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Suzuki SWIFT Service Manual

Rs413/rs415

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WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the words

WARNING

CAUTION

,

!

!

lighted by these signal words.

WARNING

!

Indicates a potential hazard that could result in death or injury.

CAUTION

!

Indicates a potential hazard that could result in vehicle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

WARNING

!

This service manual is intended for authorized Suzuki dealers and qualified service technicians only.

Inexperienced technicians or technicians without the proper tools and equipment may not be able to

properly perform the services described in this manual.

Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver

and passengers.

WARNING

!

For vehicles equipped with a Supplemental Restraint or Air Bag System:

• Service on and around the air bag system components or wiring must be performed only by an

authorized SUZUKI dealer. Refer to "Air Bag System Components and Wiring Location View" under

"General Description" in air bag system section in order to confirm whether you are performing ser-

vice on or near the air bag system components or wiring. Please observe all WARNINGS and "Ser-

vice Precautions" under "On-Vehicle Service" in air bag system section before performing service

on or around the air bag system components or wiring. Failure to follow WARNINGS could result in

unintentional activation of the system or could render the system inoperative. Either of these two

conditions may result in severe injury.

• If the air bag system and another vehicle system both need repair, Suzuki recommends that the air

bag system be repaired first, to help avoid unintended air bag system activation.

• Do not modify the steering wheel, instrument panel or any other air bag system component on or

around air bag system components or wiring. Modifications can adversely affect air bag system

performance and lead to injury.

• If the vehicle will be exposed to temperatures over 93 °C (200 °F), for example, during a paint baking

process, remove the air bag system components, that is air bag or inflator modules, SDM and/or

seat belt with pretensioner, beforehand to avoid component damage or unintended activation.

The circle with a slash in this manual means "Don't do this" or "Don't let this happen".

IMPORTANT

and NOTE have special meanings. Pay special attention to the messages high-

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Summary of Contents for Suzuki SWIFT

