Suzuki Aerio Liana RH413 RH414D RH416 RH418 2001-2007 Workshop Repair Service Manual PDF - MSZKLN0107OPMK.zip

A full factory-level repair guide for the 2001-2007 Suzuki Aerio and Liana, complete with Electrical Wiring Diagrams, providing everything you need to service, troubleshoot, fix, and rebuild your vehicle the way a trained technician would.

The Suzuki Aerio, Liana workshop service repair manual contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

Suzuki Aerio/Liana 2001-2007 Workshop Repair Service Manual.pdf

MAKE: Suzuki

YEAR: 2001 2002 2003 2004 2005 2006 2007

MODEL: Liana (aka Aerio) (RH413, RH414D, RH416, RH418 Series)

LANGUAGE: EN/FR/DE/ES

FORMAT: PDF (919 MB)

TABLE OF CONTENTS

99500-54G00-01E...2

99500_54G00_01E_1...3

IMPORTANT...3

WARNING/CAUTION/NOTE...3

FOREWORD...4

TABLE OF CONTENTS...6

SECTION 0A...8

How To Use This Manual...9

Precautions...10

Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System...10

Diagnosis...10

Servicing and handling...11

General Precautions...13

Precautions for Catalytic Converter...16

Precaution for Installing Mobile Communication Equipment...16

Precaution for Vehicle Tie-Down Hooks...17

Precaution in Servicing Full-Time 4WD Vehicle...17

Precautions for Electrical Circuit Service...18

Electrical Circuit Inspection Procedure...21

Open circuit check...21

Short circuit check (wire harness to ground)...23

Intermittent and Poor Connection...24

Identification Information...26

Vehicle Identification Number...26

Engine Identification Number...26

Transmission Identification Number...26

Warning, Caution and Information Labels...27

Vehicle Lifting Points...28

Abbreviations and Symbols May Be Used in This Manual...30

Fastener Information...33

Metric Fasteners...33

Fastener Strength Identification...33

Standard Tightening Torque...33

SECTION 0B...36

Maintenance Schedule...37

Maintenance Schedule Under Normal Driving Conditions...37

Maintenance Recommended under Severe Driving Conditions...39

Maintenance Service...40

Engine...40

Drive belt...40

Valve lash (clearance)...41

Engine oil and oil filter...41

Engine coolant...43

Exhaust system...43

Ignition System...43

Spark plugs...43

Fuel System...44

Air cleaner filter...44

Fuel lines and connections...44

Fuel filter...44

Fuel tank...45

Emission Control System...45

PCV valve...45

Fuel evaporative emission control system...45

Brake...45

Brake discs and pads (front)...45

Brake drums and shoes (rear)...46

Brake hoses and pipes...46

Brake fluid...46

Brake lever and cable...46

Chassis and Body...47

Clutch...47

Tires / Wheels...47

Suspension system...48

Steering system...48

Drive shaft (axle) boots / Propeller shafts (4WD)...49

Manual transaxle oil...50

Automatic transaxle fluid...50

Transfer oil (4WD A/T) and rear differential oil (4WD)...51

All latches, hinges and locks...52

Power steering (P/S) system (if equipped)...52

Final Inspection...53

Recommended Fluids and Lubricants...55

SECTION 1A...56

General Description...57

Wiring Circuit...58

Diagnosis...59

Diagnosis Table...59

On-Vehicle Service...60

Blower Unit...60

Blower Motor...61

Blower Motor Resistor...62

Heater Unit...63

Heater Controller...64

Air Inlet Actuator...66

Blower Motor and Blower Motor High Relays...67

Center Ventilation Louver...68

Side Ventilation Louver...68

SECTION 1B...70

General Description...72

Sub-cool System...72

A/C Evaporator Inlet Air Temperature Sensor and A/C Evaporator Outlet Air Temperature Sensor...73

