MARUTI SUZUKI Wagon R Manual
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MARUTI SUZUKI Wagon R Manual

MARUTI SUZUKI Wagon R Manual

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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............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication ................................. 0B-1
Engine ......................................................................... 1-i
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Aux. Emission Control Devices ...............................1B-*
Engine Electrical Devices.......................................1C-1
Engine Mechanical.................................................1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System.......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System.......................................................1H-1
Starting System........................................................ 1I-*
Charging System.....................................................1J-1
Exhaust System ......................................................1K-*
Suspension................................................................. 2-i
Precautions ............................................................... 2-*
Suspension General Diagnosis...............................2A-*
Front Suspension ....................................................2B-*
Rear Suspension....................................................2C-1
Wheels and Tires ................................................... 2D-*
Driveline / Axle ........................................................... 3-*
Precautions ............................................................... 3-*
Drive Shaft / Axle ....................................................3A-*
Brakes ......................................................................... 4-*
Precautions ............................................................... 4-*
Brake Control System and Diagnosis .....................4A-*
Front Brakes............................................................4B-*
Rear Brakes ........................................................... 4C-*
Parking Brake......................................................... 4D-*
ABS .........................................................................4E-*
TABLE OF CONTENTS
Transmission / Transaxle ..........................................5-*
Precautions ...............................................................5-*
Manual Transmission/Transaxle ............................ 5B-*
Clutch ..................................................................... 5C-*
Steering .......................................................................6-*
Precautions ...............................................................6-*
Steering General Diagnosis ................................... 6A-*
Steering Wheel and Column .................................. 6B-*
Power Assisted Steering System ........................... 6C-*
HVAC ...........................................................................7-*
Precautions ...............................................................7-*
HVAC System ........................................................ 7B-*
Restraint......................................................................8-*
Precautions ...............................................................8-*
Seat Belts............................................................... 8A-*
Air Bag System ...................................................... 8B-*
Body, Cab and Accessories ...................................... 9-i
Precautions ...............................................................9-*
Wiring Systems ......................................................9A-1
Lighting Systems.................................................... 9B-*
Instrumentation / Driver Info. / Horn .......................9C-1
Wipers / Washers ................................................... 9D-*
Glass / Windows / Mirrors ...................................... 9E-*
Security and Locks..................................................9F-*
Seats ...................................................................... 9G-*
Exterior Trim / Interior Trim .................................... 9H-*
Hood / Fenders / Doors........................................... 9J-*
Body Structure ....................................................... 9K-*
Paint / Coatings .......................................................9L-*
Audio Visual / Navigation ....................................... 9O-*
Control Systems....................................................... 10-i
Precautions .............................................................10-*
Immobilizer Control System .................................10C-1
Communication System ....................................... 10H-*
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  • Page 1 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............... 00-i Transmission / Transaxle ..........5-* Precautions ............

  • Page 3: Table Of Contents

    Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Air Bag Warning ..........00-9 LPG Warning............00-9 Precautions............00-1 Fastener Caution..........00-9 Precautions for Vehicles Equipped with a Suspension Caution ..........00-9 Supplemental Restraint (Air Bag) System ..00-1 Wheels and Tires Caution........

  • Page 4: Precautions

    • If the air bag system and another vehicle system both need repair, MARUTI SUZUKI recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
  • Page 5 Precautions: 00-2 • When carrying a live air bag (inflator) WARNING module, make sure the bag opening is pointed away from you. In case of an accidental deployment, the bag will then • For handling and storage of a SDM, select deploy with minimal chance of injury.

  • Page 6: Precautions For Lpg Vehicles

    00-3 Precautions: • Never expose air bag system component parts • The LPG cylinder, piping and all components of the directly to hot air (drying or baking the vehicle after system should be examined for corrosion, painting) or flames. deterioration and for any modification affecting compliance, at least once in a year or incase of •...
  • Page 7 Precautions: 00-4 • New and used engine oil can be • When performing service to electrical parts that does hazardous. Children and pets may be not require use of battery power, disconnect the harmed by swallowing new or used oil. negative cable of the battery.
  • Page 8 00-5 Precautions: • Whenever you use oil seals, gaskets, packing, O- rings, locking washers, split pins, self-locking nuts, and certain other parts as specified, be sure to use new ones. Also, before installing new gaskets, packing, etc., be sure to remove any residual material from the mating surfaces.

  • Page 9: Warning For Wheel (With Tire) Removal

    Precautions: 00-6 Precautions for Installing Mobile • Use care not to expose connectors and electrical parts to water which will be a cause of a trouble. Communication Equipment AENAR90A0000006 When installing mobile communication equipment such as CB (Citizens-Band)-radio or cellular-telephone, be sure to observe the following precautions.

  • Page 10: Precautions For Electrical Circuit Service

    00-7 Precautions: Precautions for Electrical Circuit Service AENAR90A0000009 • When replacing a fuse, make sure to use a fuse of the specified capacity. Use of a fuse with a larger capacity will cause a damage to the electrical parts and a fire. I2RH01010041-01 •...
  • Page 11 Precautions: 00-8 • Be careful not to touch the electrical terminals of parts • When connecting meter probe (2) from terminal side which use microcomputers (e.g. electronic control unit of connector (1) because it can’t be connected from like as ECM, P/S controller, etc.). The static electricity harness side, use extra care not to bend male from your body can damage these parts.

  • Page 12: Air Bag Warning

    If the correct only by a MARUTI SUZUKI authorized part number fastener is not available, a dealer. Refer to “Air Bag System fastener of equal size and strength (or Component, Wiring and Connector stronger) may be used.

  • Page 13: Abs Caution

    Precautions: 00-10 ABS Caution AENAR90A0000015 • When ABS control module is removed / installed, do not use impact wrenches which generate shock or impact to avoid damaging sensors in ABS control module. Brake Caution AENAR90A0000016 CAUTION All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense.
  • Page 14 00-11 Precautions: Continuity Check Voltage between “C-1” and body ground: Approx. 5 V 1) Measure resistance between connector terminals at “B-1” and body ground: Approx. 5 V both ends of the circuit being checked (between “A- “A-1” and body ground: Approx. 3 V 1”...

  • Page 15: Intermittent And Poor Connection Inspection

    Precautions: 00-12 Intermittent and Poor Connection Inspection AENAR90A0006002 Most intermittent are caused by faulty electrical connections or wiring, although a sticking relay or solenoid can occasionally be at fault. When checking it for proper connection, perform careful check of suspect circuits for: •...

  • Page 16: Special Tools And Equipment

    00-13 Precautions: • Poor terminal-to-wire connection. • Wiring broken inside the insulation. This condition Check each wire harness in problem circuits for poor could cause continuity check to show a good circuit, connection by shaking it by hand lightly. If any but if only 1 or 2 strands of a multi-strand-type wire abnormal condition is found, repair or replace.
  • Page 17 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 Air Cleaner Filter Replacement ......
  • Page 18 0A-1 General Information: General Information General Information General Description Abbreviations EGT: Exhaust Gas Temperature AENAR90A0101001 ELR: Emergency Locking Retractor EOP: Engine Oil Pressure A/B: Air Bag EPS: Electronic Power Steering ABDC: After Bottom Dead Center ® : Electronic Stability Program ABS: Anti-lock Brake System EVAP: Evaporative Emission AC: Alternating Current...
  • Page 19 General Information: 0A-2 TCSS: Traction Control Support System PCM: Powertrain Control Module TDC: Top Dead Center PCV: Positive Crankcase Ventilation TP: Throttle Position PM: Particulate Matter TPMS: Tire Pressure Monitoring System PNP: Park / Neutral Position TWC: Three Way Catalytic converter P/S: Power Steering PSP: Power Steering Pressure Switch USB: Universal Serial Bus...
  • Page 20 0A-3 General Information: Wire Color Symbols AENAR90A0101003 Symbol Wire Color Symbol Wire Color Black O, Or Orange Blue Brown White Green Yellow Gray Pink LT BLU Light blue Violet LT GRN Light green There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire.
  • Page 21 General Information: 0A-4 JIS-TO-ISO main fasteners comparison table Nominal diameter M8 M10 M12 M14 Thread pitch 1.0 1.25 1.25 1.25 1.5 Width across flats Thread pitch 1.0 1.25 1.5 Width across flats I4RH0A010005-01 Fastener Strength Identification Most commonly used metric fastener strength property classes are 4T, 6.8, 7T, 8.8 and radial line with the class identification embossed on the head of each bolt.
  • Page 22 0A-5 General Information: Standard Tightening Torque Each fastener should be tightened to the torque specified in each section. 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 23 General Information: 0A-6 Vehicle Lifting Points AENAR90A0101005 WARNING • Before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending on what part to be removed. • Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
  • Page 24 0A-7 General Information: When Using Floor Jack In raising front or rear vehicle end off the floor by jacking, be sure to put the jack against front suspension frame WARNING (1) or center portion of rear axle (2). If the vehicle to be jacked up only at the front or rear end, be sure to block the wheels on ground in order to ensure safety.
  • Page 25 General Information: 0A-8 Vehicle Identification Number AENAR90A0101006 The number is punched and attached on the left side of cowl top panel in engine compartment. I9R90A010004-01 Engine Identification Number AENAR90A0101007 The number is punched on cylinder block. I9R90A010003-01 [A]: Front [B]: Rear I3RH01010003-01 LPG Compliance Plate AENAR90A0101008...
  • Page 26 0A-9 General Information: Component Location Warning, Caution and Information Labels Location AENAR90A0103001 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 27 General Information: 0A-10 LPG Labels NOTE These labels are attached on vehicle equipped with bi-fuel LPG system only. I9R90A010008-01 1. LPG label on windshield glass 2. LPG label on rear end door glass 3. LPG label on glove box...
  • Page 28 0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance and Lubrication AENAR90A0200001 Air Bag Warning Refer to “Air Bag Warning”: in Section 00. Scheduled Maintenance Maintenance Schedule under Normal Driving Conditions (Petrol Model) AENAR90A0205001 NOTE • This interval should be judged by odometer reading or months, whichever comes first. •...
  • Page 29 Maintenance and Lubrication: 0B-2 Km (x 1,000) Interval Months Master cylinder and wheel cylinder or caliper boot kit (oil leakage, boot cut) Parking brake lever and cable (damage, play) (I: Wheel Tire (air pressure, abnormal wear, crack, Rotate (O)) I & O I & O I & O I & O I & O I & O I & O I & O I & O Wheels (damage) Front / Rear wheel bearings (loose, damage) —...
  • Page 30 0B-3 Maintenance and Lubrication: Periodic Maintenance Schedule (Bi-Fuel LPG Model) AENAR90A0205002 NOTE • This table shows services for LPG system only. Make sure to carry out services additionally, according to the table of “Maintenance Schedule under Normal Driving Conditions (Petrol Model)”: . •...
  • Page 31 Maintenance and Lubrication: 0B-4 LPG Cylinder Inspection AENAR90A0206017 Check LPG cylinder. LPG Fuel Pressure Regulator Filter Replacement AENAR90A0206018 Replace LPG fuel pressure regulator filter.
  • Page 32 0B-5 Maintenance and Lubrication:...
  • Page 33 Table of Contents 1- i Section 1 Engine 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 ..........1-1 Scan Tool Data ..........1A-31 Visual Inspection ..........1A-38 Precautions.............
  • Page 34 1-ii Table of Contents DTC P2665 / P2667 .......... 1A-66 IAT Sensor Inspection......... 1C-* DTC P2668 ............1A-68 LPG MAP and Temperature Sensor Removal DTC U0073 (LPG Control Module) ....1A-70 and Installation (Bi-Fuel LPG Model) ....1C-3 DTC U0100 ............1A-70 LPG MAP and Temperature Sensor Inspection of ECM and Its Circuit......
  • Page 35 Table of Contents 1-iii Cylinder Head No.1 Bolt Inspection ....1D-* Engine Cooling System Symptom Diagnosis..1F-2 Valve Spring Inspection ........1D-* Radiator Cooling Fan Control System Check ..1F-2 Piston, Piston Ring and Connecting Rod Repair Instructions ..........1F-5 Components............
  • Page 36 1-iv Table of Contents Fuel Leakage Check Procedure....... 1G-12 Ignition Coil Assembly Removal and Fuel Line On-Vehicle Inspection ...... 1G-14 Installation ............1H-* Fuel Pipe Removal and Installation..... 1G-* Ignition Coil Assembly Inspection ....... 1H-* Fuel Filter Removal and Installation....1G-14 Ignition Timing Inspection ........

