Suzuki K9K User manual

IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
, and NOTE have special meanings. Pay special attention to the messages high-
lighted by these signal words.
The circle with a slash in this manual means “Don’t do this” or “Don’t let this happen”.
WARNING
!CAUTION !
Indicates a potential hazard that could result in death or injury.
WARNING
!
Indicates a potential hazard that could result in vehicle damage.
CAUTION
!
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
This service manual is intended for authorized Suzuki dealers and qualified service technicians only.
Inexperienced technicians or technicians 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 technician 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 ser-
vice 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, that is air bag (inflator) modules, SDM and/or seat
belt with pretensioner, beforehand to avoid component damage or unintended activation.
WARNING
!

RECOMMENDATON OF GENUINE SUZUKI PARTS AND ACCESSORIES USE
SUZUKI strongly recommends the use of genuine SUZUKI parts* and accessories. Genuine SUZUKI parts and
accessories are built to the highest standards of quality and performance, and are designed to fit the vehicle's
exact specifications.
A wide variety of non-genuine replacement parts and accessories for SUZUKI vehicles are currently available in
the market. Using these parts and accessories can affect the vehicle performance and shorten its useful life.
Therefore, installation of non-genuine SUZUKI parts and accessories is not covered under warranty.
Non-Genuine SUZUKI Parts and Accessories
Some parts and accessories may be approved by certain authorities in your country.
Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genu-
ine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are
non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty.
Re-use of Genuine SUZUKI Parts and Accessories
The resale or re-use of the following items which could give rise to safety hazards for users is expressly forbid-
den:
1) Air bag components and all other pyrotechnic items, including their components (e.g. cushion, control
devices and sensors)
2) Seatbelt system, including their components (e.g. webbing, buckles, and retractors)
The air bag and seat belt pretensioner components contain explosive chemicals. These components should be
removed and disposed of properly by SUZUKI authorized service shop or scrap yard to avoid unintended explo-
sion before scrapping.
*The parts remanufactured under SUZUKI's approval can be used as genuine SUZUKI parts in Europe.

TABLE OF CONTENTS
GENERAL INFORMATION Engine and Emission Control System
(M13 Engine)
6E 0A 6E
General Information 0A 0B 6E2
Maintenance and Lubrication 0B Engine and Emission Control System
(K9K Engine)
6E2 6F
HEATING AND AIR CONDITIONING 1A 6G
Heater and Ventilation 1A Ignition System (Electronic Ignition System) 6F 1B 6G2
Air Conditioning (Optional) 1B Cranking System (M13 Engine) 6G 6H
STEERING, SUSPENSION, WHEELS AND
TIRES Cranking System (K9K Engine) 6G2 36H2
Charging System (M13 Engine) 6H 3A 6K
Steering, Suspension, Wheels and Tires 3Charging System (K9K Engine) 6H2 3B 6K2
Front Wheel Alignment 3A Exhaust System (M13 Engine) 6K 3B1
Steering Gear Box (Manual Type) and
Linkage 3B Exhaust System (K9K Engine) 6K2 3C 7A
TRANSMISSION, CLUTCH AND DIFFEREN-
TIAL 3D 7A2
Power Steering (P/S) System (if equipped) 3B1 3E 7B
Steering Wheel and Column 3C Manual Transmission (M13 Engine Model) 7A 3F 7C
Front Suspension 3D Manual Transmission (K9K Engine Model) 7A2 7C2
Rear Suspension 3E Automatic Transmission 7B 4B 7D
Wheels and Tires 3F Clutch (M13 Engine Model) 7C 7E
DRIVE SHAFT AND PROPELLER SHAFT Clutch (K9K Engine Model) 7C2 57F
Propeller Shafts 4B Transfer 7D 5E
BRAKE SYSTEM Front Differential 7E 8
Brakes 5Rear Differential 7F 6-1 8G
Antilock Brake System (ABS) 5E ELECTRICAL SYSTEM 6-2 8G2
ENGINE Body Electrical System 86-3
Engine General Information and Diagnosis
(M13 Engine without VVT) 6-1 Immobilizer Control System (M13 Engine Model) (if equipped) 8G 6A1 9
6A2
Engine General Information and Diagnosis
(K9K Engine) 6-2 Immobilizer Control System (K9K Engine
Model) 8G2 6A3 10
6B 10B
Engine General Information and Diagnosis
(M13 Engine with VVT) 6-3 BODY SERVICE 6B2
Body Service 96C
Engine Mechanical (M13 Engine without
VVT) 6A1 RESTRAINT SYSTEM 6C2
Restraint System 10
Engine Mechanical (K9K Engine) 6A2 Air Bag System 10B
Engine Mechanical (M13 Engine with VVT) 6A3
Engine Cooling (M13 Engine) 6B
Engine Cooling (K9K Engine) 6B2
Engine Fuel (M13 Engine) 6C
Engine Fuel (K9K Engine) 6C2
NOTE:
For the screen toned Section in the above table, refer to the same section of the Service Manuals men-
tioned in FOREWORD of this manual.