Refrigerant Type...73

Major Components and Location...74

Diagnosis...75

General Diagnosis Table...75

Abnormal Noise Diagnosis...77

Quickly Checking of Refrigerant Charge...79

Performance Diagnosis...80

Performance diagnosis table...82

Detail diagnosis table (ambient temperature at 30°C (86°F))...83

Electrical Diagnosis...84

A/C System Inspection of ECM and Its Circuits...84

Wiring diagram...84

Voltage check...85

Refrigerant Recovery, Evacuating and Charging...87

Operation Procedure for Refrigerant Charging...87

Recovery...88

Replenishing Compressor Oil...88

Evacuating...89

Evacuating procedure...89

Checking system for pressure leaks...90

Charging...91

Charging procedure...91

Replacement of refrigerant container in charging procedure...92

Leak Test...93

Liquid leak detectors...93

On-vehicle Service...94

Service Precaution ...94

Handling refrigerant HFC-134a (R-134a)...94

Refrigerant Line...94

Condenser Assembly...95

Desiccant...97

Condenser Cooling Fan...97

Heater and Cooling Unit...99

A/C Evaporator...101

A/C Evaporator Inlet and Outlet Air Temperature Sensors...103

Expansion Valve...103

A/C Refrigerant Pressure Switch...104

A/C Switch and Defroster Switch in Heater Controller...105

Compressor Relay and Condenser Cooling Fan Relay...105

Compressor...106

Compressor Drive Belt...106

Magnet Clutch...107

Required Service Material...110

Special Tool...110

SECTION 3...112

CONTENTS...112

Diagnosis...114

General Diagnosis...114

Diagnosis Table...114

Specifications...118

On-Vehicle Service...119

Front Wheel Alignment...119

Preliminary checks prior to adjustment front wheel alignment...119

Toe inspection and adjustment...120

Steering angle check and adjustment...121

Reference information...121

Rear Wheel Alignment...122

Toe inspection and adjustment...122

Reference information...122

General Description...124

P/S System Description...124

Specifications...125

Specification and Service Data...125

Diagnosis...126

Diagnosis Table...126

Steering Wheel Play Check...127

Steering Force Check...128

Power Steering Fluid Level Check...128

Power Steering Belt Check...128

Power Steering Belt Tension Adjustment...129

Idle Up System Check...129

Fluid Leakage Check...130

Hydraulic Pressure in P/S Circuit Check...131

Steering Rack Boot Check...132

Tie Rod End Boot Check...133

Steering Shaft Joint Check...133

Air Bleeding Procedure...133

On-vehicle Service...134

Power Steering Belt...134

Tie Rod End...134

Power Steering Gear Box...137

Tie Rod/Rack Boot...140

Power Steering Pump...142

Tightening Torque Specification...149

Required Service Material...150

Special Tool...150

General Description...151

Steering Column...151

Steering Wheel and Driver Air Bag (Inflator) Module...152

Diagnosis...152

Inspection and Repair Required after Accident...152

On-Vehicle Service...153

Service Precautions...153

Service and diagnosis...153

Disabling air bag system...153

Enabling air bag system...153

Handling and storage...154

Disposal...154

Driver Air Bag (Inflator) Module...154

Steering Wheel...156

Centering Contact Coil...157

Contact Coil and Combination Switch Assembly...158

Steering Column Assembly...160

Steering Lock Assembly (Ignition Switch)...165

Steering Lower Shaft...166

Checking Steering Column Assembly and Lower Shaft for Accident Damage...168

Special Tool...168

General Description...169

Construction...169

Diagnosis...170

Diagnosis Table...170

Stabilizer Bar and/or Bushing Check...170

Strut Assembly Check...170

Suspension Control Arm/Steering Knuckle Check...171

Suspension Control Arm Bushing Check...171

Suspension Control Arm Joint Check...171

Front Suspension Frame Check...172

Front Suspension Fasteners Check...172

Wheel Disc, Nut and Bearing Check...172

On-vehicle Service...173

Strut Assembly...173

Stabilizer Bar and/or Bushings...176

Wheel Hub and Steering Knuckle...178

Suspension Control Arm/Bushing...184

Front Suspension Frame...187

Required Service Material...189

Special Tool...190

General Description...192

Construction...192

Diagnosis...193

Strut Assembly Check...193

Stabilizer Bar, Bushing and/or Joint Check...193

Suspension Knuckle Check...194

Control Rod Check...194

Trailing Rod Check...195

Suspension Frame, Bushing and Pad Check...195

Rear Suspension Fasteners...195

Wheel Disc, Nut and Bearing Check...195

On-vehicle Service...196

Rear Strut Assembly...196

Stabilizer Bar and/or Bushings...200

Control Rod...202

Trailing Rod...204

Suspension Frame...205

Wheel Hub, Wheel Bearing and Wheel Stud...207

Knuckle...209

Tightening Torque Specifications...212

Required Service Material...212

Special Tool...213

General Description...215

Construction...215

On-vehicle Service...216

Rear Suspension Frame...216

Wheel Hub, Wheel Stud/Wheel Bearing Outside Inner Race...218

Knuckle, Wheel Bearing/Oil Seal...220

Tightening Torque Specifications...221

Required Service Material...222

Special Tool...222

General Description...223

Tires...223

Tire placard...223

Inflation of tires...223

Matched tires and wheels (steel type)...224

Replacement tires...224

Wheels...225

Wheel maintenance...225

Replacement wheels...225

How to measure wheel runout...225

Metric lug nuts and wheel studs...225

Specifications...226

Diagnosis...226

Diagnosis Table...226

Irregular and/or Premature Wear...226

Wear Indicators...227

Radial Tire Waddle...227

Radial Tire Lead/Pull...228

Balancing Wheels...228

General Balance Procedures...229

On-Vehicle Service...230

Wheel...230

Tire...231

SECTION 4A...232

General Description...233

Component...233

Diagnosis...233

Diagnosis Table...233

Drive Shaft Boot Check...233

On-Vehicle Service...234

Drive Shaft Assembly...235

Tightening Torque Specification...248

Required Service Material...248