  • Page 37: Precautions

    Precautions: Precautions Engine Precautions Precautions for Engine AENAR90A1000001 Air Bag Warning Refer to “Air Bag Warning”: in Section 00. LPG Warning Refer to “LPG Warning”: in Section 00. Precautions for Engine Service Refer to “Precaution for ECM and LPG Control Module Circuits Inspection”: Bi-Fuel LPG model in Section 1A. Precautions for Diagnosing Trouble Refer to “Precautions for Diagnosing Trouble”: Bi-Fuel LPG model in Section 1A.

  • Page 38: Engine General Information And Diagnosis

    1A-1 Engine General Information and Diagnosis: Bi-Fuel LPG model Engine General Information and Diagnosis Engine Bi-Fuel LPG model Precautions Precautions for Engine Service • Be sure to read “Precaution for CAN Communication AENAR90A1100001 System”: in Section 00 before inspection and observe WARNING what is written there.

  • Page 39: Precaution For Ecm And Lpg Control Module Circuits Inspection

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-2 • Communication of LPG control module, ECM and combination meter is established by CAN (Controller Area Network). (For more details of CAN communication for LPG control module, refer to “CAN Communication System Description”: in Section 10H).
  • Page 40 1A-3 Engine General Information and Diagnosis: Bi-Fuel LPG model • For some malfunctions, ECM adopts the 2 D/C Freeze Frame Data detecting logic to prevent erroneous detection. With ECM stores the engine and driving conditions (in the this logic, MIL is turned on when the malfunction is form of data as shown) at the moment of the detection of detected in 2 consecutive driving cycles.
  • Page 41 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-4 System Readiness Test – For sensor where the output voltage of The system readiness test is to check if the on-board related sensor is increase to the valve diagnosis of each system related to exhaust emission travel, it displays 80% (= the ratio has been completed or not using a scan tool (SUZUKI between power supply voltage and...
  • Page 42 1A-5 Engine General Information and Diagnosis: Bi-Fuel LPG model function, it is possible to know the order of detection of these malfunctions. This is helpful when rechecking or diagnosing a trouble. For details of freeze frame data that can be read from LPG control module, refer to the following table.

  • Page 43: Dlc Description

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-6 Bi-Fuel LPG System Description Freeze frame data clearance The freeze frame data is cleared at the same time as AENAR90A1101007 Bi-fuel LPG system consists of two kinds of fuel system clearance of DTC. (petrol and LPG).

  • Page 44: Bi-Fuel Lpg System Construction

    1A-7 Engine General Information and Diagnosis: Bi-Fuel LPG model Bi-Fuel LPG System Construction AENAR90A1101008 IAR90A110031-01 A1: Fuel injector No.1 control signal from ECM 4. Fuel control relay No.1 16. Fuel select switch A2: Fuel injector No.2 control signal from ECM 5.

  • Page 45: Electronic Control System Description

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-8 Fail safe control module which controls various electric control devices When LPG control module fails to control, operating according to the signals from various sensors and mode is switched to “Petrol MODE” automatically and various electric control devices.
  • Page 46 1A-9 Engine General Information and Diagnosis: Bi-Fuel LPG model Function Output Input • Ignition switch • Starter switch • ECT sensor • CKP sensor • CMP sensor • TP sensor Ignition control Ignition coil assembly • MAP sensor • IAT sensor •...
  • Page 47 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-10 Function Output Input • Ignition switch • ECT sensor • CKP sensor • TP sensor EVAP canister purge EVAP purge control valve • MAP sensor • IAT sensor • HO2S • VSS •...

  • Page 48: Schematic And Routing Diagram

    1A-11 Engine General Information and Diagnosis: Bi-Fuel LPG model Function Output Input • Ignition switch • ECT sensor • MAP sensor LPG injection control LPG fuel injector • LPG pressure-and-temperature sensor • Fuel select switch • ECM • Ignition switch Shut off valve of LPG LPG shut off valve control pressure regulator / LPG...
  • Page 49 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-12 IAR90A110032-01...

  • Page 50: Engine Control System Circuit Diagram

    1A-13 Engine General Information and Diagnosis: Bi-Fuel LPG model Engine Control System Circuit Diagram AENAR90A1102002 NOTE For identification of each cylinder, refer to “Cylinder Identification Description”: .
  • Page 51 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-14 BLK/RED RED/YEL C01-35 C01-2 BRN/YEL C01-1 C01-33 C01-14 WHT/GRN RED/GRN C01-18 BLK/ORN C01-36 C01-12 BLU/BLK GRY/RED C01-11 C01-17 LT GRN/RED BLK/YEL C01-38 C01-34 GRY/BLU C01-26 E01-7 GRN/BLK RED/BLK C01-20 GRN/ORN C01-16 +BB2 LT GRN C01-19...
  • Page 52 1A-15 Engine General Information and Diagnosis: Bi-Fuel LPG model b: To LPG control module “C13-16” 17. A/C switch 37. Main relay c: To LPG control module “C13-7” 18. DLC 38. “DOME” fuse d: To LPG control module “C13-25” 19. Combination meter 39.
  • Page 53 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-16 NOTE For circuit name and terminal voltage, refer to “Inspection of ECM and Its Circuit”: Bi-Fuel LPG model. LPG Control Module BLK/RED BLK/RED C13-6 BLK/RED BLU/YEL C13-1 WHT/BLK RED/WHT BRN/YEL C13-8 C13-14 BLU/WHT BLK/RED...
  • Page 54 1A-17 Engine General Information and Diagnosis: Bi-Fuel LPG model Terminal Arrangement of LPG Control Module Connector E485 11 10 11 10 19 18 19 18 28 27 28 27 IAR90A110035-01 [A]: LPG control module connector (View: A) NOTE For circuit name and terminal voltage, refer to “Inspection of LPG Control Module and Its Circuit”: Bi- Fuel LPG model.

  • Page 55: Component Location

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-18 Component Location Electronic Control System Component Location AENAR90A1103001 IAR90A110036-01...

  • Page 56: Diagnostic Information And Procedures

    1A-19 Engine General Information and Diagnosis: Bi-Fuel LPG model Information sensors / switches Control devices Others 1. Knock sensor [a]: EVAP canister purge valve [1]: ECM 2. CMP sensor [b]: Radiator cooling fan relay [2]: Relay box 3. IAT sensor [c]: Starting motor relay [3]: Combination meter 4.
  • Page 57 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-20 Step Action Trouble symptom confirmation Go to Step 6. Go to Step 7. 1) Confirm trouble symptom. Is trouble symptom identified? Rechecking and recording DTC / freeze frame data Go to Step 9. Go to Step 8.
  • Page 58 1A-21 Engine General Information and Diagnosis: Bi-Fuel LPG model Step 1: Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information required for proper analysis and diagnosis. Customer problem inspection form (Example) I7V20A111010-01 NOTE...

  • Page 59: Lpg Warning Light Check

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-22 Step 2: DTC / Freeze Frame Data Check, Record and Clearance First, check DTC (current and pending DTC). If DTC is indicated, print it and freeze frame data or write them down and then clear them. Step 3 and 4: Visual Inspection As a preliminary step, be sure to perform visual check of the items that support proper function of engine.

  • Page 60: Dtc Check

    1A-23 Engine General Information and Diagnosis: Bi-Fuel LPG model DTC Check AENAR90A1104004 NOTE In case that MIL lights while engine is running, the malfunction(s) is detected by ECM and it stores the trouble information (DTC, freeze frame data, etc.) in its memory. 1) With ignition switch turned OFF, connect SUZUKI scan tool to DLC (1) located on underside of instrument panel at driver’s seat side.

  • Page 61: Dtc Table

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-24 LPG Control Module 4) After completing the clearance, turn OFF ignition switch and disconnect scan tool from DLC. 1) With ignition switch turned OFF, connect SUZUKI scan tool to DLC. NOTE 2) Turn ignition switch to ON position.
  • Page 62 1A-25 Engine General Information and Diagnosis: Bi-Fuel LPG model DTC name DTC detecting condition detection logic Crankshaft Position Sensor “A” CKP sensor signal is not input for more than 3 sec. P0335 1 D/C Applicable Circuit even if CMP sensor signal is inputting. Crankshaft Position Sensor “A”...
  • Page 63 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-26 DTC name DTC detecting condition detection logic Control Module ECM fails to transmit and receive the data via CAN U0073 1 D/C Communication Bus Off for specified time continuously. applicable Lost Communication With Receiving error of the data from LPG control U0108 Alternative Fuel Control...

  • Page 64: Fail-Safe Table

    1A-27 Engine General Information and Diagnosis: Bi-Fuel LPG model DTC name DTC detecting condition detection warning logic light Any of the following conditions is met. • Monitor signal of either of fuel control relays is “Petrol” side for 5 sec. with engine running on Fuel Injector Control Module P0612 LPG.
  • Page 65 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-28 DTC name Fail-safe operation Throttle / Pedal Position Sensor / Switch “A” • ECM controls engine assuming that throttle opening P0122 Circuit Low angle is about 20°. Throttle / Pedal Position Sensor / Switch “A” P0123 •...