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 service manual. Precautions............... 00-i Steering ............... 6-i Precautions ............
Page 7: Table Of Contents
Table of Contents 00- i Section 00 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 service manual. Precautions ..........00-1 Air Bag Warning ...........00-* Air Bag System Service Warning ......00-* Precautions............
Page 8: Precautions
00-1 Precautions: Precautions Precautions General Precautions • Be sure to observe following instructions S5RS0B0000002 when handling service materials such as The WARNING and CAUTION describe some general fuel, oil, fluid, coolant, grease, sealant, precautions that you should observe when servicing a thread lock cement, etc.
Page 9 Precautions: 00-2 • When performing service to electrical parts that does • Whenever you use oil seals, gaskets, packing, O- not require use of battery power, disconnect the rings, locking washers, split pins, self-locking nuts, negative cable of the battery. and certain other parts as specified, be sure to use new ones.
Page 10 00-3 Precautions: • When disconnecting vacuum hoses, attach a tag • Use care not to expose connectors and electrical describing the correct installation positions so that the parts to water which will be a cause of a trouble. hoses can be reinstalled correctly. I2RH01010035-01 I2RH01010032-01 •...
Page 11 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 service manual. General Information ........ 0A-1 Exhaust System Inspection.........
Page 12: General Description
0A-1 General Information: General Information General Description Transmission Identification Number S5RS0B0101009 The manual transmission identification number is located on transmission case. I5RS0B010001-02 Component Location Warning, Caution and Information Labels Location S5RS0B0103001 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.
Page 13 General Information: 0A-2 I5RS0B010003-01 1. Air bag label on driver air bag (inflator) module 6. Air bag label on SDM 2. Air bag label on contact coil assembly 7. Pretensioner label on seat belt retractor 3. Air bag label on passenger air bag (inflator) module 8.
Page 14: Maintenance And Lubrication
0B-1 Maintenance and Lubrication: Maintenance and Lubrication Scheduled Maintenance Maintenance Schedule under Normal Driving Conditions S5RS0B0205001 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 15: Maintenance Recommended Under Severe Driving Conditions
Maintenance and Lubrication: 0B-2 Maintenance Recommended under Severe Driving Conditions S5RS0B0205002 If the vehicle is usually used under the conditions corresponding to any severe condition code given below, IT IS RECOMMENDED that applicable maintenance operation be performed at the particular interval as shown in the following table.
Page 16: Repair Instructions
0B-3 Maintenance and Lubrication: Repair Instructions Engine accessory Drive Belt and Tensioner Engine Oil and Filter Change S5RS0B0206004 Inspection WARNING S5RS0B0206001 WARNING • New and used engine oil can be All inspection and replacement are to be hazardous. performed with ENGINE NOT RUNNING. Be sure to read “WARNING”...
Page 17 Maintenance and Lubrication: 0B-4 2) Drain engine oil by removing drain plug (1). 5) Replenish oil until oil level is brought to FULL level mark on dipstick. (about 3.2 liters (5.6 lmp pt.)) The 3) After draining oil, wipe drain plug clean and replace filler inlet is by the engine oil filter.
Page 18 0B-5 Maintenance and Lubrication: Engine Coolant Change Fuel Filter Replacement S5RS0B0206005 S5RS0B0206011 WARNING WARNING To help avoid danger of being burned, do not This work must be performed in a well remove degassing tank cap while engine and ventilated area and away from any open radiator are still hot.
Page 19: Tightening Torque Specifications
Maintenance and Lubrication: 0B-6 Specifications Tightening Torque Specifications S5RS0B0207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Engine oil drain plug 14.5 Oil filter housing cover 18.5 Reference: For the tightening torque of fastener not specified in this section, refer to “Fasteners Information: in Section 0A”. Special Tools and Equipment Recommended Fluids and Lubricants S5RS0B0208001...
Page 20 0B-7 Maintenance and Lubrication:...
Page 21 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 service manual. Precautions ..........1-1 B-18, Check: Intermittent Faults......1A-37 B-19, Programming ECM ........1A-38 Precautions.............
Page 22 1-ii Table of Contents C-19, Fuel Rail Pressure Control Valve Accelerator Pedal Position (APP) Circuit .............. 1A-87 Sensor Components .........1C-4 C-20, Camshaft Position Sensor Circuit....1A-89 Accelerator Pedal Position (APP) Sensor C-21, Brake Switch Circuit ........ 1A-91 Removal and Installation........1C-4 C-22, Clutch Switch Circuit .......1A-96 Accelerator Pedal Position (APP) Sensor C-23, Injector Circuit .........1A-97 Inspection............1C-5...
Page 23 Table of Contents 1-iii Valves and Cylinder Head Components Cooling System Refill .......... 1F-6 Inspection............1D-39 Cooling System Flush and Refill ......1F-6 Pistons, Piston Rings, Connecting Rods and Cooling Water Pipes or Hoses Removal Cylinder Components ........1D-40 and Installation ..........1F-7 Pistons, Piston Rings, Connecting Rods and Thermostat Case Assembly Removal and Cylinder Removal and Installation ....1D-41...
Page 24 1-iv Table of Contents Fuel Pump Assembly Removal and Diagnostic Information and Procedures .... 1J-2 Installation ............1G-21 Battery Inspection ..........1J-2 Fuel Pump Inspection ........1G-22 Generator Symptom Diagnosis ......1J-3 Fuel Filter Element Removal and Generator Test (Undercharged Battery Installation ............
Page 25: Precautions For Catalytic Converter
Precautions: Precautions Precautions Precautions for Engine S5RS0B1000001 Air Bag Warning Refer to “Air Bag Warning: in Section 00”. 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”. Precautions on Fuel System Service Refer to “Precautions on Fuel System Service: in Section 1G”.
Page 26: Engine General Information And Diagnosis
• Diagnostic information stored in ECM memory can be reliable engine performance. cleared as well as checked by using SUZUKI scan tool. Before using scan tool, read its Operator’s • When raising or supporting engine for any reason, do (Instruction) Manual carefully to have good not use a jack under oil pan.
Page 27: Engine Diagnosis General Description
The main purpose of a vehicle diagnostic concept is position, the shape of connector and pin assignment. locating and eliminating faults in the shortest time K (4) line of ISO 9141 is used for SUZUKI scan tool to possible. communication with ECM, ABS control module, EPS...
Page 28: Can Communication System Description
1A-3 Engine General Information and Diagnosis: CAN Communication System Description S5RS0B1101004 Communication of ECM (3), BCM (2) and combination meter (1), is established by CAN (Controller Area Network). [T]: Transmit [R]: Receive I5RS0B110002-01 CAN communication system uses the serial communication in which data is transmitted at a high speed. It uses a twisted pair of two communication lines for the high-speed data transmission.
Page 29: Electronic Control System Description
Engine General Information and Diagnosis: 1A-4 Electronic Control System Description S5RS0B1101003 System Diagram I3RM0B112003-01 1. Air cleaner 10. Glow plug 19. Fuel filter 2. MAF and IAT sensor 11. ECT sensor 20. Fuel pump 3. Turbocharger 12. CKP sensor (Engine speed sensor) 21.
Page 30 1A-5 Engine General Information and Diagnosis: System Wiring Circuit Diagram D05-25 D05-47 D05-16 D05-56 D05-21 D05-49 D05-17 D05-43 D05-48 D05-59 D05-31 E62-38 D05-46 D05-1 E62-56 E62-34 D05-65 E62-62 D05-5 D05-23 D05-4 D05-41 D05-34 D05-24 E62-70 D05-8 D05-6 E62-74 D05-38 E62-37 E62-87 E62-10 E62-7...
Page 31 Engine General Information and Diagnosis: 1A-6 1. Boost pressure sensor 13. BCM 25. EPS control module 37. Brake switch 2. Fuel pressure sensor 14. ABS control module 26. Compressor relay (if equipped) 38. Fuel heating relay 3. CMP sensor 15. Combination meter 27.
Page 32 1A-7 Engine General Information and Diagnosis: Terminal Circuit Terminal Circuit — — Ground for ECT sensor CKP sensor signal (–) — — Connector: E62 Terminal Circuit Terminal Circuit Ground for ECM — Ground for ECM — Ground for ECM Power source for ECM Main power supply —...
Page 33: Schematic And Routing Diagram
Engine General Information and Diagnosis: 1A-8 Terminal Circuit Terminal Circuit — — Schematic and Routing Diagram Air Intake System Diagram S5RS0B1102001 I3RM0B112006-01 1. Air cleaner 5. Intercooler inlet hose 9. Intake manifold 2. MAF and IAT sensor 6. Intercooler 10. Exhaust manifold 3.
Page 34: Component Location
1A-9 Engine General Information and Diagnosis: Component Location Electronic Control System Components Location S5RS0B1103001 I5RS0B110005-03 Information sensors Control devices Others 1. Boost pressure sensor a: Fuel injector A: ECM 2. Fuel pressure sensor b: Fuel pressure regulator B: Combination meter 3.
Page 35: Diagnostic Information And Procedures
5) After completing the check, turn ignition switch off and disconnect scan tool from data link connector. DTC Clearance S5RS0B1104002 1) Connect SUZUKI scan tool to data link connector in the same manner as when making this connection for DTC check. 2) Turn ignition switch OFF and then ON (but engine at stop).
Page 36: A: Engine Diagnostic System Check
1A-11 Engine General Information and Diagnosis: A: Engine Diagnostic System Check S5RS0B1104003 Test Work order description Nominal value Customer Complaint Validation • Record customer complaint for later use. Is the malfunction reproducible? • Verify and validate the recorded customer complaint. Yes: T02 No: T10 System Operation as Designed...
Page 37 Engine General Information and Diagnosis: 1A-12 Test Work order description Nominal value DTC Check NOTE DTCs are only a reference on faults in a subgroup of the system. DTCs are not a direct reference on a defective component. • Read and record DTCs. •...
Page 38: B-01, Dtc Table
1A-13 Engine General Information and Diagnosis: Test Work order description Nominal value Intermittent System Operation Most intermittent problems are caused by faulty electrical connectors, faulty ground connections, broken wiring, temperature problems or radio interference. Intermittent faults can be traced either by using history DTCs or the snapshot function of the scan tool in combination with the following tests: •...
Page 39 Engine General Information and Diagnosis: 1A-14 Detecting Condition Referring DTC No. Detecting Item (DTC will set when detecting:) Table Camshaft Position Sensor P0340 Camshaft position sensor signal no inputted — — C-20 Circuit 1 driving P0380 Glow Plug Circuit Glow plug signal circuit open or short —...
Page 40 1A-15 Engine General Information and Diagnosis: Detecting Condition Referring DTC No. Detecting Item (DTC will set when detecting:) Table Rail Pressure Higher Than Measured fuel rail pressure is higher than 1 driving P1192 — C-18 Maximum specification cycle Radiator Fan Output 1 1 driving P1481 Radiator fan output 1 circuit open or short...
Page 41: B-02, Data List
Engine General Information and Diagnosis: 1A-16 B-02, Data List S5RS0B1104005 As the data values 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 vehicle is in good condition, there may be cases where the checked value does not fall within each specified data range.
Page 42 1A-17 Engine General Information and Diagnosis: Test Work order description Nominal value Tester Display – APP sensor 2 Voltage • Ignition ON greater than 1.8 V • Engine OFF • All consumers turned off • Accelerator pedal actuated to full load stop •...
Page 43 Engine General Information and Diagnosis: 1A-18 Test Work order description Nominal value Tester Display – Coolant Temperature 80 – 110 °C (176 – 230 °F) • Engine running at idle speed, operating temperature • All consumers turned off 2.50 – 0.40 V Concerned Terminals: Scan tool display depending on “D05-29”, “D05-54”...
Page 44 1A-19 Engine General Information and Diagnosis: Test Work order description Nominal value Tester Display – EGR Valve (Exhaust-Gas Recirculation) • Ignition ON • Engine OFF • All consumers turned off • Engine running at idle speed, operating temperature • Accelerator pedal briefly actuated to full load stop •...
Page 45 Engine General Information and Diagnosis: 1A-20 Test Work order description Nominal value Tester Display – A/C Switch NOTE This data list parameter is only valid if the concerned component is installed. • Ignition ON • Engine OFF • All consumers turned off •...
Page 46 1A-21 Engine General Information and Diagnosis: Test Work order description Nominal value Tester Display – Brake Switch • Ignition ON • Engine OFF • All consumers turned off • Brake pedal actuated Concerned Terminals: “E62-68”, “E62-81” Yes: T29 No: C-21 Tester Display –...
Page 47: B-03, Connect Scan Tool And Establish Communication
B-03, Connect Scan Tool and Establish Communication S5RS0B1104006 Update the diagnostic software for SUZUKI scan tool referring to “Tech2 Programing Manual” in case that the diagnosis can not be performed due to the old diagnostic software. In case that the diagnosis can not be performed even though the diagnostic software whose version is appropriate, is used, go to “C-01, No Communication between...
Page 48: B-06, Complaint: Engine Start
1A-23 Engine General Information and Diagnosis: B-06, Complaint: Engine Start S5RS0B1104013 Customer complaint Remedy Engine does not start, starter slow Perform the following test step: / does not turn • Refer to “C-43, Starter Circuit: ” Engine does not start, starter runs The following test steps must be performed in the given order.
Page 49 Engine General Information and Diagnosis: 1A-24 Customer complaint Remedy Engine idle speed is increased The following test steps must be performed in the given order. If a fault is found in one test step, the subsequent test steps can be skipped. •...
Page 50: B-08, Complaint: Engine Behavior Under Normal Driving Conditions
1A-25 Engine General Information and Diagnosis: B-08, Complaint: Engine Behavior Under Normal Driving Conditions S5RS0B1104015 Customer complaint Remedy Engine stalls during operation, no The following test steps must be performed in the given order. If a fault is found in restart possible one test step, the subsequent test steps can be skipped.
Page 51 Engine General Information and Diagnosis: 1A-26 Customer complaint Remedy Jerky engine operation The following test steps must be performed in the given order. If a fault is found in one test step, the subsequent test steps can be skipped. • Refer to “T01: Battery Voltage” in “B-02, Data List: ”. •...
Page 52: B-09, Complaint: Engine Performance
1A-27 Engine General Information and Diagnosis: B-09, Complaint: Engine Performance S5RS0B1104016 Customer complaint Remedy Reduced cut-off speed The following test steps must be performed in the given order. If a fault is found in one test step, the subsequent test steps can be skipped. •...
Page 53 Engine General Information and Diagnosis: 1A-28 Customer complaint Remedy Poor engine response The following test steps must be performed in the given order. If a fault is found in one test step, the subsequent test steps can be skipped. • Refer to “T01: Battery Voltage” in “B-02, Data List: ”. •...
Page 54: B-10, Complaint: Exhaust Gas
1A-29 Engine General Information and Diagnosis: B-10, Complaint: Exhaust Gas S5RS0B1104017 Customer complaint Remedy Excessive white smoke The following test steps must be performed in the given order. If a fault is found in one test step, the subsequent test steps can be skipped. •...
Page 55: B-11, Complaint: Oil / Coolant / Fuel-System
Engine General Information and Diagnosis: 1A-30 Customer complaint Remedy Excessive blue smoke The following test steps must be performed in the given order. If a fault is found in one test step, the subsequent test steps can be skipped. The following tests must be performed in the given order: •...
Page 56: B-12, Complaint: Engine Mechanic
1A-31 Engine General Information and Diagnosis: B-12, Complaint: Engine Mechanic S5RS0B1104019 Customer complaint Remedy Mechanical engine problem The following test steps must be performed in the given order. If a fault is found in one test step, the subsequent test steps can be skipped. •...
Page 57: B-14, Actuator Test
Engine General Information and Diagnosis: 1A-32 B-14, Actuator Test S5RS0B1104007 Test Work order description Nominal value Tester Display – Fuel Pump Control • Ignition ON • Engine OFF • Press corresponding key in the system main menu to select Output Tests under Misc. Test, select the desired test and confirm with ENTER.
Page 58 1A-33 Engine General Information and Diagnosis: Test Work order description Nominal value Tester Display – Glow Plug Control • Ignition ON • Engine OFF • Press corresponding key in the system main menu to select Output Tests under Misc. Test, select the desired test and confirm with ENTER.
Page 59 Engine General Information and Diagnosis: 1A-34 Test Work order description Nominal value Tester Display – SVS Lamp Control • Ignition ON • Engine OFF • Press corresponding key in the system main menu to select Output Tests under Misc. Test, select the desired test and confirm with ENTER.
Page 60: B-15, Additional Functions
1A-35 Engine General Information and Diagnosis: B-15, Additional Functions S5RS0B1104008 Test Work order description Nominal value Tester Display – Read ECM Identification • Ignition ON • Engine OFF • Press corresponding key in the system main menu to select Data Displayed value okay? List of Vehicle variant registration under ECM setting (MISC.
Page 61: B-17, Ecu Control
Engine General Information and Diagnosis: 1A-36 B-17, ECU Control S5RS0B1104010 Test Work order description Nominal value Tester Display – RPM Control • Engine idling • Press corresponding key in the system main menu to select Output Tests under Misc. Test, select the desired test and confirm with ENTER.
Page 62: B-18, Check: Intermittent Faults
1A-37 Engine General Information and Diagnosis: B-18, Check: Intermittent Faults S5RS0B1104021 Test Work order description Nominal value Intermittent System Operation NOTE Refer to “Intermittent and Poor Connection Inspection: in Section 00” for further details. Preliminary diagnostic check (visual inspection) • Check all sensors, actuators and the wiring harness of the system for corrosion and damages.
Page 63 Engine General Information and Diagnosis: 1A-38 Test Work order description Nominal value Symptoms / Customer Complaints • Check if one of the symptoms in the following table match the previously recorded customer complaint and perform the following additional test steps, while performing the troubleshooting in the C-x tables.
Page 64: B-21, Fuel System
1A-39 Engine General Information and Diagnosis: B-21, Fuel System S5RS0B1104024 Test Work order description Nominal value Check: Fuel Pipes and Fuel Filter System okay? CAUTION The fuel system is very sensitive. Work should be done with high cleanliness and care. Air in the fuel system can cause damage to the high-pressure fuel pump.
Page 65: B-23, Check: Intake-Air System
Engine General Information and Diagnosis: 1A-40 Test Work order description Nominal value Check: Fault Location The following test steps must be performed in the given order. If a fault is found in one test step, the subsequent test steps can be skipped. •...
Page 66: B-25, Check: Charge-Air System
1A-41 Engine General Information and Diagnosis: B-25, Check: Charge-Air System S5RS0B1104028 Test Work order description Nominal value Check: Function-Group Charge-Air System The following test steps must be performed in the given order. If a fault is found in one test step, the subsequent test steps can be skipped. •...
Page 67: B-27, Check: Distance Signal
Engine General Information and Diagnosis: 1A-42 B-27, Check: Distance Signal S5RS0B1104029 Test Work order description Nominal value Vehicle Speed Information Check The following test steps must be performed in the given order. If a fault is found in one test step, the subsequent test steps can be skipped. •...
Page 68: B-30, Check: High Pressure Area
1A-43 Engine General Information and Diagnosis: B-30, Check: High Pressure Area S5RS0B1104032 WARNING Refer to “Precautions on Fuel System Service: in Section 1G” before servicing fuel system. CAUTION The fuel system is very sensitive. Work should be done with high cleanliness and care. Air in the fuel system can cause damage to the high-pressure fuel pump.
Page 69: B-31, Check: Low And High Pressure Section
Engine General Information and Diagnosis: 1A-44 B-31, Check: Low and High Pressure Section S5RS0B1104033 WARNING Refer to “Precautions on Fuel System Service: in Section 1G” before servicing fuel system. CAUTION The fuel system is very sensitive. Work should be done with high cleanliness and care. Air in the fuel system can cause damage to the high-pressure fuel pump.
Page 70: B-33, Check: Injectors
1A-45 Engine General Information and Diagnosis: B-33, Check: Injectors S5RS0B1104090 WARNING Refer to “Precautions on Fuel System Service: in Section 1G” before servicing fuel system. Test Work order description Nominal value Check: Mechanic and/or Hydraulics • Check injectors for condition referring to “Fuel Injector On-Vehicle Test okay? Inspection: in Section 1G”.
Page 71: B-36, Trouble Codes: Check 3
Engine General Information and Diagnosis: 1A-46 B-36, Trouble Codes: Check 3 S5RS0B1104037 Test Work order description Nominal value Check: DTC stored • Is the DTC P0201 stored? Yes: C-24 No: T02 Check: DTC stored • Is the DTC P0202 stored? Yes: C-25 No: T03 Check: DTC stored...
Page 72: C-01, No Communication Between Scan Tool And Control Unit
1A-47 Engine General Information and Diagnosis: C-01, No Communication between Scan Tool and Control Unit S5RS0B1104040 Test Table Test Work order description Nominal value Check: Interruption of Voltage Supply Circuit • Ignition OFF greater than 11 V • All consumers turned off •...
Page 73 Engine General Information and Diagnosis: 1A-48 Test Work order description Nominal value Check: Interruption of Voltage Supply Circuit • Measure voltage between the following terminals: greater than 11 V Circuit Fuse – Input contact & Ground Yes: E04 No: T08 Check: Short to Ground / Interruption of Voltage Supply Circuit •...
Page 74 1A-49 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Short to Ground of Voltage Supply Circuit • Remove fused jumper wire. Test okay? • Connect fused jumper wire to: Ignition Switch – Wiring harness connector (wiring harness side) terminal “G21-6”...
Page 75 Engine General Information and Diagnosis: 1A-50 Test Work order description Nominal value Check: Short to Ground of Voltage Supply Circuit • Disconnect wiring harness connector from: Test okay? – Glow Controller • Insert new fuse into the socket of the fused jumper wire and then check this fuse for proper operation.
Page 76 1A-51 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Short to Ground of Voltage Supply Circuit • Disconnect wiring harness connector from: Test okay? – Immobilizer Control Module • Connect fused jumper wire to: Circuit Fuse – Output contact &...
Page 77 Engine General Information and Diagnosis: 1A-52 Result Cause of fault • Circuit interruption between: Ignition Switch – Wiring harness connector (wiring harness side) terminal “G21-6” & Circuit Fuse – Input contact • Defective component: – Ignition Switch • Circuit interruption between: Circuit Fuse –...
Page 78: C-02, Control Unit Hard- And Software
1A-53 Engine General Information and Diagnosis: Result Cause of fault • Defective component: – Immobilizer Control Module • Short circuit to ground between: Circuit Fuse – Output contact & ECM – Wiring harness connector (wiring harness side) terminal “E62-50” • Defective component: –...
Page 79: C-03, System Voltage Circuit
Engine General Information and Diagnosis: 1A-54 C-03, System Voltage Circuit S5RS0B1104042 Test Table Test Work order description Nominal value Check: Short to Ground / Interruption of Voltage Supply Circuit • Engine running 13 – 15 V • Increase engine speed to 3000 rpm •...
Page 80: C-04, Control Unit Main Relay Circuit
1A-55 Engine General Information and Diagnosis: Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – ECM • High transition resistance between: Ground &...
Page 81 Engine General Information and Diagnosis: 1A-56 Test Work order description Nominal value Check: Interruption of Voltage Supply Circuit • Ignition OFF greater than 11 V • Connect fused jumper wire to: Main Relay – Socket Terminal “E72-4” & Battery positive (+) terminal •...
Page 82 1A-57 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Short to Ground of Voltage Supply Circuit • Remove fused jumper wire. Test okay? • Connect fused jumper wire to: Main Relay – Socket Terminal “E72-3” & Battery voltage •...
Page 83 Engine General Information and Diagnosis: 1A-58 Result Cause of fault • Short circuit to voltage between: Circuit Fuse – Input contact & ECM – Wiring harness connector (wiring harness side) terminal “E62-4”, “E62-6” • Circuit interruption between: Circuit Main Fuse – Output contact &...
Page 84: C-05, Crankshaft Sensor Circuit
1A-59 Engine General Information and Diagnosis: C-05, Crankshaft Sensor Circuit S5RS0B1104044 Test Table Test Work order description Nominal value Check: Short to Voltage / Ground / Interruption of Signal Circuit • Ignition OFF 1.2 – 1.8 V • Disconnect wiring harness connector from: –...
Page 85: C-06, Fuel Pump Relay Circuit
Engine General Information and Diagnosis: 1A-60 Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – ECM • Defective component: – Crankshaft Position Sensor •...
Page 86 1A-61 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Short to Ground / Interruption of Signal Circuit • Ignition OFF greater than 500 kΩ • Measure resistance between the following terminals: ECM – Wiring harness connector (wiring harness side) terminal “E62- 75”...
Page 87 Engine General Information and Diagnosis: 1A-62 Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – ECM • Defective component: – Fuel Pump Relay •...
Page 88: C-07, 5 V Circuit 1
1A-63 Engine General Information and Diagnosis: C-07, 5 V Circuit 1 S5RS0B1104046 Test Table Test Work order description Nominal value Check: Short to Voltage / Ground / Interruption of Voltage Supply • Ignition OFF 4.8 – 5.2 V • Disconnect wiring harness connector from: –...
Page 89 Engine General Information and Diagnosis: 1A-64 Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – Boost Pressure Sensor • Short circuit to voltage / interruption of circuit between: Boost Pressure Sensor –...
Page 90: C-08, 5 V Circuit 2
1A-65 Engine General Information and Diagnosis: C-08, 5 V Circuit 2 S5RS0B1104047 Test Table Test Work order description Nominal value Check: Short to Voltage / Interruption of Voltage Supply Circuit • Ignition OFF 4.8 – 5.2 V • Disconnect wiring harness connector from: –...
Page 91 Engine General Information and Diagnosis: 1A-66 Test Work order description Nominal value Check: Short to Voltage of Voltage Supply Circuit • Ignition OFF 4.8 – 5.2 V • Disconnect wiring harness connector from: – Camshaft Position Sensor • Ignition ON •...
Page 92: C-09, 5 V Circuit 3
1A-67 Engine General Information and Diagnosis: Result Cause of fault • Short circuit to voltage between: MAF and IAT Sensor – Wiring harness connector (wiring harness side) terminal “E68-4” & ECM – Wiring harness connector (wiring harness side) terminal “E62-38” APP Sensor –...
Page 93 Engine General Information and Diagnosis: 1A-68 Test Work order description Nominal value Check: Short to Ground of Voltage Supply Circuit • Ignition OFF greater than 4.8 V • Disconnect wiring harness connector from: – A/C Pressure Sensor • Ignition ON •...
Page 94 1A-69 Engine General Information and Diagnosis: Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – APP Sensor • Short to voltage / ground / interruption of circuit between: APP Sensor –...