ENGINE MECHANICAL (K9K ENGINE) 6A2-5
4) Install special tools (Oil pressure gauge) to vacated threaded
hole.
Special tool
(A): 09915-77311
(B): 09915-77420
(C): 09915-77430
5) Start engine and warm it up to normal operating tempera-
ture.
6) After warming up, measure oil pressure.
Oil pressure specification:
100 – 140 kPa (1.0 – 1.4 kg/cm2, 14.2 – 20.0 psi) at idle
speed
330 – 370 kPa (3.3 – 3.7 kg/cm2, 46.9 – 52.5 psi) at 3,000 r/
min
7) Stop engine and remove oil pressure gauge and attachment.
8) Reinstall oil pressure switch (1), and tighten switch to speci-
fied torque.
Tightening torque
Oil pressure switch (a): 35 N·m (3.5 kg-m, 25.5 lb-ft)
9) Connect oil pressure switch coupler (2).
10) Install degassing tank to its bracket.
11) Start engine and check oil pressure switch for oil leakage.
If oil leakage is found, repair it.
CAUTION:
Be careful not to make special tool touch exhaust mani-
fold when installing because exhaust manifold becomes
very hot.
(A)
(B)
(C)
NOTE:
Be sure to place transmission gear shift lever in “Neu-
tral” and set parking brake and block drive wheels.
1, (a) 2

6A2-6 ENGINE MECHANICAL (K9K ENGINE)
Valve Lash (Clearance)
Measurement of valve lash (clearance)
1) Disconnect negative (–) cable at battery.
2) Remove cylinder head cover referring to “Cylinder Head
Cover Removal and Installation” in this section.
3) Turn crankshaft pulley clockwise until cam lobes become
perpendicular to tappet faces at valves “1” and “6” as shown
in figure.
4) Measure valve lashes with thickness gauge (1) according to
the following procedure.
a) Check valve lashes at valves “1” and “6”.
b) Turn camshaft by 90°(by turning crankshaft with wrench).
c) Make sure that cam lobes are perpendicular to tappet faces
at valves to be checked (in this case, “5” and “8”), if not,
adjust it by turning crankshaft. Check valve lashes.
d) In the same manner as b) – c), check valve lashes at valves
“4” and “7”.
e) In the same manner as b) – c), check valve lashes at valves
“2” and “3”.
If valve lash (clearance) is out of specification, record valve lash
(clearance) and adjust it to specification by replacing tappet.
Refer to “Replacement of tappet” under “Valve Lash (Clearance)”
in this section.
Valve lash (clearance) specification
Replacement of tappet
1) Measure valve lashes referring to “Measurement of Valve
Lash (Clearance)” under “Valve Lash (Clearance)” in this
section.
2) Remove tappet referring to “Camshaft and Tappet” in this
section.
3) Using micrometer, measure the thickness of the removed
tappet, and determine replacement tappet by calculating the
thickness of new tappet with the following formula and table.
Intake side
A = B + C – 0.1875 mm (0.007382 in.)
Exhaust side
A = B + C – 0.3875 mm (0.015256 in.)
A: Thickness of new tappet
B: Thickness of removed tappet
C: Measured valve lash (clearance)
When cold
Intake 0.125 – 0.250 mm (0.00493 – 0.00984 in.)
Exhaust 0.325 – 0.450 mm (0.01280 – 0.01771 in.)
1
"1" "2" "3" "4" "5" "6" "7" "8"

ENGINE MECHANICAL (K9K ENGINE) 6A2-7
Example of intake side:
When thickness of removed tappet is 7.8875 mm (0.310531 in.),
and measured valve lash (clearance) is 0.200 mm (0.00787 in.).
A = 7.8875 mm (0.310531 in.) + 0.200 mm (0.00787 in.) –0.1875
mm (0.007382 in.) = 7.900 mm (0.31102 in.)
Calculated thickness of new tappet = 7.900 mm (0.31102 in.)
4) Select new tappet (1) with a thickness as close as possible
to calculated value.
Available new tappets
5) Install new tappet and camshaft referring to “Camshaft and
Tappet Removal and Installation” in this section.
6) Measure valve lashes again referring to “Measurement of
Valve Lash (Clearance)” under “Valve Lash (Clearance)” in
this section.
7) Install cylinder head cover referring to “Cylinder Head Cover
Removal and Installation” in this section.
Thickness
mm (in.) Thickness mm (in.)
7.550 mm (0.29724 in.) 7.875 mm (0.31004 in.)
7.575 mm (0.29823 in.) 7.900 mm (0.31102 in.)
7.600 mm (0.29921 in.) 7.925 mm (0.31201 in.)
7.625 mm (0.30020 in.) 7.950 mm (0.31299 in.)
7.650 mm (0.30118 in.) 7.975 mm (0.31398 in.)
7.675 mm (0.30217 in.) 8.000 mm (0.31496 in.)
7.700 mm (0.30315 in.) 8.025 mm (0.31595 in.)
7.725 mm (0.30413 in.) 8.050 mm (0.31693 in.)
7.750 mm (0.30512 in.) 8.075 mm (0.31791 in.)
7.775 mm (0.30610 in.) 8.100 mm (0.31890 in.)
7.800 mm (0.30709 in.) 8.125 mm (0.31988 in.)
7.825 mm (0.30807 in.) 8.150 mm (0.32087 in.)
7.850 mm (0.30906 in.)
2. Tappet thickness
2
1