  • Page 66: Scan Tool Data

    1A-29 Engine General Information and Diagnosis: Bi-Fuel LPG model DTC name Fail-safe operation LPG control module stops LPG control and then shifts P0607 Control Module Performance operating mode to “Petrol MODE”. P0612 Fuel Injector Control Module Relay Control — P062F Internal Control Module EEPROM Error —...
  • Page 67 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-30 Normal condition / Scan tool data Vehicle condition reference value • Engine condition: Specified idle speed with no load after warming up 5 ± 5° BTDC • Fuel select mode: Petrol MODE •...
  • Page 68 1A-31 Engine General Information and Diagnosis: Bi-Fuel LPG model Normal condition / Scan tool data Vehicle condition reference value • Engine condition: Specified idle speed with no load after warming up 0 msec Inj Pulse Width (CNG/ • Fuel select mode: Petrol MODE LPG) •...
  • Page 69 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-32 Inj Pulse Width (Fuel Injection Pulse Width, msec) 0%: Minimum idle air flow This parameter indicates the time of the injector drive 100%: Maximum idle air flow (valve opening) pulse which is output from ECM (but injector drive time of No.1 cylinder for multiport fuel TP Sensor 1 Volt (TP Sensor Output Voltage, V) injection).
  • Page 70 1A-33 Engine General Information and Diagnosis: Bi-Fuel LPG model Auto: AUTO MODE is selected. Brake Switch (ON / OFF) Petrol: Petrol MODE is selected. This parameter indicates the state of the brake switch. Gas: Forced LPG MODE is selected. ON: Brake pedal is depressed position OFF: Brake pedal is released position Radiator Fan (Radiator Cooling Fan Relay, ON / OFF) This parameter indicates the state of radiator cooling fan...
  • Page 71 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-34 Normal condition / Scan tool data Vehicle condition reference value • Engine condition: Specified idle speed with no load after warming up Approx. 1.5 – 4.5 msec • Fuel select mode: Petrol MODE Inj Pulse Width #3 •...
  • Page 72 1A-35 Engine General Information and Diagnosis: Bi-Fuel LPG model Normal condition / Scan tool data Vehicle condition reference value • Engine condition: Idle speed after warming up CNG/LPG Inj Pressure Approx. 45 – 115 kPa • Fuel select mode: Forced LPG MODE Fuel Tank Level Ignition switch: ON 0 to 100%...

  • Page 73: Visual Inspection

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-36 Fuel Running Status (Petrol / Gas) Ignition Switch (ON / OFF) This parameter indicates the state of fuel. This parameter indicates the state of ignition switch. Petrol: Engine is running on petrol. Gas: Engine is running on LPG.

  • Page 74: Engine Basic Inspection

    1A-37 Engine General Information and Diagnosis: Bi-Fuel LPG model Inspection Item Referring section Disconnection — Looseness — Vacuum hoses of air intake system Deterioration — Bend — Disconnection — Connectors of electric wire harness Pinch — Fuses Burning — Installation —...
  • Page 75 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-38 Step Action Check “AUTO MODE” operation Go to Step 8. Go to “Engine Symptom Diagnosis”: Bi-Fuel LPG 1) Select “AUTO MODE”. model. 2) Start engine. 3) Check fuel change over from petrol to LPG automatically.

  • Page 76: Engine Symptom Diagnosis

    1A-39 Engine General Information and Diagnosis: Bi-Fuel LPG model Step Action 17 Check ignition spark Go to Step 18. Go to “Ignition System Check”: in Section 1H. 1) Check ignition spark. Is it in good condition? 18 Check LPG fuel injector for operation Go to “Engine Symptom Go to “Fuel Injector Diagnosis”: Bi-Fuel LPG...
  • Page 77 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-40 Condition Possible cause Correction / Reference Item Engine noise – Valve Improper valve clearance “Camshaft and Tappet Inspection”: in Section noise Worn valve stem and guide “Valve and Valve Guide Inspection”: in Section Weak or broken valve spring “Valve Spring Inspection”: in Section NOTE...
  • Page 78 1A-41 Engine General Information and Diagnosis: Bi-Fuel LPG model Condition Possible cause Correction / Reference Item Engine overheating Inoperative thermostat “Thermostat Inspection”: in Section Poor water pump performance “Water Pump Inspection”: in Section Clogged or leaky radiator “Radiator On-Vehicle Inspection and Cleaning”: in Section Improper engine oil grade “Engine Oil and Filter Change”: in Section...
  • Page 79 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-42 Condition Possible cause Correction / Reference Item Engine hesitates – Spark plug faulty or plug gap out of “Spark Plug Inspection”: in Section Momentary lack of adjustment response as accelerator Petrol and/or LPG fuel pressure out of “Fuel Pressure Check”: LPG in Section 1G is depressed.
  • Page 80 1A-43 Engine General Information and Diagnosis: Bi-Fuel LPG model Condition Possible cause Correction / Reference Item Excessive detonation – Faulty spark plug “Spark Plug Inspection”: in Section Engine makes Engine overheating Condition “Engine overheating” continuously sharp Clogged petrol fuel filter (faulty fuel “Fuel Line On-Vehicle Inspection”: LPG in metallic knocks that pump) or petrol fuel lines...
  • Page 81 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-44 Condition Possible cause Correction / Reference Item Improper engine idling or Faulty spark plug “Spark Plug Inspection”: in Section engine fails to idle Faulty ignition coil with ignitor “Ignition Coil Assembly Inspection”: in Section Petrol and/or LPG fuel pressure out of “Fuel Pressure Basic Check”: LPG in Section specification...

  • Page 82: Mil Does Not Come On With Ignition Switch In On Position And Engine Stopped (But Engine Can Be Started)

    1A-45 Engine General Information and Diagnosis: Bi-Fuel LPG model Condition Possible cause Correction / Reference Item Unusable LPG (“AUTO Faulty shut off valve of LPG tank valve “LPG Tank with Tank Valve On-Vehicle MODE” or “Forced LPG Inspection”: LPG in Section 1G MODE”...

  • Page 83: Lpg Warning Light Does Not Come On With Ignition Switch In On Position And Engine Stopped

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-46 LPG Warning Light Does Not Come ON with Ignition Switch in ON Position and Engine Stopped AENAR90A1104015 Wiring Diagram G240-1 RED/WHT G240-4 E01-22 G240-8 E01-26 G240-6 C01-40 C13-25 E485-21 BLK/WHT C13-33 C01-39 C13-9 C13-17...
  • Page 84 1A-47 Engine General Information and Diagnosis: Bi-Fuel LPG model Step Action LPG warning light power supply check Go to Step 2. Go to Step 4. 1) Turn ignition switch to ON position. Do other warning lights come ON? DTC check in ECM and LPG control module for CAN- Go to troubleshooting Go to Step 3.

  • Page 85: Lpg Warning Light Remains On After Engine Starts

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-48 LPG Warning Light Remains ON after Engine Starts AENAR90A1104016 Wiring Diagram Refer to “LPG Warning Light Does Not Come ON with Ignition Switch in ON Position and Engine Stopped”: Bi-Fuel LPG model. Circuit Description Refer to “LPG Warning Light Does Not Come ON with Ignition Switch in ON Position and Engine Stopped”: Bi-Fuel LPG model.

  • Page 86: Dtc P0005 / P0007

    1A-49 Engine General Information and Diagnosis: Bi-Fuel LPG model DTC P0005 / P0007 AENAR90A1104039 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area P0005: Fuel Shutoff Valve “A” Control Circuit/Open • Shut off valve of LPG pressure regulator Monitor voltage of shut off valve of LPG pressure regulator is lower than and/or its circuit specified voltage for 5 sec.
  • Page 87 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-50 2) Operate fuel select switch and select “Forced LPG MODE”. 3) Keep it for 10 sec. 4) Select “Petrol MODE”. 5) Keep it for 10 sec. DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2.
  • Page 88 1A-51 Engine General Information and Diagnosis: Bi-Fuel LPG model Step Action Shut off valve of LPG pressure regulator power supply Go to Step 8. Repair or replace shut circuit check off valve of LPG pressure regulator 1) Turn ignition switch to OFF position and then disconnect power supply circuit.

  • Page 89: Dtc P0182 / P0183

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-52 DTC P0182 / P0183 AENAR90A1104040 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area P0182: Fuel Temperature Sensor “A” Circuit Low • LPG pressure-and-temperature Voltage of LPG temperature sensor signal circuit is lower than 0.1 V for 5 sec. sensor and/or its circuit (2 D/C detection logic) •...

  • Page 90: Dtc P0192 / P0193

    1A-53 Engine General Information and Diagnosis: Bi-Fuel LPG model Step Action LPG temperature sensor signal circuit and ground Go to Step 3. Repair or replace LPG circuit check temperature sensor signal circuit and/or 1) Turn ignition switch to OFF position and then disconnect LPG pressure-and- connectors from LPG pressure-and-temperature sensor temperature sensor...
  • Page 91 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-54 Wiring Diagram Refer to “DTC P0182 / P0183”: Bi-Fuel LPG model. DTC Confirmation Procedure 1) Turn ignition switch to ON position and keep it for 10 sec. DTC Troubleshooting Step Action Was “Engine and Emission Control System Check”...

  • Page 92: Dtc P0201 / P0202 / P0203

    1A-55 Engine General Information and Diagnosis: Bi-Fuel LPG model Step Action LPG pressure sensor signal circuit check Go to Step 6. Repair or replace LPG pressure sensor signal 1) Turn ignition switch to OFF position and then disconnect circuit. connectors from LPG control module. 2) Check for proper terminal connection to LPG control module connectors.
  • Page 93 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-56 Wiring Diagram BLK/RED BLK/RED C13-6 BLU/YEL BLK/RED C13-1 WHT/BLK RED/WHT C01-2 BRN/YEL C13-8 C13-14 BLU/WHT BLK/RED C13-10 RED/WHT C13-16 C01-1 C13-5 BLU/RED BLK/RED C13-18 WHT/BLU RED/WHT WHT/GRN C01-14 C13-7 12V 5V C01-40 C13-25 E485-1...

  • Page 94: Dtc P0607

    1A-57 Engine General Information and Diagnosis: Bi-Fuel LPG model DTC Confirmation Procedure 1) Turn ignition switch to ON position and keep it for 10 sec. DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control...
  • Page 95 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-58 Wiring Diagram Refer to “DTC P0005 / P0007”: Bi-Fuel LPG model. DTC Confirmation Procedure 1) Turn ignition switch to ON position and keep it for 10 sec. DTC Troubleshooting Step Action Was “Engine and Emission Control System Check”...

  • Page 96: Dtc P0612

    1A-59 Engine General Information and Diagnosis: Bi-Fuel LPG model DTC P0612 AENAR90A1104045 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area P0612: Fuel Injector Control Module Relay Control • Fuel injector control circuit between Any of the following conditions is met. ECM and LPG control module •...

  • Page 97: Dtc P1432 / P1433

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-60 Step Action LPG control module power and ground circuit check Substitute a known- Repair or replace good LPG control defective wire harness. 1) Check LPG control module power supply circuit and module and recheck.