Page 95: C-10, Accelerator Pedal Position (App) Sensor Circuit
Engine General Information and Diagnosis: 1A-70 C-10, Accelerator Pedal Position (APP) Sensor Circuit S5RS0B1104049 Test Table Test Work order description Nominal value Check: Short to Voltage / Ground / Interruption of Voltage Supply • Ignition OFF 4.8 – 5.2 V •...
Page 96 1A-71 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Short to Ground of Signal Circuit • Ignition OFF 2.4 – 2.6 V • Connect fused jumper wire to: APP Sensor – Wiring harness connector (wiring harness side) terminal “E61-6”...
Page 97 Engine General Information and Diagnosis: 1A-72 Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – APP Sensor • Short circuit to voltage between: ECM –...
Page 98: C-11, Barometer Sensor Circuit
1A-73 Engine General Information and Diagnosis: Result Cause of fault • Circuit interruption between: APP Sensor – Wiring harness connector (wiring harness side) terminal “E61-3” & ECM – Wiring harness connector (wiring harness side) terminal “E62-35” • Defective component: – ECM •...
Page 99: C-12, Boost Pressure Sensor Circuit
Engine General Information and Diagnosis: 1A-74 C-12, Boost Pressure Sensor Circuit S5RS0B1104051 Test Table Test Work order description Nominal value Check: Circuit Interruption of Ground Circuit • Ignition OFF 4.8 – 5.2 V • Disconnect wiring harness connector from: – Boost Pressure Sensor •...
Page 100 1A-75 Engine General Information and Diagnosis: Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – Boost Pressure Sensor or – ECM NOTE The replacement of the components must be done in the listed order.
Page 101: C-13, Intake Air Temperature Sensor Circuit
Engine General Information and Diagnosis: 1A-76 C-13, Intake Air Temperature Sensor Circuit S5RS0B1104052 Test Table Test Work order description Nominal value Check: Short to Voltage / Ground / Interruption of Signal Circuit • Ignition OFF 4.8 – 5.2 V • Disconnect wiring harness connector from: –...
Page 102: C-14, Mass Or Volume Air Flow Circuit
1A-77 Engine General Information and Diagnosis: Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – MAF and IAT Sensor • Short circuit to voltage / interruption of circuit between: MAF and IAT Sensor –...
Page 103 Engine General Information and Diagnosis: 1A-78 Test Work order description Nominal value Check: Short to Voltage / Ground / Interruption of Voltage Supply • Measure voltage between the following terminals: 4.8 – 5.2 V MAF and IAT Sensor – Wiring harness connector (wiring harness side) terminal “E68-4”...
Page 104 1A-79 Engine General Information and Diagnosis: Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – MAF and IAT Sensor or – ECM NOTE The replacement of the components must be done in the listed order.
Page 105: C-15, Engine Coolant Temperature Sensor Circuit
Engine General Information and Diagnosis: 1A-80 C-15, Engine Coolant Temperature Sensor Circuit S5RS0B1104054 Test Table Test Work order description Nominal value Check: Short to Voltage / Ground / Interruption of Signal Circuit • Ignition OFF 4.8 – 5.2 V • Disconnect wiring harness connector from: –...
Page 106 1A-81 Engine General Information and Diagnosis: Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – ECT Sensor • Defective component: – ECM •...
Page 107: C-16, Fuel Temperature Sensor Circuit
Engine General Information and Diagnosis: 1A-82 C-16, Fuel Temperature Sensor Circuit S5RS0B1104055 Test Table Test Work order description Nominal value Check: Short to Voltage of Signal Circuit • Ignition OFF less than 0.3 V • Disconnect wiring harness connector from: –...
Page 108 1A-83 Engine General Information and Diagnosis: Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – Fuel Heater and Temperature Sensor or – ECM NOTE The replacement of the components must be done in the listed order.
Page 109: C-17, Fuel Rail Pressure Sensor Circuit
Engine General Information and Diagnosis: 1A-84 C-17, Fuel Rail Pressure Sensor Circuit S5RS0B1104056 NOTE Before starting diagnosis, check the value of the fuel rail pressure by using scan tool. For checking the value, refer to “B-02, Data List: ”. If the value is less than 0.15 V or more than 4.85 V, go to the following table. If not, go to “C-18, Rail Oil Pressure Sensor Circuit: ”.
Page 110 1A-85 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Short to Voltage / Ground / Interruption of Signal Circuit • Ignition OFF greater than 5.2 V • Disconnect wiring harness connector from: – Fuel Pressure Sensor •...
Page 111: C-18, Rail Oil Pressure Sensor Circuit
Engine General Information and Diagnosis: 1A-86 Result Cause of fault • Short circuit to ground / interruption of circuit between: ECM – Wiring harness connector (wiring harness side) terminal “D05-8” & Fuel Pressure Sensor – Wiring harness connector (wiring harness side) terminal “D03-3” •...
Page 112 1A-87 Engine General Information and Diagnosis: C-19, Fuel Rail Pressure Control Valve Circuit S5RS0B1104058 Test Table WARNING Refer to “Precautions on Fuel System Service: in Section 1G” before servicing fuel system. Test Work order description Nominal value Check: Component and/or Hydraulics •...
Page 113 Engine General Information and Diagnosis: 1A-88 Test Work order description Nominal value Check: Short to Ground of Signal Circuit • Ignition OFF greater than 500 kΩ • Disconnect wiring harness connector from: – ECM (Wiring Harness Connector “D05”) • Measure resistance between the following terminals: Fuel Pressure Regulator –...
Page 114 1A-89 Engine General Information and Diagnosis: Result Cause of fault • Circuit interruption between: ECM – Wiring harness connector (wiring harness side) terminal “D05-4” & Fuel Pressure Regulator – Wiring harness connector (wiring harness side) terminal “D02-1” • Short circuit to ground between: ECM –...
Page 115 Engine General Information and Diagnosis: 1A-90 Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – Camshaft Position Sensor or – ECM NOTE The replacement of the components must be done in the listed order.
Page 116 1A-91 Engine General Information and Diagnosis: C-21, Brake Switch Circuit S5RS0B1104060 Test Table Test Work order description Nominal value Check: Short to Ground / Interruption of Voltage Supply Circuit • Ignition OFF greater than 11 V • Disconnect wiring harness connector from: Brake Light Switch •...
Page 117 Engine General Information and Diagnosis: 1A-92 Test Work order description Nominal value Check: Component • Remove fused jumper wire. less than 0.3 V • Ignition OFF • Disconnect harness connector from: – ECM • Ignition ON • Measure voltage between the following terminals: ECM –...
Page 118 1A-93 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Short to Ground of Voltage Supply Circuit • Disconnect wiring harness connector from: Test okay? – ECM • Connect fused jumper wire to: Brake Light Switch – Wiring harness connector (wiring harness side) terminal “E47-2”...
Page 119 Engine General Information and Diagnosis: 1A-94 Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – Brake Light Switch or – ECM NOTE The replacement of the components must be done in the listed order.
Page 120 1A-95 Engine General Information and Diagnosis: Result Cause of fault • Circuit interruption between: Circuit Main Fuse – Output contact & Circuit Fuse – Input contact • Defective component: – Brake Light Switch • Short circuit to ground between: Brake Light Switch – Wiring harness connector (wiring harness side) terminal “E47-1” &...
Page 121 Engine General Information and Diagnosis: 1A-96 C-22, Clutch Switch Circuit S5RS0B1104061 Test Table Test Work order description Nominal value Check: Interruption of Signal Circuit • Ignition OFF greater than 11 V • Disconnect wiring harness connector from: – Clutch Switch •...
Page 122 1A-97 Engine General Information and Diagnosis: Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – Clutch Switch or – ECM NOTE The replacement of the components must be done in the listed order. The system must be checked for proper operation after every replacement.
Page 123 Engine General Information and Diagnosis: 1A-98 Test Work order description Nominal value Check: Short to Voltage of Signal Circuit • Ignition OFF less than 0.3 V • Disconnect wiring harness connector from: – ECM (Wiring Harness Connector “D05”) • Ignition ON •...
Page 124 1A-99 Engine General Information and Diagnosis: Result Table NOTE • If an injector has been replaced, the fuel injector calibration code of the new injector must be programmed to the ECM referring to “ECM Registration: in Section 1C”. • If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”.
Page 125 Engine General Information and Diagnosis: 1A-100 Test Work order description Nominal value Check: Short to Voltage of Signal Circuit • Ignition OFF less than 0.3 V • Disconnect wiring harness connector from: – ECM (Wiring Harness Connector “D05”) • Ignition ON •...
Page 126 1A-101 Engine General Information and Diagnosis: Result Table NOTE • If an injector has been replaced, the fuel injector calibration code of the new injector must be programmed to the ECM referring to “ECM Registration: in Section 1C”. • If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”.
Page 127 Engine General Information and Diagnosis: 1A-102 Test Work order description Nominal value Check: Short to Voltage of Signal Circuit • Ignition OFF less than 0.3 V • Disconnect wiring harness connector from: – ECM (Wiring Harness Connector “D05”) • Ignition ON •...
Page 128 1A-103 Engine General Information and Diagnosis: Result Table NOTE • If an injector has been replaced, the fuel injector calibration code of the new injector must be programmed to the ECM referring to “ECM Registration: in Section 1C”. • If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”.
Page 129 Engine General Information and Diagnosis: 1A-104 Test Work order description Nominal value Check: Short to Voltage of Signal Circuit • Ignition OFF less than 0.3 V • Disconnect wiring harness connector from: – ECM (Wiring Harness Connector “D05”) • Ignition ON •...
Page 130 1A-105 Engine General Information and Diagnosis: Result Table NOTE • If an injector has been replaced, the fuel injector calibration code of the new injector must be programmed to the ECM referring to “ECM Registration: in Section 1C”. • If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”.
Page 131 Engine General Information and Diagnosis: 1A-106 C-28, Exhaust Gas Recirculation Valve Circuit S5RS0B1104067 Test Table Test Work order description Nominal value Check: Interruption of Voltage Supply Circuit • Ignition OFF greater than 11 V • Disconnect wiring harness connector from: –...
Page 132 1A-107 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Short to Ground / Interruption of Voltage Supply Circuit • Ignition OFF greater than 500 kΩ • Measure resistance between: DRL Controller – Wiring harness connector (wiring harness side) terminal “G39-9”...
Page 133 Engine General Information and Diagnosis: 1A-108 Result Cause of fault • Circuit interruption between: DRL Controller – Wiring harness connector (wiring harness side) terminal “G39-9” &Exhaust Gas Recirculation Valve – Wiring harness connector (wiring harness side) terminal “D08-1” • Circuit interruption between: Circuit Fuse –...
Page 134 1A-109 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Short to Ground / Interruption of Signal Circuit • Ignition OFF greater than 500 kΩ • Disconnect wiring harness connector from: – ECM (Wiring Harness Connector “E62”) •...
Page 135 Engine General Information and Diagnosis: 1A-110 Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Circuit interruption between: ECM – Wiring harness connector (wiring harness side) terminal “E62-87” &...
Page 136 1A-111 Engine General Information and Diagnosis: C-30, Engine Oil Pressure Switch Circuit S5RS0B1104069 Test Table Test Work order description Nominal value Check: Interruption of Signal Circuit • Ignition OFF greater than 11 V • Disconnect wiring harness connector from: – Oil Pressure Switch •...
Page 137 Engine General Information and Diagnosis: 1A-112 Result Cause of fault • Circuit interruption between: Oil Pressure Switch – Wiring harness connector (wiring harness side) terminal “D04-1” & ECM – Wiring harness connector (wiring harness side) terminal “D05-9” C-31, Air Conditioning System Relay Circuit S5RS0B1104070 Test Table Test...
Page 138 1A-113 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Short to Ground / Interruption of Voltage Supply Circuit • Ignition OFF greater than 11 V • Disconnect wiring harness connector from: – A/C Compressor • Connect fused jumper wire to: ECM –...
Page 139 Engine General Information and Diagnosis: 1A-114 Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – ECM • Defective component: – A/C Compressor •...
Page 140 1A-115 Engine General Information and Diagnosis: Result Cause of fault • Short circuit to ground between: Circuit Main Fuse – Output contact & Compressor Relay – Socket terminal “E36-2” • Defective component: – Compressor Relay • Short circuit to ground between: Compressor Relay –...
Page 141 Engine General Information and Diagnosis: 1A-116 Test Work order description Nominal value Check: Short to Voltage / Interruption of Signal Circuit • Connect test light (20 to 40 Ω) to: Test light ON? Radiator Fan Relay No.3 – Socket terminal “E30-3” &...
Page 142 1A-117 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Interruption of Voltage Supply Circuit • Ignition OFF greater than 11 V • Measure voltage between the following terminals: Radiator Fan Relay No.2 – Socket terminal “E30-2” &...
Page 143 Engine General Information and Diagnosis: 1A-118 Test Work order description Nominal value Check: Short to Voltage / Interruption of Signal Circuit • Connect test light (20 to 40 Ω) to: Test light ON? Radiator Fan Relay No.1 – Socket terminal “E28-3” &...
Page 144 1A-119 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Short to Ground of Voltage Supply Circuit • Install electrical component from socket: Test okay? Radiator Fan Relay No.3 • Insert new circuit fuse and then check the fuse for proper operation. Yes: T24 No: E02 Check: Short to Ground of Voltage Supply Circuit...
Page 145 Engine General Information and Diagnosis: 1A-120 Result Cause of fault • Circuit interruption between: Radiator Fan Relay No.3 – Socket Terminal “E30-1” & Radiator Fan Motor – Wiring harness connector “E17-4” • Circuit interruption between: Radiator Fan Relay No.3 – Socket Terminal “E30-5” &...
Page 146 1A-121 Engine General Information and Diagnosis: Result Cause of fault • Circuit interruption between: Main fuse – Output contact & Circuit fuse – Input contact • Short circuit to ground between: Radiator Fan Relay No.1 – Socket Terminal “E28-5” & ECM –...
Page 147 Engine General Information and Diagnosis: 1A-122 C-33, Glow Time Relay Circuit S5RS0B1104072 Test Table Test Work order description Nominal value Check: Component • Check the following component for proper operation: Inspection okay? – Glow Plug Yes: T02 No: E13 Check: Short to Ground / Interruption of Voltage Supply Circuit •...
Page 148 1A-123 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Interruption of Signal Circuit • Remove fused jumper wire. greater than 11 V • Scan Tool MISC test: – Glow plug control • Press YES key • Measure voltage between the following terminals: Glow Controller –...
Page 149 Engine General Information and Diagnosis: 1A-124 Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Circuit interruption between: Glow Controller – Wiring harness connector (wiring harness side) terminal “E73-4”, “E73-5” &...
Page 150 1A-125 Engine General Information and Diagnosis: Result Cause of fault • Circuit interruption between: Glow Controller – Wiring harness connector (wiring harness side) terminal “E73-6” & Ground • Circuit interruption between: Circuit Main Fuse – Output contact & Glow Controller – Wiring harness connector (wiring harness side) terminal “E73-7” •...
Page 151 Engine General Information and Diagnosis: 1A-126 Test Work order description Nominal value Check: Short to Voltage of CAN Communication Circuit • Ignition ON less than 0.3 V • Measure voltage between the following terminals: BCM – Wiring harness connector (wiring harness side) terminal “G37- 4”...
Page 152 1A-127 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Short to Voltage of CAN Communication Circuit • Ignition ON less than 0.3 V • Measure voltage between the following terminals: ECM – Wiring harness connector (wiring harness side) terminal “E62- 64”...
Page 153 Engine General Information and Diagnosis: 1A-128 Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – Combination Meter • Short circuit to ground between: BCM –...
Page 154 1A-129 Engine General Information and Diagnosis: Result Cause of fault • Circuit interruption between: ECM – Wiring harness connector (wiring harness side) terminal “E62-40” & BCM – Wiring harness connector (wiring harness side) terminal “E46-2” • Short circuit between: ECM – Wiring harness connector (wiring harness side) terminal “E62-64” &...
Page 155 Engine General Information and Diagnosis: 1A-130 Test Work order description Nominal value Check: Interruption of Signal Circuit less than 5 Ω • Measure resistance between: ECM – Wiring harness connector (wiring harness side) terminal “E62- 76” & Fuel Heating Relay – Socket Terminal “E71-1” Yes: T07 No: E05 Check: Interruption of Voltage Supply Circuit...
Page 156 1A-131 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Short to Voltage of Voltage Supply Circuit • Ignition OFF less than 0.3 V • Disconnect wiring harness connector from: – Fuel Heater and Temperature Sensor • Ignition ON •...
Page 157 Engine General Information and Diagnosis: 1A-132 Result Cause of fault • Circuit interruption between: ECM – Wiring harness connector (wiring harness side) terminal “E62-76” & Fuel Heating Relay – Socket Terminal “E71-1” • Short circuit to ground between: ECM – Wiring harness connector (wiring harness side) terminal “E62-76” &...
Page 158 1A-133 Engine General Information and Diagnosis: C-36, Malfunction Indicator Lamp (MIL) Circuit S5RS0B1104075 Test Table Test Work order description Nominal value Check: Component • Ignition OFF Test okay? • Ignition ON • Is at least one of the following indicator ON? –...
Page 159 Engine General Information and Diagnosis: 1A-134 Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – ECM • Short circuit to voltage between: ECM –...
Page 160 1A-135 Engine General Information and Diagnosis: C-37, Vehicle Speed Sensor Circuit S5RS0B1104079 Test Table Test Work order description Nominal value Check: Vehicle Speed Output Signal • Perform vehicle speed output signal check: Test okay? Refer to “Vehicle Speed Output Signal Inspection: in Section 4E” Yes: T02 No: E01 Check: EPS Control Module...
Page 161 Engine General Information and Diagnosis: 1A-136 Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Defective component: – ABS Hydraulic Unit / Control Module Assembly •...
Page 162 1A-137 Engine General Information and Diagnosis: C-39, Function-Group Fuel System S5RS0B1104081 Test Table Test Work order description Nominal value Check: DTC stored Is the following DTC stored? P1660 – Shut Off Valve Yes: E01 No: E02 Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”.
Page 163 Engine General Information and Diagnosis: 1A-138 C-41, Function-Group Low and High Pressure Section S5RS0B1104083 Result Table NOTE If ECM is replaced, register vehicle specification into ECM referring to “ECM Registration: in Section 1C”. Result Cause of fault • Mechanical fault in the low-pressure section •...
Page 164 1A-139 Engine General Information and Diagnosis: C-43, Starter Circuit S5RS0B1104085 Test Table Test Work order description Nominal value Check: Starter • Check the following component for proper operation: Does the starter crank? – Starting Motor • Turn ignition switch to ST position. Yes: T02 No: T14 Check: Battery Voltage...
Page 165 Engine General Information and Diagnosis: 1A-140 Test Work order description Nominal value Check: Component • Check stall current. Does the stall current change to Remove consecutively all fuses from the fuse-boxes. a value less than 50 mA after removing a fuse? Yes: T08 No: E02 Check: Component...
Page 166 1A-141 Engine General Information and Diagnosis: Test Work order description Nominal value Check: Component • Measure voltage between the following terminals: greater than 11 V Starting Motor – Wiring harness connector (wiring harness side) terminal “C57-1” & Ground • Turn ignition switch to ST position. Yes: T11 No: T16 Check: Component...
Page 167 Engine General Information and Diagnosis: 1A-142 Test Work order description Nominal value Check: Interruption of Starting Motor Control Circuit less than 5 Ω • Ignition OFF • Remove fused jumper wire • Measure resistance between the following terminals: Circuit Fuse – Output contact &...
Page 168 1A-143 Engine General Information and Diagnosis: Result Cause of fault • Mechanical engine problem • Defective component: – Starting Motor NOTE The replacement of the components must be done in the listed order. The system must be checked for proper operation after every replacement. •...
Page 169: Special Tool
This trouble code is set when an engine protection function is activated. (overheating protection) Special Tools and Equipment Special Tool S5RS0B1108001 SUZUKI scan tool — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5.
Page 170: Aux. Emission Control Devices
1B-1 Aux. Emission Control Devices: Aux. Emission Control Devices Repair Instructions Vacuum Pump Removal and Installation Installation S5RS0B1206001 1) Install new gasket to vacuum pump. CAUTION 2) Install vacuum pump (1) to camshaft housing. Never disassemble vacuum pump. Fit the dogs of vacuum pump coupling into the slot of Disassembly will spoil its original function.
Page 171 Aux. Emission Control Devices: 1B-2 EGR Valve Assembly Components S5RS0B1206002 25 N·m (2.5 kg-m) 22 N·m (2.2 kg-m) I3RB0A123006-01 1. EGR valve 4. EGR cooler pipe 7. EGR valve assembly mounting bolt : Tightening torque 2. EGR cooler 5. Clamp 8.
Page 172: Installation
1B-3 Aux. Emission Control Devices: EGR Valve Assembly Removal and Installation Installation S5RS0B1206003 Reverse removal procedure noting the following. • Clean mating surface of EGR valve assembly and Removal cylinder head. 1) Remove battery and battery tray from vehicle. • Use new gaskets. 2) Drain cooling system.
Page 173 Aux. Emission Control Devices: 1B-4 Crankcase Ventilation System Component S5RS0B1206004 I5RS0B120005-01 1. Oil separator 6. Gasket 11. To breather pipe 2. Clamp 7. Oil separator mounting bolt 12. To connector 3. Ventilation hose No.1 8. Ventilation hose No.2 : Tightening torque 4.
Page 174: Tightening Torque Specifications
1B-5 Aux. Emission Control Devices: Tightening torque 7) Disconnect ventilation hose No.2 (2) from oil separator. Crankcase ventilation cover mounting bolt (a): 9 N·m (0.9 kgf-m, 6.5 lb-ft) 8) Loosen ventilation hose No.1 clamp at oil separator Oil separator mounting bolt (b): 9 N·m (0.9 kgf-m, side.
Page 175: Engine Electrical Devices
3) Turn all electrical loads off. system and secret key code for immobilizer 4) Using SUZUKI scan tool, verify that idle speed is system) into ECM referring to “ECM within specification. Registration: ” and “Procedure after ECM Replacement: in Section 10C”.
Page 176 Removal S5RS0B1306004 1) Disconnect negative cable at battery and coupler 1) Connect SUZUKI scan tool to data link connector from MAF and IAT sensor (1). (DLC) located on underside of instrument panel at 2) Disconnect air cleaner outlet hose (2) from MAF and driver’s seat side.
Page 177 Engine Electrical Devices: 1C-3 Glow Plug Removal and Installation Installation S5RS0B1306006 For installation, reverse removal procedure noting the Removal following. • Using special tool, tightening glow plug to specified CAUTION torque. • Do not damage heating section of the glow Special tool plug.
Page 178 1C-4 Engine Electrical Devices: Accelerator Pedal Position (APP) Sensor Components S5RS0B1306007 5.5 N·m (0.55 kgf-m) I5RS0B130006-01 1. Accelerator pedal assembly 3. APP sensor connector : Tightening torque 2. Accelerator pedal bracket 4. APP sensor connector lock lever Accelerator Pedal Position (APP) Sensor Installation Reverse removal procedure for installation noting the Removal and Installation...
Page 179 Engine Electrical Devices: 1C-5 Accelerator Pedal Position (APP) Sensor 3) Measure output voltage variation while accelerator pedal is no depressed and fully depressed as Inspection following specification. S5RS0B1306018 Check accelerator pedal position (APP) sensor (main If sensor voltage is out of specified value or does not and sub) output voltage as following steps.
Page 180: Tightening Torque
1C-6 Engine Electrical Devices: Engine Coolant Temperature (ECT) Sensor Camshaft Position (CMP) Sensor Removal and Removal and Installation Installation S5RS0B1306009 S5RS0B1306011 Removal Removal 1) Remove battery from vehicle. 1) Disconnect negative cable at battery. 2) Drain cooling system. 2) Disconnect CMP sensor connector. 3) Remove air cleaner assembly from vehicle referring 3) Remove CMP sensor (1) from camshaft housing (2).
Page 181 Engine Electrical Devices: 1C-7 Crankshaft Position (CKP) Sensor (Engine Boost Pressure Sensor Removal and Speed Sensor) Removal and Installation Installation S5RS0B1306012 S5RS0B1306014 Removal Removal 1) Disconnect negative cable at battery. 1) Disconnect negative cable at battery. 2) Remove air cleaner assembly from vehicle referring 2) Disconnect connector from boost pressure sensor as to “Air Cleaner Assembly Removal and Installation: follows.
Page 182 1C-8 Engine Electrical Devices: Fuel Pump Relay, Starting Motor Control Relay, Installation Main Relay and Fuel Heating Relay Inspection 1) Check O-ring (2) of boost pressure sensor (1) S5RS0B1306016 deformed or damage. NOTE If malfunction is found, replace boost pressure Check for installation position of each relay sensor.
Page 183: Special Tools And Equipment
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information: in Section 0A”. Special Tools and Equipment Special Tool S5RS0B1308001 09911–78610 SUZUKI scan tool Glow plug wrench — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3.
Page 184: Engine Mechanical
1D-1 Engine Mechanical: Engine Mechanical Diagnostic Information and Procedures Compression Check S5RS0B1404001 Check compression pressure on all 4 cylinders as follows: 1) Warm up engine. 2) Stop engine after warming up. NOTE After warming up engine, place transmission gear shift lever in “Neutral” and set parking brake and block drive wheels.
Page 185: Timing Check
Engine Mechanical: 1D-2 10) Crank engine with fully charged battery and read 5) Disconnect wiring harness connector of injectors, highest pressure on compression gauge. CMP sensor and glow plugs. 11) Carry out Steps 7) to 10) on each cylinder in order 6) Remove camshaft housing plugs (1).
Page 186: Air Cleaner Components
1D-3 Engine Mechanical: 10) After checking, remove all special tools inserted in Tightening torque Step 8) and 9). Common rail bracket bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft) 11) Apply thread lock compound to thread part of camshaft housing plugs (1), and install them. “A”: Loctite omnifit 100M spezial®...
Page 187: Air Cleaner Assembly Removal And Installation
Engine Mechanical: 1D-4 1. Air cleaner assembly 7. Air cleaner outlet hose 13. To engine 2. Air cleaner grommet 8. Hose clamp 14. Upper member Be sure to position clamp screw in specified place as shown in the figure. 3. MAF sensor assembly 9.
Page 188 1D-5 Engine Mechanical: Intercooler Components S5RS0B1406005 I5RS0B140009-01 1. Intercooler 7. Intercooler outlet No.1 hose 13. To air intake joint 2. Intercooler bolt 8. Intercooler outlet No.2 hose 14. Upper member 3. Intercooler inlet No. 1 hose 9. Intercooler outlet pipe 15.
