Page 1 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.
Page 3 And for any section, item or description not found in this supplement, refer to the related manual below. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
Page 4 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.
Page 5 TABLE OF CONTENTS NOTE For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same sections of the service manual mentioned in the “FOREWORD” of this manual. Precautions..............0-i Transmission / Transaxle .......... 5-i Precautions ............
Page 7: Table Of Contents
Table of Contents 0- i Section 0 Precautions CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........00-1 Precautions for Installing Mobile Communication Equipment ........00-* Precautions............
Page 8: Precautions
00-1 Precautions: Precautions Precautions General Precautions • New and used engine oil can be S5JB0B0000002 hazardous. Children and pets may be The WARNING and CAUTION describe some general harmed by swallowing new or used oil. precautions that you should observe when servicing a Keep new and used oil and used engine oil vehicle.
Page 9 • When use of a certain type of lubricant, cable, and replace the terminal cover. bond or sealant is specified, be sure to remove the old one thoroughly and use the specified type. “A”: Sealant 99000–31150 (SUZUKI Bond No.1207C) I2RH01010027-01 I2RH01010030-01...
Page 10 00-3 Precautions: • Be sure to use special tools when • When servicing fuel system, be sure to instructed. observe WARNING in “Precautions on Fuel System Service: in Section 1G” to reduce Special tool the risk of fire and personal injury. (A): 09917–98221 •...
Page 11: Precaution For Vehicle Equipped With Esp® System
Precautions: 00-4 Precaution for Vehicle Equipped with ESP® Precautions for Catalytic Converter and Diesel System Particulate Filter S5JB0B0000016 S5JB0B0000004 • When testing with any of the following equipments • Use only specified fuel and be careful not to let a large (when vehicle is tested by rotating wheels (tires) amount of unburned fuel enter the converter and filter under vehicle stop), be sure to deactivate ESP®...
Page 12 00-5 Precautions:...
Page 13 Table of Contents 0- i Section 0 General Information CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. General Information ........ 0A-1 Fuel Lines and Connections Inspection ....0B-5 Fuel Filter Replacement ........0B-5 General Description ..........0A-1...
Page 14 0A-1 General Information: General Information General Description Abbreviations S5JB0B0101001 FWD: Front Wheel Drive 4WD: 4 Wheel Drive ABDC: After Bottom Dead Center ABS: Anti-lock Brake System GEN: Generator AC: Alternating Current GND: Ground A/C: Air Conditioning A-ELR: Automatic-Emergency Locking Retractor HC: Hydrocarbons A/F: Air Fuel Mixture Ratio HO2S: Heated Oxygen Sensor...
Page 15 General Information: 0A-2 SAE: Society of Automotive Engineers JIS-TO-ISO Main Fasteners Comparison Table SDM: Sensing and Diagnostic Module (Air Bag Nominal diameter Controller, Air bag Control Module) M10 M12 M14 SFI: Sequential Multiport Fuel Injection Thread pitch 1.25 1.25 1.25 SOHC: Single Over Head Camshaft Width across flats Thread pitch...
Page 16 0A-3 General Information: Standard Tightening Torque Each fastener should be tightened to the torque specified in each section of this manual. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.
Page 17 General Information: 0A-4 Engine Identification Number S5JB0B0101009 The number is punched on the cylinder block. I5JB0B010001-01 Transmission Identification Number S5JB0B0101010 The number is located on the transmission case. I5JB0B010002-01...
Page 18 0A-5 General Information: Component Location Warning, Caution and Information Label Location S5JB0B0103001 The figure shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels. If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.
Page 19 General Information: 0A-6 I5JB0B010004-03 1. Air bag label on driver air bag (inflator) module 4. Air bag label on passenger air bag (inflator) module 7. Air bag label on side air bag module 2. Air bag label on contact coil assembly 5.
Page 20 0B-1 Maintenance and Lubrication: Maintenance and Lubrication Scheduled Maintenance MIZOGUCHI Maintenance Schedule under Normal Driving Conditions S5JB0B0205001 NOTE • This interval should be judged by odometer reading or months, whichever comes first. • This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at the same intervals respectively.
Page 21 Maintenance and Lubrication: 0B-2 Maintenance Recommended under Severe Driving Conditions S5JB0B0205002 If the vehicle is usually used under the conditions corresponding to any severe condition code, IT IS RECOMMENDED that applicable maintenance operation be performed at the particular interval as shown in the following table. Severe condition code: A: Repeated short trips B: Driving on rough and/or muddy roads...
Page 22 0B-3 Maintenance and Lubrication: Repair Instructions Engine Accessory Drive Belt, Tensioner and Engine Oil and Filter Change S5JB0B0206004 Idler Replacement WARNING S5JB0B0206002 WARNING • New and used engine oil can be Replacement must be performed with battery hazardous. negative cable disconnected to avoid a Be sure to read “General Precautions: in personal injury.
Page 23 Maintenance and Lubrication: 0B-4 4) Apply engine oil to new oil filter gasket. 8) Check oil filter and drain plug for oil leakage. 9) Start engine and run it for 3 minutes. Stop it and wait 10 minutes before checking oil level. Add oil, as necessary, to bring oil level to FULL level mark (1) on dipstick.
Page 24 0B-5 Maintenance and Lubrication: Fuel Lines and Connections Inspection 5) Check boots of steering linkage for damage (leaks, S5JB0B0206010 detachment, tear, dent, etc.). If damage is found, Visually inspect fuel lines and connections for evidence replace it with new one. of fuel leakage, hose cracking and damage.
Page 25 Maintenance and Lubrication: 0B-6 5) Tighten level / filler plug to specified torque referring Power Steering (P/S) System Inspection to “Manual Transmission Oil Change: in Section S5JB0B0206036 1) Visually check power steering system for fluid 5B”. leakage and hose for damage and deterioration. Repair or replace defective parts, if any.
Page 26 0B-7 Maintenance and Lubrication: Specifications Tightening Torque Specifications Tightening torque Fastening part Note N⋅m kgf-m lb-ft Engine oil drain plug 25.5 Reference: For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Fluids and Lubricants S5JB0B0208001...
Page 27 Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC P0105: Manifold Absolute Pressure / Barometric Pressure Circuit Malfunction..1A-34 Precautions............. 1-1 DTC P0110: Intake Air Temperature Sensor Precautions for Engine.......... 1-1 1 Circuit Malfunction........1A-34 Engine General Information and DTC P0115: Engine Coolant Temperature Circuit Malfunction...........1A-36 Diagnosis ..........
Page 28 1-ii Table of Contents DTC P0480: Fan 1 Control Circuit ....1A-56 DTC P2264: Water in Fuel Sensor Circuit DTC P0481: Fan 2 Control Circuit ....1A-57 Malfunction............1A-90 DTC P0486: Exhaust Gas Recirculation DTC P2413: Exhaust Gas Recirculation Sensor “B” Circuit Malfunction ......1A-58 System Performance Malfunction ....1A-91 DTC P0500: Vehicle Speed Sensor “A”...
Page 29 Table of Contents 1-iii Engine Control Module (ECM) Removal Air Cleaner Components........1D-4 and Installation ..........1C-2 Air Cleaner Removal and Installation....1D-4 Registration Procedure for the ECM ....1C-2 Air Cleaner Filter Removal and Installation..1D-4 Registration Procedure for the Fuel Air Cleaner Filter Inspection and Cleaning..1D-5 Injector Calibration Code ........1C-3 Intercooler and Air Intake Pipe Components ..1D-5 EGR Valve Data Initialization ......1C-3...
Page 30 1-iv Table of Contents Main Bearing, Crankshaft and Cylinder Radiator On-Vehicle Inspection and Block Component..........1D-55 Cleaning ............1F-9 Main Bearing, Crankshaft and Cylinder Radiator Removal and Installation ...... 1F-9 Block Removal and Installation .......1D-56 Water Pump Removal and Installation ....1F-9 Crankshaft Inspection ........1D-61 Water Pump Inspection ........
Page 31 Table of Contents 1-v Starting System .........1I-1 Generator Components........1J-7 Generator Dismounting and Remounting.... 1J-8 General Description ..........1I-1 Generator Disassembly and Assembly ....1J-8 Cranking Circuit Introduction........ 1I-1 Drive End Frame / Bearing Disassembly Starting Motor Circuit Description ......1I-1 and Assembly..........
Page 32: Precaution For Can Communication System
1-1 Precautions: Precautions Precautions Precautions for Engine S5JB0B1000001 Air Bag Warning Refer to “Air Bag Warning: in Section 00 in related manual”. Precautions on Engine Service Refer to “Precautions on Engine Service: in Section 1A”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble: in Section 1A”. Statement on Cleanliness and Care Refer to “Statement on Cleanliness and Care: in Section 1A”.
Page 33: Engine General Information And
• Diagnostic information stored in ECM memory can be reliable engine performance. cleared as well as checked by using SUZUKI scan tool or OBD generic scan tool. Before using scan tool, • When raising or supporting engine for any reason, do read its Operator’s (Instruction) Manual carefully to...
Page 34: Statement On Cleanliness And Care
1A-2 Engine General Information and Diagnosis: Statement on Cleanliness and Care Failure to disconnect cables may result in damage to S5JB0B1100003 wire harness or other electrical parts. An automobile engine is a combination of many • The four cylinders of the engine are identified by machined, honed, polished and lapped surfaces with numbers;...
Page 35 ON and K line (3) of ISO 9141 is used for SUZUKI scan tool or stores the malfunction area in its memory. OBD generic scan tool to communicate with ECM, Air •...
Page 36: Can Communication System Description
1A-4 Engine General Information and Diagnosis: CAN Communication System Description S5JB0B1101005 ECM (1), ABS or ESP® control module (2), BCM (3), 4WD control module (4), combination meter (5) and immobilizer control module (6) of this vehicle communicate control data between each control module. Communication of each control module is established by CAN (Controller Area Network) communication system.
Page 37 Engine General Information and Diagnosis: 1A-5 ECM Transmission Data 4WD control ABS control Combination Transmits data ESP® control module module Meter module (if equipped) of ECM (if equipped) (if equipped) Engine torque signal Accelerator pedal position Engine speed Throttle position Engine emissions related malfunction Injection warning light...
Page 38: Electronic Control System Description
1A-6 Engine General Information and Diagnosis: Electronic Control System Description S5JB0B1101004 System Diagram I5JB0B110006-04 1. ECM 20. Boost pressure control solenoid valve 39. 4WD control module...
Page 39 Engine General Information and Diagnosis: 1A-7 2. Exhaust gas temperature sensor 3 21. Common rail (High pressure fuel injection 40. Immobilizer control module rail) 3. Diesel particulate filter 22. Fuel pressure sensor 41. BCM 4. Exhaust gas temperature sensor 2 23.
Page 40 1A-8 Engine General Information and Diagnosis: System Wiring Circuit Diagram C85-32 C85-9 YEL/GRN C85-27 E66-28 GRN/WHT PNK/BLK C85-29 RED/BLK C85-25 E66-30 PNK/GRN C85-30 RED/GRN C85-26 C86-7 PNK/BLU C85-31 C85-17 BRN/YEL RED/BLU C85-28 C85-1 WHT/BLU C86-17 BRN/WHT WHT/RED C86-16 BRN/BLK WHT/GRN C86-15 BRNYEL BLK/YEL...
Page 41 Engine General Information and Diagnosis: 1A-9 4. Fuel injector No.3 24. Fuel flow actuator 46. Ignition switch 5. Fuel injector No.4 25. Glow plug control module 47. Fuel heater relay 6. CKP sensor 26. Glow plug 48. Fuel heater 7. CMP sensor 27.
Page 42 1A-10 Engine General Information and Diagnosis: Connector: C86 Terminal Circuit Terminal Circuit — EGR valve output — EGR valve output Main power supply Inlet throttle valve feedback — — — Exhaust gas temperature sensor 3 signal — — Fuel flow actuator Exhaust gas temperature sensor 2 signal —...
Page 43: Diesel Particulate Filter Regeneration Description
3) Driving performance will be limited by lowering the engine torque to avoid “Natural regeneration”. Therefore, the driver will recognize the malfunction of diesel particulate filter. In this situation, “After-sales regeneration” using SUZUKI scan tool will be necessary or diesel particulate filter has to be replaced in the worst case.
Page 44: Electronic Control System Components Location
1A-12 Engine General Information and Diagnosis: Component Location Electronic Control System Components Location S5JB0B1103001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I5JB0B110010-03 Information sensors Control devices Others 1.
Page 45: Malfunction Indicator Lamp (Mil) Check
Engine General Information and Diagnosis: 1A-13 Information sensors Control devices Others t: Inlet throttle valve u: EGR valve v: Boost pressure control solenoid valve w: Additional heater relay No.1 x: Additional heater relay No.2 y: Additional heater relay No.3 Diagnostic Information and Procedures Malfunction Indicator Lamp (MIL) Check Injection Warning Light (Gravity 1 Fault) Check S5JB0B1104001...
Page 46: Engine And Emission Control System
1A-14 Engine General Information and Diagnosis: Engine and Emission Control System Check S5JB0B1104004 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis referring to “Step 1: Customer Complaint Analysis: ”.
Page 47 Engine General Information and Diagnosis: 1A-15 Customer problem inspection form (Example) I2RH01110010-01 NOTE The form is a standard sample. It should be modified according to conditions characteristic of each market.
Page 48: Dtc Check
(e.g., wire harness, connector, etc.), referring to S5JB0B1104006 “Intermittent and Poor Connection Inspection: in Section 1) Connect SUZUKI scan tool to data link connector in 00 in related manual” and related circuit of DTC the same manner as when making this connection recorded in Step 2.
Page 49 Engine General Information and Diagnosis: 1A-17 DTC Table S5JB0B1104007 DTC No. Detecting Condition (SUZUKI scan Detecting Item (DTC will set when detecting:) tool) Crankshaft Position – Camshaft Position CKP sensor signal frequency above a given P0016 Correlation threshold. • Boost pressure control solenoid valve circuit...
Page 50 1A-18 Engine General Information and Diagnosis: DTC No. Detecting Condition (SUZUKI scan Detecting Item (DTC will set when detecting:) tool) • EGR valve actuator circuit shorted to ground circuit Exhaust Gas Recirculation Control Circuit P0403 • EGR valve actuator circuit open or shorted to power circuit •...
Page 51 Engine General Information and Diagnosis: 1A-19 DTC No. Detecting Condition (SUZUKI scan Detecting Item (DTC will set when detecting:) tool) Sensor Reference Voltage “B” circuit / open Sensor power source voltage is too high or too low from ECM (Accelerator pedal position (APP) sensor...
Page 52: Indicator Lamp Operation Table
1A-20 Engine General Information and Diagnosis: Indicator lamp operation table S5JB0B1104008 Malfunction Injection Red Stop DTC No. (SUZUKI Detecting Item Indicator Warning Light Warning Light scan tool) Lamp (MIL) (Gravity 1 Fault) (Gravity 2 Fault) Crankshaft Position – Camshaft Position —...
Page 53 Engine General Information and Diagnosis: 1A-21 Malfunction Injection Red Stop DTC No. (SUZUKI Detecting Item Indicator Warning Light Warning Light scan tool) Lamp (MIL) (Gravity 1 Fault) (Gravity 2 Fault) Fan 2 Control Circuit — — — P0481 Exhaust Gas Recirculation Sensor “B”...
Page 54 1A-22 Engine General Information and Diagnosis: Malfunction Injection Red Stop DTC No. (SUZUKI Detecting Item Indicator Warning Light Warning Light scan tool) Lamp (MIL) (Gravity 1 Fault) (Gravity 2 Fault) Exhaust Gas Recirculation Throttle Control — 1 driving cycle —...
Page 55: Scan Tool Data
As the data values below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a SUZUKI scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each specified data range. Therefore, judgment as abnormal should not be made by checking with these data alone.
Page 56 1A-24 Engine General Information and Diagnosis: Normal condition / reference Scan tool data Vehicle condition values Cyl 1 FF Correction At specified idle speed without engine load after –1.0 mg/str – 1.0 mg/str Cyl 2 FF Correction warming up to normal operating temperature Cyl 3 FF Correction Cyl 4 FF Correction 100 °C –...
Page 57: Visual Inspection
Engine General Information and Diagnosis: 1A-25 Visual Inspection S5JB0B1104009 Visually check the following parts and systems. Inspection item Referring section • Engine oil-level, leakage “Engine Oil and Filter Change: in Section 0B” • Engine coolant-level, leakage “Coolant Level Check: in Section 1F” •...
Page 58: Dtc P0016: Crankshaft Position-Camshaft Position Correlation Malfunction
• Use service wire for any operation on the ECM connectors. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition 1.DEF Inconsistency of signal Troubleshooting Check the CKP sensor and CMP sensor connections.
Page 59: Dtc P0033: Turbo Charger Bypass Valve Control Circuit Malfunction
The fault is declared present after: – Engine start. – A road test. – Output test “Boost pressure valve” on SUZUKI scan tool. • If the fault is present: – Turbocharging is no longer authorized. – The EGR function is inhibited.
Page 60: Dtc P0089: Fuel Pressure Regulator 1 Performance Malfunction
“C90-2” wire. – Clear any solenoid valve faults and perform output test “Boost pressure valve” on SUZUKI scan tool. The voltmeter should display five cycles of two successive voltages: ~ 2.5 V (opening cyclic ratio of 20%) then ~ 8.75 V (opening cyclic ratio of 70%).
Page 61 Engine General Information and Diagnosis: 1A-29 Detecting Condition Displaying on SUZUKI scan tool Detecting condition CC.1 Short circuit to +12 V CC.0 Short circuit to vehicle body ground Open circuit 1.DEF Internal electronic fault 2.DEF Measured pressure too low 3.DEF Measured pressure too high 4.DEF...
Page 62 “C83-2” wire of the fuel flow actuator connector, clear any fuel flow actuator faults, then perform “IMV/Flow actuator” on SUZUKI scan tool: The oscilloscope should display a square-wave signal of an amplitude of 12.5 V at a frequency of 185 Hz (with an opening cyclic ratio alternating from 25 to 75%).
Page 63 Check that the fuel pressure sensor is operating correctly using command “IMV/Flow actuator” on SUZUKI scan tool. Display the parameter “Fuel pressure” on Data List of SUZUKI scan tool, and refer to “SUZUKI Scan Tool Data” to check the operating values.
Page 64: Dtc P0100: Mass Or Volume Air Flow Circuit Malfunction
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition CC.1 Short circuit to +12 V CO.0 Open circuit or short circuit to vehicle body ground 1.DEF...
Page 65 Engine General Information and Diagnosis: 1A-33 Troubleshooting for 1.DEF: Offset at maximum threshold and 2.DEF: Offset at minimum threshold NOTE Conditions for applying fault finding procedures to stored faults: The fault is declared present after ignition switch has been turned OFF for 40 seconds. Check the MAF sensor assembly with IAT sensor connections.
Page 66: Dtc P0105: Manifold Absolute Pressure / Barometric Pressure Circuit Malfunction
The fault is declared present after an attempted start, or with the engine running. • If the fault is present: – The air temperature value changes to safe mode, “Intake Air Temp” on Data List of SUZUKI scan tool = 45.1 °C, 113.2 °F.
Page 67 Engine General Information and Diagnosis: 1A-35 Troubleshooting for CO.1: Open circuit or short circuit to +12 V Check the MAF sensor assembly with IAT sensor connections. Check the ECM connections. Repair if necessary. Check the continuity of the following connection: •...
Page 68: Dtc P0115: Engine Coolant Temperature Circuit Malfunction
– With the engine running • If the fault is present: – The coolant temperature: “Coolant Temp” on Data List of SUZUKI scan tool is fixed at 118.1 °C, 244.6 °F with engine running, 0.1 °C, 32 °F with engine stopping –...
Page 69: Dtc P0190: Fuel Rail Pressure Sensor Circuit Malfunction
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition CC.0 Short circuit to vehicle body ground CO.1 Open circuit or short circuit to +12 V 1.DEF...
Page 70: Dtc P0201: Fuel Injector Circuit / Open Malfunction-Cylinder 1
• Use service wire for all operations on the ECM connectors. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition CC.1 Short circuit to +12 V Open circuit Short circuit 1.DEF...
Page 71: Dtc P0202: Fuel Injector Circuit / Open Malfunction-Cylinder 2
• Use service wire for all operations on the ECM connectors. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition CC.1 Short circuit to +12 V Open circuit Short circuit 1.DEF...
Page 72: Dtc P0203: Fuel Injector Circuit / Open Malfunction-Cylinder 3
• Use service wire for all operations on the ECM connectors. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition CC.1 Short circuit to +12 V Open circuit Short circuit 1.DEF...
Page 73: Dtc P0204: Fuel Injector Circuit / Open Malfunction-Cylinder 4
• Use service wire for all operations on the ECM connectors. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition CC.1 Short circuit to +12 V Open circuit Short circuit 1.DEF...
Page 74: Dtc P0225: Accelerator Pedal Position
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition CO.0 Open circuit or short circuit to vehicle body ground CC.1...
Page 75 Engine General Information and Diagnosis: 1A-43 Troubleshooting for CO.0: Open circuit or short circuit to vehicle body ground NOTE Priorities when dealing with a number of faults: • If fault “DTC P2120: Throttle/Pedal Position Sensor/Switch “D” Circuit Malfunction: ” is present at the same time, check that the accelerator pedal position (APP) sensor assembly connector is connected correctly.
Page 76: Dtc P0235: Turbo / Super Charger Boost Sensor "A" Circuit Malfunction
• Pedal blocked by an external component. Repair if necessary. Vary the position of the pedal and display the parameter “Pedal position” on Data List of SUZUKI scan tool. If the values displayed are inconsistent, replace the accelerator pedal position (APP) sensor assembly.
Page 77: Dtc P0243: Turbo / Super Charger Wastegate Solenoid "A" Malfunction
Malfunction: ”, display parameter “Turbo Pressure” on Data List of SUZUKI scan tool. If this value is locked at 1000 hPa and “Barometric Pres” on Data List of SUZUKI scan tool is displaying a different value, replace the boost pressure sensor.
Page 78 1A-46 Engine General Information and Diagnosis: Troubleshooting for 1.DEF: Pressure too low Check the boost pressure sensor connections. Check the connections of the boost pressure control solenoid valve. Check the ECM connections. Repair if necessary. Check the sealing of the high pressure air circuit: •...
Page 79: Dtc P0297: Vehicle Overspeed Condition Malfunction
Check the connections of the boost pressure control solenoid valve. Check the ECM connections. Repair if necessary. Check the conformity of the turbocharging pressure signal. (Refer to “Turbo Pressure” on Data List of SUZUKI scan tool). Make sure the turbocharging limit solenoid valve is not blocked open: •...
Page 80: Dtc P0301: Cylinder 1 Misfire Detected Malfunction
Troubleshooting Check that the fuel injector No.1 calibration code using SUZUKI scan tool is correctly entered and that it corresponds to the code inscribed on the corresponding injector. Enter the code into an fuel injector that has not been programmed or where the code has been entered incorrectly, if necessary.
Page 81: Dtc P0303: Cylinder 3 Misfire Detected Malfunction
Troubleshooting Check that the fuel injector No.3 calibration code using SUZUKI scan tool is correctly entered and that it corresponds to the code inscribed on the corresponding injector. Enter the code into an fuel injector that has not been programmed or where the code has been entered incorrectly, if necessary.
Page 82: Dtc P0335: Crankshaft Position Sensor "A" Circuit Malfunction
– The Red stop warning light (gravity 2 warning light) is lit. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition 1.DEF Signal absent 2.DEF...
Page 83: Dtc P0340: Camshaft Position Sensor "A" Circuit Malfunction
• Use service wire for all operations on the ECM connectors. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition 1.DEF No signal 2.DEF...
Page 84: Dtc P0380: Glow Plug / Heater Circuit "A" Malfunction
NOTE • Conditions for applying fault finding procedures to stored faults: The fault is declared present after output test “Pre/Post Heater Relay Control” on SUZUKI scan tool, or after an attempted engine start. • If the fault is present, it is difficult or even impossible to start the vehicle when cold.
Page 85: Dtc P0403: Exhaust Gas Recirculation Control Circuit Malfunction
Check the operation of the EGR valve: Perform “Initialize EGR valve data” on SUZUKI scan tool to reinitialise the operating values of the valve and launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: in Section 1C”).
Page 86: Dtc P0409: Exhaust Gas Recirculation Sensor "A" Circuit Malfunction
Check the operation of the EGR valve: Perform “Initialize EGR valve data” on SUZUKI scan tool to reinitialise the operating values of the valve and launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: in Section 1C”).
Page 87: Dtc P0470: Exhaust Pressure Sensor Malfunction
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Open circuit CO.0 Open circuit or short circuit to vehicle body ground CC.1...
Page 88: Dtc P0480: Fan 1 Control Circuit
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition CO.0 Open circuit or short circuit to vehicle body ground CO.1...
Page 89: Dtc P0481: Fan 2 Control Circuit
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition CO.0 Open circuit or short circuit to vehicle body ground CO.1...
Page 90: Dtc P0486: Exhaust Gas Recirculation Sensor "B" Circuit Malfunction
Check the operation of the EGR valve: Perform “Initialize EGR valve data” on SUZUKI scan tool to reinitialise the operating values of the valve and launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: in Section 1C”).
Page 91: Dtc P0500: Vehicle Speed Sensor "A" Malfunction
Check the operation of the EGR valve: Perform “Initialize EGR valve data” on SUZUKI scan tool to reinitialise the operating values of the valve and launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: in Section 1C”).
Page 92: Dtc P0530: A/C Refrigerant Pressure Sensor "A" Circuit Malfunction
Repair if necessary. Connect an air conditioning filling station (equipped with a high pressure gauge) to the vehicle. Display parameter “REFRIGERANT PRESSURE” on HVAC control module with SUZUKI scan tool and compare the value displayed by the filling station. If the values match, carry out a fault finding procedure as described in the fault finding note for that vehicle.
Page 93: Dtc P0544: Exhaust Gas Temperature Sensor Circuit Malfunction
Check for the presence of ground on “C88-2” wire of the exhaust gas temperature sensor 3 connector. Check the sensor resistance between “C88-1” and “C88-2” terminals of the exhaust gas temperature sensor 3 connector according to parameter “Diesel PF out Temp” on Data list of SUZUKI scan tool. Exhaust gas temperature sensor resistance: 132500 Ω...
Page 94: Dtc P0560: System Voltage Malfunction
• Use service wire for all operations on the ECM connectors. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition 1.DEF Overvoltage 2.DEF Undervoltage Troubleshooting for 1.DEF: Overvoltage...
Page 95: Dtc P0571: Brake Switch "A" Circuit Malfunction
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition 1. DEF Open circuit or short circuit 2. DEF Inconsistency of signal Troubleshooting for 1.DEF: Open circuit or short circuit...
Page 96: Dtc P0575: Cruise Control Input Circuit Malfunction
1A-64 Engine General Information and Diagnosis: DTC P0575: Cruise Control Input Circuit Malfunction S5JB0B1104121 CAUTION • This fault may appear if the wiring harness has been damaged. Follow the procedure described in “Electrical Circuit Inspection Procedure: in Section 00 in related manual”.
Page 97 Engine General Information and Diagnosis: 1A-65 Detecting Condition Displaying on SUZUKI scan tool Detecting condition 1.DEF Permanent high level 2.DEF Permanent low signal 3.DEF Configuration absent or incorrect 4.DEF Analogue/digital converter fault 5.DEF Communication disrupted 6.DEF EEPROM fault 7.DEF Watchdog Activation 8.DEF...
Page 98: Dtc P0611: Fuel Injector Control Module Performance Malfunction
Program the fuel injector codes again. If the fault is still present, substitute a known-good ECM and recheck. • Otherwise clear the fault memory using DTC clearance on SUZUKI Scan tool referring to “DTC Clearance: ”. Troubleshooting for 2.DEF: No code in memory NOTE This fault appears on any blank computer (new or recently reprogrammed).
Page 99: Dtc P0615: Starter Relay Circuit Malfunction
• Use service wire for all operations on the ECM connectors. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition 1.DEF Voltage outside permitted range of values Troubleshooting Check continuity and make sure there is no interference resistance on the following connection: •...
Page 100: Dtc P0627: Fuel Pump "A" Control Circuit / Open
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition CO.0 Open circuit or short circuit to vehicle body ground COC.1...
Page 101: Dtc P0638: Throttle Actuator Control Range / Performance Malfunction
NOTE After any inlet throttle valve procedures, it is necessary to perform “Initialize inlet throttle valve data” on SUZUKI scan tool. Then turn OFF ignition switch and wait 40 seconds. Check the connections of the inlet throttle valve. Check the ECM connections.
Page 102 NOTE After any inlet throttle valve procedures, it is necessary to perform “Initialize inlet throttle valve data” on SUZUKI scan tool. Inlet throttle valve fault adaptives. Then turn OFF ignition switch and wait 40 seconds. Check the connections of the inlet throttle valve.
Page 103 • Between “C75-4” wire of inlet throttle valve connector and “C86-27” terminal of ECM connector Repair if necessary. • Perform “Initialize inlet throttle valve data” on SUZUKI scan tool. • If the fault is still present, check that the ECM output stage is working correctly.
Page 104: Dtc P0641: Sensor Reference Voltage "A" Circuit / Open Malfunction
• Use service wire for all operations on the ECM connectors. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition 1.DEF Sensor reference voltage too low 2.DEF...
Page 105 Engine General Information and Diagnosis: 1A-73 Troubleshooting NOTE Priorities when dealing with a number of faults: If fault “DTC P0225: Accelerator Pedal Position (APP) Sensor Assembly / Switch “C” Circuit Malfunction: ” is present at the same time, check that the sensor is connected correctly. In the event of the simultaneous presence of fault “DTC P0235: Turbo / Super Charger Boost Sensor “A”...
Page 106: Dtc P0645: A/C Clutch Relay Control Circuit
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition CO.0 Open circuit or short circuit to vehicle body ground CO.1...
Page 107: Dtc P0651: Sensor Reference Voltage "B" Circuit / Open Malfunction
• Use service wire for all operations on the ECM connectors. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition 1.DEF Sensor reference voltage too low 2.DEF...
Page 108 1A-76 Engine General Information and Diagnosis: Troubleshooting The sensors connected to supply No.2 are: • EGR valve position sensor. • Sensor for accelerator pedal position (APP) sensor (sub). To locate any faulty sensor and/or connection, disconnect one of the sensors then check whether the fault becomes stored.
Page 109: Dtc P0670: Glow Plug Module Control Circuit Malfunction
• Conditions for applying fault finding procedures to stored faults: The fault is declared present after several attempts to start the engine, or perform output test “Pre/ post Heater Relay Control” on SUZUKI scan tool. • It is difficult or even impossible to start the engine when cold.
Page 110: Dtc P0685: Ecm / Pcm Power Relay Control Circuit / Open Malfunction
• Use service wire for all operations on the ECM connectors. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition 1.DEF Relay cut out too soon 2.DEF...
Page 111 Engine General Information and Diagnosis: 1A-79 Troubleshooting The sensors connected to supply No.3 are: • Fuel pressure sensor. • MAF sensor assembly with IAT sensor. To locate any faulty sensor and/or connection, disconnect one of the sensors then check whether the fault becomes stored.
Page 112: Dtc P0830: Clutch Pedal Switch "A" Circuit Malfunction
The parameters must be reinitialised after any procedure is carried out on the diesel particulate filter. Use command “Initialize Diesel PF data” on SUZUKI scan tool, and diesel particulate filter after-sales regeneration referring to “Diesel Particulate Filter After-sales Regeneration Procedure: in Section 1C”...
Page 113: Dtc P1436: Regeneration Request Failures Malfunction
• The parameters must be reinitialised after any procedure is carried out on the diesel particulate filter. Use command “Initialize Diesel PF data” on SUZUKI scan tool, and diesel particulate filter after- sales regeneration referring to “Diesel Particulate Filter After-sales Regeneration Procedure: in Section 1C”...
Page 114: Dtc P1480: Defective Particulate Filter Inlet Pick-Off Failures Malfunction
– The Injection warning light (gravity 1 warning light) is lit. – The diagnostic of the diesel particulate filter is inhibited. – Diesel particulate filter regenerations are inhibited. Detecting Condition Displaying on SUZUKI scan tool Detecting condition 1.DEF Inconsistency of signal...
Page 115: Dtc P1642: Additional Heater Relay No.2 And 3 Control Circuit
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition CO.0 Open circuit or short circuit to vehicle body ground CC.1...
Page 116: Dtc P2002: Particulate Trap Efficiency Below Threshold Malfunction
The parameters must be reinitialised after any procedure is carried out on the diesel particulate filter. Use command “Initialize Diesel PF data” on SUZUKI scan tool, and diesel particulate filter after-sales regeneration referring to “Diesel Particulate Filter After-sales Regeneration Procedure: in Section 1C”...
Page 117: Dtc P2031: Exhaust Gas Temperature Sensor Circuit Malfunction
Check for the presence of ground on “C87-1” wire of the exhaust gas temperature sensor 2 connector. Check the exhaust gas temperature sensor 2 resistance between “C87-1” and “C87-2” terminals of the connector according to parameter “Diesel PF in Temp” on Data List of SUZUKI scan tool. Diesel particulate filter upstream temperature: 106000 Ω...