6A2-8 ENGINE MECHANICAL (K9K ENGINE)
Repair Instructions
Air Cleaner Filter Removal and Installation
Removal
1) Open air cleaner case (2) unhooking its clamps (1).
2) Remove air cleaner filter from case.
Installation
Reverse removal procedure for installation.
Air Cleaner Filter Inspection and Cleaning
Inspection
Check filter for dirt. Replace if excessively dirty filter.
Cleaning
When cleaning filter, blow off dust by compressed air from air out-
let side of filter. (i.e., the side facing up when installed in air
cleaner case.)
Air Cleaner Assembly Removal and Installa-
tion
Removal
1) Disconnect negative (–) cable at battery.
2) Remove boost pressure control solenoid valve (4) from air
cleaner assembly.
3) Disconnect MAF and IAT sensor connector (1).
4) Disconnect air cleaner outlet hose (2) from air cleaner
assembly (3).
5) Remove air cleaner assembly from vehicle.
2
1
3
1
2
4

ENGINE MECHANICAL (K9K ENGINE) 6A2-9
Installation
Reverse removal procedure for installation noting the following.
• Tighten air cleaner outlet hose clamp (1) to specified torque.
Tightening torque
Air cleaner outlet hose clamp (a):
2.5 N·m (0.25 kg-m, 2.0 lb-ft)
Intercooler Components
1, (a)
1. Intercooler 8. Intercooler bracket bolt
2. Intercooler bracket 9. Intercooler hose clamp No.1
3. Intercooler hose clamp 10. Intercooler hose clamp No.2
4. Intercooler outlet hose No.1 11. Intercooler outlet pipe bolt
5. Intercooler inlet hose Tightening torque
6. Intercooler outlet pipe
7. Intercooler outlet hose No.2
7
6
10
5
9
3
4
1
2
8
8
11
25 N·m (2.5 kg-m)
28 N·m (2.8 kg-m)
25 N·m (2.5 kg-m)
4 N·m (0.4 kg-m)
5 N·m (0.5 kg-m)
4 N·m (0.4 kg-m)
9

6A2-10 ENGINE MECHANICAL (K9K ENGINE)
Intercooler Removal and Installation
Removal
1) Remove front bumper.
2) Remove intercooler inlet hose (1) and outlet hose (2) from
intercooler.
3) Remove intercooler (3) and its bracket (4).
Installation
Reverse removal procedure for installation noting the following.
• Install intercooler hose clamp (1) in specified direction as
shown in figure.
• Tighten intercooler bracket bolts and intercooler hose
clamps (1) to specified torque.
Tightening torque
Intercooler bracket bolt: 25 N·m (2.5 kg-m, 18.0 lb-ft)
Intercooler hose clamp No.1 (a): 4 N·m (0.4 kg-m, 3.0 lb-ft)
• Install front bumper.
2
1
3
4
[A]: Upper side
1, (a)

ENGINE MECHANICAL (K9K ENGINE) 6A2-11
Cylinder Head Cover Components
Cylinder Head Cover Removal and Installa-
tion
Removal
1) Disconnect negative (–) cable at battery.
2) Remove drive belt referring to “Generator Drive Belt
Removal and Installation” in Section 6H2.
3) Remove injector cover (1), generator upper bracket (2), tim-
ing belt upper cover (3) and injector return hose cover .
4) Disconnect breather hose from cylinder head cover.
1. Cylinder head cover bolt
: Tighten 12 N·m (1.2 kg-m, 9.0 lb-ft) by
the specified procedure.
3. Cylinder head cover gasket Tightening torque
2. Cylinder head cover 4. Cylinder head
: Apply Loctite 518® referring to “Installation” under “Cylin-
der Head Cover Removal and Installation”. Do not reuse.
1
2
3
4518
1
2
3