Page 189 Engine Mechanical: 1D-6 Intercooler Removal and Installation S5RS0B1406006 Removal 1) Remove front bumper referring to “Front Bumper and Rear Bumper Components: in Section 9K”. 2) Disconnect intercooler outlet No.1 hose (1) and inlet No.1 hose (2) from intercooler assembly (3). 3) Remove intercooler inlet pipe bolt (4) and intercooler assembly from vehicle.
Page 190 1D-7 Engine Mechanical: Turbocharger Components S5RS0B1406007 I5RS0B140012-03 1. Exhaust manifold 8. Catalytic converter bolt 15. Catalytic converter mounting bolt 2. Turbocharger nut 9. Union bolt : 25 N⋅m (2.5 kg-m, 18.0 lb-ft) 3. Turbocharger 10. Turbocharger lubrication pipe : 12 N⋅m (1.2 kg-m, 9.0 lb-ft) 4.
Page 191: And Installation
Engine Mechanical: 1D-8 Turbocharger Removal and Installation 8) Remove lubrication pipe (1). S5RS0B1406008 Removal WARNING To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down. 1) Disconnect negative (–) cable at battery. 2) Remove engine cover from engine assembly.
Page 192 1D-9 Engine Mechanical: 11) Remove exhaust pipe No.1 referring to “Exhaust 14) Remove catalytic converter (2) from turbocharger Pipe and Muffler Removal and Installation: in after unbending lock plate (1) and loosening bolts. Section 1K”. 12) Remove bolts (1) and hood lock brace (2). I3RM0B142017-01 15) Remove oil return pipe (1) from turbocharger.
Page 193 Engine Mechanical: 1D-10 5) Install hood lock brace and adjust hood latch 2) Install new gasket, catalytic converter (1) and new lock plate (2) to turbocharger. referring to “Hood Inspection and Adjustment: in Section 9J”. Tightening torque 6) Install exhaust manifold cover (1). Catalytic converter bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft) Tightening torque...
Page 194: Turbocharger Inspection
1D-11 Engine Mechanical: 13) Install intercooler referring to “Intercooler Removal 9) Install lubrication pipe (1) with new gasket. and Installation: ”. Tightening torque 14) Install air cleaner assembly with MAF sensor Lubrication pipe union bolt (a): 12 N·m (1.2 kgf- assembly, referring to “Air Cleaner Assembly m, 9.0 lb-ft) Removal and Installation: ”.
Page 195: Intake Manifold Removal And Installation
Engine Mechanical: 1D-12 Intake Manifold Components S5RS0B1406010 I5RS0B140018-01 1. Intake manifold 5. Intake manifold bolt : 25 N⋅m (2.5 kg-m, 18.0 lb-ft) 2. Air intake joint 6. EGR pipe : Do not reuse. 3. Air intake joint gasket 7. EGR pipe gasket 4.
Page 196 1D-13 Engine Mechanical: 12) Remove intake manifold (1) and gasket from cylinder • Install oil level gauge guide (1) with level gauge. head. Tightening torque 13) Remove EGR pipe and air intake joint (2) from intake Oil level gauge guide mounting bolt (a): 9 N·m ( manifold.
Page 197 Engine Mechanical: 1D-14 Engine Mounting Components S5RS0B1406031 I5RS0B140020-01 [A]: View A 10. Engine right mounting bolt 21. Engine rear mounting No. 2 bracket bolt F: Vehicle front 11. Engine right mounting nut 22. Yellow mark 1. Engine right mounting 12. Engine right mounting bracket bolt 23.
Page 198 1D-15 Engine Mechanical: Engine Assembly Removal and Installation 14) With hose connected, detach A/C compressor from S5RS0B1406012 its bracket (if equipped) referring to “Compressor Removal Assembly Removal and Installation: in Section 7B”. 1) Disconnect negative (–) and positive (+) cable at CAUTION battery.
Page 199 Engine Mechanical: 1D-16 17) Disconnect the following cables from transaxle: 18) Remove right and left side engine under covers. • Gear select control cable (26) 19) Remove exhaust No.1, No.2 and center pipes referring to “Exhaust Pipe and Muffler Removal and •...
Page 200 1D-17 Engine Mechanical: 26) Before removing engine with transaxle from engine compartment, recheck to make sure all hoses, pipes, 1, (a) electric wires and cables are disconnected from engine and transaxle. 27) Lower engine with transaxle from engine compartment. 2, (b) I4RS0A140009-01 28) Disconnect transaxle from engine referring to “Manual Transaxle Unit Dismounting and...
Page 201 Engine Mechanical: 1D-18 18) Install air cleaner assembly with MAF sensor 22) Refill cooling system with coolant referring to assembly referring to “Air Cleaner Assembly “Cooling System Flush and Refill: in Section 1F”. Removal and Installation: ”. 23) Refill clutch fluid and bleed air from system referring 19) Install engine cover.
Page 202 1D-19 Engine Mechanical: Timing Chain Cover and Timing Chain Removal 6) Remove engine right mounting bracket (1). and Installation 7) Remove water pump assembly (2) referring to S5RS0B1406014 “Water Pump Removal and Installation: in Section 1F”. Removal 8) Remove water pump / generator drive belt tensioner 1) Remove engine assembly from engine compartment (3) referring to “Water Pump / Generator Drive Belt referring to “Engine Assembly Removal and...
Page 203 Engine Mechanical: 1D-20 13) Lock flywheel (1) using special tool (B). 18) Lock crankshaft (1) installing special tool (C) as shown in the figure. Special tool (B): 09916–98610 NOTE Be sure to align hole (2) of special tool with knock pin securely. Special tool (C): 09912–38300 I3RB0A143011-01...
Page 204 1D-21 Engine Mechanical: 21) Remove timing chain tensioner adjuster assembly 3) Install timing chain (1) to camshaft timing sprocket (1). (2). 22) Remove timing chain tensioner (2). 4) Install crankshaft timing sprocket (5) to timing chain with its long taper side (3) faced to outside (4) as 23) Remove timing chain guide (3).
Page 205 Engine Mechanical: 1D-22 8) Push plunger (1) in timing chain tensioner adjuster 12) Apply sealant to camshaft housing / cylinder head / body (2) till plunger is held in place as shown in the cylinder block as shown in the figure. figure.
Page 206 1D-23 Engine Mechanical: 14) Install knock pin (1) to crankshaft (2), if removed. 19) Remove special tool (D) installed at step 16). 20) Turn crankshaft two revolutions clockwise. NOTE 21) Lock camshafts (3) inserting special tools (A) to Be sure to install knock pin to φ 6.75 mm camshaft housing plug holes after aligning camshaft (0.266 in.) hole of crankshaft.
Page 207 Engine Mechanical: 1D-24 25) Install crankshaft pulley (1), and tighten crankshaft 30) Install common rail bracket (2) and engine hook (1) pulley bolts (2) to specified torque. to camshaft housing. Tighten common rail bracket bolts to specified Tightening torque torque. Crankshaft pulley bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft) Tightening torque...
Page 208 1D-25 Engine Mechanical: Timing Chain Cover and Timing Chain Timing Chain Guide Check shoe (1) for wear or damage. Inspection If any malcondition is found, replace timing chain guide. S5RS0B1406015 Timing Chain Tensioner Check shoe (1) for wear or damage. If any malcondition is found, replace timing chain tensioner.
Page 209 Engine Mechanical: 1D-26 Camshaft Housing Components S5RS0B1406016 I3RB0A143043-01 1. Camshaft housing 7. Camshaft housing gasket 13. Cylinder head 2. Camshaft housing bolt 8. Intake manifold side camshaft 14. Knock pin : Tighten 18 N⋅m (1.8 kgf-m, 13.0 lb-ft) by : Apply engine oil to sliding surface the specified procedure 3.
Page 210 1D-27 Engine Mechanical: Camshaft Housing Assembly Removal and Installation Installation 1) Clean mating surface of camshaft housing and S5RS0B1406017 cylinder head. 2) Install knock pins (1) to cylinder head, if removed. Removal 3) Install new camshaft housing gasket (2) to cylinder 1) Remove engine assembly from engine compartment head.
Page 211 Engine Mechanical: 1D-28 4) Install camshaft housing assembly (1) to cylinder 5) Measure bump “a” between camshaft housing (1) head (2) as follows. and cylinder head (2) (flatness) using dial gauge (3) and special tool (A) as shown in the figure. a) Install camshaft housing assembly, and tighten If it is out of specification, remove camshaft housing camshaft housing bolt (3) and camshaft housing...
Page 212 1D-29 Engine Mechanical: Camshaft Housing Assembly Disassembly and Reassembly S5RS0B1406018 Disassembly 1) Remove camshaft housing assembly referring to “Camshaft Housing Assembly Removal and Installation: ”. 2) Remove vacuum pump referring to “Vacuum Pump Removal and Installation: in Section 1B”. 3) Remove injection pump referring to “Injection Pump Removal and Installation: in Section 1G”.
Page 213 Engine Mechanical: 1D-30 2) Install special tools (A) as follows. 4) Tighten camshaft timing sprocket bolt and camshaft gear bolts as follows. a) Align camshaft housing plug hole (1) with camshaft gap (2) turning intake manifold side a) Lock camshaft timing sprocket (1) using special and exhaust manifold side camshaft as shown in tool.
Page 214: Camshaft Inspection
1D-31 Engine Mechanical: 5) Install CMP sensor referring to “Camshaft Position (CMP) Sensor Removal and Installation: in Section 1C”. 6) Install injection pump referring to “Injection Pump Removal and Installation: in Section 1G”. 7) Install vacuum pump referring to “Vacuum Pump Removal and Installation: in Section 1B”.
Page 215: Camshaft Housing
Engine Mechanical: 1D-32 Camshaft Housing Camshaft Timing Sprocket Check camshaft timing sprocket for pitting, scratches or • Check camshaft journals and camshaft housings for damage. pitting, scratches, wear or damage. If any malcondition is found, replace camshaft timing If any malcondition is found, replace camshaft sprocket.
Page 216: Valves And Cylinder Head Components
1D-33 Engine Mechanical: Valves and Cylinder Head Components S5RS0B1406020 I3RB0A143062-01 1. Valve rocker arm 8. Valve guide 15. Cylinder block 2. Hydraulic valve lash 9. Intake valve 16. Plug adjuster : Apply sealant 99000-85E00 to all around thread part of plug. 3.
Page 217: Thermostat Case Assembly Removal And Installation
Engine Mechanical: 1D-34 Valves and Cylinder Head Assembly Removal and Installation S5RS0B1406021 CAUTION Note original position in which each valve rocker arms and hydraulic valve lash adjuster ware installed, and then install them to original position. If each valve rocker arm or hydraulic valve lash adjuster is not installed to original position, engine will spoil its original performance.
Page 218 1D-35 Engine Mechanical: Installation 1) Clean mating surface of cylinder head and cylinder “a” block. 2) Install knock pins (1) to cylinder block (2), if removed. I3RB0A143067-01 I3RB0A143065-01 3. Cylinder block 4. Crankshaft pulley side 3) Select and install new cylinder head gasket as follows.
Page 219 Engine Mechanical: 1D-36 d) Select cylinder head gasket according to maximum value of protrusion “a” measured at step b). Available piston Gasket thickness protrusion 0.67 – 0.77 mm 0.028 – 0.127 mm Type A (0.0264 – 0.0303 in.) (0.00111 – 0.00500 in) 0.77 –...
Page 220 1D-37 Engine Mechanical: Valves and Cylinder Head Assembly 6) Apply engine oil around hydraulic valve lash adjuster (1) and valve rocker arm (2), and install them to Disassembly and Reassembly cylinder head. S5RS0B1406022 CAUTION Note original position in which each valve and valve spring seat ware installed, and then install them to original position.
Page 221 Engine Mechanical: 1D-38 Reassembly 3) Apply engine oil to stem seal, valve guide bore and valve stem, and then install valve to valve guide. 1) Install valve spring seats to cylinder head. 4) Install valve spring and valve spring retainer. 2) Install new valve stem seal (1) to valve guide.
Page 222 1D-39 Engine Mechanical: Valves and Cylinder Head Components Valve Springs Referring to data given below, check to be sure that each Inspection spring is in sound condition, free of any evidence of S5RS0B1406023 breakage or weakening. Cylinder Head Remember, weakened valve springs can cause chatter, •...
Page 223 Engine Mechanical: 1D-40 Pistons, Piston Rings, Connecting Rods and Cylinder Components S5RS0B1406024 CAUTION • Connecting rod and connecting rod bearing cap must be replaced as a set when either replacement becomes necessary. • Note original position in which each piston, piston ring, connecting rod and connecting rod bearing cap were installed, and install them to original position.
Page 224 1D-41 Engine Mechanical: Pistons, Piston Rings, Connecting Rods and 5) Mark cylinder number on all pistons using silver pencil or quick drying paint for installation. Cylinder Removal and Installation S5RS0B1406025 6) Remove connecting rod bearing caps (1). CAUTION • Connecting rod and connecting rod bearing cap must be replaced as a set when either replacement becomes necessary.
Page 225 Engine Mechanical: 1D-42 3) Install piston and connecting rod assembly into 5) Lock crankshaft (1) using special tool. cylinder bore matching cylinder number marked in NOTE removal. Use special tool (piston ring compressor) to compress rings. Guide connecting rod into place on Be sure to align hole (2) of special tool with crankshaft.
Page 226 1D-43 Engine Mechanical: Pistons, Piston Rings, Connecting Rods and Cylinder Disassembly and Reassembly S5RS0B1406026 Disassembly 1) Using piston ring expander, remove top and 2nd compression rings and oil ring from piston. 2) Remove piston pin from connecting rod as follows. a) Using flat head screw driver (2) or the like, remove piston pin circlips (1).
Page 227 Engine Mechanical: 1D-44 Pistons, Piston Rings, Connecting Rods and Pistons Cylinder Inspection Visual inspection S5RS0B1406027 Inspect piston for faults, cracks or other damaged. Cylinder Damaged or faulty piston should be replaced. Visual inspection Ring groove clearance Inspect cylinder walls for scratches, roughness or ridges Before checking, piston grooves must be clean, dry and which indicate excessive wear.
Page 228: Connecting Rod
1D-45 Engine Mechanical: Piston Pin Piston Rings Piston ring end gap • Check piston pin, connecting rod small end bore and To measure end gap, insert piston ring (1) into cylinder piston bore for wear or damage, paying particular bore and then measure the gap by using thickness attention to condition of small end bore bush.
Page 229 Engine Mechanical: 1D-46 Crank Pin and Connecting Rod Bearings 4) Install connecting rod and bearing cap referring to “Pistons, Piston Rings, Connecting Rods and Connecting rod bearing general information Cylinder Components: ”. • Connecting rod bearing of cap side (1) has oil hole (2) 5) Using a scale (1) on gauging plastic (2) envelope, as shown in the figure.
Page 230: Main Bearings, Crankshaft And Cylinder Block Components
1D-47 Engine Mechanical: Main Bearings, Crankshaft and Cylinder Block Components S5RS0B1406028 CAUTION Note original position in which each main bearing were installed, and install them to original position. If each main bearing is not installed to original position, engine will spoil its original performance. I3RB0A143104-01 1.
Page 231: Main Bearings, Crankshaft And Cylinder Block Removal And Installation
Engine Mechanical: 1D-48 Main Bearings, Crankshaft and Cylinder Block 9) Remove timing chain oil jet (1) from cylinder block. Removal and Installation S5RS0B1406029 CAUTION Note original position in which each main bearing were installed, and install them to original position. If each main bearing is not installed to original position, engine will spoil its original performance.
Page 232 1D-49 Engine Mechanical: 14) Remove lower crankcase (1) from cylinder block Installation using special tool. 1) Install knock pin (1) to cylinder block, if removed. Special tool 2) Install oil jet (2) to cylinder block, if removed. (A): 09921–96510 Tightening torque Oil jet bolt (a): 9 N·m (0.9 kgf-m, 6.5 lb-ft) I3RB0A143109-01 15) Remove crankshaft (1) and flywheel side crankshaft...
Page 233 Engine Mechanical: 1D-50 4) Install knock pin (1) to crankshaft, if removed. 8) Tighten crankcase bolts (M10) (“1” – “10”) and crankcase bolts (M8) (“11” – “20”) as follows. NOTE NOTE Be sure to install knock pin to φ 6.75 mm (0.266 in.) hole of crankshaft.
Page 234 1D-51 Engine Mechanical: 9) Using special tools, install flywheel side crankshaft 13) Install generator bracket (1) to cylinder block. oil seal (1) as follows. Tightening torque Special tool Generator bracket bolt (a): 25 N·m (2.5 kgf-m, (A): 09913–58620 18.0 lb-ft) (B): 09924–74510 a) Fit crankshaft oil seal to special tool (A).
Page 235: Main Bearings, Crankshaft And Cylinder Block Inspection
Engine Mechanical: 1D-52 Main Bearings, Crankshaft and Cylinder Block Main bearing clearance Inspection NOTE S5RS0B1406030 Do not rotate crankshaft while gauging Crankshaft Thrust Play plastic is installed. 1) Install main bearing, main bearing (with thrust 1) Before checking bearing clearance, clean bearing bearing), crankshaft and lower crankcase referring to “Main Bearings, Crankshaft and Cylinder Block and crankshaft journal.
Page 236: Tightening Torque Specifications
1D-53 Engine Mechanical: Flywheel side crankshaft oil seal Carefully inspect flywheel side crankshaft oil seal (1) for wear or damage. If its lip is worn or damaged, replace it. I3RB0A143126-01 Specifications Tightening Torque Specifications S5RS0B1407001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft...
Page 237 Engine Mechanical: 1D-54 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Connecting rod bearing cap bolt Tighten 20 N⋅m (2.0 kgf-m, 14.5 lb-ft) and 40° by the specified procedure. Oil jet bolt Crankcase bolt Tighten 20 N⋅m (2.0 kgf-m, 14.5 lb-ft) and 80°...
Page 238: Special Tools And Equipment
1D-55 Engine Mechanical: Special Tools and Equipment Recommended Service Material S5RS0B1408001 Material SUZUKI recommended product or Specification Note Loctite 5900® Loctite 5900 — Loctite omnifit 100M Loctite omnifit 100M spezial — spezial® NOTE Required service material is also described in the following.
Page 239 Engine Mechanical: 1D-56 09916–77310 09916–84511 Piston ring compressor (50- Forceps 125 mm) 09916–98610 09917–68221 Flywheel locking tool Camshaft pulley holder KM-652 09917–68610 09917–98221 Camshaft locking tool Valve guide stem attachment EN-46781 09917–98610 09921–96510 Valve stem seal pliers Oil pan seal cutter KM-840 09924–74510 Bearing and oil seal handle...
Page 240: Engine Lubrication System
1E-1 Engine Lubrication System: Engine Lubrication System Diagnostic Information and Procedures Oil Pressure Check 3) Install special tools to vacated threaded hole. S5RS0B1504001 CAUTION WARNING Be careful not to make special tool touch To avoid danger of being burned, do not exhaust manifold when installing because touch exhaust manifold when exhaust exhaust manifold becomes very hot.
Page 241: Repair Instructions
Engine Lubrication System: 1E-2 Repair Instructions Oil Pressure Switch Removal and Installation Installation S5RS0B1506001 Reverse removal procedure for installation noting the Removal following. 1) Remove engine cover. • Tighten oil pressure switch (1) to specified torque. 2) Disconnect oil pressure switch connector. Tightening torque 3) Remove oil pressure switch (1) and gasket (2) from Oil pressure switch (a): 32 N·m (3.2 kgf-m, 23.5...
Page 242 1E-3 Engine Lubrication System: Oil Cooler Removal and Installation 7) Disconnect wire harness clamps (1) from filler port S5RS0B1506003 (2). 8) Remove oil filter housing cover (3) and oil filter. CAUTION 9) Remove oil cooler assembly (4). Never disassemble oil cooler assembly. Disassembly will spoil its original function.
Page 243 Engine Lubrication System: 1E-4 5) Install lubrication pipe referring to “Turbocharger 4) Install coolant feed pipe (1) and lower hose. Removal and Installation: in Section 1D”. Tightening torque 6) Install intercooler referring to “Intercooler Removal Coolant feed pipe bolt (a): 9 N·m (0.9 kgf-m, 7.0 and Installation: in Section 1D”.
Page 244 1E-5 Engine Lubrication System: 7) Cut sealant at hatched part shown in the figure using Installation special tool and hammer (1). 1) Clean mating surfaces of oil pan and lower crankcase. Special tool (A): 09921–96510 NOTE Be careful not to damage stud bolt (4) between oil pan and crankcase when cutting sealant.
Page 245 Engine Lubrication System: 1E-6 Oil Pump / Oil Pump Strainer Components 3) After fitting oil pan to lower crankcase, run in securing bolts and start tightening at the center: S5RS0B1506008 CAUTION move wrench outward, tightening one bolt at a time. Tighten oil pan bolts and nuts to specified torque.
Page 246: Oil Pump Inspection
1E-7 Engine Lubrication System: Oil Pump / Oil Pump Strainer Removal and Oil Pump Strainer Cleaning S5RS0B1506010 Installation Clean oil pump strainer screen. S5RS0B1506009 CAUTION Do not disassemble oil pump from timing chain cover. Disassembly will spoil its original function. If any malcondition is found in oil pump, replace timing chain cover.
Page 247 Reference: For the tightening torque of fastener not specified in this section, refer to “Fasteners Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5RS0B1508001 Material SUZUKI recommended product or Specification Note Loctite 5900® Loctite 5900® — NOTE Required service material is also described in the following.
Page 248: Engine Cooling System
1F-1 Engine Cooling System: Engine Cooling System General Description Cooling System Description NOTE S5RS0B1601001 The cooling system consists of the degassing tank cap, • Alcohol or methanol base coolant or plain radiator, degassing tank, hoses, water pump, cooling fan water alone should not be used in cooling and thermostat.
Page 249: Coolant Circulation
Engine Cooling System: 1F-2 Schematic and Routing Diagram Coolant Circulation S5RS0B1602001 I3RM0B162002-01 [A]: When thermostat is close 3. Engine oil cooler 7. Water pump [B]: When thermostat is open 4. Engine 8. Heater 1. Radiator 5. Degassing tank 9. EGR cooler 2.
Page 250: Radiator Fan Control System Inspection
1F-3 Engine Cooling System: Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis S5RS0B1604001 Condition Possible cause Correction / Reference Item Engine overheats (It is in Loose or broken water pump belt Adjust or replace. case that radiator fan Not enough coolant Check coolant level and add as necessary.
Page 251: Cooling System Components
Engine Cooling System: 1F-4 Repair Instructions Cooling System Components S5RS0B1606001 I5RS0B160002-01 1. Radiator 10. Radiator inlet hose 19. Hose clip : Be sure to position clip in specified direction as shown in the figure. 2. Radiator cooling fan assembly 11. Radiator outlet hose 20.
Page 252: Coolant Level Check
1F-5 Engine Cooling System: Coolant Level Check Engine Cooling System Inspection and S5RS0B1606002 Cleaning WARNING S5RS0B1606003 WARNING To help avoid danger of being burned, do not remove degassing tank cap while engine and To help avoid danger of being burned, do not radiator are still hot.
Page 253: Cooling System Draining
Engine Cooling System: 1F-6 Cooling System Draining Cooling System Flush and Refill S5RS0B1606004 S5RS0B1606006 WARNING WARNING To help avoid danger of being burned, do not To help avoid danger of being burned, do not remove degassing tank cap while engine and remove degassing tank cap while engine and radiator are still hot.
Page 254: Installation
1F-7 Engine Cooling System: Removal 7) Disconnect coolant hose of upper side from thermostat case. If it is hard to disconnect it after 1) Drain coolant referring to “Cooling System Draining: removing clip, push to insert hose to pipe a little ”.
Page 255: Radiator Cooling Fan Assembly On-Vehicle Inspection
Engine Cooling System: 1F-8 Radiator Cooling Fan Assembly On-Vehicle Radiator Cooling Fan Relay Inspection S5RS0B1606018 Inspection 1) Disconnect negative (–) and positive (+) cable at S5RS0B1606009 battery. 1) Check low speed operation of radiator cooling fan as follows. 2) Remove battery. a) Connect battery to fan motor coupler as shown 3) Remove radiator cooling fan relay No.1 (1), No.2 (2) in the figure.
Page 256: Radiator Cooling Fan Assembly Removal And Installation
1F-9 Engine Cooling System: Radiator Cooling Fan Assembly Removal and 10) Remove cooling fan mounting bolts (1). Installation S5RS0B1606010 Removal 1) Disconnect negative (–) cable at battery. 2) Drain coolant referring to “Cooling System Draining: ”. 3) Remove air cleaner assembly with MAF sensor assembly referring to “Air Cleaner Assembly Removal and Installation: in Section 1D”.
Page 257: Radiator Removal And Installation
Engine Cooling System: 1F-10 Radiator Removal and Installation Water Pump / Generator Drive Belt Tension S5RS0B1606012 Inspection S5RS0B1606013 Removal WARNING 1) Disconnect negative (–) cable at battery. To help avoid danger of being burned, do not 2) Drain coolant referring to “Cooling System Draining: remove degassing tank cap while engine and ”.
Page 258: Water Pump / Generator Drive Belt Removal And Installation
1F-11 Engine Cooling System: Water Pump / Generator Drive Belt Removal and Water Pump / Generator Drive Belt Tensioner Installation Assembly Removal and Installation S5RS0B1606014 S5RS0B1606015 Removal CAUTION 1) Remove drive belt (2) while turning tensioner (1) Do not disassemble drive belt tensioner clockwise until stopping.
Page 259: Water Pump Removal And Installation
Engine Cooling System: 1F-12 Water Pump Removal and Installation Water Pump Inspection S5RS0B1606016 S5RS0B1606017 Removal CAUTION 1) Disconnect negative (–) cable at battery. Do not disassemble water pump. 2) Drain coolant referring to “Cooling System Draining: If any repair is required on pump, replace it ”.
Page 260: Specifications
1F-13 Engine Cooling System: Specifications Tightening Torque Specifications S5RS0B1607001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Thermostat case bolt 18.0 Tensioner bolt 36.5 Water pump nut NOTE The specified tightening torque is also described in the following. “Cooling System Components: ” Reference: For the tightening torque of fastener not specified in this section, refer to “Fasteners Information: in Section 0A”.
Page 261: Fuel System
Fuel System: 1G-1 Fuel System Precautions Precautions on Fuel System Service S5RS0B1700001 WARNING • Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk or fire and personal injury. –...
Page 262 1G-2 Fuel System: • When servicing on the high pressure direct injection system, must be performed under very clean conditions. This means that no impurities (particles a few microns in side) get into the system during dismantling or into the circuits via the fuel unions.
Page 263: General Description
Fuel System: 1G-3 • 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. I3RB0A173003-01 •...
Page 264: Schematic And Routing Diagram
1G-4 Fuel System: Schematic and Routing Diagram Fuel Delivery System Diagram S5RS0B1702001 I3RM0B172002-01 [A]: Fuel feed line 2. Fuel pump 5. Injection pump [B]: Fuel return line 3. Fuel filter 6. Common rail (High pressure fuel injection rail) 1. Fuel tank 4.
Page 265: Repair Instructions
Fuel System: 1G-5 Repair Instructions Fuel Hose Disconnecting and Reconnecting S5RS0B1706028 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 Conventional Clamp Fuel tank system NOTE Be sure to install hose to spool of pipe surely.
Page 266 1G-6 Fuel System: The other than fuel tank system [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 267: Fuel Leakage Check Procedure
Fuel System: 1G-7 Water Draining of Fuel Filter For Quick Joint (Fuel Pump) S5RS0B1706004 1) Disconnect negative (–) cable at battery. Disconnecting 2) Hoist vehicle. 1) Remove mud, dust and/or foreign material between pipe (1) and quick joint (fuel pump) (2) by blowing 3) Place container under bleed screw (1), and drain fuel compressed air.
Page 268: Fuel Delivery System (High Pressure) Components
1G-8 Fuel System: Fuel Delivery System (High Pressure) Components S5RS0B1706002 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. I5RS0B170005-02 1. Fuel injector 8.
Page 269: Fuel Injector On-Vehicle Inspection
Fuel System: 1G-9 Fuel Injector On-Vehicle Inspection Fuel Injector Removal and Installation S5RS0B1706008 S5RS0B1706009 1) Using sound scope or such, check operating sound WARNING of injector when engine is running or cranking. Cycle of operating sound should vary according to Before starting the following procedure, be engine speed.
Page 270 1G-10 Fuel System: Removal 4) Disconnect fuel injector connectors (3). 1) Disconnect negative (–) cable at battery. 2) Remove engine cover (1) and engine cover bracket (2). I3RM0B172011-01 5) Remove high pressure pipes (1). When loosening union nut of high pressure pipe, holding union nut (7) of fuel injector (4) with wrench.
Page 271 Fuel System: 1G-11 Installation 7) Connect return hose (2) to fuel injectors and then install clips (1) to fuel injectors. 1) Install new sealing rings (2) to fuel injectors (1). 8) Connect fuel injector connectors (3). 2) Set fuel injector bracket (3) to fuel injectors. 3) Install fuel injectors to camshaft housing and tighten fuel injector bracket nut (4) temporarily by hand.
Page 272: Common Rail
1G-12 Fuel System: Common Rail (High Pressure Fuel Injection Installation Rail) Removal and Installation 1) Install common rail (1) to its bracket (2) and tighten S5RS0B1706010 common rail bolts (3) temporarily by hand. WARNING 2) Install new high pressure pipes for injectors and new high pressure supply pipe (4).
Page 273: Injection Pump Removal And Installation
Fuel System: 1G-13 Injection Pump Removal and Installation Installation S5RS0B1706011 1) Clean mating surfaces of injection pump and WARNING camshaft housing. 2) Install new gasket (1) to injection pump. Before starting the following procedure, be sure to observe “Precautions on Fuel System 3) Install injection pump (2) to camshaft housing.
Page 274: Fuel Pressure Sensor Removal And Installation
1G-14 Fuel System: Fuel Pressure Sensor Removal and Installation 5) Connect fuel feed hose (1) and fuel return hose (2) to injection pump. S5RS0B1706014 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.
Page 275: Fuel Pressure Regulator Removal And Installation
Fuel System: 1G-15 Fuel Pressure Regulator Removal and Fuel Pressure Regulator Inspection S5RS0B1706016 Installation Check resistance between terminals of fuel pressure S5RS0B1706015 regulator. WARNING If resistance is out of specification, replace fuel pressure regulator referring to “Fuel Pressure Regulator Removal Before starting the following procedure, be and Installation: ”.
Page 276: Fuel Delivery System (Low Pressure) Components
1G-16 Fuel System: Fuel Delivery System (Low Pressure) Components S5RS0B1706029 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. I5RS0B170001-01...
Page 277: Fuel Lines On-Vehicle Inspection
Fuel System: 1G-17 [A]: For LH steering vehicle 5. Fuel filter element 13. Fuel No. 2 pipe 21. Quick joint (fuel pipe) [B]: For RH steering vehicle 6. Fuel filter fastener 14. Fuel return pipe 22. Quick joint (fuel pump) F: Forward 7.
Page 278: Fuel Filler Cap Inspection
1G-18 Fuel System: NOTE Installation 1) Install clamps to marked location on pipes. If clamp If cap requires replacement, only a cap with is deformed or its claw is bent or broken, replace it the same features should be used. Failure to with new one.
Page 279 Fuel System: 1G-19 4) Hoist vehicle, and remove clamp (2), fuel filler hose 9) Lower fuel tank (1) until fuel level (2) in fuel tank is (1) and breather hose (3) from fuel tank. lower than installation position of quick joint (fuel pipe) (3) in order to prevent fuel outflow after disconnecting quick joint (fuel pipe).
Page 280: Fuel Tank Inspection
1G-20 Fuel System: Installation 5) Connect fuel filler hose (1) and breather hose (2) to filler neck (3) as shown in the figure and clamp them CAUTION securely. • When connecting joint, clean outside Tightening torque surfaces of pipe where joint is to be Fuel filler hose clamp bolt (a): 2 N·m (0.2 kgf-m, inserted, push joint into pipe till joint lock 1.5 lb-ft)
Page 281: Fuel Tank Purging Procedure
Fuel System: 1G-21 Fuel Tank Purging Procedure Fuel Pump Assembly Removal and Installation S5RS0B1706022 S5RS0B1706024 WARNING WARNING Before starting the following procedure, be • Before starting the following procedure, be sure to observe “Precautions on Fuel System sure to observe “Precautions on Fuel Service: ”.
Page 282: Fuel Pump Inspection
1G-22 Fuel System: Installation CAUTION When connecting joint, clean outside surface of pipe where joint is to be inserted, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur. 1) Clean mating surfaces of fuel pump assembly (1) and fuel tank.
Page 283: Fuel Filter Element Removal And Installation
Fuel System: 1G-23 Fuel Filter Element Removal and Installation S5RS0B1706026 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. Removal 1) Disconnect negative (–) cable at battery. 2) Remove ECM referring to “Engine Control Module (ECM) Removal and Installation: in Section 1C”.
Page 284: Fuel Filter Assembly Removal And Installation
1G-24 Fuel System: Fuel Filter Assembly Removal and Installation Installation Reverse removal procedure for installation noting the S5RS0B1706027 WARNING following. • Be sure to replace fuel filter element and O-ring as Before starting the following procedure, be new one. sure to observe “Precautions on Fuel System •...
Page 285: Fuel Temperature Sensor Inspection
Fuel System: 1G-25 Fuel Temperature Sensor Inspection S5RS0B1706013 1) Remove fuel temperature sensor referring to “Fuel Heater and Temperature Sensor Removal and Installation: ”. 2) Check for resistance between fuel temperature sensor terminals. If not as specified, replace fuel heater and temperature sensor. Fuel temperature sensor resistance Water temperature °C (°F) Resistance (kΩ)
Page 286: Special Tools And Equipment
1G-26 Fuel System: Special Tools and Equipment Special Tool S5RS0B1708001 09914–65420 09916–50010 Plug cap for 8HY fuel Fuel system, plug set system OUT0000173/9780.E1 09919–47020 09919–48310 Quick joint remover Plug kit KM-6015 09919–48320 09919–48610 Plug kit Fuel filter locking tool KM-807 (EN-46784) 09941–51010 Lock ring wrench...
Page 287: Starting System
Starting System: 1I-1 Starting System General Description Cranking System Description S5RS0B1901001 Cranking Circuit The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These components are connected electrically. Starting Motor Circuit In the circuit shown in “Cranking System Circuit Diagram: ”, the magnetic switch coils are magnetized when the ignition switch is closed.
Page 288: Diagnostic Information And Procedures
1I-2 Starting System: Diagnostic Information and Procedures Cranking System Symptom Diagnosis Do not remove motor just because starting motor does S5RS0B1904001 not run. Check the following items and narrow down Possible symptoms due to starting system trouble would scope of possible causes. be as follows: 1) Condition of trouble •...
Page 289: Cranking System Test
Starting System: 1I-3 Condition Possible cause Correction / Reference Item Noise Abnormally worn bush Replace starting motor. Worn pinion or worn teeth of ring gear Replace starting motor or flywheel. Poor sliding of pinion (failure in return Replace starting motor. movement) Worn internal or planetary gear teeth Replace starting motor.
Page 290: Starting Motor Dismounting And Remounting
1I-4 Starting System: No-Load Performance Test Connect lead wire (1) to terminal “M” (2). Connect battery to starting motor as shown. Check that starting motor rotates smoothly and steadily with pinion moving out. If check result is not satisfactory, replace starting motor assembly. I3RM0B190001-01 Repair Instructions Starting Motor Dismounting and Remounting...
Page 291: Specifications
Starting System: 1I-5 Remounting Reverse the dismounting procedure noting the following. • Make sure that starting motor mount bolt (upper side) does not fall into transaxle case. • Tighten starting motor mount bolts to specified torque. Tightening torque Starting motor mount bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft) Magnetic switch lead wire nut (b): 7 N·m (0.7 kgf-m, 5.0 lb-ft) Battery cable nut (c): 15 N·m (1.5 kgf-m, 11.0 lb-ft) 4, (a)
Page 292: Charging System
1J-1 Charging System: Charging System General Description Generator Description S5RS0B1A01002 The generator is a small and high performance type with an IC regulator incorporated. The generator features are as follows: • Solid state regulator is mounted inside the generator. • All regulator components are enclosed into a solid mold.
Page 293: Diagnostic Information And Procedures
Charging System: 1J-2 Diagnostic Information and Procedures Battery Inspection Hydrometer Test S5RS0B1A04001 The direct method of checking the battery for state of Common Causes of Failure charge is to carry out a high rate discharge test, which A battery is not designed to last indefinitely; however, involves a special precise voltmeter and an expensive with proper care, it will provide many years of service.
Page 294: Generator Symptom Diagnosis
1J-3 Charging System: Generator Symptom Diagnosis S5RS0B1A04002 CAUTION • Do not connect any load between “L” and “E” terminals. • When connecting charger or booster battery to vehicle battery, refer to “Jump Starting in Case of Emergency: ”. Trouble in charging system will show up as one or more of the following conditions: 1) Faulty indicator lamp operation.
Page 295: Generator Test
Charging System: 1J-4 Generator Test (Undercharged Battery Check) NOTE S5RS0B1A04003 Consideration should be taken that voltage This condition, as evidenced by slow cranking or low will differ somewhat with regulator case specific gravity can be caused by one or more of the temperature as shown in the figure.
Page 296: Repair Instructions
1J-5 Charging System: Repair Instructions Battery Dismounting and Remounting Handling S5RS0B1A06002 When handling battery, the following safety precautions Dismounting should be followed: 1) Disconnect negative cable (1). • Hydrogen gas is produced by battery. A flame or 2) Disconnect positive cable (2). spark near battery may cause the gas to ignite.
Page 297: Specifications
Charging System: 1J-6 Specifications Charging System Specifications S5RS0B1A07001 Battery Battery type CCA 370 A Nominal output 12 V 60 Ah / 20 h Rated capacity 46Ah / 5 h Generator Generator type 90 A type Rated voltage 12 V Nominal output 90 A Polarity Negative ground...
Page 298: Exhaust System
1K-1 Exhaust System: Exhaust System General Description Exhaust System Description S5RS0B1B01001 The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC), a turbocharger, exhaust pipe, a muffler and seal, gasket and etc. The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
Page 299: Repair Instructions
Exhaust System: 1K-2 Repair Instructions Exhaust System Components S5RS0B1B06001 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. I5RS0B1B0001-02 1.
Page 300: Exhaust Manifold Components
1K-3 Exhaust System: Exhaust Manifold Components S5RS0B1B06002 I5RS0B1B0002-01 1. Exhaust manifold cover 5. Exhaust manifold nut : 23 N⋅m (2.3 kg-m, 17.0 lb-ft) 2. Exhaust manifold gasket 6. Exhaust manifold cover nut : 9 N⋅m (9.0 kg-m, 6.5 lb-ft) 3. Exhaust manifold 7.
Page 301: Exhaust Manifold Removal And Installation
Exhaust System: 1K-4 Exhaust Manifold Removal and Installation Installation S5RS0B1B06003 1) Install exhaust manifold (1) with new gasket (3) using new nut (2). Removal Tightening torque WARNING Exhaust manifold nut (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft) To avoid danger of being burned, do not service exhaust system while it is still hot.
Page 302: Exhaust Manifold Inspection
1K-5 Exhaust System: Exhaust Manifold Inspection S5RS0B1B06004 Check gasket and seal for deterioration or damage. Replace them as necessary. Catalytic Converter Removal and Installation S5RS0B1B06005 Refer to “Turbocharger Removal and Installation: in Section 1D”. Exhaust Pipe and Muffler Removal and Installation S5RS0B1B06006 For replacement of exhaust pipe, be sure to hoist vehicle and observe WARNING under “Exhaust System Components: ”...
Page 303 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 service manual. Precautions ..........2-* Front Stabilizer Bar, Bushing and/or Joint Check ..............
Page 304 2-ii Table of Contents Irregular and/or Premature Wear Tire Rotation............2D-* Description ............2D-* Wheel Removal and Installation......2D-* Wear Indicators Description ........ 2D-* Tire Mounting and Dismounting ......2D-* Radial Tire Waddle Description......2D-* Tire Repair ............2D-* Radial Tire Lead / Pull Description...... 2D-* Specifications ............
Page 305: Front Suspension Frame, Stabilizer Bar And/Or Bushings Removal And Installation
Front Suspension: 2B-1 Front Suspension Repair Instructions Front Suspension Frame, Stabilizer Bar and/or 9) By using chain hoist (1), support engine assemble with engine hungers (2). Bushings Removal and Installation S5RS0B2206015 CAUTION Removal Be sure to remove / disconnect part(s) that 1) Hoist vehicle and remove wheels (right &...
Page 306 2B-2 Front Suspension: 12) Remove engine rear mounting bolts (1) from engine 14) Remove suspension frame mounting bolts (1), and rear mounting (2). then lower mission jack and remove suspension frame (2) with stabilizer bar and steering gear case. I4RS0A220041-01 I4RS0A220043-01 3.
Page 307 Front Suspension: 2B-3 Installation 4) Mount steering gear case (1) to suspension frame (2) and tighten gear case mounting No.1 bolts (3) 1) When installing stabilizer, loosely assemble all and No.2 bolts (4) to specified torque. components while insuring that stabilizer is centered, side-to-side.
Page 308 2B-4 Front Suspension: 7) Tighten suspension frame mounting bolts (a) to 11) Remove chain hoist from engine. specified torque. 12) Install oil level gauge guide and oil level gauge. Tightening torque 13) Reverse disconnected electric wires and connectors for connection in removal procedure. Suspension frame mounting bolt (a): 150 N·m ( 15.0 kgf-m, 108.5 lb-ft) 14) Install intercooler outlet pipe referring to “Intercooler...
Page 309: Driveline / Axle
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 service manual. Precautions ..........3-* Front Drive Shaft Assembly On-Vehicle Inspection............3A-3 Precautions..............
Page 310: Drive Shaft / Axle
3A-1 Drive Shaft / Axle: Drive Shaft / Axle General Description Front Drive Shaft Construction S5RS0B3101001 A constant velocity double offset joint (DOJ) is used on the differential side (or center shaft side) of both right and left side drive shaft assemblies. A constant velocity ball joint is used on the wheel side of both right and left side drive shaft assemblies.
Page 311: Diagnostic Information And Procedures
Drive Shaft / Axle: 3A-2 Diagnostic Information and Procedures Front Drive Shaft Symptom Diagnosis S5RS0B3104001 Condition Possible cause Correction / Reference Item Abnormal noise Worn or breakage of the drive shaft joint Replace. Worn or breakage of the center bearing Replace. Repair Instructions Front Drive Shaft Components S5RS0B3106001...
Page 312: Front Drive Shaft Assembly On-Vehicle Inspection
3A-3 Drive Shaft / Axle: Front Drive Shaft Assembly On-Vehicle Inspection S5RS0B3106002 • Check boots for breakage or deterioration. • Check wheel side joint for rattle or smooth rotation. • Check differential side (or center shaft side) joint for smooth rotation. If any abnormality is found, replace.
Page 313: Front Drive Shaft Disassembly And Assembly
Drive Shaft / Axle: 3A-4 Installation Front Drive Shaft Disassembly and Assembly S5RS0B3106004 CAUTION Disassembly • Be careful not to damage oil seals and CAUTION boots when installing drive shaft. • Do not hit joint boot with hammer. Disassembly of wheel side joint is not Inserting joint only by hands is allowed.
Page 314 3A-5 Drive Shaft / Axle: 2) Remove differential side (or center shaft side) boot 5) Draw away cage (1) by using bearing puller (2), and small band (1) using flat end rod (2) or the like. remove boot (3) from shaft. I5RS0B310005-01 3) Slide boot (1) toward the center of shaft and remove snap ring (2) from outer race, and then take shaft out...
Page 315 Drive Shaft / Axle: 3A-6 Assembly 8) Place new wheel side boot big band (3) and small Judging from abnormality noted before disassembly and band (4) onto boot putting band outer end (1) against what is found through visual check of component parts forward rotation (2) as shown in figure.
Page 316 3A-7 Drive Shaft / Axle: 10) Set new differential side (or center shaft side) small 15) Apply grease (including in spare parts) to inside of band and new differential side (or center shaft side) joint housing (1). boot on shaft temporarily. Grease color 11) Drive in the cage (1) by using special tool.
Page 317 Drive Shaft / Axle: 3A-8 18) Place differential side boot (or center shaft side) new big band (3) and new small band (4) onto boot putting band outer end (1) against forward rotation (2) as shown in figure. I5JB0A311006-01 19) Fasten differential side (or center shaft side) boot band.
Page 318 “a”: 3.5 – 4.5 mm (0.14 – 0.17 in.) • Be sure to apply grease to oil seal lip and bearing side space indicated in the figure. “A”: Grease 99000–25010 (SUZUKI Super Grease Grease amount “A”: 2.0 – 3.0 g (0.07 – 0.11 oz) I5RS0B310015-01 4) Remove center bearing from center bearing support.
Page 319: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information: in Section 0A”. Special Tools and Equipment Recommended Service Material S5RS0B3108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 NOTE Required service material is also described in the following.
Page 320 3A-11 Drive Shaft / Axle:...
Page 321 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 service manual. Precautions ..........4-* Front Disc Brake Components ......
Page 322 4-ii Table of Contents Parking Brake Cable Removal and DTC C1041 / C1045 / C1051 / C1055, DTC Installation ............4D-* C1042 / C1046 / C1052 / C1056: Right-Front Parking Brake Lever Removal and / Left-Front / Right-Rear / Left-Rear Inlet Installation ............
Page 323: General Description
ABS: 4E-1 General Description ABS Hydraulic Unit / Control Module Assembly Description S5RS0B4501002 ABS control module is a component of ABS hydraulic unit / control module assembly and has the following functions. Self-Diagnosis Function ABS control module diagnoses conditions of the system component parts (whether or not there is any abnormality) all the time and indicates the results (warning of abnormality occurrence and DTC) through the ABS warning lamp as described.
Page 324: Abs Schematic
4E-2 ABS: Schematic and Routing Diagram ABS Schematic S5RS0B4502001 INPUT OUTPUT ABS 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 325: Abs Wiring Circuit Diagram
ABS: 4E-3 1. ABS hydraulic unit / control module assembly 9. Stop lamp switch 17. Wheel speed sensor (Left-rear) 2. ABS control module 10. ABS warning lamp 18. Battery 3. ABS hydraulic unit 11. EBD warning lamp (Brake warning lamp) 19.
Page 326 4E-4 ABS: [A]: Terminal arrangement of ABS hydraulic unit / 8. Lamp driver module 17. Left-front wheel speed sensor control module assembly a: Upside 9. ABS hydraulic unit / control module assembly 18. Data link connector 1. Battery 10. Solenoid valve power supply driver (transistor) 19.
Page 327: Serial Data Link Circuit Check
ABS: 4E-5 Diagnostic Information and Procedures Serial Data Link Circuit Check S5RS0B4504012 I5RS0B450003-01 [A]: ABS hydraulic unit / control module connector E03 1. Battery 4. Circuit fuse box 7. Lamp driver module 10. ABS hydraulic unit / control module assembly 2.
Page 328 4E-6 ABS: Step Action 1) Turn ignition switch to OFF position. Go to Step 6. Ground circuit for ABS hydraulic unit / control 2) Check for proper connection to ABS hydraulic unit / module open or high control module connector at terminals “E03-13” and resistance.
Page 329: Rear Wheel Speed Sensor Removal And Installation
ABS: 4E-7 Repair Instructions Rear Wheel Speed Sensor Removal and 3) Hoist vehicle. Installation 4) Detach ABS wheel sensor wire harness (1). S5RS0B4506009 NOTE Removal Do not detach clip of rear wheel speed 1) Disconnect negative cable from battery. sensor connector from vehicle body unless 2) Disconnect rear wheel speed sensor connector as replacement is necessary.
Page 330 4E-8 ABS: Vehicle Speed Output Signal Inspection • Be sure to install wheel speed sensor (2) and its bolt at the correct (upper) position as shown in figure. S5RS0B4506015 1) Check DTC of ABS control module referring to “DTC Tighten sensor bolt (1) and harness clamp bolts to Check: ”.
Page 331: Transmission / Transaxle
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 service manual. Precautions ..........5-* Differential Disassembly and Assembly ....5B-28 Differential Adjustment ........5B-30 Precautions..............
Page 332: Manual Transmission
5B-1 Manual Transmission: Manual Transmission General Description Manual Transaxle Construction and Servicing S5RS0B5201001 The transaxle provides five forward speeds and one reverse speed by means of three synchronizers and three shafts- cluster gear (input shaft), main shaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.
Page 333 Manual Transmission: 5B-2 I5RS0B520001-01 1. 5th gear hub assembly 7. Extension case cover 13. 2nd gear 2. Cluster 5th speed gear 8. 5th gear 14. 3rd gear 3. Reverse gear shaft 9. Extension bearing plate case 15. 3rd & 4th gear hub assembly 4.
Page 334 5B-3 Manual Transmission: Diagnostic Information and Procedures Manual Transaxle Symptom Diagnosis S5RS0B5204001 Condition Possible cause Correction / Reference Item Gears slipping out of Gear shift / select control cables faulty Replace. mesh Worn gear selector rod Replace. Worn gear selector fork or synchronizer Replace.
Page 335: Manual Transaxle Oil Change
Manual Transmission: 5B-4 Repair Instructions Manual Transaxle Oil Change S5RS0B5206001 CAUTION Do not reuse circlip, spring pin, E-ring, oil seal, gasket, self locking nut and specified parts. Reuse of it can result in trouble. 1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally.
Page 336 1) Lift up vehicle and drain transaxle oil referring to sure of its smoothness. “Manual Transaxle Oil Change: ”. “A”: Grease 99000–25010 (SUZUKI Super 2) Remove left side drive shaft or center shaft referring Grease A) to “Front Drive Shaft Assembly Removal and Installation: in Section 3A”.
Page 337: Gear Shift Control Lever And Cable Components
Manual Transmission: 5B-6 Gear Shift Control Lever and Cable Components S5RS0B5206003 13 N·m (1.3 kgf-m) 10 N·m (1.0 kgf-m) 12 N·m (1.2 kgf-m) I5RS0B520003-01 1. Gear shift control lever assembly 4. Cable bracket bolt : Tightening torque 2. Shift & select cable assembly 5.
Page 338 5B-7 Manual Transmission: Gear Shift Control Lever and Cable Removal NOTE and Installation Install the shift cable first. S5RS0B5206004 Removal 1) Remove console box. 2) Disconnect shift and select control cables (1) from gear shift control lever assembly (2). a) While pushing claw (4), disconnect cable assembly from bracket (5).
Page 339 Manual Transmission: 5B-8 Back Up Lamp Switch Removal and Installation Back Up Lamp Switch Inspection S5RS0B5206005 S5RS0B5206006 Removal Check back up lamp switch for function using ohmmeter. 1) Disconnect negative cable at battery. Back up lamp switch specification 2) Remove air cleaner, and then disconnect back up Switch ON (Push): Continuity lamp switch coupler (1).
Page 340 5B-9 Manual Transmission: Manual Transaxle Unit Components S5RS0B5206007 60 N·m (6.0 kgf-m) 55 N·m (5.5 kgf-m) 60 N·m (6.0 kgf-m) 40 N·m (4.0 kgf-m) 30 N·m (3.0 kgf-m) 55 N·m (5.5 kgf-m) I5RS0B520006-01 [A]: Forward 5. Transaxle to engine bracket 10.
Page 341: Manual Transaxle Unit Dismounting And Remounting
Manual Transmission: 5B-10 Manual Transaxle Unit Dismounting and Remounting S5RS0B5206011 Dismounting 1) Remove battery and battery tray. 2) Remove air cleaner and resonator. 3) Remove clutch fluid pipe referring to “Clutch Fluid Pipe Removal and Installation: in Section 5C”. 4) Disconnect shift and select cables from transaxle and then remove its bracket on transaxle.
Page 342 5B-11 Manual Transmission: 8) Drain transaxle oil. Remounting For remounting, reverse dismounting procedure noting 9) Remove front drive shafts and center shaft referring the following. to “Front Drive Shaft Assembly Removal and Installation: in Section 3A”. • Refer to “Manual Transaxle Unit Components: ” for fastener specified torque.
Page 343: Manual Transaxle Assembly Components
Manual Transmission: 5B-12 Manual Transaxle Assembly Components S5RS0B5206020 15 N·m (1.5 kg-m) 20 N·m (2.0 kg-m) 22 N·m (2.2 kg-m) 12 N·m (1.2 kg-m) 23-1 29 N·m (2.9 kg-m) 9 N·m (0.9 kg-m) 22 N·m (2.2 kg-m) 18 N·m (1.8 kg-m) I3RM0B522011-01...
Page 344: Tightening Torque
5B-13 Manual Transmission: 1. Transaxle case 15. 5th gear selector fork bolt 28. Differential cover bolt 2. Transmission end plate 16. Oil seal 29. Selector lever cover bolt : Apply grease 99000-25010 to oil seal lip. 3. Extension case cover 17.
Page 345 Manual Transmission: 5B-14 5th Gears Removal and Installation 5) Remove 5th gear needle bearing from main shaft. S5RS0B5206013 6) Remove cluster 5th gear (1) from cluster gear using gear puller. Removal 1) Remove extension case cover bolts and take off extension case cover.
Page 346 5B-15 Manual Transmission: 3) Install needle bearing, 5th gear and synchronizer 6) Install extension case cover (1) with new gasket and ring onto main shaft. then tighten bolts to specified torque. Drive 5th gear assembly onto main shaft facing Tightening torque chamfer of sleeve to extension case cover side, Extension case cover bolt (a): 29 N·m (2.9 kgf- using special tool and hammer.
Page 347 Manual Transmission: 5B-16 Gear Selector, Cluster Gear and Main Shaft Components S5RS0B5206008 7 N·m (0.7 kg-m) 7 N·m (0.7 kg-m) I3RM0B522012-01 1. Extension bearing plate case 10. 3rd & 4th gear selector fork 19. Reverse gear shaft ball 2. Gear shift rod locking bush 11.
Page 348 5B-17 Manual Transmission: Gear Selector, Cluster Gear and Main Shaft 4) Remove gear shift rod connector bolt (1). Removal and Installation 5) Engage 2nd, 3rd and 5th gear and then remove gear S5RS0B5206014 shift rod connector (2). Removal NOTE 1) Remove bearing plate case bolt (1) and then detach If fastening bolts are stiff, heat extension transmission end plate (2) from transaxle case.
Page 349 Manual Transmission: 5B-18 7) Remove 5th gear shift fork. 11) Drive out cluster gear (1) and main shaft (2) from extension bearing plate case (4) using special tool 8) Remove 1st & 2nd selector fork pin (1), 1st & 2nd and then take off 5th gear inner bearing ring (3).
Page 350 5B-19 Manual Transmission: 14) Remove cluster gear ball bearing (1) and main shaft 3) Install main shaft (1) and cluster gear (2) using ball bearing (2) from extension bearing plate case special tools and hydraulic press. using special tool. Special tool Special tool (A): 09922–58620 (A): 09913–75810...
Page 351 Manual Transmission: 5B-20 5) Install 1st & 2nd gear selector rod (1) and selector 9) Install 3rd & 4th gear selector rod (1) and selector fork (2) to extension bearing plate case and then fork (2) in the same manner as Step 5). drive in new selector fork pin (3).
Page 352: Transaxle Case Disassembly And Assembly
5B-21 Manual Transmission: Transaxle Case Disassembly and Assembly 12) Install 5th gear pawl (1) to extension bearing plate case (2) and tighten bolts to specified torque. S5RS0B5206015 Disassembly CAUTION 1) Remove pinion needle bearing (1) from transaxle Do not reuse 5th gear pawl bolt (3). Be sure to case (3) using special tools.
Page 353 Manual Transmission: 5B-22 4) Remove left and right side differential side oil seals Special tool referring to “Differential Side Oil Seal Replacement: (A): 09925–68630 ”. (B): 09925–68610 (C): 09919–08610 5) Remove lock plate bolt (1) and then retaining ring lock plate (2). NOTE Mark position (3) of differential bearing retaining ring (4) to transaxle case (5).
Page 354 5B-23 Manual Transmission: 2) Apply transaxle oil to new O-ring and then install O- 7) Install left side oil seal referring to “Differential Side ring to groove of differential bearing retaining ring. Oil Seal Replacement: ”. 3) Install left side differential side bearing outer race (1) 8) Install differential side oil seal referring to to bearing ring using special tools.
Page 355 Manual Transmission: 5B-24 Counter Gear and Main Shaft Components S5RS0B5206009 I3RM0B522013-01 1. Transaxle cluster gear 9. 4th gear wear plate 17. 1st gear synchronizer outer ring 2. Transaxle main shaft 10. 2nd gear thrust washer 18. 1st gear synchronizer intermediate ring 3.