  • Page 98: Dtc P1601

    1A-61 Engine General Information and Diagnosis: Bi-Fuel LPG model Step Action LPG level sensor signal circuit and ground circuit check Go to Step 3. Repair or replace LPG level sensor signal 1) Turn ignition switch to OFF position and then disconnect circuit or LPG level connectors from LPG level sensor and LPG control sensor ground circuit.

  • Page 99: Dtc P2665 / P2667

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-62 Step Action DTC recheck Replace known-good End. ECM and recheck. 1) Replace known-good LPG control module. 2) Perform DTC confirmation procedure and check DTC. Is DTC P1601 is still detect? DTC P2665 / P2667 AENAR90A1104049 DTC Detecting Condition and Trouble Area DTC detecting condition...

  • Page 100: Dtc P2668

    1A-63 Engine General Information and Diagnosis: Bi-Fuel LPG model Step Action Shut off valve power supply circuit check Go to Step 5. Repair or replace shut off valve of LPG 1) Check shut off valve of LPG pressure regulator power pressure regulator supply circuit and shut off valve of LPG tank valve power power supply circuit...
  • Page 101 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-64 Wiring Diagram BLK/WHT E485-29 LT GRN LT GRN/BLK E485 11 10 11 10 19 18 19 18 28 27 28 27 IAR90A110048-01 [A]: LPG control module connector (View: A) B1: Fuel select switch ground circuit 2.

  • Page 102: Dtc U0073 (Lpg Control Module)

    1A-65 Engine General Information and Diagnosis: Bi-Fuel LPG model Step Action Fuel select switch signal circuit check Go to Step 4. Repair or replace fuel select switch signal 1) Turn ignition switch to OFF position and then disconnect circuit. connector from LPG control module. 2) Check for proper terminal connection to LPG control module connectors.

  • Page 103: Inspection Of Ecm And Its Circuit

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-66 Inspection of ECM and Its Circuit AENAR90A1104052 Voltage Check NOTE • As each terminal voltage is affected by battery voltage, confirm that it is 11 V or more when ignition switch is turned to ON position. •...
  • Page 104 1A-67 Engine General Information and Diagnosis: Bi-Fuel LPG model Terminal No. Wire color Circuit Normal voltage Condition 10 – 14 V Ignition switch: ON 0 – 1 V Fuel injector No.3 C01-14* WHT/GRN ↑ ↓ Engine: Idle speed after control circuit 10 –...
  • Page 105 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-68 Terminal No. Wire color Circuit Normal voltage Condition 0 – 1 V or 4 – 5 V Ignition switch: ON 0 – 1 V CKP sensor signal C01-33* ↑ ↓ Engine: Idle speed after circuit 4 –...
  • Page 106 1A-69 Engine General Information and Diagnosis: Bi-Fuel LPG model Terminal No. Wire color Circuit Normal voltage Condition Ignition switch: ON 10 – 14 V ECT < 95 °C (203 °F) Radiator cooling fan A/C switch: OFF E01-6 LT GRN/RED relay drive circuit Ignition switch: ON 0 –...
  • Page 107 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-70 Terminal No. Wire color Circuit Normal voltage Condition Ignition switch: ON 10 – 14 V A/C switch: OFF Blower speed selector: OFF A/C SW input signal E01-19 WHT/GRN Ignition switch: ON circuit A/C switch: ON 2 V or less...
  • Page 108 1A-71 Engine General Information and Diagnosis: Bi-Fuel LPG model Ignition coil No.1 signal (2): Channel Probe Terminal No. C01-30 – C01-8 CMP sensor signal (3): Channel Probe Terminal No. C01-35 – C01-8 CKP sensor signal (4): Channel Probe Terminal No. I7V10A111015-01 C01-33 5.
  • Page 109 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-72 Measurement condition Channel Probe Terminal No. Engine: Idle speed after warming up C01-43 – C01-8 Generator control signal (2): Channel Probe Terminal No. C01-42 – C01-8 Measurement condition • Engine: Idle speed after warming up •...
  • Page 110 1A-73 Engine General Information and Diagnosis: Bi-Fuel LPG model Measurement condition Engine: Idle speed after warming up I9C50A110031-01 1. ISC valve signal I9R90A111017-03 EVAP canister purge valve signal Vehicle speed signal for P/S control module Channel Probe Terminal No. Channel Probe Terminal No.
  • Page 111 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-74 Engine revolution signal for P/S control module Channel Probe Terminal No. E01-10 – C01-8 Measurement condition Engine: Idle speed after warming up I9L60A110034-01 Knock sensor signal Channel Probe Terminal No. C01-9 –...
  • Page 112 1A-75 Engine General Information and Diagnosis: Bi-Fuel LPG model Inspection of LPG Control Module and Its Circuit AENAR90A1104053 Voltage Check NOTE • As each terminal voltage is affected by battery voltage, confirm that it is 11 V or more when ignition switch is turned to ON position.
  • Page 113 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-76 Terminal No. Wire color Circuit Normal voltage Condition 10 – 14 V Ignition switch: ON 0 – 1 V Engine: Idle speed after LPG fuel injector No.2 C13-10 ↑ ↓ warming up control circuit 10 –...
  • Page 114 1A-77 Engine General Information and Diagnosis: Bi-Fuel LPG model Terminal No. Wire color Circuit Normal voltage Condition Main power supply 10 – 14 V Ignition switch: ON E485-10 RED/WHT circuit 2 0 – 1 V Ignition switch: OFF E485-11 — —...
  • Page 115 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-78 Terminal No. Wire color Circuit Normal voltage Condition 0 – 1 V Ignition switch: ON Engine: Running Shut off valve of LPG 10 – 15 V Fuel select mode: Petrol E485-34 BLU/BLK tank valve control MODE...

  • Page 116: Ecm Power And Ground Circuit Check

    1A-79 Engine General Information and Diagnosis: Bi-Fuel LPG model Petrol fuel injector control signal (3): Measurement condition Channel Probe Terminal No. • Ignition switch: ON C13-6 (No.1) • Fuel select mode: Petrol control in “AUTO MODE” C13-14 (No.2) • Remaining LPG: Low C13-5 (No.3) –...
  • Page 117 Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-80 Wiring Diagram E01-17 WHT/RED WHT/BLK GRY/RED C01-11 E01-2 BLK/WHT LT GRN/RED C01-17 C01-34 E01-12 GRN/YEL BLK/YEL GRY/BLU C01-26 RED/BLK C01-20 E01-1 BLK/RED BLK/YEL GRN/ORN C01-16 E01-11 BLK/RED GRY/RED E01-9 C01-8 C01-28 BLU/RED E01-13 C01-29...
  • Page 118 1A-81 Engine General Information and Diagnosis: Bi-Fuel LPG model Troubleshooting NOTE Before troubleshooting, perform following items. • Be sure to confirm related fuses of ECM power circuit for not blown out. If fuse is blown out, replace fuse(s) and check circuits connected to blown fuse(s) for short circuit to ground.

  • Page 119: Lpg Control Module Power And Ground Circuit Check

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-82 Step Action Main relay circuit check Go to Step 7. Repair or replace defective wire harness. 1) Measure the following circuits resistance between main relay and ECM connector. • Main relay drive circuit (C2) •...
  • Page 120 1A-83 Engine General Information and Diagnosis: Bi-Fuel LPG model [A]: LPG control module connector (View: A) D3: LPG control module ground circuit 3 7. “IG COIL” fuse A1: Ignition switch signal circuit 1. LPG control module 8. “FI” fuse B1: Main power supply circuit 1 2.

  • Page 121: Repair Instructions

    Engine General Information and Diagnosis: Bi-Fuel LPG model 1A-84 Step Action Sensor power source circuit check Check internal short Repair or replace circuit of LPG pressure- defective wire harness. 1) Disconnect connector from LPG pressure-and- and-temperature temperature sensor. sensor. 2) Measure LPG pressure sensor power supply circuit (C1) resistance between LPG pressure-and-temperature sensor and LPG control module connectors.

  • Page 122: Special Tools And Equipment

    1A-85 Engine General Information and Diagnosis: Bi-Fuel LPG model Special Tools and Equipment Special Tool AENAR90A1108001 SUZUKI scan tool (SUZUKI- SDT) — This kit includes following items. 1. SUZUKI-SDT 2. DLC cable 3. USB cable 4. AC/DC power supply 5. Voltage meter probe 6.

  • Page 123: Repair Instructions

    1C-1 Engine Electrical Devices: Engine Electrical Devices Engine Repair Instructions LPG Control Module Removal and Installation (Bi-Fuel LPG Model) AENAR90A1306028 CAUTION As LPG control module consists of precision parts, be careful not to expose it to excessive shock. I9C50A130005-01 Removal 1.

  • Page 124: Cmp Sensor On-Vehicle Inspection

    Engine Electrical Devices: 1C-2 NOTE Sensor temperature of sensor affects resistance value largely. Make sure that sensor heater is at specified temperature. HO2S heater resistance 5.0 – 6.4 Ω at 20 °C (68 °F) I9C50A130010-01 1. HO2S sensor side connector (viewed from terminal side) CMP Sensor On-Vehicle Inspection AENAR90A1306012 1) Disconnect connector of CMP sensor with ignition...

  • Page 125: Ckp Sensor Inspection

    1C-3 Engine Electrical Devices: LPG MAP and Temperature Sensor Inspection 2) Turn ignition switch to ON position and check that voltage of CKP sensor connector (vehicle side) (Bi-Fuel LPG Model) between terminals “1” and “2” is battery voltage. AENAR90A1306030 If faulty condition is found, check power supply LPG Temperature Sensor Inspection circuit, ground circuit and connections.

  • Page 126: Special Tools And Equipment

    Engine Electrical Devices: 1C-4 LPG MAP Sensor Inspection 1) Relieve fuel pressure in LPG fuel line. 2) Disconnect fuel hose between LPG fuel delivery pipe and LPG fuel pressure regulator. 3) Install pressure gauge between LPG fuel pressure regulator and LPG fuel delivery pipe, referring to “Fuel Pressure Basic Check”: LPG in Section 1G.

  • Page 127: Engine Mechanical

    Engine Mechanical: 1D-1 Engine Mechanical Engine Diagnostic Information and Procedures Engine Vacuum Check AENAR90A1404002 The engine vacuum that develops in the intake line is a good indicator of the condition of the engine. Using SUZUKI Scan Tool 1) Warm up engine to normal operating temperature. 2) Place transaxle gear shift lever in “Neutral”...
  • Page 128 1D-2 Engine Mechanical: 4) Using wrench, turn crankshaft pulley (1) clockwise Exhaust: 0.30 – 0.40 mm (0.0123 – 0.0153 in.) (When until cam lobes (2) become perpendicular to tappet cold (ECT: 15 – 25 °C (59 – 77 °F))) faces (3) at valves “1” and “6” as shown in figure. Adjustment 5) Measure valve clearance with feeler gauge (4) according the following procedures.