Page 118: Dtc P2120: Throttle/Pedal Position Sensor/Switch "D" Circuit Malfunction
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition CO.0 Open circuit or short circuit to vehicle body ground CC.1...
Page 119 Engine General Information and Diagnosis: 1A-87 Troubleshooting for CC.1: Short circuit to +12 V NOTE Priorities when dealing with a number of faults: If fault “DTC P0225: Accelerator Pedal Position (APP) Sensor Assembly / Switch “C” Circuit Malfunction: ” is present at the same time, check that the sensor is connected correctly. Check the connections of the accelerator pedal position (APP) sensor.
Page 120: Dtc P2141: Exhaust Gas Recirculation Throttle Control Circuit Low Malfunction
Perform Test 7 referring to “Test 7: Exhaust gas recirculation valve: ”. • If the fault if still present, perform “Initialization EGR valve data” on SUZUKI scan tool to reintialise the operating values of the valve and launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: in Section 1C”).
Page 121: Dtc P2142: Exhaust Gas Recirculation Throttle Control Circuit High Malfunction
Perform Test 7 referring to “Test 7: Exhaust gas recirculation valve: ”. • If the fault if still present, perform “Initialization EGR valve data” on SUZUKI scan tool to reinitialize the operating values of the valve and launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: in Section 1C”).
Page 122: Dtc P2264: Water In Fuel Sensor Circuit Malfunction
1A-90 Engine General Information and Diagnosis: DTC P2264: Water in Fuel Sensor Circuit Malfunction S5JB0B1104140 NOTE Conditions for applying fault finding procedures to stored faults: The fault is declared present after the engine is started or following a road test. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL): in Section 9A”.
Page 123: Dtc P2413: Exhaust Gas Recirculation System Performance Malfunction
Perform Test 7 referring to “Test 7: Exhaust gas recirculation valve: ”. • If the fault if still present, perform “Initialization EGR valve data” on SUZUKI scan tool to reinitialize the operating values of the valve and launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: in Section 1C”).
Page 124: Dtc P242A: Turbine Inlet Temperature Sensor And Wake-Up Sensor Failure Malfunction
Check the exhaust gas temperature sensor 1 resistance between “C73-1” and “C73-2” terminals of the yellow connector according to parameter “Turbo upst temp.” on Data List of SUZUKI scan tool. exhaust gas temperature sensor 1 resistance: 1572 – 1972 Ω at 400 °C, 752 °F 675 –...
Page 125: Dtc P242B: Turbine Inlet Temperature Sensor Regulation Failure Malfunction
Check for the presence of ground on “C73-2” wire of the exhaust gas temperature sensor 1 connector. Check the sensor resistance between “C73-1” and “C73-2” terminals of the connector according to parameter “Turbo upst temp.” on Data List of SUZUKI scan tool. exhaust gas temperature sensor 1 resistance: 1572 –...
Page 126: Dtc P2600: Coolant Pump Control Circuit / Open Malfunction
• Conditions for applying the fault finding procedure to stored faults: The fault is declared present after ignition switch has been turned OFF and after an interval of 40 seconds, or after output test “Turbo charger cooling pump” on SUZUKI scan tool. • If the fault is present: –...
Page 127: Dtc P3031: Temperature Threshold Overshoot Failures During After-Sales Regeneration
Before carrying out the procedures associated with customer complaints, check for the absence of faults and the conformity (or otherwise) of the parameters and statuses, using SUZUKI scan tool. If the customer complaint is not eliminated, then proceed according to the corresponding fault finding chart.
Page 128 1A-96 Engine General Information and Diagnosis: Table 1: No dialogue with the ECM S5JB0B1104154 Troubleshooting Try the scan tool on another vehicle. Check the ECM earth point. Check: • Check the connection between the scan tool and the data link connector •...
Page 129 Go to Step 3. Carry out the required Check that engine speed reaches 250 rpm under the starter repairs. motor, as displayed on SUZUKI scan tool. Is the starter motor working properly? Check ECM for DTC(s). Go to “DTC P0335: Go to Step 4.
Page 130 Check the conformity of the air flow signal “MAF” on Data List of SUZUKI scan tool or perform test 3 referring to “Test 3: Checking the turbocharged air inlet circuit: ”. Is there in good condition? If the injection noise occur at all engine speeds: End of fault finding.
Page 131 Engine General Information and Diagnosis: 1A-99 Table 5: Poor Performance with Smoke S5JB0B1104158 NOTE In the case of engine overheating to more than 119 °C, 246°F the computer deliberately limits the fuel flow (overheating warning light illuminates from 115 °C, 239 °F). Troubleshooting Step Action...
Page 132 ”. • The oil vapour rebreathing system is connected. • The fuel flow actuator (blocked/seized, perform output test “IMV/Flow actuator” on SUZUKI scan tool.). • The engine timing (and the position of the high pressure pump sprocket). Is there in good condition? Are the compressions correct? End of fault finding.
Page 133 Engine General Information and Diagnosis: 1A-101 Table 7: Irregular Engine Operation S5JB0B1104160 Troubleshooting Step Action If the engine races during gear changes, check, if there is a Go to Step 2. Carry out the required floor carpet, that this is not blocking the accelerator pedal, repairs.
Page 134 1A-102 Engine General Information and Diagnosis: Table 8: Fuel System Leaks S5JB0B1104161 WARNING When servicing fuel system, be sure to observe WARNING in “Precautions on Fuel System Service: in Section 1G” to reduce the risk of fire and personal injury. Procedure for checking for an external leak on the fuel circuit: Clean away traces of grease with clean thinner and wipe the part or the parts concerned with cleaning cloths.
Page 135 Is there in good condition? Check the conformity of the fuel injector calibration codes Go to Step 6. Register the fuel injector using SUZUKI scan tool. calibration code into ECM referring to Is it correct codes? “Registration Procedure...
Page 136: Fault Finding-Tests
Substitute a known- pressure”, “Engine speed” and “Metering unit duty” on Data good ECM and recheck. List of SUZUKI scan tool for 30 seconds. Does the fuel pressure difference between min. and max. less than 50 bar? Table 10: Oil leaks from the turbocharger...
Page 137 Engine General Information and Diagnosis: 1A-105 Test 1: Exhaust system check S5JB0B1104166 WARNING To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. Step Action Engine stopped: Check that the muffler tail end is not...
Page 138: Test 2: Low Pressure Circuit Check
1A-106 Engine General Information and Diagnosis: Test 2: Low pressure circuit check S5JB0B1104167 Step Action Check the fuel filter: Go to Step 2. Repair or replace the defective part. • Conformity of the fuel filter. • Positioning and degree of contamination of the filter cartridge.
Page 139: Test 3: Checking The Turbocharged Air Inlet Circuit
Engine General Information and Diagnosis: 1A-107 Test 3: Checking the turbocharged air inlet circuit S5JB0B1104168 Step Action Engine stopped: Check the low and high pressure air circuits Go to Step 2. Carry out the necessary for leaks (air leaks in or out, before and after the repairs.
Page 140: Test 4: Maf Sensor
1A-108 Engine General Information and Diagnosis: Test 4: MAF sensor S5JB0B1104169 Step Action BREAKAGE OF ELECTRICAL COMPONENTS: Go to Step 2. Replace the MAF Visual inspection: remove the MAF sensor assembly with sensor assembly with IAT sensor, the components must not be broken IAT sensor if necessary.
Page 141: Test 5: Variable Geometry Turbocharger Control
Engine General Information and Diagnosis: 1A-109 Test 5: Variable geometry turbocharger control S5JB0B1104170 Step Action Engine stopped: Replace the Go to Step 2. Check manually if the variable geometry control rod is turbocharger. blocked. Is the rod blocked? At idle speed, with boost pressure control solenoid valve The turbocharging Go to Step 3.
Page 142: Test 6: Rotating Part Of A Turbocharger
1A-110 Engine General Information and Diagnosis: Test 6: Rotating part of a turbocharger S5JB0B1104171 Step Action With the engine cold and stopped, remove the air inlet duct Go to Step 2. Replace the from the turbocharger, check manually if the compressor turbocharger.
Page 143: Test 7: Exhaust Gas Recirculation Valve
• Switch ON the ignition again. • Check the movement of the valve with displaying “EGR position sensor” on Data List of SUZUKI scan tool (0 to 2.5 mm travel for an opening cyclic ratio of 40% and when fully open, ~ 5 mm, for an opening cyclic ratio of 95%).
Page 144: Test 8: Injector Malfunction
• With the engine at idle speed, coolant temperature > 80 °C, 176 °F, display the each injector fuel flow correction values “Cyl # FF Correction” on Data List of SUZUKI scan tool. The normal value for fuel flow correction for an injector is ±...
Page 145 Engine General Information and Diagnosis: 1A-113 Step Action CONFIRMATION OF THE FAULT FINDING FOR THE Go to step 4. Repair as necessary. CORRECTION OF THE FLOW, INJECTOR BY INJECTOR: Clear the fault(s) and carry out a test with the engine at idle speed, coolant temperature >...
Page 146: Special Tools And Equipment
”). Is there in good condition? Special Tools and Equipment Special Tool S5JB0B1108001 09912–96540 SUZUKI scan tool Injector flow measuring kit — Mot. 1711 This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5.
Page 147: Aux. Emission Control Devices
“5”, confirm EGR valve operates fully open. b) When disconnecting battery from EGR valve, confirm EGR valve operates fully close. I5JB0B120010-01 CAUTION When replacing EGR valve, perform “Initialize EGR valve data” mode of SUZUKI scan tool referring to “EGR Valve Data Initialization”.
Page 148 1B-2 Aux. Emission Control Devices: 3) Remove exhaust gas temperature sensor 1 (1), 2 (2) and/or 3 (3). 1, (a) 2, (b) 3, (c) I5JB0B120013-01 4. Battery 5. Diesel particulate filter I5JB0B120012-01 2) Connect exhaust gas temperature sensor 1, 2 and/or 4.
Page 149: Exhaust Gas Temperature Sensor 1, 2 And 3 Inspection
Aux. Emission Control Devices: 1B-3 Exhaust Gas Temperature Sensor 1, 2 and 3 Diesel Particulate Filter Differential Pressure Inspection Sensor Removal and Installation S5JB0B1206008 S5JB0B1206009 Removal 1) Disconnect negative (–) cable at battery. 1) Disconnect negative (–) cable at battery. 2) Disconnect exhaust gas temperature sensor 1, 2 and/or 3 connectors.
Page 150: Engine Electrical Devices
1C-1 Engine Electrical Devices: Engine Electrical Devices Precautions Precaution in Replacing ECM – Fuel injector calibration codes S5JB0B1300001 – EGR/Inlet throttle valve data • If ECM is replaced with new one or a used one, the – Diesel PF (Diesel Particulate Filter) data engine cannot be started unless the key verification •...
Page 151: Repair Instructions
1) Shift transmission into Neutral. 2) Start engine and warm it up to normal operating temperature. 3) Turn all electrical loads OFF. 4) Using SUZUKI scan tool, verify that idle speed is within specification. Engine speed 750 – 850 rpm 5) If not, refer to “SUZUKI Scan Tool Operator’s...
Page 152: Registration Procedure For The Fuel Injector Calibration Code
1C-3 Engine Electrical Devices: Registration Procedure for the Fuel Injector 1) Register fuel injector calibration codes as follows. Calibration Code a) Connect SUZUKI scan tool to DLC with ignition S5JB0B1306006 switch OFF. After one or more fuel injector(s) is replaced, register the b) Turn IG switch to ON position.
Page 153: Inlet Throttle Valve Data Initialization
Engine Electrical Devices: 1C-4 Inlet Throttle Valve Data Initialization Diesel Particulate Filter After-sales S5JB0B1306026 Regeneration Procedure 1) Connect SUZUKI scan tool to data link connector S5JB0B1306028 (DLC) (1) with ignition switch OFF. WARNING Special tool During after-sales regeneration, exhaust gas...
Page 154: Glow Plug Removal And Installation
7) Confirm “Diesel PF inlet Temp” under “Data list” of SUZUKI scan tool, and wait until it decreases to 200 °C (392 °F) or less. 8) Stop engine. 9) Turn ignition switch to OFF position, and wait for 10 minutes or more.
Page 155: Glow Plug Inspection
Removal and Installation: ”. • Do not expose accelerator pedal position (APP) sensor assembly to excessive shock 2) Connect SUZUKI scan tool to DLC with ignition like a dropping it. If accelerator pedal switch turned OFF. position (APP) sensor assembly has been...
Page 156: Accelerator Pedal Position (App) Sensor Assembly Inspection
1C-7 Engine Electrical Devices: Installation 2) For accelerator pedal position (APP) sensor (sub), Reverse removal procedure for installation noting the arrange 3 new 1.5 V batteries (1) in series (check following. that total voltage is 4.7 – 5.0 V) and connect its positive terminal to “Vin 2”...
Page 157: Engine Coolant Temperature (Ect) Sensor Removal And Installation
Engine Electrical Devices: 1C-8 Engine Coolant Temperature (ECT) Sensor Engine Coolant Temperature (ECT) Sensor Removal and Installation Inspection S5JB0B1306011 S5JB0B1306012 Removal 1) Remove ECT sensor referring to “Engine Coolant 1) Disconnect negative cable at battery. Temperature (ECT) Sensor Removal and Installation: ”.
Page 158: Camshaft Position (Cmp) Sensor Removal And Installation
1C-9 Engine Electrical Devices: Camshaft Position (CMP) Sensor Removal and Crankshaft Position (CKP) Sensor (Engine Installation Speed Sensor) Removal and Installation S5JB0B1306013 S5JB0B1306014 Removal Removal 1) Disconnect negative cable at battery. 1) Disconnect negative cable at battery. 2) Remove injector cover referring to “Cylinder Head 2) Hoist vehicle.
Page 159: Crankshaft Position (Ckp) (Engine Speed Sensor) Sensor Inspection
Engine Electrical Devices: 1C-10 Crankshaft Position (CKP) (Engine Speed Boost Pressure Sensor Removal and Sensor) Sensor Inspection Installation S5JB0B1306015 S5JB0B1306020 Removal 1) Remove CKP sensor referring to “Crankshaft Position (CKP) Sensor (Engine Speed Sensor) 1) Disconnect negative cable at battery. Removal and Installation: ”.
Page 160: Pre-Heating Unit Removal And Installation
1C-11 Engine Electrical Devices: Boost Pressure Control Solenoid Valve 3) Check that there is no continuity between terminal “c” and “d”. Removal and Installation If there is continuity, replace relay. S5JB0B1306029 Removal 4) Connect battery positive (+) terminal to terminal “b” 1) Disconnect negative cable at battery.
Page 161: Boost Pressure Control Solenoid Valve Inspection
Engine Electrical Devices: 1C-12 Boost Pressure Control Solenoid Valve Turbocharger Electric Water Pump Removal Inspection and Installation S5JB0B1306030 S5JB0B1306031 Removal 1) Remove boost pressure control solenoid valve referring to “Boost Pressure Control Solenoid Valve 1) Disconnect negative cable at battery. Removal and Installation: ”.
Page 162: Mass Air Flow (Maf) And Intake Air Temperature (Iat) Removal And Installation
• Tighten MAF and IAT sensor screws to specified Do not disassembly inlet throttle valve. torque. Tightening torque 1) Connect SUZUKI scan tool to data link connector MAF and IAT sensor screw: 6 N·m (0.6 kgf-m, 4.5 (DLC) with ignition switch OFF. lb-ft) 2) Check that no abnormality is detected in ECM.
Page 163: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Special Tool S5JB0B1308001 09917–47011 SUZUKI scan tool Vacuum pump gauge — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3.
Page 164: Engine Mechanical
1D-1 Engine Mechanical: Engine Mechanical Diagnostic Information and Procedures Compression Check 5) Remove all glow plugs referring to “Glow Plug S5JB0B1404001 Removal and Installation: in Section 1C”. Check compression pressure on all 4 cylinders as 6) Connect negative (–) cable at battery. follows: 7) Install special tools into glow plug hole.
Page 165: Valve Lash (Clearance) Inspection
Engine Mechanical: 1D-2 9) Crank engine with fully charged battery, and read the If valve lash (clearance) is out of specification, highest pressure on compression gauge. record valve lash (clearance) and adjust it to specification referring to “Valve Lash (Clearance) NOTE Adjustment: ”.
Page 166: Valve Lash (Clearance) Adjustment
1D-3 Engine Mechanical: Valve Lash (Clearance) Adjustment 5) Select new tappet with a thickness as close as S5JB0B1404004 possible to calculated value. 1) Measure valve lash (clearance) referring to “Valve Lash (Clearance) Inspection: ”. Available new tappet Thickness 2) Remove tappet referring to “Camshaft and Tappet mm (in.) Removal and Installation: ”.
Page 167: Repair Instructions
Engine Mechanical: 1D-4 Repair Instructions Air Cleaner Components S5JB0B1406072 I5JB0B140143-01 1. MAF sensor 3. Air cleaner filter 5. Gasket 2. Air cleaner upper case 4. Air cleaner lower case : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) Air Cleaner Removal and Installation Air Cleaner Filter Removal and Installation S5JB0B1406073 S5JB0B1406001...
Page 168: Air Cleaner Filter Inspection And Cleaning
1D-5 Engine Mechanical: Air Cleaner Filter Inspection and Cleaning S5JB0B1406002 Inspection Check air cleaner filter for dirt. Replace excessive dirty filter. Cleaning Blow off dust by compressed air from air outlet side of filter. I2RH0B140150-01 Intercooler and Air Intake Pipe Components S5JB0B1406045 I5JB0B140006-02 1.
Page 169: Air Intake Pipe Removal And Installation
Engine Mechanical: 1D-6 Air intake Pipe Removal and Installation 3) Disconnect intercooler inlet hose (1) and outlet hose (2) from intercooler (4). S5JB0B1406074 4) Remove intercooler brackets (3) and intercooler (4). Removal 1) Disconnect negative (–) cable at battery. 2) Disconnect boost presser sensor connector (1) and intake throttle valve connector (2).
Page 170: Cylinder Head Cover Components
1D-7 Engine Mechanical: Cylinder Head Cover Components S5JB0B1406047 I5JB0B140010-01 1. Cylinder head cover 3. Cylinder head cover gasket : Do not reuse. 2. Cylinder head cover bolt gasket : Tighten 12 N⋅m (1.2 kgf-m, 9.0 lb-ft) by the specified procedure. Cylinder Head Cover Removal and Installation 5) Disconnect ventilation hose No.3 (4) from oil vapor S5JB0B1406048...
Page 171 Engine Mechanical: 1D-8 8) Remove cylinder head cover (1), cylinder head cover 3) Tighten cylinder head cover bolts evenly and gasket (2) and cylinder head cover bolt gaskets (3). gradually in numerical order (“1” through “3”) by repeating tightening sequence two or three times until specified torque is obtained.
Page 172: Oil Separator Components
1D-9 Engine Mechanical: 9) Install timing belt cover No.2 (1) and harness bracket. Tightening torque Timing belt cover No.2 bolt (a): 55 N·m (5.5 kgf- m, 40.0 lb-ft) I5JB0B140018-01 Oil Separator Components S5JB0B1406075 I5JB0B140145-02 1. Ventilation hose No.2 6. Ventilation hose No.1 : 25 N⋅m (2.5 kgf-m, 18.5 lb-ft) 2.
Page 173: Vacuum Pump Removal And Installation
Engine Mechanical: 1D-10 Installation Installation 1) Install oil separator (5) to cylinder head. 1) Install vacuum pump (1) to cylinder head with new gasket. Tightening torque Oil separator bolt (a): 25 N·m (2.5 kgf-m, 18.5 lb- Tightening torque Vacuum pump bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft) 2) Connect ventilation hose No.2 (1), oil separator return hose (2), flesh air vent hose (3) and ventilation...
Page 174: Timing Belt And Belt Tensioner Components
1D-11 Engine Mechanical: Timing Belt and Belt Tensioner Components S5JB0B1406050 I5JB0B140021-01 1. Timing belt : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft) 2. Timing belt cover No.1 : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft) 3. Camshaft pulley : Tighten 40 N⋅m (4.0 kgf-m, 29.0 lb-ft) and 110° by the specified procedure. 4.
Page 175: Timing Belt And Belt Tensioner Removal And Installation
Engine Mechanical: 1D-12 Timing Belt and Belt Tensioner Removal and 3) Turn crankshaft pulley clockwise, and stop turning crankshaft pulley immediately before mark (2) of Installation camshaft pulley (3) matches with mark (1) of belt S5JB0B1406051 inner cover. CAUTION • Never turn injection pump pulley counterclockwise.
Page 176 1D-13 Engine Mechanical: 5) Turn crankshaft pulley clockwise until crankshaft 7) Remove tensioner pulley (1) and timing belt (2). touches special tool (A). 6) Remove crankshaft pulley as follows. a) Lock ring gear (2) of flywheel by inserting flat head screw driver (1) or the like into hole of clutch housing.
Page 177 Engine Mechanical: 1D-14 Installation 4) Install crankshaft timing belt pulley (1), if removed. 1) Confirm that special tool (A) is inserted into TDC pin 5) Install timing belt tensioner plate (2), if removed. hole. Tightening torque If special tool (A) is removed, insert special tool (A) Timing belt tensioner plate bolt (a): 10 N·m (1.0 referring to Step 5) of “Installation”...
Page 178 1D-15 Engine Mechanical: 8) Remove special tool (A) from TDC pin hole. d) Measure timing belt tension using special tool as follows. 9) Adjust timing belt tension as follows. a) Tighten crankshaft pulley bolt to crankshaft Special tool temporarily by hand. (G): 09919–76540 b) Install adjusting bolt (1) to timing belt tensioner Place sensor (2) of special tool (G) on the...
Page 179 Engine Mechanical: 1D-16 Turn crankshaft two revolutions clockwise until n) Confirm number of timing belt teeth between mark (1) of camshaft pulley (2) matches with mark (1) of camshaft pulley (2) and mark (3) of mark (3) of timing belt inner cover (4). injection pump pulley (4) is 29.
Page 180: Timing Belt And Belt Tensioner Inspection
1D-17 Engine Mechanical: Timing Belt and Belt Tensioner Inspection 11) Apply sealant “A” to thread of TDC pin cap (1), and tighten TDC pin cap as specified torque. S5JB0B1406052 Tightening torque Timing belt TDC pin cap (a): 20 N·m (2.0 kgf-m, 14.5 lb-ft) Inspect timing belt for wear or crack.Replace it as necessary.
Page 181: Engine Mounting Components
Engine Mechanical: 1D-18 Engine Mounting Components S5JB0B1406011 I5JB0B140039-01 A: Forward 5. Engine left mounting bracket damper 1. Engine right mounting bracket 6. Engine rear mounting 2. Engine right mounting 7. Engine rear mounting bracket : Be sure to align dowel pin with dowel hole of engine right mounting bracket. 3.
Page 182: Engine Assembly Removal And Installation
1D-19 Engine Mechanical: Engine Assembly Removal and Installation 11) Disconnect P/S suction hose and low pressure S5JB0B1406053 return hose from P/S fluid reservoir referring to “P/S WARNING Hose / Pipe Components: in Section 6C”. 12) Disconnect MAF sensor connector (1), and remove Before servicing fuel system, be sure to air cleaner case (2) and turbocharger inlet hose (3).
Page 183 Engine Mechanical: 1D-20 15) Remove relay box (1), fuse box No.1 (2) and boost pressure control solenoid valve (3) from vehicle body. I5JB0B140042-01...
Page 184 1D-21 Engine Mechanical: 16) Disconnect the following hoses. CAUTION After disconnecting, plug fuel line with plug cap immediately referring to “Precautions on Fuel System Service: in Section 1G”. • Radiator inlet hose No.1 (1) from radiator inlet pipe • Radiator outlet hoses No.1 (2) from radiator •...
Page 185 Engine Mechanical: 1D-22 21) Before lowering engine with transmission and front CAUTION suspension frame from engine compartment, Before lowering engine, in order to avoid recheck to make sure all hoses, electric wires and damage to A/C compressor, make clearance cables are disconnected. by rising them.
Page 186 1D-23 Engine Mechanical: 7) Connect connectors and wire harness disconnected 11) Connect P/S suction hose and low pressure return in removal procedure. hose referring to “P/S Hose / Pipe Components: in Section 6C”. 8) Connect hoses disconnected in removal procedure. 12) Install A/C compressor to its bracket referring to 9) Install intercooler inlet pipe (1).
Page 187: Egr Valve Components
Engine Mechanical: 1D-24 EGR Valve Components S5JB0B1406054 I5JB0B140047-06 1. EGR valve 5. EGR cooler : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Gasket 6-1. EGR pipe stiffener bolt (with washer) : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 3-1. Clamp (type A) 6-2.
Page 188: Egr Valve Removal And Installation
Tightening torque EGR valve bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft) When replacing EGR valve, perform “Initialize EGR valve data” mode of SUZUKI 2) Connect EGR valve connector (2) and EGR pipe (3) scan tool referring to “EGR Valve Data to EGR valve.
Page 189: Egr Pipe And Egr Cooler Removal And Installation
Engine Mechanical: 1D-26 EGR Pipe and EGR Cooler Removal and 9) Remove EGR pipe as follows, if necessary. Installation CAUTION S5JB0B1406055 EGR pipe clamp has two types as shown in Removal figure. And, Type A is disposable one and it 1) Remove engine assembly referring to “Engine has not already been supplied.
Page 190 1D-27 Engine Mechanical: Installation 2) Install EGR pipe as follows, if necessary. 1) Install EGR cooler (1), EGR pipe (2) and EGR joint • For Type A (3) with new gaskets. Type A EGR pipe clamp is disposable one, install new Type B EGR pipe clamp as below-mentioned.
Page 191: Turbocharger Components
Engine Mechanical: 1D-28 Turbocharger Components S5JB0B1406056 I5JB0B140052-05 1. Turbocharger assembly 8. Turbocharger inlet pipe : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft) : Do not disassemble. 2. Turbocharger lubrication pipe 9. Copper ring : 44 N⋅m (4.4 kgf-m, 32.0 lb-ft) 3. Oil return pipe No.1 10.
Page 192 1D-29 Engine Mechanical: 6) Remove exhaust manifold heat shield (4) from 12) Remove turbocharger inlet pipe (5) from exhaust manifold. turbocharger. 7) Remove oil return pipe No.1 (5) and No.2 (6). 13) Remove turbocharger lubrication pipe (1), turbocharger lubrication pipe union nut (2), 8) Disconnect turbocharger lubrication pipe (7) and turbocharger water inlet pipe (3) and turbochanger lubrication pipe stiffeners from cylinder block.
Page 193 Engine Mechanical: 1D-30 2) Install turbocharger (1) to exhaust manifold with new 11) Connect turbocharger outlet hose (10) to gasket. turbocharger (1). Tightening torque Tightening torque Turbocharger nut (a): 37 N·m (3.7 kgf-m, 27.0 lb- Turbocharger outlet hose clamp (turbocharger side) (j): 5 N·m (0.5 kgf-m, 4.0 lb-ft) 3) Fit turbocharger inlet pipe (11) to turbocharger and install turbocharger stiffener (2).
Page 194: Turbocharger Assembly Inspection
1D-31 Engine Mechanical: Turbocharger Assembly Inspection Turbocharger Assembly Adjustment S5JB0B1406069 S5JB0B1406070 1) Loosen lock nut (1). Turbocharger 2) Tighten or loose adjusting wheel (2) so as to adjust Rotate turbine shaft (1) by hand and verify that it turns stroke of boost presser control valve rod with smoothly without any abnormal noise and excessive applying specified pressure.
Page 195: Intake Manifold And Exhaust Manifold Components
Engine Mechanical: 1D-32 Intake Manifold and Exhaust Manifold Components S5JB0B1406058 I5JB0B140057-01 1. Intake manifold 3. Intake and exhaust manifold gasket : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 2. Exhaust manifold 4. Exhaust manifold heat shield : Do not reuse. 3. Intake and exhaust manifold gasket : Tighten 28 N⋅m (0.8 kgf-m, 6.0 lb-ft) by the specified procedure.
Page 196: Intake Manifold And Exhaust Manifold Removal And Installation
1D-33 Engine Mechanical: Intake Manifold and Exhaust Manifold Removal Installation and Installation 1) Install exhaust gas temperature sensor-1 to exhaust S5JB0B1406059 manifold “Exhaust Gas Temperature Sensor 1, 2 and 3 Removal and Installation: in Section 1B”, if Removal removed. 1) Remove turbocharger assembly referring to 2) Install intake and exhaust manifolds as follows.
Page 197: Camshaft And Tappet Components
Engine Mechanical: 1D-34 Camshaft and Tappet Components S5JB0B1406060 I5JB0B140062-02 1. Camshaft : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) : Apply engine oil to sliding surface. 2. Tappet : Tighten 20 N⋅m (2.0 kgf-m, 14.5 lb-ft) by the specified : Apply engine oil to sliding surface. procedure.
Page 198: Camshaft And Tappet Removal And Installation
1D-35 Engine Mechanical: Camshaft and Tappet Removal and Installation 9) Remove camshaft housing and camshaft from S5JB0B1406061 cylinder head. 10) Remove camshaft oil seal from camshaft. Removal 11) Remove tappet (1) from cylinder head. 1) Remove engine assembly referring to “Engine Assembly Removal and Installation: ”.
Page 199 Engine Mechanical: 1D-36 2) Install camshaft to cylinder head as follows. e) Tighten camshaft pulley bolt temporarily by hand. a) Apply engine oil to sliding surface of each camshaft and camshaft journal. Turn camshaft pulley clockwise, and stop turning crankshaft immediately before mark (1) of b) Fit camshaft (1) to cylinder head (2).
Page 200 1D-37 Engine Mechanical: iii) Fit camshaft holder to cylinder head. 5) Install camshaft pulley (2) to camshaft (4) aligning key (1) to groove (3). iv) Apply “A” to camshaft housing bolt thread. v) Tighten camshaft housing bolts evenly and gradually in numerical order (“1” through “10”) by repeating tightening sequence two or three times until specified torque is obtained.
Page 201: Camshaft And Tappet Inspection
Engine Mechanical: 1D-38 Camshaft and Tappet Inspection Cam Wear S5JB0B1406023 Using a micrometer, measure cam height “a”. If measured height underruns its limit, replace camshaft. Camshaft • Check journals and cam faces for wear or damage. Camshaft Journal Wear If any malcondition is found, replace camshaft. Check camshaft journals and camshaft housings for pitting, scratches, wear or damage.
Page 202: Valve And Cylinder Head Assembly Components
1D-39 Engine Mechanical: Measure cylinder head bore and tappet outside diameter to determine cylinder head-to-tappet clearance. If measured clearance is out of specification, replace tappet and/or cylinder head. Cylinder head to tappet clearance 0.015 – 0.074 mm (0.00059 – 0.00291 in.) Tappet outside diameter [A] 34.965 –...
Page 203: Valve And Cylinder Head Assembly Removal And Installation
Engine Mechanical: 1D-40 3. Valve spring 8. Valve guide : Tighten 30 N⋅m (3.0 kgf-m, 22.0 lb-ft), 100°, 0 N⋅m (0.0 kgf-m, 0.0 lb-ft), 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) and 213° by the specified procedure. 4. Valve stem seat 9.
Page 204 1D-41 Engine Mechanical: Installation 13) Install cylinder head to cylinder block, and tighten new cylinder head bolts as follows. 1) Remove oil, old sealant and dust from bolt holes and mating surface of cylinder head and cylinder block. a) Tighten cylinder head bolts to 30 N⋅m (3.0 kgf-m, 22.0 lb-ft) according to numerical order (“1”...
Page 205: Valve And Cylinder Head Assembly Inspection
Engine Mechanical: 1D-42 Valve and Cylinder Head Assembly Inspection 2) Release special tool and remove spring retainer, S5JB0B1406063 valve spring and spring seat from cylinder head. 3) Remove valve from combustion chamber side. Cylinder Head Assembly Specifications (for Reference) Valve and cylinder head specification Item Specification Valve protrusion...
Page 206 1D-43 Engine Mechanical: 5) Remove stem seal (1) from valve guide using special a) Install fitting (2) to valve stem in order to prevent tool. stem seal from damage, and install stem seal (1) to valve stem. Special tool (A): 09916–48110 NOTE •...
Page 207: Valves And Valve Guides Inspection
Engine Mechanical: 1D-44 3) Install spring seat, valve spring and spring retainer. 4) Using special tool (A) and (B), compress valve spring. And, fit two valve cotters (1) into groove of valve stem using special tool (C) as shown in figure. Special tool (A): 09916–19030 (B): 09916–14521...
Page 208 1D-45 Engine Mechanical: Valve Valve seat Item Specification Visual inspection 1.8 mm Valve seat width “a” (0.071 in.) • Remove all carbon from valves. Valve seat angle “b” 89.5° • Inspect each valve for wear, burn or distortion at its 36.967 –...
Page 209: Cylinder Head Inspection
Engine Mechanical: 1D-46 Cylinder Head Inspection Cylinder Head and Related Parts Specification (for S5JB0B1406028 Reference) • Remove all carbon deposits from combustion Cylinder head with valve guide chambers. Item Specification NOTE 80.65 – 81.45 mm Valve guide position “a” (3.1752 – 3.2066 in.) Do not use any sharp-edged tool to scrape Valve guide angle “b”...
Page 210: Valve Spring Inspection
1D-47 Engine Mechanical: Cylinder head Cylinder head gasket Item Specification Item Specification 161.00 – 164.50 mm Cylinder head gasket 1.27 – 1.37 mm Cylinder head height “a” (6.3386 – 6.4763 in.) thickness “a” (0.0500 – 0.0539 in.) 36.877 – 36.907 mm Valve seat Intake valve (1.45185 –...
Page 211: Piston, Piston Ring, Connecting Rod And Cylinder Components
Engine Mechanical: 1D-48 Piston, Piston Ring, Connecting Rod and Cylinder Components S5JB0B1406030 I5JB0B140096-01 1. Top ring 8. Piston pin 2. 2nd ring 9. Piston pin circlip 3. Oil ring : Tighten 20 N⋅m (2.0 kgf-m, 14.5 lb-ft) and 40° by the specified procedure. 4.
Page 212 1D-49 Engine Mechanical: 6) Remove connecting rod bearing caps. Installation 7) Decarbon top of cylinder bore before removing 1) Decarbonize piston head and ring grooves using a piston from cylinder. suitable tool. 8) Push piston and connecting rod assembly out 2) Install piston ring to piston noting the following, if through the top of cylinder bore.
Page 213 Engine Mechanical: 1D-50 b) Set connecting rod (1) and bearing (2) to special 5) Apply engine oil to pistons, rings, cylinder walls, tool (A) and (B) as shown in figure. connecting rod bearings and crank pins. c) Install connecting rod bearing to connecting rod NOTE by pushing special tool (B) as shown in figure.
Page 214: Cylinders, Pistons And Piston Rings Inspection
1D-51 Engine Mechanical: 8) Install piston and connecting rod assembly into 10) Turn crankshaft clockwise until key groove (1) cylinder bore with matching cylinder number marked comes in middle of two ribs (2) and install special in removal. Use special tool to compress rings. tool (A) to TDC pin hole.
Page 215: Piston Pins And Connecting Rods Inspection
Engine Mechanical: 1D-52 Piston and Related Parts Specifications (for Piston diameter As indicated in the figure, piston diameter should be Reference) measured at a position “a” from piston skirt end in the Piston ring direction perpendicular to piston pin. Item Specification Piston diameter specification 2.47 –...
Page 216: Crank Pin And Connecting Rod Bearings Inspection
1D-53 Engine Mechanical: Crank Pin and Connecting Rod Bearings Connecting Rod Inspection Connecting rod thrust play S5JB0B1406035 Check big-end of connecting rod for thrust play, with rod Crank Pin Diameter fitted and connected to its crank pin in the normal Inspect crank pin for uneven wear or damage.
Page 217 Engine Mechanical: 1D-54 4) Install bearing cap referring to connecting rod and 3) Check connecting rod length referring to bearing cap referring to Step 9) of “Installation” under “Connecting Rod and Related Parts Specification “Piston, Piston Ring and Connecting Rod Removal (for Reference)”...
Page 218: Main Bearing, Crankshaft And Cylinder Block Component
1D-55 Engine Mechanical: d) Select new piston so that distance “e” is within range of distance “d” of new piston. NOTE Piston class (1) is marked on piston top as shown in figure. Available new piston class Piston class (1) Distance “d”...
Page 219: Main Bearing, Crankshaft And Cylinder Block Removal And Installation
Engine Mechanical: 1D-56 Main Bearing, Crankshaft and Cylinder Block 5) Remove main bearing caps (No.2 through No.5) and crankshaft from cylinder block. Removal and Installation S5JB0B1406066 6) Remove main bearings (1) and thrust bearings (2). Removal 1) Remove piston and connecting rod referring to “Piston, Piston Ring and Connecting Rod Removal and Installation: ”.
Page 220 1D-57 Engine Mechanical: 8) Remove oil jet as follows, if necessary. Installation a) Pack rag into cylinder in order to prevent swart NOTE from entering. • Use new bearing cap bolts. They are b) Remove spring stop (1) and spring (2) using 7 deformed after tightening once because mm (0.28 in.) diameter drill (4).
Page 221 Engine Mechanical: 1D-58 a) Install plate (1) to cylinder block by head b) Fit main bearing (1) in special tool (A) as shown tightening plate bolts (2). in figure, and then press bearing end “a” until it becomes flush with cylinder block. b) Install guide rod (3) to plate aligning guide rod end with oil jet hole.
Page 222 1D-59 Engine Mechanical: 4) Install oil fresh air vent pipe using special tool as 6) Install thrust bearings (1) to crankshaft journal No.2 follows, if removed. facing its oil groove (2) to outside. Special tool (A): 09914–86510 I5JB0B140127-01 I5JB0B140125-02 7) Apply engine oil to bearings and crankshaft. 1.
Page 223 Engine Mechanical: 1D-60 10) Install main bearing caps in proper position mating 12) Cut excess bearing cap seal that protrudes from cylinder number marked in removal. main bearing cap No.1. 11) Tighten new main bearing cap bolts as follows. 13) Using special tool, install flywheel side crankshaft oil seal as follows.
Page 224: Crankshaft Inspection
1D-61 Engine Mechanical: Crankshaft Inspection Main Bearings Inspection S5JB0B1406038 S5JB0B1406039 Thrust Bearing General Information General Information Service thrust bearing has 4 kinds of bearings differing in • Upper half of bearing (1) has oil groove (2) as shown tolerance. in the figure. Install this half with oil groove to cylinder block.
Page 225: Specifications
Engine Mechanical: 1D-62 4) Install main bearing caps referring to “Main Bearing, Crankshaft and Cylinder Block Removal and Installation: ”. 5) Remove bearing caps and using scale (1) on gauging plastic envelop (2), measure gauging plastic width at its widest point. If clearance exceeds its limit, replace bearing.
Page 226 1D-63 Engine Mechanical: Tightening torque Fastening part Note N⋅m kgf-m lb-ft Turbocharger outlet hose clamp (turbocharger side) Intake and exhaust manifolds nut Tighten 28 N⋅m (0.8 kgf-m, 6.0 lb-ft) by the specified procedure Engine hanger bolt 18.5 Timing belt inner cover bolt Camshaft housing bolt Tighten 20 N⋅m (2.0 kgf-m, 14.5 lb-ft) by the specified procedure...
Page 227: Special Tools And Equipment
Engine Mechanical: 1D-64 Special Tools and Equipment Recommended Service Material S5JB0B1408001 Material SUZUKI recommended product or Specification Note Loctite 518® Loctite 518® — Loctite FRENETANCH® Loctite FRENETANCH® — Loctite rhodorseal 5661® Loctite rhodorseal 5661® — NOTE Required service material is also described in the following.
Page 228 1D-65 Engine Mechanical: 09913–86520 09913–98110 Bearing fitting adapter Connecting rod bearing fitting Mot. 1492-01 (Mot. 1492) 09914–86510 09915–67311 Oil return pipe installer Vacuum gauge Mot. 1551 09916–14521 09916–19030 Valve spring compressor Valve lifter attachment 09916–48110 09916–48120 Valve stem seal pliers Oil jet remover (Mot.
Page 229 Engine Mechanical: 1D-66 09918–08210 09918–26510 Vacuum gauge hose joint Dummy heater plug (F9Q) Mot. 1592 09919–76510 09919–76520 Timing pulley adapter Pre-tensioner adapter Rou. 15-01 Mot. 1705 09919–76530 09919–76540 Timing belt pre-tensioner Belt tension device Mot. 1543 Mot. 1505 09926–37610–001 Bearing puller...
Page 230: Special Tool
1E-1 Engine Lubrication System: Engine Lubrication System General Description Engine Lubrication Description S5JB0B1501001 The oil pump is of a gear type, and mounted downward in the cylinder block. Oil is drawn up through the oil pump strainer and passed through the pump to the heat exchanger, then the oil filter, and the filtered oil flow to each engine part.
Page 231: Repair Instructions
Engine Lubrication System: 1E-2 7) Tighten oil pressure switch (2) to specified torque. Tightening torque 2, (a) Oil pressure switch (a): 38 N·m (3.8 kgf-m, 27.5 lb-ft) 8) Start engine and check oil pressure switch for oil leakage. If oil leakage is found, repair it. 9) Connect oil pressure switch coupler (1).
Page 232: Oil Pan And Oil Pump Strainer Removal And Installation
1E-3 Engine Lubrication System: Oil Pan and Oil Pump Strainer Removal and 7) Loosen lower oil pan stiffener bolts in numerical order (“1” through “4”) as shown in figure, and Installation remove them. S5JB0B1506002 8) Remove lower oil pan stiffener No.1 (1) and No.2 (2). Removal 1) Drain engine oil referring to “Engine Oil and Filter Change: in Section 0B”.
Page 233 Engine Lubrication System: 1E-4 12) Lower suspension member referring to “Front 17) Remove oil pan baffle plate (1), if necessary. Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation: in Section 2B in related manual”. 13) Disconnect ventilation pipe No.1 (1) and ventilation hose No.3 (2) from upper oil pan.
Page 234 1E-5 Engine Lubrication System: Installation 5) Apply sealant to hatched part of cylinder block, gasket holder plate and main bearing cap No.1 as 1) Remove oil, old sealant and dust from mating shown in figure. surface of upper oil pan, cylinder block and lower oil pan.
Page 235 Engine Lubrication System: 1E-6 7) Tighten transmission to engine bolts referring to 11) Install lower oil pan (1) to upper oil pan with new “Manual Transmission Assembly Dismounting and gasket, and tighten lower oil pan bolts evenly and Remounting: in Section 5B”. gradually in numerical order (“1”...
Page 236 1E-7 Engine Lubrication System: 13) Install oil pump strainer No.1 (1) and oil separator 15) Connect lower oil pan hose (1) to oil separator return return pipe (2) with new O-rings. pipe. 16) Connect oil separator return hose (2) to oil separator Tightening torque return pipe.
Page 237: Oil Pump, Oil Pump Chain And Gasket Holder Plate Component
Engine Lubrication System: 1E-8 Oil Pump, Oil Pump Chain and Gasket Holder Plate Component S5JB0B1506003 CAUTION Never disassemble oil pump. Disassembly will spoil its original function. If faulty condition is found, replace it with new one. I5JB0B150043-01 1. Oil pump 4.
Page 238 1E-9 Engine Lubrication System: 5) Remove oil pump chain (1) and oil pump drive 3) Install oil pump drive sprocket (1) with oil pump chain sprocket (2). (2). I5JB0B150032-01 I5JB0B150032-01 6) Remove crankshaft oil seal (1) from gasket holder 4) Install gasket holder plate (1) with new gasket to plate (2).
Page 239: Oil Pump, Oil Pump Chain And Gasket Holder Plate Inspection
Engine Lubrication System: 1E-10 6) Install oil pan and oil pump strainer referring to “Oil Oil Pump Chain Pan and Oil Pump Strainer Removal and Installation: Check oil pump chain for wear or damage. ”. If any malcondition is found, replace oil pump chain. 7) Install new crankshaft oil seal to gasket holder plate using special tool as follows.
Page 240: Specifications
1E-11 Engine Lubrication System: Installation 1) Install heat exchanger (1) with new gasket. Tightening torque Oil filter stand bolt (a): 15 N·m (1.5 kgf-m, 11.0 lb-ft) 2) Connect water hoses (2) to heat exchanger. 3) Install oil filter referring to “Engine Oil and Filter Change: in Section 0B”.
Page 241: Special Tools And Equipment
Engine Lubrication System: 1E-12 Special Tools and Equipment Recommended Service Material S5JB0B1508001 Material SUZUKI recommended product or Specification Note Loctite rhodorseal 5661® Loctite rhodorseal 5661® — Thread lock cement Thread Lock Cement Super 1303B P/No.: 99000–32030 NOTE Required service material is also described in the following.
Page 242: Engine Cooling System
1F-1 Engine Cooling System: Engine Cooling System General Description Cooling System Description The coolant recovery system is standard. The coolant in S5JB0B1601001 the radiator expands with heat, and the coolant is The cooling system consists of a degassing tank, a overflowed to the reservoir.
Page 243: Schematic And Routing Diagram
Engine Cooling System: 1F-2 Schematic and Routing Diagram Coolant Circulation S5JB0B1602001 I5JB0B160001-03 [A]: When thermostat is close 4. Cylinder block and cylinder head 9. Water pump [B]: When thermostat is open 5. Radiator 10. Turbo charger electric water pump 1. Heater core 6.
Page 244: Diagnostic Information And Procedures
1F-3 Engine Cooling System: Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis S5JB0B1604001 Condition Possible cause Correction / Reference Item Engine overheats Loose or timing belt Adjust. (Radiator fan operates) Not enough coolant Check coolant level and add as necessary. Faulty thermostat Replace.
Page 245: Repair Instructions
Engine Cooling System: 1F-4 Repair Instructions Cooling System Components S5JB0B1606001 I5JB0B160013-01 1. Radiator 13. Radiator inlet hose No.2 25. Turbocharger inlet hose 2. Degassing tank cap 14. Radiator outlet hose No.1 26. Heater outlet hose No.1 3. Degassing tank 15. Radiator outlet pipe No.1 27.
Page 246: Coolant Level Check
1F-5 Engine Cooling System: Coolant Level Check 4) Using a pressure tester (1), check system and S5JB0B1606002 degassing tank cap (2) for proper pressure holding WARNING capacity. If replacement of cap is required, use a proper cap To help avoid danger of being burned, do not for this vehicle.
Page 247: Cooling System Refilling
Engine Cooling System: 1F-6 Cooling System Refilling S5JB0B1606005 WARNING To help avoid danger of being burned, do not remove degassing tank cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if cap is taken off too soon.
Page 248: Cooling Water Pipe Or Hose Removal And Installation
1F-7 Engine Cooling System: Thermostat Assembly Removal and Installation 6) Install degassing tank cap (1). S5JB0B1606019 CAUTION Never disassemble thermostat assembly. Disassembly will spoil its original function. If faulty condition is found, replace it with new one. Removal 1) Remove engine assembly referring to “Engine Assembly Removal and Installation: in Section 1D”.
Page 249: Radiator Cooling Fan Motor On-Vehicle Inspection
Engine Cooling System: 1F-8 Radiator Cooling Fan Motor On-Vehicle c) Connect battery negative (–) terminal to terminal “A” of relay. Inspection S5JB0B1606009 d) Check continuity between terminals “C” and “D”. 1) Check main and/or sub fan operation of radiator If there is no continuity, replace relay. cooling fans as follows.
Page 250: Radiator Cooling Fan Assembly Removal And Installation
1F-9 Engine Cooling System: Radiator Cooling Fan Assembly Removal and Cleaning Clean frontal area of radiator cores. Installation S5JB0B1606011 Removal 1) Disconnect negative (–) cable at battery. 2) Disconnect connectors (1) of cooling fan motors. I2RH01160014-01 Radiator Removal and Installation S5JB0B1606013 Removal 1) Disconnect negative cable at battery.
Page 251: Water Pump Inspection
Reference: For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0B1608001 Material SUZUKI recommended product or Specification Note Thread lock cement LOCTITE® FRENETANCH —...
Page 252: Fuel System
1G-1 Fuel System: Fuel System Precautions Precautions on Fuel System Service S5JB0B1700001 WARNING • Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk of fire and personal injury. –...
Page 253 Fuel System: 1G-2 • The fuel system must be checked for leaks after service work referring to “Fuel Leakage Check Procedure: ”. • The fuel system is very sensitive to contamination. The risks caused by the introduction of contamination are: –...
Page 254 1G-3 Fuel System: I5JB0B170045-02 1. Plug cap : Do not reuse.
Page 255 Fuel System: 1G-4 • Ensure that you have hermetically resalable plastic bags for storing removed parts. Stored parts will therefore be less subject to the risk of impurities. The bags must be used only once, and after use they must be thrown away. I4RH0A170052-01 •...
Page 256: Fuel System Description
1G-5 Fuel System: Fuel System Description S5JB0B1700003 CAUTION This engine requires the unleaded fuel only. The leaded and/or low lead fuel can result in engine damage and reduce the effectiveness of the emission control system. Low-pressure fuel supply circuit [A] The fuel in the fuel tank (1) is pumped up to the high pressure fuel supply circuit [B] through the priming pump (2), the fuel filter (3) and the fuel heater (4) by the low pressure fuel pump (5) built in the injection pump (6).
Page 257: Repair Instructions
Fuel System: 1G-6 Repair Instructions Fuel System Components S5JB0B1706001 I5JB0B170047-01 1. Fuel tank 13. O-ring 25. To injection pump 2. Fuel pump assembly 14. Fuel heater 26. To fuel filter...
Page 258: Fuel Pressure Relief Procedure
Fuel Leakage Check Procedure S5JB0B1706002 S5JB0B1706003 1) Check that engine is cold. 1) Prime fuel line using priming pump (1). 2) Connect SUZUKI scan tool to DLC (1) with ignition switch turned OFF. Special tool (A): SUZUKI scan tool I5JB0B170002-01 2) Check low pressure fuel supply circuit for fuel leakage.
Page 259: Water Draining Of Fuel Filter
Fuel System: 1G-8 Water Draining of Fuel Filter Fuel Filter and Fuel Heater Removal and S5JB0B1706023 Installation 1) Disconnect negative (–) cable at battery. S5JB0B1706025 Removal 2) Place container under fuel filter (1). 1) Disconnect negative (–) cable at battery. 3) Loosen bleed screw (2), and drain water until fuel 2) Disconnect fuel heater connector (1) and fuel filter flow out from fuel filter.
Page 260: Fuel Heater Inspection
1G-9 Fuel System: Fuel Heater Inspection Installation S5JB0B1706026 1) Clean fuel heater and fuel filter case. • Check for terminals of fuel heater for damage. 2) Install fuel heater (1) and fuel filter (2) to fuel filter If damage is found, replace fuel heater. case (3) after applying diesel fuel to its new O-rings •...
Page 261: Fuel Hose Disconnecting And Reconnecting
Fuel System: 1G-10 Fuel Hose Disconnecting and Reconnecting S5JB0B1706038 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: ” in order to reduce the risk or fire and personal injury. For Connection Other Than Quick Joint •...
Page 262 1G-11 Fuel System: • Other than clamp around fuel tank [A]: With short pipe, fit hose as far as it reaches pipe joint as shown. [B]: With the following type pipe, fit hose as far as its peripheral projection as shown. [C]: With bent pipe, fit hose as its bent part as shown or till depth “b”.
Page 263: Fuel Lines Inspection
Fuel System: 1G-12 Fuel Lines Inspection Fuel Pipe Removal and Installation S5JB0B1706004 S5JB0B1706005 CAUTION WARNING Due to the fact that fuel feed line is under Before servicing fuel system, be sure to high pressure, use special care when observe “Precautions on Fuel System servicing it.
Page 264: High Pressure Pipe Removal And Installation
1G-13 Fuel System: High Pressure Pipe Removal and Installation 8) Remove high pressure pipe as follows. S5JB0B1706027 • For high pressure pipe between fuel injector and WARNING common rail a. Loosen high pressure pipe union nut (1) using Before servicing fuel system, be sure to special tool and wrench.
Page 265 Fuel System: 1G-14 Installation • For high pressure pipe between injection pump and common rail CAUTION a. Loosen high pressure pipe union nut (1) using special tool and wrench. • Do not touch pipes with wrench when tightening union nut to avoid a damage of CAUTION high pressure pipe.
Page 266 1G-15 Fuel System: 1) Loosen common rail mounting bolts fully in order not CAUTION to install high pressure pipe under stress. When tightening union nut of injection pump 2) Install new high pressure pipes as follows. side, hold union nut (2) with wrench (3) as shown in figure.
Page 267: Fuel Injector On-Vehicle Inspection
DTC is stored in ECM and warning light is injector. turned ON. Also calibration codes If resistance is out of specification, replace fuel registration in ECM can be checked by injector. SUZUKI scan tool. Fuel Injector Resistance Approx. 2 Ω or less I5JB0B170015-01 I5JB0B170014-01...
Page 268: Injection Pump Components
1G-17 Fuel System: 3) Remove plug caps from fuel injector. 1) Remove high pressure pipe between fuel injector and common rail referring to “High Pressure Pipe 4) Install new sealing washer to fuel injector hole. Removal and Installation: ”. 5) Install fuel injector (1) with bracket (2) to cylinder 2) Disconnect fuel injector connector (1) from fuel head, and tighten fuel injector bracket bolt to injector.
Page 269: Injection Pump Removal And Installation
Fuel System: 1G-18 Injection Pump Removal and Installation 9) Remove injection pump rear bracket (1). S5JB0B1706030 WARNING Before servicing fuel system, be sure to observe “Precautions on Fuel System Service: ”. CAUTION Never disassemble injection pump. Disassembly will spoil its original function. If faulty condition is found, replace it with new I5JB0B170019-02 one.
Page 270 1G-19 Fuel System: d) Fit special tool (A) and (B) to injection pulley (1). Installation 1) Support injection pump front bracket (1) using vise Special tool (2). (A): 09912–96510 2) Install injection pump (3) to injection pump front (B): 09912–96520 bracket, if removed.
Page 271 Fuel System: 1G-20 b) Install special tool to injection pump front bracket 6) Install injection pump rear bracket (1). (1) in order to fit injection pump pulley (2). Tightening torque Special tool Injection pump rear bracket bolt (a): 44 N·m (4.4 (A): 09912–96530 kgf-m, 32.0 lb-ft) c) Tighten injection pulley nut to specified torque.
Page 272: Fuel Flow Actuator Inspection
1G-21 Fuel System: Fuel Flow Actuator Inspection Removal S5JB0B1706033 1) Relief fuel pressure referring to “Fuel Pressure Relief Check resistance between terminals of fuel flow Procedure: ”. actuator. 2) Disconnect negative (–) cable at battery. If resistance is out of specification, replace fuel flow actuator referring to “Fuel Flow Actuator Removal and 3) Clean fuel flow actuator and its surrounding area.
Page 273: Common Rail (High Pressure Fuel Injection Rail) Removal And Installation
Fuel System: 1G-22 Common Rail (High Pressure Fuel Injection 4) Install oil separator referring to “Oil Separator Removal and Installation:”. Rail) Removal and Installation S5JB0B1706034 5) Install fuel injector cover, throttle body and engine WARNING cover referring to Step 3) through 6) of “Installation” under “High Pressure Pipe Removal and Installation: Before servicing fuel system, be sure to ”.
Page 274: Fuel Filler Cap Inspection
1G-23 Fuel System: Fuel Filler Cap Inspection 7) For 5 door model, disconnect fuel pump connector S5JB0B1706011 (1). WARNING Before servicing fuel system, be sure to observe “Precautions on Fuel System Service: ”. CAUTION If cap requires replacement, only a cap with the same features should be used.
Page 275: Fuel Tank Inspection
Fuel System: 1G-24 11) For 3 door model, lower fuel tank a little so as to 4) Connect fuel filler hose (1) and breather hose to filler disconnect connectors (1) of fuel pump (2) and sub neck as shown in figure, and clamp them securely. fuel level gauge (3), then remove fuel tank.
Page 276: Fuel Tank Purging Procedure
1G-25 Fuel System: Fuel Tank Purging Procedure 3) Hoist vehicle, and remove clamp (2) and fuel filler S5JB0B1706014 hose (1) from fuel filler neck. WARNING This purging procedure will not remove all fuel vapor. Do not attempt any repair on tank using heat of flame as an explosion resulting in personal injury could occur.
Page 277: Fuel Tank Inlet Valve Inspection
Fuel System: 1G-26 Fuel Tank Inlet Valve Inspection Installation S5JB0B1706016 Check fuel tank inlet valve for the following. CAUTION If any damage or malfunction is found, replace. When connecting joint, clean outside surface • Damage of pipe where joint is to be inserted, push •...
Page 278: Fuel Pump Inspection
1G-27 Fuel System: Fuel Pump Inspection Main Fuel Level Gauge Inspection S5JB0B1706043 S5JB0B1706041 • Check fuel pump assembly for damage. • Check main fuel level gauge for damage. • Check fuel suction filter for evidence of dirt and • For inspection of main fuel level gauge (1), refer to contamination.
Page 279: Sub Fuel Level Gauge Inspection
Fuel System: 1G-28 Sub Fuel Level Gauge Inspection Installation Reverse removal procedure for installation noting the S5JB0B1706042 • Check sub fuel level gauge for damage. following. • For inspection of sub fuel level gauge (1), refer to • Replace O-ring with new one using care not to “Fuel Level Sensor Inspection: in Section 9C”.
Page 280: Special Tools And Equipment
Mot. 1525-03 09912–96530 09919–47020 Injection pump pulley Quick joint remover locking Mot. 1668 SUZUKI scan tool — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback adapter, 7.
Page 281: Starting System
Starting System: 1I-1 Starting System General Description Cranking Circuit Introduction S5JB0B1901001 The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These components are connected electrically. Starting Motor Circuit Description S5JB0B1901002 • The magnetic switch coils are magnetized when the ignition switch is closed. •...
Page 282: Diagnostic Information And Procedures
1I-2 Starting System: Diagnostic Information and Procedures Cranking System Symptom Diagnosis S5JB0B1904001 Possible symptoms due to starting system trouble would be as follows: • Starting motor does not run (or runs slowly) • Starting motor runs but fails to crank engine •...
Page 283: Starting Motor Performance Test
Starting System: 1I-3 Condition Possible cause Correction / Reference Item Starting motor running, Worn pinion tip Replace over-running clutch. but not cranking engine Poor sliding of over-running clutch Repair. Over-running clutch slipping Replace over-running clutch. Worn teeth of ring gear Replace flywheel (M/T) or drive plate (A/T).
Page 284: Repair Instructions
1I-4 Starting System: No-Load Performance Test 1) Connect battery and ammeter to starter as shown. 2) Check that starter rotates smoothly and steadily with pinion moving out. Check that ammeter indicates specified current. Specified current (no-load performance test) 90A MAX. at 11V NOTE Use wires as thick as possible and tighten each terminal fully.
Page 285: Starting Motor Dismounting And Remounting
Starting System: 1I-5 3. Magnetic switch bolt 7. Spring 11. Nut 15. Snap ring 4. Through bolt 8. Magnetic switch 12. Washer : Do not reuse. Starting Motor Dismounting and Remounting 3) Loosen magnetic switch screw (1) and then remove S5JB0B1906001 front housing (2).
Page 286 1I-6 Starting System: 7) Remove planetary carrier shaft assembly (1) from Assembly yoke (2). 1) Install over-running clutch (1) to planetary carrier shaft (3), using care for installing direction of pinion CAUTION stop ring (2). Don’t disassemble motor. If defective, replace as a complete assembly.
Page 287: Starting Motor Inspection
Starting System: 1I-7 Starting Motor Inspection 4) Install spring (5) and magnetic switch (2) to plunger and then tighten magnetic switch inner screw (4). S5JB0B1906004 Plunger CAUTION Inspect plunger for wear. Replace if necessary. With marks (1) on magnetic switch (2) and planetary carrier shaft assembly (3) marked before remove aligned to each other.
Page 288: Specifications
1I-8 Starting System: Hold-in coil open circuit test Pinion and Over-Running Clutch Check for continuity across magnetic switch “S” terminal • Inspect pinion for wear, damage or other abnormal and coil case. If no continuity exists, coil is open and conditions.
Page 289: Charging System
Charging System: 1J-1 Charging System General Description Battery Description Care of battery S5JB0B1A01001 The battery has three major functions in the electrical WARNING system. • Never expose battery to open flame or • It is a source of electrical energy for cranking the electric spark because of battery generate engine.
Page 290: Generator Description
1J-2 Charging System: Generator Description S5JB0B1A01002 The generator is a small and high performance type with an IC regulator incorporated. The internal components are connected electrically as shown in the following figure. The generator features are as follows: • Solid state regulator is mounted inside the generator. •...
Page 291: Diagnostic Information And Procedures
Charging System: 1J-3 Diagnostic Information and Procedures Battery Inspection How to use the temperature-corrected state-of- S5JB0B1A04001 charge graph Common Causes of Failure Suppose your S.G. reading is 1.28 and the battery A battery is not designed to last indefinitely; however, temperature is –5 °C (23 °F).
Page 292: Generator Symptom Diagnosis
1J-4 Charging System: Generator Symptom Diagnosis Noise from generator may be caused by loose drive S5JB0B1A04002 pulley, loose mounting bolts, worn or dirty bearings, CAUTION defective diode, or defective stator. • Do not connect any load between “L” and “E” terminals. •...
Page 293: Generator Test (Overcharged Battery Check)
Charging System: 1J-5 Generator Test (Overcharged Battery Check) 2) Run engine from idling up to 2,000 rpm with all accessories turned off and read meters. S5JB0B1A04004 1) To determine battery condition, refer to “Battery If voltage is higher than standard value, check Description: ”.
Page 294: Repair Instructions
1J-6 Charging System: Repair Instructions Jump Starting in Case of Emergency 5) Attach one end of the remaining negative cable to S5JB0B1A06001 negative terminal of booster battery, and the other With Auxiliary (Booster) Battery end to a solid engine ground (such as exhaust manifold) at least 45 cm (18 in.) away from battery of CAUTION vehicle being started.
Page 295: Generator Components
Charging System: 1J-7 Remounting 1) Reverse removal procedure. 2) Torque battery cables to specification. NOTE Check to be sure that ground cable has enough clearance to hood panel by terminal. Tightening torque Battery ground bolt (a): 12 N·m (1.2 kgf-m, 9.0 lb-ft) I5JB0B1A0006-01 Generator Components...
Page 296: Generator Dismounting And Remounting
1J-8 Charging System: Generator Dismounting and Remounting Generator Disassembly and Assembly S5JB0B1A06003 S5JB0B1A06009 Dismounting Disassembly 1) Disconnect negative (–) cable at battery. NOTE 2) Remove accessory drive belt. Refer to “Accessory Before disassembling generator, be sure to Drive Belt and Idler Pulley Removal and Installation: put match marks at 1 locations (A (drive end ”.
Page 297 Charging System: 1J-9 5) Remove coil assembly (1) from rotor (2) and then 3) Install wave washer (3) and coil assembly (2) to rotor remove wave washer (3). (1). NOTE With marks on drive end frame and coil assembly marked before remove aligned to each other.
Page 298: Drive End Frame / Bearing Disassembly And Assembly
1J-10 Charging System: c) Remove pin from brush holder. Assembly 6) Install insulator (3). 1) Press-fit drive end bearing by using special tools and press (1). 7) Install rear end cover (2) to coil assembly and tighten rear end cover nut (1) to specified torque. Special tool (A): 09913–76010 CAUTION...
Page 299 Charging System: 1J-11 Stator Rectifier 1) Check resistance between the following leads of 1) Check continuity of rectifier by using an ohm meter. stator. If there is no continuity, replace coil assembly. 2) Reverse the polarity of the tester probes and repeat Step 1).
Page 300: Accessory Drive Belt And Idler Pulley Removal And Installation
1J-12 Charging System: Accessory Drive Belt and Idler Pulley Removal Installation and Installation 1) Install adapter (6) and then tighten adapter. S5JB0B1A06006 2) Install idler pulley (5) and then tighten idler pulley Removal bolt (7) to specified torque. WARNING Tightening torque Idler pulley bolt (b): 50 N·m (5.0 kgf-m, 36.5 lb-ft) Disconnect negative (–) cable at battery before removing and installing generator...
Page 301: Accessory Drive Belt Inspection
Charging System: 1J-13 Accessory Drive Belt Inspection Installation S5JB0B1A06007 1) Install accessory drive belt tensioner. Check accessory drive belt for cracks, cuts, deformation, 2) Tighten accessory drive belt tensioner bolt No.1 and wear and cleanliness, and replace as required. No.2 to specified torque. Accessory Drive Belt Tensioner Removal and Tightening torque Installation...
Page 302: Special Tools And Equipment
1J-14 Charging System: Tightening Torque Specifications S5JB0B1A07002 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Battery ground bolt Generator mounting bolt 32.0 “B” terminal nut Idler pulley bolt 36.5 Accessory drive belt and belt tensioner bolt 36.5 No.1 Accessory drive belt tensioner bolt No.2 16.0 Accessory drive belt tensioner bolt No.1 36.5...
Page 303: Exhaust System
Exhaust System: 1K-1 Exhaust System General Description Exhaust System Description Diesel Particurate Filter S5JB0B1B01001 S5JB0B1B01002 The exhaust system consists of an exhaust manifold, a The diesel particurate filter is emission control device turbo charger, a catalytic converter in a catalyst case, a added to the exhaust system after catalytic converter, diesel particurate filter, an exhaust pipes, a muffler and and it accumulates the diesel particular in the exhaust...
Page 304: Repair Instructions
1K-2 Exhaust System: Repair Instructions Exhaust System Components S5JB0B1B06001 WARNING To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. I5JB0B1B0001-02 1.
Page 305: Exhaust System Components
“Exhaust System Components: ”. • When replacing diesel particulate filter, perform CAUTION “Initialize diesel PF data” mode of SUZUKI scan tool referring to “SUZUKI Tech 2 Operator's Manual”. When replacing diesel particulate filter, perform “Initialize diesel PF data” mode of SUZUKI scan tool referring to “SUZUKI Tech...
Page 306 1K-4 Exhaust System:...
Page 307 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........3-1 Repair Instructions ..........3B-1 Front Differential Oil Change.......
Page 308 3-ii Table of Contents 4WD Control System Operation......3C-* Inspection of 4WD Control Module and Its 4WD Control System Wiring Circuit Diagram..3C-2 Circuits .............. 3C-* Terminal Arrangement of 4WD Control Repair Instructions ..........3C-12 Module .............. 3C-* Transfer Oil Level Check........3C-* Input / Output Signal Table of 4WD Control Transfer Oil Change..........
Page 309 Precautions: Precautions Precautions Precautions for Driveline / Axle S5JB0B3000001 Differential Gear Oil Note Refer to “Differential Gear Oil Note: in Section 00 in related manual”. Fastener Caution Refer to “Fastener Caution: in Section 00 in related manual”. Precautions for Transfer Refer to “Precautions in Diagnosing Trouble: in Section 3C in related manual”.
Page 310 3B-1 Differential: Front Differential Front Repair Instructions Front Differential Unit Components S5JB0B3216002 I5JB0B321001-02 [A]: Damper without rear mounting bracket 4. Differential mounting bolt 9. Damper [B]: Damper with rear mounting bracket 5. Rear mounting bolt 10. Damper bolt 1. Front differential 6.
Page 311 Differential: Rear 3B-2 Rear Repair Instructions Rear Differential Dismounting and Remounting S5JB0B3226003 Dismounting 1) Lift up vehicle and drain oil from rear differential. 2) Remove rear propeller shaft referring to “Propeller Shaft Removal and Installation: in Section 3D”. 3) Remove exhaust center pipe referring to “Exhaust System Components: in Section 1K”. 4) Remove rear drive shafts referring to “Rear Drive Shaft Assembly Removal and Installation: Rear in Section 3A in related manual”.
Page 312 3C-1 Transfer: Transfer Precautions Transfer Warning S5JB0B3300001 WARNING This transfer has a center differential. When testing with 2-wheel chassis dynamometer, speedometer tester or brake tester, be sure to make the vehicle as rear wheel drive temporarily as follows. Otherwise, front wheels drive rear wheels or vise-versa and personal injury may result. 1) Remove front propeller shaft referring to “Propeller Shaft Removal and Installation: in Section 3D”.
Page 313: 4Wd Control System Wiring Circuit Diagram
Transfer: 3C-2 General Description 4WD Control System Wiring Circuit Diagram S5JB0B3301006 E91-18 LT GRN G59-2 C54-1 E91-2 E91-19 BLU/BLK G59-3 E91-3 C54-4 E91-20 BLU/ORN G59-4 C54-2 E91-25 C54-3 RED/BLK E91-26 C54-5 BLK/YEL E91-24 E91-13 PNK/WHT E91-14 RED/GRN BLK/ORN E91-7 E91-8 E91-21 PPL/WHT E91-22...
Page 314: Module
3C-3 Transfer: Input / Output Signal Table of 4WD Control Module S5JB0B3301008 4WD control module outputs the following signals to actuators, indicators, warning buzzer, according to the transfer switch operation. Output signal (to each component parts) Transfer Differential Warning shift lock 4L indicator N indicator buzzer...
Page 315: Diagnostic Information And Procedures
Transfer: 3C-4 Diagnostic Information and Procedures Visual Inspection S5JB0B3304004 Check the following parts and systems visually. Inspection Item Referring • Front differential oil ---- level, leakage “Front Differential Oil Change: Front in Section 3B in related manual” • Rear differential oil ---- level, leakage “Rear Differential Oil Change: Rear in Section 3B in related manual”...
Page 316 3C-5 Transfer: Transfer Detecting condition DTC No. Detecting item position (DTC will set when detecting) indicators Receiving error of 4WD control module from U1100 Lost communication with ECM ECM for specified time continuously. Receiving error of 4WD control module from Lost communication with ABS / U1121 ABS / ESP®...
Page 317 Transfer: 3C-6 Scan Tool Data Definitions S5JB0B3304010 Vehicle Speed (KM/H, MPH): This parameter indicates vehicle speed calculated by 4WD control module. Engine Speed (RPM): This parameter indicates engine revolution calculated by 4WD control module. Actuator Pos Sen (Transfer shift actuator motor position switch) (4H / 4H-lock / 4L-lock / N / 4H-lock-4H / 4H-N / N-4L-lock): This parameter indicates transfer shift actuator motor position switch status detected by 4WD control module.
Page 318 3C-7 Transfer: 4WD Control Symptom Diagnosis S5JB0B3304011 Diagnose transfer assembly after performing the following inspections. 1) Perform 4WD control system check referring to “4WD Control System Check: in related manual”. 2) Confirm 4WD control system operation referring to “4WD Control System Operation: in related manual” Condition Possible cause Correction / Reference Item...
Page 319: Dtc U1073: Control Module Communication Buss Off
Transfer: 3C-8 DTC U1073: Control Module Communication Buss Off S5JB0B3304026 Wiring Diagram G31-2 G31-4 G31-1 G31-3 WHT/RED E23-4 WHT/BLU E23-19 E91-22 E91-23 E03-8 WHT/BLU E53-46 E03-10 WHT/RED E53-42 E92-17 E03-12 E53-13 E92-7 E03-6 E53-44 G44-19 G28-10 G44-18 G28-8 18 17 13 12 34 33 32 31 30 29 24 23...
Page 320 3C-9 Transfer: [D]: ABS hydraulic unit/control module connector (viewed from terminal side) 4. Keyless start control module (if equipped) [E]: Combination meter connector (viewed from harness side) 5. ECM [F]: 4WD control module connector (viewed from harness side) 6. ABS hydraulic unit / control module (if equipped) [G]: BCM connector (viewed from harness side) 7.
Page 321: Dtc U1100: Lost Communication With Ecm
Transfer: 3C-10 DTC U1100: Lost Communication with ECM S5JB0B3304027 Wiring Diagram Refer to “DTC U1073: Control Module Communication Buss Off: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for ECM is detected for •...
Page 322: Dtc U1121: Lost Communication With Abs / Electronic Stability Program Hydraulic Unit / Control Module
3C-11 Transfer: DTC U1121: Lost Communication with ABS / Electronic Stability Program Hydraulic Unit / Control Module S5JB0B3304029 Wiring Diagram Refer to “DTC U1073: Control Module Communication Buss Off: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for ABS / ESP®...
Page 323: Repair Instructions
Transfer: 3C-12 Repair Instructions Transfer Assembly Components S5JB0B3306008 1217G 1217G 1217G 1322 1217G I5JB0B330001-09...
Page 324: Transfer Assembly Disassembly And
3C-13 Transfer: [A]: Flange is fixed type 19. Snap ring 41. Oil pump outer rotor [B]: Flange is not fixed type 20. Washer 42. Oil pump inner rotor 1. Front oil seal No.1 21. Shim 43. Oil pump drive pin : Apply grease 99000-25010 to oil seal lip.
Page 325 Transfer: 3C-14 4) Remove front output flange follows, if equipped. 8) Remove rear case bolts (1) and clamp (2) and then separate center case (3) using special tool. a) Uncaulk front output flange nut. b) Remove front output flange nut while holding Special tool flange by using special tool.
Page 326 3C-15 Transfer: 11) Remove needle bearing (1), snap ring (2), washer 15) Remove front drive sprocket bush (1) from rear (3) and shim(s) (4) from rear output shaft (5). output shaft (2). I5JB0A331019-01 I5JB0A331023-01 12) Remove reduction shift sleeve (1), center differential 16) Take out front drive sprocket (1), front output shaft and low gear from rear output shaft (2).
Page 327 1) Install new front oil seal No.2 to front case (1) using special tool, and then apply grease to oil seal lip. Special tool (A): 09913–76010 : Grease 99000–25010 (SUZUKI Super Grease A) Special tool (A): 09913–85210 I5JB0A331027-01 20) Remove input gear plate bolts (1) from front case (2).
Page 328 5) Install new rear oil seal (1) to rear case (2) using special tool as shown in figure, and then apply grease to oil seal lip. “A”: Grease 99000–25010 (SUZUKI Super Grease A) Distance between case and oil seal “a”...
Page 329 Transfer: 3C-18 10) Install thrust needle bearing (4), front drive shaft (1) 12) Select shim (1) as follows. and needle bearings (2) to rear output shaft (3). a) Install shim, washer (2) and used snap ring (3) into rear output shaft (4). b) Check clearance between shim and washer.
Page 330 (0.047 in.) in diameter, mate center case with rear : 0 – 0.5 mm (0 – 0.008 in.) case and then tighten bolts (2) to specified torque. Special tool “A”: Sealant 99000–31260 (SUZUKI Bond (A): 09913–76010 No.1217G) (B): 09925–98210 Tightening torque Rear case bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft)
Page 331 (0.047 in.) in diameter, mate oil pump cover with rear center case and then tighten bolts (2) to specified case and then tighten bolts (3) to specified torque. torque. “A”: Sealant 99000–31260 (SUZUKI Bond “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) No.1217G)
Page 332 4L/N switch (b): 20 N·m (2.0 kgf-m, 14.5 lb-ft) bolts (3) to which thread lock cement has been applied and control cover dowel bolts (4) to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) “B”: Thread lock cement 99000–32110 (Thread Lock Cement Super 1322) Tightening torque Control cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-...
Page 333: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0B3308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G...
Page 334 3C-23 Transfer: 09922–66021 09925–98210 Flange holder Input shaft bearing installer 09928–36510 Transfer cap...
Page 335: Propeller Shafts
Propeller Shafts: 3D-1 Propeller Shafts General Description Propeller Shaft Construction S5JB0B3401001 Most universal joints and ball joints require no maintenance. They are lubricated for life and can not be lubricated on the vehicle. If a universal joint becomes noisy or worn, it must be replaced. The propeller shaft is a balanced unit.
Page 336 (where oil seal contacts) before installation and if even small dent or scratch exists, correct end clean it I5JB0A340004-01 again. Then apply grease inside splines of propeller shaft. [A]: Front propeller shaft [B]: Rear propeller shaft “B”: Grease 99000–25010 (SUZUKI Super Grease IYSQ01521009-01...
Page 337 For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0B3408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010...
Page 338 3D-4 Propeller Shafts:...
Page 339 Table of Contents 4- i Section 4 Brakes CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........4-* General Description ..........4B-* Front Disc Brake Caliper Assembly Precautions..............
Page 340 4-ii Table of Contents Parking Brake Check and Adjustment ....4D-* DTC U1073: Control Module Communication Parking Brake Lever Removal and Bus Off ............4E-28 Installation ............4D-* DTC U1100: Lost Communication with Parking Brake Cable Removal and ECM (Reception Error)........4E-30 Installation ............
Page 341 Table of Contents 4-iii EBD Warning Lamp (Brake Warning Lamp) DTC C1075 / 1076 / 1077 / 1078: Steering Check.............. 4F-12 Angle Sensor / Master Cylinder Pressure DTC Check ............4F-13 Sensor / Longitudinal G Sensor / Lateral G DTC Table............4F-13 Sensor in Yaw Rate / G Sensor DTC Clearance ..........
Page 342 4-iv Table of Contents Special Tool ............4F-53...
Page 343 • Diagnostic information stored in ABS (ESP®) control module memory can be cleared as well as checked by using SUZUKI scan tool. Before using scan tool, read its Operator's (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
Page 344 4E-2 ABS: General Description ABS Description ABS Hydraulic Unit / Control Module Assembly S5JB0B4501001 Description ABS is controlled by ABS control module or by ESP® S5JB0B4501002 control module (if equipped). ABS (ESP®) control module is a component of ABS ABS activation and control with ESP® are done by (ESP®) hydraulic unit / control module assembly and ESP®...
Page 345 ABS: 4E-3 CAN Communication System Description S5JB0B4501003 Refer to “CAN Communication System Description: in Section 1A” for CAN communication system description. ABS communicates control data with each control module as follows. ABS Transmission Data 4WD control module Combination Meter (if equipped) Torque up request Wheel speed signal (front) Wheel speed signal (rear right)
Page 346 4E-4 ABS: Schematic and Routing Diagram ABS Schematic S5JB0B4502001 INPUT OUTPUT ABS (ESP®) control module Hydraulic unit Wheel speed sensor (LF) Pump motor Wheel speed sensor (LR) Pump motor driver (transistor) Wheel speed sensor (RF) Solenoid valve power supply driver (transistor) Wheel speed sensor (RR) LF inlet solenoid valve Stop lamp switch...
Page 347 ABS: 4E-5 3. ABS (ESP®) hydraulic unit 12. Lamp driver module 21. ECM 4. Solenoid valve power supply driver (transistor) 13. Data link connector 22. 4 way joint 5. Solenoid valve driver (transistor) 14. Wheel speed sensor (Right-front) 23. Yaw rate / G sensor assembly 6.
Page 348 4E-6 ABS: 1. Battery 13. Solenoid valves 25. G sensor (4WD vehicle only) 2. Main fuse box 14. Right-rear wheel speed sensor 26. ECM 3. Ignition switch 15. Left-rear wheel speed sensor 27. BCM 4. Junction block assembly 16. Right-front wheel speed sensor 28.
Page 349 ABS: 4E-7 Component Location ABS Components Location S5JB0B4503001 NOTE As for the difference of RH steering vehicle and LH steering vehicle, the location of the combination meter, data link connector, stop lamp switch and the brake master cylinder assembly only changes. I6JB01450004-01 1.
Page 350: Diagnostic Information And Procedures
4E-8 ABS: Diagnostic Information and Procedures ABS Check S5JB0B4504001 Refer to the following items for the details of each step. Step Action Malfunction analysis Go to Step 4. Go to Step 2. 1) Perform “Customer complaint analysis: ”. 2) Perform “Problem symptom confirmation: ”. 3) Perform “DTC check, record and clearance: ”...
Page 351 ABS: 4E-9 Customer questionnaire (Example) I2RH01450014-01 Problem symptom confirmation Check if what the customer claimed in “Customer Questionnaire” is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. (This step should be shared with the customer if possible.) Check warning lamps related to brake system referring to “EBD Warning Lamp (Brake Warning Lamp) Check: in related manual”...
Page 352 I5JB0A450001-01 I5JB0A450008-01 3) Turn ignition switch to ON position. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further details. NOTE If SUZUKI scan tool can not communicate ABS (ESP®) hydraulic unit / control module,...
Page 353 • Turn OFF all electric loads (except ignition). DTC (displayed on Diagnostic Items SUZUKI scan tool) • No DTC. NO DTC Normal • ABS is not operated. (Normal braking operation) G sensor circuit failure (for 4WD...
Page 354 4E-12 ABS: ABS Warning Lamp Does Not Come ON at Ignition Switch ON S5JB0B4504008 Wiring Diagram WHT/BLU E53-32 WHT/BLU E03-1 WHT/RED E53-1 WHT/RED E03-14 E53-35 WHT/GRN BLK/YEL GRN/ORN GRN/ORN E03-7 PPL/RED E53-13 E03-12 E53-44 E03-6 E53-16 E03-13 E53-47 E03-26 I6JB01450005-01 [A]: With ESP®...
Page 355 ABS: 4E-13 Troubleshooting Step Action 1) Turn ignition switch to ON position. Go to Step 2. Go to Step 3. Do other warning lamps come ON? 1) Connect scan tool to DLC with ignition switch turned Go to “DTC U1073: Substitute a known- OFF.
Page 356 4E-14 ABS: ABS Warning Lamp Comes ON Steady S5JB0B4504009 Wiring Diagram Refer to “ABS Warning Lamp Does Not Come ON at Ignition Switch ON: ”. Circuit Description Operation (ON/OFF) of ABS warning lamp is controlled by ABS (ESP®) control module through lamp driver module in combination meter.
Page 357 ABS: 4E-15 EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady S5JB0B4504011 Wiring Diagram WHT/BLU E53-32 WHT/BLU E03-1 WHT/RED E53-1 WHT/RED E03-14 E53-35 WHT/GRN BLK/YEL GRN/ORN GRN/ORN E03-7 PPL/RED E53-13 E03-12 E53-44 E03-6 E53-16 E03-13 E53-47 E03-26 RED/BLK RED/BLK I6JB01450006-02 [A]: With ESP®...
Page 358 4E-16 ABS: Troubleshooting Step Action 1) Make sure that: Go to Step 2. Release parking brake completely and/or • Parking brake is completely released. replenish brake fluid. • Brake fluid level is upper than the minimum level. Are the check results OK? 1) Turn ignition switch to ON position.
Page 359 ABS: 4E-17 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Encoder Failure S5JB0B4504014 Wiring Diagram BLK/YEL GRN/ORN E53-35 GRN/ORN E03-7 E53-14 E03-22 BLU/BLK BLU/BLK E53-15 E03-21...
Page 360 4E-18 ABS: DTC Detecting Condition The ABS (ESP®) control module monitors the voltage at the terminal of each sensor while the ignition switch is ON. When the voltage is not within the specified range, an applicable DTC will be set. Also, when no sensor signal is inputted at running, an applicable DTC will be set.
Page 361 ABS: 4E-19 Step Action 1) Remove applicable ABS wheel speed sensor. Go to Step 5. Clean, repair or replace. 2) Check sensor for damage or foreign material attached. Is it in good condition? Check front and/or rear encoder for the following (remove Go to Step 6.
Page 362 4E-20 ABS: DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Inlet Solenoid Circuit Failure, Outlet Solenoid Circuit Failure, Master Cylinder Cut Solenoid Circuit Failure, Low Pressure Solenoid Circuit Failure S5JB0B4504015 DTC C1041 / C1045 / C1051 / C1055: Right-Front / Left-Front / Right-Rear / Left-Rear Inlet Solenoid Circuit Failure...
Page 363 ABS: 4E-21 [B]: Without ESP® 2. Main fuse box 6. Solenoid valve power supply driver (transistor) [C]: ESP® control module connector (viewed from terminal 3. ESP® hydraulic unit / control module 7. Solenoid valve driver side) assembly [D]: ABS control module connector (viewed from terminal 4.
Page 364 4E-22 ABS: DTC C1057: ABS (EPS®) Control Module Power Supply Circuit Failure S5JB0B4504016 Wiring Diagram WHT/RED WHT/RED E53-1 E03-14 E53-16 E03-13 E53-47 E03-26 I6JB01450009-02 [A]: With ESP® [D]: ABS control module connector (viewed from 3. ESP® hydraulic unit / control module assembly terminal side) [B]: Without ESP®...
Page 365 ABS: 4E-23 DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check: ”. 1) Disconnect ABS (ESP®) hydraulic unit / control module Go to Step 5. Go to Step 3. connector with ignition switch turned OFF. 2) Check for proper connection to ABS hydraulic unit / control module connector at terminals “E03-14”...
Page 366 4E-24 ABS: DTC C1061: Pump Motor and/or Motor Driver Circuit Failure S5JB0B4504017 Wiring Diagram WHT/BLU E53-32 WHT/BLU E03-1 E53-16 E03-13 E53-47 E03-26 I6JB01450010-01 [A]: With ESP® 1. Battery 5. ESP® hydraulic unit / control module assembly [B]: Without ESP® 2. Main fuse box 6.
Page 367 ABS: 4E-25 Step Action Measure resistance between terminal “E03-13” and “E03- Substitute a known- Ground circuit for ABS 26” (or “E53-16” and “E53-47”) of ABS (ESP®) hydraulic unit good ABS (ESP®) (ESP®) hydraulic unit / / control module connector and vehicle body ground. hydraulic unit / control control module open or module assembly and...
Page 368 4E-26 ABS: DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check: ”. Check battery voltage. Go to Step 3. Check charging system referring to “Battery Is it about 11 V or higher? Inspection: in Section 1J”...
Page 369 ABS: 4E-27 DTC C1071: ABS (ESP®) Control Module Internal Defect S5JB0B4504019 Wiring Diagram WHT/BLU E53-32 WHT/BLU E03-1 E53-1 E03-14 WHT/RED WHT/RED E53-16 E03-13 E53-47 E03-26 I6JB01450012-02 [A]: With ESP® [D]: ABS control module connector (viewed 3. Power control unit from terminal side) [B]: Without ESP®...
Page 370 4E-28 ABS: DTC U1073: Control Module Communication Bus Off S5JB0B4504020 Wiring Diagram WHT/RED E66-32 E53-42 WHT/RED E03-10 WHT/RED WHT/BLU WHT/BLU E53-46 WHT/BLU E03-8 E66-26 E53-13 E03-12 E53-44 E03-6 G24-6 G24-5 E91-22 G28-10 E91-23 G28-8 G31-1 G31-3 G45-10 G45-9 G31-4 G31-2 15 14 13 18 17 13 12...
Page 371 ABS: 4E-29 DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check: ”. 1) Check connection of connectors of all control modules Go to Step 3. Intermittent trouble. communicating by means of CAN. Check for intermittent referring to “Intermittent 2) Recheck DTC.
Page 372 4E-30 ABS: DTC U1100: Lost Communication with ECM (Reception Error) S5JB0B4504021 Wiring Diagram Refer to “DTC U1073: Control Module Communication Bus Off: ”. DTC Detecting Condition Reception error of communication data for ECM is detected more than specified time continuously. DTC Troubleshooting Step Action...
Page 373: Repair Instructions
Step on brake pedal (1) and then select testing 2) Check that battery voltage is 11 V or higher. wheel by SUZUKI scan tool and the wheel (2) should be turned by another person’s hand. At this 3) Lift up vehicle.
Page 374 4E-32 ABS: ABS (ESP®) Hydraulic Unit / Control Module Assembly On-Vehicle Inspection S5JB0B4506003 CAUTION Never disassemble ABS (ESP®) hydraulic unit / control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ABS (ESP®) hydraulic unit / control module assembly.
Page 375 ABS: 4E-33 Removal 6) Remove ABS (ESP®) hydraulic unit / control module with bracket from vehicle by removing bracket bolt 1) Disconnect negative (–) cable from battery. and two bracket nuts. 2) Remove ECM referring to “Engine Control Module 7) Remove bolt and pull out ABS (ESP®) hydraulic unit (ECM) Removal and Installation: in Section 1C”.
Page 376: Specifications
4E-34 ABS: 3) Install ECM referring to “Engine Control Module 2) Connect ABS (ESP®) control module connector and lock it as shown in figure. (ECM) Removal and Installation: in Section 1C”. 4) Connect negative (–) cable at battery. 5) Bleed air from brake system referring to “Air Bleeding of Brake System: in Section 4A in related manual”.
Page 377: Special Tools And Equipment
ABS: 4E-35 Special Tools and Equipment Special Tool S5JB0B4508001 09950–78220 SUZUKI scan tool Flare nut wrench (10 mm) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback adapter, 7.
Page 378: Precautions In Diagnosing Troubles
Therefore, be sure to read “Precaution for CAN SUZUKI scan tool. Before using scan tool, read its Communication System: in Section 00 in related Operator’s (Instruction) Manual carefully to have good manual”...
Page 379: General Description
When performing speedometer or other tests using speedometer tester or chassis dynamometer, ESP® function must be deactivated by using SUZUKI scan tool (not by ESP® OFF switch) to complete the tests correctly. ESP® OFF switch turns ESP® function off temporarily and ESP® function recovers and activates at 30 km/h (18.5 mph) or more.
Page 380 4F-3 Electronic Stability Program: • When an abnormality in the system is detected, some of ABS warning lamp, EBD warning lamp (brake warning lamp), ESP® warning lamp, SLIP indicator lamp and/or ESP® OFF lamp are turned ON and the area where that abnormality lies is stored in the memory in ESP®...
Page 381: Can Communication System Description
Electronic Stability Program: 4F-4 The followings are the condition and operation of warning lamps and indicator lamps. Warning lamp / Indicator lamp Condition and operation ABS warning lamp If ABS has abnormality, the lamp turns “ON”. EBD warning lamp (brake warning •...
Page 382 4F-5 Electronic Stability Program: ESP® Control Module Reception Data 4WD control Steering angle module sensor (if equipped) Engine torque signal Accelerator pedal position Engine speed Cruise control signal (if equipped) ESP® control Receive DATA Brake pedal switch signal module Brake fluid level switch signal Parking brake switch signal 4WD shift position (if equipped) Steering angle signal...
Page 383: Schematic And Routing Diagram
Electronic Stability Program: 4F-6 Schematic and Routing Diagram Electronic Stability Program Schematic S5JB0B4602003 INPUT OUTPUT ESP® hydraulic unit/control module assembly Hydraulic unit Master cylinder pressure sensor ESP® control module Pump motor driver Pump motor (transistor) Solenoid valve power supply driver (transistor) Battery Voltage Ignition Voltage LF inlet solenoid valve...
Page 384 4F-7 Electronic Stability Program: Electronic Stability Program Wiring Circuit Diagram S5JB0B4602004 WHT/BLU WHT/RED WHT/GRN BLK/YEL GRN/ORN E53-35 G45-3 E53-10 G45-1 GRN/ORN G45-9 G45-2 PPL/RED E53-7 BLU/WHT G45-10 E53-16 E53-47 WHT/RED WHT/BLU E53-1 E53-32 G31-1 E53-13 G31-3 E53-44 RED/BLK G31-7 GRN/WHT RED/BLK G31-8 E66-32...
Page 385 Electronic Stability Program: 4F-8 6. CAN driver 20. Brake fluid level switch 34. Power control unit 7. Combination meter 21. Parking brake switch 35. Internal memory 8. SLIP indicator lamp 22. Yaw rate / G sensor assembly 36. Pump motor driver (transistor) 9.
Page 386: Component Location
4F-9 Electronic Stability Program: Component Location Electronic Stability Program Component Location S5JB0B4603002 I6JB01460010-03 1. ESP® warning lamp 7. ESP® OFF switch 13. Yaw rate / G sensor assembly 2. EBD warning lamp (brake warning lamp) 8. Rear wheel speed sensor 14.
Page 387: Diagnostic Information And Procedures
Electronic Stability Program: 4F-10 Diagnostic Information and Procedures Electronic Stability Program Check S5JB0B4604046 Refer to the following items for the details of each step. Step Action Malfunction analysis Go to Step 4. Go to Step 2. 1) Perform “Customer complaint analysis: ”. 2) Perform “Problem symptom confirmation: ”.
Page 388 4F-11 Electronic Stability Program: Customer questionnaire (Example) I6JB01460011-02 Problem symptom confirmation If symptom in “Customer Questionnaire” is found or reproduced in the vehicle, confirm the symptom is problem or not. (This step should be done with the customer if possible.) Check warning lamps related to brake system referring to “EBD Warning Lamp (Brake Warning Lamp) Check: in Section 4E in related manual”, “ABS Warning Lamp Check: in Section 4E”...
Page 389: Abs Warning Lamp Check
Electronic Stability Program: 4F-12 Step 2: Driving Test Test the vehicle turning (counter) clockwise at 40 km/h for more than a minute and check if any trouble symptom (such as abnormal lighting of ESP® warning lamp and/or ABS warning lamp) exists. If the malfunction DTC is confirmed at ignition switch ON, proceed to Step 3.
Page 390: Dtc Check
4) Read DTC according to instructions displayed on 1) Turn ignition switch to OFF position. SUZUKI scan tool and print it or write it down. Refer 2) Connect SUZUKI scan tool to data link connector to SUZUKI scan tool operator’s manual for further (1).
Page 391 Electronic Stability Program: 4F-14 ESP® (displayed Detecting condition (DTC will be Diagnostic Items warning warning warning on SUZUKI set when detecting) lamp lamp lamp scan tool) C1022 Wheel speed C1026 Abnormal wheel speed sensor signal sensor or encoder is detected.
Page 392 4F-15 Electronic Stability Program: ESP® (displayed Detecting condition (DTC will be Diagnostic Items warning warning warning on SUZUKI set when detecting) lamp lamp lamp scan tool) Inlet solenoid valve C1041 circuit failure Outlet solenoid C1042 valve circuit failure Inlet solenoid valve...
Page 393 Electronic Stability Program: 4F-16 ESP® (displayed Detecting condition (DTC will be Diagnostic Items warning warning warning on SUZUKI set when detecting) lamp lamp lamp scan tool) ECM data in CAN line ECM sent invalid signal to ESP® C1091 failure control module.
Page 394: Dtc Clearance
SUZUKI scan tool. 4) After completing the clearance, turn ignition switch 1) Connect SUZUKI scan tool to data link connector in OFF and disconnect scan tool from data link the same manner as when making this connection connector.
Page 395 Electronic Stability Program: 4F-18 Fail-safe operation DTC No. TCS / Fail-safe condition resolutive stability C1028 C1034 C1037 When no DTC is detected by ESP® control module, after ignition switch turned OFF to ON. C1038 C1039 C1040 C1041 C1042 C1043 C1044 C1045 C1046 When no DTC is detected by ESP®...
Page 396 4F-19 Electronic Stability Program: Fail-safe operation DTC No. TCS / Fail-safe condition resolutive stability C1090 C1091 C1093 U1073 When no DTC is detected by ESP® control module, after ignition switch turned OFF to ON. U1100 U1126 U1139 U1140 NOTE • : Activated •...
Page 397: Scan Tool Data
Electronic Stability Program: 4F-20 Scan Tool Data S5JB0B4604054 The parameter data below are values measured with the scan tool when the normally operating vehicle is under the following conditions. When taking measurements for comparison by using the scan tool, be sure to check that the vehicle is under the following conditions.
Page 398 4F-21 Electronic Stability Program: ESP® Warning Lamp Does Not Come ON at Ignition Switch ON S5JB0B4604055 Wiring Diagram WHT/BLU E53-32 WHT/RED E53-1 E53-35 WHT/GRN BLK/YEL GRN/ORN PPL/RED E53-13 E53-44 E53-16 E53-47 I6JB01460013-01 [A]: ESP® control module connector (viewed from 4. Junction block assembly 8.
Page 399 Electronic Stability Program: 4F-22 Step Action 1) Remove combination meter with ignition switch turned Go to Step 6. Repair power supply OFF. circuit for combination meter. 2) Check for proper connection to “PPL/RED” and “BLK” wire of combination meter connector. 3) If OK, turn ON ignition switch and measure voltage at “PPL/RED”...
Page 400: Serial Data Link Circuit Check
4F-23 Electronic Stability Program: Step Action 1) Check CAN communication circuit between combination Substitute a known- Repair or replace. meter and ESP® control module referring to “DTC good combination meter U1073: Control Module Communication Bus Off: ”. and recheck. If ESP® warning lamp remains Is CAN communication circuit in good condition? ON, substitute a known-...
Page 401 Electronic Stability Program: 4F-24 Step Action 1) Turn ignition switch to OFF position. Go to Step 5. “WHT/RED” and/or “WHT/BLU” wire circuit 2) Check for proper connection to ESP® control module open. connector at terminals “E53-1” and “E53-32”. 3) If OK then turn ignition switch to ON position and measure voltage between each terminal of “E53-1”, “E53-32”...
Page 402: 4Wd Vehicle)
4F-25 Electronic Stability Program: DTC C1015 / C1017 / C1023: Longitudinal G Sensor / Lateral G Sensor / Yaw Rate Sensor in Yaw Rate / G Sensor Assembly Failure S5JB0B4604058 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area C1015: •...
Page 403 Electronic Stability Program: 4F-26 DTC C1016: Stop Lamp Switch Circuit Failure S5JB0B4604059 Wiring Diagram GRN/WHT E66-29 E66-32 WHT/RED E53-42 E66-26 WHT/BLU E53-46 I5JB0B460005-01 [A]: ESP® control module connector (viewed from 3. Junction block assembly 7. CAN driver terminal side) [B]: ECM connector (viewed from harness side) 4.
Page 404 4F-27 Electronic Stability Program: DTC C1018: Brake Fluid Level Switch Failure S5JB0B4604060 Wiring Diagram G31-1 E53-13 G31-3 E53-44 RED/BLK G31-7 18 17 13 12 39 38 28 27 24 23 I5JB0B460006-01 [A]: ESP® control module connector (viewed from 2. CAN driver 5.
Page 405 Electronic Stability Program: 4F-28 Step Action Check brake fluid level switch Go to Step 5. Replace brake fluid level switch. 1) Turn ignition switch to OFF position. 2) Disconnect brake fluid level switch connector. 3) Check for proper connection at each terminal of brake fluid level switch connector.
Page 406: Dtc C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor Circuit Or Encoder Failure
4F-29 Electronic Stability Program: DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Encoder Failure S5JB0B4604087 Refer to “DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor Circuit or Encoder Failure: in Section 4E”.
Page 407 Electronic Stability Program: 4F-30 DTC C1027: ESP® OFF Switch Circuit Failure S5JB0B4604064 Wiring Diagram BLU/WHT E53-7 I6JB01460018-01 [A]: ESP® control module connector (viewed from terminal side) 1. ESP® OFF Switch 2. ESP® hydraulic unit control module assembly DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Mechanical switch failure, failure in switch wiring is...