Page 356 5B-25 Manual Transmission: Main Shaft Disassembly and Assembly 4) Remove 2nd gear needle bearing. S5RS0B5206016 5) Remove 2nd gear thrust washer (1) and 4th gear wear plate (2). Disassembly 6) Take out 3rd gear (3), 3rd gear needle bearing and 1) Remove 1st gear wear plate (2) and then take out 3rd &...
Page 357 Manual Transmission: 5B-26 Assembly 5) Install 4th gear (2) and synchronizer ring onto main shaft. 1) Clean all components thoroughly, inspect them for Press-fit 3rd & 4th gear hub assembly (1) onto main any abnormality and replace with new ones as shaft facing groove of chamfer of sleeve to 3rd gear necessary.
Page 358 5B-27 Manual Transmission: 10) Assemble 2nd gear (1), 2nd gear synchronizer ring 12) Install new 2nd gear snap ring (1) using special tool. assembly (2), 2nd gear needle bearing (3) and 1st & Special tool 2nd gear hub assembly (hub (4), sleeve (5) and keys (A): 09900–06107 (6)).
Page 359: Differential Components
Manual Transmission: 5B-28 Differential Components S5RS0B5206010 1322 I3RM0B522014-03 1. Plastic cage 7. Final gear bolt : Tighten to 70 N⋅m (7.0 kgf-m), 30° and 15° by the specified procedure. : Apply thread lock 99000-32110 to all around thread part of bolt. 2.
Page 360 5B-29 Manual Transmission: 5) Hold differential gear assembly (1) with soft jawed vise. Remove final gear bolts and then take out final gear. 6) Remove pinion shaft washer from pinion shaft (2). Drive out pinion shaft and then disassemble component parts. “A”, (a) I3RM0B522075-01 4) Press-fit differential side bearings (right and left) (1)
Page 361: Differential Adjustment
Manual Transmission: 5B-30 Differential Adjustment S5RS0B5206019 Adjust differential rotating torque to specified value below by tightening or loosening differential bearing retaining ring (1), using special tools. Maintain specified rotating torque at test speed of 1 revolution per second. Special tool (A): 09922–78610 (B): 09922–78620 Differential rotating torque...
Page 362: Tightening Torque Specifications
5B-31 Manual Transmission: Specifications Tightening Torque Specifications S5RS0B5207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Differential cover bolt 13.0 Transaxle oil level plug 4 N⋅m (0.4 kgf-m, 3.0 lb-ft) and 45° to 180° by the specified procedure Breather plug 4 N⋅m (0.4 kgf-m, 3.0 lb-ft) and 180°...
Page 363: Recommended Service Material
Manual Transmission: 5B-32 Special Tools and Equipment Recommended Service Material S5RS0B5208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 NOTE Required service material is also described in the following.
Page 364 5B-33 Manual Transmission: 09922–58610 09922–58620 Transaxle shaft installer Transaxle shaft installer KM-6338 KM-6337 09922–68610 09922–78610 Transaxle shaft thrust piece Friction coefficient meter KM-6335 MKM-536-A 09922–78620 09922–89810 Adapter Shifter lock pin remover (3.5 KM-6037 09924–07710 09924–07720 Synchronizer hub installer Synchronizer hub installer 09924–07730 09925–08610 Bearing installer...
Page 365 Manual Transmission: 5B-34 09926–28610 09926–58610 Oil seal installer Bearing remover KM-446 MKM-599...
Page 366: Clutch (Hydraulic Type) Construction
5C-1 Clutch: Clutch General Description Clutch (Hydraulic Type) Construction S5RS0B5301001 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. The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.
Page 367: Diagnostic Information And Procedures
Clutch: 5C-2 Diagnostic Information and Procedures Clutch System Symptom Diagnosis S5RS0B5304001 Condition Possible cause Correction / Reference Item Slipping Improper clutch pedal free travel Bleed air or replace master cylinder. Worn or oily clutch disc facing Replace disc. Warped disc, pressure plate or flywheel Replace disc, clutch cover or flywheel.
Page 368: Repair Instructions
5C-3 Clutch: Repair Instructions Clutch Pedal Inspection S5RS0B5306001 Cylinder Push Rod Play “A” 1) Press clutch pedal (1) gradually with finger, stop when slight increase of resistance is felt and measure how much pedal has moved (push rod play) as represented by “A” as shown. Push rod play “A”: Max.
Page 369: Clutch Fluid Pipe Removal And Installation
Clutch: 5C-4 Clutch Fluid Pipe and Hose Location S5RS0B5306004 I5RS0B530002-01 [A]: RH steering vehicle 3. Clutch reservoir hose 1. Master cylinder 4. Brake master cylinder reservoir 2. Clutch fluid pipe Clutch Fluid Pipe Removal and Installation Installation S5RS0B5306005 Reverse removal procedure for installation noting the following.
Page 370: Clutch Operating Cylinder Assembly Removal And Installation
(4). 5) Remove clutch operating cylinder assembly from transaxle front case. I4RS0B530005-01 3. Brake booster Installation Reverse removal procedure for installation noting the following. • Apply grease to push rod tip. “A”: Grease 99000–25100 (SUZUKI Silicone Grease) “A” I5RS0B530005-02 I4RS0B530006-01...
Page 371 Clutch: 5C-6 Installation 4) Remount transaxle assembly referring to “Manual Transaxle Unit Dismounting and Remounting: in 1) Install clutch operating cylinder assembly (2) to Section 5B”. transaxle front case. Tighten mounting bolts to specified torque. 5) Fill reservoir with specified brake fluid and check for fluid leakage.
Page 372 5C-7 Clutch: Clutch Pedal and Clutch Pedal Bracket Components S5RS0B5306009 I5RS0B530010-02 [A]: LH steering vehicle 7. Pedal shaft nut [B]: RH steering vehicle 8. Clutch pedal : Apply grease 99000-25010 to outside surface of pin. 1. Clutch pedal bracket 9. Pedal pad 2.
Page 373 Clutch: 5C-8 Clutch Cover and Clutch Disc Components S5RS0B5306010 I5RS0B530008-02 1. Clutch cover 3. Clutch cover bolt 2. Clutch disc : 15 N⋅m (1.5 kgf-m, 11.0 lb-ft) Clutch Cover and Clutch Disc Removal and Installation S5RS0B5306011 Removal 1) Dismount manual transaxle assembly referring to “Manual Transaxle Unit Dismounting and Remounting: in Section 5B”.
Page 374 2) Slightly apply grease to input shaft (1), then join manual transaxle assembly with engine referring to “Manual Transaxle Unit Dismounting and Remounting: in Section 5B”. “A”: Grease 99000–25210 (SUZUKI Super Grease I) NOTE When inserting transaxle input shaft to clutch disc, turn crankshaft little by little to match the splines.
Page 375: Tightening Torque Specifications
Clutch: 5C-10 Clutch Cover and Clutch Disc Inspection Clutch Cover S5RS0B5306012 1) Check diaphragm spring (1) for abnormal wear or damage. Clutch Disc 2) Inspect pressure plate (2) for wear or heat spots. Measure depth of rivet head depression, i.e. distance between rivet head and facing surface.
Page 376: Special Tools And Equipment
5C-11 Clutch: Special Tools and Equipment Recommended Service Material S5RS0B5308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Silicone Grease P/No.: 99000–25100 SUZUKI Super Grease I P/No.: 99000–25210 NOTE Required service material is also described in the following. “Clutch Pedal and Clutch Pedal Bracket Components: ”...
Page 377 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 service manual. Precautions ..........6-* Schematic and Routing Diagram ......6C-2 EPS System Wiring Circuit Diagram ....6C-2 Precautions..............
Page 378 6-ii Table of Contents Tie-Rod / Rack Boot Removal and Motor Assembly Inspection ......... 6C-* Installation ............6C-* Specifications .............6C-13 Steering Rack Plunger Removal and Tightening Torque Specifications......6C-13 Installation ............6C-* Special Tools and Equipment ......6C-14 Steering Rack Plunger Inspection....... 6C-* Recommended Service Material .......6C-14 P/S Control Module Removal and Special Tool ............6C-14...
Page 379: Power Assisted Steering System
Power Assisted Steering System: 6C-1 Power Assisted Steering System General Description P/S System Description S5RS0B6301001 This power steering (P/S) system consists of a P/S control module (3), a torque sensor (4), a motor (5). In this system, the P/S control module determines the level and direction of the assist force for the steering wheel (1) according to the signals from the torque sensor and the vehicle speed signal from ABS hydraulic unit / control module assembly (VSS) (right-front).
Page 380: Eps System Wiring Circuit Diagram
6C-2 Power Assisted Steering System: Schematic and Routing Diagram EPS System Wiring Circuit Diagram S5RS0B6302001 E49-2 E51-1 E49-1 E51-2 LT GRN/BLK E52-1 RED/BLK E52-18 G28-31 G28-25 E52-5 E52-6 E52-8 E52-4 E52-20 E52-9 E52-16 E52-12 E52-19 PPL/WHT E52-11 12 13 14 15 16 17 18 19 20 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 32 31 30 29 28 27...
Page 381: Dtc Table
Power Assisted Steering System: 6C-3 [A]: Connector “E52” (viewed from harness side) 4. Fuse 11. P/S control module [B]: Connector “E49” (viewed from harness side) 5. Vehicle speed signal 12. P/S motor [C]: Connector “E51” (viewed from harness side) 6. ABS hydraulic unit / control module 13.
Page 382 6C-4 Power Assisted Steering System: Detecting condition DTC No. Detecting item (DTC will set when detecting) P/S control module detects all the following conditions for 20 seconds or more 1 driving C1122 Engine speed signal circuit failure • Vehicle speed signal 50 km/h (31 mph) cycle or more •...
Page 383: Normal Condition
Power Assisted Steering System: 6C-5 Scan Tool Data TQS (Torque sensor) Sub Torque S5RS0B6304006 The torque sensor is installed to detect the steering force Scan tool data Normal condition and the steering direction. It consists of two potentiometers and the sub-torque sensor is one of 10 –...
Page 384: P/S System Symptom Diagnosis
6C-6 Power Assisted Steering System: P/S System Symptom Diagnosis S5RS0B6304007 This section describes trouble diagnosis of the P/S system parts whose trouble is not indicated by the on-board diagnostic system (self-diagnostic function). When no malfunction is indicated by the on-board diagnostic system (self-diagnosis function) and assuredly those steering basic parts as described in “Steering Symptom Diagnosis: in Section 6A”...
Page 385: Troubleshooting
Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check: ”. 1) Make sure that SUZUKI scan tool is free from Go to Step 3. Connect SUZUKI scan malfunction and that correct program card (software) for tool to DLC properly.
Page 386 6C-8 Power Assisted Steering System: DTC C1121 / C1123 / C1124: VSS Circuit Failure S5RS0B6304014 DTC C1121: VSS Circuit Signal Not Input (60 Seconds or More) DTC C1123: VSS Circuit Signal Not Input (30 Seconds or More) DTC C1124: VSS Circuit Failure (Abnormal Deceleration) Wiring Diagram E49-2 12 13 14 15 16 17 18 19 20...
Page 387: Dtc Troubleshooting
Power Assisted Steering System: 6C-9 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC C1121: • High resistance, open or short in vehicle speed signal No vehicle speed signal is inputted to P/S control module circuit in either one of the following two conditions •...
Page 388 6C-10 Power Assisted Steering System: DTC C1122: Engine Speed Signal Circuit Failure S5RS0B6304015 Wiring Diagram E49-2 E49-1 LT GRN/BLK E52-1 12 13 14 15 16 17 18 19 20 RED/BLU E52-14 E52-12 I4RS0B630008-02 [A]: Connector “E52” (viewed from harness side) 2.
Page 389: Inspection Of P/S Control Module And Its Circuits
Power Assisted Steering System: 6C-11 Inspection of P/S Control Module and Its Circuits S5RS0B6304019 The P/S control module (1) and its circuits can be checked at the P/S control module wiring couplers (2) by measuring voltage and resistance. CAUTION P/S control module cannot be checked by itself.
Page 390 6C-12 Power Assisted Steering System: Terminal Wire color Circuit Normal voltage Condition P/S control module power E49-1 10 – 14 V — supply from battery E49-2 Ground — — Engine idling and steering wheel at E51-1 Motor output 1 5 – 7 V straight position Engine idling and steering wheel at E51-2...
Page 391 Power Assisted Steering System: 6C-13 Specifications Tightening Torque Specifications S5RS0B6307001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Tie-rod end nut 32.5 Tie-rod end lock nut 32.5 Wheel bolt 61.5 Steering gear case mounting No.1 bolt 40.0 Steering gear case mounting No.2 bolt 40.0 Engine rear mounting bracket bolt Steering shaft joint bolt...
Page 392: Special Tools And Equipment
6C-14 Power Assisted Steering System: Special Tools and Equipment Recommended Service Material S5RS0B6308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease E P/No.: 99000–25050 Silicone sealant Silicone sealant P/No.: 99000–31120 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110...
Page 393 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 service manual. Precautions ..........7-* DTC B1556: Engine Speed Data Malfunction............7A-15 Precautions..............
Page 394 7-ii Table of Contents Air Filter Cleaning (If Equipped) ......7A-* Condenser Assembly Removal and Installation ............7B-* Specifications.............7A-23 Desiccant Removal and Installation ....7B-18 Tightening Torque Specifications......7A-23 HVAC Unit Components ........7B-19 Special Tools and Equipment ......7A-23 HVAC Unit Removal and Installation ....7B-20 Special Tool ............7A-23 Evaporator Inspection .........
Page 395: Heater And Ventilation
Heater and Ventilation: 7A-1 Heater and Ventilation General Description Heater and Ventilation Construction S5RS0B7101001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I5RS0B710001-02...
Page 396: Supplementary Heater System Description
7A-2 Heater and Ventilation: 1. HVAC unit 5. Side ventilation air 9. Fresh air 13. Blower motor 2. Ventilator duct 6. Foot air 10. Recirculation air 14. Resistance board 3. Defroster nozzle 7. Front defroster air 11. Center ventilation air 15.
Page 397: Supplementary Heater System Electronic Input / Output Table
• Supplementary heater relay DTC can be checked by SUZUKI scan tool connected to DLC (1). • Back-up power supply for supplementary heater controller Special tool •...
Page 398: Schematic And Routing Diagram
7A-4 Heater and Ventilation: Schematic and Routing Diagram Heater and Ventilation Wiring Circuit Diagram S5RS0B7102001 BLU/BLK G49-18 G49-19 YEL/BLU G49-7 PPL/WHT GRN/RED G49-9 BLU/RED GRN/WHT G49-8 BLU/YEL G49-15 RED/BLK WHT/RED G49-2 G49-16 G49-6 G49-5 GRY/RED G49-13 RED/WHT RED/BLK G49-1 G49-14 G49-12 BLK/YEL G49-3...
Page 399: Diagnostic Information And Procedures
Heater and Ventilation: 7A-5 Diagnostic Information and Procedures Heater and Ventilation Symptom Diagnosis S5RS0B7104001 Condition Possible cause Correction / Reference Item Blower motor does not Fuse blown Check related fuses, and then check for short operate with blower circuit to ground. speed selector ON.
Page 400: Dtc Check For Supplementary Heater System
DTC Check for Supplementary Heater System 3) Turn ignition switch to ON position. S5RS0B7104002 4) Check DTC with SUZUKI scan tool and print them or NOTE write them down. Refer to SUZUKI scan tool When checking DTC after connecting battery operator’s manual for further details.
Page 401: Scan Tool Data
Heater and Ventilation: 7A-7 Scan Tool Data S5RS0B7104005 As the data values given in the following are standard values estimated on the basis of values obtained from the normally operation 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 402: Dtc B1536: Supplementary Heater Relay No.1 Output Malfunction
7A-8 Heater and Ventilation: DTC B1536: Supplementary Heater Relay No.1 Output Malfunction S5RS0B7104006 Wiring Diagram BLU/BLK 10 9 8 7 6 5 4 3 2 1 G49-8 GRN/WHT 20 19 1817 16 15 1413 12 11 I5RS0B710006-01 1. Supplementary heater controller 2.
Page 403: Dtc B1537: Supplementary Heater Relay No.2 And No.3 Output Malfunction
Heater and Ventilation: 7A-9 DTC B1537: Supplementary Heater Relay No.2 and No.3 Output Malfunction S5RS0B7104007 Wiring Diagram BLU/RED BLU/YEL 10 9 8 7 6 5 4 3 2 1 GRN/RED G49-9 20 19 1817 16 15 1413 12 11 I5RS0B710007-01 1.
Page 404: Dtc B1541: Supplementary Heater Controller Back-Up Power Supply Malfunction
7A-10 Heater and Ventilation: DTC B1541: Supplementary Heater Controller Back-Up Power Supply Malfunction S5RS0B7104008 Wiring Diagram WHT/RED G49-2 10 9 8 7 6 5 4 3 2 1 20 19 1817 16 15 1413 12 11 I5RS0B710008-01 1. Supplementary heater controller 2.
Page 405: Dtc B1542: Blower Motor Power Supply Malfunction
Heater and Ventilation: 7A-11 DTC B1542: Blower Motor Power Supply Malfunction S5RS0B7104009 Wiring Diagram BLK/YEL G49-3 G49-11 BLK/WHT BLK/YEL BLK/WHT G19-6 G19-7 G19-1 BLU/WHT G19-3 G19-2 10 9 8 7 6 5 4 3 2 1 20 19 1817 16 15 1413 12 11 I5RS0B710009-01 1.
Page 406 7A-12 Heater and Ventilation: DTC Troubleshooting Step Action Wire harness check Substitute a known- Go to Step 2. good supplementary 1) Turn OFF ignition switch. heater controller and 2) Disconnect supplementary heater controller connector recheck. referring to “Supplementary Heater Controller Removal and Installation (If Equipped): ”.
Page 407: Dtc B1551: Serial Communication Circuit Malfunction
Heater and Ventilation: 7A-13 DTC B1551: Serial Communication Circuit Malfunction S5RS0B7104010 Wiring Diagram G37-11 G49-6 10 9 8 7 6 5 4 3 2 1 20 19 1817 16 15 1413 12 11 G37-10 G49-5 GRY/RED I5RS0B710010-03 1. Supplementary heater controller 2.
Page 408: Dtc B1552: Serial Communication Data Malfunction
7A-14 Heater and Ventilation: DTC B1552: Serial Communication Data Malfunction S5RS0B7104011 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Supplementary heater controller receives error data from BCM • BCM (included in junction block assembly) continuously. • Supplementary heater controller DTC Troubleshooting Step Action...
Page 409: Dtc B1556: Engine Speed Data Malfunction
Heater and Ventilation: 7A-15 DTC B1556: Engine Speed Data Malfunction S5RS0B7104013 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Supplementary heater controller receives error code from BCM • Engine speed signal from BCM continuously. • Supplementary heater controller DTC Troubleshooting Step Action...
Page 410: Dtc B1561: Engine Coolant Temperature Data Malfunction
7A-16 Heater and Ventilation: DTC B1561: Engine Coolant Temperature Data Malfunction S5RS0B7104016 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Supplementary heater controller receives error code from BCM • Engine coolant temperature signal continuously. • Supplementary heater controller DTC Troubleshooting Step Action...
Page 411: Inspection Of Supplementary Heater Controller And Its Circuit (If Equipped)
Heater and Ventilation: 7A-17 Inspection of Supplementary Heater Controller and Its Circuit (If Equipped) S5RS0B7104018 Supplementary heater controller and its circuits can be checked at supplementary heater controller wiring couplers by measuring voltage. CAUTION Supplementary heater controller can not be checked by itself. It is strictly prohibited to connect voltmeter to supplementary heater controller with connector disconnected from it.
Page 412 7A-18 Heater and Ventilation: Normal Terminal Wire Color Circuit Condition Voltage G49-1 RED/BLK Electric power source 10 – 14 V Ignition switch turned ON Electric power source for G49-2 WHT/RED 10 – 14 V Constantly back-up G49-3 BLK/YEL Blower motor input (+) 10 –...
Page 413: Repair Instructions
Heater and Ventilation: 7A-19 Repair Instructions HVAC Unit Components S5RS0B7106001 I5RS0B710012-01...
Page 414: Blower Motor Resistor Inspection
7A-20 Heater and Ventilation: 1. Fresh air inlet duct 7. Airflow control door assembly 13. Heater core 19. Cable lock clamp 2. Blower upper case 8. Temperature control door assembly 14. Temperature control lever 20. Air resistance board 3. Air intake control actuator 9.
Page 415: Supplementary Heater Removal And Installation (If Equipped)
Heater and Ventilation: 7A-21 Supplementary Heater Relay 4) Disconnect connectors from supplementary heater. 1) Remove front bumper referring to “Front Bumper 5) Remove supplementary heater (1) from HVAC unit and Rear Bumper Components: in Section 9K”. by removing screws (2). 2) Remove left side headlight housing referring to “Headlight Housing Removal and Installation: in Section 9B”.
Page 416: Supplementary Heater Controller Removal And Installation (If Equipped)
7A-22 Heater and Ventilation: Supplementary Heater Controller Removal and Max Hot Switch Removal and Installation (If Installation (If Equipped) Equipped) S5RS0B7106020 S5RS0B7106021 Removal Removal 1) Disconnect negative (–) cable from battery. 1) Detach accelerator pedal with connector connected. 2) Disable air bag system referring to “Disabling Air 2) Remove Max hot switch (1) from HVAC unit by Bag System: in Section 8B”.
Page 417: Air Intake Control Actuator Removal And Installation
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information: in Section 0A”. Special Tools and Equipment Special Tool S5RS0B7108001 SUZUKI scan tool — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5.
Page 418: Air Conditioning System
7B-1 Air Conditioning System: Air Conditioning System Precautions Precautions on Servicing A/C System S5RS0B7200002 WARNING Should refrigerant HFC-134a (R-134a) is exposed to your eye(s), consult a doctor immediately. • Do not use your hand to rub affected eye(s). Instead, use fresh cold water to splash it over affected area to thus gradually raise its temperature above the freezing point.
Page 419: General Description
Air Conditioning System: 7B-2 • Check local governmental regulations regarding working with refrigerator systems and its tooling. • Route drain hose so that drained water does not make any contact to vehicle components. • If pipes or hoses are replaced, replenish specified amount of compressor oil to compressor suction side referring to “Replenishing Compressor Oil”...
Page 420: A/C Operation Description
7B-3 Air Conditioning System: [A]: Liquid 2. Magnet clutch 6. Expansion valve 10. Desiccant [B]: Vapor 3. Condenser 7. A/C evaporator 11. Cap with filter [C]: Superheated vapor 4. Receiver/dryer (Modulator) 8. Condensation part 12. Vapor refrigerant 1. Compressor 5. Refrigerant pressure sensor 9.
Page 421 Air Conditioning System: 7B-4 BLK/YEL BLK/WHT G19-6 G19-7 G19-1 RED/BLK BLU/WHT G19-3 G19-2 G19-5 BRN/WHT G18-6 G18-5 GRN/WHT RED/BLK G18-14 G18-13 G18-9 G18-10 BLK/ORN G18-8 BLK/RED G18-7 RED/YEL G18-4 G18-3 E62-64 E62-40 BLK/YEL BRN/WHT E62-80 BLK/YEL BLK/RED BLK/RED E62-4 BLK/YEL E62-6 BLK/RED E62-79...
Page 422: Diagnostic Information And Procedures
7B-5 Air Conditioning System: Diagnostic Information and Procedures A/C System Symptom Diagnosis S5RS0B7204001 Condition Possible cause Correction / Reference Item No cool air comes out (A/ No refrigerant Perform recovery, evacuation and charge C system does not referring to “Operation Procedure for operate) Refrigerant Charge: ”.
Page 423 Air Conditioning System: 7B-6 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 “Condenser operation) Assembly On-Vehicle Inspection: ”.
Page 424: Abnormal Noise Symptom Diagnosis Of A/C System
7B-7 Air Conditioning System: Abnormal Noise Symptom Diagnosis of A/C System S5RS0B7204002 Abnormal Noise from Compressor Condition Possible cause Correction / Reference Item During compressor Inadequate clearance in scroll area Replace compressor. operation, a rumbling noise is heard proportional to engine revolutions A loud noise is heard at a Loose or faulty compressor drive belt...
Page 425: A/C System Performance Inspection
Air Conditioning System: 7B-8 Abnormal Noise from A/C Evaporator Condition Possible cause Correction / Reference Item Whistling sound is heard Depending on the combination of the At times, slightly decreasing refrigerant volume from A/C evaporator interior / exterior temperatures, engine may stop this noise.
Page 426 7B-9 Air Conditioning System: NOTE 5) Warm up engine to the normal operating temperature and keep it at the specified idle speed. Pressure registered on gauge varies with 6) Turn A/C switch ON, set blower speed selector at ambient temperature. Therefore, use the maximum speed position, temperature selector at graphs when determining if pressures are maximum cold position, airflow selector at face...
Page 427 Air Conditioning System: 7B-10 Low pressure gauge Condition Possible cause Correction Pressure is higher than Expansion valve malfunction (valve opens too Check expansion valve. acceptable range wide) (“C” area) Compressor malfunction (Insufficient Check compressor. compression) Pressure is lower than Insufficient refrigerant (Insufficient charge or Check for leakage, repair if necessary acceptable range leakage)
Page 428 7B-11 Air Conditioning System: Thermometer at center duct Condition Possible cause Correction Crossing point is higher Insufficient or excessive charge of refrigerant Check refrigerant pressure. than acceptable range Dirty or bent A/C evaporator fins Clean or repair. (“E” area) Air leakage from cooling (heater) unit or air duct Repair or replace.
Page 429 Air Conditioning System: 7B-12 Condition Manifold gauge MPa (kg/cm ) (psi) Possible cause Correction Detail 0.40 – 0.45 2.0 – 2.5 High pressure reading on Overcharged A/C Adjust refrigerant to (4.0 – 4.5) (20 – 25) both low and high pressure system.
Page 430: Repair Instructions
7B-13 Air Conditioning System: Repair Instructions Operation Procedure for Refrigerant Charge S5RS0B7206001 WARNING • Your eyes should not be exposed to refrigerant (liquid). Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately – 6 °C (21.2 °F) below freezing point. Should liquid HFC-134a (R-134a) is exposed to your eyes, it may cause a serious injury.
Page 431 Air Conditioning System: 7B-14 Recovery When charging refrigerant only When discharging refrigerant out of A/C system, always When charging refrigerant without replacing any recover it by using refrigerant recovery and recycling component, replenish the same amount of measured oil equipment because discharging refrigerant HFC-134a when recovering refrigerant (if not measure, replenish 30 (R-134a) into atmosphere would cause adverse effect to (30 cc) oil).
Page 432 7B-15 Air Conditioning System: Evacuation 5) Evacuation should be carried out for a total of at least 15 minutes. CAUTION 6) Continue evacuation until low pressure gauge Do not evacuate before recovering indicates a vacuum less than –100 kPa (–1.0 kg/cm refrigerant in A/C system.
Page 433 Air Conditioning System: 7B-16 Charge The initial charge of the A/C system is performed through the high pressure side with the engine stopped. CAUTION And next, this method must be followed by charging from the low pressure side with the engine running. •...
Page 434 7B-17 Air Conditioning System: 8) After the system has been charged with specified 7) When refrigerant container (1) is emptied, use the amount (370 ± 20 g) of refrigerant or when low following procedure to replace it with a new refrigerant container.
Page 435: Condenser Assembly Removal And Installation
Air Conditioning System: 7B-18 Check A/C System for Refrigerant Leaks Desiccant Removal and Installation Whenever a refrigerant leak is suspected in the system S5RS0B7206004 Removal or any service operation has been performed which may 1) Remove condenser assembly referring to result in malfunction of lines and connections, it is “Condenser Assembly Removal and Installation: ”.
Page 436: Hvac Unit Components
7B-19 Air Conditioning System: HVAC Unit Components S5RS0B7206005 I5RS0B720010-01...
Page 437: Hvac Unit Removal And Installation
Air Conditioning System: 7B-20 1. Fresh air inlet duct 8. Temperature control door assembly 15. Airflow control lever 22. Drain hose 2. Blower upper case 9. Blower motor resistor 16. Evaporator 23. Cable lock clamp 3. Air intake control actuator 10.
Page 438: Compressor Relay Inspection
7B-21 Air Conditioning System: Compressor Relay Inspection Removal S5RS0B7206015 1) Run engine at idle speed with A/C ON for 10 1) Disconnect negative (–) cable from battery. minutes. 2) Remove compressor relay (1) from main fuse box. 2) Stop the engine. 3) Check that there is no continuity between terminal 3) Disconnect negative (–) cable from battery.
Page 439: Magnet Clutch Inspection
Air Conditioning System: 7B-22 Magnet Clutch Inspection Relief Valve Inspection S5RS0B7206020 S5RS0B7206024 By using special tool, check if there is refrigerant • Check armature plate and magnet clutch pulley for leakage. wear and oil soak respectively. If there is refrigerant leakage, replace the compressor •...
Page 440: Special Tools And Equipment
7B-23 Air Conditioning System: Special Tools and Equipment Recommended Service Material S5RS0B7208001 Material SUZUKI recommended product or Specification Note Compressor oil Compressor oil (SP10) P/No.: 99000–990C5– NOTE Required service material is also described in the following. “Precautions on Servicing A/C System: ”...
Page 441: Body, Cab And Accessories
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 service manual. Precautions ..........
Page 442 9-ii Table of Contents A-4 Cooling System Circuit Diagram (DSL) ..9A-57 O Connector............9A-127 A-5 Engine and A/C Control System Circuit R Connector ............9A-127 Diagram (Petrol)..........9A-58 Lighting Systems........9B-* A-5 Engine and A/C Control System (DSL) ..9A-63 A-6 A/T Control System Circuit Diagram...9A-68 Component Location ...........
Page 443 Table of Contents 9-iii Front Fog Light Aiming Adjustment with VSS Inspection............9C-5 Screen (If Equipped) ..........9B-* Brake Fluid Level Switch Inspection ....9C-* Headlight Levering Switch (If Equipped) Parking Brake Switch Inspection......9C-* Inspection............9B-* Door Switch (Front / Rear Door) Inspection ..9C-* Headlight Leveling Actuator Inspection (If Rear End Door Switch Inspection .......
Page 444 9-iv Table of Contents Rear End Door Window Defogger System Power Door Lock System Symptom Description ............9E-* Diagnosis ............9F-* Windshield Construction ........9E-* Power Door Lock System Operation Rear Quarter Window Construction ....9E-* Inspection............9F-* Keyless Entry System Symptom Diagnosis Diagnostic Information and Procedures....
Page 445 Table of Contents 9-v Specifications............9H-* Body Structure..........9K-* Tightening Torque Specifications......9H-* Repair Instructions ..........9K-* Front Bumper and Rear Bumper Hood / Fenders / Doors ......9J-* Components............9K-* Repair Instructions ..........9J-* Cowl Top Components........9K-* Hood Removal and Installation ......9J-* Specifications ............
Page 446: Precautions
SUZUKI dealer. Observe all the much as possible. If necessary, protect the wiring warnings of the “Air Bag System” and harness by winding tape or the like around on it.
Page 447: General Description
Wiring Systems: 9A-2 General Description Abbreviations S5RS0B9101002 Abbreviation Full term Abbreviation Full term 2 wheel drive vehicles Illumination 4 wheel drive vehicles Indicator Air bag Intermittent Air conditioning Idle speed control Automatic transaxle Junction block Accessory Joint connector Body control module Left Controller area network Light emitting diode...
Page 448: Symbols And Marks
9A-3 Wiring Systems: Symbols and Marks S5RS0B9101004 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 IYSQ01910928-01 Buzzer Chime...
Page 449: How To Read Connector Layout Diagram
Wiring Systems: 9A-4 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 450: How To Read Connector Codes And Terminal Nos
9A-5 Wiring Systems: L26 (TO O01) Connector code L 36 [A-1] [A-2] L01 (TO G01) L02 (TO E04) L03 (TO E05) L07 (TO K02) I2RH01910901-01 How to Read Connector Codes and Terminal Nos. S5RS0B9101006 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.
Page 451 Wiring Systems: 9A-6 2) Connector type I2RH01910903-01 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 452: Cross-Reference
9A-7 Wiring Systems: 5) 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 453: How To Read Ground Point
Wiring Systems: 9A-8 How to Read Ground Point S5RS0B9101007 Refer to “System Circuit Diagram: ”. Refer to “Ground (earth) 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...
Page 454: How To Read Power Supply Diagram
9A-9 Wiring Systems: How to Read Power Supply Diagram S5RS0B9101008 Refer to “Power Supply Diagram (Petrol): ”. 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...
Page 455 Wiring Systems: 9A-10 [D]: Terminals-in-one-connector mark [E]: Wire color [F]: Shield wire [G]: Ground point [H]: “From” or “To” (With ID letter (s)) [I]: Specification variation The white arrow between A and B means “or”. [J]: “From” (With ID letter (s)) [K] “To”...
Page 456: Harness Routing And Connector Layout Diagram
9A-11 Wiring Systems: Harness Routing and Connector Layout Diagram Connector Layout Diagram S5RS0B910A001 Refer to “Engine Compartment: ”. Refer to “Instrument Panel: ”. Refer to “Door, Roof: ”. Refer to “Floor: ”. Refer to “Rear: ”. Engine Compartment S5RS0B910A002 A: Battery cable / C: Engine harness (MT, AT) (M15A) (A/T) (M/T)
Page 457 Wiring Systems: 9A-12 No./Color Connective position No./Color Connective position C08/BLK or C28/GRY CMP sensor Trans axle range sensor (A/T) C29/GRY C09/GRN ECT sensor Shift solenoid (A/T) C30/BLK C10/GRY EGR stepper motor Back-up light switch (M/T) C11/BLK Throttle position sensor C31/- Main fuse box C12/BLK MAP sensor...
Page 458: C: Engine Harness (Dsl)
9A-13 Wiring Systems: No./Color Connective position No./Color Connective position C05/GRY Injector #2 C33/- Main fuse box C06/GRY Injector #3 C36/N Main harness (To E24) C07/GRY Injector #4 C37/GRY ECM C08/GRY CMP sensor C38/- Weld splice C09/GRN ECT sensor C39/- Weld splice C10/GRY EGR stepper motor C40/- Weld splice...
Page 459: D: Injector Harness (Dsl)
Wiring Systems: 9A-14 D: Injector harness (DSL) D03 D14 D06 D15 D05 (TO E63) (TO E69) I5RS0B910902-02 D: Injector harness No./Color Connective position No./Color Connective position ECT sensor Main harness (To E63) Fuel pressure regulator Main harness (To E69) Fuel pressure sensor Injector #1 Oil level switch Injector #2...
Page 460: E: Main Harness (Rhd) (Petrol)
9A-15 Wiring Systems: E: Main harness (RHD) (Petrol) (TO C36) (TO C53) I5RS0B910903-05 E: Main harness No./Color Connective position No./Color Connective position E01/GRY Windshield wiper motor E22/N Front position light (L) E02/BRN Brake fluid level switch E23/GRY ECM E03/BLK ABS control module E24/N Engine Harness (To C36) E04/BLK...
Page 461: E: Main Harness (Lhd) (Petrol)
Wiring Systems: 9A-16 E: Main harness (LHD) (Petrol) (TO C36) (TO C53) I5RS0B910904-04 E: Main harness No./Color Connective position No./Color Connective position E01/GRY Windshield wiper motor E22/N Front position light (L) E02/BRN Brake fluid level switch E23/GRY ECM E03/BLK ABS control module E24/N Engine Harness (To C36) E04/BLK...
Page 462: E: Main Harness (Rhd) (Dsl)
9A-17 Wiring Systems: E: Main harness (RHD) (DSL) S5RS0B910A007 (TO D12) 7 23 24 (TO C60) E05 E04 E27 E26 (TO D13) I5RS0B910973-01 E: Main harness No./Color Connective position No./Color Connective position E01/GRY Windshield wiper motor E27/BRN Main fuse box E02/BRN Brake fluid level switch E28/BLK...
Page 463: E: Main Harness (Lhd) (Dsl)
Wiring Systems: 9A-18 E: Main harness (LHD) (DSL) S5RS0B910A008 (TO D12) (TO C60) E05 E04 (TO D13) I5RS0B910972-02 E: Main harness No./Color Connective position No./Color Connective position E01/GRY Windshield wiper motor E30/BLK Radiator fan relay #3 E02/BRN Brake fluid level switch E31/BLK Starting motor relay E03/BLK...
Page 464: Instrument Panel
9A-19 Wiring Systems: No./Color Connective position No./Color Connective position E28/BLK Radiator fan relay #1 E80/- BLANK E29/BLK Radiator fan relay #2 E81/- BLANK Instrument Panel S5RS0B910A003 E: Main harness and power steering wire (RHD) (DSL) (TO G35) (TO G36) Power steering wire (TO L03) (TO L02) I5RS0B910905-03...
Page 465: E: Main Harness And Power Steering Wire (Lhd)
Wiring Systems: 9A-20 E: Main harness and power steering wire (LHD) (DSL) (DSL) (DSL) (TO G35) (TO G36) (DSL) (DSL) Power steering wire E54 E53 E49 E51 E52 (TO L02) (TO L03) I5RS0B910906-01 E: Main harness No./Color Connective position No./Color Connective position E37/GRY Instrument panel harness (To G35) E46/BLU...
Page 466: G: Instrument Panel Harness (Rhd)
9A-21 Wiring Systems: G: Instrument panel harness (RHD) (TO E37) (TO E38) (TO L51) (Petrol) (Petrol) (TO L33) (TO L32) I5RS0B910907-04 G: Instrument panel harness No./Color Connective position No./Color Connective position G01/YEL Fresh / Recircle actuator G23/BLK COMB switch G02/N Keyless receiver G24/BLK G03/N...
Page 467 Wiring Systems: 9A-22 G: Instrument panel harness (LHD) (Petrol) (DSL) (DSL) (DSL) (TO E37) (TO E38) (TO L51) (DSL) (Petrol) (TO L32) (TO L33) I5RS0B910908-04 G: Instrument panel harness No./Color Connective position No./Color Connective position G01/YEL Fresh / Recircle actuator G26/YEL Driver inflator G02/N...
Page 468: Door, Roof
9A-23 Wiring Systems: Door, Roof S5RS0B910A004 J: Front and rear door wire and rear door joint wire / K: Roof wire (RHD) (TO L37) (TO L07) (TO L13) (TO L31) I4RS0B910910-03 J: Front door wire (Drive side) No./Color Connective position No./Color Connective position J01/N...
Page 469: J: Front And Rear Door Wire And Rear Door Joint Wire
Wiring Systems: 9A-24 J: Front and rear door wire and rear door joint wire / K: Roof wire (LHD) (TO L37) (TO L31) (TO L13) (TO L07) I4RS0B910911-03 J: Front door wire (Drive side) No./Color Connective position No./Color Connective position J01/N Floor harness (To L07) J06/N...
Page 470: Floor
9A-25 Wiring Systems: Floor S5RS0B910A005 L: Floor harness, ACC socket wire, License plate wire / R: Fuel pump wire (RHD, 5dr) IF EQPD (TO J09) (TO G03) (TO G43) (TO J21) (TO G04) (##) (A/T) (TO E45) (TO E44) (TO O01) (TO J01) (##) Licence...
Page 471: R: Fuel Pump Wire (Rhd, 5Dr)
Wiring Systems: 9A-26 L: Floor harness No./Color Connective position No./Color Connective position L01/BLU L27/BLK Parking brake switch L02/N Main harness (To E45) L29/PNK A/B SDM L29/BRN (With Side A/B, L03/YEL Main harness (To E44) A/B SDM Curtain A/B System) L30/YEL (IF L04/YEL Side air-bag inflator (Passenger side) EQPD)
Page 472: L: Floor Harness, Acc Socket Wire, License Plate Wire
9A-27 Wiring Systems: L: Floor harness, ACC socket wire, License plate wire / R: Fuel pump wire (LHD, 5dr) IF EQPD (TO J01) (TO J21) (TO E44) (A/T) 17 18 (TO E45) (TO G04) (TO O01) (TO G43) (TO G03) (##) (TO J09) (##)
Page 473: R: Fuel Pump Wire (Lhd, 5Dr)
Wiring Systems: 9A-28 L: Floor harness No./Color Connective position No./Color Connective position L29/BRN (With Side A/B, L01/BLU A/B SDM Curtain A/B System) L30/YEL (IF L02/N Main harness (To E45) Side air-bag inflator (Passenger side) EQPD) L03/YEL Main harness (To E44) L31/N Front door wire (Passenger side) (To J09) L04/YEL...
Page 474 9A-29 Wiring Systems: L: Floor harness, ACC socket wire, License plate wire / R: Fuel pump wire (RHD, 3dr) IF EQPD (TO G03) (TO G43) (TO J09) (TO G04) (##) (A/T) (TO E45) (TO E44) (TO O01) (TO J01) (##) Licence (##) plate...
Page 475: R: Fuel Pump Wire (Rhd, 3Dr)
Wiring Systems: 9A-30 L: Floor harness No./Color Connective position No./Color Connective position L01/BLU L29/PNK A/B SDM L29/BRN (With Side A/B, L02/N Main harness (To E45) A/B SDM Curtain A/B System) L30/YEL (IF L03/YEL Main harness (To E44) Side air-bag inflator (Passenger side) EQPD) L04/YEL L31/N...
Page 476: L: Floor Harness, Acc Socket Wire, License Plate Wire
9A-31 Wiring Systems: L: Floor harness, ACC socket wire, License plate wire / R: Fuel pump wire (LHD, 3dr) IF EQPD (TO J01) (TO E44) (A/T) (TO E45) (TO G04) (TO O01) (TO G43) (TO G03) (##) (TO J09) (##) Licence (##) plate...
Page 477: R: Fuel Pump Wire (Lhd, 3Dr)
Wiring Systems: 9A-32 L: Floor harness No./Color Connective position No./Color Connective position L30/YEL (IF L01/BLU Side air-bag inflator (Passenger side) EQPD) L02/N Main harness (To E45) L31/N Front door wire (Passenger side) (To J09) L03/YEL Main harness (To E44) L32/YEL Instrument panel harness (To G04) L04/YEL L33/N...
Page 478: Rear
9A-33 Wiring Systems: Rear S5RS0B910A006 O: Rear end door harness, Rear defogger wire Rear defogger wire (TO L42) I4RS0A910970-01 O: Rear end door harness No./Color Connective position No./Color Connective position O01/N Floor harness (To L42) O04/N Rear end door lock solenoid O02/BLK Rear defogger (+) O05/GRN...
Page 479: Ground Point
Wiring Systems: 9A-34 Ground Point Ground (earth) Point S5RS0B910C001 Refer to “Connector Layout Diagram: ”. RHD Shown (RH) 11 12 (LH) 15 16 25 26 DSL LHD (LH) LHD Shown (RH) Petrol 7 21 23 24 (RHD) 7 21 Petrol I5RS0B910913-01...
Page 480: Power Supply Diagram
9A-35 Wiring Systems: Power Supply Diagram Power Supply Diagram (Petrol) S5RS0B910D001 Generator "A-2" Battery Main fuse box BLK/GRY WHT/BLU Starting motor "A-1" J/B (E40- "Junction Block Inner circuit" Individual circuit fuse box BLU/YEL WHT/BLU WHT/GRN WHT/RED BLK/YEL YEL/BLU WHT/RED YEL/BLU WHT/BLU WHT/BLU J/B (E39-...
Page 481: Power Supply Diagram (Dsl)
Wiring Systems: 9A-36 Power Supply Diagram (DSL) S5RS0B910D009 Generator "A-2" Battery Main fuse box 100A BLK/GRY Starting Glow Fuel heating PTC relay #1 PTC relay #2 PTC relay #3 J/B (E40- motor controller relay "E-2" "E-2" "E-2" "Junction Block "A-1" "A-5"...
Page 482: Fuses And The Protected Parts
9A-37 Wiring Systems: Fuses and the Protected Parts S5RS0B910D002 The chart below describes what parts each fuse protects. Fuses in Main Fuse Box (Petrol) S5RS0B910D003 I4RS0B910974-01 Fuses in Main Fuse Box (DSL) S5RS0B910D010 I5RS0B910916-01 Fuse Protected circuit All electric circuit 80 A Battery Generator...
Page 483: Individual Circuit Fuse Box No. 1 (Petrol)
Wiring Systems: 9A-38 Individual Circuit Fuse Box No. 1 (Petrol) S5RS0B910D004 Automated Manual Transaxle Starting Throttle motor motor Compressor Relay #1 relay relay Main relay Relay Relay Relay "E-1" "A-5" "A-4" "A-1" "A-9" "A-5" "D-3" A/T relay Relay #2 "A-4" "A-6"...
Page 484: Individual Circuit Fuse Box No. 3 (Dsl)
9A-39 Wiring Systems: Fuse Description on the cover Protected circuit 30 A HTR FAN Heater relay 20 A Main relay 10 A A/C CPRSR A/C compressor relay 15 A AT ETM A/T relay 15 A STOP LAMP Brake light switch 30 A ABS MOT ABS control module...
Page 485 Wiring Systems: 9A-40 Individual Circuit Fuse Box No. 2 (In J/B) S5RS0B910D005 USE THE DESINGNATED FUSES AND RELAYS ONLY. *1: DEICER / RR FOG *2: DIESEL / HID L *3: MTA / HID R I5RS0B910919-02 Fuse Description on the cover Protected circuit BLANK BLANK...
Page 486 9A-41 Wiring Systems: Fuse Description on the cover Protected circuit COMB switch Rear washer motor Rear wiper motor 15 A WIPER Rear wiper relay Windshield washer motor Windshield wiper motor DRL controller A/T relay (A/T) Power steering control module 10 A IG1 SIG Automated Manual Transaxle control module Brake light switch...
Page 487: Junction Block (J/B) Connector / Fuse Layout
Wiring Systems: 9A-42 Junction Block (J/B) Connector / Fuse Layout S5RS0B910D006 BCM side BCM (J/B side connector) 10 11 1213 19 20 2122 23 22 21 2019 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 12 11 14 13 10 9...
Page 488: Fuse Side
9A-43 Wiring Systems: Fuse side Heater relay 3 4 5 6 Relay 6 5 4 3 Relay Relay 5 6 7 8 9 10 10 9 8 7 6 5 1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1 12 13 14 15 16 17 18 16 15 14...
Page 489: Junction Block Inner Circuit (Overview)
Wiring Systems: 9A-44 Junction Block Inner Circuit (Overview) S5RS0B910D007 * : Not used To instrument panel harness To roof harness (G32) (K01) To instrument panel harness (G33 , G34 ) To main RR FOG SW harness DEF LP (E40) TAIL SW (Upper) TAIL SW (HAZ,ASH,ILL) Lamp FL (FL BOX) TURN-L...
Page 490: Junction Block Inner Circuit (Detail)
9A-45 Wiring Systems: Junction Block Inner Circuit (Detail) S5RS0B910D008 Connector No. / Terminal No. K01 L04 IMMOBI IG IG COIL IG Coil, etc BCM ;IG1 METER MTR Power, etc A/B CONT A/BAG K-LINE K-LINE A/B SIGNAL A/B SIGNAL A/B SIG A/B SIG AUTOMATED MANUAL TRANSAXLE EPS AT...
Page 491 Wiring Systems: 9A-46 (Continued) Connector No. / Terminal No. K01 L04 Serial OUT Serial INF DISP HORN RELAY HORN HORN SW SECURITY IN ANSWER BACK HAZARD SW METER (R) Flasher Relay FR TURN (R) GND SW-L SW-R LP-L LP-R RR-TURN (R) METER (L) FR TURN (L) R-TURN (L)
Page 492 9A-47 Wiring Systems: (Continued) Connector No. / Terminal No. K01 L04 DEF LP HTR MIR (R) HTR MIR (L) RR-DEF RLY RR DEF RR DEF RR DEF CONTROL RR FOG SW DEICER LP DEICER DEICER / RR FOG DEICER DEICER CONTROL MTA / AUTOMATED MANUAL TRANSAXLE...
Page 493 Wiring Systems: 9A-48 (Continued) Connector No. / Terminal No. K01 L04 ACC SW ACC (BCM) ACC 1 R/C MIR (ACC) CIGAR RADIO, CLOCK ACC 2 ACC SOCKET IG2FL IG2SW R-WIP (CONT) R-WIP RLY R-WIP (-) R-WIP (+) F-Washer F-WIP WIPER F-WIP SEAT HTR SEAT HEATER...
Page 494 9A-49 Wiring Systems: (Continued) Connector No. / Terminal No. K01 L04 HEATER RLY IG2 SIG HTR Fuse (30A) Starter SW ST SIG ST RLY COIL POWER GND GND (IP) GND (Roof) Individual circuit fuse box No.2 (In J/B) GND (POWER) SIGNAL BCM SIG GND GND (BCM)
Page 495: System Circuit Diagram
Wiring Systems: 9A-50 System Circuit Diagram System Circuit Diagram S5RS0B910E001 Refer to “A-1 Cranking System Circuit Diagram (Petrol): ”. Refer to “A-1 Cranking System Circuit Diagram (DSL): ”. Refer to “A-2 Charging System Circuit Diagram (Petrol): ”. Refer to “A-2 Charging System Circuit Diagram (DSL): ”. Refer to “A-3 Ignition System Circuit Diagram (Petrol): ”.
Page 496 9A-51 Wiring Systems: A-1 Cranking System Circuit Diagram (Petrol) S5RS0B910E002 ST MOT LOCK Individual circuit fuse box (No.1) GRN/WHT Battery ST SIG ST SIG RED/WHT BLK/GRY RED/WHT RED/WHT M/T,A/T Starting motor Neutral relay switch YEL/GRN (##) YEL/GRN "A-5" Transaxle M/T, Automated range sensor Manual Transaxle Automated Manual...
Page 497 Wiring Systems: 9A-52 A-1 Cranking System Circuit Diagram (DSL) S5RS0B910E040 ST MOT LOCK Individual circuit fuse box (No.1) GRN/WHT Battery ST SIG RED/WHT Starting motor relay Starting motor I5RS0B910922-01...
Page 498: Charging System Circuit Diagram (Petrol)
9A-53 Wiring Systems: A-2 Charging System Circuit Diagram (Petrol) S5RS0B910E003 IG COIL Main fuse box BLK/WHT "A-8" WHT/BLU WHT/BLU BLK/WHT Weld splice BLK/WHT Generator regulator I5RS0B910965-01...
Page 499: Charging System Circuit Diagram (Dsl)
Wiring Systems: 9A-54 A-2 Charging System Circuit Diagram (DSL) S5RS0B910E041 Main fuse box "A-8" WHT/BLU WHT/BLU Generator regulator I5RS0B910923-02...
Page 500: Ignition System Circuit Diagram (Petrol)
9A-55 Wiring Systems: A-3 Ignition System Circuit Diagram (Petrol) S5RS0B910E004 IG COIL BLK/WHT BLK/WHT GRN/WHT Weld splice BLK/WHT GRN/YEL BLK/WHT IG COIL #2 IG COIL #1 I4RS0A910917-01...
Page 501: Cooling System Circuit Diagram (Petrol)
Wiring Systems: 9A-56 A-4 Cooling System Circuit Diagram (Petrol) S5RS0B910E005 RDTR Individual circuit fuse box (No.1) BLK/YEL BLK/YEL Main relay "A-5" BLK/RED Relay #1 Relay #2 Relay #3 BRN/WHT BLU/BLK LT GRN BLU/RED BLU/RED BLU/RED BLU/RED "A-5" BLU/WHT I5RS0B910924-02...
Page 502: Cooling System Circuit Diagram (Dsl)
9A-57 Wiring Systems: A-4 Cooling System Circuit Diagram (DSL) S5RS0B910E042 Individual circuit RDTR fuse box (No.1) Relay #1 Relay #2 Relay #3 BLU/BLK WHT/GRN BLU/WHT LT GRN BLU/RED "A-5" "A-5" "A-5" I5RS0B910925-01...
Page 503: Engine And A/C Control System Circuit Diagram (Petrol)
Wiring Systems: 9A-58 A-5 Engine and A/C Control System Circuit Diagram (Petrol) S5RS0B910E006 Individual circuit IG COIL COMP fuse box (No.1) BLK/YEL BLK/WHT Main relay BLU/YEL BLK/RED BLK/RED E24 C36 BLK/RED BRN/WHT BLK/WHT Weld splice Compressor Relay relay BLK/RED BLK/RED GRN/WHT BLK/WHT BLK/WHT BLK/WHT...
Page 504 9A-59 Wiring Systems: Individual circuit RDTR fuse box (No.1) Weld splice E24 C36 BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED YEL/BLU BLK/RED BLK/RED BLK/RED EVAP Throttle canister motor purge relay valve Relay #1 BLU/ORN RED/YEL LT GRN BLU/RED BLU/BLK BLU/YEL BLU/WHT BLU/GRN BLU/RED "A-4"...
Page 505 Wiring Systems: 9A-60 M13A M15A Weld splice BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED BLK/RED Vehicle speed sensor sensor sensor valve stepper RED/WHT motor RED/YEL BLK/ORN BLK/ORN BLK/ORN GRN/ORN GRN/RED WHT/RED BRN/YEL "A-6" WHT/BLK BLU/WHT BLK/ORN BLK/ORN BLK/ORN BLK/ORN BLU/WHT GRY/RED Heater fan WHT/BLK switch Weld splice...
Page 506 9A-61 Wiring Systems: RADIO Transaxle range sensor "A-1" Cont.M Starting motor Brake light switch relay "A-7" "F-3" "D-7" "A-1" M/T, Starting motor Automated relay Manual RED/BLU YEL/BLK GRN/WHT WHT/RED WHT/RED YEL/RED "A-1" Transaxle WHT/RED GRN/WHT YEL/GRN PPL/WHT GRN/WHT GRN/YEL BLK/ORN Navigation WHT/RED "G-4"...
Page 507 Wiring Systems: 9A-62 Automated Manual Transaxle Throttle position sensor Throttle sensor Acceleration pedal sensor MAIN MAIN close open close open close open close open Throttle motor LT GRN/RED LT GRN/BLK Relay #2 Relay #3 "A-4" GRY/BLU PPL/WHT ##: Automated Manual Transaxle (##) Automated Manual Transaxle Automated...
Page 508: Engine And A/C Control System (Dsl)
9A-63 Wiring Systems: A-5 Engine and A/C Control System (DSL) S5RS0B910E043 Individual Main circuit STOP fuse fuse box (No.1) BLK/WHT BLK/WHT Glow controller Brake light switch GRY/BLU GRN/WHT GRN/YEL GRN/WHT Diesel engine control circuit GRN/RED GRN/RED LT GRN/BLK RED/YEL A/C pressure sensor POT1 POT2 Acceleration pedal sensor...
Page 509 Wiring Systems: 9A-64 Individual circuit fuse (No.1) "A-4" "C-3" BLK/WHT LT GRN/RED BLK/YEL GRN/BLK BLU/BLK Relay #1 "A-4" controller "D-1" Main relay Relay Relay #2 LT GRN BLU/BLK GRN/BLK BRN/WHT BLK/RED BLU/BLK valve BLK/RED "A-4" (Fuel) "C-1" YEL/RED YEL/RED YEL/RED BLK/ORN BLK/ORN YEL/RED...
Page 510 9A-65 Wiring Systems: Main fuse coil BLK/WHT BLK/WHT Fuel temperature sensor Fuel heating relay BLK/WHT BLK/YEL BLU/ORN YEL/BLU BLK/WHT Clutch switch RED/BLU YEL/GRN Diesel engine control circuit I5RS0B910930-02...
Page 511 Wiring Systems: 9A-66 Individual circuit RADIO DIESEL fuse (No.1) BLK/WHT BLU/YEL BLK/ORN WHT/RED PPL/WHT PPL/WHT PPL/WHT PPL/WHT Compressor relay Compressor level CMP sensor Fuel pressure sensor Boost pressure sensor switch Diesel engine control circuit BLK/ORN I5RS0B910931-04...
Page 512 9A-67 Wiring Systems: BLK/WHT Air frow meter "A-8" "A-8" BLU/WHT BLU/RED BLU/YEL BLU/ORN (CAN line) WHT/BLK WHT/GRN WHT/BLK Relay #3 "A-4" Cont.M "F-3" "A-7" Navigation "G-4" Cont.M Cont.M "F-3" "F-2" I5RS0B910932-02...
Page 513: A-6 A/T Control System Circuit Diagram
Wiring Systems: 9A-68 A-6 A/T Control System Circuit Diagram S5RS0B910E007 BACK RADIO STOP Individual circuit LAMP fuse box (No.1) RED/BLK WHT/RED RED/BLK Vehicle speed sensor "A-5" Transaxle range sensor E24 C36 PNK/BLK E24 C36 PNK/BLK GRN/ORN LT GRN/BLK GRN/YEL Back-up light PNK/BLK "D-8"...
Page 514 9A-69 Wiring Systems: RADIO IG1 SIG Individual circuit fuse box (No.1) LT GRN/BLK YEL/BLU WHT/RED WHT/RED A/T relay YEL/BLK WHT/RED YEL/BLK LT GRN/BLK LT GRN WHT/BLK WHT/BLU BLU/BLK BLK/YEL Pressure Lock up Timing Shift A/T fluid Shift control solenoid solenoid temperature solenoid solenoid...
Page 515 Wiring Systems: 9A-70 A-7 Immobilizer System Circuit Diagram (Petrol) S5RS0B910E008 RADIO IG COIL WHT/RED BLK/WHT BLK/WHT YEL/RED YEL/BLK YEL/BLK YEL/RED PPL/WHT PPL/WHT WHT/RED BLK/ORN "A-8" BLK/ORN BLK/ORN WHT/BLK RED/BLK PPL/WHT BLK/ORN (CAN line) BLK/ORN I5RS0B910934-01...
Page 516 9A-71 Wiring Systems: A-7 Immobilizer System Circuit Diagram (DSL) S5RS0B910E044 RADIO IG COIL DIESEL BLK/WHT BLK/WHT BLU/BLK WHT/BLK WHT/BLK BLU/BLK PPL/WHT PPL/WHT BLK/ORN PPL/WHT WHT/RED "A-8" BLK/ORN BLK/ORN WHT/BLK RED/BLK PPL/WHT BLK/ORN (CAN line) BLK/ORN I5RS0B910935-03...
Page 517: Petrol
Wiring Systems: 9A-72 A-8 Body Control System Circuit Diagram S5RS0B910E009 RADIO Cont.M Cont.M "F-2" "F-3" "A-5" "A-6" Receiver "B-5" PPL/WHT PPL/WHT PPL/WHT WHT/RED Petrol WHT/RED LT GRN BRN/WHT PPL/WHT WHT/RED PPL/WHT Petrol BLU/BLK RED/BLK WHT/BLK BLK/ORN PPL/WHT (CAN line) (CAN line) (CAN line) PPL/WHT WHT/RED...
Page 518 9A-73 Wiring Systems: RADIO WHT/RED Petrol WHT/RED WHT/RED YEL/BLK Ambient Main switch temperature (Key switch) sensor BLU/YEL Petrol BLU/YEL YEL/RED BLU/YEL BLK/RED GRY/RED RED/BLK BRN/YEL RED/BLK LT GRN GRY/RED Front door switch GRY/WHT LT GRN/BLK Brake Seat Parking controller fluid pressure belt brake...
Page 519 Wiring Systems: 9A-74 J/B side connector (BCM) Luggage compartment light "D-5" BLK/YEL "Junction Block Inner circuit" BLK/YEL Relay Flasher relay Relay Rear end BLK/YEL J/B (BCM- 12 ) J/B (BCM- 16 ) J/B (BCM- 18 ) Solenoid "D-5" WHT/RED RED/BLU GRN/WHT Interior light "D-5"...
Page 520 9A-75 Wiring Systems: LOCK Main fuse box "Junction Block Inner circuit" Heater relay Relay ACC 1 METER RADIO J/B (BCM- 17 ) J/B (BCM- 20 ) WHT/BLU RED/YEL RED/YEL RED/YEL Generator "A-2" Front position Multi information light display "D-2" BLK/ORN BLK/ORN RED/YEL RED/YEL...
Page 521: Automated Manual Transaxle Control System Circuit Diagram (Petrol)
Wiring Systems: 9A-76 A-9 Automated Manual Transaxle Control System Circuit Diagram (Petrol) S5RS0B910E010 IG1 SIG RADIO STOP Individual circuit LAMP fuse box (No.1) ##: Automated Manual Transaxle GRN/WHT WHT/RED LT GRN/BLK BLK/WHT GRN/WHT LT GRN/BLK GRN/WHT Brake (##) light switch GRN/WHT PNK/BLK PPL/WHT...
Page 522 9A-77 Wiring Systems: Individual circuit ST SIG RADIO fuse box (No.1) RED/WHT WHT/RED Automated Manual Transaxle relay RED/WHT RED/BLU WHT/BLK Neutral switch GRY/BLU PPL/WHT GRN/BLK RED/BLU WHT/BLK (##) GRN/BLK GRN/BLK RED/WHT RED/BLU RED/BLK GRN/YEL LT GRN/RED LT GRN/BLK LT GRN GRN/BLK Automated Manual Transaxle shift lever switch...
Page 523 Wiring Systems: 9A-78 Shift stroke sensor Select stroke sensor Clutch stroke sensor MAIN MAIN MAIN Starting Back-up motor light relay switch "A-1" "D-8" YEL/GRN BLU/RED BLK/YEL RED/YEL BLU/ORN BRN/WHT GRN/ORN WHT/BLU BLK/WHT RED/BLK YEL/GRN BLK/ORN WHT/RED BLU/WHT BRN/YEL BLU/BLK BLU/YEL RED/WHT WHT/GRN (##)
Page 524: B-1 Windshield Wiper And Washer Circuit Diagram
9A-79 Wiring Systems: B-1 Windshield Wiper and Washer Circuit Diagram S5RS0B910E011 WIPER BLU/ORN BLU/ORN Switch Switch INT1 INT2 MIST INT Unit BLU/RED BLU/YEL BLU/WHT BLU/YEL BLU/RED BLU/YEL BLU/WHT Petrol, DSL (RHD) Petrol DSL (LHD) I5RS0B910939-01...
Page 525: B-2 Rear Wiper And Washer Circuit Diagram
Wiring Systems: 9A-80 B-2 Rear Wiper and Washer Circuit Diagram S5RS0B910E012 J/B side connector (BCM) WIPER Relay Drive circuit BLU/BLK YEL/RED YEL/RED R.INT WASH Switch ON+WASH I4RS0B910939-02...
Page 526: B-3 Rear Defogger Circuit Diagram
9A-81 Wiring Systems: B-3 Rear Defogger Circuit Diagram S5RS0B910E013 J/B side connector (BCM) Relay BLK/RED BLK/RED Mode control switch BLK/ORN BLK/ORN I5RS0B910940-01...
Page 527: B-4 Power Window Circuit Diagram
Wiring Systems: 9A-82 B-4 Power Window Circuit Diagram S5RS0B910E014 WHT/BLU WHT/BLU DRIVER SWITCH PASSENGER SWITCH UNLOCK DOWN Main switch LOCK DOWN RED/WHT GRN/WHT WHT/BLU RED/WHT GRN/WHT RED/WHT GRN/WHT WHT/BLU ASU ASD UNLOCK DOWN LOCK Sub switch DOWN Front Front Motor Motor I4RS0B910941-01...
Page 528: B-5 Power Door Lock Circuit Diagram
9A-83 Wiring Systems: B-5 Power Door Lock Circuit Diagram S5RS0B910E015 Receiver LT GRN BRN/WHT GRY/WHT LT GRN/BLK GRN/RED RED/BLU BLU/ORN GRY/WHT LT GRN/BLK GRN/RED RED/BLU BLU/ORN LOCK UNLOCK LOCK UNLOCK Front DOWN DOWN Main switch Switch I4RS0B910942-02...
Page 529 Wiring Systems: 9A-84 J/B side connector (BCM) BLU/ORN RED/BLU BLU/YEL RED/BLU BLU/ORN RED/BLU BLU/YEL BLU/ORN Rear end Rear end Solenoid Switch BLU/ORN RED/BLU BLU/ORN RED/BLU BLU/ORN RED/BLU BLU/ORN RED/BLU BLU/ORN RED/BLU BLU/ORN RED/BLU Front Rear motor (L) Rear motor (R) Motor I5RS0B910941-01...
Page 530: B-6 Power Mirror Circuit Diagram
9A-85 Wiring Systems: B-6 Power Mirror Circuit Diagram S5RS0B910E016 ACC 1 Relay BLU/WHT BLU/WHT IG GND M2L M1 IG GND M2R M1 Switch DOWN DOWN Mode control switch "B-3" BRN/WHT GRN/ORN LT GRN BRN/WHT GRN/ORN LT GRN BLK/RED BRN/WHT GRN/ORN LT GRN BLK/RED BRN/WHT...
Page 531: B-7 Horn Circuit Diagram
Wiring Systems: 9A-86 B-7 Horn Circuit Diagram S5RS0B910E017 HAZ-HORN METER Flasher relay Relay Combination switch (Horn) J/B side connector (BCM) I4RS0B910973-01...
Page 532: B-8 Seat Heater Circuit Diagram
9A-87 Wiring Systems: B-8 Seat Heater Circuit Diagram S5RS0B910E018 SEAT "D-4" RED/YEL LT GRN RED/YEL LT GRN RED/YEL LT GRN RED/YEL FREE LOCK FREE LOCK Switch Switch RED/BLK IF EQPD IF EQPD RED/BLK Cont.M Cont.M "E-2" "E-2" I5RS0B910943-01...
Page 533: B-9 Smart Key System Circuit Diagram
Wiring Systems: 9A-88 B-9 Smart Key System Circuit Diagram S5RS0B910E019 RADIO ACC2 BACK WHT/RED Door antenna Door antenna Inside Luggage Rear end antenna antenna antenna WHT/RED WHT/RED WHT/RED BLK/YEL STEERING STEERING LOCK PUSH LOCK UNIT SWITCH Main switch WHT/RED GRN/WHT RED/BLU (Key switch) BLU/YEL...
Page 534: Combination Meter Circuit Diagram (Meter)
9A-89 Wiring Systems: C-1 Combination Meter Circuit Diagram (Meter) S5RS0B910E020 METER RADIO "A-8" RED/BLK WHT/RED (CAN line) Hight (Dial) (Pointer) (Display) Voltage regulator Micro controller Stepper motor and LED output driver SPEED TACHO TEMP FUEL Interface circuit YEL/RED BLK/ORN BLK/ORN Petrol YEL/RED BLK/ORN...
Page 535: Combination Meter Circuit Diagram (Indicator)
Wiring Systems: 9A-90 C-2 Combination Meter Circuit Diagram (Indicator) S5RS0B910E021 METER METER RADIO Flasher relay SW-L SW-R LP-L LP-R GRN/RED BLU/YEL BLU/RED RED/BLU "D-10" "A-8" BLU/ORN RED/BLK WHT/RED Turn signal switch "D-6" (CAN line) Hight Voltage regulator TURN Micro controller Stepper motor and LED output driver BLK /ORN...
Page 536: Combination Meter Circuit Diagram (Warning Light)
9A-91 Wiring Systems: C-3 Combination Meter Circuit Diagram (Warning Light) S5RS0B910E022 Without seat heater With seat heater METER Petrol RED/BLK Smart Smart (CAN line) "B-9" "B-9" "A-5" (CAN line) RED/BLK BRN/YEL RED/BLK Hight Voltage regulator Micro controller Stepper motor and LED output driver Interface circuit Seat...
Page 537 Wiring Systems: 9A-92 RADIO WHT/RED IMMOBI* IMMOBI (Petrol) SVS (DSL) I5RS0B910975-01...
Page 538: D-1 Headlight System Circuit Diagram
9A-93 Wiring Systems: D-1 Headlight System Circuit Diagram S5RS0B910E023 Individual circuit H/L,L H/L,R TAIL METER fuse box (No.1) WHT/RED WHT/BLU RED/BLK Headlight Headlight RED/WHT RED/WHT BEAM RED/WHT WHT/RED WHT/RED RED/WHT RED/WHT BLU/WHT (ED) Dimmer / Passing FLASH switch TAIL HEAD Light switch RED/YEL RED/BLK...
Page 539 Wiring Systems: 9A-94 With DRL controller WIPER (DSL) (Petrol) "A-5" "A-8" BLU/WHT RED/WHT WHT/RED controller RED/BLK RED/YEL BLK/ORN BLK/ORN "D-4" I5RS0B910949-01...
Page 540: D-2 Position, Tail And Licence Plate Light System Circuit Diagram
9A-95 Wiring Systems: D-2 Position, Tail and Licence Plate Light System Circuit Diagram S5RS0B910E024 TAIL J/B side connector (BCM) Without DRL controller WHT/RED RED/YEL RED/YEL With DRL controller RED/YEL TAIL HEAD RED/YEL RED/YEL RED/BLK controller RED/YEL RED/YEL RED/YEL Licence plate light Front Tail light...
Page 541: D-3 Front Fog Light System Circuit Diagram
Wiring Systems: 9A-96 D-3 Front Fog Light System Circuit Diagram S5RS0B910E025 Individual circuit fuse box (No.1) "D-4" WHT/GRN GRY/RED RED/YEL Relay RED/YEL GRY/RED LT GRN TERMINAL LOAD POSITION LT GRN LT GRN FREE Switch PUSH Petrol Petrol, DSL (RHD) DSL (LHD) J/B side connector (BCM) I5RS0B910951-01...
Page 542: D-4 Illumination Light System Circuit Diagram
9A-97 Wiring Systems: D-4 Illumination Light System Circuit Diagram S5RS0B910E026 J/B side connector (BCM) Without DRL controller With DRL controller TAIL WHT/RED RED/BLK RED/YEL RED/YEL TAIL HEAD controller RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL Cigar lighter IF EQPD RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL...
Page 543: D-5 Interior Light System Circuit Diagram
Wiring Systems: 9A-98 D-5 Interior Light System Circuit Diagram S5RS0B910E027 RADIO J/B side connector (BCM) WHT/RED WHT/RED Luggage compartment light Interior light DOOR BLK/YEL BLK/YEL Rear end BLK/RED Solenoid GRY/RED BLK/RED BLK/RED BLK/RED Front door Front door switch switch Rear door switch I4RS0A910948-01...
Page 544: D-6 Turn Signal And Hazard Warning Light System Circuit Diagram
9A-99 Wiring Systems: D-6 Turn Signal and Hazard Warning Light System Circuit Diagram S5RS0B910E028 HAZ-HORN METER Flasher relay SW-L SW-R LP-L LP-R RED/YEL "D-4" BLU/YEL BLU/RED RED/BLU GRN/RED RED/YEL Rear turn signal light TURN Switch Turn signal switch BLK/ORN BLK/ORN BLK/ORN J/B side connector (BCM) I4RS0B910955-02...
Page 545 Wiring Systems: 9A-100 GRN/RED BLU/YEL GRN/RED BLU/YEL (Turn (L)) (Turn (R)) "C-2" Front turn Side turn signal signal light (L) light (L) Front turn Side turn signal signal light (R) light (R) Petrol, DSL (RHD) DSL (LHD) I5RS0B910953-01...
Page 546: D-7 Brake Light System Circuit Diagram
9A-101 Wiring Systems: D-7 Brake Light System Circuit Diagram S5RS0B910E029 STOP Individual circuit IG1 SIN Automated Manual Transaxle fuse box (No.1) LAMP coil BLK/YEL LT GRN/BLK "A-6" LT GRN/BLK PNK/BLK Brake light switch PNK/BLK GRN/YEL GRN/WHT GRN/YEL PNK/BLK A/T shift lever "A-6"...
Page 547: D-8 Back-Up Light System Circuit Diagram
Wiring Systems: 9A-102 D-8 Back-Up Light System Circuit Diagram S5RS0B910E030 BACK RED/BLK RED/BLK Transaxle M/T, Automated Manual Transaxle range sensor RED/BLK Back-up light switch "A-6" Connector of reversing signal pick-up for optional navigation Back-up light I5RS0B910968-01...
Page 548: D-9 Headlight Beam Leveling System Circuit Diagram
9A-103 Wiring Systems: D-9 Headlight Beam Leveling System Circuit Diagram S5RS0B910E031 BACK RED/BLK RED/BLK RED/BLK RED/BLK Actuator (L) Actuator (R) RED/BLK switch Petrol I5RS0B910954-01...
Page 549: D-10 Rear Fog Light Circuit Diagram
Wiring Systems: 9A-104 D-10 Rear Fog Light Circuit Diagram S5RS0B910E032 YEL/BLK BLU/ORN BLU/ORN "C-2" I4RS0B910960-02...
Page 550: E-1 Heater System Circuit Diagram
9A-105 Wiring Systems: E-1 Heater System Circuit Diagram S5RS0B910E033 BACK Relay "B-3" "D-4" "B-3" "A-8" RED/BLK GRN/WHT RED/YEL RED/BLK RED/BLK Fresh / Recircle RED/YEL BLK/RED actuator BRN/WHT HARF REO CIRCUIT Mode control switch BLK/ORN BLK/ORN I4RS0B910961-01...
Page 551 Wiring Systems: 9A-106 Individual circuit fuse box (No.1) Heater relay BLK/YEL Blower motor Heater resister BLK/WHT "A-5" BLU/WHT BLK/WHT BRN/WHT BLU/WHT BLK/WHT Heater fan switch I5RS0B910955-03...
Page 552: Ptc Heater Circuit Diagram (Dsl)
9A-107 Wiring Systems: E-3 PTC Heater Circuit Diagram (DSL) S5RS0B910E045 RADIO BACK RED/BLK Seat Heater "B-8" "A-8" RED/BLK WHT/RED RED/BLK GRY/RED RED/BLK Cont.M PPL/WHT BLU/BLK RED/WHT WHT/RED PPL/WHT RED/WHT WHT/RED Max hot switch BLK/ORN Multi information Combination display controller switch "G-2"...
Page 553 Wiring Systems: 9A-108 Main fuse Fuel heating relay relay relay relay "A-5" YEL/BLU GRN/WHT GRN/RED GRN/RED YEL/BLU GRN/WHT GRN/RED BLU/BLK BLU/YEL BLU/RED Cont.M BLK/WHT BLK/YEL BLK/WHT BLK/YEL Combination Blower fan switch motor "D-1" "E-1" heater heater #2,3 I5RS0B910957-02...
Page 554: F-1 Air-Bag System Circuit Diagram
9A-109 Wiring Systems: F-1 Air-Bag System Circuit Diagram S5RS0B910E034 A/BAG Forward sensor (R) "A-8" PPL/WHT PNK/BLK PNK/BLK GRN/RED BLU/RED YEL/RED BLU/RED BLU/ORN BLU/YEL GRN/RED GRN/YEL GRN/ORN YEL/RED Contact coil I5RS0B910966-01...
Page 555 Wiring Systems: 9A-110 IF EQPD "C-3" YEL/BLK Side air-bag sensor Side air-bag sensor WHT/RED LT GRN/BLK WHT/GRN LT GRN YEL/BLK BLK/YEL BRN/YEL GRY/RED BRN/WHT YEL/GRN YEL/BLU Side air-bag Side air-bag Side curtain Side curtain I5RS0B910969-01...
Page 556: F-2 Anti-Lock Brake System Circuit Diagram
9A-111 Wiring Systems: F-2 Anti-Lock Brake System Circuit Diagram S5RS0B910E035 Individual circuit fuse box (No.1) (ABS) Brake light switch "C-3" "A-5" "D-7" GRN/ORN WHT/BLU WHT/RED GRN/WHT PNK/BLK RED/BLU GRN/WHT PNK/BLK RED/BLU Cont.M I5RS0B910958-01...
Page 557 Wiring Systems: 9A-112 RADIO WHT/RED Wheel speed Wheel speed Wheel speed Wheel speed sensor sensor sensor sensor (RL) (RR) (FL) (FR) LT GRN LT GRN/BLK Petrol RED/BLK WHT/BLK WHT/RED LT GRN LT GRN/BLK Cont.M PPL/WHT PPL/WHT WHT/RED BLK/ORN "A-8" BLK/ORN PPL/WHT BLK/ORN RED/BLK...
Page 558: F-3 Power Steering System Circuit Diagram
9A-113 Wiring Systems: F-3 Power Steering System Circuit Diagram S5RS0B910E036 Individual circuit IG1 SIG fuse box (No.1) LT GRN/BLK LT GRN/BLK Cont.M RED/BLU RED/BLU "A-5" Torque sensor I4RS0B910965-02...
Page 559 Wiring Systems: 9A-114 RADIO METER RED/BLK WHT/RED "A-5" Petrol WHT/RED WHT/RED Cont.M PPL/WHT WHT/RED PPL/WHT PPL/WHT "A-8" Motor PPL/WHT RED/BLK WHT/BLK BLK/ORN BLK/ORN BLK/ORN I5RS0B910971-01...
Page 560: G-1 Audio System Circuit Diagram
9A-115 Wiring Systems: G-1 Audio System Circuit Diagram S5RS0B910E037 5 dr 3 dr RADIO ACC 2 Petrol "A-8" "D-4" BLU/WHT WHT/RED RED/YEL Steering switch (COMB switch) WHT/RED BLU/WHT BLU/WHT RED/YEL WHT/RED BLK/YEL Audio LT GRN/BLK YEL/RED YEL/BLK LT GRN GRY/RED LT GRN/BLK YEL/RED YEL/BLK...
Page 561: G-2 Multi Information Display / Accessory Socket System Circuit Diagram
Wiring Systems: 9A-116 G-2 Multi Information Display / Accessory Socket System Circuit Diagram S5RS0B910E038 ACC 2 RADIO Ambient temperature sensor YEL/BLK YEL/RED BLU/WHT BLU/WHT Petrol Petrol BLU/WHT BLU/WHT WHT/RED Push Cigar lighter Multi information display BLK/YEL BLK/ORN ILL cancel switch "D-4"...
Page 562: G-4 Navigation System Circuit Diagram
9A-117 Wiring Systems: G-4 Navigation System Circuit Diagram S5RS0B910E039 M/T, Automated Manual Transaxle Back-up Transaxle light switch range sensor "D-8" "D-8" "A-5" Navigation RED/BLK RED/BLK Parking brake switch "C-3" I4RS0B910969-03...
Page 563: List Of Connectors
Wiring Systems: 9A-118 List of Connectors List of Connectors S5RS0B910F001 Refer to “C Connector: ”. Refer to “D Connector (DSL): ”. Refer to “E Connector: ”. Refer to “G Connector: ”. Refer to “J Connector: ”. Refer to “K Connector: ”. Refer to “L Connector: ”.
Page 564: D Connector (Dsl)
9A-119 Wiring Systems: 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 29 30 Weld Weld Weld splice splice splice 31 32 33 34 35 36 37 38 39 40 46 47 48 49 50 51 52 53 54 55 MCONF600002-01...
Page 565: E Connector
Wiring Systems: 9A-120 MCONM020036-01 MCONM020037-01 MCONF060056-01 MCONF060056-01 MCONF020174-01 MCONF020174-01 MCONF020174-01 MCONF020174-01 MCONM010029-01 MCONM010029-01 MCONM010029-01 MCONM010029-01 E Connector S5RS0B910F003 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 MCONF060062-01 MCONF020184-01 MCONF260011-01...
Page 566 9A-121 Wiring Systems: E37 (TO G35) MCONF040004-01 MCONF040004-01 MCONF040004-01 MCONF040004-01 MCONM150001-01 Petrol E38 (TO G36) 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 5 6 7 8 9 10 MCONM200008-01 MCONF100003-01 MCONF020202-01 MCONF160034-01 E44 (TO L03) A A B B A A B B...
Page 567: G Connector
Wiring Systems: 9A-122 E65 (TO C60) E69 (TO D13) 5 4 3 2 1 MCONF040045-01 MCONF010074-01 MCONF020204-01 MCONM050007-01 MCONM060024-01 MCONF020181-01 MCONF050029-01 MCONF040007-01 MCONF080023-01 MCONF040084-01 MCONF020148-01 MCONF010074-01 MCONF040004-01 MCONF050015-01 MCONF040004-01 MCONF040004-01 MCONF040004-01 MCONF020189-01 MCONF040027-01 G Connector S5RS0B910F004 G03 (TO L33) G04 (TO L32) 5 4 3 2 1 1 2 3 4 5 6 7 1 2 3 4...
Page 568 9A-123 Wiring Systems: 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 MCONF160023-01 MCONF060063-01 MCONF080014-01 MCONF100038-01 1 2 3 4 5 11 12 13 MCONF120026-01 MCONF130010-01 MCONF020212-01...
Page 569: J Connector
Wiring Systems: 9A-124 J Connector S5RS0B910F005 J01 (TO L06) 4 3 2 9 10 MCONM280004-01 MCONF020134-01 MCONM080010-01 MCONF020009-01 MCONF060046-01 MCONF100054-01 J09 (TO L31) 1 2 3 4 5 6 7 8 8 9 10 11 9 10 11 12 13 14 15 16 17 18 MCONF130011-01 MCONF180011-01 MCONM280004-01...
Page 570: L Connector
9A-125 Wiring Systems: L Connector S5RS0B910F007 L02 (TO E45) L03 (TO E44) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 MCONF180012-01 MCONM170001-01 MCONM040022-01 MCONF040033-01 L07 (TO J01) 1 2 3 4 5 6 7 8 9 12 13 14 15 16 17 18 MCONF180013-01...
Page 571 Wiring Systems: 9A-126 L31 (TO J09) 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 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 MCONF510002-01 MCONF020212-01 MCONF280006-01...
Page 572: O Connector
9A-127 Wiring Systems: O Connector S5RS0B910F008 O01 (TO L42) 4 5 6 7 8 MCONF080027-01 MCONF010061-01 MCONF040012-01 MCONF040095-01 MCONF040095-01 MCONF010061-01 R Connector S5RS0B910F009 R01 (TO L15) 1 2 3 4 MCONF040100-01 MCONF040085-01...
Page 573: Instrumentation / Driver Info. / Horn
Instrumentation / Driver Info. / Horn: 9C-1 Instrumentation / Driver Info. / Horn General Description CAN Communication Data of Combination Meter S5RS0B9301001 Combination meter receives the following information from each control module. For details of CAN communication, refer to “CAN Communication System Description: in Section 1A”. Data which combination meter receives from ECM •...
Page 574: Combination Meter Circuit Diagram
9C-2 Instrumentation / Driver Info. / Horn: Schematic and Routing Diagram Combination Meter Circuit Diagram S5RS0B9302001 G28-21 G28-16 G28-26 G28-1 G28-25 G28-22 G28-20 G28-10 G28-8 G28-29 G28-30 G28-13 G28-3 G28-14 G28-5 G28-31 G28-32 I5RS0B930001-02 1. Main fuse 7. ECT meter 13.
Page 575: Speedometer And Vss Symptom Diagnosis
Instrumentation / Driver Info. / Horn: 9C-3 Terminal arrangement of coupler viewed from combination meter side NOTE Molded numbers (1) have no relation to the terminal numbers. G28-16 G28-1 G28-17 G28-32 I4RS0A930003-02 Terminal Circuit Terminal Circuit G28-1 To turn signal light switch (turn R) G28-17 —...
Page 576: Information Display Symptom Diagnosis (If Equipped)
9C-4 Instrumentation / Driver Info. / Horn: Information Display Symptom Diagnosis (If Equipped) S5RS0B9304016 NOTE This thermometer indicates the ambient temperature in back of front bumper member. Under any one of the following listed conditions, however, even when the ambient temperature goes up, the thermometer display does not rise so as to correct the rise of the ambient temperature caused by the radiant heat of the engine.
Page 577 Instrumentation / Driver Info. / Horn: 9C-5 Repair Instructions Oil Pressure Switch Removal and Installation VSS Removal and Installation S5RS0B9306006 S5RS0B9306008 For removal and installation, refer to “Oil Pressure For removal and installation, refer to “Front Wheel Speed Check: in Section 1E”. Sensor Removal and Installation: in Section 4E”.
Page 578 9C-6 Instrumentation / Driver Info. / Horn:...
Page 579: Control Systems
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 service manual. Precautions ..........10-* DTC U1100 (No.
Page 580 10-ii Table of Contents DTC B3043: W-Line Circuit Malfunction DTC P1614: Incorrect Signal from Shorted to Battery .........10C-11 Immobilizer Control Module ......10C-17 DTC B3055: No Transponder ......10C-12 Registration Procedure of Immobilizer DTC B3056: No Fix Code Registered .....10C-13 Control System Components ......10C-17 DTC B3057: No Password Registered....10C-13 Inspection of Immobilizer Control Module DTC B3059: No Request from ECM ....10C-14...
Page 581: Body Electrical Control System
The BCM makes the alarm indicator lamp flash at certain intervals after the ignition switch is turned off until it is turned on again. Also, to check DTCs stored in BCM without using a SUZUKI scan tool when diagnosing troubles, it is possible to identify them by flashing patters of the alarm indicator lamp.
Page 582 10B-2 Body Electrical Control System: Schematic and Routing Diagram Body Electrical Control System Wiring Circuit Diagram S5RS0BA202001 NOTE This wiring diagram shows circuits related to only BCM, not the entire circuits of BCM and junction block. Refer to “Power Supply Diagram (Petrol): in Section 9A” for wiring circuits other than the figure below.
Page 583 Body Electrical Control System: 10B-3 E39-9 L05-5 L05-9 BLU/BLK G37-21 G37-22 WASH BLU/YEL L01-11 WASH, ON E46-1 YEL/RED E46-10 E46-2 YEL/BLK E46-8 BLU/YEL G37-16 G37-4 G37-2 G37-3 RED/BLK G37-8 G37-1 WHT/BLK GRY/RED G37-10 E46-9 PPL/WHT G37-11 G37-5 PPL/WHT L04-3 PPL/WHT E46-4 WHT/BLU L01-10...
Page 584 10B-4 Body Electrical Control System: 1. BCM (included in junction block assembly) 19. Door key cylinder switch (included in door lock 37. Interior light actuator) 2. Rear washer motor 20. Manual door lock switch 38. Air bag control module 3. Rear wiper motor 21.
Page 585: Bcm And Related System Component Location
Body Electrical Control System: 10B-5 Component Location BCM and Related System Component Location S5RS0BA203001 I5RS0BA20002-01 1. Generator 11. Keyless entry receiver 21. Supplementary heater controller (if equipped) 2. Brake fluid level switch 12. Parking brake switch 22. Junction block assembly 3.
Page 586: Bcm Self-Diagnosis Function
• DTC can be checked in either one of following ways. – DTC can be checked by SUZUKI scan tool (2) connected to DTC (1). – DTC can be read from flashing pattern of alarm indicator lamp (3). Also, DTC is displayed on combinations meter (4) at the same time.
Page 587 Body Electrical Control System: 10B-7 Control Input Output • Key reminder switch • Warning buzzer (located in BCM) Warning buzzer • Tail light switch • Driver side door switch • Rear end door window defogger switch • Rear end door window defogger Rear end door window relay defogger...
Page 588 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 589: Dtc Table
Body Electrical Control System: 10B-9 DTC Table S5RS0BA204004 DTC (indicated DTC (displayed on (displayed on by alarm odometer in Detected item Detecting condition SUZUKI scan indicator lamp) combination meter) tool) NO DTC 0000 0000 — No DTC detected B1133 1133...
Page 590 10B-10 Body Electrical Control System: DTC B1133 (DTC No. 1133): Battery Voltage Too High S5RS0BA204008 Wiring Diagram I4RS0AA20008-01 [A]: Junction block assembly connector viewed from harness side 3. Ignition switch 1. BCM 4. Battery 2. Junction block assembly DTC Detecting Condition and Possible cause DTC detecting condition Possible cause Power voltage supplied from battery to BCM is...
Page 591: Dtc U1001 (No. 1001): High Speed Can Communication (Transmission Error)
Body Electrical Control System: 10B-11 DTC U1001 (No. 1001): High Speed CAN Communication (Transmission Error) S5RS0BA204013 Wiring Diagram G28-8 G37-4 G28-10 G37-2 E62-64 E46-1 E46-2 E62-40 I5RS0BA20003-01 [A]: BCM connector (viewed from harness side) 2. Junction block assembly [B]: ECM connector (viewed from harness side) 3.
Page 592 10B-12 Body Electrical Control System: DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch turned OFF. 2) Turn ON ignition switch and clear DTC by using scan tool. 3) Start engine and run it for 1 min. or more. 4) Check DTC.
Page 593 Body Electrical Control System: 10B-13 DTC U1073 (No. 1073): Control Module Communication Bus Off S5RS0BA204014 Wiring Diagram G28-8 G37-4 G28-10 G37-2 E62-64 E46-1 E46-2 E62-40 I5RS0BA20003-01 [A]: BCM connector (viewed from harness side) 2. Junction block assembly [B]: ECM connector (viewed from harness side) 3.
Page 594 10B-14 Body Electrical Control System: DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch turned OFF. 2) Turn ON ignition switch and clear DTC by using scan tool. 3) Start engine and run it for 1 min. or more. 4) Check DTC and pending DTC.
Page 595 Body Electrical Control System: 10B-15 DTC U1100 (No. 1100): Lost communication with ECM S5RS0BA204015 Wiring Diagram E62-64 E46-1 E62-40 E46-2 I5RS0BA20004-01 [A]: BCM connector (viewed from harness side) 1. BCM 3. ECM [B]: ECM connector (viewed from harness side) 2. Junction block assembly DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 596: Inspection Of Bcm And Its Circuits
10B-16 Body Electrical Control System: Troubleshooting Step Action Check DTC in BCM Go to “DTC U1073 (No. Go to Step 2. 1073): Control Module Is DTC U1100 (No. 1100) and DTC U1073 (No. 1073) Communication Bus detected together? Off: ”. Check DTC in ECM Go to applicable DTC Go to Step 3.
Page 597 Body Electrical Control System: 10B-17 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 598 10B-18 Body Electrical Control System: Terminal Wire color Circuit Normal voltage Condition Driver side door key cylinder switch is at any 10 – 14 V Driver side door key cylinder position other than unlock position L01-17 switch (Unlock) Driver side door key cylinder switch is at unlock position L01-18 —...
Page 599 Body Electrical Control System: 10B-19 Terminal Wire color Circuit Normal voltage Condition G37-9 — — — — *0 – 1 V ↑↓ Serial communication line G37-10 GRY/RED for supplementary heater 10 – 14 V Ignition switch is at ON position controller (“Reference waveform No.
Page 600 10B-20 Body Electrical Control System: Junction block connector “E41” Terminal Wire color Circuit Normal voltage Condition 10 – 14 V Horn switch is at ON position E41-3 Horn Horn switch is at OFF position Junction block connector “G32” Terminal Wire color Circuit Normal voltage Condition...
Page 601 Body Electrical Control System: 10B-21 Terminal Wire color Circuit Normal voltage Condition Engine is running and rear end door window 10 – 14 V defogger is in operation L05-6 BLK/RED Right side door mirror heater Engine is running and rear end door window defogger is not in operation Engine is running and rear end door window 10 –...
Page 602 10B-22 Body Electrical Control System: Reference waveform No. 1 Reference waveform No. 3 Parking brake or brake fluid level switch signal (1) BCM – ECM CAN communication signal Measurement terminal Parking brake switch Measurement terminal CH2: “E46-1” to “G33-3” CH2: “L01-6” to “G33-3” CH3: “E46-2”...
Page 603 Body Electrical Control System: 10B-23 Reference waveform No. 5 Reference waveform No. 7 BCM – combination meter CAN communication signal Information display serial communication signal (1) Measurement terminal CH2: “G37-2” to “G33-3” Measurement terminal CH2: “G37-11” to “G33-3” CH3: “G37-4” to “G33-3” Oscilloscope setting CH2: 5 V / DIV Oscilloscope setting...
Page 604 10B-24 Body Electrical Control System: Reference waveform No. 9 Reference waveform No. 11 A/C switch signal (1) Rear wiper LOW signal (1) Measurement terminal CH2: “G37-18” to “G33-3” Measurement terminal CH2: “G37-22” to “G33-3” Oscilloscope setting CH2: 5 V / DIV Oscilloscope setting CH2: 5 V / DIV TIME: 10 ms / DIV...
Page 605: Immobilizer Control System
ECM. • DTC stored in Immobilizer 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 606: Immobilizer Control Module
10C-2 Immobilizer Control System: General Description Immobilizer Control System Operation Immobilizer Control Module Immobilizer Control Module (1) is installed to steering Description column beside ignition key switch. The coil antenna is S5RS0BA301001 1) Each ignition key has its own FIX CODE stored in installed to Immobilizer Control Module.
Page 607: On-Board Diagnostic System Description
OBD-II serial data line (K line of ISO 9141) (2) is used for As soon as the ignition switch is turned to SUZUKI scan tool to communicate with Immobilizer ON position, ECM and Immobilizer Control Control Module, Air bag SDM, ABS control module, etc.
Page 608: Schematic And Routing Diagram
10C-4 Immobilizer Control System: Schematic and Routing Diagram Immobilizer Control System Wiring Circuit Diagram S5RS0BA302001 E46-1 E62-40 E62-50 E46-2 E62-64 BLU/BLK E62-78 G37-2 G37-4 E62-1 E62-2 E62-66 E62-3 WHT/BLK G24-5 BLU/BLK G24-4 G24-6 BLK/WHT G28-8 G28-10 G24-2 BLK/ORN G24-1 G24-3 PPL/WHT BLK/ORN 9 8 7...
Page 609: Diagnostic Information And Procedures
(DLC) (1) located system of another vehicle. If communication is under instrument panel at driver’s seat side. possible in this case, SUZUKI scan tool is in good Special tool condition. Then, check data link connector and serial...
Page 610: Dtc Clearance
SUZUKI scan tool referring to scan tool operator’s Immobilizer Control Module manual for further details. 1) Connect SUZUKI scan tool to data link connector 4) After completing the clearance, turn ignition switch to (DLC) located under instrument panel at driver’s OFF position and disconnect SUZUKI scan tool from seat side.
Page 611: Scan Tool Data
Wait Time The time it must be waited for reinput password for programming SUZUKI scan tool indicates “0 SEC.” when a correct password is input after wait time. If failed to input correct password, it increase according to the times of misinput.
Page 612: Svs Lamp Does Not Come On With Ignition Switch On And Engine Stop
10C-8 Immobilizer Control System: SVS Lamp Does Not Come ON with Ignition Switch ON and Engine Stop S5RS0BA304023 Wiring Diagram E62-40 E46-1 E62-50 E46-2 E62-64 BLU/BLK E62-78 G37-2 G37-4 E62-1 E62-2 E62-66 E62-3 WHT/BLK G24-5 G24-4 BLU/BLK G24-6 BLK/WHT G28-8 G28-10 G24-2 G28-31 RED/BLK...
Page 613: Circuit Description
Immobilizer Control System: 10C-9 Circuit Description When the ignition switch is turned ON, immobilizer control module read the code by the coil antenna from ignition key. Then if the code in transponder in the key match with the one registered with immobilizer control module and ECM, ECM transmits indication ON signal of SVS lamp to combination meter in order to turn SVS lamp on.
Page 614: Svs Lamp Remains On After Ignition Switch
10C-10 Immobilizer Control System: SVS Lamp Remains On after Ignition Switch ON S5RS0BA304024 When SVS lamp remains ON for more than 5 seconds after turning ignition switch to ON position, DTC is recorded to immobilizer control module and ECM. After completion of immobilizer system repair, perform clearance of DTC. DTC B3040: W-Line Communication Failure S5RS0BA304007 Wiring Diagram...
Page 615: Dtc B3042: W-Line Circuit Malfunction Shorted To Ground
Immobilizer Control System: 10C-11 DTC B3042: W-Line Circuit Malfunction Shorted to Ground S5RS0BA304008 Wiring Diagram Refer to “Immobilizer Control System Wiring Circuit Diagram: ”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area W-line circuit voltage is low. W-line circuit DTC Troubleshooting Step...
Page 616: Dtc B3055: No Transponder
10C-12 Immobilizer Control System: DTC Troubleshooting Step Action 1) Ignition switch at OFF position. Go to Step 2. Repair or replace. 2) Disconnect connector from ECM. 3) Check for proper connection to ECM at “E62-66” terminal. Is it in good condition? 1) Connect connector to ECM.
Page 617: Dtc B3056: No Fix Code Registered
Transponder to “How to Register Ignition Key: ”. CODE(s) is registered. registration procedure is not completed correctly. 2) Check SUZUKI scan tool DATA LIST “Number of Fix Register ignition key Code”. again. Is it 1 or more? DTC B3057: No Password Registered...
Page 618: Dtc B3059: No Request From Ecm
1) Register transponder referring to “How to Register Transponder FIX CODE Transponder Ignition Key: ”. is registered. registration procedure is not completed correctly. 2) Check SUZUKI scan tool DATA LIST for “Fix Code (IGN Register ignition key key)”. again. Is it registered?
Page 619: Dtc B3061: Transponder Communication Failure
DTC Troubleshooting Step Action 1) Register SECRET KEY CODE and password by using Perform registration ECM is registered SUZUKI scan tool. Refer to “Procedure after ECM procedure again and correctly. Replacement: ”. recheck. 2) Check DTC. Is DTC P1610 still output?
Page 620: Dtc P1611: Password Is Not Matched
10C-16 Immobilizer Control System: DTC P1611: Password Is Not Matched S5RS0BA304018 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Password registered in ECM is not correct. DTC Troubleshooting Step Action 1) Register password and SECRET KEY CODE by Substitute a known- ECM is in good referring to “Procedure after ECM Replacement: ”.
Page 621: Dtc P1614: Incorrect Signal From Immobilizer Control Module
Immobilizer Control System: 10C-17 DTC P1614: Incorrect Signal from Immobilizer Control Module S5RS0BA304020 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Signal from Immobilizer Control Module is not • Ignition key with built-in transponder internally faulty matched. •...
Page 622: Inspection Of Immobilizer Control Module And Its Circuit
0 – 1 V Anytime Power supply 10 – 14 V Anytime 10 – 14 V SUZUKI scan tool connected PPL/WHT Data link connector 0 – 1 V SUZUKI scan tool disconnected 0 – 1 V Ignition switch ON position...
Page 623: Repair Instructions
“Driver Air Bag (Inflator) Module Removal and “Register New IG Key (Fix Code)” modes by using Installation: in Section 8B”. SUZUKI scan tool. For your details, refer to “SUZUKI 4) Remove steering wheel referring to “Steering Wheel Tech2 Operator’s Manual”.
Page 624: Special Tools And Equipment
10C-20 Immobilizer Control System: Special Tools and Equipment Special Tool S5RS0BA308001 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. Battery power cable, 8.
Page 625 Prepared by 1st Ed. Apr., 2005...