  • Page 129: Repair Instructions

    Engine Mechanical: 1D-3 Repair Instructions Intake Manifold Removal and Installation 9) Remove intake manifold (1) and intake manifold AENAR90A1406010 gasket. Removal 1) For bi-fuel LPG model, relieve LPG fuel pressure in LPG fuel feed line. 2) Disconnect negative (–) cable from battery. 3) Remove air cleaner assembly.
  • Page 130 1D-4 Engine Mechanical: Removal CAUTION 1) Remove cylinder head cover. • Use the following bolt for timing chain 2) Turn crankshaft clockwise with wrench, and position tensioner fixing bolt. piston No.1 at TDC according to the following procedure. a) Align both intake and exhaust camshaft timing sprocket marks (1) with top face of cylinder head (2) respectively.

  • Page 131: Installation

    Engine Mechanical: 1D-5 5) Put marks (2) matching with intake and exhaust camshaft timing sprocket marks (1) on timing chain. I7V20A141016-01 2) Apply engine oil to sliding part of camshaft, and set camshaft to cylinder head as follows. I9R90A140035-01 6) With hexagonal section of exhaust camshaft held a) Align match mark (1) on intake camshaft stationary with spanner or adjustable wrench, loosen sprocket with painted link (2) of timing chain.
  • Page 132 1D-6 Engine Mechanical: Tightening torque CAUTION Camshaft housing bolt* (a): 5.0 N⋅m → 8.0 In case of extension special tool combined N⋅m → 11 N⋅m (0.51 kgf-m → 0.82 kgf-m → 1.1 with torque wrench, reading value of torque kgf-m, 4.0 lbf-ft → 6.0 lbf-ft → 8.5 lbf-ft) wrench is smaller than specified tightening torque.
  • Page 133 Engine Mechanical: 1D-7 Engine Assembly Removal and Installation AENAR90A1406017 Removal 1) Relieve fuel pressure in fuel feed line. • Petrol model: Reference “Fuel Pressure Relief Procedure: Petrol Model” in Section 1G in related manual mentioned in the Foreword of this manual •...
  • Page 134 1D-8 Engine Mechanical: 13) Disconnect the following electric wires and connectors. • ECM connector (1) • Ground cable (2) • Ground terminal (3) from exhaust manifold • Connectors (4) in battery positive terminal • Connector (5) in relay box • A/C compressor magnet clutch connector (6) •...

  • Page 135: Installation

    Engine Mechanical: 1D-9 31) Remove following components from engine assembly if necessary. • Engine harness • Transaxle: • Clutch cover and disc: • Flywheel: Installation 1) Install following components to engine assembly if removed. • Flywheel: • Clutch cover and clutch disc: •...
  • Page 136 1D-10 Engine Mechanical: 18) Install right side engine under cover. 19) Install front bumper. 20) Install accelerator cable to throttle body. 21) Install air cleaner assembly. 22) Make sure that all electric wires, connectors are installed at original locations. 23) Make sure that all removed components are installed at original locations.

  • Page 137: Installation

    Engine Mechanical: 1D-11 Timing Chain and Chain Tensioner Removal NOTE and Installation If it is necessary to rotate the camshaft after AENAR90A1406023 removing timing chain, turn crankshaft NOTE counterclockwise and position key (1) within specified range (30° – 90°) as shown in figure For identification of each cylinder, refer to before rotating camshaft.
  • Page 138 1D-12 Engine Mechanical: 8) Install timing chain tensioner (2) and tighten tensioner bolt to specified torque. Tightening torque Timing chain tensioner bolt (b): 25 N·m (2.5 kgf- m, 18.5 lbf-ft) I7V20A141062-03 9) Make sure all blue plates (2) are aligned with match I7V20A141060-01 marks (1) on corresponding timing sprockets.

  • Page 139: Valve And Cylinder Head Removal And Installation

    Engine Mechanical: 1D-13 Tighten timing chain tensioner adjuster bolts to 5) Loosen cylinder head No.1 bolts in numerical order specified torque, and then remove a retainer from (“1” – “8”) evenly and gradually. timing chain tensioner adjuster. NOTE Tightening torque Use 12-point socket wrench for cylinder head Timing chain tensioner adjuster bolt (a): 11 N·m No.1 bolts.

  • Page 140: Piston, Piston Ring And Connecting Rod

    1D-14 Engine Mechanical: “3”, (a) “1”, (a) “7”, (a) “5”, (a) “8”, (a) “2”, (a) 1, (b) “4”, (a) “6”, (a) I8C50A140050-01 I8C50A140049-01 6) Install intake and exhaust camshaft and tappet. 5) Install cylinder head to cylinder block as follows. 7) Install timing chain.
  • Page 141 Engine Mechanical: 1D-15 2) Remove piston pin from connecting rod as follows. NOTE a) Remove piston pin circlips (1), as shown. Be sure to position front mark (4) on piston and oil hole (5) of connecting rod (2) at specified position as shown in figure. c) Insert piston pin to piston and connecting rod.

  • Page 142: Crankshaft Pin And Connecting Rod Bearings

    1D-16 Engine Mechanical: I7V20A141094-01 1. Front mark 4. 2nd ring end gap and oil ring spacer gap 2. Oil ring upper rail gap 5. Oil ring lower rail gap 3. 1st ring end gap 6. 45° Crankshaft Pin and Connecting Rod Bearings Inspection AENAR90A1406037 NOTE...
  • Page 143 Engine Mechanical: 1D-17 Connecting Rod Bearing Clearance Replace bearings with one size thicker or regrind crankshaft pin to under size and use 0.25 mm CAUTION (0.0098 in.) undersize bearings. Do not rotate crankshaft while gauging • Less than standard: plastic is installed. Replace bearings with one size thinner or regrind crankshaft pin to under size and use 0.25 mm (0.0098 in.) undersize bearings.

  • Page 144: Main Bearing, Crankshaft And Cylinder Block

    1D-18 Engine Mechanical: “a” I8C50A140067-02 1. Crankshaft pin No.1 3. Crankshaft pin No.3 2. Crankshaft pin No.2 I8C50A140068-01 3) From numbers stamped on connecting rods and its Main Bearings, Crankshaft and Cylinder Block caps and alphabets stamped on crank web No.6, Removal and Installation determine new standard bearings to be installed to AENAR90A1406039...
  • Page 145 Engine Mechanical: 1D-19 5) Remove CKP sensor. CAUTION 6) Remove main bearing cap bolts in numerical order • Align spring pin hole (4) on sensor plate evenly and gradually as indicated in figure. with spring pin on crankshaft. • Inside edge (5) of sensor plate is bent. “7”...
  • Page 146 1D-20 Engine Mechanical: 4) Confirm that dowel pins (3) are installed to intake c) In the same manner as Step a), retighten them to side of each journal. 60°. Tightening torque Main bearing cap bolt* : 20 N⋅m → 40 N⋅m → +60°...

  • Page 147: Tightening Torque Specifications

    Engine Mechanical: 1D-21 “a” “A” “b” “A” 2,(a) I7V20A141112-01 3. Crankshaft side I7V20A141111-01 13) Apply engine oil to oil seal lip, then install engine rear 15) Install pistons and connecting rods. crankshaft oil seal housing (1) using special tool. 16) Install CKP sensor. 14) Tighten new engine rear crankshaft oil seal housing bolts (2) to specified torque.

  • Page 148: Recommended Service Material

    1D-22 Engine Mechanical: Recommended Service Material AENAR90A1408001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Special Tool AENAR90A1408002 09911M05120 09911M16300 Box end wrench (14 mm) Oil seal installer 09911M97720 09914M06310 Oil seal installer Guide, camshaft sprocket 09915M67311 SUZUKI scan tool (SUZUKI- SDT)

  • Page 149: Engine Lubrication System

    Engine Lubrication System: 1E-1 Engine Lubrication System Engine Diagnostic Information and Procedures Oil Pressure Check Oil pressure specification AENAR90A1504001 300 – 500 kPa (3.1 – 5.1 kgf/cm , 43.5 – 72.5 psi) NOTE at 4,000 rpm. Prior to checking oil pressure, check the 8) After checking oil pressure, stop engine and remove following.
  • Page 150 1E-2 Engine Lubrication System: • DTC Clearance – Bi-Fuel LPG model: – Petrol model: Reference “DTC Check: Petrol Model” in Section 1A in related manual mentioned in the Foreword of this manual. Tightening Torque Specifications AENAR90A1507001 Tightening torque Fastening part Note N⋅m kgf-m...

  • Page 151: Engine Cooling System

    Engine Cooling System: 1F-1 Engine Cooling System Engine General Description Coolant Description NOTE AENAR90A1601002 The coolant recovery system is a standard system, • Ethanol or methanol base coolant or plain which allows part of coolant to flow from the radiator into water alone should not be used in cooling the coolant reservoir when it is expanded by heat.

  • Page 152: Diagnostic Information And Procedures

    1F-2 Engine Cooling System: [A]: Engine is cool (thermostat closed) 4. Throttle body outlet hose 11. Heater core [B]: Engine is normal operating temperature (thermostat open) 5. Thermostat 12. Radiator [C]: Petrol model 6. Water pump 13. LPG pressure regulator [D]: Bi-Fuel LPG model 7.
  • Page 153 Engine Cooling System: 1F-3 NOTE • For details about engine cooling fan operation, refer to “Cooling Fan Description”: . • Before beginning troubleshooting, be sure to read “Precautions for ECM Circuit Inspection: Petrol model” in Section 1A in related manual mentioned in the Foreword of this manual or “Radiator Cooling Fan Relay Inspection”: .

  • Page 154: Repair Instructions

    1F-4 Engine Cooling System: Step Action Radiator cooling fan motor check Substitute a known- Replace radiator cooling good ECM and recheck. fan motor. 1) Check radiator cooling fan motor. Is it in good condition? Repair Instructions Cooling System Components AENAR90A1606001 1207F I9R90A160003-02 [A]: Petrol model...

  • Page 155: Radiator Cooling Fan Assembly On-Vehicle

    Engine Cooling System: 1F-5 Cooling System Refilling AENAR90A1606006 WARNING To avoid getting burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can gush out under pressure if cap is taken off too soon.

  • Page 156: Special Tool

    1F-6 Engine Cooling System: Radiator Cooling Fan Motor 3) Check that radiator cooling fan motor rotate smoothly and properly. 1) Disconnect radiator cooling fan motor connector (1). If any abnormality is found, replace radiator cooling 2) Using service wire, connect radiator cooling fan fan motor.

  • Page 157: Fuel System

    1G-1 Fuel System: LPG Fuel System Engine Precautions Precautions for Fuel System Service AENAR90A1700001 WARNING Before servicing on fuel system, the following points should be always observed in order to reduce the risk of fire and personal injury. • Disconnect negative (–) cable at battery. •...

  • Page 158: Lpg Filler Valve Description

    Fuel System: LPG 1G-2 LPG Tank Description For system diagram, refer to “Fuel Delivery System Diagram”: LPG. AENAR90A1701005 The material of LPG tank is IS 6240 revised. The vehicle is equipped with one LPG tank with a LPG Filler Valve Description capacity of 28 liters (water filling capacity) in the luggage AENAR90A1701004 compartment.

  • Page 159: Lpg Fuel Filter Description

    1G-3 Fuel System: LPG 1. Strainer 11. Solenoid Coil 21. Tank valve Body 2. Float 12. Nut 22. Empty Position 3. Suction Pipe 13. Nut Cap 23. Full Position 4. Gasket 14. Gas outlet 24. O-ring 5. Allen Screw 15. Solenoid Assembly 25.

  • Page 160: Schematic And Routing Diagram

    Fuel System: LPG 1G-4 IAR90A170002-01 1. Filter Bowl 2. Solenoid Valve 3. Regulator Body 4. Gas outlet connector 5. Gas Inlet 6. Coolant Connectors Schematic and Routing Diagram Fuel Delivery System Diagram AENAR90A1702001 LPG System IAR90A170003-01 1. LPG tank 5. Shut-off valve 9.

  • Page 161: Fuel Injector Control System Circuit Diagram

    1G-5 Fuel System: LPG Fuel Injector Control System Circuit Diagram AENAR90A1702002 NOTE For identification of each cylinder, refer to “Cylinder Identification Description”: in Section . Circuit Diagram E01-17 WHT/BLK WHT/RED BLK/WHT E01-2 C01-8 C01-28 BLK C01-29 BLK/YEL BLK/YEL GRN/YEL E01-12 BLK/RED E01-1 BLK/YEL...

  • Page 162: Diagnostic Information And Procedures

    Fuel System: LPG 1G-6 Circuit Diagram Refer to “Fuel Pump Control System Circuit Diagram: Petrol Model” in Section 1G in related manual mentioned in the Foreword of this manual. Diagnostic Information and Procedures Power Balance Test • Ignition coil circuit AENAR90A1704002 •...

  • Page 163: Fuel Pump And Its Circuit Check

    1G-7 Fuel System: LPG Fuel Pump and Its Circuit Check AENAR90A1704004 Refer to “Fuel Pump Control System Circuit Diagram”: LPG about circuit diagram. Fuel Pressure Check AENAR90A1704005 LPG System CAUTION Do not use special tools that had been used for a petrol fuel line. If petrol mixes in the LPG fuel line, it could damage the LPG fuel injector.

  • Page 164: Fuel Pressure Basic Check

    Fuel System: LPG 1G-8 Step Action LPG fuel feed line check 2 Go to Step 5. Repair or replace defective part. 1) Check LPG fuel pipe, LPG fuel hose and joint for LPG fuel leakage. Are they in good condition? LPG pressure check Go to Step 6.

  • Page 165: Fuel Cut Operation Check

    1G-9 Fuel System: LPG Fuel Cut Operation Check AENAR90A1704007 1) Place gear shift lever in “Neutral” and apply parking brake. 2) Warm up engine to normal operating temperature. 3) While listening to sound of injector (2) by using sound scope (1) or the like, increase engine speed to higher than 3,000 rpm.
  • Page 166 Fuel System: LPG 1G-10 LPG System View-A View-A IAR90A170005-02...

  • Page 167: Fuel Pressure Relief Procedure

    1G-11 Fuel System: LPG 1. LPG Pipe no.1 21. LPG Hose clip 41. LPG regulator water hose clip 2. LPG Pipe Joint 22. LPG Pipe Bracket Bolt 42. LPG Injector Hose Clip (Injection side) 3. LPG Pipe no.2 23. LPG Hose-Water Tube Inlet no. 1 43.
  • Page 168 Fuel System: LPG 1G-12 After performing any service on LPG system, check that there is no LPG fuel leakage as follows. 1) Clean inspection points. 2) Visually inspect LPG fuel pipes, joints, and operating parts for damage, corrosion, and wear. 3) Turn ignition switch to ON position and select “Forced LPG MODE”...

  • Page 169: Fuel Line On-Vehicle Inspection

    1G-13 Fuel System: LPG 6) If LPG fuel leak has been detected, relieve LPG pressure and then replace the faulty parts or retighten LPG fuel pipe nuts. Recheck LPG fuel leakage after replacing the faulty parts or retightening LPG fuel pipe nuts. When Using Gas Leak Detection Liquid 1) Apply gas leak detection liquid (1) to inspection points and wait for 10 minutes.

  • Page 170: Fuel Injector On-Vehicle Inspection

    Fuel System: LPG 1G-14 I9R90A172019-01 • Check for LPG fuel leaks. I9R90A172017-01 Installation Fuel Injector On-Vehicle Inspection Reverse removal procedure for installation noting the AENAR90A1706008 LPG System following. 1) Remove air cleaner assembly. • Check LPG fuel filter (3) for evidence of dirt and contamination.

  • Page 171: Fuel Lpg Inspection

    1G-15 Fuel System: LPG Fuel LPG Inspection AENAR90A1706010 LPG System Connect ohmmeter between terminals of LPG fuel injector and check resistance. If resistance is out of reference value greatly, replace LPG fuel injector assembly. Reference resistance of LPG fuel injector 1.19 –1.31 Ω...

  • Page 172: Lpg Pressure Regulator Removal And

    Fuel System: LPG 1G-16 c) Select “LPG Tank Pressure” under “Data List” mode on scan tool. Check LPG pressure displayed on scan tool. d) Check that LPG pressure on LPG pressure gauge and “LPG Tank Pressure” on SUZUKI scan tool is similarly decreased, when LPG pressure is relieved.

  • Page 173: Lpg Pressure Regulator Inspection

    1G-17 Fuel System: LPG LPG Pressure Regulator Inspection AENAR90A1706013 Shut-Off Valve Resistance check Measure resistance between terminals of shut-off valve (1). If resistance is out of reference value greatly, replace LPG pressure regulator. Reference resistance of shut-off valve 8.0 – 10.0 Ω at 20 °C (68 °F) IAR90A170022-03 Operation check Check that shut-off valve (1) actuate with click sound...

  • Page 174: Lpg Pressure Regulator Plunger Assembly

    Fuel System: LPG 1G-18 7) Clean or replace Filter (6) as necessary. CAUTION Clean Filter (6) using pressurized air only. Do not use any liquid for cleaning. Installation Reverse removal procedure for installation noting the following. • Use new O-rings (2), (5), (7), (8), (9), (10) and new Magnet (4).

  • Page 175: Lpg Pressure Regulator Overhauling

    1G-19 Fuel System: LPG Tightening torque • Check for LPG fuel leaks. Coil Cap (a): 12 N·m (1.2 kgf-m, 8.85 lbf-ft) LPG Pressure Regulator Overhauling AENAR90A1706032 Removal 1) Relieve LPG pressure in LPG fuel feed line. 2) Remove Fuel Pressure Regulator. IAR90A170018-03 3) Mount LPG pressure regulator on nylon bench vise with Cover High Pressure side (11) upwards.

  • Page 176: Installation

    Fuel System: LPG 1G-20 CAUTION Hold the Cover Low pressure side while removing the Screws (13) 13) Remove Regulator group (15) and Spring (16). 14) Rotate Diaphragm to 90° with PRD group (17) in order to unlock it from Lever group (21) and remove PRD group (17) with O-ring (18).

  • Page 177: Lpg Tank With Tank Valve Removal And Installation

    1G-21 Fuel System: LPG d) Check that shut-off valve (1) actuate with click sound when battery voltage is conducted. If check result is not satisfactory, replace LPG tank valve. IAR90A170025-02 LPG Tank with Tank Valve Removal and Installation AENAR90A1706027 WARNING LPG tank should be installed or removed by 2 or more persons.

  • Page 178: Lpg Filler Valve On-Vehicle Inspection

    Fuel System: LPG 1G-22 LPG Filler Valve On-Vehicle Inspection AENAR90A1706028 • Check LPG Filler Valve for cracks, deformation or damage. If any faulty condition is found, replace LPG Filler Valve. • Check O-ring for cracks, deformation or damage. If any faulty condition is found, replace O-ring. •...

  • Page 179: Specifications

    1G-23 Fuel System: LPG Installation • Use new O-ring. Reverse removal procedure for installation noting the following. Specifications Tightening Torque Specifications AENAR90A1707001 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft LPG fuel filter lower case 0.82 LPG fuel injector hose clamp 0.14 LPG fuel pipe nut 12.5...

  • Page 180: 1H-1 Ignition System

    1H-1 Ignition System: Ignition System Engine Component Location Ignition System Component Location AENAR90A1803001 Refer to “Electronic Control System Component Location: Petrol model” in Section 1A in related manual as mentioned in FOREWORD this manual or “Electronic Control System Component Location”: Bi-Fuel LPG model in Section 1A. Diagnostic Information and Procedures Ignition System Check AENAR90A1804001...
  • Page 181 Ignition System: 1H-2 Step Action Ignition coil assembly drive circuit check Go to Step 8. Repair or replace malfunctioning part. 1) Check drive circuits of each ignition coil assembly for open, short and poor connection. Are circuits in good condition? Ignition coil assembly power supply and ground circuit Substitute a known- Repair or replace...

  • Page 182: Diagnostic Information And Procedures

    1J-1 Charging System: Charging System Engine Diagnostic Information and Procedures Generator Symptom Diagnosis AENAR90A1A04002 Trouble in charging system will show up as one or more of the following conditions. Charge Warning Light Operation Condition Possible cause Correction / Reference Item Charge warning light Fuse blown Replace fuse.
  • Page 183 Charging System: 1J-2 I9R90A1A0006-01 Installation I9R90A1A0005-02 5) Remove battery tray and battery bracket (1) as 1) Reverse removal procedure. necessary. 2) Tighten battery cables securely. NOTE NOTE Before removing battery bracket, perform the Check to be sure that ground cable has following procedure.
  • Page 184 1J-3 Charging System:...
  • Page 185 Table of Contents 2- i Section 2 Suspension 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 ..........2-* Rear Suspension ........2C-1 Precautions..............

  • Page 186: Repair Instructions

    2C-1 Rear Suspension: Rear Suspension Suspension Repair Instructions Rear Coil Spring, Bump Stopper and Spring Upper Seat Removal and Installation AENAR90A2306005 CAUTION • Be careful not to let trailing arm down too much. It may cause damage to rear brake flexible hose, rear wheel speed sensor lead wire (ABS model) and parking brake cable.
  • Page 187 Rear Suspension: 2C-2 4) Jack up rear axle at trailing arm ends with floor jacks (1) and install rear shock absorbers to rear axle, then tighten new upper bolts and new lower nuts temporarily by hand. NOTE Before jack working, place shop cloth on top of the jack to protect paint surface of the lifted portion from damaging.
  • Page 188 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-* A-9 CAN Circuit Diagram ........9A-38 A-10 Security Control System Circuit Diagram ..
  • Page 189 9-ii Table of Contents Lighting System Description........ 9B-* Diagnostic Information and Procedures ....9C-4 Combination Meter System Check...... 9C-* Schematic and Routing Diagram......9B-* Inspection of Combination Meter and Its Lighting System Circuit Diagram......9B-* Circuit ..............9C-4 Component Location ........... 9B-* Inspection of Selector Switch and Its Circuit Headlight Leveling System Component (Bi-Fuel Model)..........9C-6...
  • Page 190 Table of Contents 9-iii Diagnostic Information and Procedures.....9E-* Rear End Door Window Defogger Control Power Window System Symptom Diagnosis System Description (If Equipped).......9F-* (If Equipped) ............9E-* Schematic and Routing Diagram ......9F-* Rear End Door Window Defogger Symptom Power Door Lock Circuit Diagram......9F-* Diagnosis (If Equipped)........9E-* Component Location ..........9F-* Power Door Mirror Control System Symptom...
  • Page 191 9-iv Table of Contents Paint / Coatings ........9L-* Rear Door Assembly Components....... 9J-* Rear Door Assembly Removal and Precautions............9L-* Installation ............9J-* Precautions for Working on Air Bag System ..9L-* Rear End Door Assembly Components ....9J-* General Description ..........9L-* Rear End Door Assembly Removal and Anti-Corrosion Treatment Construction....9L-* Installation ............

  • Page 192: Wiring Systems

    Wiring Systems: 9A-1 Wiring Systems Body, Cab and Accessories Precautions Cautions in Body Electrical System Servicing AENAR90A9100001 When servicing the electric systems, observe the cautions described in “Precautions for Electrical Circuit Service”: in Section 00 to protect electrical parts and to prevent a fire. General Description Abbreviations AENAR90A9101001...

  • Page 193: Symbols And Marks

    9A-2 Wiring Systems: Symbols and Marks AENAR90A9101003 Battery Ring-terminal ground Ground Normal fuse Slow blow fuse I2RH01910910-01 IYSQ01910915-01 IYSQ01910916-01 IYSQ01910918-01 IYSQ01910917-01 Circuit breaker Coil, Solenoid Heater Bulb Bulb IYSQ01910923-01 IYSQ01910922-01 IYSQ01910921-01 IYSQ01910919-01 IYSQ01910920-01 Cigarette lighter Motor Pump Horn Speaker IYSQ01910924-01 I5JB0B910995-02 I2RH01910911-01 IYSQ01910925-01...
  • Page 194 Wiring Systems: 9A-3 Ignition switch Keyless entry Immobilizer system Combination meter Lighting switch I3JA01910902-01 I5RH01910901-01 I2RH01910915-01 I2RH01910916-01 I2RH01910912-01 Head light leveling Hazard warning light Front fog light Rear fog light Spark plug I3JA01910907-01 I3JA01910906-01 I3JA01910904-01 I3JA01910905-01 I2RH01910921-01 Radiator cooling fan Fuel pump Fuel injector XX control module...

  • Page 195: How To Read Connector Layout Diagram

    9A-4 Wiring Systems: How to Read Connector Layout Diagram AENAR90A9101004 [A-1]: Harness Symbol and Corresponding Harness Name A: Battery cable B: A/C harness C: Engine harness D: Injector harness, Oil pressure switch wire E: Main harness, Power steering wire F: Console wire G: Instrument panel harness, Instrument panel antenna wire J: Side door wire (including P/W related wires) K: Interior light harness, Roof wire, Roof radio antenna wire, Rear speaker wire...

  • Page 196: How To Read Connector Codes And Terminal Nos

    Wiring Systems: 9A-5 How to Read Connector Codes and Terminal Nos. AENAR90A9101005 1) Connector code/Terminal No./Terminal layout • The connector shape and terminal layout shown in this manual are those when viewed from “Z” in the illustration. Refer to “List of Connectors”: . View Z "CONNECTOR LIST"...
  • Page 197 9A-6 Wiring Systems: 3) Terminals in one connector (Broken line) (B15)/Terminals in different connectors (B14, B16) I2RH01910904-01 4) Joint connector (J/C) • The joint connector (J/C) connects several different wires with the same wire color at one place instead of connecting them by welding or caulking one by one.
  • Page 198 Wiring Systems: 9A-7 6) Junction block (J/B) Example J/B inner circuit Connector No. / Terminal No. K01 L04 IMMOBI IG BLK/WHT IG Coil IG Coil, etc BCM ;IG1 MTR Power, etc A/B CONT K-LINE K-LINE A/B SIGNAL A/B SIGNAL A/B SIG A/B SIG IG Sig EPS AT...

  • Page 199: How To Read Ground Point

    9A-8 Wiring Systems: How to Read Ground Point AENAR90A9101006 Refer to “System Circuit Diagram”: . Refer to “Ground Point”: . "SYSTEM CIRCUIT DIAGRAM" "GROUND POINT" Individual circuit fuse box YEL/BLU 10 11 12 BLU/BLK BLU/RED BLU/WHT Windoshield Windoshield washer wiper motor motor Circuit...

  • Page 200: How To Read Power Supply Diagram

    Wiring Systems: 9A-9 How to Read Power Supply Diagram AENAR90A9101007 Refer to “Power Supply Diagram”: . Refer to “System Circuit Diagram”: . "POWER SUPPLY DIAGRAM" Battery Fuse number Main fuse box Supplementary fuse box WHT/BLU WHT/RED BLU/RED WHT/BLU WHT/YEL WHT/GRN WHT/GRN WHT/GRN Individual...

  • Page 201: How To Read System Circuit Diagram

    9A-10 Wiring Systems: How to Read System Circuit Diagram AENAR90A9101008 The circuit diagram is designed so the current flows from the top of the diagram (power source) to the bottom of the diagram (ground) as if giving an image of water flow. [A]: Fuse No.
  • Page 202 Wiring Systems: 9A-11 [K] [L] 4-DOOR 2-DOOR Fuse Fuse "XX" BLK/RED GRN/BLK Solenoid Main GRN/RED GRN/RED relay GRN/BLK GRN/RED Cont.M GRN/BLK Switch BRN/RED Sensor Motor Motor BRN/RED Other system circuit BRN/RED BRN/RED GRN/RED YEL/RED I8RW0A910A46-02...

  • Page 203: Connector Layout Diagram

    9A-12 Wiring Systems: Connector Layout Diagram Connector Layout Diagram AENAR90A910A001 Refer to “Engine Compartment”: . Refer to “Instrument Panel”: . Refer to “Door, Roof”: . Refer to “Floor”: . Refer to “Rear”: . Engine Compartment AENAR90A910A002 A: Battery Cable / C: Engine Harness (Bi-Fuel Using LPG Model) C196 C123 C121...
  • Page 204 Wiring Systems: 9A-13 Color Connective position Remarks Fuel injector #3 C101 Ignition coil #1 C102 Ignition coil #2 C103 Ignition coil #3 C121 ISC valve C123 EVAP canister purge valve C141 A/C compressor C162 Engine oil pressure switch C165 Back-up light switch C192 Generator (+B) C194...

  • Page 205: Instrument Panel

    9A-14 Wiring Systems: Color Connective position Remarks Headlight leveling actuator (L) E134 Regulator shutoff valve Bi-fuel using LPG model E151 Headlight (R) E152 Headlight (L) E159 Front turn signal light (R) E160 Front turn signal light (L) E161 Front position light (R) E162 Front position light (L) E163...
  • Page 206 Wiring Systems: 9A-15 E: Main Harness E181 E268 E266 E317 E323 E324 E381 (To G333) E382 (To G334) E387 (To L371) I9R90A910904-01 E: Main Harness Color Connective position Remarks E181 Brake light switch E266 Option #1 Option E268 Option #3 Option E317 Individual circuit fuse box No.2...
  • Page 207 9A-16 Wiring Systems: G: Instrument Panel Harness, Instrument Panel Antenna Wire / S: Contact Coil Instrument panel antenna wire G259 G153 G267 G248 G234 G147 G240 G17 G141 G144 G220 G146 G115 G164 G151 G152 G271 G343 (To L376) G333 (To E381) G334 (To E382)
  • Page 208 Wiring Systems: 9A-17 Color Connective position Remarks G343 Floor harness (To L376) If equipped G346 Contact coil (To S171) G347 Contact coil (To S172) If equipped G: Instrument Panel Antenna Wire Color Connective position Remarks G220 Roof audio antenna amplifier G267 Audio S: Contact Coil...

  • Page 209: Power Supply Diagram

    9A-18 Wiring Systems: Color Connective position Remarks L135 Rear fog light If equipped L161 Front door switch (Driver side) L162 Front door switch (Passenger side) L163 Rear door switch (R) L164 Rear door switch (L) L165 Rear end door opener switch L167 Parking brake switch L170...
  • Page 210 Wiring Systems: 9A-19 Individual Circuit Fuse Box No. 1 USE THE DESINGNATED FUSE ONLY I9R90A910913-02 1. Front fog light relay 3. Fuel shutoff valve relay 5. Radiator cooling fan relay 7. Main relay 2. Starting motor relay 4. A/C compressor relay 6.
  • Page 211 9A-20 Wiring Systems: Individual Circuit Fuse Box No. 2 (In J/B) 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 USE THE DESINGNATED FUSES ONLY I9R90A910914-05 1. Rear defogger relay Fuse Description on the cover Protected circuit 10 A...

  • Page 212: J/B Inner Circuit (Detail)

    Wiring Systems: 9A-21 Fuse Description on the cover Protected circuit BLANK BLANK BLANK BLANK BLANK BLANK Keyless / security control module 20 A Door lock control module Option #3 Horn relay 15 A HORN HAZ Flasher relay Option #3 15 A RR DEF Rear defogger relay Audio...
  • Page 213 9A-22 Wiring Systems: Connector No. / Terminal No. E323 E324 G271 L313 L314 L315 MAIN SW IMMOBI IG COIL IG COIL SPEEDOMETER BCM FLOOR MAIN SW FL BOX BAT #2 SPEEDOMETER A/B CONT A/B CONT EPS CONT IG1 SIG A/C SW BACK BACK UP LP SW Individual circuit fuse box No.2...
  • Page 214 Wiring Systems: 9A-23 Connector No. / Terminal No. E323 E324 G271 L313 L314 L315 MAIN SW IMMOBI IG COIL IG COIL SPEEDOMETER BCM FLOOR A/B CONT MAIN SW FL BOX BAT #2 SPEEDOMETER A/B CONT A/B CONT EPS CONT IG1 SIG ABS CONT A/C SW BACK...
  • Page 215 9A-24 Wiring Systems: (Continued) Connector No. / Terminal No. E323 E324 G271 L313 L314 L315 HORN RELAY HORN COMB SW HORN HAZ SW SPEEDOMETER Flasher Relay FR TURN RH GND SW-L SW-R LP-L LP-R RR COMB LP (R) SPEEDOMETER FR TURN LH RR COMB LP (L) COMB SW LP COMB SW LP...
  • Page 216 Wiring Systems: 9A-25 (Continued) Connector No. / Terminal No. E323 E324 G271 L313 L314 L315 RR DEF RR DEF RLY RR DEF HVAC CONT STOP STOP LP SW TAIL COMB SW LP BLOWER MOTOR RLY BLW FAN MOT H/L LVL POWER GND INST GND LVL SW...
  • Page 217 9A-26 Wiring Systems: (Continued) Connector No. / Terminal No. E323 E324 G271 L313 L314 L315 MAIN SW MRR SW CIGAR MAIN SW ST SIG R/B (ST RLY COIL) MAIN SW COMB SW WIP WIPER MOT RR WIPER P/W MAIN SW P/W SW DR IG2 SIG Individual circuit fuse box No.2 (In J/B)

  • Page 218: System Circuit Diagram

    Wiring Systems: 9A-27 System Circuit Diagram System Circuit Diagram AENAR90A910E001 Refer to “A-1 Cranking System Circuit Diagram”: . Refer to “A-2 Charging System Circuit Diagram”: . Refer to “A-3 Ignition System Circuit Diagram”: . Refer to “A-4 Cooling System Circuit Diagram”: . Refer to “A-5 Engine and A/C Control System Circuit Diagram (Petrol Model)”: .
  • Page 219 9A-28 Wiring Systems: Main fuse box IG COIL E323 C283 BLK/WHT "C-1" "A-5" WHT/BLU G333 E381 WHT/BLU E371 C343 WHT/BLU PNK/BLU BLK/WHT C194 C192 Generator IC regulator IAR90A910905-01...
  • Page 220 Wiring Systems: 9A-29 A-5 Engine and A/C Control System Circuit Diagram (Petrol Model) AENAR90A910E006 Individual circuit CPRSR IG COIL fuse box No.1 E323 BLK/YEL E221 Main relay BLK/RED BLK/RED BLU/YEL BLK/RED E229 GRN/YEL BLK/RED BLK/RED E227 Compressor relay Relay GRN/BLK BLK/WHT BLK/RED BLK/RED...
  • Page 221 9A-30 Wiring Systems: Individual circuit RDTR fuse box No.1 E371 C343 BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED E222 BLK/RED BLK/RED BLK/RED BLK/RED Relay LT GRN/RED BLU/RED BLU/YEL BLU/WHT BLU/RED motor "A-4" LT GRN RED/GRN GRY/RED LT GRN/RED RED/BLK GRY/BLU Open TP sensor sensor sensor sensor...
  • Page 222 Wiring Systems: 9A-31 STOP DOME E323 Starting E181 Immobilizer motor BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED control module relay "A-7" "A-1" Brake C123 light switch EVAP canister C121 purge valve valve sensor sensor BLU/BLK BLK/YEL GRN/WHT RED/YEL YEL/RED YEL/BLK WHT/RED YEL/GRN PNK/BLU Generator "A-2"...
  • Page 223 9A-32 Wiring Systems: "A-9","C-1" Cont.M (CAN) G333 E381 (CAN) (CAN) WHT/BLK RED/BLK ABS model BLU/WHT WHT/GRN GRY/RED BLU/RED GRN/ORN GRN/YEL GRN/WHT GRN/BLK E381 G333 WHT/GRN BLU/WHT HVAC Ignition coil Ignition coil Ignition coil Evaporator control Cont.M temperature refrigerant unit "A-3" sensor pressure "E-1"...
  • Page 224 Wiring Systems: 9A-33 A-5 Engine and A/C Control System Circuit Diagram (Bi-Fuel Using LPG Model) AENAR90A910E007 Individual circuit CPRSR IG COIL fuse box No.1 E323 BLK/YEL E221 Main relay BLK/RED BLK/RED BLU/YEL BLK/RED GRN/YEL BLK/RED BLK/RED E229 E227 Relay Compressor relay BLK/RED BLK/RED...
  • Page 225 9A-34 Wiring Systems: Individual circuit Individual circuit RDTR fuse box No.1 fuse box No.2 7.5A E317 BLK/RED RED/WHT E371 E371 C343 C343 BLK/RED BLK/RED RED/WHT BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED RED/WHT RED/WHT RED/WHT RED/WHT E222 Relay LT GRN/RED BLU/RED BLU/YEL BLU/WHT...
  • Page 226 Wiring Systems: 9A-35 STOP DOME E323 E181 BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED Brake light switch C123 C121 EVAP canister valve purge sensor valve sensor Starting Immobilizer motor control module relay "A-7" "A-1" BLU/BLK BLK/YEL GRN/WHT RED/YEL YEL/RED YEL/BLK WHT/RED YEL/GRN PNK/BLU Generator "A-2"...
  • Page 227 9A-36 Wiring Systems: Individual circuit IG COIL fuse box No.1 7.5A E323 WHT/BLK E387 E382 L371 G334 WHT/BLK WHT/BLK RED/WHT BLK/WHT BLK/WHT BLK/WHT E134 L103 E265 G115 Fuel Regulator Fuel shutoff shutoff shutoff select valve valve valve switch relay BLU/BLK WHT/BLK BLK/ORN BLK/WHT...

  • Page 228: List Of Connector

    Wiring Systems: 9A-37 A-9 CAN Circuit Diagram AENAR90A910E009 Cont.M G240 (CAN) (CAN) (CAN) WHT/BLK RED/BLK G333 E381 G211 Bi-fuel using LPG model IAR90A910910-01 List of Connector List of Connectors AENAR90A910F001 Refer to “C Connector”: . Refer to “E Connector”: . Refer to “G Connector”: .

  • Page 229: E Connector

    9A-38 Wiring Systems: MCONF020366-01 MCONF020366-01 MCONF020366-01 MCONF020176-01 MCONF020328-01 MCONF040008-01 Bi-fuel using LPG Bi-fuel using LPG Bi-fuel using LPG model model model C101 C102 C103 C121 MCONF030103-02 MCONF030103-02 MCONF030103-02 MCONF030085-01 MCONF020328-01 MCONF020328-01 C123 C141 C162 C165 C192 C194 MCONF010078-01 MCONF010076-01 MCONF010029-01 MCONF020176-01 MCONF020176-01 MCONF040127-01...

  • Page 230: G Connector

    Wiring Systems: 9A-39 MCONF010076-01 MCONF040009-01 MCONF040131-01 MCONF040131-01 MCONF040131-01 MCONF020115-01 If equipped E227 E229 E234 E265 E266 E267 MCONF020008-01 MCONF020008-01 MCONF040131-01 MCONF040131-01 MCONF040131-01 MCONF040131-01 Bi-fuel using LPG If equipped Option Option model E268 E281 E282 E302 E303 E304 MCONF010130-01 MCONF010130-01 MCONF010130-01 MCONF010130-01 MCONF020277-01 MCONF020008-01...

  • Page 231: J Connector

    9A-40 Wiring Systems: 1 2 3 4 3 4 5 6 MCONF020268-01 MCONF040157-01 MCONF080050-01 MCONF060063-01 MCONF060065-01 If equipped G154 G155 G164 G211 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 9 10 11 12 13 14 15 16 MCONF100099-01 MCONF080050-01...

  • Page 232: K Connector

    Wiring Systems: 9A-41 If equipped If equipped If equipped If equipped J142 J145 J146 J215 (To L379) J216 (To L380) J217 (To L381) 9 10 11 MCONF020008-01 MCONF020008-01 MCONF020008-01 MCONF110014-01 MCONM280004-01 MCONM280004-01 J218 (To L382) 9 10 11 MCONF110014-01 K Connector AENAR90A910F006 K159 (To L432) 1 2 3...

  • Page 233: O Connector

    9A-42 Wiring Systems: 5 4 3 2 1 1 2 3 20 19 18 17 16 15 14 13 12 11 MCONF030134-01 MCONF140008-01 MCONM200008-01 L374 (To G341) L376 (To G343) L379 (To J215) L380 (To J216) L381 (To J217) 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 10 9 8 MCONF040099-01...

  • Page 234: General Description

    9C-1 Instrumentation / Driver Info. / Horn: Instrumentation / Driver Info. / Horn Body, Cab and Accessories General Description Selector Switch Description (Bi-Fuel LPG Model) AENAR90A9301002 Selector switch (1) consists of changeover switch (3), petrol indicator (4), LPG indicator (2) and LPG pressure indicator (green (5) and red (6)).
  • Page 235 Instrumentation / Driver Info. / Horn: 9C-2 IAR90A930003-01 [A]: Petrol MODE [F]: Abnormal condition [B]: Forced LPG MODE (LPG is full) [a]: Lighting up [C]: Forced LPG MODE (LPG is less than approx. 7 Lts) [b]: Blinking [D]: AUTO MODE (in petrol system) [c]: Lighting up depending on the remaining amount of LPG [E]: AUTO MODE (in LPG system)
  • Page 236 9C-3 Instrumentation / Driver Info. / Horn: Schematic and Routing Diagram Combination Meter Circuit Diagram AENAR90A9302001 WHT/RED G240-2 RED/WHT G240-1 G240-6 G240-8 IG +B WHT/BLK G240-7 RED/BLK G240-9 G240-5 YEL/RED G240-21 BLK/ORN G240-3 RED/YEL G240-27 BRN/YEL YEL/BLK G240-12 G240-17 BLU/ORN G240-13 YEL/GRN G240-28...
  • Page 237 Instrumentation / Driver Info. / Horn: 9C-4 NOTE For circuit name and terminal voltage, refer to “Inspection of Combination Meter and Its Circuit”: . Selector Switch Circuit Diagram (Bi-Fuel LPG Model) AENAR90A9302002 E485-29 LT GRN G115-2 G115-4 BLK/WHT E485-22 G115-1 G115-5 LT GRN/BLK G115...
  • Page 238 9C-5 Instrumentation / Driver Info. / Horn: Terminal Circuit Normal voltage Condition G240-4 Ground Ignition switch is at all positions. G240-5* Fuel level sensor signal Refer to reference waveform. G240-6* CAN communication line (low) to ECM Refer to reference waveform. G240-7* CAN communication line (low) to DLC “CAN Communication Signal”...
  • Page 239 Instrumentation / Driver Info. / Horn: 9C-6 Reference Waveform • Fuel (Petrol): Full NOTE • Waveform analysis is as follows. I9R90A930005-01 1. Fuel level sensor signal • Ignition switch: ON • Fuel (Petrol): Empty I8T401111066-01 [A]: Waveform of channel 1 [C]: VOLT/DIV of each channel [B]: Ground level of each channel [D]: TIME/DIV...
  • Page 240 9C-7 Instrumentation / Driver Info. / Horn: Terminal Circuit Normal voltage Condition Ignition switch: ON 0 – 1 V Refer to reference waveform. G115-2* Indicator signal circuit ↑ ↓ “Selector switch indicator signal” under 10 – 14 V “Inspection of ECM and Its Circuit”: Bi-Fuel LPG model in Section 1A.

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