Page 408 4F-31 Electronic Stability Program: DTC C1028: Master Cylinder Pressure Sensor Circuit Failure S5JB0B4604065 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Input signal voltage from master cylinder pressure sensor • Leakage or air in the hydraulic brake system in ESP®...
Page 409 Electronic Stability Program: 4F-32 DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program Check: ”. DTC check for ESP® Go to applicable DTC Go to Step 3. diag. flow. 1) Connect scan tool to DLC with ignition switch turned OFF.
Page 410 4F-33 Electronic Stability Program: DTC C1037: Steering Angle Sensor Power Supply Failure S5JB0B4604067 Wiring Diagram BLK/YEL WHT/GRN G45-3 G45-1 GRN/ORN G45-10 E53-13 G45-9 E53-44 G45-2 10 9 3 2 1 I6JB01460020-02 [A]: ESP® control module connector (viewed from 3. Ignition switch 7.
Page 411 Electronic Stability Program: 4F-34 Step Action Check steering angle sensor power supply circuit Go to Step 6. “BLK” wire circuit open or high resistance. 1) Turn ignition switch to OFF position. 2) Measure resistance between connector terminal “E45-2” and vehicle body ground. Ω...
Page 412: Dtc
4F-35 Electronic Stability Program: DTC C1039: Yaw Rate / G Sensor Assembly Internal Failure S5JB0B4604088 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Yaw rate / G sensor assembly internal failure is detected. • Yaw rate / G sensor assembly •...
Page 413 Electronic Stability Program: 4F-36 DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Inlet Solenoid Circuit Failure, Outlet Solenoid Circuit Failure, Master Cylinder Cut Solenoid Circuit Failure, Low Pressure Solenoid Circuit Failure S5JB0B4604071 DTC C1041 / C1045 / C1051 / C1055: Right-Front / Left-Front / Right-Rear / Left-Rear Inlet Solenoid...
Page 414: Dtc C1061: Pump Motor And/Or Motor Driver Circuit Failure
4F-37 Electronic Stability Program: DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program Check: ”. Check back up light switch and its circuit Go to Step 3. Repair or replace. 1) Turn ignition switch to ON position.
Page 415 Electronic Stability Program: 4F-38 DTC C1073: Lost Communication With Yaw Rate / G Sensor Assembly S5JB0B4604077 Wiring Diagram L39-2 E53-29 L39-1 E53-25 L39-3 PNK/WHT E53-37 PNK/GRN L39-5 E53-31 I6JB01460022-03 [A]: ESP® control module connector (viewed from 1. Yaw rate / G sensor assembly 3.
Page 416 4F-39 Electronic Stability Program: Step Action Check yaw rate / G sensor assembly Substitute a known- Yaw rate / G sensor good ESP® hydraulic assembly malfunction. 1) Substitute a known-good yaw rate / G sensor assembly. unit / control module 2) Connect connectors to ESP®...
Page 417: Dtc U1073: Control Module Communication Bus Off
Electronic Stability Program: 4F-40 DTC C1090: ECM Detect Rolling Counter Failure with ESP® Control Module S5JB0B4604079 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area ESP® control module rolling counter failure is detected by • CAN communication circuit ECM.
Page 418 4F-41 Electronic Stability Program: DTC U1126: Lost Communication with Steering Angle Sensor (Reception Error) S5JB0B4604084 Wiring Diagram E53-44 WHT/BLU WHT/BLU E66-26 E53-13 WHT/RED WHT/RED E66-32 E53-42 E53-46 G24-6 G24-5 E91-22 G28-10 E91-23 G28-8 G31-1 G31-3 G45-9 G45-10 G31-4 G31-2 15 14 13 18 17 13 12 39 38...
Page 419 Electronic Stability Program: 4F-42 DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program Check: ”. DTC check for ESP® Go to “DTC U1073: Go to Step 3. Control Module 1) Check DTC for ESP®. Communication Bus Is DTC U1126 and DTC U1073 detected together? Off: in Section 4E”.
Page 420 4F-43 Electronic Stability Program: DTC U1139: Lost Communication with 4WD Control Module (Reception Error) (If Equipped 4WD Control Module) S5JB0B4604085 Wiring Diagram Refer to “DTC U1126: Lost Communication with Steering Angle Sensor (Reception Error): ”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area 4WD control module message data is missing from CAN...
Page 421 Electronic Stability Program: 4F-44 Step Action DTC check for ESP® Check ESP® control Check applicable module power and control module power 1) Connect connectors of disconnected control modules ground circuit. If circuits and ground circuit. If communicating by means of CAN. are OK, substitute a circuit is OK, substitute 2) Disconnect each connector and check DTC for ESP®...
Page 422 4F-45 Electronic Stability Program: DTC U1140: Lost Communication with BCM (Reception Error) S5JB0B4604086 Wiring Diagram Refer to “DTC U1126: Lost Communication with Steering Angle Sensor (Reception Error): ”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area BCM message data is missing from CAN communication. • CAN communication circuit •...
Page 423: Repair Instructions
1) Set steering wheel in straight-ahead position. steering angle sensor should be calibrated. 2) Connect SUZUKI scan tool to data link connector 1) Set steering wheel in straight-ahead position. (DLC) (1) with ignition switch OFF.
Page 424: Front Wheel Speed Sensor On-Vehicle Inspection
“Brake Diagnosis Note: in Section 4A in related manual”. Rear Wheel Speed Sensor Inspection 3) Connect SUZUKI scan tool to data link connector S5JB0B4606096 (DLC) (1) with ignition switch OFF. Refer to “Rear Wheel Speed Sensor Inspection: ” since...
Page 425 0 ± 0.1 G Level condition “DATA LIST” of SUZUKI scan tool. 0.1 ± 0.1 G Front-up condition If pressure displayed on SUZUKI scan tool is out of –0.1 ± 0.1 G Rear-up condition specification, replace ESP® hydraulic unit / control module assembly.
Page 426 –0.1 ± 0.1 G Left-up condition wheels with chokes. 3) Check yaw rate / G sensor assembly installation condition. 4) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool “a”...
Page 427 Electronic Stability Program: 4F-50 Yaw Rate / G Sensor Assembly Removal and 4) Turn ignition switch to ON position and select menu “DATA LIST” mode of SUZUKI scan tool. Refer to Installation scan tool operator's manual for further derails. S5JB0B4606103 5) Check “Yaw rate sensor”...
Page 428 0.8 kgf-m, 6.0 lb-ft) If calibration is incompleted, calibrate sensor referring to “Sensor Calibration: ”. 1) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool...
Page 429 Electronic Stability Program: 4F-52 Steering Angle Sensor Removal and Installation ESP® OFF Switch Inspection S5JB0B4606106 S5JB0B4606108 Refer to “Steering Angle Sensor Removal and Check for continuity between terminals at each switch Installation: in Section 6B”. position. If check result is not as specified, replace ESP® OFF switch.
Page 430 For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Special Tool S5JB0B4608001 09956–02311 SUZUKI scan tool Brake pressure gauge — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3.
Page 431 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........5-1 Reverse Idle Gear Assembly Disassembly and Reassembly ..........5B-31 Precautions.............
Page 432 5-ii Table of Contents Tightening Torque Specifications......5C-7 Special Tool ............5C-7 Special Tools and Equipment ......5C-7 Recommended Service Material ......5C-7...
Page 433: Precautions
Precautions: Precautions Precautions Precautions for Transmission / Transaxle S5JB0B5000001 Air Bag Warning Refer to “Air Bag Warning: in Section 00 in related manual”. Fastener Caution Refer to “Fastener Caution: in Section 00 in related manual”.
Page 434: Manual Transmission/Transaxle
5B-1 Manual Transmission/Transaxle: Manual Transmission/Transaxle General Description Manual Transmission Construction S5JB0B5201001 The manual transmission consists of the input shaft, main shaft, countershaft and reverse idle gear shaft which are installed in the die-cast aluminum alloy case. This transmission provides five forward speeds and one reverse speed. The 1st, 2nd and 3rd speeds are for speed reduction drive, 4th speed is for direct drive 5th speed is for speed increasing drive.
Page 435: Manual Transmission Symptom Diagnosis
Manual Transmission/Transaxle: 5B-2 Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis S5JB0B5204001 Condition Possible cause Correction / Reference Item Gear slipping out of mesh Worn shift fork shaft Replace. Worn shift fork or synchronizer sleeve Replace. Weak or damaged locating spring Replace.
Page 436: Repair Instructions
5B-3 Manual Transmission/Transaxle: Repair Instructions Manual Transmission Assembly Components S5JB0B5206001 I5JB0B520099-02 1. Transmission front case 19. Reverse shift limit cam spring 37. Reverse idle gear case No.1 bolt : Apply sealant 99000-31110 to mating surface of front case and rear case. 2.
Page 437: Gear Shift Lever Case Assembly
Manual Transmission/Transaxle: 5B-4 4. Gear shift lever case assembly 22. Reverse idle gear needle bearing 40. High speed gear shift yoke : Apply sealant 99000-31110 to mating surface of gear shift lever case assembly and rear case. 5. Adapter case oil seal 23.
Page 438 5B-5 Manual Transmission/Transaxle: Gear Shift Lever Case Assembly Components S5JB0B5206002 I5JB0B520003-03 [A]: Fix with bolt type 10. Gear shift lever case front plug 21. Gear shift lever case plate screw [B]: Fix without bolt type 11. Gear shift shaft 22. Control lever boot cover bolt 1.
Page 439: Gear Shift Shaft And Fork Components
Manual Transmission/Transaxle: 5B-6 Gear Shift Shaft and Fork Components S5JB0B5206004 I5JB0B520100-01 1. 5th & reverse gear shift shaft 7. 5th & reverse gear shift yoke 13. Pin 2. High speed gear shift shaft 8. High speed gear shift yoke 14. Gear shift shaft ball : Apply grease 99000-25010 to ball.
Page 440: Input Shaft Assembly, Main Shaft Assembly And Countershaft Assembly Components
5B-7 Manual Transmission/Transaxle: Input Shaft Assembly, Main Shaft Assembly and Countershaft Assembly Components S5JB0B5206005 I5JB0B520005-01 [A]: Input shaft assembly 15. 2nd gear 32. 5th gear synchronizer ring [B]: Main shaft assembly 16. 2nd gear needle bearing 33. 5th gear...
Page 441: Manual Transmission Oil Level Check
Manual Transmission/Transaxle: 5B-8 [C]: Countershaft assembly 17. Low speed synchronizer hub circlip 34. Input shaft rear bearing 1. Input shaft front bearing circlip 18. 2nd gear synchronizer ring assembly 35. Input shaft rear bearing circlip 2. Input shaft front bearing 19.
Page 442: Transmission Shift Control Lever Removal And Installation
Tightening torque Control lever locating bolt (a): 10 N·m (1.0 kgf- m, 7.5 lb-ft) 2) Apply grease to pivot portions and seat, then install shift control lever. “A”: Grease 99000–25010 (SUZUKI Super Grease A) I5JB0A520022-02 “A” 80W-90 75W-85, 75W-90...
Page 443 Control lever locating bolt (a): 10 N·m (1.0 kgf- m, 7.5 lb-ft) 2) Apply grease to pivot portions and seat, then install shift control lever. “A”: Grease 99000–25010 (SUZUKI Super Grease A) “A” I5JB0B520009-01 5) Install sheet, boot (1) with boot cover (2) to floor panel.
Page 444: Transmission Shift Control Lever Inspection
• Check boot for damage. install back up light switch (1), new washer (2) and pin Correct or replace if necessary. to transmission front case. “A”: Grease 99000–25010 (SUZUKI Super Grease Back Up Light Switch Removal and Installation S5JB0B5206009 Tightening torque Removal Back up light switch (a): 39 N·m (3.9 kgf-m, 28.5...
Page 445: Gear Shift Lever Case Assembly Removal And Installation
1.5 mm (0.059 in.) in diameter, and then 1) Dismount transmission assembly referring to mate it with gear shift lever case. “Manual Transmission Assembly Dismounting and “A”: Sealant 99000–31110 (SUZUKI Bond Remounting: ” No.1215) 2) Remove gear shift lever case assembly (1) from 2) Install lever case to adapter case, and then tighten transmission adapter case.
Page 446: Gear Shift Lever Case Assembly Disassembly And Reassembly
5B-13 Manual Transmission/Transaxle: Gear Shift Lever Case Assembly Disassembly 4) Install gear shift case plate to gear shift lever case and tighten them to specified torque. and Reassembly S5JB0B5206015 Tightening torque Gear shift lever case plate screw: 6 N·m (0.6 kgf- Disassembly m, 4.5 lb-ft) 1) Remove gear shift case plate.
Page 447: Manual Transmission Assembly Dismounting And Remounting
Manual Transmission/Transaxle: 5B-14 Manual Transmission Assembly Dismounting 4) Detach engine harness clamps and ground wire harness from transmission front case. and Remounting S5JB0B5206018 5) Remove starting motor fastening bolts and Dismounting transmission fastening bolts. 1) Disconnect negative (–) cable of battery. 6) Disconnect clutch fluid pipe from joint referring to 2) Remove transmission shift control lever referring to “Clutch Fluid Pipe and Hose Removal and...
Page 448 • Install noise suppressor wire (1) at specified position Remounting as shown in figure. For remounting, reverse dismounting procedure noting the following. • Apply grease to input shaft. “A”: Grease 99000–25010 (SUZUKI Super Grease “A” I5JB0B520020-01 [A]: Forward 2. Installation position (90°) I5JB0A520031-01 •...
Page 449: Manual Transmission Unit Disassembly
Manual Transmission/Transaxle: 5B-16 • Install shift control lever referring to “Transmission 4) Remove select return bolt (3), springs and guide Shift Control Lever Removal and Installation: ”. pins, and then remove adapter case (1) from rear case (2). • Connect clutch fluid joint to pipe of clutch operating cylinder assembly referring to “Clutch Operating Cylinder Assembly Removal and Installation: in Section 5C”.
Page 450 5B-17 Manual Transmission/Transaxle: 7) Remove rear bearing plate (1), oil gutter (2) and 10) Remove rear case to front case bolts (1), then reverse shift shaft (3) from rear case (4). separate rear case (2) from front case (3) using special tool.
Page 451: Manual Transmission Unit Reassembly
Manual Transmission/Transaxle: 5B-18 12) Remove input shaft bearing retainer to front case 15) Remove input shaft assembly, main shaft assembly bolt (1), then separate input shaft bearing retainer (2) (1) and countershaft assembly (2) all together from from front case (3). front case (3) tapping input shaft end by plastic hammer lightly.
Page 452 (5) between low speed gear shift shaft and high speed gear shift shaft. Special tool (A): 09913–76010 “A”: Grease 99000–25010 (SUZUKI Super Grease A) “A”: Grease 99000–25010 (SUZUKI Super Grease A) Install position oil seal “a”: 0 –...
Page 453 Drive each gear shift shaft pin by shift locating bolts (3), and then tighten bolts to using special tool. specified torque. Special tool “A”: Grease 99000–25010 (SUZUKI Super (A): 09922–85811 Grease A) “B”: Sealant 99000–31110 (SUZUKI Bond No.1215) “b”...
Page 454 19) Set new gear shift shaft inner pin (4) and outer pin mate it with adapter case. (5) facing each gap (“a”, “b”) in the opposite direction as shown in figure. Drive gear shift shaft pins by “A”: Sealant 99000–31110 (SUZUKI Bond using special tool. No.1215) Special tool 23) Install rear case to adapter case.
Page 455: Locating Spring Inspection
Removal and Installation: ”. amount that its section is 1.5 mm (0.059 in.) in diameter, and then mate it with rear case. “A”: Sealant 99000–31110 (SUZUKI Bond No.1215) 25) Install reverse idle gear case to rear case with new bolts. Tighten No.1 bolts (3) and No.2 bolts (4) to specified torque.
Page 456: Input Shaft Inspection
5B-23 Manual Transmission/Transaxle: Main Shaft Disassembly Reassembly S5JB0B5206022 1) Clean all components thoroughly, inspect them for 1) Remove main shaft bearing circlip using snap ring any abnormality and replace with new ones as pliers. necessary. 2) Remove main shaft bearing (1) from main shaft (2) 2) Drive in input shaft bearing (1) onto input shaft facing using bearing puller and hydraulic press.
Page 457: Main Shaft Inspection
Manual Transmission/Transaxle: 5B-24 10) Remove reverse gear (1), reverse gear synchronizer 5) Remove 2nd gear needle bearing and 2nd gear synchronizer ring assembly. ring and 5th & reverse synchronizer hub (2) using bearing puller and hydraulic press, and then reverse 6) Remove circlip (1) using snap ring pliers (2) and then gear needle bearing.
Page 458 5B-25 Manual Transmission/Transaxle: • Put synchronizer outer ring (1), inner ring (2) and • Check clearance “d” between synchronizer center center cone (3) together and then measure step cone (1) and gear (2) while lightly pushing difference “b” between outer ring and inner ring using synchronizer outer ring by the hand, and also check straight edge (4).
Page 459: Main Shaft Reassembly
Manual Transmission/Transaxle: 5B-26 Main Shaft Reassembly • Check clearance “a” between fork (1) and sleeve (2). Replace those parts if it exceeds limit. S5JB0B5206024 NOTE NOTE • Before installation, wash each part and For correct judgement of parts replacement, apply specified gear oil to sliding faces of carefully inspect contact portion of fork and bearing and gear.
Page 460 5B-27 Manual Transmission/Transaxle: 4) Drive in 5th & reverse synchronizer assembly (1) 8) Select circlip (1) that will make thrust clearance “a” of using bearing puller, special tools and hydraulic bearing 0.15 mm (0.006 in) or less and install it. press.
Page 461 Manual Transmission/Transaxle: 5B-28 11) Drive in low speed synchronizer assembly (1) using 13) Apply oil to 2nd gear needle bearing, and then install bearing puller, special tools and hydraulic press, in 2nd gear synchronizer ring assembly, needle specified direction as shown in figure. bearing and 2nd gear (1) to main shaft.
Page 462: Countershaft Assembly Disassembly And Reassembly
5B-29 Manual Transmission/Transaxle: Countershaft Assembly Disassembly and 17) Drive in high speed synchronizer assembly (1) using bearing puller, special tools and hydraulic press, in Reassembly specified direction as shown in figure. S5JB0B5206025 Special tool Disassembly (A): 09913–84510 1) Remove countershaft rear bearing (1) using bearing puller, special tool and hydraulic press.
Page 463 Manual Transmission/Transaxle: 5B-30 3) Remove countershaft 5th gear (1) using bearing Reassembly puller and hydraulic press. 1) Clean all components thoroughly, inspect them for any abnormality and replace with new one as necessary. 2) Drive in countershaft 5th gear (1) to countershaft (2) facing its long flange (3) side downward in figure using bearing puller, special tools and hydraulic press.
Page 464: Reverse Idle Gear Assembly Disassembly And Reassembly
5B-31 Manual Transmission/Transaxle: 6) Drive in countershaft high speed gear spacer (1) to 9) Drive in countershaft front bearing (1) using bearing countershaft (2) using bearing puller, special tool and puller, special tool and hydraulic press. hydraulic press. Special tool Special tool (A): 09913–76010 (A): 09913–85210...
Page 465: Countershaft And Reverse Idle Gear Inspection
Special tool (A): 09913–75520 “A”: Grease 99000–25010 (SUZUKI Super Grease A) Installation position oil seal “a”: 1.5 – 2.5 mm (0.059 – 0.098 in.) I5JB0B520095-01...
Page 466: Specifications
5B-33 Manual Transmission/Transaxle: Specifications Tightening Torque Specifications S5JB0B5207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Transmission oil level / filler plug 25.0 Transmission oil drain plug 25.0 Oil filler plug 25.0 Control lever locating bolt Case cover bolt Control lever boot cover bolt Back up light switch 28.5 Gear shift lever front case bolt...
Page 467 Manual Transmission/Transaxle: 5B-34 Special Tools and Equipment Recommended Service Material S5JB0B5208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1215 P/No.: 99000–31110 NOTE Required service material is also described in the following.
Page 468 5B-35 Manual Transmission/Transaxle: 09925–98220 09925–98221 Bearing installer Bearing installer 09940–54910 09945–55410 Front fork oil seal install Bushing installer driver...
Page 469 Clutch: 5C-1 Clutch General Description Clutch (Hydraulic Type) Construction S5JB0B5301001 The clutch is a diaphragm-spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type, which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
Page 470 5C-2 Clutch: Component Location Clutch Fluid Pipe and Hose Location S5JB0B5303001 I5JB0A530002-03 [A]: Right-hand steering vehicle 3. Clutch fluid hose 6. Brake master cylinder reservoir 1. Clutch master cylinder 4. Clutch operating cylinder assembly 7. Clutch fluid pipe joint 2. Clutch fluid pipe 5.
Page 471 CAUTION • Apply grease to push rod clevis pin (1). • Do not allow fluid to get on painted “A”: Grease 99000–25100 (SUZUKI Silicone Grease) surfaces. It may cause painted surface • Tighten master cylinder attaching nuts (2) to specified damage.
Page 472 5C-4 Clutch: Clutch Operating Cylinder Assembly Removal Installation and Installation 1) Install clutch operating cylinder assembly (2) to S5JB0B5306007 transmission front case. Tighten mounting bolts to CAUTION specified torque. • Do not allow fluid to get on painted Tightening torque surfaces.
Page 473 Clutch: 5C-5 Clutch Cover, Clutch Disc and Flywheel Components S5JB0B5306008 I5JB0A530022-01 1. Input shaft bearing 4. Clutch cover : 20 N⋅m (2.0 kgf-m, 14.5 lb-ft) 2. Flywheel 5. Clutch cover bolt : 65 N⋅m (6.5 kgf-m, 47.0 lb-ft) 3. Clutch disc 6.
Page 474 2) Using special tool, install input shaft bearing to flywheel. IYSQ01530023-01 4) Slightly apply grease to input shaft (1). Special tool “A”: Grease 99000–25210 (SUZUKI Super (B): 09925–98210 Grease I) 5) Join transmission assembly with engine. Refer to “Manual Transmission Assembly Dismounting and Remounting: in Section 5B”.
Page 475: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5JB0B5308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Silicone Grease P/No.: 99000–25100 SUZUKI Super Grease I P/No.: 99000–25210...
Page 476 5C-8 Clutch:...
Page 477 Table of Contents 6- i Section 6 Steering CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........6-* Adjustable Steering Column Release Lever Inspection..........
Page 478 6-ii Table of Contents Steering Gear Case Mount Bushing P/S Pump Inspection.........6C-10 Inspection............6C-* Specifications .............6C-11 Rack Boot / Tie-Rod Removal and Tightening Torque Specifications......6C-11 Installation ............6C-* Special Tools and Equipment ......6C-11 P/S Hose / Pipe Components ......6C-9 Special Tool ............6C-11 P/S Pump Removal and Installation....6C-10 P/S Pump Assembly Components ....6C-10...
Page 479 Steering Wheel and Column: 6B-1 Steering Wheel and Column General Description Steering Wheel and Column Construction S5JB0B6201001 This double tube type steering column has the following three important features in addition to the steering function: • The column is energy absorbing, designed to compress in a front-end collision. •...
Page 480 6B-2 Steering Wheel and Column: I6JB01620001-01 1. Steering wheel 9. Steering column lower seal 17. Steering lower shaft assembly upper joint bolt : After tightening all mounting bolts and nuts and all joint bolts and nuts, tighten lower shaft lower joint bolt. 2.
Page 481: Installation
Steering Wheel and Column: 6B-3 Repair Instructions Contact Coil Cable Assembly Removal and 5) Disconnect all connectors for contact coil cable assembly. Installation S5JB0B6206003 6) Remove contact coil cable assembly (1) with steering angle sensor (if equipped) from steering CAUTION column.
Page 482: Steering Angle Sensor Removal And Installation
6B-4 Steering Wheel and Column: Steering Angle Sensor Removal and Installation 3) Connect all connectors that have been removed in “Removal”. S5JB0B6206014 4) Install steering column upper cover (2) and lower Removal cover (3), and then tighten steering column cover 1) Remove steering wheel and contact coil cable screws (1).
Page 483: Steering Column Assembly Removal And Installation
Steering Wheel and Column: 6B-5 Steering Column Assembly Removal and Installation S5JB0B6206006 CAUTION Once the steering column assembly is removed from the vehicle, the column is extremely susceptible to damage. Dropping the column assembly on its end could collapse the steering shaft or loosen I5JB0A620018-01 the plastic shear pins which maintain column 5) Remove immobilizer control module (ICM) referring...
Page 484 6B-6 Steering Wheel and Column: 5) Install new steering upper shaft upper joint bolt (2) 11) Remove column support bracket. (if equipped) and nut (1). Tighten new steering upper shaft upper 12) Remove steering column assembly (1) mounting joint nut (1) to specified torque. bolts (2) and nuts (3).
Page 485: And Installation
Steering Wheel and Column: 6B-7 11) Install instrument panel under cover (1) to instrument 12) Install steering wheel and contact coil cable panel. assembly by referring to “Steering Wheel Removal and Installation: in related manual” and “Contact Coil Cable Assembly Removal and Installation: ”. 13) Connect negative (–) cable to battery.
Page 486: Power Assisted Steering System
6C-1 Power Assisted Steering System: Power Assisted Steering System General Description P/S System Construction S5JB0B6301001 The power steering (P/S) system in this vehicle reduces the driver’s effort needed in turning the steering wheel by utilizing the hydraulic pressure generated by the power steering (P/S) pump (2) which is driven by the engine. It is an integral type with the rack and pinion gears and the control valve unit, hydraulic pressure cylinder unit all built in the steering gear case (1).
Page 487: P/S Pump Construction
Power Assisted Steering System: 6C-2 P/S Pump Construction S5JB0B6301003 The power steering pump is a vane type and is driven by the V-ribbed belt from the crankshaft. Power steering (P/S) pump specifications Model Vane type Hydraulic pressure Relieved pressure 7850 kPa (79.3 kg/cm , 1128 psi) control Control device...
Page 488: Steering Force Check
6C-3 Power Assisted Steering System: Condition Possible cause Correction / Reference Item Steering wheel play is Refer to “Steering Symptom Diagnosis: large and vehicle wanders in Section 6A in related manual”. Fluid leakage Loose joints of (hydraulic pressure) Retighten. pipes and hoses Deformed or damaged pipes or hoses Replace defective part.
Page 489: Hydraulic Pressure In P/S Circuit Check
Power Assisted Steering System: 6C-4 Hydraulic Pressure in P/S Circuit Check 2) Check each connection for fluid leakage and bleed S5JB0B6304006 air. Refer to “P/S System Air Bleeding Procedure: in 1) After cleaning joint of high pressure hose and P/S related manual”.
Page 490 6C-5 Power Assisted Steering System: 5) Check relief pressure. b) Open gauge valve fully and increase engine speed to about 1500 r/min. (rpm). Then turn a) Increase engine speed to about 600 r/min. (rpm). steering wheel to the left or right fully and take Close gauge valve gradually while watching reading of relief pressure.
Page 491: Repair Instructions
Power Assisted Steering System: 6C-6 Repair Instructions P/S Fluid Level Check P/S Fluid Leakage Check S5JB0B6306002 S5JB0B6306003 With engine stopped, check fluid level indicated on P/S Start engine and turn steering wheel fully to the right and fluid reservoir, which should be between “UPPER” and left so that maximum hydraulic pressure is provided.
Page 492: P/S Gear Case Assembly Removal And Installation
6C-7 Power Assisted Steering System: P/S Gear Case Assembly Removal and 8) Disconnect steering lower shaft assembly (1) from pinion shaft of P/S gear case assembly (2) referring Installation to Step 5) of “Removal” in “Steering Lower Shaft S5JB0B6306014 CAUTION Assembly Removal and Installation: in Section 6B in related manual”.
Page 493 Power Assisted Steering System: 6C-8 14) Remove bolts (1) and then take off P/S gear case CAUTION assembly from left side of vehicle. Be sure to confirm that steering wheel and NOTE front tires (wheels) are in straight position when inserting steering lower joint into P/S gear case assembly cannot be removed steering pinion shaft.
Page 494: P/S Hose / Pipe Components
6C-9 Power Assisted Steering System: P/S Hose / Pipe Components S5JB0B6306018 I5JB0B630006-02 [A]: LH steering vehicle 6. Low pressure return hose 13. Washer [B]: RH steering vehicle 7. P/S fluid reservoir bracket : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 1. P/S pump assembly 8.
Page 495: P/S Pump Removal And Installation
Power Assisted Steering System: 6C-10 P/S Pump Removal and Installation Installation S5JB0B6306019 Reverse removal procedure, and then noting the following instructions. Removal NOTE CAUTION Fill specified power steering fluid after Never disassemble P/S pump for diesel installation and bleed air without failure. engine model.
Page 496: Specifications
6C-11 Power Assisted Steering System: Specifications Tightening Torque Specifications S5JB0B6307001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Steering lower shaft bolt 18.5 Gear case high pressure pipe union bolt 25.5 Gear case cylinder pipe flare nut 18.0 Gear case mounting bolt 10.5 76.0 Gear case low pressure pipe flare nut...
Page 497 Table of Contents 7- i Section 7 HVAC CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........7-* Blower Motor Controller Inspection ..... 7A-* Blower Motor Relay Inspection ......
Page 498 7-ii Table of Contents General Description ..........7B-3 DTC B1552: Serial Communication AUTO A/C System Description ......7B-* Circuit Malfunction..........7B-* HVAC Control System Description...... 7B-* DTC B1553: CAN Communication Circuit Auto A/C Electronic Control Input / Output Malfunction............7B-* Table ..............7B-3 DTC B1556: Camshaft Position (CMP) Sensor and/or Its Circuit Malfunction ....
Page 499 Table of Contents 7-iii A/C Compressor Drive Belt Removal and Magnet Clutch Operating Check .......7B-28 Installation ............7B-25 Magnet Clutch Removal and Installation...7B-29 A/C Compressor Relay Inspection ....7B-26 Relief Valve On-Vehicle Inspection....7B-31 Compressor Assembly On-Vehicle Specifications .............7B-31 Inspection............7B-26 Tightening Torque Specifications......7B-31 Compressor Assembly and Compressor Special Tools and Equipment ......7B-32...
Page 500 7A-1 Heater and Ventilation: Heater and Ventilation General Description Additional Heater System Description S5JB0B7101005 This system, consisting of ECM, additional heater assembly and 3 relays, warms up the engine coolant which flows through the heater core while the engine is warmed up, thereby promoting interior heating.
Page 501 Heater and Ventilation: 7A-2 Additional Heater System Input / Output Table S5JB0B7102004 CKP senser Additional heater relay No.1 Battery voltage Additional heater relay No.2 IAT sencer Additional heater relay No.3 ECT senser I5JB0B710003-02 Additional Heater System Component Location S5JB0B7102005 I5JB0B710004-01 1.
Page 502 7A-3 Heater and Ventilation: Diagnostic Information and Procedures Heater and Ventilation Symptom Diagnosis S5JB0B7104008 Condition Possible cause Correction / Reference Item Blower won’t work even Blower fuse blown Replace fuse to check for short. when blower speed Blower motor faulty Check blower motor referring to “Blower Motor selector is ON Inspection: in related manual”.
Page 503 Heater and Ventilation: 7A-4 Condition Possible cause Correction / Reference Item Heating performance is Fuse blown Check related fuses and check for short circuit poor (for additional heater to ground. system) Additional heater relays faulty Check additional heater relays referring to “Additional Heater Relay Inspection: ”.
Page 504 7A-5 Heater and Ventilation: Additional Heater Assembly On-Vehicle Additional Heater Assembly Removal and Inspection Installation S5JB0B7106025 S5JB0B7106026 1) Disconnect negative (–) cable at battery. Removal 2) Disconnect wires from additional heater terminals. 1) Disconnect negative (–) cable at battery. NOTE 2) Drain engine coolant referring to “Cooling System Draining: in Section 1F”.
Page 505 Heater and Ventilation: 7A-6 Specifications Tightening Torque Specifications S5JB0B7107001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Additional heater wire nut Reference: For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”.
Page 506 7B-1 Air Conditioning System: Air Conditioning System Precautions Precautions on Servicing Refrigerant Line S5JB0B7200005 • When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to seats of coupling nuts and O-ring. I5JB0B720021-04 [A]: LH steering vehicle 2.
Page 507 Air Conditioning System: 7B-2 Precautions on Replenishing Compressor Oil Amount of oil in new compressor S5JB0B7200008 150 (+20, –0) cm (150 (+20, –0) cc) When replacing air conditioning parts with new ones, it is Amount of compressor oil to be replenished after necessary to replenish oil by the amount supposedly part replacement remaining in each part.
Page 508 7B-3 Air Conditioning System: General Description Auto A/C Electronic Control Input / Output Table S5JB0B7201003 HVAC control module Temperature selector Data link connector MODE (air flow) selector Blower speed selector Air intake selector A/C refrigerant pressure sensor A/C switch AUTO switch ECT sensor Additional heater relay Temperature control actuator...
Page 509 Air Conditioning System: 7B-4 Schematic and Routing Diagram A/C System Wiring Circuit Diagram S5JB0B7202001 BLK/RED BLU/BLK WHT/GRN WHT/RED BLK/RED WHT/GRN YEL/GRN BLU/WHT BLK/RED G52-8 G52-1 PPL/RED G52-15 RED/BLK G52-16 PPL/GRN G52-2 BLU/WHT G52-4 BLU/BLK RED/YEL BLU/BLK G52-14 WHT/BLU 34 RED/WHT WHT/BLK G52-19 BLK/RED...
Page 510 7B-5 Air Conditioning System: 4. To radiator fan relay No.1 23. Blower motor selector 42. To compressor relay 5. To radiator fan relay No.3 24. Radiator fan relay No.1 43. To rear defogger relay 6. Ignition switch 25. Radiator fan No.1 44.
Page 511 Air Conditioning System: 7B-6 Component Location A/C Control System Components Location S5JB0B7203002 NOTE The figure shows left-hand steering vehicle. For right-hand vehicle, parts with (*) are installed at the opposite side. 24 26 I5JB0B720004-04 1. Outside temperature sensor 10. Blower motor 19.
Page 512 7B-7 Air Conditioning System: 2. Sunload sensor 11. Blower motor controller 20. Blower speed selector / Air intake selector 3. Inside temperature sensor 12. Temperature selector / A/C switch 21. Rear defogger switch 4. ECT sensor 13. “DEF” switch 22. “REC” indicator lamp 5.
Page 513 Air Conditioning System: 7B-8 Diagnostic Information and Procedures Scan Tool Data S5JB0B7204006 As the data values given below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicles are in good condition, there may be cases where the checked values do not fall within each specifies data range.
Page 514 7B-9 Air Conditioning System: Normal Condition / Scan Tool Data Condition Reference Value Additional heater relay No.2 is ON. SUPPLEMENT HT 2 Additional heater relay No.2 is OFF. Additional heater relay No.3 is ON. SUPPLEMENT HT 3 Additional heater relay No.3 is OFF. VEHICLE SPEED Vehicle stops.
Page 515 Air Conditioning System: 7B-10 A/C System Performance Inspection 5) Warm up engine to normal operating temperature (engine coolant temperature at 80 – 90 °C (176 – S5JB0B7204008 1) Confirm that vehicle and environmental conditions 194 °F)) and keep it at specified idle speed. are as follows.
Page 516 7B-11 Air Conditioning System: 10) Check for each pressure of low side and high side if it is within shaded range of graph. If each gauge kg/cm reading is out of specified pressure, correct defective 327.1 2300 part referring to the table. 312.9 2200 298.7 2100 Low side and high side pressure example,...
Page 517 Air Conditioning System: 7B-12 11) Check inlet port temperature-to-outlet port temperature relationship using graph. For example, if A/C evaporator inlet port temperature is 30 °C (86 °F) and center ventilation louver temperature is 15 °C (59 °F), their crossing point is within acceptable range as shown in the graph in this case, cooling performance is satisfactory and proper.
Page 518 7B-13 Air Conditioning System: Condition Manifold Gauge (kg/cm Possible Cause Correction Detail (psi) 0.23 – 0.33 1.57 – 1.97 (2.3 – 3.3) (15.7 – 19.7) Normal condition — — (33 – 47) (223 – 280) The low pressure side Clean expansion valve. reads a negative pressure, Dust particles or water Replace it if it cannot be...
Page 519 Air Conditioning System: 7B-14 Condition Manifold Gauge (kg/cm Possible Cause Correction Detail (psi) Overcharged A/C Adjust refrigerant to system. High pressure reading on specified amount. Faulty condenser both low and high pressure Clean condenser. cooling operation. sides. Inspect and repair Faulty radiator fan radiator fan.
Page 520 7B-15 Air Conditioning System: Condition Possible cause Correction / Reference Item No cool air comes out Fuse blown Check related fuses, and then check for short (radiator cooling fan circuit to ground. motor does not operate) Wiring or grounding faulty Repair as necessary.
Page 521 Air Conditioning System: 7B-16 Condition Possible cause Correction / Reference Item Cool air does not come Insufficient or excessive charge of Check the amount of refrigerant and system out or insufficient cooling refrigerant for leaks. (A/C system normal Condenser clogged Check condenser referring to “A/C Condenser operation) Assembly On-Vehicle Inspection: in related...
Page 522 7B-17 Air Conditioning System: Condition Possible cause Correction / Reference Item Cool air comes out only at Condenser clogged Check condenser referring to “A/C Condenser high speed Assembly On-Vehicle Inspection: in related manual”. Insufficient charge of refrigerant Check the amount of refrigerant and system for leaks.
Page 523 Air Conditioning System: 7B-18 DTC B1561: Engine Coolant Temperature Sensor and/or Its Circuit Malfunction S5JB0B7204029 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area HVAC control module receives error code from BCM continuously. • ECT sensor circuit • ECT sensor •...
Page 524 7B-19 Air Conditioning System: Repair Instructions Operation Procedure for Charging A/C with Refrigerant S5JB0B7206001 WARNING • Your eyes should not be exposed to refrigerant (liquid). Any liquid Refrigerant-134a escaping by accident shows a temperature as low as approx. –6 °C (21.2 °F) below freezing point.
Page 525 Air Conditioning System: 7B-20 Recovery 2) Attach center charging hose (6) of manifold gauge When discharging refrigerant out of A/C system, always set (3) to vacuum pump (7). recover it by using refrigerant recovery and recycling 3) Operate vacuum pump (7), and then open equipment (1).
Page 526 7B-21 Air Conditioning System: NOTE Checking of A/C System for Pressure Leaks After completing the evacuation, close manifold gauge The A/C system contains HFC-134a (R-134a). high pressure valve (Hi) and low-pressure valve (Lo) and Described here is a method to charge the A/C wait 10 minutes.
Page 527 Air Conditioning System: 7B-22 5) Start engine and keep engine speed at 1,500 rpm. Then, operate A/C system. 6) Charge A/C system with refrigerant in vapor state. At this time, refrigerant container should be held upright. 7) When refrigerant container (3) is emptied, the use following procedure to replace it with a new refrigerant container (3).
Page 528 7B-23 Air Conditioning System: 1) Disconnect negative (–) cable at battery. Liquid leak detector 2) Disable air bag system referring to “Disabling Air WARNING Bag System: in Section 8B in related manual”. 3) Recover refrigerant from A/C system using recovery •...
Page 529 Air Conditioning System: 7B-24 A/C Refrigerant Pressure Sensor and Its Circuit Installation Inspection 1) Install HVAC unit by reversing removal procedure, S5JB0B7206015 noting the following items. 1) Connect manifold gauge set to the charging valves. • When installing each part, be careful not to catch 2) Check output voltage for A/C refrigerant pressure any wiring harness.
Page 530: A/C Compressor Drive Belt Removal And Installation
7B-25 Air Conditioning System: A/C Refrigerant Pressure Sensor Removal and Installation Reverse removal procedure noting the following Installation instructions. S5JB0B7206016 Removal • Apply compressor oil to O-ring of A/C refrigerant 1) Recover refrigerant from the A/C system with the pressure sensor. recovery and recycling equipment referring to •...
Page 531: A/C Compressor Relay Inspection
Air Conditioning System: 7B-26 A/C Compressor Relay Inspection Compressor Assembly On-Vehicle Inspection S5JB0B7206032 S5JB0B7206033 1) Disconnect negative (–) cable at battery. 1) Install manifold gauge set (1) as shown in figure. 2) Remove compressor relay (1) from vehicle. 2) Close Hi (4) and Lo (5) side valves. 3) Check that there is no continuity between terminal “c”...
Page 532: Compressor Assembly Removal And Installation
7B-27 Air Conditioning System: Compressor Assembly and Compressor Bracket Components S5JB0B7206047 I5JB0B720017-05 1. Compressor assembly 8. Compressor bracket mount bolt 2. Compressor bracket 9. Idler bolt No.1 3. Idler pulley No.1 10. Idler bolt No.2 4. Idler pulley No.2 : 25 N⋅m (2.5 kgf-m, 18.5 lb-ft) 5.
Page 533: Magnet Clutch Components
Air Conditioning System: 7B-28 Magnet Clutch Components S5JB0B7206037 I5JB0B720018-02 1. Armature plate bolt 4. Circlip 7. Compressor body assembly 2. Armature plate 5. Magnet clutch pulley : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft) 3. Shim(s) 6. Magnet clutch coil : Do not reuse. Magnet Clutch Operating Check S5JB0B7206039 Check the following items.
Page 534: Magnet Clutch Removal And Installation
7B-29 Air Conditioning System: Magnet Clutch Removal and Installation 6) Remove magnet clutch pulley (1) with puller (2). S5JB0B7206041 NOTE Removal Be careful not to damage pulley. 1) Remove compressor from vehicle referring to “Compressor Assembly Removal and Installation: ”. 2) Fix armature plate (1) with special tool (A) and remove armature plate bolt.
Page 535 Air Conditioning System: 7B-30 2) Install new snap ring (1) using special tool (A). 4) Install armature plate (1). 5) Using special tool (A), tighten new armature plate Special tool bolt (2) to specified torque. (B): 09900–06107 Tightening torque Armature plate bolt (a): 21 N·m (2.1 kgf-m, 15.5 lb-ft) Special tool (A): 09991–06310...
Page 536: Relief Valve On-Vehicle Inspection
7B-31 Air Conditioning System: 7) Install compressor to vehicle referring to Relief Valve On-Vehicle Inspection “Compressor Assembly Removal and Installation: ”. S5JB0B7206045 Using special tool (A), check is there is refrigerant leakage. If there is refrigerant leakage, replace compressor body. Special tool (A): 09990–86011 I5JB0B720020-01...
Page 537: Special Tools And Equipment
Air Conditioning System: 7B-32 Special Tools and Equipment Recommended Service Material S5JB0B7208001 Material SUZUKI recommended product or Specification Note Compressor oil Compressor oil (DH-PS, 250cc) P/No.: 99000–99022– NOTE Required service material is also described in the following. “Precautions on Servicing Refrigerant Line: ”...
Page 538 7B-33 Air Conditioning System:...
Page 539 Table of Contents 9- i Section 9 Body, Cab and Accessories CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........9-* E: Main harness, Controller wire (DSL RHD)..
Page 540 9-ii Table of Contents Junction Block (J/B) Connector / Fuse D-9 Headlight Beam Leveling System Layout .............9A-53 Circuit Diagram (Auto Leveling) ....9A-126 Fuse side..............9A-53 D-10 Rear Fog Light Circuit Diagram ....9A-127 Junction Block Inner Circuit (Overview) ....9A-54 E-2 Auto A/C System Circuit Diagram ....9A-128 Junction Block Inner Circuit (Detail) ....9A-55 F-1 Air-Bag System Circuit Diagram (4ch) ..9A-130 F-1 Air-Bag System Circuit Diagram (8ch) ..9A-131...
Page 541 Table of Contents 9-iii DRL System Symptom Diagnosis (If Headlight Manual Leveling Switch (If Equipped)............9B-* Equipped) Inspection ........9B-* Headlight Auto Leveling System Symptom Headlight Leveling Actuator Inspection (If Diagnosis (If Equipped)........9B-* Equipped)............9B-* Headlight Manual Leveling System Rear Fog Light Switch Inspection (If Equipped)............
Page 542 9-iv Table of Contents Audio System Symptom Diagnosis (If Wipers and Washers Components ..... 9D-* Equipped)............9C-* Washer Tank and Washer Pump Removal Remote Audio Control Switch Symptom and Installation ..........9D-* Diagnosis (If Equipped)........9C-* Washer Pump Inspection ........9D-* Navigation Symptom Diagnosis (If Windshield Wiper Removal and Installation ..
Page 543 Table of Contents 9-v Rear End Door Window Defogger Relay Keyless Entry Receiver and Its Circuit Inspection............9E-* Inspection............9F-* Rear End Door Window Defogger Wire Specifications ............9F-* Inspection............9E-* Tightening Torque Specifications......9F-* Rear End Door Window Defogger Wire Special Tools and Equipment ......9F-* Repair ..............9E-* Recommended Service Material ......9F-* Power Window Main Switch Inspection ....9E-*...
Page 544 9-vi Table of Contents Front Door Assembly Removal and Panel Clearance..........9K-* Installation ............9J-* Paint / Coatings ........9L-* Rear Door Assembly Components....... 9J-* Rear Door Assembly Removal and General Description ..........9L-* Installation ............9J-* Anti-Corrosion Treatment Construction....9L-* Rear End Door Assembly Components ....9J-* Plastic Parts Finishing ..........9L-* Rear End Door Assembly Removal and Component Location ..........9L-*...
Page 545: Wiring Systems
Wiring Systems: 9A-1 Wiring Systems General Description Abbreviations S5JB0B9101001 Abbreviation Full term Abbreviation Full term 2 wheel drive vehicles IF EQPD If equipped 4 wheel drive vehicles Ignition Air bag IG COIL Ignition coil Air conditioning Illumination A/LEV Auto leveling Indicator Automatic transaxle Intermittent...
Page 546: Symbols And Marks
9A-2 Wiring Systems: Symbols and Marks S5JB0B9101003 Battery Ground Normal fuse Slow blow fuse I2RH01910910-01 IYSQ01910915-01 IYSQ01910916-01 IYSQ01910917-01 IYSQ01910918-01 Circuit breaker Coil, Solenoid Heater Bulb IYSQ01910919-01 IYSQ01910920-01 IYSQ01910921-01 IYSQ01910922-01 IYSQ01910923-01 Cigarette lighter Motor Pump Horn Speaker IYSQ01910924-01 IYSQ01910925-01 IYSQ01910926-01 I2RH01910911-01 I5JB0B910995-02 Buzzer Chime...
Page 547: Harness Routing And Connector Layout Diagram
Wiring Systems: 9A-3 Ignition switch Keyless entry Immobilizer system Combination meter Lighting switch I2RH01910912-01 I3JA01910902-01 I5RH01910901-01 I2RH01910915-01 I2RH01910916-01 Headlight leveling Hazard warning light Front fog light Rear fog light Spark plug I3JA01910904-01 I3JA01910905-01 I3JA01910906-01 I3JA01910907-01 I2RH01910921-01 Radiator fan Fuel pump Injector XX control module Windshield wiper...
Page 548: Engine Compartment
9A-4 Wiring Systems: Engine Compartment S5JB0B910A002 C: Engine harness (M16A RHD) (TO E55) (TO E54) C04 C40 I5JB0A910901-05 C: Engine harness No./Color Connective position No./Color Connective position C01/- Battery (–) C21/GRN Generator #1 C02/- Battery fuse box C22/- Generator #2 C03/- Fuse box No.1 C23/BLK...
Page 549: C: Engine Harness (M16A Lhd)
Wiring Systems: 9A-5 C: Engine harness (M16A LHD) (TO E55) (TO E54) C04 C40 I5JB0A910902-05 C: Engine harness No./Color Connective position No./Color Connective position C01/- Battery (–) C21/GRN Generator #1 C02/- Battery fuse box C22/- Generator #2 C03/- Fuse box No.1 C23/BLK Starting motor #1 C04/GRY Injector #1...
Page 550: C: Engine Harness (J20A Rhd)
9A-6 Wiring Systems: C: Engine harness (J20A RHD) (A/T) (TO E89) (M/T) (A/T) (TO E87) (TO E88) (A/T) (TO E54) (TO E55) I5JB0B910901-03 C: Engine harness No./Color Connective position No./Color Connective position C30/BLK C01/- Battery (–) Back-up light switch (M/T) C02/- Battery fuse box C31/-...
Page 551: C: Engine Harness (J20A Lhd)
Wiring Systems: 9A-7 No./Color Connective position No./Color Connective position C23/BLK Starting motor #1 C51/BLU C24/- Starting motor #2 C52/BLK T/F 4L switch C25/BLU (A/ Output shaft speed sensor C53/N T/F position switch C26/GRY Knock sensor C54/GRY T/F actuator C27/BLU (A/ Input shaft speed sensor C55/- Weld splice...
Page 552 9A-8 Wiring Systems: C: Engine harness No./Color Connective position No./Color Connective position C30/BLK C01/- Battery (–) Back-up light switch (M/T) C02/- Battery fuse box C31/- Battery fuse box C03/- Fuse box No.1 C32/- Fuse box No.1 C04/GRY Injector #1 C33/N P/S pump pressure switch C05/GRY Injector #2 C34/N...
Page 553: C: Engine Harness / D: Injector Harness (H27A Rhd)
Wiring Systems: 9A-9 C: Engine harness / D: Injector harness (H27A RHD) C54 C52 C53 (M/T) (A/T) (A/T) (TO E89) (A/T) (TO E87) (TO E88) (A/T) (TO E54) (TO E55) D03 D01 I5JB0B910903-03...
Page 554 9A-10 Wiring Systems: C: Engine harness No./Color Connective position No./Color Connective position C01/- Battery (–) C34/N Main harness (To E54) C02/- Battery fuse box C35/BLU Main harness (To E55) C03/- Fuse box No.1 C36/GRY A/F sensor #1 C08/GRY CMP sensor C37/N C09/BLK ECT sensor...
Page 555 Wiring Systems: 9A-11 C: Engine harness / D: Injector harness (DSL RHD) (TO E88) (TO E89) (TO E54) (TO E55) C84 C59 C18 C91 I5JB0B910904-02 C: Engine harness No./Color Connective position No./Color Connective position C01/- Battery (–) C59/- Weld splice C02/- Battery fuse box C70/BLK...
Page 556 9A-12 Wiring Systems: No./Color Connective position No./Color Connective position C31/- Battery fuse box C87/GRY Up stream temperature sensor C32/- Fuse box No.1 C88/GRY Down stream temperature sensor C34/N Main harness (To E54) C89/BLK Differential temperature sensor C35/N Main harness (To E55) C90/BLK Turbo cooling control valve C39/GRY Fuse box No.1...
Page 557 Wiring Systems: 9A-13 C: Engine harness No./Color Connective position No./Color Connective position C01/- Battery (–) C59/- Weld splice C02/- Battery fuse box C70/BLK Turbo cooling pump C03/- Fuse box No.1 C71/BLK Injector harness (To D11) C04/BLK Injector #1 C72/BLK Injector harness (To D12) C05/BLK Injector #2 C73/YEL...
Page 558 9A-14 Wiring Systems: B: A/C compressor wire / E: Main harness, Front height sensor wire (Petrol RHD) (TO C35) (TO C34) Front height sensor wire I5JB0B910906-04 B: A/C compressor wire No./Color Connective position No./Color Connective position B01/BLK Main Harness (To E17) B02/BLK A/C compressor E: Main harness...
Page 559 Wiring Systems: 9A-15 No./Color Connective position No./Color Connective position E09/GRY Front turn signal light (R) E42/N Fuse box No.2 E43/GRY (5 E10/N Windshield washer motor HID headlight (R) E44/BLK (5 E11/N Rear washer motor Headlight LO (R) E12/BLK Front fog light (R) E45/GRY Headlight beam leveling actuator (R) E46/BLK (5 E13/YEL...
Page 560: E: Main Harness, Front Height Sensor Wire (Dsl Rhd)
9A-16 Wiring Systems: E: Main harness, Front height sensor wire (DSL RHD) (TO C35) (TO C34) Front height sensor wire I5JB0B910907-04...
Page 561 Wiring Systems: 9A-17 E: Main harness No./Color Connective position No./Color Connective position Fuse box No.2 (Heater motor relay & Main E01/GRY Windshield wiper motor E33/BLK relay & A/C compressor relay) Fuse box No.2 (Fuel heater relay & Turbo E02/GRY Brake fluid level switch E34/N cooling pump relay) Power integration No.1 (Mirror heater relay...
Page 562: B: A/C Compressor Wire / E: Main Harness, Front Height Sensor Wire (Petrol Lhd)
9A-18 Wiring Systems: B: A/C compressor wire / E: Main harness, Front height sensor wire (Petrol LHD) (TO C35) (TO C34) Front height sensor wire I5JB0B910908-03 B: A/C compressor wire No./Color Connective position No./Color Connective position B01/BLK Main Harness (To E17) B02/BLK A/C compressor E: Main harness...
Page 563 Wiring Systems: 9A-19 No./Color Connective position No./Color Connective position E44/BLK (5 E11/N Rear washer motor Headlight LO (R) E12/BLK Front fog light (R) E45/GRY Headlight beam leveling actuator (R) E46/BLK (5 E13/YEL Forward sensor (Driver side) Headlight HI (R) E47/GRY (5 E14/BLK Ambient temperature sensor HID headlight (L)
Page 564: E: Main Harness, Front Height Sensor Wire (Dsl Lhd)
9A-20 Wiring Systems: E: Main harness, Front height sensor wire (DSL LHD) (TO C35) (TO C34) Front height sensor wire I5JB0B910909-03...
Page 565 Wiring Systems: 9A-21 E: Main harness No./Color Connective position No./Color Connective position Fuse box No.2 (Heater motor relay & Main E01/GRY Windshield wiper motor E33/BLK relay & A/C compressor relay) Fuse box No.2 (Fuel heater relay & Turbo E02/GRY Brake fluid level switch E34/N cooling pump relay) Power integration No.1 (Mirror heater relay...
Page 566: Instrument Panel
9A-22 Wiring Systems: Instrument Panel S5JB0B910A003 E: Main harness, Controller wire (Petrol RHD) (M/T) (TO L01) (TO G04) (TO L03) (TO G06) (TO G71) (TO G05) (TO C48) (A/T) Controller wire (TO C50) (TO C49) (TO G37) (TO G36) I5JB0A910907-04 E: Main harness No./Color Connective position...
Page 567: E: Main Harness, Controller Wire (Dsl Rhd)
Wiring Systems: 9A-23 E: Main harness, Controller wire (DSL RHD) (TO L01) (TO G04) (TO L03) (TO G06) (TO G71) (TO G05) Controller wire (TO C50) (TO C49) (TO G37) (TO G36) I5JB0B910910-04 E: Main harness No./Color Connective position No./Color Connective position E67/N Brake lamp switch...
Page 568: E: Main Harness, Controller Wire (Petrol Lhd)
9A-24 Wiring Systems: E: Main harness, Controller wire (Petrol LHD) (TO G05) (TO L03) (TO G06) (TO G71) (TO G04) (TO C48) Controller wire (TO C50) (TO G37) (TO L01) (TO C49) (TO G36) I5JB0A910908-04 E: Main harness No./Color Connective position No./Color Connective position E67/N...
Page 569: E: Main Harness, Controller Wire (Dsl Lhd)
Wiring Systems: 9A-25 E: Main harness, Controller wire (DSL LHD) (TO G05) (TO L03) (TO G06) (TO G71) (TO G04) Controller wire (TO C50) (TO G37) (TO L01) (TO C49) (TO G36) I5JB0B910911-04 E: Main harness No./Color Connective position No./Color Connective position E67/N Brake lamp switch...
Page 570: B: A/C Wire / F: Console Wire / G: Instrument Panel Harness / Q: A/B Wire (Rhd)
9A-26 Wiring Systems: B: A/C wire / F: Console wire / G: Instrument panel harness / Q: A/B wire (RHD) (TO E90) (TO E76) (TO E78) (TO L28) (TO L27) (TO L09) (TO L08) (TO E75) (J20A) (A/T) (TO L29) (TO E74) (TO E77) I5JB0B910912-06...
Page 571 Wiring Systems: 9A-27 No./Color Connective position No./Color Connective position G17/N Fan driver G56/N Console wire (To F01) G18/N Blower fan motor G57/N Console wire (To F05) G58/N (IF G19/BLK Diode #2 Ashtray ILL EQPD) G20/BLK G59/GRN 4WD switch G60/GRN (IF G21/N IG switch ESP®...
Page 572: B: A/C Wire / F: Console Wire / G: Instrument Panel Harness / Q: A/B Wire (Lhd)
9A-28 Wiring Systems: B: A/C wire / F: Console wire / G: Instrument panel harness / Q: A/B wire (LHD) G44 G78 Q02 G64 (TO L27) (TO E90) (TO L28) (TO E76) (TO E77) (TO L09) (TO L08) (TO E75) (J20A) (A/T) (TO E78)
Page 573 Wiring Systems: 9A-29 G: Instrument panel harness No./Color Connective position No./Color Connective position G01/N G39/ORN HLC switch G02/N G40/N Headlight beam leveling switch G03/N G41/GRY ILL cancel switch G04/N Main harness (To E76) G43/BLK Diagnosis connector #4 G05/GRY Main harness (To E78) G44/N Smart ECM G45/N (IF...
Page 574: Door, Roof
9A-30 Wiring Systems: Door, Roof S5JB0B910A004 J: Front and rear door wire, rear door joint wire / K: Roof wire (RHD, 5dr) (TO L37) (TO L31) Rear door wire Front door wire (TO L07) Rear door wire (TO L13) I5JB0A910911-03 J: Front door wire (Drive side) No./Color Connective position...
Page 575: J: Front And Rear Door Wire, Rear Door Joint Wire / K: Roof Wire (Lhd, 5Dr)
Wiring Systems: 9A-31 J: Front and rear door wire, rear door joint wire / K: Roof wire (LHD, 5dr) (TO L37) Front door wire (TO L07) Rear door wire (TO L31) (TO L13) Rear door wire I5JB0A910912-04 J: Front door wire (Drive side) No./Color Connective position No./Color...
Page 576: J: Front And Rear Door Wire / K: Roof Wire (Rhd, 3Dr)
9A-32 Wiring Systems: J: Front and rear door wire / K: Roof wire (RHD, 3dr) (TO L31) Front door wire (TO L07) I5JB0A910913-03 J: Front door wire (Drive side) No./Color Connective position No./Color Connective position J01/GRY Floor harness (To L07) J06/N Front door lock motor (Driver side) J03/N...
Page 577: J: Front And Rear Door Wire / K: Roof Wire (Lhd, 3Dr)
Wiring Systems: 9A-33 J: Front and rear door wire / K: Roof wire (LHD, 3dr) Front door wire (TO L07) (TO L31) I5JB0A910914-04 J: Front door wire (Drive side) No./Color Connective position No./Color Connective position J01/GRY Floor harness (To L07) J08/GRY Power window main switch J05/BLK...
Page 578: Floor
9A-34 Wiring Systems: Floor S5JB0B910A005 L: Floor harness, Rear height sensor wire / R: Fuel pump wire (RHD, 5dr) (TO J27) (TO J09) (TO G72) (TO G55) (TO O01) (TO G08) (TO G72) (TO G07) (TO E80) (TO E79) (TO J01) (TO J16) Rear height sensor wire Fuel pump wire...
Page 579: L: Floor Harness, Rear Height Sensor Wire / R: Fuel Pump Wire (Lhd, 5Dr)
Wiring Systems: 9A-35 No./Color Connective position No./Color Connective position L24/BLK (IF L54/N Rear end door switch EQPD) L25/YEL Side air-bag inflator (R) L56/N Seat belt switch (Without seat heater) Seat heater & Seat belt switch (Driver L27/N Instrument panel harness (To G72) L57/N side) L28/N...
Page 580 9A-36 Wiring Systems: L: Floor harness No./Color Connective position No./Color Connective position L01/N Main harness (To E80) L30/YEL Side air-bag inflator (L) L03/YEL Main harness (To E79) L31/GRY Front door wire (Passenger side) (To J09) L04/BLK Turn signal relay L32/YEL (8ch) A/B SDM L05/N L33/YEL (8ch) A/B SDM L06/N...
Page 581: L: Floor Harness, Luggage Compartment Light Wire, Rear Height Sensor Wire / R: Fuel Pump Wire (Rhd, 3Dr)
Wiring Systems: 9A-37 L: Floor harness, Luggage compartment light wire, Rear height sensor wire / R: Fuel pump wire (RHD, 3dr) (TO J09) (TO G72) (TO G55) Luggage compartment light wire (TO G72) (TO G08) (TO G80) (TO G07) (TO J01) (TO E79) (TO O01) Fuel pomp wire...
Page 582: L: Floor Harness, Luggage Compartment Light Wire, Rear Height Sensor Wire / R: Fuel Pump Wire (Lhd, 3Dr)
9A-38 Wiring Systems: L: Luggage compartment light wire No./Color Connective position No./Color Connective position L68/N Floor harness (To L19) L69/N Luggage compartment light R: Fuel pump wire No./Color Connective position No./Color Connective position R01/GRY Floor harness (To L15) R03/N Fuel pump sub gauge R02/GRY or Fuel pump and gauge L: Floor harness, Luggage compartment light wire, Rear height sensor wire / R: Fuel pump wire (LHD, 3dr)
Page 583 Wiring Systems: 9A-39 L: Floor harness No./Color Connective position No./Color Connective position L01/N Main harness (To E80) L30/YEL Side air-bag inflator (L) L03/YEL Main harness (To E79) L31/GRY Front door wire (Passenger side) (To J09) L04/BLK Turn signal relay L32/YEL (8ch) A/B SDM L05/N L33/YEL (8ch) A/B SDM L06/N...
Page 584: Rear
9A-40 Wiring Systems: Rear S5JB0B910A006 O: Rear end door harness (TO L42) I5JB0A910919-02 O: Rear end door harness No./Color Connective position No./Color Connective position O01/N Floor harness (To L42) O06/BLK Rear defogger (–) O02/BLK Rear defogger (+) O07/N High mounted stop lamp O03/N Rear wiper motor O08/N...
Page 585: Ground Point
Wiring Systems: 9A-41 Ground Point Ground (earth) Point S5JB0B910C001 Refer to “Connector Layout Diagram: ”. M16A, J20A, DSL Right side shown On fuel tank 13 14 Passenger side Driver side J20A, DSL LHD shown RHD oppsite M16A 15 16 J20A J20A Front M16A...
Page 586: H27A
9A-42 Wiring Systems: H27A Right side shown On fuel tank 13 14 Front Right side shown I5JB0B910998-04...
Page 587: Power Supply Diagram
Wiring Systems: 9A-43 Power Supply Diagram Power Supply Diagram S5JB0B910D001 H27A Battery 120A Battery fuse 150A Battery fuse M16A, J20A Petrol Generator Petrol "A-2" BLK/GRY BLK/GRY RED/BLK WHT/BLU BLK/RED Starting motor BLK/RED Thermo plug Thermo plug Thermo plug Glow plug "A-1"...
Page 588 9A-44 Wiring Systems: Shift lock 7.5A relay relay Tail light relay 7.5A M16A WHT/GRN WHT/GRN WHT/GRN WHT/GRN BLK/RED Fuse Fuse No.2 No.2 GRN BLU/RED PNK/BLU BLU/RED BLU/BLK WHT/GRN WHT/GRN RED/YEL Mirror Horn heater relay relay relay relay Power BLU/BLK integration BLK/RED No.1 BLU/BLK...
Page 589 Wiring Systems: 9A-45 BLK/YEL BLK/YEL 7.5A YEL/GRN BLK/WHT Weld Weld splice splice WHT/GRN YEL/GRN BLK/WHT BLK/WHT Power integration No.2 Heated compressor oxgen relay relay relay WHT/RED BLU/RED BLK/WHT J20A Weld Weld Weld splice splice splice WHT/RED BLK/WHT H27A A/F sensor compressor "A-5"...
Page 590: Fuses And The Protected Parts
9A-46 Wiring Systems: Fuses and the Protected Parts S5JB0B910D002 The chart below describes what parts each fuse protects. Fuses in Battery Fuse Box, Fuse Box No.1 (Petrol) S5JB0B910D003 M16A, J20A H27A 120A I5JB0B910922-01 Fuse Protected circuit All electric circuit 80 A (M16A, J20A) Battery 120 A (H27A) Fuse box No.1...
Page 591: Fuses In Battery Fuse Box, Fuse Box No.1 (Dsl)
Wiring Systems: 9A-47 Fuses in Battery Fuse Box, Fuse Box No.1 (DSL) S5JB0B910D009 I5JB0B910923-01 Fuse Protected circuit 40 A Radiator fan relay #2 40 A Radiator fan relay #1 40 A 4WD control module 50 A IG switch Fuse box No.2 60 A Headlight LO relay Power integration No.1...
Page 592: Fuse Box No.2 (In Power Integration No.1, Power Integration No.2), Relay Box (Petrol)
9A-48 Wiring Systems: Fuse Box No.2 (In Power Integration No.1, Power Integration No.2), Relay Box (Petrol) S5JB0B910D004 M16A Compressor Relay "A-5" Headlight J20A, H27A HI relay Heated oxygen "D-1" Relay Relay "A-5" "A-5" Main relay Headlight LO relay "A-5" "D-1" Heater motor relay...
Page 593 Wiring Systems: 9A-49 Fuse Description on the cover Protected circuit 30 A H/L CLNR HLC motor Headlight (L) 10 A H/L L Headlight HI (L) Headlight (R) 10 A H/L R Headlight HI (R) Headlight HI relay 10 A Headlight LO relay 40 A Starting motor relay 40 A...
Page 594 9A-50 Wiring Systems: Fuse Description on the cover Protected circuit 30 A F/HTR Fuel heater relay 10 A T/C P Turbo cooling pump relay 15 A A/C compressor relay 10 A Fuel pump relay 25 A RR DEF Rear defogger relay 15 A HORN Horn relay...
Page 595: Fuse Box
Wiring Systems: 9A-51 Fuse Box No.3 (In J/B) S5JB0B910D005 Tail light relay "D-2" ACC relay 48 47 46 45 44 43 42 41 40 39 "G-2" Shift lock relay 38 37 36 35 34 33 32 31 30 29 "A-6" I5JB0A910926-02 Fuse Description on the cover...
Page 596 9A-52 Wiring Systems: Fuse Description on the cover Protected circuit COMB meter 10 A METER Turn signal relay Auto A/C unit ACC relay Power mirror switch 15 A Smart ECM Audio Multi information display Sub woofer relay 20 A 10 A TAIL Tail light relay Audio...
Page 597: Junction Block (J/B) Connector / Fuse Layout
Wiring Systems: 9A-53 Junction Block (J/B) Connector / Fuse Layout S5JB0B910D006 Fuse side Tail light Shift relay lock relay relay "D-2" "A-6" "G-2" 9 10 9 10 11 12 13 9 10 11 12 13 1 2 3 4 5 6 9 10 11 12 13 14 15 16 17 18 19 20...
Page 598: Junction Block Inner Circuit (Overview)
9A-54 Wiring Systems: Junction Block Inner Circuit (Overview) S5JB0B910D007 * : Not used To roof harness (K01) IG2 SIG IG SW ST ST SIG 7.5A (G02) IG COIL BACK S/H SW DR AS COMB SW WIPER A/B CONT ABS/ESP LEV SW STRG SNSR METER CIGAR...
Page 599: Junction Block Inner Circuit (Detail)
Wiring Systems: 9A-55 Junction Block Inner Circuit (Detail) S5JB0B910D008 Connector No. / Terminal No. IG2 SIG 15A S/H SW DR AS SUN ROOF CONT RLY +S P/W 30A P/W SW DR P/W SW AS P/W SW RL P/W SW RR WIP 20A FR WIPER MTR FR WASHER MTR...
Page 600 9A-56 Wiring Systems: Connector No. / Terminal No. ACC 15A RADIO MIRR SW SUB WOOFER FL LAMP ACC 2 15A CIGAR ACC SOKET-2 ACC RLY ACC 3 15A ACC SOCKET (RR) CTR DOME LP INP EARTH J/C VANITY LP SHIFT SW SHIFT LOCK RLY SHIFT LEVER STOP LP SW...
Page 601 Wiring Systems: 9A-57 Connector No. / Terminal No. S/R 25A SUN ROOF CONT HAZ 15A TURN CONT D/L 20A P/W T 20A P/W SW DR RR FOG 7.5A COMB SW LP STOP 15A STOP LP SW RR BLW 20A REAR BLOW TAIL RLY TAIL 10A FR POS LP L...
Page 602 9A-58 Wiring Systems: Connector No. / Terminal No. BCM DOME FR RR DOME LP LUGGAGE TURN CONT RR COMB LP L FR TURN LP L SIDE TURN LP L METER TURN CONT FR TURN LP R SIDE TURN LP R METER RR COMB LP R 1 2 3 4 5 6...
Page 603 Wiring Systems: 9A-59 System Circuit Diagram System Circuit Diagram S5JB0B910E001 Refer to “A-1 Cranking System Circuit Diagram: ”. Refer to “A-2 Charging System Circuit Diagram: ”. Refer to “A-3 Ignition System Circuit Diagram (M16A): ”. Refer to “A-3 Ignition System Circuit Diagram (J20A): ”. Refer to “A-3 Ignition System Circuit Diagram (H27A): ”.
Page 604: A-1 Cranking System Circuit Diagram
9A-60 Wiring Systems: A-1 Cranking System Circuit Diagram S5JB0B910E002 Fuse LOCK No.2 BLK/YEL Battery fuse box Battery ST SIG 7.5A BLK/GRY BLK/GRY BLK/RED BLK/YEL 11or3 9or1 Starting motor relay 12or4 12or4 10or2 BLK/YEL BLK/RED BLK/YEL BLK/RED Petrol Weld splice Petrol Transmission range sensor BLK/ORN...
Page 605: A-2 Charging System Circuit Diagram
Wiring Systems: 9A-61 A-2 Charging System Circuit Diagram S5JB0B910E003 M16A, J20A H27A Battery IG COIL fuse box 120A 150A BLK/WHT Weld splice Fuse box No.1 "A-5" "A-8" WHT/RED BLK/RED BRN/BLK BRN/BLK BRN/RED WHT/RED BLK/WHT J20A M16A, H27A Weld splice WHT/RED BLK/WHT Generator IC regulator...
Page 606: Ignition System Circuit Diagram (M16A)
9A-62 Wiring Systems: A-3 Ignition System Circuit Diagram (M16A) S5JB0B910E004 IG COIL BLK/WHT Weld splice BLK/WHT BLK/WHT BRN/BLK Weld splice BLK/WHT BLK/WHT BLK/WHT IG coil #2 IG coil #1 Noise filter BLK/ORN BLK/ORN BLK/ORN I5JB0A910931-02...
Page 607: Ignition System Circuit Diagram (J20A)
Wiring Systems: 9A-63 A-3 Ignition System Circuit Diagram (J20A) S5JB0B910E005 IG COIL BLK/WHT Weld splice BLK/WHT BLK/WHT BRN/BLK BRN/WHT BRN/YEL Weld splice BLK/WHT BRN/BLK BLK/WHT BRN/WHT BLK/WHT BRN/YEL BLK/WHT BLK/WHT Noise filter IG coil IG coil IG coil IG coil BLK/ORN BLK/ORN BLK/ORN...
Page 608: Ignition System Circuit Diagram (H27A)
9A-64 Wiring Systems: A-3 Ignition System Circuit Diagram (H27A) S5JB0B910E045 IG COIL BLK/WHT Weld splice BLK/WHT BLK/WHT BRN/BLK BRN/WHT BRN/YEL Weld splice BLK/WHT BRN/BLK BLK/WHT BRN/WHT BLK/WHT BRN/YEL BLK/WHT IG coil IG coil IG coil IG coil BLK/ORN BLK/ORN BLK/ORN BLK/ORN Weld splice...
Page 609 Wiring Systems: 9A-65 BRN/RED PPL/RED Weld splice BLK/WHT BRN/RED BLK/WHT PPL/RED BLK/WHT Noise filter IG coil IG coil BLK/ORN BLK/ORN BLK/ORN Weld splice I5JB0B910933-02...
Page 610: Cooling System Circuit Diagram (Petrol)
9A-66 Wiring Systems: A-4 Cooling System Circuit Diagram (Petrol) S5JB0B910E006 Fuse RDTR2 RDTR IG2 SIG No.1 BLU/WHT BLU/BLK YEL/GRN Weld splice YEL/GRN BLU/WHT YEL/GRN BLU/BLK YEL/GRN BLU/YEL Relay #1 Relay #2 Relay #3 Motor #1 RED/BLK BLU/RED RED/YEL BLU/RED "A-5" "A-5"...
Page 611: Cooling System Circuit Diagram (Dsl)
Wiring Systems: 9A-67 A-4 Cooling System Circuit Diagram (DSL) S5JB0B910E046 Fuse RDTR2 RDTR No.1 "A-5" BLU/BLK Weld BLU/WHT BLU/BLK splice BLU/BLK BLU/BLK Weld splice BLU/BLK BLU/WHT BLU/BLK BLU/BLK BLU/BLK BLU/YEL Relay #1 Relay #2 Relay #3 Motor #1 RED/YEL RED/BLK BLU/RED RED/YEL BLU/RED...
Page 612: Engine And A/C Control System Circuit Diagram (M16A)
9A-68 Wiring Systems: A-5 Engine and A/C Control System Circuit Diagram (M16A) S5JB0B910E007 Fuse CPRSR IG COIL No.2 Fuse box No.2 BLK/RED BLK/WHT Heated Main oxgen YEL/GRN BLK/WHT relay relay BLU/BLK Weld splice Weld splice BLU/BLK YEL/GRN BLK/WHT BLK/WHT BLK/WHT Relay Compressor relay...
Page 613 Wiring Systems: 9A-69 RDTR2 RDTR Fuse box Fuse box No.2 No.1 BLU/WHT BLU/BLK YEL/GRN Weld splice E55 C35 BLU/BLK BLU/BLK Weld splice BLU/BLK BLU/BLK BLU/RED YEL/GRN BLU/WHT YEL/GRN BLU/BLK YEL/GRN BLU/YEL BLU/BLK BLU/BLK BLU/BLK BLU/BLK BLU/BLK EVAP canister Throttle purge motor valve relay...
Page 614 9A-70 Wiring Systems: Weld splice BLU/BLK BLU/BLK BLU/BLK BLU/BLK sensor sensor stepper motor WHT/RED BLK/YEL BLK/YEL YEL/RED YEL/BLK YEL/GRN WHT/BLU BLK/YEL BLU/ORN BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/ORN BLK/ORN BLK/YEL Pump pressure switch I5JB0B910938-02...
Page 615 Wiring Systems: 9A-71 STOP DOME Starting motor relay "A-7" "A-1" Brake light switch BLK/YEL GRY/BLU PNK/BLU GRN/WHT PPL/WHT BRN/RED WHT/RED WHT/BLU BRN/BLK BRN/BLK (CAN line) Generator IG COIL #2 IG COIL #1 "A-2" "A-3" Cont.M PPL/WHT BLK/YEL "F-2" BLK/YEL "A-8" BLK/YEL PPL/WHT (CAN line)
Page 616 9A-72 Wiring Systems: Throttle position sensor Throttle sensor Acceleration pedal sensor MAIN MAIN close open close open close open close open Throttle motor ORN/BLU BLU/YEL BLU/YEL BLU/RED BLU/GRN WHT/BLU IF EQPD Clutch switch Diagnosis connector #1 Weld splice I5JB0B910939-01...
Page 617: Engine And A/C Control System Circuit Diagram (J20A)
Wiring Systems: 9A-73 A-5 Engine and A/C Control System Circuit Diagram (J20A) S5JB0B910E008 Fuse Power CPRSR IG COIL integration No.2 No.2 Power BLK/RED BLK/WHT integration No.2 Heated oxgen Main YEL/GRN BLK/WHT relay relay BLU/BLK Weld splice Weld splice YEL/GRN BLU/BLK Compressor BLK/WHT BLK/WHT BLK/WHT...
Page 618 9A-74 Wiring Systems: Fuse RDTR2 RDTR No.1 Power integration BLU/WHT BLU/BLK YEL/GRN No.2 Weld splice E55 C35 BLU/BLK BLU/BLK Weld splice BLU/BLK BLU/BLK BLU/RED YEL/GRN BLU/WHT YEL/GRN BLU/BLK YEL/GRN BLU/YEL BLU/BLK BLU/BLK BLU/BLK BLU/BLK BLU/BLK EVAP canister Throttle purge motor valve relay Relay...
Page 619 Wiring Systems: 9A-75 Weld splice BLU/BLK BLU/BLK BLU/BLK BLU/BLK Intake control sensor valve stepper motor BLK/YEL WHT/RED GRY/RED YEL/RED YEL/BLK YEL/GRN BLU/ORN BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/ORN BLK/ORN BLK/YEL sensor BLK/YEL Pump pressure switch I5JB0B910942-01...
Page 620 9A-76 Wiring Systems: CRUISE STOP DOME BLU/BLK BLU/BLK BLU/BLK BLU/BLK Starting motor relay "A-7" "A-1" Steering switch Brake (Auto CANCEL SET/ RESUME/ MAIN light cruise) COAST ACCEL switch BLK/YEL GRY/BLU PNK/BLU BLK/YEL LT GRN BLK/WHT BLK/YEL LT GRN BLK/WHT YEL/GRN GRN/WHT IF EQPD PPL/WHT...
Page 621 Wiring Systems: 9A-77 Throttle position sensor Throttle sensor Acceleration pedal sensor MAIN MAIN close open close open close open close open Throttle motor ORN/BLU BLU/YEL BLU/YEL BLU/RED BLU/GRN WHT/BLU IF EQPD Clutch switch Diagnosis connector #1 Weld splice I5JB0B910944-01...
Page 622: Engine And A/C Control System Circuit Diagram (H27A)
9A-78 Wiring Systems: A-5 Engine and A/C Control System Circuit Diagram (H27A) S5JB0B910E047 Fuse Power CPRSR IG COIL integration No.2 No.2 Power BLK/RED BLK/WHT integration No.2 Heated oxgen Main YEL/GRN BLK/WHT relay relay BLU/BLK Weld splice Weld splice YEL/GRN BLU/BLK Compressor BLK/WHT BLK/WHT BLK/WHT...
Page 623 Wiring Systems: 9A-79 Fuse RDTR2 RDTR No.1 Power integration BLU/WHT BLU/BLK YEL/GRN No.2 Weld splice E55 C35 BLU/BLK BLU/BLK Weld splice BLU/BLK BLU/BLK BLU/RED YEL/GRN BLU/WHT YEL/GRN BLU/BLK YEL/GRN BLU/YEL BLU/BLK BLU/BLK BLU/BLK EVAP canister Throttle purge motor valve relay Relay Relay Relay...
Page 624 9A-80 Wiring Systems: Weld splice BLU/BLK BLU/BLK BLU/BLK BLU/BLK BLU/BLK BLU/BLK BLU/BLK BLU/BLK BLU/BLK BLU/BLK Intake control sensor sensor valve PNK/BLK PNK/GRN PNK/BLU GRY/GRN GRY/BLK GRY/RED BLK/YEL WHT/RED BLK/YEL WHT/BLU PNK/BLK PNK/GRN PNK/BLU GRY/GRN GRY/BLK GRY/RED RED/WHT GRY/RED GRY/RED GRY/BLK BLK/YEL BLK/YEL BLK/YEL BLK/YEL...
Page 625 Wiring Systems: 9A-81 CRUISE STOP DOME BLU/BLK BLU/BLK BLU/BLK BLU/BLK Starting motor relay "A-7" "A-1" Steering switch Brake (Auto CANCEL SET/ RESUME/ MAIN light cruise) COAST ACCEL switch BLK/YEL GRY/BLU PNK/BLU BLK/YEL LT GRN BLK/WHT BLK/YEL LT GRN BLK/WHT YEL/GRN GRN/WHT IF EQPD PPL/WHT...
Page 626 9A-82 Wiring Systems: Throttle position sensor Throttle sensor Acceleration pedal sensor MAIN MAIN close open close open close open close open Throttle motor ORN/BLU BLU/YEL BLU/RED BLU/YEL BLU/GRN WHT/BLU BLU/RED BLU/YEL Clutch switch Weld splice I5JB0B910949-01...
Page 627: Engine And A/C Control System Circuit Diagram (Dsl)
Wiring Systems: 9A-83 A-5 Engine and A/C Control System Circuit Diagram (DSL) S5JB0B910E048 Fuse F/HTR IG COIL No.2 Fuse box No.2 BLK/RED PNK/BLU BLK/WHT Fuel BLK/WHT heater Main relay relay BLU/BLK Weld splice BLU/BLK BLU/YEL BLU/BLK BLU/BLK BLK/WHT BLK/WHT Compressor Relay Weld relay...
Page 628 9A-84 Wiring Systems: Fuse box T/C P RDTR2 RDTR No.1 Fuse box No.2 BLU/RED BLU/WHT BLU/BLK Weld splice E55 C35 BLU/BLK BLU/BLK BLU/BLK BLU/RED BLU/BLK BLU/WHT BLU/BLKBLU/BLK BLU/BLKBLU/YEL BLU/BLK BLU/BLK Turbo Turbo cooling cooling pump Relay Relay Relay control relay valve WHT/BLU BLU/WHT RED/BLK...
Page 629 Wiring Systems: 9A-85 Battery fuse WHT/BLU RED/BLK Weld splice BLU/BLK BLU/BLK WHT/BLU BLU/BLK RED/BLK BLU/BLK BLU/BLK BLU/YEL BLU/BLK BLU/BLK Thermo Thermo Thermo plug plug plug Flow Inlet Water in relay relay relay governor throttle valve fuel sensor BLU/RED YEL/RED BLU/WHT Up stream sensor temperature...
Page 630 9A-86 Wiring Systems: STOP DOME Weld splice BLU/BLK BLU/BLK BLU/BLK Steering LT GRN/BLK switch Brake (Auto light CANCEL SET/ RESUME/ MAIN cruise) switch COAST ACCEL stepper motor BLK/YEL LT GRN BLK/WHT YEL/GRN LT GRN/RED LT GRN BLK/YEL LT GRN BLK/WHT YEL/GRN GRN/WHT IF EQPD...
Page 631 Wiring Systems: 9A-87 Battery fuse Acceleration pedal sensor BLK/RED MAIN close open close open Glow plug relay BRN/WHT BRN/BLK BRN/YEL BRN/RED ORN/BLU BLU/GRN BLU/YEL WHT/BLU Clutch switch Weld splice I5JB0B910954-01...
Page 632: A-6 A/T Control System Circuit Diagram
9A-88 Wiring Systems: A-6 A/T Control System Circuit Diagram S5JB0B910E009 STOP CRUISE BACK DOME ACC relay "G-2" Shift rock relay Transmission PNK/GRN range sensor BLU/BLK GRN/WHT PNK/GRN PNK/GRN PNK/BLU GRN/WHT YEL/GRN GRN/ORN PNK/GRN PNK/GRN PNK/BLU YEL/GRN GRN/ORN GRN/WHT Brake light Back-up light switch "D-8"...
Page 633 Wiring Systems: 9A-89 "A-8" (CAN line) BRN/RED YEL/RED PPL/WHT GRN/YEL GRN/BLK GRN/RED GRY GRY/BLU LT GRN/RED LT GRN/BLK BRN/BLU LT GRN YEL/BLK BRN/RED YEL/RED PPL/WHT GRN/YEL GRN/BLK GRN/RED GRY GRY/BLU LT GRN/RED LT GRN/BLK BRN/BLU LT GRN YEL/BLK Pressure Lock up Linear Linear Shift...
Page 634 9A-90 Wiring Systems: Power integration DOME IG COIL No.2 BLK/WHT Weld splice BLK/WHT relay BLK/WHT Weld splice BLK/WHT BLK/WHT BLK/ORN BLK/ORN BLK/ORN BLK/ORN Input shaft Output shaft BLK/ORN speed sensor speed sensor M16A, J20A H27A I5JB0B910957-03...
Page 635: A-7 Immobilizer System Circuit Diagram
Wiring Systems: 9A-91 A-7 Immobilizer System Circuit Diagram S5JB0B910E010 M16A, J20A H27A IG COIL DOME "A-5" "A-8" BLU/BLK Weld splice BLK/WHT BLU/BLK BLU/BLK Weld splice Weld splice BLU/BLK BLK/WHT GRY/BLU GRY/BLU BLK/WHT PNK/BLU PNK/BLU BLU/BLK BLK/RED PPL/WHT PPL/WHT Main switch (Key switch) PPL/WHT "A-8"...
Page 636: A-8 Body Control System Circuit Diagram
9A-92 Wiring Systems: A-8 Body Control System Circuit Diagram S5JB0B910E011 DOME Receiver relay "B-5" "B-2" YEL/GRN YEL/BLK YEL/GRN YEL/BLK GRN/YEL PPL/WHT GRN/RED BLK/YEL (CAN line) (CAN line) PPL/WHT BLK/YEL BLK/YEL Switch "B-2" Steering Smart angle Cont.M Cont.M sensor "C-1" "F-3" "A-7"...
Page 637 Wiring Systems: 9A-93 Without seat heater With seat heater METER DOME J20A, H27A, DSL M16A Petrol Ambient PPL/RED WHT/BLK temperature Petrol sensor Main switch BLK/RED WHT/BLK (Key switch) PPL/RED WHT/BLK BLU/RED WHT/BLK BLK/RED Curtain lamp LT GRN/RED "D-4" "D-5" Security ORN/BLU RED/BLK PPL/GRN...
Page 638 9A-94 Wiring Systems: Luggage compartment Interiorlight light "D-5" "D-5" BLK/RED BLK/RED RED/WHT BLK/RED BLU/BLK LT GRN GRN/RED BLU/BLK BLU/BLK LT GRN GRN/RED LT GRN GRN/RED LT GRN GRN/RED LT GRN GRN/RED Navigation A/LEV "G-4" Cont.M "D-9" LT GRN GRN/RED LT GRN GRN/RED LT GRN GRN/RED...
Page 639 Wiring Systems: 9A-95 2-Action 1-Action Horn relay "B-7" IF EQPD Headlight LO relay Diode #1 "D-1" "D-1" RED/BLU Steering switch RED/BLU (Horn) "B-7" BLU/WHT BLU/BLK BLU/YEL BLU/RED BLU/YEL BLU/RED BLU/RED BLU/RED BLU/YEL BLU/RED BLU/YEL BLU/RED BLU/YEL BLU/RED BLU/YEL BLU/RED 10or5 19or14 10or5 19or14...
Page 640 9A-96 Wiring Systems: Without seat heater With seat heater J20A, H27A, DSL M16A LHD without Rear fog light Headlight relay relay HI relay Headlight HI Headlight "B-3" "D-3" "D-4" "D-1" "D-1" "D-1" BLU/BLK LT GRN/RED BLU/BLK LT GRN/RED RED/BLU WHT/RED YEL/RED PNK/BLU YEL/RED...
Page 641: A-10 4Wd Control System Circuit Diagram
Wiring Systems: 9A-97 A-10 4WD Control System Circuit Diagram S5JB0B910E012 Fuse IG COIL No.1 BLK/WHT Weld splice "A-8" BLK/WHT Weld splice Petrol BLK/WHT (CAN line) BLK/WHT DRIVER Cont.M IF EQPD RED/GRN PNK/WHT RED/BLK BLK/YEL RED/GRN PNK/WHT RED/BLK BLK/YEL Diagnosis PNK/WHT connector #3 T/F 4L position...
Page 642 9A-98 Wiring Systems: DOME TAIL Tail light relay RED/YEL RED/BLU "A-8" Cont.M RED/YEL BLK/ORN LT GRN BLU/BLK BLU/ORN BLK/ORN LT GRN BLU/BLK BLU/ORN PPL/WHT BLK/ORN N 4H 4HL 4LL Clutch switch switch PPL/WHT BLK/YEL BLK/YEL RED/BLU "A-8" Weld splice BLK/YEL PPL/WHT WHT RED (CAN line)
Page 643: B-1 Windshield Wiper And Washer Circuit Diagram
Wiring Systems: 9A-99 B-1 Windshield Wiper and Washer Circuit Diagram S5JB0B910E013 RHD without Rear fog light LHD & RHD with Rear fog light YEL/RED YEL/RED YEL/RED BLU/BLK BLU/BLK Switch Switch INT1 INT2 MIST INT Unit BLU/RED BLU/WHT BLU/RED BLU/WHT Weld splice J20A, H27A, DSL M16A...
Page 644: Rear Wiper And Washer Circuit Diagram . 9A-100
9A-100 Wiring Systems: B-2 Rear Wiper and Washer Circuit Diagram S5JB0B910E014 RHD without Rear fog light LHD & RHD with Rear fog light YEL/RED YEL/RED YEL/RED "A-8" GRN/RED BLU/YEL Relay BLU/YEL BLU/YEL YEL/RED GRN/YEL GRN/YEL R.INT WASH Switch ON+WASH GRN/YEL "A-8"...
Page 645: B-3 Rear Defogger Circuit Diagram
Wiring Systems: 9A-101 B-3 Rear Defogger Circuit Diagram S5JB0B910E015 Power integration No.1 Relay BLK/RED BLU/BLK BLK/RED BLU/BLK "A-8" BLK/RED BLK/RED Auto unit I5JB0A910955-05...
Page 646: B-4 Power Window Circuit Diagram
9A-102 Wiring Systems: B-4 Power Window Circuit Diagram S5JB0B910E016 BLU/WHT BLU/WHT BLU/WHT BLU/WHT BLU/WHT DRIVER SWITCH PASSENGER SWITCH REAR R SWITCH REAR L SWITCH UNLOCK DOWN Main switch LOCK DOWN RED/YEL GRN/BLK RED/BLK GRN/WHT RED/WHT GRN/YEL GRN/BLK RED/BLK BLU/WHT GRN/BLK RED/BLK BLU/WHT ASU ASD...
Page 647 Wiring Systems: 9A-103 BLU/WHT BLU/WHT RED/YEL GRN/YEL RED/WHT GRN/WHT GRN/YEL RED/YEL GRN/WHT RED/WHT GRN/YEL RED/YEL BLU/WHT GRN/YEL RED/YEL BLU/WHT RRU RRD UNLOCK UNLOCK DOWN DOWN Rear (L) Rear (R) Sub switch Sub switch LOCK LOCK DOWN DOWN Rear Rear Motor (L) Motor (R) IF EQPD I5JB0A910957-03...
Page 648: B-5 Power Door Lock Circuit Diagram
9A-104 Wiring Systems: B-5 Power Door Lock Circuit Diagram S5JB0B910E017 IF EQPD Receiver 2-Action 1-Action YEL/BLK YEL/GRN YEL/BLK YEL/GRN IF EQPD PNK/BLK PNK/GRN PNK/BLU BLU/YEL BLU/RED LT GRN GRN/RED BLU/BLK PNK/BLK PNK/GRN PNK/BLU BLU/YEL BLU/YEL IF EQPD BLU/YEL BLU/RED LT GRN GRN/RED BLU/RED LT GRN GRN/RED...
Page 649 Wiring Systems: 9A-105 2-Action 1-Action RED/WHT BLU/WHT BLU/YEL BLU/RED BLU/YEL IF EQPD LT GRN GRN/RED BLU/RED BLU/YEL BLU/WHT BLU/YEL BLU/RED LT GRN GRN/RED BLU/YEL BLU/RED LT GRN GRN/RED 10or5 19or14 BLU/WHT BLU/YEL BLU/RED LT GRN GRN/RED BLU/YEL BLU/RED LT GRN GRN/RED 4or2 4or2...
Page 650: B-6 Power Mirror Circuit Diagram
9A-106 Wiring Systems: B-6 Power Mirror Circuit Diagram S5JB0B910E018 Power integration No.1 Mirror heater relay WHT/BLK RED/GRN BLU/BLK WHT/BLK BLU/BLK IG GND M2L M1 IG GND M2R M1 "A-8" Switch DOWN DOWN GRY/RED LT GRN/BLK BRN/YEL GRN/WHT GRY/RED LT GRN/BLK GRN/WHT BRN/YEL RED/GRN...
Page 651: B-7 Horn Circuit Diagram
Wiring Systems: 9A-107 B-7 Horn Circuit Diagram S5JB0B910E019 Without Auto cruise With Auto cruise HORN Power integration Horn No.1 relay GRN/BLK "A-8" Steering switch (Contact coil) GRN/BLK GRN/BLK Horn Horn (HI) Horn (LO) switch I5JB0B910996-01...
Page 652: B-8 Seat Heater Circuit Diagram
9A-108 Wiring Systems: B-8 Seat Heater Circuit Diagram S5JB0B910E020 TAIL Tail light relay RED/YEL RED/BLU YEL/GRN "A-8" YEL/GRN RED/YEL YEL/GRN RED/YEL FREE LOCK FREE LOCK Switch Switch GRN/RED RED/GRN RED/BLK RED/GRN GRN/RED RED/BLK RED/GRN J20A, H27A, DSL M16A I5JB0B910969-01...
Page 653: B-9 Smart Key System Circuit Diagram
Wiring Systems: 9A-109 B-9 Smart Key System Circuit Diagram S5JB0B910E021 DOME BACK Door antenna Door antenna Inside Luggage Rear end antenna antenna antenna WHT/BLU WHT/RED GRY/GRN ORN/BLU BLK/RED GRY/BLK STEERING STEERING LOCK PUSH LOCK UNIT SWITCH IF EQPD Main switch WHT/BLK WHT/BLU WHT/RED...
Page 654: B-10 Sliding Roof Circuit Diagram
9A-110 Wiring Systems: B-10 Sliding Roof Circuit Diagram S5JB0B910E022 YEL/GRN Sliding roof unit PNK/BLK PNK/BLU Sliding roof switch I5JB0A910964-03...
Page 655: B-11 Headlight Cleaner Circuit Diagram
Wiring Systems: 9A-111 B-11 Headlight Cleaner Circuit Diagram S5JB0B910E023 Fuse CNLR No.2 Headlight LO BLU/YEL relay "B-1" "D-1" "D-4" RED/BLU RED/YEL motor RED/BLU RED/BLU RED/YEL switch YEL/RED BLU/BLK RED/BLU BLU/WHT RED/GRN Cont.M I5JB0A910965-08...
Page 656 9A-112 Wiring Systems: C-1 Combination Meter Circuit Diagram S5JB0B910E024 METER DOME Turn signal relay "A-8" "D-10" "D-6" GRN/ORN GRN/RED GRN/YEL PPL/RED GRN/RED GRN/YEL PPL/RED (CAN line) SPEED TACHO TEMP FUEL High Voltage regulator YEL/RED BLK/YEL BLU/WHT YEL/BLK YEL/RED BLK/YEL YEL/RED BLK/YEL YEL/RED BLK/YEL...
Page 657 Wiring Systems: 9A-113 I5JB0B910972-03...
Page 658: Headlight System Circuit Diagram (One Bulb Type)
9A-114 Wiring Systems: D-1 Headlight System Circuit Diagram (One bulb type) S5JB0B910E025 RHD without Rear fog light LHD & RHD with Rear fog light Fuse H/L L H/L R No.2 WHT/BLU WHT/RED RED/BLU Headlight Headlight RED/WHT RED/WHT RED/BLU RED/BLU RED/WHT 3or7 1or5 7or11...
Page 659: Headlight System Circuit Diagram (With Projector Light)
Wiring Systems: 9A-115 D-1 Headlight System Circuit Diagram (With Projector light) S5JB0B910E026 RHD without Rear fog light LHD with Rear fog light & Fuse RHD with Rear fog light H/L L H/L LO L H/L R H/L LO R No.2 LHD without Rear fog light WHT/BLU WHT/BLU...
Page 660: Headlight System Circuit Diagram (With Discharge Bulb)
9A-116 Wiring Systems: D-1 Headlight System Circuit Diagram (With Discharge bulb) S5JB0B910E027 RHD without Rear fog light LHD with Rear fog light Fuse Fuse & RHD with Rear fog light H/L L H/L R LAMP No.1 LHD without Rear fog light No.2 WHT/BLU WHT/RED...
Page 661: D-2 Position, Tail And Licence Plate Light System Circuit Diagram
Wiring Systems: 9A-117 D-2 Position, Tail and Licence Plate Light System Circuit Diagram S5JB0B910E028 RHD without Rear fog light LHD & RHD with Rear fog light TAIL Tail light relay RED/BLU RED/YEL RED/YEL RED/YEL RED/YEL RED/BLU Head Tail RED/YEL RED/YEL RED/YEL Licence Licence...
Page 662: D-3 Front Fog Light System Circuit Diagram
9A-118 Wiring Systems: D-3 Front Fog Light System Circuit Diagram S5JB0B910E029 Power integration TAIL No.1 Tail light relay RED/YEL RED/BLU RED/YEL "A-8" Relay LT GRN/RED LT GRN RED/YEL RED/YEL LT GRN/RED LT GRN LT GRN Switch LT GRN/BLK RED/GRN LT GRN/RED Weld Weld splice...
Page 663: D-4 Illumination Light System Circuit Diagram
Wiring Systems: 9A-119 D-4 Illumination Light System Circuit Diagram S5JB0B910E030 TAIL HORN Tail Horn light relay relay RED/BLU GRN/BLK RHD without Rear fog light LHD & RHD RED/BLU RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL with Rear fog light Head Tail light (L) Tail light (R) Steering Horn...
Page 664: D-5 Interior Light System Circuit Diagram
9A-120 Wiring Systems: D-5 Interior Light System Circuit Diagram S5JB0B910E031 DOME VANTIY 7.5A BLK/RED IF EQPD IF EQPD IF EQPD Vanity Vanity Curtsy Curtsy Console lamp lamp lamp lamp lamp DOOR DOOR BLK/BLU BLK/ORN Interior Rear light interior BLK/RED BLK/RED light 5 dr Luggage...
Page 665: D-6 Turn Signal And Hazard Warning Light System Circuit Diagram
Wiring Systems: 9A-121 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram S5JB0B910E032 METER TAIL Tail light relay RED/BLU "A-8" PPL/RED WHT/GRN GRN/RED GRN/YEL RED/YEL YEL/RED "A-8" GRN/RED GRN/YEL RED/YEL YEL/RED YEL/RED GRN/RED GRN/YEL YEL/RED Turn signal relay TURN Switch Turn signal switch RED/GRN...
Page 666 9A-122 Wiring Systems: GRN/RED GRN/YEL GRN/RED GRN/RED GRN/YEL GRN/YEL GRN/RED GRN/YEL (Turn (L)) (Turn (R)) "C-1" Side turn Front turn Side turn Front turn Rear turn signal light (L) signal light (L) signal light (R) signal light (R) signal light Weld Weld splice...
Page 667: D-7 Brake Light System Circuit Diagram
Wiring Systems: 9A-123 D-7 Brake Light System Circuit Diagram S5JB0B910E033 CRUISE STOP "A-5" BLU/BLK BLU/BLK Weld splice BLU/BLK BLU/BLK BLU/BLK BLU/BLK Weld splice Brake BLU/BLK BLU/BLK light switch BLU/BLK YEL/GRN GRN/WHT YEL/GRN Steering switch YEL/GRN "A-5" "A-5" IF EQPD Steering switch "A-5"...
Page 668: D-8 Back-Up Light System Circuit Diagram
9A-124 Wiring Systems: D-8 Back-Up Light System Circuit Diagram S5JB0B910E034 BACK Transmission range sensor Back-up light switch "A-6" Back-up light I5JB0B910981-01...
Page 669: Headlight Beam Leveling System Circuit Diagram (Manual Leveling)
Wiring Systems: 9A-125 D-9 Headlight Beam Leveling System Circuit Diagram (Manual Leveling) S5JB0B910E035 BACK YEL/GRN YEL/RED Actuator (L) Actuator (R) switch Weld splice I5JB0B910982-01...
Page 670: Headlight Beam Leveling System Circuit Diagram (Auto Leveling)
9A-126 Wiring Systems: D-9 Headlight Beam Leveling System Circuit Diagram (Auto Leveling) S5JB0B910E036 BACK Headlight LO relay Actuator (L) Actuator (R) "C-1" "A-8" "D-1" GRN/BLK YEL/GRN GRN/RED YEL/RED RED/BLU GRN/BLK YEL/GRN GRN/RED YEL/RED BLU/WHT BLU/BLK RED/BLU A/LEV Cont.M BLU/RED BLU/YEL BLU/BLK GRN/YEL GRN/WHT...
Page 671: D-10 Rear Fog Light Circuit Diagram
Wiring Systems: 9A-127 D-10 Rear Fog Light Circuit Diagram S5JB0B910E037 7.5A PNK/BLU Switch (COMB switch) GRN/ORN GRN/ORN "C-1" I5JB0B910997-01...
Page 672: E-2 Auto A/C System Circuit Diagram
9A-128 Wiring Systems: E-2 Auto A/C System Circuit Diagram S5JB0B910E038 TAIL METER DOME Tail light relay RED/BLU "A-8" "A-8" "A-8" PPL/RED RED/YEL YEL/RED "A-8" RED/YEL PNK/GRN PNK/BLK YEL/RED PPL/RED Auto Auto A/C panel unit IF EQPD PPL/WHT RED/GRN Sunlight sensor "A-8"...
Page 673 Wiring Systems: 9A-129 Fuse DOME No.2 YEL/GRN Weld splice Petrol YEL/GRN Heater motor relay BLU/WHT BLU/WHT BLU/WHT driver Blower Diode motor PPL/GRN RED/BLK RED/BLK RED/BLK RED/BLK Auto unit BLU/BLK BLK/RED WHT/BLK GRY/RED GRY/BLK WHT/BLU RED/WHT GRY/BLU WHT/RED WHT/GRN Weld splice GRY/BLK WHT/BLU RED/WHT...
Page 674: Air-Bag System Circuit Diagram (4Ch)
9A-130 Wiring Systems: F-1 Air-Bag System Circuit Diagram (4ch) S5JB0B910E039 DOME Forward sensor Forward sensor "C-1" "A-8" YEL/BLK PNK/BLK PNK/BLU PNK/BLK PNK/BLU Check terminal GRN/RED BLU/RED YEL/RED GRN/YEL GRN/ORN BLU/ORN BLU/YEL Diagnosis PPL/WHT BLU/RED YEL/RED GRN/YEL GRN/ORN BLU/ORN BLU/YEL connector #2 IF EQPD "A-8"...
Page 675: Air-Bag System Circuit Diagram (8Ch)
Wiring Systems: 9A-131 F-1 Air-Bag System Circuit Diagram (8ch) S5JB0B910E040 DOME Forward sensor Forward sensor "C-1" "A-8" YEL/BLK PNK/BLK PNK/BLU PNK/BLK PNK/BLU Check terminal GRN/RED BLU/RED YEL/RED GRN/YEL GRN/ORN BLU/ORN BLU/YEL Diagnosis PPL/WHT BLU/RED YEL/RED connector #2 IF EQPD "A-8" BLK/YEL BLK/YEL Contact...
Page 676 9A-132 Wiring Systems: sensor sensor WHT/GRN LT GRN WHT/RED LT GRN/BLK YEL/GRN YEL/BLU BRN/WHT GRY/RED BLK/YEL BRN/YEL I5JB0A910986-06...
Page 677: F-2 Anti-Lock Brake System Circuit Diagram
Wiring Systems: 9A-133 F-2 Anti-Lock Brake System Circuit Diagram S5JB0B910E041 Fuse ABS1 ABS2 No.2 "A-5" "A-8" WHT/BLU WHT/RED WHT/BLU WHT/RED GRN/ORN (CAN line) (CAN line) Cont.M I5JB0B910988-01...
Page 678 9A-134 Wiring Systems: DOME Wheel speed Wheel speed Wheel speed Wheel speed sensor sensor sensor sensor (RL) (RR) (FL) (FR) LT GRN/BLK YEL/BLK LT GRN BLU/BLK GRN/BLK LT GRN/BLK YEL/BLK LT GRN Cont.M PPL/WHT BLK/YEL BLK/YEL PPL/WHT Diagnosis connector #3 "A-8"...
Page 679: F-3 Electronic Stability Program System Circuit Diagram
Wiring Systems: 9A-135 F-3 Electronic Stability Program System Circuit Diagram S5JB0B910E049 Fuse ABS1 ABS2 DOME No.2 Back-up light switch "D-8" "A-5" "A-8" WHT/BLU WHT/RED WHT/BLU WHT/RED GRN/ORN GRN/ORN Steering angle sensor (CAN line) (CAN line) Cont.M BLU/WHT "D-4" PNK/WHT PNK/GRN BLU/WHT RED/YEL PNK/WHT...
Page 680 9A-136 Wiring Systems: DOME Wheel speed Wheel speed Wheel speed Wheel speed sensor sensor sensor sensor (RL) (RR) (FL) (FR) LT GRN/BLK LT GRN YEL/BLK BLU/BLK GRN/BLK LT GRN/BLK YEL/BLK LT GRN Cont.M PPL/WHT BLK/YEL PPL/WHT BLK/YEL "A-8" BLK/YEL PPL/WHT (CAN line) ESP is a registered trademark of Daimler Chrysler AG.
Page 681: G-1 Audio System Circuit Diagram
Wiring Systems: 9A-137 G-1 Audio System Circuit Diagram S5JB0B910E042 5 dr DOME 3 dr Without Auto cruise With Auto cruise WHT/BLK WHT/BLK WHT/BLK woofer "D-4" relay Antenna WHT/BLK WHT/BLU RED/YEL Steering switch (Volume / seek etc) Antenna amplifer WHT/BLK WHT/BLU PNK/BLK RED/YEL Audio...
Page 682: G-2 Multi Information Display / Accessory Socket System Circuit Diagram
9A-138 Wiring Systems: G-2 Multi Information Display / Accessory Socket System Circuit Diagram S5JB0B910E043 Fuse box No.1 relay ACC 2 ACC 3 DOME Ambient temperature sensor IF EQPD WHT/BLK BLK/RED "D-4" WHT/BLK BLK/RED RED/YEL WHT/BLU WHT/BLK YEL/RED WHT/BLU WHT/BLU RED/YEL WHT/BLK YEL/RED WHT/BLU...
Page 683: G-4 Navigation System Circuit Diagram
Wiring Systems: 9A-139 G-4 Navigation System Circuit Diagram S5JB0B910E044 Back-up Transmission light switch range sensor "D-8" "D-8" "A-8" RED/BLK BLU/BLK Navigation I5JB0A910991-05 List of Connectors List of Connectors S5JB0B910F001 Refer to “B Connector: ”. Refer to “C Connector: ”. Refer to “E Connector: ”. Refer to “F Connector: ”.
Page 684: C Connector
9A-140 Wiring Systems: C Connector S5JB0B910F003 MCONF010070-02 MCONF010083-01 MCONF010071-01 MCONF010084-01 MCONF020065-01 MCONF020238-01 Petrol Petrol MCONF020065-01 MCONF020238-01 MCONF020065-01 MCONF020238-01 MCONF020065-01 MCONF020238-01 Petrol Petrol Petrol 1 2 3 1 2 3 4 5 6 MCONF030053-01 MCONF030115-01 MCONF020042-01 MCONF040111-01 MCONF060018-01 MCONF060074-01 Petrol Petrol Petrol 1 2 3 4 5 6 1 2 3 4 5 6...
Page 685 Wiring Systems: 9A-141 C34 (TO E54) C35 (TO E55) 6 7 8 9 11 12 13 14 MCONF010085-01 MCONF010090-01 MCONF010001-01 MCONF160010-01 MCONF140001-01 MCONF080039-01 M16A, J20A H27A, DSL Petrol Petrol 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 29 30...
Page 686 9A-142 Wiring Systems: C60 (TO D07) C71 (TO D11) C72 (TO D12) Weld splice MCONN000002-01 MCONF080028-02 MCONF080039-01 MCONF020239-01 MCONF020240-01 MCONM010035-01 H27A, DSL H27A H27A 1 2 3 1 2 3 4 1 2 3 4 6 7 8 MCONF020167-01 MCONF080042-01 MCONF040072-01 MCONF040110-01 MCONF010093-01...
Page 687: D Connector
Wiring Systems: 9A-143 D Connector S5JB0B910F013 MCONF020065-01 MCONF020065-01 MCONF020065-01 MCONF020065-01 MCONF020065-01 MCONF020065-01 H27A H27A H27A H27A H27A H27A D07 (TO C60) D11 (TO C71) D12 (TO C72) MCONM080015-01 MCONF010092-01 MCONF010092-01 MCONF010092-01 MCONM020050-01 MCONF010091-01 H27A E Connector S5JB0B910F004 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 MCONF050027-01 MCONF020115-01...
Page 688 9A-144 Wiring Systems: MCONF020183-01 MCONF050015-01 MCONF050015-01 MCONF050015-01 MCONF050015-01 MCONF120030-01 MCONF120030-01 MCONF100032-01 M16A MCONF080019-01 MCONF080036-01 MCONF080037-01 J20A, H27A MCONF080038-01 MCONF010081-01 MCONF010081-01 MCONF010086-01 MCONF020044-01 J20A, H27A J20A, H27A Petrol MCONF030101-01 MCONF020229-01 MCONF030111-01 MCONF020230-01 MCONF020044-01 Petrol Petrol E52 (TO E85) MCONF030101-01 MCONF020229-01 MCONF030111-01 MCONF020230-01 MCONF020231-01 MCONF040008-01...
Page 689 Wiring Systems: 9A-145 1 2 3 1 2 3 4 5 6 4 5 6 MCONF060068-01 MCONF060044-01 MCONF020232-01 MCONF020151-01 MCONF020008-01 IF EQPD Petrol E74 (TO G36) E75 (TO G37) E76 (TO G04) E77 (TO G06) 10 11 12 13 21 22 23 24 31 32 MCONF020157-01...
Page 690: F Connector
9A-146 Wiring Systems: F Connector S5JB0B910F005 F01 (TO G56) F05 (TO G57) MCONF130006-01 MCONF060046-01 MCONF060046-01 MCONF040095-01 MCONF130006-01 MCONF060046-01 LHD A/T MCONF060046-01 MCONF020116-01 RHD A/T G Connector S5JB0B910F006 G04 (TO E76) 1 2 3 4 5 6 1 2 3 4 5 6 9 10 9 10 11 12 13 14 15 16...
Page 691 Wiring Systems: 9A-147 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 9 10 11 12 11 12 13 14 15 18 19 20 21 22 13 14 15 16 17 18 19 20 21 22 23 24 MCONF040099-01 MCONF220006-01...
Page 692 9A-148 Wiring Systems: G67 (TO Q01) 1 2 3 1 2 3 4 5 6 1 2 3 4 5 1 2 3 MCONF060040-01 MCONF050024-01 MCONF060003-01 MCONF010010-01 MCONF030078-01 MCONF040099-01 IF EQPD IF EQPD G71 (TO E90) G72 (TO L27) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 12 13 14 15 16 17...
Page 693: J Connector
Wiring Systems: 9A-149 J Connector S5JB0B910F007 J01 (TO L07) 5 6 7 8 9 10 MCONM340003-02 MCONF020159-01 MCONM070004-01 MCONF020008-01 MCONF020236-01 MCONF100061-01 J09 (TO L31) 5 6 7 8 9 10 11 12 13 14 15 16 17 18 8 9 10 11 MCONF130011-01 MCONF180006-01 MCONM340003-02...
Page 694: K Connector
9A-150 Wiring Systems: J21 (TO L37) 1 2 3 4 5 5 6 7 8 9 10 MCONF020008-01 MCONF020236-01 MCONF050021-01 MCONF100061-01 MCONM210001-01 MCONF020008-01 1 2 3 4 5 5 6 7 8 9 10 MCONF020236-01 MCONF050001-01 MCONF100061-01 MCONM020018-01 MCONM020016-01 MCONM020018-01 MCONM020016-01 MCONM020051-01 MCONM020051-01...
Page 695: L Connector
Wiring Systems: 9A-151 L Connector S5JB0B910F009 L01 (TO E80) L03 (TO E79) 16 15 14 13 9 10 11 12 13 MCONF180009-01 MCONF040095-01 MCONF080014-01 MCONF130013-01 IF EQPD L07 (TO J01) L08 (TO G07) L09 (TO G08) 23 34 22 33 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 22 21 20 19 18 17 16 15 14 13 12...
Page 696 9A-152 Wiring Systems: L27 (TO G72) L28 (TO G73) L29 (TO G55) 18 17 11 10 MCONM170001-01 MCONM180002-01 MCONM040015-01 MCONF020212-01 IF EQPD L31 (TO J09) 23 34 22 33 6 7 8 9 10 11 12 13 14 15 16 20 29 19 28 MCONF340006-01...
Page 697: O Connector
Wiring Systems: 9A-153 L68 (TO L19) MCONM020005-01 MCONF020211-01 MCONF040054-01 3 dr 3 dr IF EQPD O Connector S5JB0B910F010 O01 (TO L42) MCONF160010-01 MCONM010034-01 MCONM040022-01 MCONF040069-01 MCONF050037-02 MCONM010034-01 MCONF020026-01 MCONM020018-01 MCONM020016-01 Q Connector S5JB0B910F011 Q01 (TO G67) MCONM040015-01 MCONF020207-01 R Connector S5JB0B910F012 R01 (TO L15) 3 2 1...
Page 698: Precautions
9C-1 Instrumentation / Driver Info. / Horn: Instrumentation / Driver Info. / Horn Precautions Precautions in Diagnosing Troubles for Combination Meter S5JB0B9300001 Combination meter uses signals (information) from each control module by CAN communication to control speedometer, tachometer, engine coolant temp meter, warning light and indicator light (other than air bag warning light, headlight leveling warning light, rear fog light and turn signal indicator lamp).
Page 699 Instrumentation / Driver Info. / Horn: 9C-2 Schematic and Routing Diagram Combination Meter Circuit Diagram S5JB0B9302001 G28-10 G28-8 G28-22 G28-16 G28-18 G28-6 G28-14 G28-13 G28-12 G28-19 G28-20 G28-15 G28-11 I5JB0B930002-01 1. Main fuse 6. Fuel meter 11. CPU 16. Illumination cancel switch (if equipped) 2.
Page 700 9C-3 Instrumentation / Driver Info. / Horn: Terminal arrangement of coupler viewed from harness side 17 16 I5JB0A930002-01 Terminal Circuit Terminal Circuit G28-1 — G28-12 To headlight auto leveling control module G28-2 — G28-13 Power source G28-3 — G28-14 Backup power source G28-4 —...
Page 701 Instrumentation / Driver Info. / Horn: 9C-4 Repair Instructions Fuel Level Sensor Inspection S5JB0B9306005 • Check that resistance between terminals “a” and “b” “a” “b” of fuel level sensor changes with change of float position. • Check resistance between terminals “a” and “b” at each float position in the following.
Page 702 9C-5 Instrumentation / Driver Info. / Horn: Oil Pressure Switch Inspection S5JB0B9306007 1) Disconnect connector from oil pressure switch (1). 2) Check for continuity between oil pressure switch terminal (2) and cylinder block (3) as shown. If check result is not as specified, replace oil pressure switch (1). Oil pressure sensor specification During engine running: No continuity At engine stop: Continuity...
Page 703 Table of Contents 10- i Section 10 Control systems CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........10-* Diagnostic Information and Procedures ..10B-6 BCM Self-Diagnosis Function ......
Page 704 10-ii Table of Contents On-Board Diagnostic System Description DTC B1706: Immobilizer Antenna Error..10C-12 (Self-diagnosis Function) ........10C-3 DTC B1707: IMM EEPROM Error ....10C-13 DTC B1708: ECM Code Error ......10C-13 Schematic and Routing Diagram......10C-4 DTC B1709: ECM Communication Error 2 ..10C-14 Immobilizer Control System Wiring Circuit DTC B1711: ECM EEPROM Error ....10C-15 Diagram ............10C-4 DTC B1712: Immobilizer Communication...
Page 705: Cruise Control System
Cruise Control System: 10A-1 Cruise Control System General Description Cruise Control System Construction S5JB0BA101001 The cruise control system is a device which maintains a preset vehicle speed while driving at a high speed, e.g., on a highway. It allows the driver to drive his vehicle at a constant speed of 40 km/h (25 mile/h) or higher without depressing the accelerator pedal.
Page 706: Components And Functions Of Cruise Control System
10A-2 Cruise Control System: Components and Functions of Cruise Control System S5JB0BA101002 Component Function ECM and fuel injectors ECM executes centralized control over all functions including setting a constant speed, resuming it, setting coast, cancelling cruise control limiting minimum speed. ECM controls fuel injector to keep actual vehicle speed at set (target) speed.
Page 707 Cruise Control System: 10A-3 Cancel Conditions of Cruise Control System S5JB0BA101003 Constant cruising is cancelled under the following conditions. • *Ignition switch is turned OFF. • MAIN switch is turned OFF. • Vehicle speed becomes lower than minimum operating speed (40 km/h (25 mile/h)). •...
Page 708 10A-4 Cruise Control System: Schematic and Routing Diagram Cruise Control System Wiring Diagram S5JB0BA102001 G28-10 G28-8 G31-1 G31-3 E91-22 E91-23 E53-13 E03-12 E53-44 E03-6 WHT/RED E53-42 E03-10 E53-46 E03-8 WHT/BLU C85-8 YEL/GRN BLU/BLK WHT/RED E66-32 E66-26 WHT/BLU E66-4 E66-28 GRN/WHT E66-3 WHT/BLU E66-5...
Page 709: Cruise Control) Inspection And Adjustment
Cruise Control System: 10A-5 Diagnostic Information and Procedures Cruise Control System Symptom Diagnosis S5JB0BA104001 NOTE • ECM uses ABS or ESP® control module and CAN communication to transmit and receive data for cruise control. Therefore, check that no DTC is detected in ECM and ABS or ESP® control module before performing this Cruise Control System Symptom Diagnosis.
Page 710 10A-6 Cruise Control System: Condition Possible cause Correction / Reference Item Cruise control at vehicle RES/ACC switch faulty Check RES/ACC switch for function referring speed stored in memory to “Cruise Control Switch Inspection: in related cannot be resumed after manual”. cruise control was Wiring or grounding faulty Repair.
Page 711: Body Electrical Control System
Precautions in Diagnosing Trouble S5JB0BA200001 • Diagnostic information stored in BCM memory can be cleared as well as checked by using SUZUKI scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
Page 712 10B-2 Body Electrical Control System: BCM Reception Data 4WD Control Module (if equipped) Engine speed signal Engine coolant temp. signal Vehicle speed signal Stop (brake) lamp switch signal Magnet clutch signal Receive DATA A/C refrigerant pressure signal Distance kilometers per liter of fuel signal Additional heater relay signal Radiator cooling fan relay signal...
Page 713: Schematic And Routing Diagram
Body Electrical Control System: 10B-3 Schematic and Routing Diagram Body Electrical Control System Wiring Circuit Diagram S5JB0BA202001 G30-22 BLU/BLK GRN/RED G30-7 G30-19 G30-6 WHT/BLK G31-24 G31-21 BLK/RED PNK/BLK G30-16 G31-17 LT GRN/RED RED/BLU G31-12 LT GRN/BLK G30-9 G31-13 GRN/YEL G31-10 WHT/RED G31-1 G31-3...
Page 714 10B-4 Body Electrical Control System: 1. BCM 22. Navigation (if equipped) 43. Dimmer and passing switch 2. Battery 23. To turn signal light 44. Horn relay 3. Rear wiper motor 24. Headlight auto leveling control module (if equipped) 45. Horn switch 4.
Page 715: Component Location
Body Electrical Control System: 10B-5 Component Location BCM and Related System Component Location S5JB0BA203001 I5JB0BA20004-01 1. Generator 10. Rear end door lock actuator (incorporated 19. Lighting switch in door switch) 2. Brake fluid level switch 11. Keyless entry receiver (if equipped) 20.
Page 716: Diagnostic Information And Procedures
10B-6 Body Electrical Control System: 7. Door switch 16. Front fog light switch (if equipped) 25. Turn signal and hazard warning relay 8. Interior light 17. Hazard warning switch Key reminder switch (included in ignition switch) 9. Luggage room light 18.
Page 717 Diagnosis Using Output Test Function of SUZUKI Scan Tool SUZUKI scan tool has the output test function which can force operation of following actuators and relays of the system controlled by BCM. When a malfunction is found in the system controlled by BCM, execute the output test which enables easy judgment whether the malfunction is on the input side or output side of BCM.
Page 718: Dtc Table
10B-8 Body Electrical Control System: DTC Table S5JB0BA204004 DTC (indicated DTC (displayed on (displayed on by theft odometer in Detected item Detecting condition SUZUKI scan deterrent light) combination meter) tool) NO DTC 0000 0000 — No DTC detected B1133 1133...
Page 719 Body Electrical Control System: 10B-9 DTC U1073 (No. 1073): Control Module Communication Bus Off S5JB0BA204013 Wiring Diagram WHT/RED E66-32 E66-26 WHT/BLU G31-4 G31-2 G31-1 G31-3 E03-8 WHT/BLU E53-46 E53-42 E03-10 WHT/RED E91-22 E53-13 E03-12 E91-23 E53-44 E03-6 G28-10 G45-9 G28-8 G45-10 18 17 13 12...
Page 720 10B-10 Body Electrical Control System: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Transmission error that is inconsistent between transmission data • CAN circuit and transmission monitor (CAN bus monitor) data is detected more • Combination meter than 7 times continuously.
Page 721 Body Electrical Control System: 10B-11 DTC U1100 (No. 1100): Lost Communication with ECM S5JB0BA204014 Wiring Diagram WHT/RED E66-32 E66-26 WHT/BLU G31-4 G31-2 G31-1 G31-3 E03-8 WHT/BLU E53-46 E53-42 E03-10 WHT/RED E91-22 E53-13 E03-12 E91-23 E53-44 E03-6 G28-10 G45-9 G28-8 G45-10 18 17 13 12 39 38...
Page 722 10B-12 Body Electrical Control System: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area BCM can not receive CAN data from ECM for • CAN communication circuit longer than specified time continuously. • BCM • ECM DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch turned OFF.
Page 723: Check
Body Electrical Control System: 10B-13 Step Action Check DTC in BCM Disconnect connectors Check power and of control modules other ground circuit of control 1) Connect connectors of disconnected control modules than the one whose module disconnect in communicating by means of CAN. connector is Step 2).
Page 724 10B-14 Body Electrical Control System: NOTE • As each terminal voltage is affected by the battery voltage, confirm that it is 11 V or more when ignition switch is ON. • Voltage with asterisk (*) can not be measured by voltmeter because it is pulse signal. Check it with oscilloscope if necessary.
Page 725 Body Electrical Control System: 10B-15 Terminal Circuit Normal voltage Condition *0 – 1 V Vehicle speed signal output (if ↑↓ G30-22 Refer to “Reference waveform No. 5: ” equipped) 10 – 14 V G30-23 — — — G30-24 — — —...
Page 726 10B-16 Body Electrical Control System: Terminal Circuit Normal voltage Condition Sensor ground for outside air G31-21 Ignition switch is at each position temperature sensor G31-22 — — — G31-23 — — — Ignition switch is at ON position and outside air G31-24 Outside air temperature sensor About 1.5 V temperature approx.
Page 727 Body Electrical Control System: 10B-17 Terminal Circuit Normal voltage Condition Unlock signal is output for passenger side door 10 – 14 V Passenger side door lock actuator lock actuator G32-9 motor control (Unlock) Unlock signal is not output for passenger side door lock actuator 10 –...
Page 728 10B-18 Body Electrical Control System: Reference waveform No. 3 Reference waveform No. 5 Rear wiper LOW or INT signal (1) Vehicle speed pulse output signal (1) Measurement terminal Rear wiper LOW signal: Measurement terminal CH1: “G30-22” to “G30-12” CH1: “G30-6” to “G30-12” Oscilloscope setting CH1: 5 V / DIV Rear wiper INT signal:...
Page 729 Body Electrical Control System: 10B-19 Reference waveform No. 7 Reference waveform No. 8 Brake fluid level, parking brake or driver seat belt switch Oil pressure switch signal (1) signal (1) Measurement terminal CH1: “G31-9” to “G30-12” Measurement terminal Brake fluid level switch signal: Oscilloscope setting CH1: 2 V / DIV CH1: “G31-7”...
Page 730: Immobilizer Control System
• DTC stored in ICM memory can be checked as well as cleared by using SUZUKI scan tool. Before using SUZUKI scan tool, read its operator’s manual carefully to know how to use it and what functions are available.
Page 731: General Description
Immobilizer Control System: 10C-2 • Do not turn ignition switch to ON position by bringing • Do not leave ignition key in a place where temperature is high. High temperature may cause radio antenna close to coil antenna. Or, the damage to the transponder built in the ignition key.
Page 732: Immobilizer Control System Components Location
ICM and ECM diagnoses if there is any trouble with the immobilizer control system. The diagnostic information is stored as the diagnostic trouble code (DTC) in ICM. To read the diagnostic information, use SUZUKI scan tool referring to “Diagnostic Trouble Code (DTC) Check: ”.
Page 733 Immobilizer Control System: 10C-4 Schematic and Routing Diagram Immobilizer Control System Wiring Circuit Diagram S5JB0BA302001 NOTE For more details about power supply and ground wire circuits for ECM, BCM, ABS control module, ® control module and combination meter, refer to “System Circuit Diagram: in Section 9A”. BLU/BLK G24-8 G24-3...
Page 734 ICM communication check Go to applicable DTC Go to step 4. diag. flow. 1) Connect SUZUKI scan tool with turn ignition switch to OFF position. 2) Check ICM for DTC referring to “Diagnostic Trouble Code (DTC) Check: ”. Is communication between ICM and SUZUKI scan tool...
Page 735: Diagnostic Trouble Code (Dtc) Table
S5JB0BA304002 S5JB0BA304003 NOTE NOTE To know how to use SUZUKI scan tool in To know how to use SUZUKI scan tool in detail, refer to its operator’s manual. detail, refer to its operator’s manual. 1) Turn the ignition switch to OFF position.
Page 736 10C-7 Immobilizer Control System: Scan Tool Data S5JB0BA304005 Scan Tool Data Vehicle Condition Normal Data NUMBER OF LEARNT KEY Ignition switch at ON position 0 – 4 INPUT YEAR Ignition switch at ON position 2005 or later INPUT MONTH Ignition switch at ON position 1 –...
Page 737: Injection Warning Light Does Not Come On With Ignition Switch On And Engine Stop
Immobilizer Control System: 10C-8 Injection Warning Light Does Not Come ON with Ignition Switch ON and Engine Stop S5JB0BA304006 Wiring Diagram Refer to “Immobilizer Control System Wiring Circuit Diagram: ”. Circuit Description When the ignition switch is turned ON, ECM transmits the indication ON signal to the combination meter to turn ON the injection warning light in case that there is not any problem with the immobilizer control system.
Page 738: Injection Warning Light Remains On After Engine Start
10C-9 Immobilizer Control System: Injection Warning Light Remains ON after Engine Start S5JB0BA304007 Wiring Diagram Refer to “Immobilizer Control System Wiring Circuit Diagram: ”. Circuit Description When ECM has any DTC(s), injection warning light remains ON after engine starts. Troubleshooting Check ECM for DTC(s) referring to “DTC Check: in Section 1A”...
Page 739 Immobilizer Control System: 10C-10 Troubleshooting Step Action Diagnostic Trouble Code (DTC) Check Go to applicable DTC Go to Step 2. diag. flow. 1) Check ECM for DTC referring to “DTC Check: in Section 1A”. ® 2) Check ABS control module or ESP control module for ®...
Page 740: Dtc B1703: Unregistered Transponder
10C-11 Immobilizer Control System: DTC B1703: Unregistered Transponder S5JB0BA304020 Detecting Condition and Trouble Area Detecting Condition Transponder code does not register in ICM NOTE Troubleshoot DTC B1703 first if both B1703 and B1712 are detected at the same time. Troubleshooting Perform “Registration of the Ignition Key: ”...
Page 741: Dtc B1705: Transponder Response Error
Immobilizer Control System: 10C-12 DTC B1705: Transponder Response Error S5JB0BA304022 Wiring Diagram Refer to “Immobilizer Control System Wiring Circuit Diagram: ”. Detecting Condition and Trouble Area Detecting Condition Trouble Area Cannot receive transponder data from transponder • Use of the ignition key without the transponder •...
Page 742: Dtc B1707: Imm Eeprom Error
10C-13 Immobilizer Control System: DTC B1707: IMM EEPROM Error S5JB0BA304024 Detecting Condition and Trouble Area Detecting Condition Trouble Area EEPROM in ICM faulty Internal failure (EEPROM corruption) of ICM Troubleshooting 1) Clear DTC(s) referring to “Diagnostic Trouble Code (DTC) Clearance: ”. 2) Turn the ignition switch to OFF position.
Page 743 Immobilizer Control System: 10C-14 Step Action ECM connector check Go to Step 6. Repair poor connection(s). 1) With the ignition key at OFF position, disconnect ECM connectors. 2) Check for proper connection at terminals and wires of ECM connector. Refer to “Intermittent and Poor Connection Inspection: in Section 00 in related manual”.
Page 744: Dtc B1711: Ecm Eeprom Error
10C-15 Immobilizer Control System: Step Action ECM poor connection check Go to Step 5. Repair poor connection(s). 1) With the ignition key at OFF position, disconnect ECM connectors. 2) Check for proper connection at terminals and wires of ECM connectors. Refer to “Intermittent and Poor Connection Inspection: in Section 00 in related manual”.
Page 745 Immobilizer Control System: 10C-16 Troubleshooting Step Action DTC check Go to applicable DTC Go to Step 2. diag. flow. 1) Check ICM for DTC referring to “Diagnostic Trouble Code (DTC) Check: ”. Is any DTC detected other than B1712? Diagnostic Trouble Code (DTC) Check Go to applicable DTC Go to Step 3.
Page 746: Dtc B1713: Immobilizer Code Error
10C-17 Immobilizer Control System: DTC B1713: Immobilizer Code Error S5JB0BA304029 Detecting Condition and Trouble Area Detecting Condition Trouble Area Verification error between ICM and ECM • ICM faulty • ECM faulty NOTE Troubleshoot DTC B1704 first if both B1704 and B1713 are detected at the same time. Troubleshooting Step Action...
Page 747: Inspection Of Immobilizer Control Module (Icm) And Its Circuit
Immobilizer Control System: 10C-18 Inspection of Immobilizer Control Module (ICM) and Its Circuit S5JB0BA304018 ICM and its circuit can be checked at ICM wiring connector by measuring voltage. CAUTION ICM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ICM with connector disconnected from it.
Page 748 10C-19 Immobilizer Control System: Connector Terminal Circuit Normal Voltage Condition 1 BLK/ Illumination ring ground • Ignition key not inserted to the key cylinder • Door opened 0 V→12 V • Ignition switch at OFF position • From the time door is closed to the time interior light faded out completely (As the interior light fades out, the voltage increases)
Page 749: Immobilizer Control Module (Icm) Removal And Installation
Immobilizer Control System: 10C-20 Reference Waveform I5JB0BA30006-01 1. CAN communication line signal (High) 2. CAN communication line signal (Low) NOTE CAN communication line signal is pulse. Pulse signal displayed with a regular frequency which varies depending on vehicle condition. Measurement terminals CH1: G24-5 to G24-7 CH2: G24-6 to G24-7 Oscilloscope settings...
Page 750: Registration Of The Ignition Key
To register key the transponder code with ICM, perform “Register Ig verification code stored in the ECM with immobilizer Key” mode of SUZUKI scan tool referring to “SUZUKI control system, perform “Replace ECM” mode of Tech 2 Operator’s Manual”.
Page 751 Prepared by 1st Ed. Nov., 2005...
Page 752 30.0 mm 30.0 mm SUPPLEMENTARY SERVICE MANUAL WITH F9Q ENGINE 99501-67J00-01E 99501-67J00-01E...

Suzuki GRAND VITARA 2005 Service Manual

Precautions

Section 1 Engine

Quick Links

Chapters

Related Manuals for Suzuki GRAND VITARA 2005

Summary of Contents for Suzuki GRAND VITARA 2005