engine SUZUKI FORENZA 2008 1.G Workshop Manual

5-19SERVICE AND APPEARANCE CARE
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When your brake fluid falls to a low level,
your brake warning light will come on. See
“Brake System Warning Light” in section 3.
What to Add
When you do need brake fluid, use only
DOT-3 brake fluid. Use new brake fluid
from a sealed container only. See “Recom-
mended Fluids and Lubricants” in section
6.
Always clean the brake fluid reservoir cap
and the area around the cap before remov-
ing it. This will help keep dirt from entering
the reservoir.Brake Wear
Your vehicle has front and rear disc brakes.
Disc brake pads have built-in wear indica-
tors that make a high-pitched warning
sound when the brake pads are worn and
new pads are needed. The sound may
come and go or be heard all the time your
vehicle is moving (except when you are
pushing on the brake pedal firmly).Some driving conditions or climates may
cause a brake squeal when the brakes are
first applied or lightly applied. This does
not mean something is wrong with your
brakes.
Properly torqued wheel nuts are necessary
to help prevent brake pulsation. When tires
are rotated, inspect brake pads for wear
and evenly tighten wheel nuts in the proper
sequence to SUZUKI torque specifica-
tions.
Brake linings should always be replaced as
complete axle sets.
See “Brake System Inspection” in section
6.
WARNING
If you have too much brake fluid, it
can spill on the engine. The fluid will
burn if the engine is hot enough. You
or others could be burned, and your
vehicle could be damaged.
WARNING
With the wrong kind of fluid in your
brake system, your brakes may not
work well, or they may not even work
at all. This could cause a crash.
Always use the proper brake fluid.
CAUTION
 Using the wrong fluid can badly
damage brake system parts. For
example, just a few drops of min-
eral-based oil, such as engine oil,
in your brake system can damage
brake system parts so badly that
they’ll have to be replaced. Don’t let
someone put in the wrong kind of
fluid.
 If you spill brake fluid on your vehi-
cle’s painted surfaces, the paint fin-
ish can be damaged. Be careful not
to spill brake fluid on your vehicle.
If you do, wash it off immediately.
See “Appearance Care” in the
Index.
WARNING
The brake wear warning sound
means that soon your brakes won’t
work well. That could lead to an acci-
dent. When you hear the brake wear
warning sound, have your vehicle
serviced.
CAUTION
Continuing to drive with worn-out
brake pads could result in costly
brake repair.
Checking Things Under the Hood:

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Brake Pedal Travel
See your SUZUKI dealer if the brake pedal
does not return to normal height, or if there
is a rapid increase in pedal travel. This
could be a sign of brake trouble.
Brake Adjustment
Every time you make a moderate brake
stop, your disc brakes adjust for wear. If
you rarely make a moderate or heavier
stop, then your brakes might not adjust
correctly. If you drive in that way, then –
very carefully – make a few moderate
brake stops about every 1,000 miles
(1,600 km), so your brakes will adjust prop-
erly.
Replacing Brake System Parts
The braking system on a vehicle is com-
plex. Its many parts have to be of top qual-
ity and work well together if the vehicle is
to have really good braking. When you
replace parts of your braking system – for
example, when your brake linings wear
down and you need new ones put in – be
sure you get new approved SUZUKI
replacement parts. If you don’t, your
brakes may no longer work properly. For
example, if someone puts in brake linings
that are wrong for your vehicle, the balance
between your front and rear brakes can
change – for the worse. The braking per-
formance you’ve come to expect can
change in many other ways if someone
puts in the wrong replacement brake parts.
BatteryYour new vehicle comes with a mainte-
nance free battery. When it’s time for a new
battery, get one that has the replacement
number shown on the original battery’s
label. See “Engine Compartment Over-
view” in this section for battery location.
Vehicle Stor ag e
If you’re not going to drive your vehicle for
25 days or more, remove the black, nega-
tive (–) cable from the battery. This will
help keep your battery from running down.
Contact your SUZUKI dealer to learn how
to prepare your vehicle for longer storage
periods.
Jump StartingIf your battery has run down, you may want
to use another vehicle and some jumper
cables to start your vehicle. Be sure to fol-
low the steps below to do it safely.
1) Check the other vehicle. It must have a
12-volt battery with a negative ground
system.
WARNING
Battery posts, terminals and related
accessories contain lead and lead
compounds, chemicals known to the
State of California to cause cancer
and reproductive harm. Wash hands
after handling.
WARNING
Batteries have acid that can burn you
and gas that can explode. You can be
badly hurt if you aren’t careful. See
the next section, “Jump Starting”, for
tips on working around a battery
without getting hurt.
WARNING
Batteries can hurt you. They can be
dangerous because:
 They contain acid that can burn
you.
 They contain gas that can explode
or ignite.
 They contain enough electricity to
burn you.
If you don’t follow these steps
exactly, some or all of these things
can hurt you.
CAUTION
Ignoring the following steps could
result in costly damage to your vehi-
cle that wouldn’t be covered by your
warranty.
Trying to start your vehicle by push-
ing or pulling it won’t work, and it
could damage your vehicle.
Checking Things Under the Hood:

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2) Get the vehicles close enough so the
jumper cables can reach, but be sure
the vehicles aren’t touching each other.
If they are, it could cause a ground con-
nection you don’t want. You wouldn’t be
able to start your vehicle, and the bad
grounding could damage the electrical
systems.
To avoid the possibility of the vehicles
rolling, set the parking brake firmly on
both vehicles involved in the jump start
procedure. Put an automatic transmis-
sion in PARK (P) or a manual transmis-
sion in NEUTRAL before setting the
parking brake.3) Turn off the ignition on both vehicles.
Unplug unnecessary accessories
plugged into the cigarette lighter or in
the accessory power outlet. Turn off the
radio and all lamps that aren’t needed.
This will avoid sparks and help save
both batteries. And it could save your
radio!
4) Open the hoods and locate the batter-
ies. Find the positive (+) and negative
(–) terminal locations on each vehicle.
Your vehicle’s positive (+) terminal is
located under a red tethered cap on the
battery. The negative (–) terminal is
located under a black tethered cap on
the battery. See “Engine Compartment
Overview” in this section for more infor-
mation on location. Flip the caps up to
access the positive (+) and negative (–)
terminals.
5) Check that the jumper cables don’t
have loose or missing insulation. If they
do, you could get a shock. The vehicles
could be damaged, too.
Before you connect the cables, here are
some basic things you should know.
Positive (+) will go to positive (+) or to a
remote positive (+) terminal if the vehi-
cle has one. Negative (–) will go to a
heavy, unpainted metal engine part or
to a remote negative (–) terminal if the
vehicle with the dead battery has one.
Don’t connect positive (+) to negative
(–) or you’ll get a short that would dam-
CAUTION
If the other system isn’t a 12-volt sys-
tem with a negative ground, both
vehicles can be damaged. Only use
vehicles with 12-volt systems with
negative grounds to jump start your
vehicle.
CAUTION
If you leave your radio or other acces-
sories on during the jump starting
procedure, they could be damaged.
The repairs wouldn’t be covered by
your warranty. Always turn off your
radio and other accessories when
jump starting your vehicle.
WARNING
An electric fan under the hood can
start up and injure you even when the
engine is not running. Keep hands,
clothing and tools away from any
underhood electric fan.
WARNING
Using a match near a battery can
cause battery gas to explode. People
have been hurt doing this, and some
have been blinded. Use a flashlight if
you need more light.
Be sure the battery has enough
water. You don’t need to add water to
the battery installed in your new vehi-
cle. But if a battery has filler caps, be
sure the right amount of fluid is
there. If it is low, add water to take
care of that first. If you don’t, explo-
sive gas could be present.
Battery fluid contains acid that can
burn you. Don’t get it on you. If you
accidentally get it in your eyes or on
your skin, flush the place with water
and get medical help immediately.
Checking Things Under the Hood:

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age the battery and maybe other parts,
too. And don’t connect the negative (–)
cable to the negative (–) terminal on the
dead battery because this can cause
sparks.
6) Connect the red positive (+) cable to
the positive (+) terminal of the dead
battery. Use a remote positive (+) termi-
nal if the vehicle has one.7) Don’t let the other end touch metal.
Connect it to the positive (+) terminal of
the good battery. Use a remote positive
(+) terminal if the vehicle has one.
8) Now connect the black negative (–)
cable to the negative (–) terminal of the
good battery. Use a remote negative (–)
terminal if the vehicle has one.
Don’t let the other end touch anything
until the next step. The other end of the
negative (–) cable doesn’t go to the
dead battery. It goes to a heavy,
unpainted metal engine part or to a
remote negative (–) terminal on the
vehicle with the dead battery.
9) Connect the other end of the negative
(–) cable at least 18 inches (45 cm)
away from the dead battery, but not
near engine parts that move. The elec-trical connection is just as good there,
and the chance of sparks getting back
to the battery is much less.
10)Now start the vehicle with the good bat-
tery and run the engine for a while.
11)Try to start the vehicle that had the
dead battery. If it won’t start after a few
tries, it probably needs service.
WARNING
An electric fan under the hood can
start up and injure you even when the
engine is not running. Keep hands,
clothing and tools away from any
underhood electric fan.
CAUTION
Damage to your vehicle may result
from electrical shorting if jumper
cables are removed incorrectly. To
prevent electrical shorting, take care
that the cables don’t touch each
other or any other metal. The repairs
wouldn’t be covered by your war-
ranty.
Checking Things Under the Hood:

5-23SERVICE AND APPEARANCE CARE
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Jumper Cable Removal
A. Heavy, Unpainted Metal Engine Part
B. Good Battery
C. Dead Battery
To disconnect the jumper cables from both
vehicles, do the following:
1) Disconnect the black negative (–) cable
from the vehicle that had the dead bat-
tery.
2) Disconnect the black negative (–) cable
from the vehicle with the good battery.
3) Disconnect the red positive (+) cable
from the vehicle with the good battery.
4) Disconnect the red positive (+) cable
from the other vehicle.
5) Return the terminal cover to its original
position.
Headlamp AimingIf your vehicle is damaged in an accident,
the headlamp aim may be affected. Aim
adjustment of the low beam may be neces-
sary if it is difficult to see lane markers, for
horizontal aim, or if oncoming drivers flash
their high beams at you, for vertical aim. If
you believe your headlamps need to be re-
aimed, we recommend that you take your
vehicle to the dealer for service. However,
it is possible for you to re-aim your head-
lamps by following the procedure in the
service manual for your vehicle.
Bulb ReplacementFor the type of bulb to use, see “Replace-
ment Bulbs” in this section. For any bulb
changing procedure not listed in this sec-
tion, contact your SUZUKI dealer.Halogen Bulbs
CAUTION
To make sure your headlamps are
aimed properly, read all the instruc-
tions before beginning. Failure to fol-
low these instructions could cause
damage to headlamp parts.
WARNING
Halogen bulbs have pressurized gas
inside and can burst if you drop or
scratch the bulb. You or others could
be injured. Be sure to read and follow
the instructions on the bulb package.
Headlamp Aiming:
Bulb Replacement:

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The following steps will tell you how to use
the jack to change a tire.Removing the Spare Tire and Tools
A. Jack
B. Wrench
C. Jack Handle
D. S c r e w d r i ve r
The compartment spare tire and tools
you’ll need are located in the trunk.
1) Remove the trim cover from the floor of
the cargo area by pulling up on the tab.
2) Remove the foam tray that contains the
tools.
3) Turn the retainer on the compact spare
tire counterclockwise and remove the
retainer.
WARNING
Changing a tire can cause an injury.
The vehicle can slip off the jack and
roll over you or other people. You and
they could be severely injured. Find a
level place to change your tire. To
help prevent the vehicle from mov-
ing:
1) Set the parking brake firmly.
2) Put an automatic transmission
shift lever in PARK (P), or shift a
manual transmission to FIRST (1)
or REVERSE (R).
3) Turn off the engine and do not
restart while the vehicle is raised.
4) Do not allow passengers to
remain in the vehicle.
To be even more certain the vehicle
won’t move, you should put blocks at
the front and rear of the tire farthest
away from the one being changed.
That would be the tire on the other
side, at the opposite end of the vehi-
cle.
WARNING
Only use the jack for lifting this car
during an emergency tire change.
Tires:

5-49SERVICE AND APPEARANCE CARE
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Vehicle IdentificationVehicle Identification Number (VIN)This is the legal identifier for your vehicle. It
appears on a plate in the front corner of
the instrument panel, on the driver’s side.
You can see it if you look through the wind-
shield from outside your vehicle. The VIN
also appears on the Vehicle Certification
and Service Parts labels and the certifi-
cates of title and registration.
Engine Identification
The 8th character in your VIN is the engine
code. This code will help you identify your
engine, specifications and replacement
parts.
Electrical SystemAdd-On Electrical EquipmentYour vehicle has an air bag system. Before
attempting to add anything electrical to
your vehicle, see “Servicing Your Air Bag-
Equipped Vehicle” in section 1.Headlamp WiringThe headlamp wiring is protected by fuses,
one for each headlamp, in the fuse block.
An electrical overload will cause the lamps
to turn off. If this happens, have your head-
lamp wiring checked right away.Windshield Wiper FusesThe windshield wiper motor is protected by
an internal circuit breaker and a fuse. If the
motor overheats due to heavy snow, etc.,
the wiper will stop until the motor cools. If
the overload is caused by some electrical
problem and not snow, etc., be sure to get
it fixed. Description Usage
Swirl Remover
Po l i s hRemoves swirl marks,
fine scratches and
other light surface
contamination.
Cleaner Wax Removes light
scratches and pro-
tects finish.
Foaming Tire
Shine Low
GlossCleans, shines and
protects in one easy
step, no wiping neces-
sary.
Wash Wax
ConcentrateMedium foaming
shampoo. Cleans and
lightly waxes. Biode-
gradable and phos-
phate free.
Spot Lifter Quickly and easily
removes spots and
stains from carpets,
vinyl and cloth uphol-
stery.
Odor
EliminatorOdorless spray odor
eliminator used on
fabrics, vinyl, leather
and carpet.
See your SUZUKI parts department for
these products.
CAUTION
Don’t add anything electrical to your
vehicle unless you check with your
SUZUKI dealer first. Some electrical
equipment can damage your vehicle
and the damage wouldn’t be covered
by your warranty. Some add-on elec-
trical equipment can keep other com-
ponents from working as they
should.
Electrical System:

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Power Windows and Other Power
OptionsCircuit breakers in the fuse block protect
the power windows and other power
accessories. When the current load is too
heavy, the circuit breaker opens, protecting
the circuit until the problem is fixed or goes
away.Fuses and Circuit BreakersThe wiring circuits in your vehicle are pro-
tected from short circuits by a combination
of fuses, circuit breakers and fusible ther-
mal links in the wiring itself.
Look at the silver-colored band inside the
fuse. If the band is broken or melted,
replace the fuse. Be sure you replace a
bad fuse with a new one of the identical
size and rating.
There are spare fuses provided in the
engine compartment fuse block. If you ever
have a problem on the road and don’t have
a spare fuse, you can borrow one that has
the same amperage. Just pick a feature of
your vehicle that you can get along without
– like the radio or cigarette lighter – and
use its fuse, if it is the correct amperage.
Replace it as soon as you can.
There are two fuse blocks in your vehicle:
the instrument panel fuse block and the
engine compartment fuse block.
There is a fuse puller located on the
engine compartment fuse block. It can beused to easily remove fuses from the fuse
block.
Instrument Panel Fuse Block
The instrument panel fuse block is located
on the end of the instrument panel on the
driver’s side of the vehicle. To access the
fuses, open the fuse panel door by pulling
the door out.
To reinstall the door, first insert the rear
edge of the fuse panel door, then push the
front of the door into the end of the instru-
ment panel to secure it.
N5U5001B
10A
AIRBAG25A
WPR10A
RADIO/CLK
10A
ECM10A
AIRBAG15A
AUX LTR
15ATRN SIG LAMPS
10A
ABS15A
LT R
10A
CLSTR
BTSI10A
BCK/UP
15A
A/C
CLK 10A
TCM10A
RKE
10A
ENG FUSE BOX
DRL
15A
HAZRD
LAMPS
20A
HVAC15A
RKE15A
RADIO
15A
S/ROOF10A
DLC10A
SPARE
Electrical System:

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Engine Compartment Fuse Block
The engine compartment fuse block is
located on the driver’s side of the vehicle,
near the battery. See “Engine Compart-
ment Overview” in this section for more
information on location.
To access the fuses, press in the side flaps
to release the cover.
To reinstall the cover, push until it is
secure. Fuses Usages
AIRBAG Air Bag
WPR Wiper
RADIO/CLK Radio/Clock
ECMEngine Control
Module
AIRBAGOccupation Classifi-
cation Sensor
AUX LTR Extra Jack
TRN SIG LAMPS Turn Signal Lamps
ABSAntilock Brake
System
LTR Cigar Lighter
CLSTR, BTSICluster, BTSI
Solenoid
RKERemote keyless
Entry
BCK/UP Back-up
BLANK Not Used
TCMTransmission
Control Module
Fuses Usages
ENG FUSE BOX,
DRLEngine Fuse box,
Daytime Running
Light
HAZRD LAMPS Hazard Lamps
A/C, CLK A/C Switch, Clock
HVACHeating, Ventilation
and Air Conditioning
RKERemote Keyless
Entry
RADIO Radio
S/ROOF Sunroof
DLC Data link Connector
SPARE Spare
CAUTION
When you inspect the fuse box on
your vehicle, refer to the fuse box
label. The type of fuse box varies
depending on the vehicle’s specifica-
tion.
CAUTION
When you inspect the fuse box on
your vehicle, refer to the fuse box
label. The type of fuse box varies
depending on the vehicle’s specifica-
tion.
Electrical System:

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Fuses Usages
HEAD LAMPS Head Lamp
ECMEngine Control
Module
I/P FUSEInstrument Panel
Fuse
FUEL PUMP Fuel Pump
A/C Air Conditioning
HORN Horn
HI BEAMHead Lamp
High-Beam
DRIVER’S PWR
WNDWDriver’s Power
Window
STOP LAMPS Stop Lamps
DR/LCK Door Lock
MIR HTD Heated Mirror
FRT FOG Front Fog
ILLUM LTLicense Plate Lamp,
Parking Lamp Left
INJ Injector
Fuses Usages
ENG SNSREVAP Canister Purge
Solenoid, HO2S,
Cooling Fan Relay,
CMP Sensor
LOW BEAM LTHead Lamp
Low-Beam Left
ILLUM RTIllumination
Circuit, Parking Lamp
Right
LOW BEAM RTHead Lamp
Low-Beam Right
SPARE Spare
SPARE Spare
SPARE Spare
BATT PWR Battery Power
ABSAntilock Brake
System
HVAC BLWR HVAC Blower
IGN 2 Ignition 2
IGN 1 Ignition 1
FUSE PLR Fuse Puller
COOL FAN LOW Cooling Fan Low
Fuses Usages
DEFOG Defog
COOL FAN HI Cooling Fan High
PWR WNDW Power Window
Relays Usages
COOL FAN LOW Cooling Fan Low
FRT FOG Front Fog
ILLUM Illumination Relay
A/C CMPRSRAir Conditioning
Compressor
HORN Horn
DEFOG Defog
FUEL PUMP Fuel Pump
MAIN Main Relay
COOL FAN HI Cooling Fan High
PWR WNDW Power Window
HEAD LAMPS Headlamp Relay
Capacities and Specifications: