected to key release cam and tighten cable bracket nut to 114 INCH lbs. (13 N.m). Remove special tool. Ensure key release cam moves smoothly when gear selector button is pushed.
4. With selector lever in Park, turn ignition key to ACC position. Ensure when knob is released, ignition key can be turned from ACC to LOCK position. Replace components removed for service.

Scheme 61

Scheme 62

KICKDOWN CABLE, THROTTLE VALVE (T.V.) CABLE

Note. Terminology differs between vehicle models. Sidekick equipped with 3-speed transmission uses a kickdown cable, Sidekick and X90 equipped with 4-speed transmission use a Throttle Valve (T.V.) cable, and Swift uses a fluid pressure control cable.

Scheme 63

1. Ensure accelerator cable is adjusted correctly. Loosen kickdown cable lock nut and adjusting nut. (Scheme 63) Fully depress and hold accelerator pedal.
2. Pull kickdown cable in direction "A". (Scheme 63) Rotate lock nut to obtain a.039" (.99 mm) lock nut-to-bracket clearance. When adjusting clearance, ensure adjusting nut does not contact bracket.
3. Release accelerator pedal. Maintain lock nut-to-bracket clearance at.039" (.99 mm). Rotate adjusting nut until it engages bracket. With adjusting nut even with bracket surface, tighten lock nut securely.

Sidekick & X90 (4-Speed AW03-72LE)

1. Ensure accelerator cable is adjusted correctly. Accelerator cable should not have any end play at throttle body with accelerator at idle position and engine off.
2. Ensure accelerator is in idle position. Measure distance between end of T.V. cable boot and cable stopper. (Scheme 64)
3. If measurement is greater than.031-.059" (0.8-1.5 mm), loosen lock nuts and adjust cable length. Tighten lock nuts and recheck measurement.

Swift

1. Ensure accelerator cable is adjusted correctly. Accelerator cable should not have any end play at throttle body with accelerator at idle position and engine off.
2. Warm engine to normal operating temperature. Accelerator must be in idle position. Remove fluid pressure cable cover. Check boot-to-inner cable stopper clearance. (Scheme 64)
3. If clearance is greater than.02" (.5 mm), loosen upper lock nuts and adjust fluid pressure cable length. If necessary, use lower lock nuts to change cable length. (Scheme 64) Tighten all lock nuts.

Scheme 64

Place gear selector lever and transmission control shaft in Neutral. Ensure cable lock nuts have clearance and have been loosened. Push cable forward until it stops. Ensure gear selector lever is in Neutral. Tighten rear cable lock nut until it contacts transmission control shaft lever. Tighten front cable lock nut. Ensure the following: vehicle will not move with selector lever in Park. Vehicle will not drive in Neutral, but can be operated as indicated in all other positions.

Sidekick (3-Speed)

1. Remove center console covers. Place gearshift in Neutral. Looking at gearshift assembly from passenger side, note 2 holes on rear of lever detent bracket, below level of console cover.
2. Both holes should be aligned. Install a pin in hole to hold gearshift in Neutral. Loosen adjusting nut and lock nut. (Scheme 65) Ensure shift lever on transmission is in Neutral.
3. Tighten adjusting nut and then lock nut. Remove pin from gearshift assembly. Ensure gearshift operates properly in all gear ranges. Install console covers.

Scheme 65

Sidekick (4-Speed) & X90

1. Place gearshift and manual shift levers in Neutral. Loosen lock nuts at transmission end of cable. Ensure transmission shift lever is in Neutral. (Scheme 66)
2. Turn adjusting nut "A" until it contacts cable joint, and then tighten lock nut "B". After adjustment, ensure gearshift operates properly in all gear ranges.

Scheme 66

1. Set parking brake. Move gearshift lever to Neutral. Loosen inner and outer lock nuts. (Scheme 67) Ensure transaxle control lever is in Neutral. Tighten outer lock nut by hand until it contacts control lever.
2. Using wrench, tighten inner lock nut. Ensure transaxle operates in all gear positions. Shift transaxle gearshift lever to Park and ensure vehicle will not move.

Scheme 67

Place gear selector lever in Neutral. Disconnect switch. Connect ohmmeter between the outside terminals (terminals No. 7 and 9 on 3-terminal side of connector). Continuity should be present when switch is in "N" position. Loosen and adjust switch as necessary.

See SIDEKICK (3-SPEED) under GEARSHIFT CABLE.

1. Set parking brake. Place gearshift in Neutral. Loosen neutral safety switch adjusting bolt. Align groove on switch with match mark on manual shift lever shaft.
2. Hold switch at this position and tighten neutral safety switch adjusting bolt to specification. See «TORQUE SPECIFICATIONS»(ref-91659-S33941689262001032600000) . Ensure starter operates with gearshift lever in Neutral and Park only.

1. Set parking brake. Place gearshift in Neutral. Loosen neutral safety switch adjusting bolt. (Scheme 67) Move neutral safety switch back and forth until a click is heard.
2. Hold switch at this position and tighten neutral safety switch adjusting bolt to specification. See «TORQUE SPECIFICATIONS»(ref-91659-S33941689262001032600000). Ensure starter operates with gearshift lever in Neutral and Park only.