00
TABLE OF CONTENTS
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication ................................. 0B-1
Engine ......................................................................... 1-i
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Aux. Emission Control Devices .............................. 1B-1
Engine Electrical Devices.......................................1C-1
Engine Mechanical.................................................1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System.......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System.......................................................1H-1
Starting System....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension................................................................. 2-i
Precautions .............................................................. 2-1
Suspension General Diagnosis.............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension....................................................2C-1
Wheels and Tires ...................................................2D-1
Driveline / Axle ........................................................... 3-i
Precautions .............................................................. 3-1
Drive Shaft / Axle ................................................... 3A-1
Brakes ......................................................................... 4-i
Precautions .............................................................. 4-1
Brake Control System and Diagnosis .................... 4A-1
Front Brakes........................................................... 4B-1
Rear Brakes ...........................................................4C-1
Parking Brake.........................................................4D-1
ABS ........................................................................ 4E-1
Electronic Stability Program ................................... 4F-1
Transmission / Transaxle .......................................... 5-i
Precautions .............................................................. 5-1
Automatic Transmission/Transaxle ........................ 5A-1
Manual Transmission/Transaxle ............................ 5B-1
Clutch .....................................................................5C-1
Steering ....................................................................... 6-i
Precautions .............................................................. 6-1 1
Steering General Diagnosis ...................................6A-1
Steering Wheel and Column ..................................6B-1
Power Assisted Steering System ...........................6C-1
HVAC ........................................................................... 7-i 2
Precautions .............................................................. 7-1
HVAC System ........................................................7B-1
Restraint...................................................................... 8-i
Precautions .............................................................. 8-1 3
Seat Belts...............................................................8A-1
Air Bag System ......................................................8B-1
Body, Cab and Accessories ...................................... 9-i
Precautions .............................................................. 9-1 4
Wiring Systems ......................................................9A-1
Lighting Systems ....................................................9B-1
Instrumentation / Driver Info. / Horn .......................9C-1
Wipers / Washers ...................................................9D-1
Glass / Windows / Mirrors ......................................9E-1 5
Security and Locks ................................................. 9F-1
Seats ..................................................................... 9G-1
Exterior Trim / Interior Trim ....................................9H-1
Hood / Fenders / Doors .......................................... 9J-1
Body Structure .......................................................9K-1 6
Paint / Coatings ...................................................... 9L-1
Audio Visual / Navigation ...................................... 9O-1
Control Systems....................................................... 10-i
Precautions ............................................................ 10-1 7
Body Electrical Control System ............................10B-1
Immobilizer Control System .................................10C-1
Keyless Start System ...........................................10E-1
Communication System .......................................10H-1
8
Engine Auto Stop Start System............................. 10I-1
Auxiliary Power Module System...........................10K-1
Electric Power Train................................................. 11-i
Precautions ............................................................ 11-1
Hybrid / EV Controls.............................................11A-1 9
10
11

Section 00
Precautions
CONTENTS
Precautions ...............................................00-1
Precautions........................................................... 00-1
General Precautions ........................................... 00-1
Precautions for Electrical Circuit Service ............ 00-3
Caution for Fastener ........................................... 00-5
Warning for ENG A-STOP System ..................... 00-5
Precautions for Catalytic Converter (Petrol
Engine Model) ................................................... 00-5
Precautions for Catalytic Converter (Diesel
Engine Model) ................................................... 00-6
Caution for Suspension....................................... 00-6
Caution for Wheel (with Tire) Removal ............... 00-6
Warning for Wheel and Tire ................................ 00-6
Table of Contents 00- i
00
Warning for Brake ............................................... 00-6
Warning for P/S System...................................... 00-6
Precautions for Vehicle Equipped with ESP®
System .............................................................. 00-6
Warning for Air Bag............................................. 00-7
Warning for Vehicle Equipped with
Supplemental Restraint (Air Bag) System......... 00-7
Precautions for Installing Mobile
Communication Equipment ............................. 00-10
Repair Instructions ............................................ 00-10
Electrical Circuit Inspection Procedure ............. 00-10
Intermittent Connection and Poor Contact
Inspection........................................................ 00-12
00-1 Precautions:

Precautions
Precautions

Precautions
General Precautions • Do not swallow any service materials.
AENJHB0B0000001 Swallowing them could cause diarrhea,
WARNING and CAUTION describe some general
nausea or other health problems. Be
precautions that you should observe when servicing a
especially careful not to allow children and
vehicle. These general precautions apply to many of the
pets to swallow them.
service procedures, but they will not necessarily be
repeated for every procedure to which they apply. • Keep all service materials out of reach of
children and pets.
! WARNING • Check that the hood is fully closed and
securely latched before driving the vehicle.
Failure to take proper precautions when
If the hood is not fully closed and latched,
servicing a vehicle can cause severe
it can fly up unexpectedly while driving,
personal injury.
obstructing the driver’s view and leading
• Whenever raising a vehicle for service, to an accident.
follow the instructions under “Vehicle
Lifting Points” in Section 0A (Page 0A-8). • Before starting any service work, cover fenders, seats
• If the service work being performed and any other parts that are likely to get scratched or
requires running the engine, check that the stained during servicing. Also, be aware that what you
parking brake is fully set, block drive wear (e.g. buttons) may cause damage to the
wheels and the transaxle is in “Neutral” or vehicle’s finish.
“P” range.
Also keep hands, hair, clothing, tools, etc.
away from the fan and belts while the
engine is running.
• When running the engine indoors, provide
a means to force exhaust gases outdoors.
• Do not perform service work in areas
where combustible materials can come
into contact with a hot exhaust system
component.
• Handle toxic or flammable materials (such
as gasoline and refrigerant) only in a well- I2RH01010025-01

ventilated area. • When performing service to electrical parts that does

• Keep away from hot metal parts such as
the radiator, exhaust manifold, tail pipe
and muffler to avoid getting burned.
• Avoid contact with new and used engine
oil. Prolonged contact with used engine oil
has been proven to cause skin cancer in
laboratory animals. Brief contact with used
oil may irritate the skin. To minimize
exposure to used engine oil, wear a long-
sleeve shirt and moisture-proof gloves
(such as dish washing gloves) when
changing engine oil. If engine oil contacts
your skin, wash thoroughly with soap and
water. Launder any clothing or rags if wet
with oil. Recycle or properly dispose of
used oil and filters.
• Whenever handling service materials, wear
safety glasses to protect your eyes. Any
service material getting into your eye may
cause inflammation. Also wear moisture-
proof gloves to protect your skin.
not require use of battery power, disconnect negative
(–) cable at battery.
• Before disconnecting the negative (–) cable at the
battery or after connecting the cable to the battery,
perform the following points.
– Set ignition “OFF”, and leave ignition “OFF” for at
least 90 seconds and then disconnect the cable.
– Check and record DTCs in all control modules if
necessary before disconnecting the cable.
– Record displayed contents of the clock, audio
system, etc. before disconnecting to be able to
restore the original settings after connecting the
cable.
• When removing the battery, disconnect the negative
(–) cable first and then the positive (+) cable. When
reconnecting the battery, connect the positive (+)
cable first and then the negative (–) cable. Reinstall
the terminal cover.
 Precautions: 00-2

• Use special tools when instructed.

Special tool
(A): 09917-XXXXX
(B): 09916-XXXXX

I2RH01010027-01

• When removing parts that are to be reused, keep

them arranged in an orderly manner so that they can
be reinstalled in the proper order and into the correct
I2RH01010031-01
positions.
• After servicing any system that is concerned with fuel,
oil, coolant, vacuum, exhaust gases or brakes, check
all related lines for leakage.

I5RW0A000002-01

• Do not reuse oil seals, gaskets, packing, O-rings, lock

washers, split pins, self-locking nuts, and other
specified parts, but use new ones. Also, before
installing new gaskets, packing, etc., remove any I2RH01010033-01
residual material from the mating surfaces.
• Never disconnect any of the fuel lines between fuel
pump and injectors without first releasing the fuel
pressure, or fuel can be sprayed out under pressure.
• When performing any work that produces a heat
exceeding 80 °C (176 °F) in the vicinity of the
electrical parts, remove the heat-sensitive electrical
part(s) beforehand.

IFFA0B000003-01

• Check that all parts used for reassembly are

thoroughly clean.
When the use of a certain type of lubricant, adhesive
or sealant is specified, use only the specified material.
“A”: Sealant 99000-XXXXX (SUZUKI Bond
No.XXXXX)
I2RH01010034-01
“A”

I5RS0B150012-01
00-3 Precautions:

• Do not expose connectors and electrical parts to • When disconnecting connectors, never pull on the
water, which will cause trouble to electrical systems. wiring harness. Unlock the connector lock first and
then pull the male and female connectors apart by
holding them.

I2RH01010035-01

• Do not handle electrical components (computers, I2RH01010040-01

relays, etc.) in a rough manner or drop them. • When connecting male and female connectors, also
hold connectors and put them together until they lock
securely (a click is heard).

I2RH01010036-01
I2RH01010041-01

Precautions for Electrical Circuit Service • When installing a wiring harness, secure it with
AENJHB0B0000002
clamps so that no slack is left.
• When replacing a fuse, use a fuse of the specified
capacity. Use of a fuse with a larger capacity will
cause damage to electrical parts and a fire.

I2RH01010042-01

• When installing vehicle parts, check that they do not

interfere with any wiring harness and they do not
catch any wiring harness under them.

I2RH01010038-01

• Before disconnecting or connecting connectors, do

either of the following depending on the type of power
supply. Otherwise, the electrical parts to which the
power is supplied may be damaged.
– Continuous power supply: Disconnect the negative
(–) cable at the battery.
– Ignition power supply: Set ignition “OFF”.
I2RH01010043-01
 Precautions: 00-4

• Protect the part of harness which may touch any edge connect the tester probe to the lead as shown. Do not
by wrapping it with tape or the like. insert the probe directly into the connector, or the
female terminal may be deformed.

IAW101000003-01

I2RH01010044-01 • When checking connection of terminals, check male

• Be careful not to touch the electrical terminals of parts
which use microcomputers (e.g. electronic control unit
such as ECM, PCM, P/S control module, etc.). The
static electricity from your body can damage these
parts.
terminals for bend, female terminals for excessive
opening, and both for locking (looseness), corrosion,
dust, etc.
• Before measuring voltage at each terminal, check that
battery voltage is 12 V or more. Terminal voltage
check at low battery voltage will lead to erroneous
results.

I3RM0A000004-01

• Never connect any tester (voltmeter, ohmmeter or

whatever) to terminals of an electronic control unit
when its connector is disconnected. Doing so may
cause damage to the electronic control unit.
• Never connect an ohmmeter to an electronic control
unit with its connector connected to it. Doing so may
cause damage to electronic control unit and sensors.
• Use only the specified voltmeter / ohmmeter.
Otherwise, accurate measurements may not be
obtained or personal injury may result. Where no
voltmeter type is specified, use a voltmeter with high
impedance (M Ω/V minimum) or a digital type
voltmeter.
• When taking measurements at electrical connectors
using a tester probe, insert the probe (2) from the wire
harness side (backside) of the connector (1).
I2RH01010048-01
• For the details of the names and installation positions
of relays and circuit fuses described in this manual,
refer to:
– “Fuses and the Protected Parts” in Section 9A
(Page 9A-40)
– “J/B Connector Layout” in Section 9A (Page 9A-45)
Wire Color
• On some connectors, some different circuits use the
same wire color.
In this case, the circuit cannot be identified by wire
color.
Check the terminal number in the wring diagram to
identify the circuit.

[a]

I2RH01010046-01
[a]
• When it is impossible to insert a tester probe from the IAP70P000002-02

harness side of connector, insert a properly sized [a]: Identical wire colors.
male terminal with a lead into the connector and
00-5 Precautions:

• Some wire harnesses in the same circuit may have
different colors [a] and [b] at both ends of the
intermediate connector.
In this case, the circuit cannot be identified by wire
color.
Check the terminal number in the wring diagram to
identify the circuit.
Aluminum Wire Harness
If aluminum wire (color LVN: lavender (light purple)) is
connected to copper wire directly, electrolytic corrosion
may occur and cause faulty electrical continuity, heating
and a fire in the worst case.
Do not connect aluminum wire to copper wire directly. If
it is necessary to repair aluminum wire, replace it as wire
harness assembly.

Caution for Fastener

AENJHB0B0000003
[b] NOTICE
Failure to use correct fasteners or to properly
use fasteners can cause parts or system
[a]
IAP70P000003-01
damage.
• When fasteners are removed, always
Terminal Number reinstall them at the locations from which
With some connectors, the numbers are molded into the they were removed.
connector. However, the numbers may not mean the • All fasteners must be replaced with
terminal numbers which represent the terminal position fasteners having the same part number. If a
described in this manual. fastener of the correct part number is not
Do not refer to the numbers on the connector for the available, a fastener of the same size
terminal numbers. having equal or higher strength may be
used.
Twist Pair Wire Harness
• This manual identifies and indicates
NOTE special conditions for all non-reusable
fasteners and fasteners requiring the use
For locations where twist pair wire harness
of thread-locking compound. Follow all
are used, refer to “System Circuit Diagram”
instructions, including torque values.
in Section 9A (Page 9A-54).

• A twist (1) in the twist pair wire harnesses except Warning for ENG A-STOP System
around the connectors (2) should be within 100 mm AENJHB0B0000004
(3.9 in.). Excessively-loose lines can be affected by ! WARNING
electric noise.
There is a risk of personal injury due to the
2 2 accidental engine starting if the service work
is performed while the ENG A-STOP OFF
switch turns off, i.e. the ENG A-STOP
warning light does not light.
Turn on the ENG A-STOP OFF switch and
check that the ENG A-STOP warning light
lights before the service work, except when
1
the service manual instructs to turn it off.
IDL10A000001-01

• Do not connect twist pair line terminals using a bypass

wire (1). Doing so makes the twist pair line receive
Precautions for Catalytic Converter (Petrol
electric noise interference. Engine Model)
AENJHB0B0000005
As this vehicle is equipped with a catalytic converter, use
only unleaded gasoline and be careful not to let a large
1
amount of unburned gasoline enter the converter, or it
can be damaged.
• Conduct a spark jump test only when necessary to the
shortest possible time without opening the throttle.
• Conduct engine compression checks within the
shortest possible time.
• Avoid any situations which can result in engine misfire
I4JA01000003-01
(e.g. starting the engine when the fuel tank is nearly
empty).

Precautions for Catalytic Converter (Diesel
Engine Model)
AENJHB0B0000006
• Use only specified fuel and be careful not to let a large
amount of unburned fuel enter the converter or it can
be damaged.
• Be careful not to expose catalytic converter to
excessive shock to avoid any damage to them.
Caution for Suspension
AENJHB0B0000007
! CAUTION
Failure to use proper suspension fasteners
or to perform proper maintenance / repair of
suspension components can cause unsafe
operating conditions.
• Replace suspension fasteners only with
fasteners having the same part number or
their equivalent. Do not use replacement
parts of lesser quality or substitute design.
• Observe the specified torque value for
each fastener to assure proper retention of
components.
• Never repair any suspension part using
heating, quenching, or straightening.
Instead, replace the part with a new one.
Caution for Wheel (with Tire) Removal
AENJHB0B0000008
! CAUTION
A wheel may fall off the axle and cause an
injury if all of the wheel nuts are removed at
the same time.
When removing the last wheel nut, hold the
wheel so that it does not fall off the axle.
Warning for Wheel and Tire
AENJHB0B0000009
! WARNING
Failure to use proper wheel fasteners or to
perform proper maintenance / repair of
wheels can cause unsafe operating
conditions.
• Replace wheel fasteners only with
fasteners having the same part number or
their equivalent. Do not use replacement
parts of lesser quality or substitute design.
• Tighten wheel fasteners to specified
torque value to assure proper retention of
wheels.
• Never repair any wheel by welding.
Excessive heat caused by welding may
damage the wheel.
Precautions: 00-6
Warning for Brake
AENJHB0B0000010
! WARNING
Failure to use proper brake fasteners or to
perform proper maintenance / repair of brake
components can cause unsafe operating
conditions.
• Replace brake fasteners only with
fasteners having the same part number or
their equivalent. Do not use replacement
parts of lesser quality or substitute design.
• Observe the specified torque values when
tightening brake fasteners to assure
proper retention of brake parts.
• Never repair any part by welding.
Excessive heat caused by welding may
damage brake components.
Warning for P/S System
AENJHB0B0000011
! WARNING
Failure to use proper steering gear fasteners
or to perform proper maintenance / repair of
steering components can cause unsafe
operating conditions.
• Replace steering gear fasteners only with
fasteners having the same part number or
their equivalent. Do not use replacement
parts of lesser quality or substitute design.
• Observe the specified torque value for
each fastener to assure proper retention of
components.
Precautions for Vehicle Equipped with ESP®
System
AENJHB0B0000012
• When testing an ESP® system equipped vehicle with
any of the following or similar equipment by rotating
wheels (tires) under vehicle stop condition, deactivate
ESP® system referring to “Test with Speedometer
Tester or Other Equipment” in Section 4F (Page 4F-1)
to obtain correct data.
– 2 or 4-wheel chassis dynamometer
– Speedometer tester
– Brake tester
ESP® Control Module
• When ESP® control module is removed / installed, do
not use an impact wrench, as shock it generates may
damage the sensors in the ESP® control module.
• After performing any of the following operations,
calibrate the steering angle sensor referring to
“Sensor Calibration” in Section 4F (Page 4F-53).
– Replacement of steering angle sensor
– Replacement of ESP® control module
00-7 Precautions:

Warning for Air Bag • Modifying any parts supporting or

AENJHB0B0000013 surrounding the air bag system
! WARNING components can adversely affect the
performance of the system and lead to
Failure to take proper precautions when
personal injury.
performing service on or around the air bag
Do not modify the steering wheel,
system components or wiring could cause
dashboard or any other parts that are near
accidental activation of the air bag system or
the air bag system components.
render the system inoperative. Either of
these may lead to personal injury. • High temperatures over 90 °C (194 °F) may
activate the air bag system or damage its
• Only an authorized SUZUKI dealer should
components.
perform service on or around the air bag
Before performing paint baking or other
system components or wiring. Refer to
operations that involve high temperatures,
“Air Bag System Component, Wiring and
remove the air bag system components
Connector Location” in Section 8B (Page
from the vehicle and place them in an area
8B-6) to check whether you are performing
away from the area where such operations
service on or near the air bag system
are to be performed.
components or wiring.
• Read and understand all “WARNING”s and Diagnosis
“Precautions for Air Bag System Service”
• When troubleshooting the air bag system, follow “Air
in Section 8B (Page 8B-1) before
Bag Diagnostic System Check” in Section 8B (Page
performing service on or around the air
8B-7).
bag system components or wiring.
Bypassing these procedures may result in extended
• All service work must be started at least 90 diagnostic time, incorrect diagnosis, and incorrect
seconds after the ignition has been set replacement of parts.
“OFF” and the negative (–) cable has been
• Never use electrical test equipment other than that
disconnected from the battery. Otherwise,
specified.
the air bag system may be activated by
reserve energy stored in the Sensing and ! WARNING
Diagnostic Module (SDM).
Measuring the resistance of any air bag
(inflator) module or any seat belt
Warning for Vehicle Equipped with pretensioner with a tester is dangerous, as
Supplemental Restraint (Air Bag) System the electric current from the tester may
AENJHB0B0000014
trigger the air bag or pretensioner.
! WARNING Never measure the resistance of an air bag
Failure to follow the proper procedures when (inflator) module or seat belt pretensioner.
servicing (removing, reinstalling and
checking) any of air bag system components
could result in personal injury due to
accidental air bag activation, damage to
components, or non-activation of the air bag
system in the event of a collision. (Page
8B-6)
When servicing any of the air bag
components, take the following precautions:
• Follow the procedures described in
“Precautions for Air Bag System Service”
in Section 8B (Page 8B-1).
• If the air bag system and another vehicle
system both require repair, repairing the IJHA0A000001-01

other system prior to the air bag system

may increase the chance of unintended
activation of the air bag system and
possible personal injury. SUZUKI
recommends that the air bag system be
repaired first.
 Precautions: 00-8

Servicing and Handling

[A]
! WARNING
Air Bag (Inflator) Module
Failure to take proper precautions when
servicing and handling air bag (inflator)
modules can cause accidental triggering of
the inflator, which can result in severe [B]
personal injury.
• Always disconnect the “A/B” fuse and air
bag (inflator) modules from the initiator
circuit when instructed in any service
procedure.
• Handle and store a live (non-deployed) air :[C]
bag (inflator) module in a dry place where IBP80A000002-01

the ambient temperature is below 65 °C [A]: Always carry air bag (inflator) module with trim cover (air bag opening)
away from body.
(150 °F), and there are no electric noise
[B]: Always place air bag (inflator) module on workbench with trim cover
sources. (air bag opening) up, away from loose objects.
• Always carry a live air bag (inflator) [C]: Air bag deployment direction
module with the air bag’s opening pointing
away from you. Doing so will help reduce
the chance of injury in case of an ! WARNING
accidental deployment of the air bag.
• Never carry a live air bag (inflator) module SDM
by its wires or connector. Failure to take proper precautions when
servicing and handling the Sensing and
• Always place a live air bag (inflator)
Diagnostic Module (SDM) can cause
module on a bench or other surface with
accidental triggering of the inflator, which
the bag side facing up to keep it away from
can result in severe personal injury.
the surface.
• Always disconnect the “A/B” fuse and air
• Do not place anything including another
bag (inflator) modules from the initiator
air bag (inflator) module on top of an air
circuit when instructed in any service
bag (inflator) module. Allowing for a free
procedure.
space above the module is essential to
minimize the risk of personal injury in the • Handle and store an SDM in a dry place
event of accidental deployment of the air where the ambient temperature is below 65
bag (inflator) module. °C (150 °F), and there are no electric noise
sources.
• Never dispose of any live air bag (inflator)
module. Before disposing of any live air • Handle the SDM very carefully during all
bag (inflator) module, deploy it according service procedures. Never strike it with
to the applicable procedure described in another object or shake it excessively.
“Air Bag (Inflator) Module and Seat Belt • Never power the air bag system when the
Pretensioner Disposal” in Section 8B SDM is not rigidly attached to the vehicle.
(Page 8B-55). Unless all fasteners of the SDM mounting
• The air bag (inflator) module is very hot bracket are firmly tightened and the arrow
immediately after deployment. Wait for at points toward the front of the vehicle, the
least half an hour to let it cool down before SDM could be accidentally activated when
proceeding to the next step. the air bag system is powered, possibly
causing the air bags to deploy.
• After deployment of an air bag (inflator)
module, there will be a powdery substance
remaining on its surface. This substance
consists primarily of cornstarch that is
used to lubricate the bag as it inflates and
by-products of a chemical reaction. Like
with many other service procedures, wear
gloves and safety glasses to protect the
skin and eyes when handling a deployed
air bag (inflator) module.
00-9 Precautions:
! WARNING
Seat Belt Pretensioner
Failure to take proper precautions when
servicing and handling the seat belt
pretensioners can cause accidental
triggering of the pretensioners, which can
result in severe personal injury.
• Always disconnect the “A/B” fuse and seat
belt pretensioners from the initiator circuit
when instructed in any service procedure.
• Handle and store a live (non-activated)
seat belt pretensioner in a dry place where
the ambient temperature is below 65 °C
(150 °F), and there are no electric noise
sources.
• Never carry a live pretensioner by its wires
or connector.
• Never put anything on top of a live
pretensioner placed on a workbench or
similar surface. Any objects on top of the
pretensioner can increase the risk of
personal injury in the event of accidental
activation.
• Never dispose of a live pretensioner.
Before disposing of a live pretensioner,
activate it according to the applicable
procedure described in “Air Bag (Inflator)
Module and Seat Belt Pretensioner
Disposal” in Section 8B (Page 8B-55).
• The seat belt pretensioner is very hot
immediately after activation. Wait for at
least half an hour to let it cool down before
proceeding to the next step.
• Like with many other service procedures,
wear gloves and safety glasses when
handling pretensioners to protect the skin
and eyes.
NOTICE
Failure to take proper precautions when
servicing the air bag and seat belt
pretensioner systems may cause faulty
operation or damage to components of the
systems.
• After any accident, even if it was not
severe enough to cause deployment of the
air bags, check the air bag system and
other related components according to the
instructions under “Repair and Inspection
Required after Accident” in Section 8B
(Page 8B-46).
• If any air bag system component is
impacted during service on other
components, remove the air bag system
component before continuing the service.
• Carefully handle the following components
not to drop or otherwise impact them: the
air bag (inflator) modules; the seat belt
pretensioners; the forward and side
sensors; and the SDM. If any of these
components receives an impact, never
disassemble and repair it but replace it
with new one.
• If any of the following components gets
contaminated with such materials as
grease, cleaning solvents, oil or water,
wipe it clean with a dry cloth: the air bag
(inflator) modules and the seat belt
pretensioners.
• The air bag harness is part of the main
harness, instrument panel harness and
floor harness. For easy identification, the
connector-side of each air bag harness
wire is covered with a yellow protection
tube and each connector is yellow in color.
Handle the air bag harness wires and
connectors very carefully.
• When an open wire or damaged connector
/ terminal is found in the air bag harness,
replace the entire harness rather than
replacing only the damaged wire or
connector/terminal.
• Apply power to the air bag system only
when all its components are connected or
a diagnostic procedure requires it. Doing
otherwise will set a DTC.
• Never use air bag system components
from another vehicle.
• When doing any electric welding,
temporarily disable the air bag system
referring to “Disabling Air Bag System” in
Section 8B (Page 8B-48).
• Never expose the air bag system
components to extremely hot air (i.e.,
placing the vehicle in an oven to dry it after
painting).
• WARNING / CAUTION labels are affixed to
every air bag system component. Follow
the instructions provided on them.
• After completing repairs on any air bag
system component, perform the
procedures in “Air Bag Diagnostic System
Check” in Section 8B (Page 8B-7).
 Precautions: 00-10

Precautions for Installing Mobile • Keep the antenna as far away as possible from the
Communication Equipment vehicle’s electronic control unit.
AENJHB0B0000015
• Keep the antenna feeder more than 20 cm (7.9 in.)
When installing mobile communication equipment such
away from any electronic control unit and its wire
as CB (citizen band) radio or cellular telephone, observe
harnesses.
the following precautions.
Failure to follow these cautions may adversely affect • Do not run the antenna feeder parallel with other wire
electronic control system. harnesses.
• Check that the antenna and feeder are correctly
adjusted.

Repair Instructions
Electrical Circuit Inspection Procedure 3) Using a male terminal for test use, check terminals
AENJHB0B0006001 on both ends of the circuit being checked for contact
While there are various electrical circuit inspection
tension of female terminals. Check each terminal
methods, the following describes the general methods
visually for cause of poor contact (dirt, corrosion,
using an ohmmeter and a voltmeter to check open and
rust, entry of foreign object, etc.). At the same time,
short circuits.
check that each terminal is held and locked in
connector fully.
Open Circuit Check
Possible causes for the open circuit are as listed below.
As defects in connectors or terminals are most often the
causes, they need to be checked particularly and
carefully.
• Loose connection of connector
• Poor contact of terminal (caused by dirt, corrosion or
rust on it, poor contact tension, entry of foreign object,
etc.) I2RH01010050-01

• Open wire harness 1. Check contact tension by inserting and removing just once.

When checking circuits including an electronic control

unit such as ECM, TCM, ESP® control module, etc., it is 4) Perform continuity test or voltage check using the
important to carefully perform check, starting with items following procedure, to check the wire harness for
which are easiest to check. open circuit and poor connection at its terminals.
1) Disconnect negative (–) cable at battery.
2) Check connectors at both ends of the circuit being
checked for loose connection. Also check lock
condition of connectors if equipped with connector
locks.

I2RH01010051-01

1. Looseness of crimping 3. Thin wire (single strand of wire)

2. Open

IFFA0B000002-01
00-11 Precautions:

Continuity Test Voltage Check

1) Measure resistance between connector terminals at
both ends of the circuit under test (between “A-1”
and “C-1” in the figure). If no continuity is indicated
(infinity or over limit), it means that the circuit is open
between terminals “A-1” and “C-1”.
I2RH01010052-01
2) Disconnect the connector included in the circuit
(connector-B in the figure) and measure resistance
between terminals “A-1” and “B-1”.
If no continuity is indicated, it means that the circuit
is open between terminals “A-1” and “B-1”. If
continuity is indicated, there is an open circuit
between terminals “B-1” and “C-1” or connector-B is
defective.
If the circuit being checked is under voltage, voltage
check can be used to check the circuit.
1) With all connectors connected and voltage applied to
the circuit being checked, measure voltage between
each terminal and ground.
a) If measurements are taken as shown in figure
and results are as listed below, it means that the
circuit is open between terminals “B-1” and “A-1”.
Voltage between
“C-1” and ground: Approx. 5 V
“B-1” and ground: Approx. 5 V
“A-1” and ground: 0 V
b) If measurements are as listed below, it means
that there is an abnormally high resistance
causing the indicated voltage drop in the circuit
between terminals “A-1” and “B-1”.
Voltage between
“C-1” and ground: Approx. 5 V
“B-1” and ground: Approx. 5 V
“A-1” and ground: Approx. 3 V

I2RH01010053-01

I5RH01000005-01
 Precautions: 00-12

Short Circuit Check (Wire Harness to Ground) 4) Disconnect the connector included in circuit
1) Disconnect negative (–) cable at battery. (connector-B) and measure resistance between “A-
1” and ground. If continuity is indicated, the circuit is
2) Disconnect connectors at both ends of the circuit to
shorted to ground between terminals “A-1” and “B-
be checked.
1”.
NOTE
If the circuit to be checked is connected to
other parts (1), disconnect all connections to
these parts.
This is essential to having correct check
results.

3) Measure resistance between the terminal at one end

of the circuit (“A-1” terminal in the figure) and
ground. If continuity is indicated, it means that the
circuit is shorted to ground between terminals “A-1”
and “C-1”. I2RH01010056-01

1. To other parts

Intermittent Connection and Poor Contact

Inspection
AENJHB0B0006002
Most intermittent connections are caused by faulty
electrical connections or wiring, although a sticking relay
or solenoid can occasionally be a cause. When checking
connections, perform check of suspect circuit for:
• Poor mating of connector halves, or terminals not fully
seated in the connector body (backed out).
• Dirt or corrosion on the terminals. The terminals must
be clean and free of any foreign material which could
impede proper terminal contact. However, cleaning
the terminal with a sand paper or the like is prohibited.
• Damaged connector body, terminals exposed to
moisture and dirt, misalignment of terminals on
component or connector and mating connector.

I5RH01000006-01

I2RH01010057-02
00-13 Precautions:

• Improperly formed or damaged terminals.
Check each connector terminal in circuit with problem
for good contact tension using a corresponding test
terminal.
If contact tension is not enough, correct terminal
shape to increase contact tension or replace harness.
• Damaged wire insulation, causing intermittent short
circuit to other wiring or parts.
• Broken wire inside the insulation. If one or two strands
of a multi stranded wire are intact, continuity check will
show good circuit, but resistance could be too high. If
the resistance is too high, repair or replace the
harness.

I2RH01010060-01

I5RH01000007-01

1. Check contact tension by inserting and removing just once.

2. Check each terminal for bend and proper alignment.

• Poor connection of terminal and wire.

Check each wire harness in circuit with problem for
poor connection by shaking it by hand lightly. If any
abnormal condition is found, repair or replace
harness.

I2RH01010059-01

Section 0
General Information
CONTENTS
General Information ................................ 0A-1
General Description .............................................0A-1
Abbreviations ...................................................... 0A-1
ISO-to-SUZUKI Term .......................................... 0A-2
Symbols .............................................................. 0A-4
Wire Color / Connector Color Symbols ............... 0A-5
Ignition Modes and Ignition Switch Positions ...... 0A-5
Fasteners Information ......................................... 0A-5
Vehicle Lifting Points........................................... 0A-8
Vehicle Identification Number ........................... 0A-11
Identification Plate............................................. 0A-12
Engine Identification Number ............................ 0A-12
Transaxle Identification Number ....................... 0A-12
Component Location .........................................0A-13
Warning, Caution and Information Location...... 0A-13
Maintenance and Lubrication................. 0B-1
Scheduled Maintenance ......................................0B-1
Maintenance Schedule under Normal Driving
Conditions ......................................................... 0B-1
Maintenance Recommended under Severe
Driving Conditions ............................................. 0B-2
Repair Instructions ..............................................0B-5
Accessory Drive Belt Inspection.......................... 0B-5
Accessory Drive Belt Replacement..................... 0B-5
Valve Lash (Clearance) Inspection (Petrol
Engine Model) ................................................... 0B-5
Engine Oil and Filter Change .............................. 0B-5
Engine Coolant Change ...................................... 0B-5
Exhaust System Inspection................................. 0B-5
Spark Plug Replacement (Petrol Engine
Model) ............................................................... 0B-6
Special Tools and Equipment ...........................0B-12
Air Cleaner Filter Inspection................................ 0B-6
Air Cleaner Filter Replacement ........................... 0B-6
Table of Contents 0- i
0
Fuel Tank, Cap Gasket and Fuel Line
Inspection..........................................................0B-6
Fuel Filter Replacement ......................................0B-6
PCV Valve Inspection (Petrol Engine Model)......0B-6
Fuel Evaporative Emission Control System
Inspection (Petrol Engine Model) ......................0B-6
Brake Disc and Pad Inspection ...........................0B-7
Brake Drum and Shoe Inspection .......................0B-7
Brake Hose and Pipe Inspection.........................0B-7
Brake Fluid Replacement....................................0B-7
Brake Pedal Inspection .......................................0B-7
Brake Fluid Inspection.........................................0B-7
Brake Lever and Cable Inspection ......................0B-7
Clutch Fluid Replacement (M/T Model)...............0B-8
Clutch Pedal Inspection (M/T Model) ..................0B-8
Clutch Fluid Inspection (M/T Model) ...................0B-8
Tire Inspection.....................................................0B-8
Wheel Disc Inspection.........................................0B-8
Wheel Bearing Inspection ...................................0B-8
Drive Shaft (Axle) Boot Inspection ......................0B-8
Suspension System Inspection ...........................0B-9
Steering System Inspection ................................0B-9
Manual Transaxle Oil Inspection (M/T Model) ..0B-10
Manual Transaxle Oil Replacement (M/T
Model) .............................................................0B-10
ATF Inspection (A/T Model) ..............................0B-10
ATF Change (A/T Model) ..................................0B-10
ATF Cooler Hose Inspection (A/T Model) .........0B-10
All Latches, Hinges and Locks Inspection.........0B-10
HVAC Air Filter Inspection ................................0B-10
HVAC Air Filter Replacement............................0B-11
Final Inspection for Maintenance Service .........0B-11
Recommended Fluids and Lubricants...............0B-12
0A-1 General Information:

General Information
General Information

General Description
Abbreviations ELR: Emergency Locking Retractor
AENJHB0B0101001 ENG A-STOP: Engine Auto Stop and Start
A:
EPS: Electronic Power Steering
A/B: Air Bag
ESP®: Electronic Stability Program
ABDC: After Bottom Dead Center
EVAP: Evaporative Emission
ABS: Anti-lock Brake System
F:
AC: Alternating Current
FET: Field-Effect Transistor
A/C: Air Conditioning
FWD: Front Wheel Drive
A-ELR: Automatic-Emergency Locking Retractor
G:
A/F: Air Fuel Ratio
GND: Ground
ALR: Automatic Locking Retractor
GPS: Global Positioning System
API: American Petroleum Institute
H:
APP: Accelerator Pedal Position
HVAC: Heating, Ventilating and Air Conditioning
A/T: Automatic Transmission, Automatic Transaxle
HC: Hydrocarbons
ATDC: After Top Dead Center
HDD: Hard Disk Drive
ATF: Automatic Transmission Fluid, Automatic
HFC: Hydro Fluorocarbon
Transaxle Fluid
HFO: Hydro Fluoroolefin
AWD: All Wheel Drive
HI: High
B:
HO2S: Heated Oxygen Sensor
BARO: Barometric Pressure
I:
BBDC: Before Bottom Dead Center
IAC: Idle Air Control
BCM: Body electrical Control Module
IAT: Intake Air Temperature
BTDC: Before Top Dead Center
IMRC: Intake Manifold Runner Control
B+: Battery Positive Voltage
IMT: Intake Manifold Tuning
BB+: Battery Positive Voltage for Backup ISC: Idle Speed Control
C: ISG: Integrated Starter Generator
CAN: Controller Area Network ISO: International Organization for Standardization
CKP: Crankshaft Position J:
CMP: Camshaft Position JIS: Japanese Industrial Standards
CO: Carbon Monoxide J/B: Junction Block
CO2: Carbon Dioxide J/C: Junction Connector
CPP: Clutch Pedal Position L:
CPU: Central Processing Unit L: Left
CVT: Continuously Variable Transmission, LCD: Liquid Crystal Display
Continuously Variable Transaxle LED: Light Emitting Diode
D: LHD: Left Hand Drive vehicle
DC: Direct Current LIN: Local Interconnect Network
D/C: Driving Cycle LO: Low
DLC: Data Link Connector LSD: Limited Slip Differential
DOHC: Double Over Head Camshaft LSPV: Load Sensing Proportioning Valve
DOJ: Double Offset Joint M:
DOT: Department of Transportation MAF: Mass Air Flow
DPF®: Diesel Particulate Filter MAP: Manifold Absolute Pressure
DRL: Daytime Running Light
Max: Maximum
DSBS: Dual Sensor Brake Support
MFI: Multiport Fuel Injection
DTC: Diagnostic Trouble Code (Diagnostic Code)
Min: Minimum
E:
MIL: Malfunction Indicator Lamp (“CHECK ENGINE”
EBD: Electronic Brake Force Distribution
Light or “SERVICE ENGINE SOON” Light)
ECM: Engine Control Module
M/T: Manual Transmission, Manual Transaxle
ECT: Engine Coolant Temperature
N:
ECU: Electronic Control Unit
NOx: Nitrogen Oxides
EEPROM: Electrically Erasable Programmable Read
O:
Only Memory
OBD: On-Board Diagnostic system
EFE Heater: Early Fuel Evaporation Heater
OCM: Occupant Classification Module
EGR: Exhaust Gas Recirculation
OCV: Oil Control Valve
EGT: Exhaust Gas Temperature
 General Information: 0A-2

O/D: Overdrive TCM: Transmission Control Module

OHC: Over Head Camshaft TCSS: Traction Control Support System
O2S: Oxygen Sensor TDC: Top Dead Center
P: TP: Throttle Position
PCM: Powertrain Control Module TPMS: Tire Pressure Monitoring System
PCV: Positive Crankcase Ventilation TWC: Three-Way Catalytic converter
PM: Particulate Mater U:
PNP: Park / Neutral Position UART: Universal Asynchronous Receiver / Transmitter
P/S: Power Steering USB: Universal Serial Bus
PSP: Power Steering Pressure V:
R: VCI: Vehicle Communication Interface
R: Right VDOP: Variable Displacement Oil Pump
RAM: Random Access Memory VFD: Vacuum Fluorescent Display
RBS: Radar Brake Support VIN: Vehicle Identification Number
RHD: Right Hand Drive Vehicle VSS: Vehicle Speed Sensor
ROM: Read Only Memory VVT: Variable Valve Timing
RPM: Engine Speed W:
S: WU-OC: Warm Up Oxidation Catalytic converter
SAE: Society of Automotive Engineers WU-TWC: Warm Up Three-Way Catalytic converter
SDM: Sensing and Diagnostic Module (Air Bag Other:
Controller, Air bag Control Module) 2WD: 2-Wheel Drive
SDT: Smart Diagnostic Tester 4WD: 4-Wheel Drive
SFI: Sequential Multiport Fuel Injection
SHVS: Smart Hybrid Vehicle by SUZUKI NOTE
SI: Système International • DPF® is a trademark of HJS
SOHC: Single Over Head Camshaft Fahrzeugtechnik GmbH & Co KG and
SOx: Sulfur Oxides SUZUKI is the trade mark licensee.
SRS: Supplemental Restraint System
• ESP® is a registered trademark of Daimler
T:
AG.
TCC: Torque Converter Clutch

ISO-to-SUZUKI Term
AENJHB0B0101002
This table lists ISO (International Organization for Standardization) TR15031 terms and abbreviations which may be
used in this manual in compliance with ISO recommendations, as well as their SUZUKI terms.
ISO term
SUZUKI term
Full spelling Abbreviation
A
Accelerator Pedal Position APP Accelerator Pedal Position (APP)
Air Cleaner ACL Air Cleaner
Air Cleaner Element ACL Element Air Cleaner Element
Air Cleaner Housing ACL Housing Air Cleaner Housing
Air Conditioning A/C Air Conditioner (A/C)
Air Conditioning System A/C System Air Conditioning System (A/C system)
Air Fuel Ratio Sensor A/F Sensor Air Fuel Ratio Sensor (A/F sensor)
Automatic Transaxle, Automatic A/T Automatic Transaxle, Automatic Transmission (A/T)
Transmission
B
Barometric Pressure BARO Barometric Pressure (BARO)
Barometric Pressure Sensor BARO Sensor Barometric Pressure Sensor (BARO sensor)
Battery Positive Voltage B+ Battery Positive Voltage (B+)
C
Camshaft Position CMP Camshaft Position
Camshaft Position Sensor CMP Sensor Camshaft Position Sensor (CMP sensor)
Carbon Monoxide CO Carbon Monoxide (CO)
Carbon Dioxide CO2 Carbon Dioxide (CO2)
Clutch Pedal Position Switch CPP Switch Clutch Pedal Position Switch (CPP switch)
Closed Loop CL Closed-Loop
Closed Throttle Position CTP Closed Throttle Position
0A-3 General Information:

ISO term
SUZUKI term
Full spelling Abbreviation
Continuously variable transaxle, CVT Continuously variable transaxle, Continuously
Continuously variable transmission variable transmission (CVT)
Crankshaft Position CKP Crankshaft Position (CKP)
Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKP sensor)
D
Data Link Connector DLC Data Link Connector (DLC)
Diagnostic Trouble Code DTC Diagnostic Trouble Code (DTC)
E
Electrically Erasable Programmable Read EEPROM Electrically Erasable Programmable Read Only
Only Memory Memory (EEPROM)
Engine Control Module ECM Engine Control Module (ECM)
Engine Coolant Temperature Sensor ECT Sensor Engine Coolant Temperature Sensor (ECT sensor)
Engine Speed RPM Engine Speed, RPM, rpm
Evaporative Emission Canister EVAP Canister Evaporative Emission Canister (EVAP canister)
Evaporative Emission Canister Purge Valve EVAP Canister EVAP canister purge valve
Purge Valve
Evaporative Emission System EVAP System Evaporative Emission System
Exhaust Gas Re-circulation EGR Exhaust Gas Recirculation (EGR)
Exhaust Gas Re-circulation Valve EGR Valve Exhaust Gas Recirculation Valve (EGR valve)
F
Fan Control FC Radiator Fan Control
Fan Control Relay FC Relay: Radiator cooling fan relay
Four Wheel Drive 4WD 4WD
Fourth Gear 4GR 4th Gear
Front Wheel Drive FWD Front Wheel Drive
Fuel Pump FP Fuel Pump
Fuel Pump Relay FP Relay Fuel Pump Relay
Full Time Four Wheel Drive F4WD Full-Time 4WD
G
Generator GEN Generator
Ground GND Ground
H
Heated Oxygen Sensor HO2S Heated Oxygen Sensor (HO2S)
Hydrocarbon HC Hydrocarbon (HC)
I
Idle Air Control IAC Idle Air Control (IAC)
Idle Speed Control ISC Idle Speed Control (ISC)
Intake Air IA Intake Air
Intake Air temperature IAT Intake Air temperature (IAT)
Intake Air temperature Sensor IAT Sensor Intake Air temperature Sensor, IAT Sensor
Input Shaft Speed ISS Input Shaft Speed
Inspection and Maintenance I/M Inspection and Maintenance
K
Knock Sensor KS Knock Sensor
L
Calculated Load Value LOAD Calculated Load Value (CALC)
M
Mass Airflow MAF Mass Airflow (MAF)
Mass Airflow Sensor MAF Sensor MAF Sensor
Malfunction Indicator Lamp MIL Malfunction Indicator Lamp (MIL)
Manifold Absolute Pressure Sensor MAP Sensor Manifold Absolute Pressure Sensor, MAP Sensor
Manual/Transaxle M/T Manual Transaxle, M/T
Manual/Transmission M/T Manual Transmission, M/T
Multiport Fuel Injection MFI Multiport Fuel Injection
N
Nitrogen Oxides NOX Nitrogen Oxides (NOx)
O
On-Board Diagnostic OBD OBD
 General Information: 0A-4

ISO term
SUZUKI term
Full spelling Abbreviation
Open Loop OL Open Loop
Output Shaft Speed Sensor OSS Sensor Output Shaft Speed Sensor
Oxygen O2 O2
Oxidation catalytic converter OC Oxidation catalytic converter
Oxygen Sensor O2S O2 Sensor, O2S
P
Positive Crankcase Ventilation PCV PCV
Positive Crankcase Ventilation Valve PCV Valve PCV Valve
Power Steering Pressure Switch PSP Switch Power Steering Pressure Switch
Powertrain Control Module PCM PCM
R
Random Access Memory RAM RAM
S
Scan Tool ST Scan Tool
Shift Solenoid SS Shift Solenoid
Shift Solenoid Valve SS Valve Shift Solenoid Valve
T
Third Gear 3GR 3rd Gear
Three Way Catalytic Converter TWC Three-Way Catalytic Converter (TWC)
Throttle Actuator Control TAC Throttle Actuator Control
Throttle Body TB Throttle body
Throttle Position TP Throttle Position, TP
Throttle Position Sensor TP Sensor TP Sensor
Torque Converter Clutch TCC Torque Converter Clutch
Torque Converter Clutch Pressure TCCP Torque Converter Clutch Pressure
Transmission Control Module TCM Transmission Control Module (TCM)
Transmission Fluid Temperature Sensor TFT Sensor Transmission Fluid Temperature Sensor
Transmission Range TR Transmission Range
Transmission Range Sensor TR Sensor Transmission Range Sensor
Transmission Range Switch TR Switch Transmission Range Switch
V
Vehicle Identification Number VIN Vehicle Identification Number, VIN
Vehicle Speed Sensor VSS Vehicle Speed Sensor, VSS
Voltage Regulator VR Voltage Regulator
W
Warm Up Three Way Catalytic Converter WU-TWC Warm Up Three-Way Catalytic Converter

Symbols
AENJHB0B0101003
Symbol Definition Symbol Definition
Tightening torque Apply SUZUKI BOND NO. 1207B
99000-31140
Apply oil (engine, transmission, transfer, Apply SILICONE SEALANT
differential) 99000-31120
Apply fluid (brake, power steering or Apply SEALING COMPOUND 366E
automatic transmission fluid) 99000-31090
Apply SUZUKI SUPER GREASE A Apply THREAD LOCK 1322
99000-25011 99000-32150
Apply SUZUKI SUPER GREASE C Apply THREAD LOCK 1333B
99000-25030 99000-32020
Apply SUZUKI SUPER GREASE E Apply THREAD LOCK 1342
99000-25050 99000-32050
Apply SUZUKI SUPER GREASE H Do not reuse
99000-25121
Apply SUZUKI SUPER GREASE I Note on reassembly
99000-25210
Apply SUZUKI BOND NO. 1215 Alert
99000-31110
0A-5 General Information:

Symbol Definition Symbol Definition

Apply SUZUKI BOND NO. 1207F Do not touch electricity
99000-31250
Apply SUZUKI BOND NO. 1217G Do not repair or disassemble
99000-31260
Apply SUZUKI BOND NO. 1216B Refer to service manual or owner’s
99000-31230 manual

Wire Color / Connector Color Symbols

AENJHB0B0101004
Symbol Wire color / Connector color Symbol Wire color / Connector color
Natural (Plastic material color: Milky
BEG Beige N
white / Light yellow)
BLK Black ORN Orange
BLU Blue RED Red
BRN Brown WHT White
GRN Green YEL Yellow
GRY Gray PNK Pink
LVN Lavender PPL Violet

There are two types of colored wire used in this vehicle. One is a single-colored type (1) and the other is a dual-
colored (striped) type (2). The dual-colored type of wire uses two color symbols such as “GRN/YEL”. The first symbol
“GRN” represents the base color (3) of the wire and the second symbol “YEL” represents the color of the stripe (4).
Also, “LT” (6) or “D” can be shown before the color symbols. They show the color variation of light or dark. “LT” stands
for “Light” and “D” stands for “Dark”. For example, “LT GRN” means light green and “D GRY” means dark gray.

2
1 GRN
GRN/YEL 1
GRN/YEL

2
C42-4 ORN C01-56
3
C42-3 WHT C01-41
4
BRN/BLK C01-55
C42-1 LT GRN C01-1
C42-2

N 5
6
IDP50B010001-01

5. Connector color

Ignition Modes and Ignition Switch Positions NOTICE

AENJHB0B0101005
In this manual, each ignition switch position (models with
a conventional ignition switch system) and the
corresponding ignition mode (models with a keyless
push start system) are indicated using the following
unified word / acronym preceded by “ignition”: START,
ON, ACC or OFF (e.g. “ignition ON”) unless there is
need to express it otherwise.
Fasteners Information
AENJHB0B0101006
Metric Fasteners
Most of the fasteners used for this vehicle are JIS-
defined and ISO-defined metric fasteners. When
replacing any fasteners, it is most important that
replacement fasteners are of the correct diameter,
thread pitch and strength.
Combining male and female fasteners with
different thread pitches will damage both
fasteners.
It is important to note that, even when the
nominal diameter (1) of the threads is the
same, JIS-defined and ISO-defined fasteners
may be different in thread pitch (2) or width
across flats (3). Refer to the following table
for these differences.
Before installing a fastener, check it for
correct thread pitch and then, screw it in or
on the mating fastener by hand. If the
fastener is too tight to turn by hand, its
thread pitch may be different from that of the
mating fastener.
 General Information: 0A-6

When replacing metric fasteners, use bolts and nuts of

JIS-to-ISO main fasteners comparison table the same strength class as or higher class than the
Nominal diameter original bolts and nuts. It is also important to select
M6 M8 M10 M12 M14 replacement fasteners of the correct diameter and
Thread pitch 1.0 1.25 1.25 1.25 1.5 thread pitch. Correct replacement bolts and nuts are
JIS
Width across flats 10 12 14 17 19 available as SUZUKI spare parts.
Thread pitch 1.0 1.25 1.5 1.5 1.5 Metric bolts and nuts: Strength class numbers or marks
ISO
Width across flats 10 13 16 18 21 (The larger the number, the greater the strength).

I4RH0A010005-01

Fastener Strength Identification

Most commonly used strength classes of metric
fasteners are 4T, 6.8, 7T and 8.8. Strength class is
indicated by a number or radial line(s) embossed on the
I5RH01010001-01
head of each bolt. Some metric nuts have a inscribed
1. Nut strength identification
number, 6 or 8 on their end surfaces. Figure shows
different strength markings.

Standard Tightening Torque

Each fastener should be tightened to the torque specified in each section. If no torque description or specification is
provided in the relevant section, refer to the following tightening torque chart for the applicable torque for each
fastener. When a fastener of greater strength than the original one is used, use the torque specified for the original
fastener.

NOTE
• The following chart is applicable only where the fastened parts are made of steel or light alloy.
• Tightening torque in this chart is also applied to the fastener with cotter pin.
• Tightening condition for the fastener is dry. Therefore, tightening torque in this chart cannot be
applied to the fastener with oily thread and/or bearing surface.
• When tightening a fastener of 6.8, 7T or 8.8 strength to a weld nut, apply tightening torque to the
corresponding fastener of 6.8 strength.
0A-7 General Information:

Tightening torque chart

Thread diameter (Nominal diameter) (mm)
Strength Unit
4 5 6 8 10 12 14 16 18
Fastener of strength class equivalent to Nm 1.5 3.0 5.5 13 29 45 65 105 160
4T kgf-m 0.15 0.30 0.55 1.3 2.9 4.5 6.5 10.5 16
lbf-ft 1.0 2.5 4.0 9.5 21.0 32.5 47.0 76.0 116.0

I2RH01010012-01
Fastener of strength class equivalent to Nm 2.4 4.7 8.4 20 42 80 125 193 280
6.8 kgf-m 0.24 0.47 0.84 2.0 4.2 8.0 12.5 19.3 28
lbf-ft 2.0 3.5 6.0 14.5 30.5 58.0 90.5 139.5 202.5

I2RH01010013-01
Flanged fastener of strength class Nm 2.4 4.9 8.8 21 44 84 133 203 298
equivalent to 6.8 kgf-m 0.24 0.49 0.88 2.1 4.4 8.4 13.3 20.3 29.8
*: Self-locking nut (6 strength) lbf-ft 2.0 3.5 6.5 15.5 32.0 61.0 96.5 147.0 215.5

I2RH01010014-01
Fastener of strength class equivalent to Nm 2.3 4.5 10 23 50 85 135 210 240
7T kgf-m 0.23 0.45 1.0 2.3 5.0 8.5 13.5 21 24
lbf-ft 2.0 3.5 7.5 17.0 36.5 61.5 98.0 152.0 174.0

I2RH01010015-01
Fastener of strength class equivalent to Nm 3.1 6.3 11 27 56 105 168 258 373
8.8 (bolt) or 8 (nut) kgf-m 0.31 0.63 1.1 2.7 5.6 10.5 16.8 25.8 37.3
lbf-ft 2.5 4.5 8.0 19.5 40.5 76.0 121.5 187.0 270.0

I2RH01010016-01
Flanged fastener of strength class Nm 3.2 6.5 12 29 59 113 175 270 395
equivalent to 8.8 (bolt) or 8 (nut) kgf-m 0.32 0.65 1.2 2.9 5.9 11.3 17.5 27 39.5
lbf-ft 2.5 5.0 9.0 21.0 43.0 82.0 126.5 195.5 286.0

I2RH01010017-01

*: Self-locking nut
 General Information: 0A-8

Vehicle Lifting Points

AENJHB0B0101007
! WARNING
Improperly lifting the vehicle using a hoist could cause serious personal injury and/or damage to the
vehicle.
Take the following precautions when lifting the vehicle with a hoist:
• Before applying the hoist arms to the underbody, keep in mind how the balance of the vehicle will
change when components are removed during the intended service.
• Before lifting up the vehicle, check that the ends of the hoist arms are not in contact with
components such as the brake and fuel lines, and related brackets.
• When using a frame contact hoist, apply the right and left arms to the symmetrically located points
shown in the figure. Lift up the vehicle until all 4 tires are slightly off the ground and check that the
vehicle will not fall off the hoist by rocking the vehicle body back and forth.
Work should be started only after this confirmation.
• Lock the hoist after the vehicle has been raised up to the desired height.

NOTICE
Failure to follow the following precautions may cause damage to the vehicle:
• When lifting up the vehicle, place attachment (pad) with groove (1), without groove (2) or with deep
groove (3) under the support position (4) as shown in figure.
• When using a frame contact hoist or the like, it is recommended to use attachment without groove
or with small groove to avoid interference (5) between the attachment and the underbody flange (6).
However, if attachment with deep groove is used, change the direction and avoid damage to the
underbody flange by hitting them with the attachment.

[A] [B]

4
4
6 6
1 5

1 5
2
4
2
3 4

3 3

IGSB0A010001-01

[A]: Proper lifting [B]: Improper lifting

0A-9 General Information:

When Using Frame Contact Hoist

NOTICE
Improper placing hoist arms to the vehicle may damage body parts such as underbody flange (4).
When lifting up the vehicle, check that there is space “b” between the ends of the hoist arms and body
parts.

[A] [B]

4 4

“b” “b” “b”

“b”

2
2

[F] 1

1
3

2
[a] “a”
IJHA0A010001-01

[A]: Front side [a]: Wheel center 2. Support position for frame contact hoist and safety stand
[B]: Rear side “a”: Approx. 1,191 – 1,316 mm (Approx. 3. Gravity center position without load in vehicle
46.89 – 51.81 in.)
[F]: Vehicle front 1. Floor jack position
 General Information: 0A-10

When Using Floor Jack In raising front or rear vehicle end off the floor by jacking,
put the jack against front suspension frame (1) or rear
! WARNING towing hook (2).
Improperly raising only the front or rear of Front
the vehicle with a jack could cause serious
personal injury and/or damage to the vehicle.
• Before jacking up a vehicle only at the
front or rear end, block all the wheels that
will remain on the ground.
• After the vehicle is jacked up, support it on
safety stands. It is extremely dangerous to
do any work on the vehicle supported by a
jack alone.

NOTICE
If you apply a jack against rear suspension
parts (i.e. torsion beam, etc.) or the vehicle
floor, these parts may get deformed.
Avoid applying a jack against any rear
suspension component or the vehicle floor.

NOTE
When jacking up the front end, the floor jack
sizes shown below are appropriate.
Jack size
Height “h”: below 145 mm (below 5.71 in.)
Length “l”: above 900 mm (above 35.4 in.)

IJHA0A010002-01

“l”

“h”
I4RS0A010002-01
0A-11 General Information:

Rear
Front

“a” “a”

1
IJHA0A010004-01

Rear

2 “a” “a”

1
IJHB0B010001-01
IJHA0A010005-01
To perform service with either front or rear vehicle end
jacked up, place safety stands (1) under the body
mounting stays (2) so that vehicle body is securely
Vehicle Identification Number
AENJHB0B0101008
supported. Then check that vehicle body does not slide The number (1) is inscribed on the right dash side of
on safety stands and the vehicle is held stable. front panel in engine compartment.
NOTICE
1
Improper placing safety stands to the vehicle
may damage body parts such as underbody
flange.
When supporting the vehicle body, check
that there is space “a” between safety stand
and body parts.

IJHA0A010006-01
 General Information: 0A-12

Identification Plate Engine Identification Number

AENJHB0B0101009 AENJHB0B0101010
Identification plate (1) is installed at the center pillar The engine identification number is inscribed on cylinder
lower side on the right side body outer panel. block.
The identification plate has the following information:
[A] [B]
• VIN (2)
• Engine type (3)

IFRA0A010009-01

[A]: K15B [B]: D13A

Transaxle Identification Number

AENJHB0B0101011
The A/T identification number (1) is inscribed on
transaxle case.
1
1

3
IFRA0A010008-01

IJHA0A010010-01
0A-13 General Information:

Component Location
Warning, Caution and Information Location
AENJHB0B0103001
The figure shows main labels that are attached to vehicle components.
When servicing and handling components, refer to WARNING / CAUTION instructions printed on labels.
If any WARNING / CAUTION label is found stained or damaged, clean or replace it.

[A]

6
4

2
8

IJHB0B010002-01

[A]: These labels are WARNING/CAUTION labels for
items not related to air bag system.
1. Battery label (petrol engine model)
2. Battery label (diesel engine model)
3. Radiator cap label (petrol engine model) 6. Steering shaft joint cover embossed notice
4. Engine cooling fan label 7. Jack label
5. Degassing tank cap label (diesel engine 8. Auxiliary power module (lithium-ion battery)
model) label
 General Information: 0A-14

[B]
1

IJHB0A010003-01

[B]: These labels are attached on vehicle equipped with air bag system only. 3. Air bag label on sun visor (passenger side)
1. Air bag label on driver air bag (inflator) module 4. Air bag label on SDM
2. Air bag label on passenger air bag (inflator) module 5. Pretensioner label on front seat belt retractor
0B-1 Maintenance and Lubrication:

Maintenance and Lubrication

General Information

Scheduled Maintenance

AENJHB0B0205001
NOTE

• The intervals should be determined based on odometer readings or months, whichever comes first.
• The following table shows the service schedule up to 180,000 km (108,000 miles). Beyond 180,000
km (108,000 miles), perform the same maintenance services at the same intervals shown in the
table.
• Class 1: Petrol engine
• Class 2: Diesel engine

NOTE
• “R”: Replace or change
• “I”: Inspect, clean, adjust, lubricate or replace it if necessary
• “L”: Lubricate
• “T”: Tighten to Specified Torque
• “O”: Rotate
• “C”: Clean
• For specified spark plug, refer to “Spark Plug Inspection” in Section 1H (Page 1H-8).

km (x 1,000) 1 5 10 20 30 40 50 60 70 80
Interval
months 1 6 12 24 36 48 60 72 84 96
Engine
Water pump drive belt [Class 1(Non-ISG)] — — I I I I I I I R
(Tension, Wear) (I:
(Page 0B-3), R: [Class 2] — — I I I I I R I I
(Page 0B-4))
ISG Belt (I: (Page 0B-
3), R: (Page 0B-4)) (Vehicle equipped with ISG) — — I I R I I R I I

Engine Coolant (Level, Leakage) (R: (Page 0B-4)) I I I R I R I R I R

Engine oil, engine oil filter and drain plug gasket (Leakage, Damage)
I I R R R R R R R R
(R: (Page 0B-4))
Cooling system hoses and connections (Leakage and Damage) I I I I I I I I I I
Engine Mounting & manifold fixing (Loose, Damage) — — I — I — I — I —
Valve Clearance (I: (Page 0B-4)) [Class 1] — — — — I — — I — —
Exhaust System (Noise, Leakage etc.) (I: (Page 0B-4)) — I — I — I — I — I
Positive Crank Case Ventilation System
(Hoses, Connections and Valve) (I: (Page [Class 1] — I — I — I — I — I
0B-5))
Fuel evaporative control system (I: (Page
[Class 1] — I — I — I — I — I
0B-5))
Exhaust Gas Recirculation Valve (I: (Page
[Class 2] — — — — C — — C — —
1B-12))
Ignition
Ignition wire (Damage, Deterioration) [Class 1] — — I — I — I — I
Spark plugs (R: (Page 0B-5)) [Class 1] — — — — — R — — — R
 Maintenance and Lubrication: 0B-2

km (x 1,000) 1 5 10 20 30 40 50 60 70 80
Interval
months 1 6 12 24 36 48 60 72 84 96
Fuel
Clean after every 5,000 KM.
[Class 1]
Replace after every 40,000 KM.
Paved road
Replace after every 20,000 KM.
[Class 2]
Cleaning not required.
Air cleaner filter element
Clean after every 2,500 KM or as required.
(R: (Page 0B-5), I: [Class 1]
Replace after every 40,000 KM.
(Page 0B-5))
Replace after every 20,000 KM.
Dusty condition
Cleaning not required.
[Class 2]
More frequent replacement if dust condition is
severe.
Fuel tank cap, fuel lines and connections (Leakage and Damage) (I:
— I — — — I — — — I
(Page 0B-5))
Fuel filter (Leakage) (R: (Page 0B-5)) [Class 1] — — — — — R — — — R
Fuel Filter and Water Draining (I: (Page 1G- [Class 2]
I I I R I R I R I R
41), R: (Page 1G-58))
Clutch and Transmission
Clutch fluid (Level, Leakage) (I: (Page 0B-7), R: (Page 0B-7)) I I I R I R I R I R
Clutch slipping (Dragging or Excess Damage) I I I I I I I I I I
Manual Transaxle Oil (Level, Leakage) (I: (Page 0B-9), R:
I I I I I I I I I I
(Page 0B-9))
Automatic Transaxle Fluid (Level, Leakage) (I: (Page 0B-9), R: Replace at 1,65,000 km or 11 years whichever
(Page 0B-9)) comes first
Automatic Transaxle Fluid Hose (I: (Page 0B-9)) I I I I I I I I I I
Gear shifter (Operation) I I I I I I I I I I
Drive Shaft
Drive shaft noise I I I I I I I I I I
Drive shaft boot (Boot Damage) (I: (Page 0B-7)) — I I I I I I I I I
0B-3 Maintenance and Lubrication:

km (x 1,000) 1 5 10 20 30 40 50 60 70 80
Interval
months 1 6 12 24 36 48 60 72 84 96
Brake
Brake Fluid (Level, Leakage) (I: (Page 0B-6), R: (Page 0B-6)) I I I R I R I R I R
Brake pedal (Pedal - wall clearance) (I: (Page 4A-9)) I I I I I I I I I I
Parking brake lever and cable (Play, Damage) (I: (Page 0B-6)) I I I I I I I I I I
Brake disc and pad (Wear) (I: (Page 0B-6)) — I I I I I I I I I
Brake drum and shoes (Wear) (I: (Page 0B-6)) — — I I I I I I I I
Brake hoses and pipes (Fluid leakage, Damage) (I: (Page 0B-6)) I I I I I I I I I I
Master cylinder, wheel cylinder and caliper piston
I I I I I I I I I I
(Fluid leakage, Boot/Seal damage)
Wheel
Tyres (Air pressure, Abnormal wear, Crack and Rotation) I I&O I&O I&O I&O I&O I&O I&O I&O I&O
Wheels (Damage) (I: (Page 0B-7)) I I I I I I I I I I
Front/Rear wheel bearing (Loose, Damage) (I: (Page 0B-7)) I I I I I I I I I I
Front / Rear Suspension
Suspension strut (Oil leakage, Damage) (I: (Page 0B-8)) I I I I I I I I I I
Suspension arms / Knuckle support and Torsion rods
— I I I I I I I I I
(Loose, Damage) (I: (Page 0B-8))
Rear spring (Damage) (I: (Page 0B-8)) I I I I I I I I I I
Shock absorbers (Oil leakage, Damage) (I: (Page 0B-8)) I I I I I I I I I I
All bolts and nuts (Loose) (I: (Page 0B-8)) — T T T T T T T T T
 Maintenance and Lubrication: 0B-4

km (x 1,000) 1 5 10 20 30 40 50 60 70 80
Interval
months 1 6 12 24 36 48 60 72 84 96
Steering
Steering wheel (Play, Loose) (I: (Page 0B-8)) I I I I I I I I I I
All rods and arms (Loose, Damage, Wear) (I: (Page 0B-8)) I I I I I I I I I I
Tilt Steering (Operation) (I: (Page 0B-8)) I I I I I I I I I I
Electrical
Battery - electrolyte (Level, leakage) and voltage (I: (Page 0B-10)) I I I I I I I I I I
Wiring harness connection (Loose, Damage) — I I I I I I I I I
Lighting system (Operation, Stains, Damage) (I: (Page 0B-10)) I I I I I I I I I I
Wiper (Operation, Stains, Damage) (I: (Page 0B-10)) I I I I I I I I I I
Horn (Operation) I I I I I I I I I I
AUX, USB and accessory socket (Operation) — I I I I I I I I I
Body
All chassis bolts and nuts (Tighten) — T T T T T T T T T
All latches, hinges and locks (Function) I I&L I&L I&L I&L I&L I&L I&L I&L I&L
Road Test
Operation of Brakes, gear shifting and speedometer I I I I I I I I I I
Body and chassis noise I I I I I I I I I I
Air Conditioner
Check belt tension (I: (Page 0B-1)) I I I I I I I I I I
Tighten compressor mounting bolt — T T T T T T T T T
All hose joint (Check, Tighten) I I I I I I I I I I
Check functioning of Recirculating flap I I I I I I I I I I
Clean condenser with low pressure water — C C C C C C C C C
Check belt for frayed edges (I: (Page 0B-1)) I I I I I I I I I I
Check all mounting bolts I I I I I I I I I I
Air conditioner filter element (I: (Page 0B-9), R: (Page 0B-10)) I I I I R I I R I I
0B-5 Maintenance and Lubrication:

Repair Instructions
Accessory Drive Belt Inspection
AENJHB0B0206001
! WARNING
There is a risk of personal injury if the service
work described below is performed while the
engine is running.
Check that the ENGINE IS NOT RUNNING
before performing the service work
described below.
Valve Lash (Clearance) Inspection (Petrol
Engine Model)
AENJHB0B0206003
Check intake and exhaust valve clearances. Adjust them
if necessary.
Refer to “Valve Clearance Inspection and Adjustment”:
K15B in Section 1D (Page 1D-6) for valve clearance
inspection and adjustment procedures.

Check belt for tension, crack, cuts, deformation, wear

and contamination. If any defect is found, replace belt.
• ISG drive belt for petrol engine model: (Page 1J-6)
• ISG drive belt for diesel engine model: (Page 1J-18)
• Water pump drive belt for diesel engine model:
(Page 1F-31)
• Compressor drive belt for manual single A/C model:
(Page 7B-48) I2RH0B020003-02

• Compressor drive belt for manual dual A/C model: 1. Camshaft 2. Feeler gauge
(Page 7B-92)
• Compressor drive belt for auto A/C model: (Page Engine Oil and Filter Change
AENJHB0B0206004
7B-134)
Change engine oil and filter.
• Petrol engine model: (Page 1E-4)
Accessory Drive Belt Replacement
AENJHB0B0206002 • Diesel engine model: (Page 1E-16)
Replace accessory drive belt with new one.
• ISG drive belt for petrol engine model: (Page 1J-7) Engine Coolant Change
AENJHB0B0206005
• ISG drive belt for diesel engine model: (Page 1J-18)
Change engine coolant with new one.
• Water pump drive belt for diesel engine model:
• Petrol engine model:
(Page 1F-31)
– Draining: (Page 1F-11)
• Compressor drive belt for manual single A/C model:
(Page 7B-49) – Refilling: (Page 1F-11)
• Compressor drive belt for manual dual A/C model: • Diesel engine model:
(Page 7B-92) – Draining: (Page 1F-25)
• Compressor drive belt for auto A/C model: (Page – Refilling: (Page 1F-25)
7B-135)
Exhaust System Inspection
AENJHB0B0206006
! CAUTION
Exhaust system components may be hot
enough to cause burns.
Check that all exhaust system components
have cooled before performing any service
work on the exhaust system.

When carrying out periodic maintenance, or the vehicle

is hoisted for other service, check exhaust system as
follows:
• Check rubber mountings for damage, deterioration
and dislocation.
• Check exhaust system for leakage, loose
connections, dents and damages.
If bolts or nuts are loose, tighten them to specification.
 Maintenance and Lubrication: 0B-6

• Check nearby body areas for damaged, missing or ill- Fuel Tank, Cap Gasket and Fuel Line Inspection
placed parts, open seams, holes, loose connections AENJHB0B0206010

or other defects which could permit exhaust fumes to • Check fuel tank, fuel filler cap (1) and fuel lines for
seep into the vehicle. loose connection, deterioration or damage which
• Check that exhaust system components have enough could cause leakage. Check that all clamps are
clearance from the underbody to avoid overheating secure.
and possible damage to floor carpet. • Check fuel filler cap gasket (2) for an even filler neck
– Petrol engine model: (Page 1K-2) imprint or any damage.
– Diesel engine model: (Page 1K-7)
• Any defects should be fixed at once.

2
Spark Plug Replacement (Petrol Engine Model)
AENJHB0B0206007
Replace spark plugs with new ones. (Page 1H-7)
1
Air Cleaner Filter Inspection
AENJHB0B0206008
IDAA0A020001-01
1) Remove air cleaner filter.
• Replace any damaged or deteriorated parts.
• Petrol engine model: (Page 1D-8) There should be no sign of fuel leakage or moisture at
• Diesel engine model: (Page 1D-82) any fuel connection.
2) Check that filter is not excessively dirty, damaged or – Petrol engine model: (Page 1G-11)
oily. Clean filter with compressed air from air outlet – Diesel engine model: (Page 1G-42)
side of filter.

[A]
Fuel Filter Replacement
AENJHB0B0206011
! WARNING
Replacing the fuel filter without adequate
ventilation may lead to a fire. Replace the fuel
filter only in a well-ventilated area away from
any open flames (e.g. a gas water heater).

Replace fuel filter.

• Petrol engine model: (Page 1G-26)
• Diesel engine model: (Page 1G-58)
[B]
IHSE0A020001-01 PCV Valve Inspection (Petrol Engine Model)
AENJHB0B0206012
[A]: Air outlet (throttle) side [B]: Air inlet (flesh air) side Check PCV valve and hose.
• PCV valve: (Page 1B-7)
3) Install air cleaner filter.
• PCV hose: (Page 1B-7)
• Petrol engine model: (Page 1D-8)
• Diesel engine model: (Page 1D-82)
Fuel Evaporative Emission Control System
Inspection (Petrol Engine Model)
Air Cleaner Filter Replacement AENJHB0B0206013
AENJHB0B0206009 Check EVAP canister and fuel vapor hose.
Replace air cleaner filter with new one.
• EVAP canister: (Page 1B-6)
• Petrol engine model: (Page 1D-8)
• EVAP connection hose: (Page 1B-7)
• diesel engine model: (Page 1D-82)
0B-7 Maintenance and Lubrication:

Brake Disc and Pad Inspection Brake Fluid Inspection

AENJHB0B0206014
1) Check lining thickness of outside and inside pads.
(Page 4B-2)
Use scale if necessary.
2) Check brake discs for excessive wear, damage and
deflection. (Page 4B-5)
Replace parts if necessary.
Brake Drum and Shoe Inspection
AENJHB0B0206015
Check rear brake drums and brake linings for excessive
wear and damage, while wheels and drums are
removed. At the same time, check wheel cylinders for
leakage. Replace these parts if necessary. (Page 4C-
3)
Brake Hose and Pipe Inspection
AENJHB0B0206016
Perform this inspection where there is enough light and
use a mirror if necessary.
• Check brake hoses and pipes for improper
connections, leakage, crack, chafing and other
damage. (Page 4A-15)
• Check that hoses and pipes are clear of sharp edges
and moving parts.
Repair or replace any of these parts if necessary.
NOTICE
Air in the brake system will cause poor
braking performance and can lead to an
accident.
After servicing the brake system, completely
bleed all air out of the system.
Brake Fluid Replacement
AENJHB0B0206017
NOTE
Clutch fluid is supplied from brake fluid
reservoir.
AENJHB0B0206019
1) Check parts around master cylinder and reservoir for
fluid leakage. If any sign of leakage is found, correct
defects.
2) Check fluid level.
If fluid level is lower than the minimum level of
reservoir, refilling is necessary. Fill reservoir with
specified brake fluid.
For the details, refer to “Brake Fluid Level
Inspection” in Section 4A (Page 4A-4).
! CAUTION
Since brake system of this vehicle is factory-
filled with brake fluid indicated on reservoir
cap, do not use or mix different type of fluid
when refilling; otherwise serious damage will
occur.
Do not use old or used brake fluid, or any
fluid from an unsealed container.
Brake fluid specification
Refer to reservoir cap of brake master cylinder.
Brake Lever and Cable Inspection
AENJHB0B0206020
1) Check brake cables for damage and smooth
movement. (Page 4D-1)
Replace deteriorated cable(s).
2) Check tooth tip of each brake lever ratchet notch for
damage or wear. If any damage or wear is found,
replace parking brake lever.
3) Check parking brake lever for proper operation and
stroke, and adjust it if necessary.
• Check: (Page 4D-2)
• Adjust: (Page 4D-2)

Change brake fluid as follows.

Drain existing fluid from brake system completely, fill
system with specified fluid and carry out air bleeding
operation.
• Replacement: (Page 4A-4)
• Air bleeding: (Page 4A-5)

Brake Pedal Inspection

AENJHB0B0206018
IDL10A020003-01
Check brake pedal travel.
• Brake pedal travel: (Page 4A-10)
• Brake pedal play: (Page 4A-10)

Clutch Fluid Replacement (M/T Model)
AENJHB0B0206021
NOTE
Clutch fluid is supplied from brake fluid
reservoir.
Change clutch fluid as follows.
Drain existing fluid from clutch system completely, fill
system with specified fluid and carry out air bleeding
operation.
For air bleeding procedure, refer to “Air Bleeding of
Clutch System” in Section 5C (Page 5C-5).
Clutch Pedal Inspection (M/T Model)
AENJHB0B0206022
Check clutch pedal travel. (Page 5C-5)
Clutch Fluid Inspection (M/T Model)
AENJHB0B0206023
1) Check clutch system for sign of fluid leakage. Repair
leaky point if any.
2) Check reservoir for fluid level.
If fluid is lower than minimum level of reservoir, refill
reservoir with specified brake fluid indicated on
reservoir cap. (Page 5C-5)
Tire Inspection
AENJHB0B0206024
1) Check tires for uneven or excessive wear, or
damage. If faulty condition is found, replace tire.
Refer to “Tire Inspection” in Section 2D (Page 2D-4)
for details.
I2RH01020022-01
1. Wear indicator
Maintenance and Lubrication: 0B-8
2) Check inflation pressure of each tire and adjust
pressure to specification if necessary.
NOTE
• Tire inflation pressure should be checked
when tires are cool.
• The tire inflation pressure will change due
to changes in atmospheric pressure,
temperature or tire temperature when
driving.
For details of tire inflation pressure, refer
to “Tire Description” in Section 2D (Page
2D-1).
• Specified tire inflation pressure is
indicated on the “Tire Placard”.
3) Rotate tires. For details, refer to “Tire Rotation” in
Section 2D (Page 2D-5).
Wheel Disc Inspection
AENJHB0B0206025
Refer to “Wheel Inspection” in Section 2D (Page 2D-5)
for details.
Wheel Bearing Inspection
AENJHB0B0206038
1) Check front wheel bearings for wear, damage and
abnormal noise. For details, refer to “Wheel Bearing
Check”: Front in Section 3A (Page 3A-16).
2) Check rear wheel bearings for wear, damage and
abnormal noise. For details, refer to “Wheel Bearing
Check”: Rear in Section 3A (Page 3A-21).
IDL10A020004-01
Drive Shaft (Axle) Boot Inspection
AENJHB0B0206026
Check drive shaft boots (wheel side and differential side)
for leakage, detachment, tear or other damage.
Replace defective parts if necessary.
IDAA0A020002-01
0B-9 Maintenance and Lubrication:

Suspension System Inspection • Check dust covers of front suspension arm ball joints
AENJHB0B0206027 for leakage, detachment, tear or any other damage.
• Check front strut assemblies and rear shock For checking procedure, refer to Steps 1) to 10) of
absorbers for sign of oil leakage, dents or any other “Joint” under “Suspension Arm Check” in Section 2B
damage on sleeves. Also check anchor ends for (Page 2B-9).
deterioration.
Replace defective parts, if any.
• Check front and rear suspension systems for
damaged, loose or missing parts. Also check them for
parts showing signs of wear or lack of lubrication.
Repair or replace defective parts, if any.
Front

IAW101020014-01

Steering System Inspection

AENJHB0B0206028
1) Check steering wheel for play and abnormal noise,
holding vehicle straight on ground.
Steering wheel play
“a”: 0 – 30 mm (0 – 1.2 in.)

IJHA0A020001-01

Rear

I2RH01020026-01

2) Check bolts and nuts for tightness and retighten

them if necessary. Repair or replace defective parts.
3) Check steering linkage for looseness and damage.
Repair or replace defective parts.
4) Check boots (1) and (2) of steering linkage and
steering gear case for damage (leakage,
detachment, tear, etc.). Replace defective steering
rack boot(s) or tie-rod end(s) with new one(s).
If any dent is found on steering gear case boots,
correct it to original shape by turning steering wheel
to the right or left as far as it stops and holding it for a
few seconds.

IJHA0A020002-01
 Maintenance and Lubrication: 0B-10

5) Check universal joints (3) of steering shaft for ATF Change (A/T Model)
abnormal noise and damage. If abnormal noise or AENJHB0B0206032

damage is detected, replace defective part with new 1) Inspect transmission case for evidence of fluid
one. leakage.
Repair leaky point, if any.
2) Check that vehicle is placed in level surface.
3) Change fluid. (Page 5A-119)
3
ATF Cooler Hose Inspection (A/T Model)
AENJHB0B0206033
Check automatic transmission fluid cooler hose for fluid
leakage, cracks, damage and deterioration. Replace
hose and/or clamp if any faulty condition is found.

All Latches, Hinges and Locks Inspection

AENJHB0B0206034
Door
Check that each door opens and closes smoothly and
locks securely when closed.
1 2 1
IFRA0A020001-01
If any malfunction is found, lubricate hinges and latch or
repair door lock system.
6) Check that steering wheel can be turned fully to the
right and left. Repair or replace defective parts, if
any.
7) Check that steering wheel can be turned fully to the
right and left with smaller force when engine is
running at idle speed than when it is stopped. Repair
power steering system if it provides no assistance.
8) Check wheel alignment referring to “Front Wheel
Alignment Inspection and Adjustment” in Section 2B
(Page 2B-2).

Manual Transaxle Oil Inspection (M/T Model)

AENJHB0B0206029 I2RH01020033-01

Check transaxle oil for leakage, contamination and level.

• K15B model: (Page 5B-8) Rear End Door
Check that rear end door opens and closes smoothly
• D13A model: (Page 5B-52) and locks securely when closed.
If any malfunction is found, adjust rear end door latch
Manual Transaxle Oil Replacement (M/T Model) striker.
AENJHB0B0206030
Change transaxle oil with new specified one.
Hood
• K15B model: (Page 5B-8) Check that secondary latch operates properly (check
• D13A model: (Page 5B-53) that secondary latch keeps hood from opening all the
way when hood release handle inside vehicle is pulled).
ATF Inspection (A/T Model) Also check that hood opens and closes smoothly and
AENJHB0B0206031 properly and hood locks securely when closed.
1) Inspect transmission case for evidence of fluid If any malfunction is found, lubricate hinges and latch, or
leakage. repair hood lock system.
Repair leaky point, if any.
2) Check that vehicle is placed in level surface for fluid HVAC Air Filter Inspection
level check. AENJHB0B0206035
Check HVAC air filter for dirt and dust. If air filter is dirty,
3) Check fluid level referring to “ATF Level Check” in
clean or replace it with new one.
Section 5A (Page 5A-117). If fluid level is low,
replenish transaxle with specified fluid. • Manual single A/C model: (Page 7B-47)
• Manual dual A/C model: (Page 7B-88)
• Auto A/C model: (Page 7B-134)
0B-11 Maintenance and Lubrication:
HVAC Air Filter Replacement
AENJHB0B0206036
Replace HVAC air filter with new one.
• Manual single A/C model: (Page 7B-47)
• Manual dual A/C model: (Page 7B-88)
• Auto A/C model: (Page 7B-134)
Final Inspection for Maintenance Service
AENJHB0B0206037
! WARNING
If you do not select a suitable route and take
proper precautions when performing a road
test, an accident can occur.
Select a level road with no traffic to minimize
the risk of an accident, and perform the test
extremely carefully.
Seat
Check that each front seat slides smoothly and locks
securely at any position. Also check that reclining
mechanism of each front seat allows the seatback to be
locked at any angle.
Seat Belt
Check seat belt systems including webbing, buckles,
latch plates, retractors and anchors for damage or wear.
Check that each seat belt locks securely. If “REPLACE
BELT” label on seat belt is visible, replace belt.
Battery Check
Battery terminal check
Check battery terminals for looseness, corrosion or
damage.
Battery electrolyte level check
• If battery is equipped with electrolyte level check lines
on the case, check that the electrolyte level of all
battery cells is between the upper and lower level
lines.
• If battery is equipped with built-in indicator, check
battery condition by the indicator.
• If battery is not equipped with check lines and built-in
indicator, it is not necessary to perform electrolyte
level check.
Accelerator Pedal Operation
Check that accelerator pedal operates smoothly without
getting caught by or interfering any other part.
Engine Start
Check the engine starts readily.
! WARNING
If you do not take proper precautions when
performing the engine start check as
described below, the vehicle could move
without warning causing personal injury and/
or property damage.
When performing the engine start check as
described below, take the following
precautions:
• Provide adequate space around the
vehicle.
• Firmly apply both the parking brake and
the foot brake.
• Do not use the accelerator pedal.
• Set ignition “OFF” immediately if the
engine starts.
For manual transaxle vehicles, place the gear shift lever
in “Neutral,” depress clutch pedal halfway and try to
start.
Starting motor should crank only when clutch pedal is
fully depressed.
For A/T vehicles, try to start the engine in each select
lever position. The starting motor should crank only in P
or N range.
Exhaust System Check
Check for leakage, crack or loose supports.
Clutch (M/T Model)
Check for the following points:
• Clutch is completely released when clutch pedal is
depressed.
• No slipping clutch occurs when releasing pedal and
accelerating.
• Clutch itself is free from any abnormal conditions.
Gear Shift or Select Lever
Check gear shift or select lever for smooth movement to
all positions and for good and correct response of
transaxle in any position.
For A/T models, also check that shift indicator indicates
position correctly according to select lever position.
For A/T models, also check that vehicle is at complete
stop when select lever is placed in P range and all
brakes are released.
Brake
Foot brake
Check the following points:
• Brake pedal has proper travel.
• Brakes work properly.
• Brakes do not generate abnormal noise.
• Vehicle does not pull to one side when brakes are
applied.
• Brakes do not drag.

Parking brake
Check that lever stroke is proper.
! WARNING
If you do not take proper precautions when
testing the parking brake on a slope, the
vehicle could move unexpectedly, causing
personal injury and/or property damage.
When testing the parking brake on a slope,
take the following precautions:
• Check that there is nothing in the way
ahead.
• Apply the foot brake quickly if the vehicle
moves.
Check that parking brake is fully effective when the
vehicle is stopped on a slope by pulling parking brake
lever all the way.
Steering
• Check that steering wheel is not instable and has no
abnormally large resistance to turn.
• Check that vehicle does not wander or pull to one
side.
Special Tools and Equipment
Recommended Fluids and Lubricants
Engine oil
Engine coolant (Ethylene glycol base coolant)
Brake fluid and clutch fluid
Manual transaxle oil (M/T model)
A/T fluid (A/T model)
Door hinges
Hood latch assembly
Key lock cylinder
Maintenance and Lubrication: 0B-12
Engine
• Check that speed changes responsively to
accelerator positions.
• Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheel and Power Train Components
Check that body, wheels and power train components
are free from any abnormal conditions such as abnormal
noise and vibration.
Meter and Gauge
Check that speedometer, odometer, fuel gauge,
temperature gauge, etc. operate accurately.
Light
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan
switch lever to highest position for this check.
AENJHB0B0208001
• Petrol engine model: Refer to “Engine Oil and Filter
Change”: K15B in Section 1E (Page 1E-4).
• Diesel engine model: Refer to “Engine Oil and Filter
Change”: D13A in Section 1E (Page 1E-16).
• Petrol engine model: Refer to “Coolant Description”:
K15B in Section 1F (Page 1F-2).
• Diesel engine model: Refer to “Coolant Description”:
D13A in Section 1F (Page 1F-19).
Refer to reservoir cap of brake master cylinder.
• K15B model: Refer to “Manual Transaxle Oil Change”:
K15B Model in Section 5B (Page 5B-8).
• D13A model: Refer to “Manual Transaxle Oil Change”:
D13A Model in Section 5B (Page 5B-53).
Refer to “ATF Change” in Section 5A (Page 5A-119)
Engine oil or water resistant chassis grease
Engine oil or water resistant chassis grease
Spray lubricant
0B-13 Maintenance and Lubrication:

Section 1
Engine
CONTENTS
Precautions .................................................1-1
Precautions............................................................. 1-1
Precautions for Engine (K15B) ............................. 1-1
Precautions for Engine (D13A) ............................. 1-2
Engine General Information and
Diagnosis ................................................. 1A-1
K15B .........................................................................1A-1
General Description .............................................1A-1
Engine Diagnosis General Description ............... 1A-1
OBD System Description .................................... 1A-1
DLC Description .................................................. 1A-4
Engine and Emission Control System
Description ........................................................ 1A-4
Air Intake System Description ............................. 1A-5
Electric Throttle Control System Description....... 1A-6
Electronic Control System Description................ 1A-6
Engine and Emission Control Input / Output
Table ................................................................. 1A-9
Schematic and Routing Diagram......................1A-12
Engine and Emission Control System
Diagram .......................................................... 1A-12
Engine and Emission Control System Flow
Diagram .......................................................... 1A-15
Electronic Control System Circuit Diagram ....... 1A-16
Component Location .........................................1A-18
Electronic Control System Component
Location .......................................................... 1A-18
Diagnostic Information and Procedures..........1A-21
Engine and Emission Control System Check.... 1A-21
MIL Check ......................................................... 1A-23
DTC Check ....................................................... 1A-23
DTC Clearance ................................................. 1A-24
DTC Table......................................................... 1A-25
Fail-Safe Table.................................................. 1A-32
Scan Tool Data ................................................. 1A-39
Visual Inspection ............................................... 1A-53
Engine Basic Inspection.................................... 1A-54
Engine Symptom Diagnosis .............................. 1A-55
MIL Does Not Come ON with Ignition “ON”
and Engine Stopped (but Engine Can Be
Started) ........................................................... 1A-65
MIL Remains ON after Engine Starts................ 1A-65
DTC P0010 / P2088 / P2089 ............................ 1A-66
Table of Contents 1- i
DTC P0011 .......................................................1A-68
DTC P0016 .......................................................1A-70
DTC P0030 / P0031 / P0032.............................1A-72
DTC P0036 / P0037 / P0038.............................1A-74
DTC P0107 / P0108 ..........................................1A-76
DTC P0112 / P0113 ..........................................1A-78
DTC P0116 .......................................................1A-79
DTC P0117 / P0118 ..........................................1A-80
DTC P0122 / P0123 ..........................................1A-82
DTC P0130 .......................................................1A-84
DTC P0131 / P0132 ..........................................1A-86
DTC P0133 .......................................................1A-88
DTC P0134 .......................................................1A-90
DTC P0137 / P0138 / P0140.............................1A-92
DTC P0171 / P0172 ..........................................1A-94
DTC P0201 / P0202 / P0203 / P0204 / P0261
/ P0262 / P0264 / P0265 / P0267 / P0268 /
P0270 / P0271 ................................................1A-97
DTC P0222 / P0223 ........................................1A-100
DTC P0300 / P0301 / P0302 / P0303 / P0304 1A-102
DTC P0327 / P0328 ........................................1A-104
DTC P0335 / P0336 ........................................1A-106
DTC P0340 .....................................................1A-108
DTC P0351 / P0352 / P0353 / P0354 / P2300
/ P2301 / P2303 / P2304 / P2306 / P2307 /
P2309 / P2310 ..............................................1A-110
DTC P0420 .....................................................1A-113
DTC P0443 / P0458 / P0459...........................1A-116
DTC P0480 / P0692 ........................................1A-118
DTC P0481 / P0694 ........................................1A-120
DTC P0500 .....................................................1A-122
DTC P0504 .....................................................1A-124
DTC P0530 .....................................................1A-126
DTC P0560 / P0562 / P0563...........................1A-127
DTC P0602 .....................................................1A-129
DTC P0606 .....................................................1A-130
DTC P0607 .....................................................1A-130
DTC P0645 / P0646 / P0647...........................1A-131
DTC P1693 .....................................................1A-133
DTC P2100 .....................................................1A-134
DTC P2101 / P2119 ........................................1A-136
DTC P2122 / P2123 ........................................1A-138
DTC P2127 / P2128 ........................................1A-140
DTC P2135 .....................................................1A-142
DTC P2138 .....................................................1A-143
1-ii Table of Contents
DTC P2176 ..................................................... 1A-145
DTC P2226 / P2227 ........................................ 1A-147
DTC P2271 ..................................................... 1A-147
DTC U0073 ..................................................... 1A-149
DTC U0101 ..................................................... 1A-149
DTC U0121 ..................................................... 1A-149
DTC U0131 ..................................................... 1A-149
DTC U0140 ..................................................... 1A-150
DTC U0155 ..................................................... 1A-150
DTC U108C..................................................... 1A-150
DTC U108E..................................................... 1A-150
Inspection of ECM and Its Circuits .................. 1A-150
ECM Power Supply and Ground Circuit
Check ............................................................ 1A-162
Fuel Cut Operation Inspection ........................ 1A-164
Repair Instructions ..........................................1A-165
Idle Speed Inspection...................................... 1A-165
Special Tools and Equipment .........................1A-165
Special Tool .................................................... 1A-165
D13A .....................................................................1A-166
General Description .........................................1A-166
Engine Diagnosis General Description ........... 1A-166
OBD System Description ................................ 1A-166
DLC Description .............................................. 1A-168
Fuel Injection Control Description ................... 1A-168
Electronic Control System Description............ 1A-168
Engine and Emission Control Input / Output
Table ............................................................. 1A-170
Schematic and Routing Diagram....................1A-172
Electronic Control System Diagram ................ 1A-172
Electronic Control System Circuit Diagram ..... 1A-173
Component Location .......................................1A-175
Electronic Control System Component
Location ........................................................ 1A-175
Diagnostic Information and Procedures........1A-177
Engine and Emission Control System Check.. 1A-177
MIL Check ....................................................... 1A-180
DTC Check...................................................... 1A-180
DTC Clearance ............................................... 1A-181
DTC Table....................................................... 1A-182
Fail-Safe Table................................................ 1A-188
Scan Tool Data ............................................... 1A-195
Visual Inspection ............................................. 1A-206
Engine Basic Inspection.................................. 1A-207
Engine Symptom Diagnosis ............................ 1A-207
MIL Does Not Come ON with Ignition “ON”
and Engine Stopped (but Engine Can Be
Started) ......................................................... 1A-221
MIL Remains ON after Engine Starts.............. 1A-222
Serial Data Link Circuit Check ........................ 1A-222
DTC P0001 ..................................................... 1A-224
DTC P0069 / P0107 / P0234........................... 1A-225
DTC P0087 ..................................................... 1A-227
DTC P0088 ..................................................... 1A-229
DTC P0089 ..................................................... 1A-230
DTC P0095 ..................................................... 1A-232
DTC P0100 ..................................................... 1A-233
DTC P0101 ..................................................... 1A-234
DTC P0110 ..................................................... 1A-236
DTC P0115 .....................................................1A-237
DTC P0120 .....................................................1A-238
DTC P0130 / P2244 ........................................1A-239
DTC P0135 .....................................................1A-240
DTC P0168 / P0180 ........................................1A-241
DTC P0190 .....................................................1A-243
DTC P0201 / P0202 / P0203 / P0204 / P2146 1A-244
DTC P0217 .....................................................1A-246
DTC P0219 .....................................................1A-248
DTC P0220 .....................................................1A-249
DTC P0230 .....................................................1A-251
DTC P0235 .....................................................1A-252
DTC P0243 .....................................................1A-253
DTC P0335 .....................................................1A-254
DTC P0340 .....................................................1A-256
DTC P0380 / P0683 ........................................1A-258
DTC P0401 / P0402 ........................................1A-259
DTC P0403 .....................................................1A-261
DTC P0480 .....................................................1A-262
DTC P0481 .....................................................1A-263
DTC P0500 .....................................................1A-265
DTC P0520 .....................................................1A-266
DTC P0530 .....................................................1A-268
DTC P0560 .....................................................1A-270
DTC P0571 / P1571 ........................................1A-271
DTC P0600 / P0601 / P0604 / P060B / P2226 1A-273
DTC P0641 .....................................................1A-275
DTC P0645 .....................................................1A-276
DTC P0651 .....................................................1A-278
DTC P0657 / P0685 ........................................1A-280
DTC P0697 .....................................................1A-281
DTC P0704 .....................................................1A-283
DTC P1647 .....................................................1A-284
DTC P2135 .....................................................1A-285
DTC P2237 / P2297 ........................................1A-286
DTC P2264 .....................................................1A-287
DTC P268A .....................................................1A-289
DTC U0073 .....................................................1A-290
DTC U0121 .....................................................1A-290
DTC U0131 .....................................................1A-290
DTC U0140 .....................................................1A-290
DTC U0141 .....................................................1A-290
DTC U2006 .....................................................1A-290
DTC U2007 .....................................................1A-290
DTC U2023 .....................................................1A-290
DTC U2024 .....................................................1A-290
DTC U2101 .....................................................1A-290
Table A-1: Fuel Pump Relay Operation Check 1A-291
Table A-2: Fuel Injector Circuit Check ............1A-293
Table A-3: Fuel Temperature Sensor Check ..1A-294
Table A-4: Fuel Pressure Sensor Circuit
Check ............................................................1A-296
Table A-5: Fuel Flow Actuator Operation
Check ............................................................1A-298
Table B-1: Air Intake / Turbocharger Circuit
Check ............................................................1A-299
Table B-2: MAF Sensor Check .......................1A-300
Table B-3: Boost Pressure Sensor Check ......1A-302
Table B-4: Barometric Pressure Check...........1A-304
Table B-5: EGR Valve Operation Check .........1A-305

Table B-6: A/F Sensor Check ......................... 1A-307
Table B-7: Boost Pressure Control Solenoid
Valve Operation Check ................................. 1A-309
Table C-1: Main Relay Operation Check ........ 1A-311
Table C-2: Engine Speed Check .................... 1A-313
Table C-3: ECT Sensor Check........................ 1A-314
Table C-4: IAT-1 Sensor Check ...................... 1A-316
Table C-5: IAT-2 Sensor Check ...................... 1A-318
Table C-6: Accelerator Pedal Check............... 1A-319
Table C-7: Speed Signal Check...................... 1A-322
Table C-8: Glow Plug Operation Check .......... 1A-323
Table C-9: Radiator Cooling Fan Operation
Check............................................................ 1A-326
Inspection of ECM and Its Circuits .................. 1A-329
Repair Instructions ..........................................1A-340
Idle Speed Inspection ..................................... 1A-340
Special Tools and Equipment .........................1A-340
Special Tool .................................................... 1A-340
Aux. Emission Control Devices ............. 1B-1
K15B .........................................................................1B-1
Diagnostic Information and Procedures............1B-1
EVAP Canister Purge System Inspection ........... 1B-1
Repair Instructions ..............................................1B-3
EVAP System Components ................................ 1B-3
EVAP Canister Purge Valve Removal and
Installation ......................................................... 1B-4
EVAP Canister Purge Valve Inspection .............. 1B-4
EVAP Canister Removal and Installation............ 1B-5
EVAP Canister Inspection................................... 1B-6
EVAP Connection Hose Inspection .................... 1B-7
PCV Hose Inspection .......................................... 1B-7
PCV Valve Inspection ......................................... 1B-7
Fuel Cut Valve Inspection ................................... 1B-8
Specifications.......................................................1B-8
Tightening Torque Specifications........................ 1B-8
Special Tools and Equipment .............................1B-9
Special Tool ........................................................ 1B-9
D13A .......................................................................1B-10
Repair Instructions ............................................1B-10
EGR Valve and EGR Cooler Components........ 1B-10
EGR Valve and EGR Cooler Removal and
Installation ....................................................... 1B-10
EGR Valve Inspection ....................................... 1B-12
Cleaning Procedure for EGR Valve .................. 1B-12
D13A .......................................................................1C-18
A/F Sensor On-Vehicle Inspection .................... 1B-14
A/F Sensor Removal and Installation................ 1B-14
Crankcase Ventilation System Components..... 1B-15
Oil Separator and Crankcase Ventilation
Cover Removal and Installation ...................... 1B-16
Oil Separator Inspection ................................... 1B-16
Specifications.....................................................1B-17
Tightening Torque Specifications...................... 1B-17
Engine Electrical Devices ....................... 1C-1
K15B .........................................................................1C-1
General Description .............................................1C-1
Engine Electrical Devices Description.................1C-1
Component Location ...........................................1C-2
Table of Contents 1-iii
Electronic Control System Component
Location.............................................................1C-2
Repair Instructions ..............................................1C-2
ECM Removal and Installation............................1C-2
Procedure after ECM Replacement ....................1C-3
Electric Throttle Body Assembly On-Vehicle
Inspection..........................................................1C-4
Electric Throttle Control System Calibration .......1C-5
ECM Learning Procedure of Engine Torque .......1C-6
APP Sensor On-Vehicle Inspection ....................1C-6
Accelerator Pedal Assembly (Incorporating
APP Sensor) Removal and Installation .............1C-7
MAP Sensor Removal and Installation................1C-7
MAP Sensor Inspection.......................................1C-8
ECT Sensor On-Vehicle Inspection ....................1C-8
ECT Sensor Removal and Installation ................1C-8
ECT Sensor Inspection .......................................1C-9
HO2S On-Vehicle Inspection ..............................1C-9
HO2S Removal and Installation ..........................1C-9
CMP Sensor Inspection ....................................1C-10
CMP Sensor Removal and Installation .............1C-11
CKP Sensor Removal and Installation ..............1C-11
CKP Sensor Inspection .....................................1C-11
Knock Sensor On-Vehicle Inspection................1C-12
Knock Sensor Removal and Installation ...........1C-12
Engine and Emission Control System Relay
Inspection........................................................1C-13
IAT Sensor On-Vehicle Inspection ....................1C-13
IAT Sensor Removal and Installation................1C-13
IAT Sensor Inspection.......................................1C-14
OCV Inspection .................................................1C-14
Electric Load Current Sensor On-Vehicle
Inspection........................................................1C-15
Electric Load Current Sensor Removal and
Installation .......................................................1C-16
Brake Stroke Sensor On-Vehicle Inspection.....1C-16
Brake Stroke Sensor Removal and
Installation .......................................................1C-16
Brake Stroke Sensor Inspection and
Adjustment ......................................................1C-16
Brake Stroke Sensor Zero Point Reset .............1C-16
Specifications .....................................................1C-17
Tightening Torque Specifications......................1C-17
Special Tools and Equipment ...........................1C-17
Special Tool ......................................................1C-17
General Description ...........................................1C-18
Description of ECM Registration .......................1C-18
Engine Electrical Devices Description...............1C-18
Component Location .........................................1C-20
Electronic Control System Component
Location...........................................................1C-20
Repair Instructions ............................................1C-20
ECM Removal and Installation..........................1C-20
Registration for ECM Replacement...................1C-21
Vehicle Variant Data (Including CAN Vehicle
Configuration Data) Registration.....................1C-22
Injector Calibration Code Registration ..............1C-22
Flywheel Data Initialization................................1C-22
1-iv Table of Contents
A/F Sensor Data Initialization............................1C-22
MAF Sensor Data Initialization..........................1C-22
Rail Pressure Sensor Initialization ....................1C-22
MAF Sensor with IAT Sensor-1 Removal and
Installation .......................................................1C-23
MAF Sensor with IAT Sensor-1 Inspection .......1C-23
Glow Plug Removal and Installation .................1C-24
Glow Plug Inspection ........................................1C-25
APP Sensor Assembly On-Vehicle Inspection ..1C-25
Accelerator Pedal Assembly (Incorporating
APP Sensor) Removal and Installation ...........1C-25
Brake Stroke Sensor On-Vehicle Inspection.....1C-25
Brake Stroke Sensor Removal and
Installation .......................................................1C-25
Brake Stroke Sensor Inspection........................1C-25
Brake Stroke Sensor Zero Point Reset .............1C-25
ECT Sensor Removal and Installation ..............1C-25
ECT Sensor Inspection .....................................1C-26
CMP Sensor Removal and Installation .............1C-26
CMP Sensor Inspection ....................................1C-27
CKP Sensor Removal and Installation ..............1C-27
CKP Sensor Inspection .....................................1C-28
Boost Pressure Sensor with IAT Sensor-2
Removal and Installation.................................1C-28
Boost Pressure Sensor with IAT Sensor-2
Inspection........................................................1C-29
Fuel Pump Relay, Starting Motor Control
Relay and Main Relay Inspection ...................1C-30
Glow Plug Control Module Removal and
Installation .......................................................1C-30
Boost Pressure Control Solenoid Valve
Removal and Installation.................................1C-31
Boost Pressure Control Solenoid Valve
Inspection........................................................1C-31
Specifications.....................................................1C-31
Tightening Torque Specifications......................1C-31
Special Tools and Equipment ...........................1C-32
Special Tool ......................................................1C-32
Engine Mechanical .................................. 1D-1
K15B .........................................................................1D-1
General Description .............................................1D-1
Engine Construction Description.........................1D-1
VVT System Description .....................................1D-2
Diagnostic Information and Procedures............1D-4
Compression Check............................................1D-4
Engine Vacuum Check........................................1D-5
Valve Clearance Inspection and Adjustment ......1D-6
Repair Instructions ..............................................1D-8
Air Cleaner Components.....................................1D-8
Air Cleaner Filter Removal and Installation.........1D-8
Air Cleaner Filter Inspection and Cleaning..........1D-9
Air Cleaner Assembly Removal and
Installation .........................................................1D-9
Throttle Body and Intake Manifold
Components....................................................1D-11
Throttle Body On-Vehicle Inspection.................1D-12
Electric Throttle Body Assembly Removal and
Installation .......................................................1D-12
Throttle Body Cleaning......................................1D-12
Intake Manifold Removal and Installation .........1D-13
Cylinder Head Cover Components ...................1D-14
Cylinder Head Cover Removal and
Installation .......................................................1D-14
Camshaft and Tappet Components ..................1D-16
Camshaft and Tappet Removal and
Installation .......................................................1D-16
VVT Actuator, Camshaft and Tappet
Inspection........................................................1D-22
Crankshaft Front Oil Seal Removal and
Installation .......................................................1D-24
Crankshaft Rear Oil Seal Removal and
Installation .......................................................1D-25
Engine Mounting Components..........................1D-26
Engine Assembly Removal and Installation ......1D-27
Timing Chain Cover Components .....................1D-32
Timing Chain Cover Removal and Installation ..1D-33
Timing Chain Cover Inspection .........................1D-36
OCV Removal and Installation ..........................1D-36
Flywheel / Drive Plate Removal and
Installation .......................................................1D-37
Flywheel / Drive Plate Inspection ......................1D-38
Timing Chain and Chain Tensioner
Components....................................................1D-38
Timing Chain and Chain Tensioner Removal
and Installation ................................................1D-39
Timing Chain and Chain Tensioner Inspection ..1D-42
Valve and Cylinder Head Components .............1D-43
Valve and Cylinder Head Removal and
Installation .......................................................1D-44
Valve and Cylinder Head Disassembly and
Reassembly ....................................................1D-46
Valve and Valve Guide Inspection ....................1D-49
Venturi Plug Inspection .....................................1D-50
Cylinder Head Inspection ..................................1D-51
Cylinder Head Bolt Inspection ...........................1D-52
Valve Spring Inspection ....................................1D-52
Piston, Piston Ring, Connecting Rod and
Cylinder Components......................................1D-53
Piston, Piston Ring, Connecting Rod and
Cylinder Removal and Installation...................1D-54
Piston, Piston Ring, Connecting Rod and
Cylinder Disassembly and Reassembly..........1D-56
Cylinder, Piston and Piston Ring Inspection .....1D-57
Piston Pin and Connecting Rod Inspection .......1D-59
Crankshaft Pin and Connecting Rod Bearing
Inspection........................................................1D-60
Main Bearing, Crankshaft and Cylinder Block
Components....................................................1D-63
Main Bearing, Crankshaft and Cylinder Block
Removal and Installation.................................1D-64
Crankshaft Inspection .......................................1D-68
Main Bearing Inspection....................................1D-69
Sensor Plate Inspection ....................................1D-74
Cylinder Block Inspection ..................................1D-74
Specifications .....................................................1D-75
Tightening Torque Specifications......................1D-75
Special Tools and Equipment ...........................1D-76
Recommended Service Material .......................1D-76

Special Tool ......................................................1D-76
D13A .......................................................................1D-79
Diagnostic Information and Procedures..........1D-79
Compression Check..........................................1D-79
Timing Check ....................................................1D-79
Repair Instructions ............................................1D-81
Air Cleaner Components...................................1D-81
Air Cleaner Filter Removal and Installation.......1D-82
Air Cleaner Filter Inspection and Cleaning........1D-82
Air Cleaner Assembly Removal and
Installation .......................................................1D-82
Intercooler Components....................................1D-83
Intercooler Removal and Installation.................1D-84
Vacuum Pump Removal and Installation ..........1D-85
Vacuum Pump Inspection .................................1D-86
Turbocharger and Exhaust Manifold
Components....................................................1D-87
Turbocharger Removal and Installation ............1D-88
Turbocharger Inspection ...................................1D-91
Exhaust Manifold Removal and Installation ......1D-91
Intake Manifold Components ............................1D-92
Intake Manifold Removal and Installation .........1D-93
Crankshaft Front Oil Seal Removal and
Installation .......................................................1D-94
Crankshaft Rear Oil Seal Removal and
Installation .......................................................1D-96
Engine Mounting Components..........................1D-98
Engine Assembly Removal and Installation ......1D-99
Timing Chain Cover and Timing Chain
Components..................................................1D-104
Timing Chain Cover and Timing Chain
Removal and Installation...............................1D-105
Timing Chain Cover and Timing Chain
Inspection......................................................1D-112
Camshaft Housing Components .....................1D-113
Camshaft Housing Assembly Removal and
Installation .....................................................1D-114
Camshaft Housing Assembly Disassembly
and Reassembly ...........................................1D-115
Camshaft Inspection .......................................1D-117
Valve and Cylinder Head Components ...........1D-119
Valve and Cylinder Head Assembly Removal
and Installation ..............................................1D-120
Valve and Cylinder Head Assembly
Disassembly and Reassembly ......................1D-123
Valve and Valve Guide Inspection ..................1D-125
Cylinder Head Inspection ................................1D-126
Valve Spring Inspection ..................................1D-127
Piston, Piston Ring, Connecting Rod and
Cylinder Components ...................................1D-128
Piston, Piston Ring, Connecting Rod and
Cylinder Removal and Installation ................1D-128
Piston, Piston Ring, Connecting Rod and
Cylinder Disassembly and Reassembly........1D-131
Cylinder, Piston and Piston Ring Inspection ...1D-132
Piston Pin and Connecting Rod Inspection.....1D-134
Crankshaft Pin and Connecting Rod Bearing
Inspection......................................................1D-135
Main Bearing, Crankshaft and Cylinder Block
Components..................................................1D-139
Table of Contents 1-v
Main Bearing, Crankshaft and Cylinder Block
Removal and Installation...............................1D-140
Main Bearing, Crankshaft and Cylinder Block
Inspection......................................................1D-144
Main Bearing Inspection..................................1D-145
Cylinder Block Inspection................................1D-149
Specifications ...................................................1D-150
Tightening Torque Specifications....................1D-150
Special Tools and Equipment .........................1D-151
Recommended Service Material .....................1D-151
Special Tool ....................................................1D-151
Engine Lubrication System .................... 1E-1
K15B .........................................................................1E-1
General Description .............................................1E-1
Engine Lubrication Description ...........................1E-1
Diagnostic Information and Procedures ............1E-3
Oil Pressure Check .............................................1E-3
Repair Instructions ..............................................1E-4
Engine Oil and Filter Change ..............................1E-4
Oil Pressure Switch On-Vehicle Inspection.........1E-5
Oil Pressure Switch Removal and Installation ....1E-5
Oil Pan and Oil Pump Strainer Components.......1E-7
Oil Pan and Oil Pump Strainer Removal and
Installation .........................................................1E-7
Oil Pump Assembly Components .....................1E-10
Oil Pump Assembly Removal and Installation ..1E-10
Oil Pump Assembly Disassembly and
Reassembly ....................................................1E-11
Oil Pump Inspection ..........................................1E-12
Specifications .....................................................1E-13
Tightening Torque Specifications......................1E-13
Special Tools and Equipment ...........................1E-14
Recommended Service Material .......................1E-14
Special Tool ......................................................1E-14
D13A .......................................................................1E-15
General Description ...........................................1E-15
Engine Lubrication Description .........................1E-15
Diagnostic Information and Procedures ..........1E-15
Oil Pressure Check ...........................................1E-15
Repair Instructions ............................................1E-16
Engine Oil Level Check.....................................1E-16
Engine Oil and Filter Change ............................1E-16
Oil Pressure Switch On-Vehicle Inspection.......1E-17
Oil Pressure Switch Removal and Installation ..1E-17
Oil Cooler Components.....................................1E-18
Oil Cooler Removal and Installation..................1E-19
Oil Pan Components .........................................1E-20
Oil Pan Removal and Installation ......................1E-20
Oil Pump / Oil Pump Strainer Components.......1E-22
Oil Pump / Oil Pump Strainer Removal and
Installation .......................................................1E-22
Oil Pump Strainer Cleaning...............................1E-23
Oil Pump Inspection ..........................................1E-23
Specifications .....................................................1E-23
Tightening Torque Specifications......................1E-23
Special Tools and Equipment ...........................1E-24
Recommended Service Material .......................1E-24
1-vi Table of Contents
Special Tool ......................................................1E-24
Engine Cooling System ...........................1F-1
K15B ......................................................................... 1F-1
Precautions........................................................... 1F-1
Precautions for Cooling System.......................... 1F-1
General Description ............................................. 1F-2
Cooling System Description ................................ 1F-2
Coolant Description............................................. 1F-2
Cooling Fan Operation Description ..................... 1F-2
Schematic and Routing Diagram........................ 1F-3
Coolant Circulation.............................................. 1F-3
Radiator Cooling Fan Control System Circuit
Diagram ............................................................ 1F-4
Diagnostic Information and Procedures............ 1F-5
Engine Cooling Symptom Diagnosis................... 1F-5
Radiator Cooling Fan System Check .................. 1F-6
Repair Instructions .............................................. 1F-9
Cooling System Components.............................. 1F-9
Coolant Level Check ......................................... 1F-10
Engine Cooling System Inspection ................... 1F-10
Cooling System Draining................................... 1F-11
Cooling System Refilling ................................... 1F-11
Water Inlet Pipe Removal and Installation ........ 1F-11
Thermostat Removal and Installation................ 1F-12
Thermostat Inspection....................................... 1F-13
Radiator Cooling Fan Assembly On-Vehicle
Inspection........................................................ 1F-14
Radiator Cooling Fan Relay Inspection............. 1F-14
Radiator Cooling Fan Assembly Removal and
Installation ....................................................... 1F-15
Radiator Cooling Fan Disassembly and
Reassembly .................................................... 1F-15
Radiator On-Vehicle Inspection and Cleaning .. 1F-16
Radiator Removal and Installation .................... 1F-16
Water Pump Removal and Installation.............. 1F-17
Water Pump Inspection..................................... 1F-18
Specifications..................................................... 1F-18
Tightening Torque Specifications...................... 1F-18
Special Tools and Equipment ........................... 1F-18
Recommended Service Material ....................... 1F-18
Special Tool ...................................................... 1F-18
D13A ....................................................................... 1F-19
Precautions......................................................... 1F-19
Precautions for Cooling System........................ 1F-19
General Description ........................................... 1F-19
Cooling System Description .............................. 1F-19
Coolant Description........................................... 1F-19
Cooling Fan Operation Description ................... 1F-20
Coolant Degassing Tank Description................ 1F-20
Water Pump Drive Belt Description................... 1F-20
Schematic and Routing Diagram...................... 1F-21
Coolant Circulation............................................ 1F-21
Diagnostic Information and Procedures.......... 1F-22
Engine Cooling Symptom Diagnosis................. 1F-22
Radiator Fan Control System Inspection .......... 1F-22
Repair Instructions ............................................ 1F-23
Cooling System Components............................ 1F-23
Coolant Level Check ......................................... 1F-24
Engine Cooling System Inspection and
Cleaning .......................................................... 1F-24
Cooling System Draining................................... 1F-25
Cooling System Refilling ................................... 1F-25
Cooling Water Pipe or Hose Removal and
Installation ....................................................... 1F-25
Thermostat Assembly Removal and
Installation ....................................................... 1F-26
Thermostat Inspection....................................... 1F-27
Radiator Cooling Fan Assembly On-Vehicle
Inspection........................................................ 1F-28
Radiator Cooling Fan Relay Inspection............. 1F-28
Radiator Cooling Fan Assembly Removal and
Installation ....................................................... 1F-28
Radiator Cooling Fan Disassembly and
Reassembly .................................................... 1F-29
Radiator On-Vehicle Inspection and Cleaning .. 1F-30
Radiator Removal and Installation .................... 1F-30
Water Pump Drive Belt Inspection .................... 1F-31
Water Pump Drive Belt Removal and
Installation ....................................................... 1F-32
Water Pump Removal and Installation .............. 1F-34
Water Pump Inspection ..................................... 1F-35
Specifications ..................................................... 1F-35
Tightening Torque Specifications...................... 1F-35
Special Tools and Equipment ........................... 1F-35
Special Tool ...................................................... 1F-35
Fuel System ............................................. 1G-1
K15B ........................................................................ 1G-1
Precautions.......................................................... 1G-1
Precautions for Fuel System Service ................. 1G-1
General Description ............................................ 1G-2
Fuel System Description .................................... 1G-2
Fuel Delivery System Description ...................... 1G-2
Fuel Pump Description....................................... 1G-2
Schematic and Routing Diagram ....................... 1G-2
Fuel Delivery System Diagram........................... 1G-2
Fuel Injector Control System Circuit Diagram .... 1G-3
Fuel Pump Control System Circuit Diagram ...... 1G-3
Diagnostic Information and Procedures ........... 1G-4
Fuel System Inspection ...................................... 1G-4
Power Balance Test ........................................... 1G-4
Fuel Injector Circuit Check ................................. 1G-5
Fuel Pump and Its Circuit Check........................ 1G-7
Fuel Pressure Check.......................................... 1G-9
Fuel Pressure Basic Check .............................. 1G-10
Repair Instructions ........................................... 1G-11
Fuel System Components................................ 1G-11
Fuel Hose Disconnection and Reconnection ... 1G-13
Fuel Pressure Relief Procedure ....................... 1G-14
Fuel Leakage Check Procedure....................... 1G-14
Fuel Line On-Vehicle Inspection ...................... 1G-14
Fuel Pipe Removal and Installation.................. 1G-15
Fuel Injector On-Vehicle Inspection ................. 1G-16
Fuel Injector Removal and Installation ............. 1G-16
Fuel Injector Inspection .................................... 1G-18
Fuel Filler Cap Inspection ................................ 1G-20

Fuel Tank Removal and Installation..................1G-21
Fuel Tank Inspection.........................................1G-23
Fuel Tank Flushing Procedure ..........................1G-23
Fuel Pump On-Vehicle Inspection ....................1G-24
Fuel Pump Assembly Removal and
Installation .......................................................1G-24
Fuel Pump Inspection .......................................1G-25
Fuel Level Sensor Removal and Installation.....1G-26
Fuel Level Sensor Inspection............................1G-26
Fuel Filter Removal and Installation..................1G-26
Specifications.....................................................1G-27
Tightening Torque Specifications......................1G-27
Special Tools and Equipment ...........................1G-27
Special Tool ......................................................1G-27
D13A .......................................................................1G-29
Precautions.........................................................1G-29
Precautions for Fuel System Service ................1G-29
General Description ...........................................1G-31
Fuel System Description ...................................1G-31
Diagnostic Information and Procedures..........1G-32
Low-Pressure Fuel Supply Circuit Check..........1G-32
High-Pressure Fuel Supply Circuit Check.........1G-36
Repair Instructions ............................................1G-39
Fuel Hose Disconnection and Reconnection ....1G-39
Fuel Pressure Relief Procedure ........................1G-41
Fuel Leakage Check Procedure .......................1G-41
Water Draining of Fuel Filter .............................1G-41
Air Bleeding of Fuel System..............................1G-41
Fuel System Components.................................1G-42
High Pressure Pipe Removal and Installation...1G-45
Fuel Injector On-Vehicle Inspection ..................1G-46
Fuel Injector Removal and Installation ..............1G-47
Common Rail Removal and Installation ............1G-48
High Pressure Pump Removal and
Installation .......................................................1G-49
Fuel Pressure Sensor Removal and
Installation .......................................................1G-50
Fuel Flow Actuator On-Vehicle Inspection ........1G-50
Fuel Line and Connection Inspection................1G-51
Fuel Pipe Removal and Installation ..................1G-51
Fuel Filler Cap Inspection .................................1G-52
Fuel Tank Inlet Valve Removal and
Installation .......................................................1G-52
Fuel Tank Inlet Valve Inspection .......................1G-53
Fuel Tank On-Vehicle Inspection ......................1G-53
Fuel Tank Removal and Installation..................1G-53
Fuel Tank Inspection.........................................1G-55
Fuel Tank Flushing Procedure ..........................1G-56
Fuel Pump On-Vehicle Inspection ....................1G-56
Fuel Pump Assembly Removal and
Installation .......................................................1G-56
Fuel Pump Inspection .......................................1G-57
Fuel Level Sensor Inspection............................1G-58
Fuel Filter Element Removal and Installation....1G-58
Fuel Filter Assembly Removal and Installation ..1G-59
Water Detection Sensor with Fuel
Temperature Sensor Removal and
Installation .......................................................1G-59
Table of Contents 1-vii
Water Detection Sensor with Fuel
Temperature Sensor Inspection..................... 1G-59
Specifications .................................................... 1G-60
Tightening Torque Specifications..................... 1G-60
Special Tools and Equipment .......................... 1G-60
Special Tool ..................................................... 1G-60
Ignition System ........................................ 1H-1
General Description .............................................1H-1
Ignition System Construction ..............................1H-1
Schematic and Routing Diagram ........................1H-2
Ignition System Circuit Diagram..........................1H-2
Component Location ...........................................1H-3
Ignition System Component Location .................1H-3
Diagnostic Information and Procedures ............1H-4
Ignition System Check ........................................1H-4
Ignition Spark Test ..............................................1H-6
Repair Instructions ..............................................1H-7
Spark Plug Removal and Installation ..................1H-7
Spark Plug Inspection .........................................1H-7
Ignition Coil Assembly Removal and
Installation .........................................................1H-8
Ignition Coil Assembly Inspection .......................1H-8
Ignition Timing Inspection ...................................1H-8
Specifications .......................................................1H-9
Tightening Torque Specifications........................1H-9
Special Tools and Equipment ...........................1H-10
Special Tool ......................................................1H-10
Starting System .........................................1I-1
K15B .......................................................................... 1I-1
General Description .............................................. 1I-1
Cranking System Description............................... 1I-1
Schematic and Routing Diagram ......................... 1I-1
Cranking System Circuit Diagram ........................ 1I-1
Diagnostic Information and Procedures ............. 1I-2
Cranking System Symptom Diagnosis................. 1I-2
Repair Instructions ............................................... 1I-4
Starting Motor Control Relay Inspection .............. 1I-4
Starting Motor Removal and Installation .............. 1I-4
Starting Motor Components ................................. 1I-6
Starting Motor Disassembly and Reassembly ..... 1I-7
Starting Motor Inspection ................................... 1I-11
Specifications ...................................................... 1I-15
Cranking System Specifications......................... 1I-15
Tightening Torque Specifications....................... 1I-15
Special Tools and Equipment ............................ 1I-15
Recommended Service Material ........................ 1I-15
D13A ........................................................................ 1I-16
General Description ............................................ 1I-16
Cranking System Description............................. 1I-16
Schematic and Routing Diagram ....................... 1I-16
Cranking System Circuit Diagram ...................... 1I-16
Diagnostic Information and Procedures ........... 1I-17
Cranking System Symptom Diagnosis............... 1I-17
Repair Instructions ............................................. 1I-19
Starting Motor Control Relay Inspection ............ 1I-19
Starting Motor Removal and Installation ............ 1I-19
1-viii Table of Contents
Starting Motor Components ............................... 1I-22
Starting Motor Disassembly and Reassembly ... 1I-23
Starting Motor Inspection ................................... 1I-25
Specifications...................................................... 1I-29
Cranking System Specifications......................... 1I-29
Tightening Torque Specifications....................... 1I-29
Special Tools and Equipment ............................ 1I-29
Recommended Service Material ........................ 1I-29
Charging System ...................................... 1J-1
K15B ......................................................................... 1J-1
Precautions........................................................... 1J-1
Precautions for Handling Battery ........................ 1J-1
Precautions for Replacing Battery....................... 1J-1
Precautions for Handling Auxiliary Power
Module (Lithium-Ion Battery)............................. 1J-1
General Description ............................................. 1J-2
Battery Description.............................................. 1J-2
Generator Description ......................................... 1J-2
Auxiliary Power Module (Lithium-Ion Battery)
Control System Description .............................. 1J-2
Diagnostic Information and Procedures............ 1J-2
Battery Inspection ............................................... 1J-2
Generator Symptom Diagnosis ........................... 1J-3
SHVS System Check .......................................... 1J-3
Generator Test .................................................... 1J-3
Repair Instructions .............................................. 1J-5
Jump-Starting in Case of Emergency ................. 1J-5
Battery Removal and Installation ........................ 1J-5
ISG Drive Belt Inspection .................................... 1J-6
ISG Drive Belt Removal and Installation ............. 1J-7
ISG Removal and Installation.............................. 1J-7
ISG Inspection..................................................... 1J-9
ISG Drive Belt Auto Tensioner / Idler Pulley
Removal and Installation................................... 1J-9
ISG Drive Belt Auto Tensioner / Idler Pulley
Inspection........................................................ 1J-10
Specifications..................................................... 1J-10
Charging System Specifications ....................... 1J-10
Tightening Torque Specifications...................... 1J-10
Special Tools and Equipment ........................... 1J-11
Special Tool ...................................................... 1J-11
D13A ....................................................................... 1J-12
Precautions......................................................... 1J-12
Precautions for Handling Battery ...................... 1J-12
Precautions for Replacing Battery..................... 1J-12
General Description ........................................... 1J-12
Battery Description............................................ 1J-12
Generator Description ....................................... 1J-13
Diagnostic Information and Procedures .......... 1J-13
Battery Inspection ............................................. 1J-13
Generator Symptom Diagnosis ......................... 1J-14
Generator Test .................................................. 1J-15
Repair Instructions ............................................ 1J-16
Jump-Starting in Case of Emergency ............... 1J-16
Battery Removal and Installation ...................... 1J-16
ISG Drive Belt Inspection .................................. 1J-18
ISG Drive Belt Removal and Installation ........... 1J-18
ISG Drive Belt Tensioner and Idler Pulley
Removal and Installation................................. 1J-19
ISG Drive Belt Tensioner and Idler Pulley
Inspection........................................................ 1J-20
ISG Removal and Installation............................ 1J-20
ISG Inspection................................................... 1J-21
Specifications ..................................................... 1J-22
Charging System Specifications ....................... 1J-22
Tightening Torque Specifications...................... 1J-22
Special Tools and Equipment ........................... 1J-22
Special Tool ...................................................... 1J-22
Exhaust System....................................... 1K-1
K15B .........................................................................1K-1
General Description .............................................1K-1
Exhaust System Description ...............................1K-1
Diagnostic Information and Procedures ............1K-1
Exhaust System Check .......................................1K-1
Repair Instructions ..............................................1K-2
Exhaust System Components .............................1K-2
Exhaust Manifold Removal and Installation ........1K-3
Exhaust Manifold Inspection ...............................1K-4
Exhaust Pipe and Muffler Removal and
Installation .........................................................1K-4
Specifications .......................................................1K-5
Tightening Torque Specifications........................1K-5
D13A .........................................................................1K-6
General Description .............................................1K-6
Exhaust System Description ...............................1K-6
Diagnostic Information and Procedures ............1K-6
Exhaust System Check .......................................1K-6
Repair Instructions ..............................................1K-7
Exhaust System Components .............................1K-7
Exhaust Manifold Removal and Installation ........1K-8
Catalytic Converter Assembly Removal and
Installation .........................................................1K-8
Exhaust Pipe and Muffler Removal and
Installation .........................................................1K-8
Specifications .......................................................1K-9
Tightening Torque Specifications........................1K-9

Precautions
Engine
Precautions
Precautions for Engine (K15B)
AENJHB0B1000001
Warning for Air Bag
Refer to “Warning for Air Bag” in Section 00 (Page 00-7).
Precautions for Catalytic Converter
Refer to “Precautions for Catalytic Converter (Petrol
Engine Model)” in Section 00 (Page 00-5).
Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3).
Reassembling Note for Wiring Harness
Observe “Reassembling Note for Wiring Harness” in
Section 9A (Page 9A-142) whenever installing wiring
harness.
Otherwise, electrical trouble may occur.
Precautions for Fuel System Service
Refer to “Precautions for Fuel System Service”: K15B in
Section 1G (Page 1G-1).
Precautions for Engine Service
• When raising or supporting engine, do not use a jack
under oil pan. Due to small clearance between oil pan
and oil pump strainer, jacking against oil pan may
cause it to be bent against strainer resulting in
damaged oil pick-up unit.
• It should be kept in mind, while working on engine,
that 12-volt electrical system involves danger of
violent and damaging short circuits. When performing
any work where electrical terminals could be
grounded, ground cable of the battery should be
disconnected at battery.
• Any time the air cleaner, throttle body or intake
manifold is removed, the intake opening should be
covered. This will protect against accidental entrance
of foreign material which could follow intake passage
into cylinder and cause extensive damage when
engine is started.
• When disconnecting connectors, do not pull wire
harness but hold connector itself. With lock type
connector, unlock before disconnection.
Attempt to disconnect connector without unlocking
may result in damage to connector. When connecting
lock type connector, insert it till clicking sound is heard
and connect it securely.
Precautions: 1-1
IYSQ01110001-01
Precautions for Diagnosing Trouble
• Diagnostic information stored in ECM memory can be
cleared as well as checked using SUZUKI scan tool or
CAN communication OBD-II generic scan tool. Before
using scan tool, read its Operator’s Manual to know
how to use it.
• Not only ECM but also TCM (A/T model) turns on MIL.
It is indistinguishable which module turns on MIL.
Therefore, for A/T model, check both ECM and TCM
for DTC when MIL lights up.
• Priorities for diagnosing troubles:
If two or more DTCs are stored, perform DTC
troubleshooting for these DTCs beginning with the
DTC detected earliest and follow the instructions
available in the troubleshooting procedure.
If no instructions are available, troubleshoot DTCs
according to the following priorities.
a. DTCs other than DTC P0171 / P0172 (Fuel
system too lean/too rich) and DTC P0300 / P0301
/ P0302 / P0303 / P0304 (Misfire detected)
b. DTC P0171 / P0172 (Fuel system too lean/too
rich)
c. DTC P0300 / P0301 / P0302 / P0303 / P0304
(Misfire detected)
• Read “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3) before inspection and observe
what is written there.
• Communication of ECM and other control module are
established via CAN. (For more detail of CAN
communication for ECM, refer to “Communication
System Description”: K15B Model in Section 10H
(Page 10H-1).)
• Before performing troubleshooting, read the
“Precautions for ECM Circuit Inspection” (Page 1-2).
• Upon completion of inspection and repair work,
perform “DTC Confirmation Procedure” and check
that the trouble has been repaired.
1-2 Precautions:
Precautions for Replacing ECM
• Before replacement of the ECM, check the following
conditions. Neglecting this check may cause damage
to new ECM.
– Resistances of all relays and actuators are as
specified.
– TP sensor, APP sensor, MAP sensor, electric load
current sensor, brake stroke sensor and A/C
refrigerant pressure sensor are in good condition
and none of their power circuits is shorted to
ground.
• Perform “Procedure after ECM Replacement”: K15B
in Section 1C (Page 1C-3).
Precautions for ECM Circuit Inspection
Do not measure circuit voltage and/or pulse signal of
ECM by inserting tester probe into a sealed terminal of
ECM.
When measuring circuit voltage and/or pulse signal of
ECM, connect service wires (5) to terminals of each
sensor / actuator (1) and sensor / actuator connector (2).
Otherwise, sealed terminals, ECM and its circuits may
be damaged.
3 or broken.
1 attaching the chain to the hooks on the engine.
2
5 negative (–) cable at the battery before starting the
4
I8C50A110001-02
3. Voltmeter 4. Oscilloscope
Precautions for Electric Throttle Control System
Calibration
Completely closed and opened throttle valve position
data are stored in ECM.
After performing any one of the following services,
calibrate the completely closed and opened throttle
valve position stored in ECM. (Page 1C-5)
• Replacement of ECM
• Clearance of DTC related to ECM
• Removal and installation of electric throttle body
assembly (cleaning or replacement)
Precautions for Engine (D13A)
AENJHB0B1000003
Warning for Air Bag
Refer to “Warning for Air Bag” in Section 00 (Page 00-7).
Precautions for Catalytic Converter
Refer to “Precautions for Catalytic Converter (Diesel
Engine Model)” in Section 00 (Page 00-6).
Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3).
Reassembling Note for Wiring Harness
Observe “Reassembling Note for Wiring Harness” in
Section 9A (Page 9A-142) whenever installing wiring
harness.
Otherwise, electrical trouble may occur.
Precautions for Fuel System Service
Refer to “Precautions for Fuel System Service”: D13A in
Section 1G (Page 1G-29).
Precautions for Engine Service
• If a jack is applied to the oil pan when raising or
supporting the engine, the oil pan could be deformed
Always use a chain hoist to support the engine by
• If the 12 V electrical system is shorted while servicing
the engine, the engine electrical circuits could be
damaged seriously.
When the intended service operation does not require
electric power supply from the battery, disconnect the
service work.
• If foreign material has entered the engine during
removal of intake system components, internal parts
of the engine could be severely damaged when the
engine is started.
Suitably cover the air intake port when the air cleaner,
intake manifold or other intake system component is
removed.
 Precautions: 1-3

• When disconnecting connectors, do not pull wire Precautions for Replacing ECM
harness but hold connector itself. With lock type • ECM must be replaced with new one.
connector, unlock before disconnection.
• Register vehicle information to new ECM according to
Attempt to disconnect connector without unlocking
“Description of ECM Registration”: D13A in Section
may result in damage to connector. When connecting
1C (Page 1C-18).
lock type connector, insert it till clicking sound is heard
Without registering all of these items, the engine
and connect it securely.
cannot be started or, even if the engine is started,
original engine performance will be affected.
If the “vehicle information” cannot be uploaded from
the replaced ECM using SUZUKI scan tool, input the
following items manually.
– Injector calibration code
– Vehicle variant data (including CAN vehicle
configuration data)
– Immobilizer ID code
IYSQ01110001-01
Precautions for ECM Circuit Inspection
Precautions for Diagnosing Trouble Do not measure circuit voltage and/or pulse signal of
ECM by inserting tester probe into a sealed terminal of
• Do not disconnect connectors from ECM, battery ECM.
cable at battery, ECM ground wire harness from When measuring circuit voltage and/or pulse signal of
engine or fuse before checking diagnostic information ECM, connect service wires (5) to terminals of each
(DTC) stored in ECM memory. sensor / actuator (1) and sensor / actuator connector (2).
Such disconnection clears memorized information in Otherwise, sealed terminals, ECM and its circuits may
ECM memory. be damaged.
• Diagnostic information stored in ECM memory can be
cleared as well as checked using SUZUKI scan tool.
Before using scan tool, read its Operator’s Manual to 3
know how to use it.
1
• Read “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3) before inspection and observe
what is written there.
• ECM communication lines consist of CAN-line and K-
line.
2
K-line is provided for scan tool to communicate with
ECM via DLC. 5
Either of SUZUKI scan tool or OBD-II generic scan
tool can be used through K-line. For details, refer to
“DLC Description”: D13A in Section 1A (Page 1A-
4
168).
I8C50A110001-02
Through CAN-line, ECM communicates with each
control module. 3. Voltmeter 4. Oscilloscope
For details of CAN communication, refer to
“Communication System Description”: D13A Model in
Section 10H (Page 10H-24).
Since CAN-line is sensitive, handle CAN
communication line with care, referring to “Twist Pair
Wire Harness” under “Precautions for Electrical
Circuit Service” in Section 00 (Page 00-3).
1A-1 Engine General Information and Diagnosis: K15B

Engine General Information and Diagnosis

Engine

K15B
General Description
Engine Diagnosis General Description • Not only SUZUKI scan tool (2) but also CAN
AENJHB0B1111001 communication OBD-II generic scan tool can
The engine and emission control system in this vehicle is
communicate with ECM via DLC (3). (Diagnostic
controlled by ECM. ECM has an OBD system which
information can be accessed using a scan tool.)
detects a malfunction in this system and abnormality of
those parts that influence the engine exhaust emission.
When diagnosing engine troubles, have full
understanding of the outline of “OBD System
Description”: K15B (Page 1A-1) and each item in 1
“Precautions for Diagnosing Trouble” under “Precautions
for Engine (K15B)” in Section 1 (Page 1-1) and execute
diagnosis according to “Engine and Emission Control
System Check”: K15B (Page 1A-21).
There is a close relationship between the engine
mechanical, engine cooling system, ignition system,
exhaust system, etc. and the engine and emission
control system in their structure and operation. In case of
an engine trouble, even when the MIL does not turn on,
it should be diagnosed according to “Engine and
Emission Control System Check”: K15B (Page 1A-21).

OBD System Description

AENJHB0B1111002
General Description
The ECM has the following functions. 3
• When ignition is “ON” with the engine at a stop, the
ECM turns on the MIL (1) to check the circuit of the
MIL.
• When ECM detects a malfunction which gives an
adverse effect to vehicle emission while the engine is
running, ECM makes the MIL in the combination
meter of the instrument panel turn on or blink (blinking
only when detecting a misfire which can cause
damage to the catalyst) and stores the malfunction
area in its memory.
(If ECM detects a malfunction only in the first driving
cycle (refer to “Driving Cycle”: K15B (Page 1A-1)) but
2
does not detect the same malfunction in the next 2
consecutive driving cycles, ECM does not turn on MIL IJHB0A111001-01
although it retains the associated DTC in its memory.)
• For some malfunctions, ECM adopts the 3 driving Warm-Up Cycle
cycle detection logic (refer to “3 Driving Cycle A “Warm-Up Cycle” means sufficient vehicle operation
Detection Logic”: K15B (Page 1A-2)) to prevent such that the coolant temperature has risen by at least
erroneous detection. 22 °C (40 °F) from engine starting and reaches a
With this logic, MIL is turned on when the same minimum temperature of at least 70 °C (160 °F).
malfunction is detected for 3 consecutive driving
cycles. Driving Cycle
A “Driving Cycle” is a duration from an engine startup to
• When a malfunction is detected, engine and driving the following engine shutoff.
conditions at the moment the malfunction was
detected are stored in ECM memory as freeze frame
data. (For the details, refer to description on “Freeze
frame data clearance”: K15B (Page 1A-3).)
 Engine General Information and Diagnosis: K15B 1A-2
3 Driving Cycle Detection Logic
The malfunction detected in the first driving cycle is
stored in ECM memory (in the form of pending DTC) but
MIL does not light at this time. ECM causes the MIL to
light up when it detects third time the same malfunction
in the next two driving cycles.
Pending DTC
“Pending DTC” is relevant to those DTCs to which the 3
driving cycle detection logic is applied. If such a DTC is
detected and stored temporarily during the first of three
consecutive driving cycles, the DTC is called pending
DTC.
Freeze Frame Data
ECM stores the engine and driving conditions at the
moment of the detection of a malfunction in its memory.
This data is called “Freeze Frame Data”.
Therefore, it is possible to know engine and driving
conditions (e.g. whether the engine was warm or not,
whether the vehicle was running or stopped, whether air/
fuel mixture was lean or rich) at the moment the
malfunction was detected by checking the freeze frame
data. Also, ECM has a function to store each freeze
frame data for three different malfunctions in detecting
order.
Utilizing this function, it is possible to know the detecting
order of the malfunctions, and facilitates recheck and
diagnosis of the trouble.
NOTE
• Absolute TP / APP indicates the ratio of the
output voltage to the power supply voltage
of related sensor.
When power supply voltage is 5.0 V and
output voltage is 4.0 V, freeze frame data is
displayed as follows.
– The sensor that the output voltage
increases according to the opening
angle, it displays 80%.
– The sensor that the output voltage
decreases according to the opening
angle, it displays 20%.
• Relative TP indicates value calculated by
formula ((output voltage – output voltage
at closed throttle position) / power supply
voltage).
When power supply voltage is 5.0 V and
output voltage at closed throttle position is
1.0 V, freeze frame data is displayed as
follows.
– At closed throttle position (output
voltage = 1.0 V), it displays 0%.
– At wide open throttle position (output
voltage = 4.0 V), it displays 60%.
However, for systems where the output is
inversely proportional to the input voltage, it
displays 100% minus the above-mentioned
formula.
Freeze frame data (For example)
IJHB0B111001-01
1A-3 Engine General Information and Diagnosis: K15B

Priority of freeze frame data

ECM has 4 freeze frames from 0 to 3 where freeze frame data can be stored.
Frame 0 is a special frame where freeze frame data concerning emission-affecting malfunction has priority over data
related to other (general) malfunctions. If any emission-affecting malfunction is detected while Frame 0 is holding a
data related to general malfunctions (priority “2” data in the following table), then the currently stored data is replaced
by the data concerning the newly detected malfunction (priority “1” data in the following table).
Priority Freeze frame data in Frame 0
Data concerning any of the following malfunctions: Misfire Detected (P0300 – P0304), System Too
1
Lean (P0171) and System Too Rich (P0172)
2 Data concerning malfunctions other than the above.

Frames 1 to 3 are assigned to general malfunctions. They individually store the freeze frame data for 3 different
general malfunctions in the order of detection (i.e., Frame 1 stores the data for the first detected malfunction and
Frame 3 the data for the last detected malfunction). Unlike the Frame 0 data, the data in these 3 frames are not
updated, so freeze frame data for any malfunction detected subsequently are not stored anywhere.

Frame 0 Frame 1 Frame 2 Frame 3

Freeze frame 1st freeze frame 2nd freeze frame 3rd freeze frame
data data data data
1 No DTC
2 P0443 P0443 data P0443 data
DTC 3 P0112 P0443 data P0443 data P0112 data
detection
order 4 P0117 P0443 data P0443 data P0112 data P0117 data
5 P0480 P0443 data P0443 data P0112 data P0117 data
6 P0171 P0171 data P0443 data P0112 data P0117 data
IDAA0A111043-01
—: No freeze frame data

Freeze frame data clearance

When a DTC is cleared, the freeze frame data for the malfunction represented by this DTC is also cleared.

System Readiness Test NOTE

The system readiness test is performed for the purpose
of checking that each of the exhaust-emission-related
systems fulfills the conditions that allow ECM to detect a
malfunction if it occurs and to set the corresponding
DTC.
The test is carried out by monitoring the specific items
(components) using a scan tool (SUZUKI scan tool or
CAN communication OBD-II generic scan tool). When
the test shows that the conditions pre-established for the
tested system are met, ECM performs an on-board
diagnosis of the system, changes the status of the
system readiness test from “Incomplete” to “Complete”,
and causes the “Complete” status to be displayed on the
scan tool.
The “Complete” status is maintained until DTC clearance
operation is performed using the scan tool.
• The system readiness test status may
change from “Complete” to “Incomplete” if
any of the following service operations is
performed.
– Disconnection of battery negative (–)
cable
– Disconnection of ECM connectors
– Removal of ECM ground cable
• The items (components) indicated in the
table below are monitored in the system
readiness test to check the readiness for
detecting the DTCs listed beside each
monitoring item.
• The “Complete” or “Incomplete” status
identified through the system readiness
test does NOT mean the “Normal” or
“Abnormal” result of on-board diagnosis.

Monitoring item of system readiness test

Monitoring item DTC related to monitoring item
Catalyst P0420 —
O2 Sensor P0133 P2271
O2 Sensor Heater — —
VVT system P0011 —
 Engine General Information and Diagnosis: K15B 1A-4

DLC Description Engine and Emission Control System

AENJHB0B1111003
DLC (1) is in compliance with SAE J1962 in the shape of
Description
AENJHB0B1111004
connector and pin assignment. The engine and emission control system is divided into 4
OBD CAN High line (6) and Low line (3) (CAN line of ISO major sub-systems: air intake system, fuel delivery
15765-4) are used for SUZUKI scan tool (Suzuki SDT-II) system, electronic control system and emission control
(7) to communicate with ECM. system.
Air intake system includes air cleaner, throttle body and
2 intake manifold.
3
Fuel delivery system includes fuel pump, delivery pipe,
1 2 3 4 5 6 7 8
etc.
9 10 11 12 13 14 15 16 Electronic control system includes ECM, various sensors
and controlled devices.
6 5 Emission control system includes EVAP and PCV
4
1 systems.
IGSB0A113002-01

IJHA0A110002-01

2. B+ (Continuous battery power) 5. Ground (Chassis ground)

4. ECM ground (Signal ground)
1A-5 Engine General Information and Diagnosis: K15B

Air Intake System Description

AENJHB0B1111005
The main components of the air intake system are the air cleaner assembly (1), the air cleaner outlet hose (2), the
electric throttle body assembly (3) and the intake manifold (4).
For the details of the electric throttle assembly, refer to “Electric Throttle Control System Description”: K15B (Page 1A-
6).
The intake air, which the amount varies corresponding to the throttle valve (5) opening and the engine speed, is
filtered by the air cleaner, distributed by the intake manifold, and finally drawn into each combustion chamber. The
electric throttle body assembly is not equipped with the IAC valve for idle speed control. The idle speed is controlled by
the throttle actuator (6) which opens/closes the throttle valve. For the details, refer to “Electric Throttle Control System
Description”: K15B (Page 1A-6).

3
6
7

IFRA0A111004-02

7. IAT sensor 8. MAP sensor

 Engine General Information and Diagnosis: K15B 1A-6

Electric Throttle Control System Description

AENJHB0B1111006
The electric throttle control system consists of the following items:
• Electric throttle body assembly incorporating the throttle valve, throttle actuator and TP sensors (main and sub)
• Accelerator pedal assembly incorporating APP sensors (main and sub)
• ECM

Operation Description
ECM (5) detects depressed extent of the accelerator pedal based on the signal voltage of the APP sensor (1). Using
that data and engine operation condition, ECM calculates the optimum throttle valve opening. On the other hand, it
detects the throttle valve opening based on the signal voltage of the TP sensor (3) in the electric throttle body
assembly (2) and compares this value with the above calculated optimum throttle valve opening. When there is a
difference between them, ECM changes the duty ratio (100% to 0%) of throttle actuator control according to this
difference to drive the throttle actuator (4) in the electric throttle body assembly. When there is no difference, ECM
fixes the duty ratio to about 15% to maintain the throttle valve opening. In this way, the throttle valve (13) is opened
and closed to achieve the optimum throttle valve opening.
In this system, TP sensor and APP sensor have 2 sensors (main and sub) each to assure highly accurate and reliable
control and abnormality detection. When ECM detects an abnormality in the system, it stops controlling the throttle
actuator.
This throttle body is not equipped with IAC valve for idle speed control. Idle speed control is performed by the throttle
actuator by adjusting the throttle valve opening.

5
8

2 9 3 6
10
1
7

13
11

12

I7Y50A110003-01

6. CPU 9. APP sensor (sub) signal circuit 12. Drive circuit of throttle actuator
7. Throttle actuator driver 10. TP sensor (main) signal circuit
8. APP sensor (main) signal circuit 11. TP sensor (sub) signal circuit

Electronic Control System Description Engine start injection control

AENJHB0B1111007
Fuel Injection Control System
The system controls fuel to be supplied into cylinder
adjusting injection timing and injection time (volume)
optimally.
Fuel injection timing and time (volume) are decided by
engine start injection control for the engine starting and
after start injection control during the normal driving.
Further, fuel cut is controlled in response to the driving
conditions.
• Fuel injection timing
The injection timing is decided corresponding to
coolant temperature and fuel is injected in sequential
order synchronizing with crank angle sensor signal.
• Fuel injection time (volume)
For engine start, the injection time is decided adding
adjustable factors such as intake air temperature,
battery voltage, engine speed (cranking speed) and
atmospheric pressure to the basic injection time.
And, the lower the coolant temperature, the longer the
injection time for good startability.
1A-7 Engine General Information and Diagnosis: K15B
After start injection control
• Fuel injection timing
– For programed finishing time of injection, start
timing of injection is calculated and fuel is injected
sequentially under normal condition.
– When fuel cut returns to normal injection or when
accelerating rapidly, fuel is injected into all cylinders
simultaneously for a short time without
synchronizing to crank angle sensor signal.
• Fuel injection time (volume)
The basic injection time is decided based on intake air
volume and engine speed, and using this basic
injection time, optimum injection time is adjusted to fit
driving conditions taking information from each
sensor.
Fuel cut control
• Engine speed fuel cut
To prevent engine over speed, this fuel cut is operated
at engine speed in the following conditions.
– While vehicle is running: When engine speed goes
up to 6,400 rpm or higher.
– While vehicle is stopped: When engine speed goes
up to 5,200 rpm (M/T model) / 4,200 rpm (A/T
model) or higher.
NOTE
Each figure in fuel cut condition shown here
is reference value (a guide line).
• Deceleration fuel cut
To restrain hydrocarbon (HC) emissions and improve
fuel economy, this fuel cut is operated during
deceleration in specified conditions.
Ignition Timing Control
• Corresponding to vehicle running conditions, ignition
timing is controlled optimally.
• There are three control modes to determine ignition
timing, i.e. engine start ignition control mode, normal
driving condition ignition control mode and ignition
timing inspection mode. Further, torque down control
is executed controlling ignition timing.
Engine start ignition control
When engine speed (cranking speed) is below 500 rpm,
ignition timing is BTDC –10° to 10°.
Normal condition control mode
• At idling
The timing is optimized adding factor of coolant
temperature to basic timing for engine start.
• Except idling
Basic timing determined by factors such as intake air
volume, engine speed and state of VVT is corrected
optimally.
Ignition timing inspection mode
When checking ignition timing with SUZUKI scan tool
(Suzuki SDT-II), the timing is fixed to BTDC 5° at idling.
Electric Throttle Control
Receiving dual voltage signals, main and sub, from APP
Sensor, a target degree of throttle opening is calculated
and to bring the throttle opening closer to the target,
throttle motor is activated. Further, the system executes
the following controls in response to the vehicle
conditions.
Engine start control
For engine start, throttle opening angle is set up
according to coolant temperature to increase intake air
for good startability. And, the lower the coolant
temperature, the wider the throttle opening for the same
purpose.
Idling control
Basic throttle opening angle is set up according to
information of coolant temperature, shift position and A/
C switch and, adding corrective factors, a target degree
of throttle opening is determined.
Normal condition control
Adding information of accelerator pedal depressing
degree, engine load, etc. to basic throttle opening
degree, a target degree of throttle opening is
determined. If actual throttle opening angle differs from
the target degree, ECM adjusts the throttle opening to
bring it closer to the target.
Deceleration control
At the time of deceleration, the system opens throttle
valve at specified degree to increase intake air and
prevents engine speed from excessive falling.
Maximum engine speed limitation control
To prevent engine over speed, throttle opening is
restricted.
• While vehicle is running: Engine speed at 6,200 rpm
or more.
• While vehicle is stopped:
– Engine speed at 5,000 rpm (M/T model) / 4,000
rpm (A/T model) or more.
– Engine speed of 3,200 rpm or more continues for
150 seconds.
NOTE
Each engine speed shown here is reference
value as a guide line.
Torque down control (ESP® model)
When torque down demand from ESP® controller is
inputted, ECM responds to reduce engine torque
controlling throttle opening and ignition timing.
 Engine General Information and Diagnosis: K15B 1A-8
Fail-safe control
When malfunction of throttle control circuit is detected,
ECM cuts off current to throttle motor. As a result, throttle
valve opening is fixed in a default angle or, movable
maximum opening of throttle valve is restricted in a
degree equivalent to the default angle. However,
minimum vehicle running is ensured by control of fuel
injection and ignition timing.
VVT System
The system controls OCV for optimum valve timing in
response to engine speed, volume of intake air, degree
of throttle opening and coolant temperature. The valve
timing is brought closer to the engine command by
feedback control detecting actual advance angle of the
valve.
Evaporative Emission Control System
Corresponding to vehicle running conditions, the system
controls ON/OFF of canister purge VSV to suck in fuel
evaporation gas absorbed in canister and feeds it into
intake manifold together with air-fuel mixture to burn.
This function restrains the fuel evaporation gas to be
released to atmosphere.
Radiator Cooling Fan Control System
Based on information of A/C switch, vehicle speed,
engine speed, coolant temperature and refrigerant
pressure, the system controls radiator fan relay No.1,
No.2 and No.3 for operation of LO, HI or stop.
Fuel Pump Control System
The system operates or stops fuel pump controlling fuel
pump relay.
ON conditions of fuel pump relay
• For specified time after ignition “ON”.
• While CKP sensor signal is being inputted to ECM
with engine running.
Main Relay Control
• Corresponding to “ON” or “OFF” of ignition mode, the
main relay is controlled for startup or stop of EPI
system.
• The main relay has a self-shutoff function which
supplies power source to internal circuit in ECM for
specified time until the system stops after ignition
“OFF”, and a countercurrent protection feature which
prevents the battery from flowing reverse current
caused by erroneous reverse connection.
A/C Control System
Based on information from A/C switch, refrigerant
pressure sensor and vehicle driving conditions through
CAN communication, the system controls ON/OFF of A/
C compressor.
HO2S Heater Control System
To quicken startup or maintain activation of HO2S
sensor, the system controls HO2S sensor heater using
duty cycle pulse signal.
CAN Communication System
Using this system, each control module transmits /
receives data and information with other control
modules.
Brake Override System
When the driver depresses accelerator pedal and brake
pedal at the same time, ECM controls engine output by
restricting throttle valve opening and prioritizes braking
force.
NOTE
• The system may not be activated
depending on the following conditions.
– Depressing amount of accelerator pedal
and brake pedal
– Vehicle speed
• The system restricts throttle valve opening
mainly. Therefore, ignition timing control
and VVT system are affected by this
system.
ISG Control System
Refer to “Description of SHVS System Control”: K15B
Model in Section 11A (Page 11A-8).
1A-9 Engine General Information and Diagnosis: K15B

Engine and Emission Control Input / Output Table

Function
Injection control Fuel injector
Fuel injector
Immobilizer control
Ignition coil assembly
Ignition control Ignition coil assembly
AENJHB0B1111008
Output Input
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
• APP sensor
• MAP sensor
• IAT sensor
• HO2S-1
• HO2S-2
• Barometric pressure sensor
• A/C refrigerant pressure sensor
• Battery voltage
• Brake light switch
• BCM (A/C switch status signal)
• ABS / ESP® control module (wheel speed signal)
• P/S control module
• TCM (engine speed limit request signal and torque up / down
request signal) (A/T model)
• Ignition “ON” signal
• BCM
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
• APP sensor
• MAP sensor
• IAT sensor
• Knock sensor
• Barometric pressure sensor
• Battery voltage
• BCM (electric load signal and A/C switch status signal)
• ABS / ESP® control module (wheel speed signal)
• TCM (engine speed limit request signal and torque down
request signal) (A/T model)
 Engine General Information and Diagnosis: K15B 1A-10

Function Output Input

• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• TP sensor
• APP sensor
• MAP sensor
• IAT sensor
• HO2S-1
Idle speed control Throttle actuator
• HO2S-2
• Barometric pressure sensor
• A/C refrigerant pressure sensor
• Brake light switch
• BCM (electric load signal and A/C switch status signal)
• ABS / ESP® control module (wheel speed signal)
• P/S control module
• TCM (transmission shift position signal and torque up / down
request signal) (A/T model)
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• TP sensor
• APP sensor
• MAP sensor
• IAT sensor
Throttle valve control Throttle actuator • HO2S-1
• HO2S-2
• Barometric pressure sensor
• A/C refrigerant pressure sensor
• Brake light switch
• BCM (electric load signal and A/C switch status signal)
• ESP® control module (torque up / down request signal) (ESP®
model)
• TCM (engine speed limit request signal and torque up / down
request signal) (A/T model)
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• TP sensor
HO2S-1 heater control HO2S-1 • MAP sensor
• IAT sensor
• Barometric pressure sensor
• CKP sensor
• Battery voltage
1A-11 Engine General Information and Diagnosis: K15B

Function Output Input

• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• TP sensor
HO2S-2 heater control HO2S-2 • MAP sensor
• IAT sensor
• Barometric pressure sensor
• CKP sensor
• Battery voltage
• Ignition “ON” signal
• ECT sensor
• CKP sensor
• TP sensor
• MAP sensor
• IAT sensor
EVAP canister purge
EVAP purge control • HO2S-1
valve
• HO2S-2
• Barometric pressure sensor
• ABS / ESP® control module (wheel speed signal)
• BCM (electric load signal and A/C switch status signal)
• TCM (engine speed limit request signal and torque up / down
request signal) (A/T model)
• Ignition “ON” signal
• ECT sensor
• CKP sensor
• CMP sensor
VVT control OCV • IAT sensor
• MAP sensor
• TP sensor
• Brake light switch
• ABS / ESP® control module (wheel speed signal)
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• TP sensor
• APP sensor
A/C compressor control A/C compressor relay
• A/C refrigerant pressure sensor
• MAP sensor
• Barometric pressure sensor
• BCM (evaporator temperature signal and A/C switch status
signal)
• ABS / ESP® control module (wheel speed signal)
• Ignition “ON” signal
• ECT sensor
Radiator cooling fan Radiator cooling fan • CKP sensor
control relay • A/C refrigerant pressure sensor
• BCM (electric load signal and A/C switch status signal)
• ABS / ESP® control module (wheel speed signal)
 Engine General Information and Diagnosis: K15B 1A-12

Function Output Input

• Ignition “ON” signal
Fuel pump control Fuel pump relay • Ignition “ST” signal
• CKP sensor
Main relay control Main relay • Ignition “ON” signal
• ECT sensor
• CKP sensor
• APP sensor
• MAF sensor
• Electric load current sensor
• Battery temperature sensor
ISG control ISG • Brake stroke sensor
• ABS / ESP® control module (wheel speed signal and ENG A-
STOP status signal)
• BCM (electric load signal and hood switch status signal)
• BCM (A/C switch status signal)
• ISG (field measured signal)
• Auxiliary power module (lithium-ion battery) (auxiliary power
module (lithium-ion battery) status signal)

Schematic and Routing Diagram

Engine and Emission Control System Diagram
AENJHB0B1112001
 37

1 18

19
5

17 20

2
21

3
4
36

6
16 34 27
8 7
1A-13 Engine General Information and Diagnosis: K15B

13
29
28
9
[B]
31
[A]

30
10 33 32 32

11 14
12 15
25 26
38

23 24 35
22
39

IJHB0A111002-01
 Engine General Information and Diagnosis: K15B 1A-14

[A]: Ignition switch model 13. ECT sensor 27. Brake light
[B]: Keyless push start model 14. HO2S-1 28. Brake light switch
1. Air cleaner 15. HO2S-2 29. Starting motor control relay
2. IAT sensor 16. OCV 30. Ignition switch
3. TP sensor 17. ECM 31. BCM
4. Throttle actuator 18. Radiator cooling fan relay No.1, 2 and 3 32. IG12 relay
5. MAP sensor 19. A/C compressor relay 33. Main relay
6. Ignition coil assembly 20. A/C refrigerant pressure sensor 34. CPP No.1 switch (M/T model) or transmission
range sensor (A/T model)
7. Fuel injector 21. ISG 35. Starting motor
8. EVAP canister purge valve 22. Fuel pump relay 36. Barometric pressure sensor
9. EVAP canister 23. CPP No.2 switch (M/T model) 37. Control modules and sensor connected by CAN
10. Fuel cut valve 24. APP sensor 38. Auxiliary power module (lithium-ion battery)
11. Fuel pump (with pressure regulator) 25. CMP sensor 39. Electric load current sensor
12. Knock sensor 26. CKP sensor
 CAN communication line Air Vapor

Exhaust gas Fuel

*: If equipped

Electric throttle Intake manifold

Air cleaner Engine Exhaust manifold
body assembly
(including TWC)
Throttle TP MAP CMP CKP Knock Ignition coil
IAT sensor
actuator sensor sensor sensor sensor sensor assembly OCV HO2S-2
HO2S-1
Fuel
injector

EVAP canister ECT

purge valve Fuel sensor
Fuel cut valve pump

EVAP Fuel
Fuel tank pump
canister
relay
1A-15 Engine General Information and Diagnosis: K15B

Engine and Emission Control System Flow Diagram

Heater Heater
control control
ECM Barometric pressure sensor

· *TCM
· ABS / ESP® control module
· P/S control module
· BCM Radiator cooling
A/C refrigerant *CPP No.1 switch
· SDM fan relay
ISG pressure sensor / *CPP No.2 switch
· Combination meter No.1, 2 and 3 Main relay
· ISG

Electric load A/C compressor

current sensor relay APP sensor Brake light switch

IJHB0A111003-01
AENJHB0B1112002
 Engine General Information and Diagnosis: K15B 1A-16

Electronic Control System Circuit Diagram

AENJHB0B1112003

1
2 33 +B
BRN E01-20 C01-51 LT GRN
3 34
BEG E01-16 C01-54 BRN
BLU E01-19 C01-13 RED
35
BLK E01-6 C01-26 GRN
36
4 YEL E01-3 C01-16 WHT
WHT E01-5 C01-15 BLK
+B C01-17 BLK 77
37
C01-31 PNK
5 C01-11 WHT 38
PPL C01-30
C01-10 RED 39

6 C01-12 GRN 40
PNK C01-39
BLK
C01-41 GRY 41
7 77
+B 42
RED C01-6 C01-42 GRN
GRN C01-7 43
BLU PPL C01-49 E01-24 RED
BLK PNK +BB
LT GRN C01-55
44 45
8 77
YEL C01-8 E01-2 LT GRN 49
BLU
BRN C01-19
BLU RED C01-52 GRN
BEG BLU
C01-56 47
L+ GRY
E01-27 GRN 48
9 H+
YEL C01-22 L-
BLK H- 46
LT GRN
BEG C01-5 50
10 E01-41 BRN
WHT C01-25 51 52
BLU C01-37 GRY GRN

11 LT BLU C01-14 53
BRN C01-27 C01-44 BRN
GRY C01-4 54
12
BLU C01-20 C01-33 GRN
55
13 BRN E01-14 C01-34 PNK
56
PNK E01-33
BLU E01-9 C01-35 LT BLU
14 57
PPL E01-42 E01-45 GRY
58
PPL E01-10 E01-49 PNK 23
15 59
E01-55 BLU

LT BLU E01-4 E01-56 BLU

16 BLU E01-48 61
17
23 PNK E01-47
BRN E01-22 31 62
22 60 63
E01-1 WHT
18
PNK E01-40
19 YEL E01-7
[B]
65 [A]
IG2
20 66
LT BLU E01-18
IG1 67
21
64 ST 68
WHT E01-37
69
+BB 24 WHT C01-2
26 RED C01-3
70
WHT E01-29 74
25 32 E01-17 GRN
RED E01-28
71 75
73
E01-43 LT GRN 72
[C]
YEL E01-21 76
27 28 E01-36 BRN
29 E01-11 GRY
30
C01-50 BLK
C01-53 BLK
: 78 : 79 : 12V : 5V : 3.3V
IJHB0B111002-01
1A-17 Engine General Information and Diagnosis: K15B

[A]: Ignition switch model 26. To other control modules and sensor 54. Ignition coil assembly No.2
connected by CAN
[B]: Keyless push start model 27. To blower motor 55. Ignition coil assembly No.3
[C]: Manual A/C model 28. Blower speed switch 56. Ignition coil assembly No.4
1. ECM 29. A/C switch 57. “A-STOP” fuse
2. APP sensor 30. To BCM 58. Main relay
3. APP sensor (main) 31. Barometric pressure sensor 59. “FI” fuse
4. APP sensor (sub) 32. CAN driver 60. “IG” fuse
5. CMP sensor 33. Electric throttle body assembly 61. IG12 relay
6. CKP sensor 34. Throttle actuator 62. IG11 relay
7. HO2S-1 35. TP sensor (main) 63. “IGN” fuse
8. HO2S-2 36. TP sensor (sub) 64. BCM
9. IAT sensor 37. Fuel injector No.1 65. Engine switch
10. Knock sensor 38. Fuel injector No.2 66. Ignition switch
11. MAP sensor 39. Fuel injector No.3 67. “KEY” fuse
12. ECT sensor 40. Fuel injector No.4 68. “KEY2” fuse
13. A/C refrigerant pressure sensor 41. EVAP canister purge valve 69. “ST” fuse
14. CPP No.2 switch (M/T model) 42. OCV 70. Starting motor control relay
15. Brake stroke sensor 43. Fuel pump relay 71. CPP No.1 switch (M/T model) or
transmission range sensor (A/T model)
16. Electric load current sensor 44. Fuel pump 72. Starting motor
17. Battery temperature sensor 45. Radiator cooling fan relay No.1 73. “ST SIG2” fuse
18. Neutral position switch (M/T model) 46. Radiator cooling fan relay No.2 74. ST2 relay (A/T model)
19. Brake light switch 47. Radiator cooling fan relay No.3 75. Main fuse box
20. Brake light 48. Radiator cooling fan 76. Battery
21. To other control modules 49. “RDTR” fuse 77. Shield wire
22. “STOP” fuse 50. A/C compressor relay 78. Engine ground
23. To auxiliary power module (lithium-ion battery) 51. A/C compressor 79. Body ground
24. ISG 52. “CPRSR” fuse
25. DLC 53. Ignition coil assembly No.1

Terminal Arrangement of ECM Connector

NOTE
For circuit names and terminal voltages, refer to “Inspection of ECM and Its Circuits”: K15B (Page 1A-
150).

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IBP60B110007-01

[A]: ECM connector (View: [a])

 Engine General Information and Diagnosis: K15B 1A-18

Component Location
Electronic Control System Component Location
AENJHB0B1113001
Engine Compartment

[2] [h] [b] [c]

[a]

[e]
[d]

[f] [g]

[1]

[2]

IJHB0B111003-01

Information sensors Control devices Others

1. Electric load current sensor
2. A/C refrigerant pressure sensor
[a]: ISG [1]: ECM
[b]: Fuel pump relay [2]: Individual circuit fuse box No.1
[c]: Radiator cooling fan relay No.3
[d]: A/C compressor relay
[e]: Main relay
[f]: Radiator cooling fan relay No.2
[g]: Radiator cooling fan relay No.1
[h]: ST2 relay (A/T model)
1A-19 Engine General Information and Diagnosis: K15B

Interior (Around Instrument Panel)

[a] [1]

[b]

[1]

5
[2]

IJHB0B111004-01

Information sensors Control devices Others

1. Brake light switch [a]: MIL [1]: Combination meter
2. CPP No.1 switch (M/T model) [b]: Immobilizer indicator light [2]: DLC
3. CPP No.2 switch (M/T model)
4. Accelerator pedal assembly (incorporating APP sensor)
5. Brake stroke sensor
 Engine General Information and Diagnosis: K15B 1A-20

Engine Assembly

[a]
[b]
7 [g]
[c] 6
[h]
[d] 1
[i]
[k]

2, [e] [m]

[f]
3

4
IJHB0A111007-01

Information sensors Control devices

1. IAT sensor [a]: Ignition coil assembly No.1
2. TP sensor [b]: Ignition coil assembly No.2
3. HO2S-1 [c]: Ignition coil assembly No.3
4. HO2S-2 [d]: Ignition coil assembly No.4
5. ECT sensor [e]: Electric throttle body assembly
6. MAP sensor [f]: EVAP canister purge valve
7. CMP sensor [g]: Fuel injector No.4
8. Knock sensor [h]: Fuel injector No.3
9. CKP sensor [i]: Fuel injector No.2
[k]: Fuel injector No.1
[m]: OCV
1A-21 Engine General Information and Diagnosis: K15B

Diagnostic Information and Procedures

Engine and Emission Control System Check
AENJHB0B1114001
Refer to the following items for the details of each step.
Step Action Yes No
1 Customer complaint analysis Go to Step 2. Perform customer
1) Perform customer complaint analysis. (Page 1A-22) complaint analysis.

Was customer complaint analysis performed?

2 DTC / freeze frame data check, record and clearance Print DTCs and freeze Go to Step 4.
1) Check for DTCs (including pending DTCs). (Page 1A- frame data or write them
23) down and clear them
referring to “DTC
Is there any DTC(s) / freeze frame data? Clearance”: K15B
(Page 1A-24), and go to
Step 3.
3 Visual inspection Repair or replace Go to Step 5.
1) Perform visual inspection. (Page 1A-23) defective part, and then
go to Step 11.
Is there any faulty condition?
4 Visual inspection Repair or replace Go to Step 8.
1) Perform visual inspection. (Page 1A-23) defective part, and then
go to Step 11.
Is there any faulty condition?
5 Trouble symptom confirmation Go to Step 6. Go to Step 7.
1) Check trouble symptom. (Page 1A-23)

Is trouble symptom identified?

6 Rechecking and recording DTC / freeze frame data Go to Step 9. Go to Step 8.
1) Recheck for DTC and freeze frame data. (Page 1A-23)

Is there any DTC(s)?

7 Rechecking and recording DTC / freeze frame data Go to Step 9. Go to Step 10.
1) Recheck for DTC and freeze frame data. (Page 1A-23)

Is there any DTC(s)?

8 Engine basic inspection and engine symptom diagnosis Go to Step 11. Check and repair
1) Check and repair. (Page 1A-23) defective part(s), and go
to Step 11.
Are check and repair complete?
9 Troubleshooting for DTC Go to Step 11. Check and repair
1) Check and repair according to applicable DTC defective part(s), and go
troubleshooting. (Page 1A-23) to Step 11.

Are check and repair complete?

10 Intermittent problem check Repair or replace Go to Step 11.
1) Check for intermittent problems. (Page 1A-23) defective part(s), and go
to Step 11.
Is there any faulty condition?
11 Final confirmation test Go to Step 6. End.
1) Clear DTC if any.
2) Perform final confirmation test. (Page 1A-23)

Is there any problem symptom, DTC or abnormal condition?

 Engine General Information and Diagnosis: K15B 1A-22

Step 1: Customer Complaint Analysis

Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose,
use of an inspection form as shown will facilitate collecting information required for proper analysis and diagnosis.

NOTE
This form is a standard sample. It should be modified according to characteristic of each market.

Customer questionnaire form (Example)

I9P60A111042-01
1A-23 Engine General Information and Diagnosis: K15B

Step 2: DTC / Freeze Frame Data Check, Record and MIL Check
Clearance AENJHB0B1114002

First, check DTC (including pending DTC). (Page 1A-
23)
If DTC is indicated, print it and freeze frame data or write
them down and then clear them. (Page 1A-24)
Steps 3 and 4: Visual Inspection
As a preliminary step, perform visual check of the items
that support proper function of the engine. (Page 1A-
53)
Step 5: Trouble Symptom Confirmation
If there is no DTC in Step 2:
Based on information obtained in “Step 1: Customer
Complaint Analysis”: K15B (Page 1A-22) and “Step 2:
DTC / Freeze Frame Data Check, Record and
Clearance”: K15B (Page 1A-23), check trouble
symptoms.
If there is any DTC in Step 2:
Recheck DTC according to “DTC Confirmation
Procedure” described in each DTC troubleshooting.
1) Set ignition “ON” (with engine at stop) and check that
MIL (1) lights.
If MIL does not light up but engine can be started, go
to “MIL Does Not Come ON with Ignition “ON” and
Engine Stopped (but Engine Can Be Started)”: K15B
(Page 1A-65) for troubleshooting.
If MIL does not light with ignition “ON” and engine
does not start though it is cranked, go to “ECM
Power Supply and Ground Circuit Check”: K15B
(Page 1A-162).
2) Start engine and check that MIL turns off.
If MIL remains on and no DTC is stored in ECM, go
to “MIL Remains ON after Engine Starts”: K15B
(Page 1A-65) for troubleshooting.
1

Steps 6 and 7: Rechecking and Recording DTC /

Freeze Frame Data
Refer to “DTC Check”: K15B (Page 1A-23) for checking
procedure. IJHB0A111008-01

Step 8: Engine Basic Inspection and Engine DTC Check

Symptom Diagnosis
1) Perform engine basic inspection. (Page 1A-54)
2) If there is no faulty part found in inspection
procedure of “Engine Basic Inspection”, perform
“Engine Symptom Diagnosis”: K15B (Page 1A-55)
based on symptom found in vehicle checking in the
following steps.
• Customer complaint analysis
• Trouble symptom confirmation
Step 9: Troubleshooting for DTC
Perform applicable DTC troubleshooting and repair or
replace faulty parts.
Step 10: Intermittent Problem Check
If there is no DTC in Step 2:
Check for intermittent problem. (Page 00-12)
If there is any DTC in Step 2:
Check parts related to detected DTC (e.g. wire harness,
connector, etc.).
AENJHB0B1114003
NOTE
In case that MIL turns on, the malfunction(s)
is detected in either ECM or TCM and it
stores the trouble information (DTC, freeze
frame data, etc.) in its memory.
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Read DTC, pending DTC and freeze frame data
according to instructions displayed on SUZUKI scan
tool and print them or write them down. Refer to
Operator's Manual of SUZUKI scan tool for further
details.

Step 11: Final Confirmation Test

Check that the problem symptom has gone and engine
is free from any abnormal conditions. If what has been
repaired is related to DTC, clear DTC once, perform
DTC confirmation procedure and check that no DTC is
indicated.
 Engine General Information and Diagnosis: K15B 1A-24
NOTE
If communication between SUZUKI scan tool
and ECM is not possible, perform the
following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-17)
• Check ECM power circuit and ground
circuit. (Page 1A-162)
1 1
2 2
(A)
IJHA0A110011-01
5) After completing the check, set ignition “OFF” and
disconnect SUZUKI scan tool from DLC.
DTC Clearance
AENJHB0B1114004
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Clear DTC and pending DTC according to
instructions displayed on SUZUKI scan tool and print
them or write them down. Refer to Operator's
Manual of SUZUKI scan tool for further details.
NOTE
If communication between SUZUKI scan tool
and ECM is not possible, perform the
following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-17)
• Check ECM power circuit and ground
circuit. (Page 1A-162)
(A)
IJHA0A110011-01
5) After completing DTC clearance, set ignition “OFF”
and disconnect SUZUKI scan tool from DLC.
NOTE
DTC and freeze frame data stored in ECM
memory are also cleared in the following
case. Be careful not to clear them before
recording them.
• When the same malfunction (DTC) is not
detected again for 40 engine warm-up
cycles. (See “Warm-Up Cycle” under “OBD
System Description”: K15B (Page 1A-1).)
6) Perform “Electric Throttle Control System
Calibration”: K15B in Section 1C (Page 1C-5).
1A-25 Engine General Information and Diagnosis: K15B

DTC Table
AENJHB0B1114005
NOTE
• When DTC P0300 / P0301 / P0302 / P0303 / P0304 is detected, MIL blinks or lights up according to
detecting condition. For details, refer to “DTC P0300 / P0301 / P0302 / P0303 / P0304”: K15B (Page
1A-102).
• With the CAN communication generic scan tool, only DTC with asterisk (*) in the following table can
be read.

DTC
DTC DTC name DTC detecting condition MIL
detection logic
Invalid Data Received From
ENG A-STOP Control
C1372 1 D/C Off
Module to ABS / ESP®
Control Module Refer to “DTC Table” in Section 10I (Page
Invalid Data Received From 10I-11).
ENG A-STOP Control
C1373 1 D/C Off
Module to ABS / ESP®
Control Module
“A” Camshaft Position
*P0010
Actuator Circuit / Open OCV drive circuit is open. 3 D/C Lights up
(Page 1A-66)
(Bank1)
“A” Camshaft Position
*P0011 (Page Timing Over Advanced or Measured CMP does not reach target CMP
3 D/C Lights up
1A-68) System Performance for specified time.
(Bank1)
Crankshaft Position –
Difference between camshaft position and
*P0016 Camshaft Position
crankshaft position is out of specified 3 D/C Lights up
(Page 1A-70) Correlation (Bank1 Sensor
range.
A)
*P0030 HO2S Heater Control Circuit
HO2S-1 heater drive circuit is open. 3 D/C Lights up
(Page 1A-72) (Bank1 Sensor1)
*P0031 HO2S Heater Control Circuit HO2S-1 heater drive circuit is shorted to
3 D/C Lights up
(Page 1A-72) Low (Bank1 Sensor1) ground.
*P0032 HO2S Heater Control Circuit HO2S-1 heater drive circuit is shorted to
3 D/C Lights up
(Page 1A-72) High (Bank1 Sensor1) power supply.
*P0036 HO2S Heater Control Circuit
HO2S-2 heater drive circuit is open. 3 D/C Lights up
(Page 1A-74) (Bank1 Sensor2)
*P0037 HO2S Heater Control Circuit HO2S-2 heater drive circuit is shorted to
3 D/C Lights up
(Page 1A-74) Low (Bank1 Sensor2) ground.
*P0038 HO2S Heater Control Circuit HO2S-2 heater drive circuit is shorted to
3 D/C Lights up
(Page 1A-74) High (Bank1 Sensor2) power supply.
Manifold Absolute Pressure / Output voltage of MAP sensor signal circuit
*P0107
Barometric Pressure Circuit is lower than specified value for specified 3 D/C Lights up
(Page 1A-76)
Low time.
Manifold Absolute Pressure / Output voltage of MAP sensor signal circuit
*P0108
Barometric Pressure Circuit is higher than specified value for specified 3 D/C Lights up
(Page 1A-76)
High time.
*P0112 (Page Intake Air Temperature Output voltage of IAT sensor signal circuit
3 D/C Lights up
1A-78) Sensor1 Circuit Low (Bank1) is lower than 0.02 V for 5 sec.
Intake Air Temperature
*P0113 (Page Output voltage of IAT sensor signal circuit
Sensor1 Circuit High 3 D/C Lights up
1A-78) is higher than 4.9 V for 5 sec.
(Bank1)
Difference between measured ECT and
Engine Coolant Temperature
*P0116 (Page estimated ECT is more than specified
Sensor 1 Circuit Range / 3 D/C Lights up
1A-79) value for specified time with engine
Performance
running.
*P0117 (Page Engine Coolant Temperature Output voltage of ECT sensor signal circuit
3 D/C Lights up
1A-80) Sensor1 Circuit Low is lower than 0.02 V for 5 sec.
 Engine General Information and Diagnosis: K15B 1A-26

DTC
DTC DTC name DTC detecting condition MIL
detection logic
*P0118 (Page Engine Coolant Temperature Output voltage of ECT sensor signal circuit
3 D/C Lights up
1A-80) Sensor1 Circuit High is higher than 4.9 V for 5 sec.
Throttle / Pedal Position
*P0122 Output voltage of TP sensor (main) signal
Sensor / Switch “A” Circuit 1 D/C Lights up
(Page 1A-82) circuit is lower than 0.2 V.
Low
Throttle / Pedal Position
*P0123 Output voltage of TP sensor (main) signal
Sensor / Switch “A” Circuit 1 D/C Lights up
(Page 1A-82) circuit is higher than 4.8 V.
High
Any of the following conditions is met.
• HO2S-1 signal voltage is between 0.06
V and 0.42 V for 30 sec. even if HO2S-2
*P0130 O2 Sensor Circuit (Bank 1
signal voltage is higher than 0.6 V. 3 D/C Lights up
(Page 1A-84) Sensor 1)
• HO2S-1 signal voltage is between 0.5 V
and 1.27 V for 25 sec. even if HO2S-2
signal voltage is lower than 0.1 V.
Output voltage of HO2S-1 circuit is lower
*P0131 O2 Sensor Circuit Low than 0.06 V for 30 sec. even if output
3 D/C Lights up
(Page 1A-86) Voltage (Bank1 Sensor1) voltage of HO2S-2 circuit is higher than 0.6
V.
*P0132 O2 Sensor Circuit High Output voltage of HO2S-1 circuit is higher
3 D/C Lights up
(Page 1A-86) Voltage (Bank1 Sensor1) than 1.27 V for 25 sec.
Cycle duration from rich to lean and lean to
*P0133 O2 Sensor Circuit Slow
rich of HO2S-1 is longer than specified 3 D/C Lights up
(Page 1A-88) Response (Bank 1 Sensor 1)
time.
*P0134 O2 Sensor Circuit No Activity Output voltage of HO2S-1 circuit stays
3 D/C Lights up
(Page 1A-90) Detected (Bank1 Sensor1) between 0.42 and 0.5 V for 25 sec.
*P0137 O2 Sensor Circuit Low Output voltage of HO2S-2 circuit is lower
3 D/C Lights up
(Page 1A-92) Voltage (Bank1 Sensor2) than 0.06 V for 30 sec. after warming up.
*P0138 O2 Sensor Circuit High Output voltage of HO2S-2 signal circuit is
3 D/C Lights up
(Page 1A-92) Voltage (Bank1 Sensor2) higher than 1.27 V for 25 sec.
*P0140 O2 Sensor Circuit No Activity Output voltage of HO2S-2 circuit stays
3 D/C Lights up
(Page 1A-92) Detected (Bank1 Sensor2) between 0.42 to 0.50 V for 25 sec.
Fuel trim correction is higher than specified
*P0171
System Too Lean (Bank 1) value for specified time under specified 3 D/C Lights up
(Page 1A-94)
vehicle condition.
Fuel trim correction is lower than specified
*P0172
System Too Rich (Bank 1) value for specified time under specified 3 D/C Lights up
(Page 1A-94)
vehicle condition.
*P0201 Injector Circuit / Open – Fuel injector No.1 and/or its circuit is open
3 D/C Lights up
(Page 1A-97) Cylinder1 with engine running.
*P0202 Injector Circuit / Open – Fuel injector No.2 and/or its circuit is open
3 D/C Lights up
(Page 1A-97) Cylinder2 with engine running.
*P0203 Injector Circuit / Open – Fuel injector No.3 and/or its circuit is open
3 D/C Lights up
(Page 1A-97) Cylinder3 with engine running.
*P0204 Injector Circuit / Open – Fuel injector No.4 and/or its circuit is open
3 D/C Lights up
(Page 1A-97) Cylinder4 with engine running.
*P0222 Throttle / Pedal Position
Output voltage of TP sensor (sub) signal
(Page 1A- Sensor / Switch “B” Circuit 1 D/C Lights up
circuit is lower than 0.2 V.
100) Low
*P0223 Throttle / Pedal Position
Output voltage of TP sensor (sub) signal
(Page 1A- Sensor / Switch “B” Circuit 1 D/C Lights up
circuit is higher than 4.8 V.
100) High
*P0261 Cylinder1 Injector Circuit Fuel injector No.1 drive circuit is shorted to
3 D/C Lights up
(Page 1A-97) Low ground with engine running.
*P0262 Cylinder1 Injector Circuit Fuel injector No.1 drive circuit is shorted to
3 D/C Lights up
(Page 1A-97) High power supply with engine running.
1A-27 Engine General Information and Diagnosis: K15B

DTC
DTC DTC name DTC detecting condition MIL
detection logic
*P0264 Cylinder2 Injector Circuit Fuel injector No.2 drive circuit is shorted to
3 D/C Lights up
(Page 1A-97) Low ground with engine running.
*P0265 Cylinder2 Injector Circuit Fuel injector No.2 drive circuit is shorted to
3 D/C Lights up
(Page 1A-97) High power supply with engine running.
*P0267 Cylinder3 Injector Circuit Fuel injector No.3 drive circuit is shorted to
3 D/C Lights up
(Page 1A-97) Low ground with engine running.
*P0268 Cylinder3 Injector Circuit Fuel injector No.3 drive circuit is shorted to
3 D/C Lights up
(Page 1A-97) High power supply with engine running.
*P0270 Cylinder4 Injector Circuit Fuel injector No.4 drive circuit is shorted to
3 D/C Lights up
(Page 1A-97) Low ground with engine running.
*P0271 Cylinder4 Injector Circuit Fuel injector No.4 drive circuit is shorted to
3 D/C Lights up
(Page 1A-97) High power supply with engine running.
Any of the following conditions is met.
• Misfire, which causes catalyst to
overheat during 200 engine revolutions,
*P0300 is detected at 2 or more cylinders. (MIL
Random / Multiple Cylinder
(Page 1A- blinks as long as misfire lasts.) 3 D/C Lights up
Misfire Detected
102) • Misfire, which affects exhaust emission
adversely during 1,000 engine
revolutions, is detected at 2 or more
cylinders.
*P0301
(Page 1A- Cylinder 1 Misfire Detected Any of the following conditions is met. 3 D/C Lights up
102)
• Misfire, which causes catalyst to
*P0302
overheat during 200 engine revolutions,
(Page 1A- Cylinder 2 Misfire Detected 3 D/C Lights up
is detected at specific cylinder. (MIL
102)
blinks as long as misfire lasts.)
*P0303
(Page 1A- Cylinder 3 Misfire Detected • Misfire, which affects exhaust emission 3 D/C Lights up
102) adversely during 1,000 engine
*P0304 revolutions, is detected at specific
(Page 1A- Cylinder 4 Misfire Detected cylinder. 3 D/C Lights up
102)
*P0327 Output voltage of knock sensor signal
Knock Sensor1 Circuit Low
(Page 1A- circuit is lower than specified value for 3 D/C Lights up
(Bank1 or Single Sensor)
104) specified time with engine running.
*P0328 Output voltage of knock sensor signal
Knock Sensor1 Circuit High
(Page 1A- circuit is higher than specified value for 3 D/C Lights up
(Bank1 or Single Sensor)
104) specified time with engine running.
*P0335
Crankshaft Position Sensor CKP sensor signal is not inputted while
(Page 1A- 3 D/C Lights up
“A” Circuit CMP sensor signal is being inputted.
106)
Any of the following conditions is met.
• Signal detecting time is longer than
*P0336 Crankshaft Position Sensor specification.
(Page 1A- “A” Circuit Range / • Number of teeth between gaps is more 3 D/C Lights up
106) Performance than specification.
• Time between adjacent two teeth is
longer than specification.
Any of the following conditions is met.
*P0340 Camshaft Position Sensor • CMP sensor signal is not inputted while
(Page 1A- “A” Circuit (Bank1 or Single CKP sensor signal is being inputted. 3 D/C Lights up
108) Sensor) • CMP sensor signal pattern is not equal
to the expected pattern.
 Engine General Information and Diagnosis: K15B 1A-28

DTC
DTC DTC name DTC detecting condition MIL
detection logic
*P0351
Ignition Coil “A” Primary / Ignition coil assembly No.1 and/or its circuit
(Page 1A- 3 D/C Lights up
Secondary Circuit is open with engine running.
110)
*P0352
Ignition Coil “B” Primary / Ignition coil assembly No.2 and/or its circuit
(Page 1A- 3 D/C Lights up
Secondary Circuit is open with engine running.
110)
*P0353
Ignition Coil “C” Primary / Ignition coil assembly No.3 and/or its circuit
(Page 1A- 3 D/C Lights up
Secondary Circuit is open with engine running.
110)
*P0354
Ignition Coil “D” Primary / Ignition coil assembly No.4 and/or its circuit
(Page 1A- 3 D/C Lights up
Secondary Circuit is open with engine running.
110)
*P0420 Average amplitude of HO2S-2 signal is
Catalyst System Efficiency
(Page 1A- more than specified value under specified 3 D/C Lights up
Below Threshold (Bank 1)
113) vehicle condition.
*P0443 Evaporative Emission
EVAP canister purge valve drive circuit is
(Page 1A- System Purge Control Valve 3 D/C Lights up
open with engine running.
116) Circuit
*P0458 Evaporative Emission
EVAP canister purge valve drive circuit is
(Page 1A- System Purge Control Valve 3 D/C Lights up
shorted to ground with engine running.
116) Circuit Low
*P0459 Evaporative Emission EVAP canister purge valve drive circuit is
(Page 1A- System Purge Control Valve shorted to power supply with engine 3 D/C Lights up
116) Circuit High running.
P0480 (Page Radiator cooling fan relay No.1 drive circuit
Fan1 Control Circuit 3 D/C Off
1A-118) is shorted to ground or open.
P0481 (Page Radiator cooling fan relay No.2 and/or No.3
Fan2 Control Circuit 3 D/C Off
1A-120) drive circuit is shorted to ground or open.
Any of the following conditions is met.
• Vehicle speed is slower than 4 km/h (2.5
mile/h) for 13 sec. at fuel cut condition.
*P0500
(Page 1A- Vehicle Speed Sensor “A” • Vehicle speed is not inputted by CAN 3 D/C Lights up
122) communication.
• Wheel speed sensor error message is
received from ABS / ESP® control
module.
*P0504
Brake Switch “A” / “B” Brake light switch signal will not switch to
(Page 1A- 1 D/C Lights up
Correlation ON or OFF for more than specified time.
124)
Any of the following conditions is met.
• Output voltage of A/C refrigerant
pressure sensor signal circuit is lower
P0530 (Page A/C Refrigerant Pressure
than 0.15 V. 3 D/C Off
1A-126) Sensor “A” Circuit
• Output voltage of A/C refrigerant
pressure sensor signal circuit is higher
than 4.93 V.
*P0560
Main power supply voltage is lower than
(Page 1A- System Voltage 3 D/C Lights up
2.54 V for 10 sec.
127)
*P0562
Main power supply circuit voltage is lower
(Page 1A- System Voltage Low 3 D/C Lights up
than 9.8 V for 10 sec. with engine running.
127)
*P0563
Main power supply circuit voltage is higher
(Page 1A- System Voltage High 3 D/C Lights up
than 16.5 V for 10 sec. with engine running.
127)
1A-29 Engine General Information and Diagnosis: K15B

DTC
DTC DTC name DTC detecting condition MIL
detection logic
*P0602
Control Module ECM internal failure (data programming
(Page 1A- 1 D/C Lights up
Programming Error error)
129)
*P0606
(Page 1A- Control Module Processor ECM internal processor failure 3 D/C Lights up
130)
*P0607
(Page 1A- Control Module Performance Internal failure in ECM is detected. 1 D/C Lights up
130)
P0645 (Page A/C Clutch Relay Control
A/C compressor relay drive circuit is open. 3 D/C Off
1A-131) Circuit
P0646 (Page A/C Clutch Relay Control A/C compressor relay drive circuit is
3 D/C Off
1A-131) Circuit Low shorted to ground.
P0647 (Page A/C Clutch Relay Control A/C compressor relay drive circuit is
3 D/C Off
1A-131) Circuit High shorted to power supply.
P0692 (Page Radiator cooling fan relay No.1 drive circuit
Fan1 Control Circuit High 3 D/C Off
1A-118) is shorted to power supply.
P0694 (Page Radiator cooling fan relay No.2 and/or No.3
Fan2 Control Circuit High 3 D/C Off
1A-120) drive circuit is shorted to power supply.
 Engine General Information and Diagnosis: K15B 1A-30

DTC
DTC DTC name DTC detecting condition MIL
detection logic
P081D Neutral Input Circuit 1 D/C Off
Clutch Pedal Switch “A” / “B”
P083F 1 D/C Off
Correlation
ENG A-STOP Battery
P1320 Current Sensor “A” Circuit 1 D/C Off
Range / Performance
ENG A-STOP Battery
P1321 Current Sensor “A” Circuit 1 D/C Off
Low
ENG A-STOP Battery
P1322 Current Sensor “A” Circuit 1 D/C Off
High
ENG A-STOP Battery
P1323 Voltage Sensor Circuit 1 D/C Off
Range / Performance
ENG A-STOP Battery
P1324 1 D/C Off
Voltage Sensor Circuit Low
ENG A-STOP Battery
P1326 Temperature Sensor Circuit 1 D/C Off
Low Refer to “DTC Table” in Section 10I (Page
ENG A-STOP Battery 10I-11).
P1327 Temperature Sensor Circuit 1 D/C Off
High
ENG A-STOP Battery
P1360 1 D/C Off
Performance
Auxiliary Power Module
P1377 1 D/C Off
Relay Malfunction
P1386 Starter Relay Malfunction 1 D/C Off
ENG A-STOP OFF Switch
P13A0 1 D/C Off
Circuit
P13B0 ISG Belt 1 D/C Off
Brake Stroke Sensor
P13D0 1 D/C Off
Plausibility
Brake Stroke Sensor Circuit
P13D1 1 D/C Off
High
Brake Stroke Sensor Circuit
P13D2 1 D/C Off
Low
P13D3 Brake Stroke Sensor Offset 1 D/C Off
Transmission Range Sensor
P13D5 1 D/C Off
Circuit
Immobilizer ID and/or
P1610 1 D/C Off
Password Not Registered
P1611 Password Not Matched Refer to “DTC Table”. 1 D/C Off
EEPROM Reading / Writing
P1622 • Ignition switch model: (Page 10C-5) 1 D/C Off
Error
Immobilizer Communication • Keyless push start model: (Page 10C-
P1642 21) 1 D/C Off
Line Error
P1644 Immobilizer ID Mismatched 1 D/C Off
P1646 ID Code Incorrectness 1 D/C Off
ECM detects incorrect vehicle variant data
P1693 (Page Equipment Information
from ABS / ESP® control module and 1 D/C Off
1A-133) Mismatched
combination meter is mismatched.
“A” Camshaft Position
*P2088
Actuator Control Circuit Low OCV drive circuit is shorted to ground. 3 D/C Lights up
(Page 1A-66)
(Bank1)
“A” Camshaft Position
*P2089 OCV drive circuit is shorted to power
Actuator Control Circuit High 3 D/C Lights up
(Page 1A-66) supply.
(Bank1)
1A-31 Engine General Information and Diagnosis: K15B

DTC
DTC DTC name DTC detecting condition MIL
detection logic
*P2100 Throttle actuator and/or its circuit
Throttle Actuator “A” Control
(Page 1A- malfunction (open, short to power supply or 1 D/C Lights up
Motor Circuit / Open
134) short to ground) is detected.
Any of the following conditions is met.
• Difference between measured throttle
*P2101 Throttle Actuator “A” Control
valve position and targeted throttle valve
(Page 1A- Motor Circuit Range / 1 D/C Lights up
position is more than specified value.
136) Performance
• Duty ratio of throttle actuator signal is
out of specified range for specified time.
Any of the following conditions is met.
• Time taken by throttle valve to return
from partially open position to
Throttle Actuator Control
*P2119 (Page mechanical default position is more than
Throttle Body Range / 1 D/C Lights up
1A-136) specified time during return spring check
Performance
process after setting ignition “OFF”.
• Measured default throttle position is out
of specified range.
*P2122 Throttle / Pedal Position
Output voltage of APP sensor (main) signal
(Page 1A- Sensor / Switch “D” Circuit 1 D/C Lights up
circuit is lower than 0.4 V.
138) Low
*P2123 Throttle / Pedal Position
Output voltage of APP sensor (main) signal
(Page 1A- Sensor / Switch “D” Circuit 1 D/C Lights up
circuit is higher than 4.8 V.
138) High
*P2127 Throttle / Pedal Position
Output voltage of APP sensor (sub) signal
(Page 1A- Sensor / Switch “E” Circuit 1 D/C Lights up
circuit is lower than 0.2 V.
140) Low
*P2128 Throttle / Pedal Position
Output voltage of APP sensor (sub) signal
(Page 1A- Sensor / Switch “E” Circuit 1 D/C Lights up
circuit is higher than 2.4 V.
140) High
*P2135 Throttle / Pedal Position Difference between TP sensor (main)
(Page 1A- Sensor / Switch “A” / “B” signal voltage and TP sensor (sub) signal 1 D/C Lights up
142) Voltage Correlation voltage is higher than specified value.
*P2138 Throttle / Pedal Position Difference between half of APP (main)
(Page 1A- Sensor / Switch “D” / “E” sensor signal and APP (sub) sensor signal 1 D/C Lights up
143) Voltage Correlation is more than specified value.
Any of the following conditions is met.
• TP sensor (main) or TP sensor (sub)
*P2176 Throttle Actuator Control
signal voltage at default position is out of
(Page 1A- System – Idle Position Not 1 D/C Lights up
specified range for specified time.
145) Learned
• Electric throttle control system
calibration is not completed.
*P2226 Barometric pressure sensor and/or its
Barometric Pressure Sensor
(Page 1A- circuit malfunction (open, short to power 3 D/C Lights up
“A” Circuit
147) supply or short to ground) is detected.
Any of the following conditions is met.
• Sensor signal is out of specified range.
*P2227 Barometric Pressure Sensor • Difference between actual and expected
(Page 1A- “A” Circuit Range / ambient pressure is more than the 3 D/C Lights up
147) Performance specified value and the fluctuation of
ambient pressure is more than the
specified value.
Output voltage of HO2S-2 signal circuit is
*P2271 O2 Sensor Signal Biased /
higher than 0.3 V for specified time after
(Page 1A- Stuck Rich (Bank 1 Sensor 3 D/C Lights up
warming up even when vehicle is in fuel cut
147) 2)
driving condition.
 Engine General Information and Diagnosis: K15B 1A-32

DTC
DTC DTC name DTC detecting condition MIL
detection logic
*P2300
Ignition Coil “A” Primary Ignition coil assembly No.1 drive circuit is
(Page 1A- 3 D/C Lights up
Control Circuit Low shorted to ground with engine running.
110)
*P2301 Ignition coil assembly No.1 drive circuit is
Ignition Coil “A” Primary
(Page 1A- shorted to power supply with engine 3 D/C Lights up
Control Circuit High
110) running.
*P2303
Ignition Coil “B” Primary Ignition coil assembly No.2 drive circuit is
(Page 1A- 3 D/C Lights up
Control Circuit Low shorted to ground with engine running.
110)
*P2304 Ignition coil assembly No.2 drive circuit is
Ignition Coil “B” Primary
(Page 1A- shorted to power supply with engine 3 D/C Lights up
Control Circuit High
110) running.
*P2306
Ignition Coil “C” Primary Ignition coil assembly No.3 drive circuit is
(Page 1A- 3 D/C Lights up
Control Circuit Low shorted to ground with engine running.
110)
*P2307 Ignition coil assembly No.3 drive circuit is
Ignition Coil “C” Primary
(Page 1A- shorted to power supply with engine 3 D/C Lights up
Control Circuit High
110) running.
*P2309
Ignition Coil “D” Primary Ignition coil assembly No.4 drive circuit is
(Page 1A- 3 D/C Lights up
Control Circuit Low shorted to ground with engine running.
110)
*P2310 Ignition coil assembly No.4 drive circuit is
Ignition Coil “D” Primary
(Page 1A- shorted to power supply with engine 3 D/C Lights up
Control Circuit High
110) running.
Refer to “DTC Table” in Section 10I (Page
P254F Engine Hood Switch Circuit 1 D/C Off
10I-11).
Control Module
U0073 1 D/C Off
Communication Bus Off
Lost Communication With
U0101 1 D/C Lights up
TCM
Lost Communication With
U0121 1 D/C Lights up
ABS / ESP® Control Module
Lost Communication With
U0131 Power Steering Control 1 D/C Off
Refer to “CAN DTC (Lost Communication
Module
and Communication Bus Off) Table”: K15B
Lost Communication With
U0140 Model in Section 10H (Page 10H-7). 1 D/C Off
Body Control Module
Lost Communication With
U0155 Instrument Panel Cluster 1 D/C Off
(IPC) Control Module
Lost Communication With
U108C 1 D/C Off
ISG
Lost Communication With
U108E 1 D/C Off
Auxiliary Power Module

Fail-Safe Table
AENJHB0B1114006
When any of the following DTCs is detected, ECM control enters the fail-safe mode as long as the failure condition
associated with the DTC continues. The fail-safe mode is canceled when ECM detects normal condition.
DTC DTC name Fail-safe operation
Invalid Data Received From ENG A- • ISG control
C1372 STOP Control Module to ABS / ESP® – ECM stops ISG control.
Control Module
• Engine auto stop start system control
Invalid Data Received From ENG A- – ECM restarts engine immediately when engine auto
C1373 STOP Control Module to ABS / ESP ® stop control is activated.
Control Module • Auxiliary power module (lithium-ion battery) control
– ECM cuts off charge and supply circuit.
1A-33 Engine General Information and Diagnosis: K15B

DTC DTC name Fail-safe operation

P0010 (Page “A” Camshaft Position Actuator Circuit /
1A-66) Open (Bank1)
“A” Camshaft Position Timing Over
P0011 (Page
Advanced or System Performance ECM stops VVT control.
1A-68)
(Bank1)
P0016 (Page Crankshaft Position – Camshaft Position
1A-70) Correlation (Bank1 Sensor A)
P0030 (Page HO2S Heater Control Circuit (Bank1
1A-72) Sensor1)
P0031 (Page HO2S Heater Control Circuit Low (Bank1
1A-72) Sensor1)
P0032 (Page HO2S Heater Control Circuit High
1A-72) (Bank1 Sensor1)
—
P0036 (Page HO2S Heater Control Circuit (Bank1
1A-74) Sensor2)
P0037 (Page HO2S Heater Control Circuit Low (Bank1
1A-74) Sensor2)
P0038 (Page HO2S Heater Control Circuit High
1A-74) (Bank1 Sensor2)
P0107 (Page Manifold Absolute Pressure / Barometric
1A-76) Pressure Circuit Low
ECM calculates MAP based on TP sensor signal.
P0108 (Page Manifold Absolute Pressure / Barometric
1A-76) Pressure Circuit High
P0112 (Page Intake Air Temperature Sensor1 Circuit
1A-78) Low (Bank1) ECM controls actuators assuming that intake air
P0113 (Page Intake Air Temperature Sensor1 Circuit temperature is 20 °C (68 °F).
1A-78) High (Bank1)
P0116 (Page Engine Coolant Temperature Sensor 1
1A-79) Circuit Range / Performance
P0117 (Page Engine Coolant Temperature Sensor1 • ECM calculates ECT value from engine load.
1A-80) Circuit Low • ECM operates radiator cooling fan. (high speed)
P0118 (Page Engine Coolant Temperature Sensor1
1A-80) Circuit High
P0122 (Page Throttle / Pedal Position Sensor / Switch
1A-82) “A” Circuit Low • ECM performs fuel cut at specified engine speed.
P0123 (Page Throttle / Pedal Position Sensor / Switch • ECM stops VVT actuator control.
1A-82) “A” Circuit High
P0130 (Page
O2 Sensor Circuit (Bank 1 Sensor 1)
1A-84)
P0131 (Page O2 Sensor Circuit Low Voltage (Bank1
ECM stops A/F feedback (closed loop) control.
1A-86) Sensor1)
P0132 (Page O2 Sensor Circuit High Voltage (Bank1
1A-86) Sensor1)
P0133 (Page O2 Sensor Circuit Slow Response (Bank
—
1A-88) 1 Sensor 1)
P0134 (Page O2 Sensor Circuit No Activity Detected
ECM stops A/F feedback (closed loop) control.
1A-90) (Bank1 Sensor1)
P0137 (Page O2 Sensor Circuit Low Voltage (Bank1
1A-92) Sensor2)
P0138 (Page O2 Sensor Circuit High Voltage (Bank1
—
1A-92) Sensor2)
P0140 (Page O2 Sensor Circuit No Activity Detected
1A-92) (Bank1 Sensor2)
P0171 (Page
System Too Lean (Bank 1)
1A-94)
—
P0172 (Page
System Too Rich (Bank 1)
1A-94)
P0201 (Page • ECM stops fuel injector No.1 control.
Injector Circuit / Open – Cylinder1
1A-97) • ECM stops A/F feedback (closed loop) control.
 Engine General Information and Diagnosis: K15B 1A-34

DTC DTC name Fail-safe operation

P0202 (Page • ECM stops fuel injector No.2 control.
Injector Circuit / Open – Cylinder2
1A-97) • ECM stops A/F feedback (closed loop) control.
P0203 (Page • ECM stops fuel injector No.3 control.
Injector Circuit / Open – Cylinder3
1A-97) • ECM stops A/F feedback (closed loop) control.
P0204 (Page • ECM stops fuel injector No.4 control.
Injector Circuit / Open – Cylinder4
1A-97) • ECM stops A/F feedback (closed loop) control.
P0222 (Page Throttle / Pedal Position Sensor / Switch
1A-100) “B” Circuit Low • ECM performs fuel cut at specified engine speed.
P0223 (Page Throttle / Pedal Position Sensor / Switch • ECM stops VVT actuator control.
1A-100) “B” Circuit High
P0261 (Page
Cylinder1 Injector Circuit Low • ECM stops fuel injector No.1 control.
1A-97)
P0262 (Page • ECM stops A/F feedback (closed loop) control.
Cylinder1 Injector Circuit High
1A-97)
P0264 (Page
Cylinder2 Injector Circuit Low • ECM stops fuel injector No.2 control.
1A-97)
P0265 (Page • ECM stops A/F feedback (closed loop) control.
Cylinder2 Injector Circuit High
1A-97)
P0267 (Page
Cylinder3 Injector Circuit Low • ECM stops fuel injector No.3 control.
1A-97)
P0268 (Page • ECM stops A/F feedback (closed loop) control.
Cylinder3 Injector Circuit High
1A-97)
P0270 (Page
Cylinder4 Injector Circuit Low • ECM stops fuel injector No.4 control.
1A-97)
P0271 (Page • ECM stops A/F feedback (closed loop) control.
Cylinder4 Injector Circuit High
1A-97)
P0300 (Page Random / Multiple Cylinder Misfire
—
1A-102) Detected
P0301 (Page
Cylinder 1 Misfire Detected ECM stops fuel injector No.1 control.
1A-102)
P0302 (Page
Cylinder 2 Misfire Detected ECM stops fuel injector No.2 control.
1A-102)
P0303 (Page
Cylinder 3 Misfire Detected ECM stops fuel injector No.3 control.
1A-102)
P0304 (Page
Cylinder 4 Misfire Detected ECM stops fuel injector No.4 control.
1A-102)
P0327 (Page Knock Sensor1 Circuit Low (Bank1 or
1A-104) Single Sensor)
ECM retards ignition timing.
P0328 (Page Knock Sensor1 Circuit High (Bank1 or
1A-104) Single Sensor)
P0335 (Page
Crankshaft Position Sensor “A” Circuit
1A-106)
ECM calculates CKP based on CMP sensor signal.
P0336 (Page Crankshaft Position Sensor “A” Circuit
1A-106) Range/Performance
P0340 (Page Camshaft Position Sensor “A” Circuit
ECM stops VVT actuator control.
1A-108) (Bank1 or Single Sensor)
P0351 (Page Ignition Coil “A” Primary / Secondary
1A-110) Circuit
P0352 (Page Ignition Coil “B” Primary / Secondary
1A-110) Circuit
—
P0353 (Page Ignition Coil “C” Primary / Secondary
1A-110) Circuit
P0354 (Page Ignition Coil “D” Primary / Secondary
1A-110) Circuit
P0420 (Page Catalyst System Efficiency Below
—
1A-113) Threshold (Bank 1)
1A-35 Engine General Information and Diagnosis: K15B

DTC DTC name Fail-safe operation

P0443 (Page Evaporative Emission System Purge
1A-116) Control Valve Circuit
P0458 (Page Evaporative Emission System Purge
—
1A-116) Control Valve Circuit Low
P0459 (Page Evaporative Emission System Purge
1A-116) Control Valve Circuit High
P0480 (Page
Fan1 Control Circuit
1A-118)
—
P0481 (Page
Fan2 Control Circuit
1A-120)
P0500 (Page ECM controls actuators assuming that vehicle speed is 0
Vehicle Speed Sensor “A”
1A-122) km/h (0 mile/h).
P0504 (Page
Brake Switch “A”/“B” Correlation —
1A-124)
P0530 (Page A/C Refrigerant Pressure Sensor “A”
ECM stops A/C compressor relay control.
1A-126) Circuit
P0560 (Page
System Voltage Throttle movement and fuel injection are limited.
1A-127)
P0562 (Page
System Voltage Low
1A-127)
—
P0563 (Page
System Voltage High
1A-127)
P0602 (Page
Control Module Programming Error
1A-129)
—
P0606 (Page
Control Module Processor
1A-130)
Any one the following operations will be taken:
P0607 (Page • ECM performs fuel cut at specified engine speed.
Control Module Performance
1A-130) • ECM stops throttle valve control and all injector control.
• ECM resets internal memory.
P0645 (Page
A/C Clutch Relay Control Circuit
1A-131)
P0646 (Page
A/C Clutch Relay Control Circuit Low —
1A-131)
P0647 (Page
A/C Clutch Relay Control Circuit High
1A-131)
P0692 (Page
Fan1 Control Circuit High
1A-118)
—
P0694 (Page
Fan2 Control Circuit High
1A-120)
P081D Neutral Input Circuit • ISG control
– ECM stops ISG control.
• Engine auto stop start system control
P083F Clutch Pedal Switch “A” / “B” Correlation – ECM sets ignition to “ON”.
• Auxiliary power module (lithium-ion battery) control
– ECM cuts off charge and supply circuit.
 Engine General Information and Diagnosis: K15B 1A-36

DTC DTC name Fail-safe operation

ENG A-STOP Battery Current Sensor
P1320
“A” Circuit Range / Performance
ENG A-STOP Battery Current Sensor
P1321
“A” Circuit Low
ENG A-STOP Battery Current Sensor • ISG control
P1322
“A” Circuit High
ENG A-STOP Battery Voltage Sensor – ECM stops ISG control.
P1323 • Engine auto stop start system control
Circuit Range / Performance
ENG A-STOP Battery Voltage Sensor – ECM restarts engine immediately when engine auto
P1324
Circuit Low stop control is activated.
ENG A-STOP Battery Temperature • Auxiliary power module (lithium-ion battery) control
P1326
Sensor Circuit Low
ENG A-STOP Battery Temperature – ECM cuts off charge and supply circuit.
P1327
Sensor Circuit High
P1360 ENG A-STOP Battery Performance
Auxiliary Power Module Relay
P1377
Malfunction
Engine auto stop start system control
P1386 Starter Relay Malfunction • ECM restarts engine immediately when engine auto
stop control is activated.
Engine auto stop start system control
P13A0 ENG A-STOP OFF Switch Circuit • ECM restarts engine immediately when engine auto
stop control is activated.
• ISG control
– ECM stops ISG control.
• Engine auto stop start system control
– For M/T model, ECM sets ignition to “ON”.
P13B0 ISG Belt
– For A/T model, ECM restarts engine immediately
when engine auto stop control is activated.
• Auxiliary power module (lithium-ion battery) control
– ECM cuts off charge and supply circuit.
P13D0 Brake Stroke Sensor Plausibility • ISG control
P13D1 Brake Stroke Sensor Circuit High – ECM stops ISG control.
P13D2 Brake Stroke Sensor Circuit Low
• Engine auto stop start system control
P13D3 Brake Stroke Sensor Offset
– ECM restarts engine immediately when engine auto
stop control is activated.
P13D5 Transmission Range Sensor Circuit • Auxiliary power module (lithium-ion battery) control
– ECM cuts off charge and supply circuit.
P1693 (Page
Equipment Information Mismatched —
1A-133)
P2088 (Page “A” Camshaft Position Actuator Control
1A-66) Circuit Low (Bank1)
ECM stops VVT actuator control.
P2089 (Page “A” Camshaft Position Actuator Control
1A-66) Circuit High (Bank1)
P2100 (Page Throttle Actuator “A” Control Motor
1A-134) Circuit / Open
P2101 (Page Throttle Actuator “A” Control Motor
ECM performs fuel cut at specified engine speed.
1A-136) Circuit Range / Performance
P2119 (Page Throttle Actuator Control Throttle Body
1A-136) Range / Performance
P2122 (Page Throttle / Pedal Position Sensor / Switch • ECM limits engine torque.
1A-138) “D” Circuit Low
P2123 (Page Throttle / Pedal Position Sensor / Switch • ECM limits engine speed, if DTC P2127 or P2128 is
1A-138) “D” Circuit High detected at the same time.
1A-37 Engine General Information and Diagnosis: K15B

DTC DTC name Fail-safe operation

P2127 (Page Throttle / Pedal Position Sensor / Switch • ECM limits engine torque.
1A-140) “E” Circuit Low
P2128 (Page Throttle / Pedal Position Sensor / Switch • ECM limits engine speed, if DTC P2122 or P2123 is
1A-140) “E” Circuit High detected at the same time.
P2135 (Page Throttle / Pedal Position Sensor / Switch • ECM performs fuel cut at specified engine speed.
1A-142) “A” / “B” Voltage Correlation • ECM stops VVT actuator control.
P2138 (Page Throttle / Pedal Position Sensor / Switch
ECM limits throttle valve to specified range.
1A-143) “D” / “E” Voltage Correlation
P2176 (Page Throttle Actuator Control System – Idle
ECM performs fuel cut at specified engine speed.
1A-145) Position Not Learned
P2226 (Page ECM controls actuators assuming that barometric
Barometric Pressure Sensor “A” Circuit
1A-147) pressure is specified value.
P2227 (Page Barometric Pressure Sensor “A” Circuit
ECM calculates BARO value from TP sensor signal.
1A-147) Range / Performance
P2271 (Page O2 Sensor Signal Biased / Stuck Rich
—
1A-147) (Bank 1 Sensor 2)
P2300 (Page Ignition Coil “A” Primary Control Circuit
1A-110) Low
P2301 (Page Ignition Coil “A” Primary Control Circuit
1A-110) High
P2303 (Page Ignition Coil “B” Primary Control Circuit
1A-110) Low
P2304 (Page Ignition Coil “B” Primary Control Circuit
—
1A-110) High
P2306 (Page Ignition Coil “C” Primary Control Circuit
1A-110) Low
P2307 (Page Ignition Coil “C” Primary Control Circuit
1A-110) High
P2309 (Page Ignition Coil “D” Primary Control Circuit
1A-110) Low
P2310 (Page Ignition Coil “D” Primary Control Circuit
—
1A-110) High
• ISG control
– ECM stops ISG control.
• Engine auto stop start system control
P254F Engine Hood Switch Circuit
– During auto-stopping: ECM sets ignition to “ON”.
• Auxiliary power module (lithium-ion battery) control
– ECM cuts off charge and supply circuit.
• ISG control
– ECM stops ISG control.
• Engine auto stop start system control
U0073 (Page – For M/T model, ECM sets ignition to “ON”.
Control Module Communication Bus Off
1A-149) – For A/T model, ECM restarts engine immediately
when engine auto stop control is activated.
• Auxiliary power module (lithium-ion battery) control
– ECM cuts off charge and supply circuit.
• ISG control
– ECM stops ISG control.
U0101 (Page
Lost Communication With TCM • Engine auto stop start system control
1A-149)
– ECM restarts engine immediately when engine auto
stop control is activated.
 Engine General Information and Diagnosis: K15B 1A-38

DTC DTC name Fail-safe operation

• ISG control
– ECM stops ISG control.
• Engine auto stop start system control
U0121 (Page Lost Communication With ABS / ESP®
1A-149) Control Module – ECM restarts engine immediately when engine auto
stop control is activated.
• Auxiliary power module (lithium-ion battery) control
– ECM cuts off charge and supply circuit.
U0131 (Page Lost Communication With Power
—
1A-149) Steering Control Module
• ISG control
– ECM stops ISG control.
• Engine auto stop start system control
U0140 (Page Lost Communication With Body Control
1A-150) Module – ECM restarts engine immediately when engine auto
stop control is activated.
• Auxiliary power module (lithium-ion battery) control
– ECM cuts off charge and supply circuit.
U0155 (Page Lost Communication With Instrument
—
1A-150) Panel Cluster (IPC) Control Module
U108C (Page • ISG control
Lost Communication With ISG
1A-150) – ECM stops ISG control.
• Engine auto stop start system control
– For M/T model, ECM sets ignition to “ON”.
U108E (Page Lost Communication With Auxiliary – For A/T model, ECM restarts engine immediately
1A-150) Power Module when engine auto stop control is activated.
• Auxiliary power module (lithium-ion battery) control
– ECM cuts off charge and supply circuit.
1A-39 Engine General Information and Diagnosis: K15B

Scan Tool Data

AENJHB0B1114007

NOTE
• If communication between SUZUKI scan tool and ECM is not possible, perform the following
checks:
– Check communication condition between PC and VCI using SUZUKI scan tool function.
– Check DLC power circuit and ground circuit.
– Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
– Check CAN communication system. (“Control Module Communication Bus Off” is detected in any
control module.) (Page 10H-17)
– Check ECM power circuit and ground circuit. (Page 1A-162)
• When checking data with engine running at idle or racing, place gear shift lever in neutral position
(M/T model) or select P range (A/T model) and apply parking brake fully. Also, if nothing or “no load”
is indicated, turn off A/C, all electric loads, P/S and all the other switches.
• *1: Close hood and set ignition “OFF”, and then parameter changes to “True”.

Normal condition /
Scan tool data Vehicle condition
Reference value
Open loop control before satisfaction of closed loop control
OL (open loop)
conditions (ECT > 10 °C, IAT, TP, HO2S-1/system = OK)
Open loop control due to driving conditions (Power
OL-Drive (open loop)
enrichment, etc.)
Fuel System (Page 1A-48) Open loop control due to system fault detected OL-Fault (open loop)
Closed loop control using HO2S-1 and HO2S-2 sensor as
CL (closed loop)
feedback sensors for fuel control
Closed loop control due to system fault detected CL-Fault (closed loop)
When engine stops with ignition “ON” —
Short Term Fuel Trim
Engine: Idle speed after warming up Approx. –20 to 20%
(Page 1A-48)
Long Term Fuel Trim (Page
Engine: Idle speed after warming up Approx. –20 to 20%
1A-48)
Total Fuel Trim (Page 1A-
Engine: Idle speed after warming up Approx. –30 to 30%
48)
Inj Pulse Width (Page 1A-
Engine: Idle speed with no load after warming up Approx. 1.6 to 4.0 msec.
48)
Ignition Advance (Page
Engine: Idle speed with no load after warming up –5 to 15° BTDC
1A-48)
Calculated Load (Page 1A-
Engine: Idle speed with no load after warming up Approx. 20 to 40%
48)
Engine: Idle speed after warming up
Radiator cooling fan: Stopped
All electrical equipment: OFF
Engine Speed (Page 1A- M/T model:
750 to 850 rpm
48)
• Gear shift lever: Neutral position
A/T model:
• Select lever: P range
Engine: Idle speed after warming up
Radiator cooling fan: Stopped
All electrical equipment: OFF
Desired Idle (Page 1A-48) M/T model: 750 to 850 rpm
• Gear shift lever: Neutral position
A/T model:
• Select lever: P range
Vehicle Speed (Page 1A- Almost the same as
Vehicle running
48) speedometer reading
MAP (Page 1A-48) Engine: Idle speed after warming up Approx. 20 to 55 kPa
 Engine General Information and Diagnosis: K15B 1A-40

Normal condition /
Scan tool data Vehicle condition
Reference value
Approx. 80 to 105 °C (176
ECT (Page 1A-48) Engine: Idle speed after warming up
– 221 °F)
–5 °C (–9 °F) +
Intake Air Temperature environmental temperature
Engine: Idle speed after warming up
(Page 1A-48) to 40 °C (72 °F) +
environmental temperature
Barometric Pres (Page 1A- Barometric pressure is
—
48) displayed.
EVAP Canist Prg Duty
Engine: Idle speed after warming up 0%
(Page 1A-48)
VVT Gap (Page 1A-48) Engine: Idle speed after warming up –1.0 to 1.0° CA
Engine: Idle speed with no load after warming up Approx. 1 to 45%
IAC Throttle Opening Engine: Idle speed after warming up
(Page 1A-48) A/C compressor: Operating Approx. 10 to 70%
Blower speed selector: Max position
Ignition: “ON”
0.8 to 1.0 V
TP Sensor 1 Volt (Page Accelerator pedal: Released
1A-48) Ignition: “ON”
4.3 to 4.5 V
Accelerator pedal: Fully depressed
Ignition: “ON”
4.0 to 4.2 V
TP Sensor 2 Volt (Page Accelerator pedal: Released
1A-48) Ignition: “ON”
0.5 to 0.7 V
Accelerator pedal: Fully depressed
Ignition: “ON”
0.70 to 0.80 V
APP Sensor 1 Voltage Accelerator pedal: Released
(Page 1A-48) Ignition: “ON”
4.35 to 4.45 V
Accelerator pedal: Fully depressed
Ignition: “ON”
0.325 to 0.425 V
APP Sensor 2 Voltage Accelerator pedal: Released
(Page 1A-48) Ignition: “ON”
2.15 to 2.25 V
Accelerator pedal: Fully depressed
Ignition: “ON”
0 to 2%
Accel Position (Page 1A- Accelerator pedal: Released
48) Ignition: “ON”
90 to 100%
Accelerator pedal: Fully depressed
Ignition: “ON”
0 to 10%
Throttle Position (Page 1A- Accelerator pedal: Released
48) Ignition: “ON”
90 to 100%
Accelerator pedal: Fully depressed
Ignition: “ON”
0 to 15%
Target Throttle Posi (Page Accelerator pedal: Released
1A-49) Ignition: “ON”
90 to 100%
Accelerator pedal: Fully depressed
O2S B1 S1 (Page 1A-49) Engine: Idle speed after warming up Approx. 0 to 1.0 V
O2S B1 S2 (Page 1A-49) Engine: 2,000 rpm for 3 min. or more after warming up Approx. 0 to 1.0 V
Battery Voltage (Page 1A-
Engine: Idle speed 10.7 to 16.0 V
49)
Fuel Tank Level (Page 1A-
Ignition: “ON” 0 to 100%
49)
Engine: Idle speed
A/C Pressure (Page 1A- A/C compressor: Operating
1,230 to 1,540 kPa
49) Blower speed selector: Max position
Ambient temperature: 30 °C (86 °F)
1A-41 Engine General Information and Diagnosis: K15B
Scan tool data
Brake Booster Pressure
(Page 1A-49)
Radiator Fan (Page 1A-49)
A/C Comp Relay (Page
1A-49)
Fuel Pump (Page 1A-49)
Starter Switch (Page 1A-
49)
A/C Switch (Page 1A-49)
Blower Fan (Page 1A-49)
Brake Booster Vacuum
Condition (Page 1A-49)
Brake Switch (Page 1A-49)
Electric Load (Page 1A-49)
PNP Signal (Page 1A-49)
Fuel Cut (Page 1A-49)
Closed Throttle Pos (Page
1A-49)
O2S B1 S1 Act (Page 1A-
49)
O2S B1 S2 Act (Page 1A-
49)
ENG A-STOP (Mon) (Page
1A-49)
ENG A-STOP (Com) (Page
1A-49)
Battery Ambient Temperature
(Page 1A-49)
Battery Voltage (Page 1A-
Engine: Idle speed
49)
Normal condition /
Vehicle condition
Reference value
When brake pedal is depressed 3 or more times with
0 kPa
engine stopped.
Engine: Idle speed
60 to 70 kPa
Brake pedal: Released
Engine: Idle speed
50 to 60 kPa
Brake pedal: Fully depressed
Radiator cooling fan: Off Off
Radiator cooling fan: Low speed Low
Radiator cooling fan: High speed High
Engine: Running
A/C compressor: Operating ON
Blower speed selector: ON
Other than above condition OFF
Engine: Running ON
Other than above condition OFF
Ignition: “START” (engine cranking) ON
Other than above condition OFF
A/C switch: ON
ON
Blower speed selector: ON
Other than above condition OFF
Blower speed selector: 4th or higher speed position ON
Blower speed selector: Other than above condition OFF
M/T model:
Value Hi (sufficient)
Specified idle speed after warming up
M/T model:
Engine condition: Stopped Value Lo (insufficient)
Brake pedal: Fully depressed several times
Brake pedal: Depressed ON
Brake pedal: Released OFF
Headlight: ON ON
Headlight: OFF OFF
A/T model:
• Engine: Running D
• Shift select lever: Other than P or N position
A/T model:
• Engine: Running P/N
• Shift select lever: P or N position
Engine: Idle speed after warming up OFF
Accelerator pedal: Released
ON
Engine condition: 2,000 rpm or more after warming up
Ignition: “ON”
ON
Accelerator pedal: Released
Ignition: “ON”
OFF
Accelerator pedal: Fully depressed
Engine: Idle speed after warming up Active
Engine: Idle speed after warming up Active
Engine is auto-stopped. Eng Stop
Other than above condition Eng Run
ECM requests engine auto stop. Req
Other than above condition Not Req
Value equivalent to
— ambient temperature
around the battery
10 to 14 V
 Engine General Information and Diagnosis: K15B 1A-42

Normal condition /
Scan tool data Vehicle condition
Reference value
Ignition: “ON” 2 to 8 A
Ignition: “ON”
14 to 24 A
Battery Current (Page 1A- Headlight: ON
49) Ignition: “ON”
Headlight: ON 22 to 35 A
Blower speed switch: MAX
Engine: Idle speed after warming up
60 to 80 kPa
Brake pedal: Released
Brake Booster (Page 1A- Engine: Idle speed after warming up
50 to 70 kPa
49) Brake pedal: Fully depressed
Ignition: “ON”
0 kPa
Brake pedal: Fully depressed 3 or more times
Ignition: “ON”
0.0 kPa
Master Cylinder Pressure Brake pedal: Released
(Page 1A-50) Ignition: “ON”
3,000 to 5,000 kPa
Brake pedal: Depressed
Ignition: “ON”
Approx. 0%
Brake pedal: Released
Brake Stroke (Page 1A-50)
Ignition: “ON”
80 to 100%
Brake pedal: Fully depressed
A/T model:
CVTF Temperature (Page After driving at 60 km/h (37 mile/h) for 15 minutes or more,
70 to 80 °C
1A-50) and ATF temperature around sensor reaches 70 to 80 °C
(158 to 176 °F)
A/T model:
Slope Range (Page 1A-50) 0%
Vehicle: Parked on level surface
Value equivalent to
Battery Temperature (Page
— ambient temperature
1A-50)
around the battery
ISG Restart Count (Page Number of engine auto
Ignition: “ON”
1A-50) restarts
Backup Start Count by
A/T model: Number of starting motor
Starting Motor (Page 1A-
Ignition: “ON” activations using ST2 relay
50)
Ignition: “ON”
0.40 to 1.56 V
Brake Stroke Sensor Voltage Brake pedal: Released
(Page 1A-50) Ignition: “ON”
1.6 to 1.8 V
Brake pedal: Fully depressed
ISG Belt Slip (Page 1A-50) Ignition: “ON” Number of ISG belt slips
ISG Equipment (Page 1A- Equipped with a proper and normally functioning ISG Equipped
50) Other than above condition Unequipped
Transmission Type (Page Transmission Type: MT MT
1A-50) Transmission Type: AT AT
M/T model:
Ignition: “ON” ON
Neutral Switch (Page 1A- Gear position: “Neutral”
50) M/T model:
Ignition: “ON” OFF
Gear position: Other than “Neutral”
Ignition: “ON”
ON
Hood Switch1 (Page 1A- Hood: Open
50) Ignition: “ON”
OFF
Hood: Closed
Ignition: “ON”
ON
Hood Switch2 (Page 1A- Hood: Open
50) Ignition: “ON”
OFF
Hood: Closed
1A-43 Engine General Information and Diagnosis: K15B

Normal condition /
Scan tool data Vehicle condition
Reference value
Ignition Switch (Page 1A- Ignition: “ON” or “START” ON
50) Other than above condition OFF
Ignition: “START”
Starting Switch (Page 1A- ON
Clutch pedal: Fully depressed (M/T model)
50)
Other than above condition OFF
M/T model:
Ignition: “ON” ON
Half Clutch Switch (Page Clutch pedal: More than halfway depressed
1A-50) M/T model:
Ignition: “ON” OFF
Clutch pedal: Released
M/T model:
Ignition: “ON” ON
Clutch Step on Switch Clutch pedal: Fully depressed
(Page 1A-50) M/T model:
Ignition: “ON” OFF
Clutch pedal: Released
Ignition: “ON”
ON
Idling Stop Prohibit Switch ENG A-STOP OFF switch: Pushed
(Page 1A-50) Ignition: “ON”
OFF
ENG A-STOP OFF switch: Released
Engine stationary ON
Charge Lamp Switch
Engine: Running or at engine auto stop control (other than
(Page 1A-50) OFF
engine auto start inhibit control)
Brake pedal: Depressed ON
Brake Switch (Page 1A-50)
Brake pedal: Released OFF
ENG A-STOP Indicator Light Ignition: “ON” ON
(Page 1A-50) Other than above condition OFF
SHVS Indicator Light ISG: Generating by deceleration energy regeneration ON
(Regeneration) (Page 1A-
Other than above condition OFF
50)
SHVS Indicator Light (Assist) ISG: Assisting engine power ON
(Page 1A-50) Other than above condition OFF
Engine stationary (other than engine auto stop control) ON
Stop Mode (Page 1A-50)
Other than above condition OFF
Starting Mode (Page 1A- During engine auto restart control ON
50) Other than above condition OFF
Auto Stop Mode (Page 1A- During engine auto stop control ON
50) Other than above condition OFF
Normal Mode (Page 1A- Engine stationary OFF
50) Engine running ON
Discharged level of lead-acid battery: ECM requests level
Charge Request 1 (Page ON
1 charge
1A-50)
Other than above condition OFF
Discharged level of lead-acid battery: ECM requests level
Charge Request 2 (Page ON
2 charge
1A-51)
Other than above condition OFF
Discharged level of lead-acid battery: ECM requests level
Charge Request 3 (Page ON
3 charge
1A-51)
Other than above condition OFF
Discharged level of lead-acid battery: ECM requests level
Charge Request 4 (Page ON
4 charge
1A-51)
Other than above condition OFF
Discharged level of lead-acid battery: ECM requests level
Charge Request 5 (Page ON
5 charge
1A-51)
Other than above condition OFF
 Engine General Information and Diagnosis: K15B 1A-44

Normal condition /
Scan tool data Vehicle condition
Reference value
Discharged level of lead-acid battery: ECM requests level
Charge Request 6 (Page ON
6 charge
1A-51)
Other than above condition OFF
Discharged level of lead-acid battery: ECM requests level
Charge Request 7 (Page ON
7 charge
1A-51)
Other than above condition OFF
Discharged level of lead-acid battery: ECM requests level
Charge Request 8 (Page ON
8 charge
1A-51)
Other than above condition OFF
Engine auto stop control: Inhibited Auto Stop Inhibit Request
Auto Stop System Request Engine auto restart control: Permitted Auto Start Request
(Page 1A-51) Engine auto restart control: Inhibited Auto Start Inhibit Request
Other than above condition No Request
A/T model:
TRUE
Idle Stop Enable (Page 1A- Engine auto stop control: Permitted by TCM
51) A/T model:
FALSE
Other than above condition
Ignition: “ON”
P
Select lever: P range
Ignition: “ON”
R
Select lever: R range
Ignition: “ON”
N
Select lever: N range
Shift Position (Page 1A-51)
Ignition: “ON”
D
Select lever: D range
Ignition: “ON”
2nd
Select lever: 2 range
Ignition: “ON”
1st
Select lever: L range
Auxiliary power module (lithium-ion battery) temperature is
Li Battery High Temperature TRUE
higher than specified value
Status (Page 1A-51)
Other than above condition FALSE
Auxiliary power module (lithium-ion battery) temperature is
Li Battery Low Temperature TRUE
lower than specified value
Status (Page 1A-51)
Other than above condition FALSE
Ignition: “ON”
ON
Driver Door Switch (Page Driver door: Open
1A-51) Ignition: “ON”
OFF
Driver door: Closed
Ignition: “ON”
Fasten
Driver Seatbelt Switch Driver seat belt: Fastened
(Page 1A-51) Ignition: “ON”
Unfasten
Driver seat belt: Unfastened
CAN communication: Malfunctioning Backup Disconnect
ABS/ESP Status for ISG ENG A-STOP control inhibition requested Inhibit
(Page 1A-51) ABS / ESP® system: Malfunctioning Failure
ABS / ESP® system: Normal condition Normal
Lead-acid battery is being charged after engine start.
Additional charge request ON
(inhibits engine auto stop control)
(Page 1A-51)
Other than above condition OFF
Air Conditioning Compressor Engine auto restart control: Requested ON
Engine Run Request
Other than above condition OFF
(Page 1A-51)
Hard braking is detected. ON
Full Braking (Page 1A-51)
Other than above condition OFF
1A-45 Engine General Information and Diagnosis: K15B

Normal condition /
Scan tool data Vehicle condition
Reference value
Any of the following conditions is met.
• Auxiliary power module (lithium-ion battery) detects
DTC Condition for A-STOP
malfunction of engine auto stop control. TRUE
Inhibition (Auxiliary Power
Module) (Page 1A-51) • Auxiliary power module (lithium-ion battery) detects
malfunction of ISG control.
Other than above condition FALSE
Any of the following conditions is met.
DTC Condition for A-STOP
• ISG detects malfunction of engine auto stop control. TRUE
Inhibition (ISG) (Page 1A-
51) • ISG detects malfunction of ISG control.
Other than above condition FALSE
Any of the following conditions is met.
• ABS / ESP® control module detects malfunction of
DTC Condition for A-STOP
engine auto stop control. TRUE
Inhibition (ABS/ESP®)
(Page 1A-51) • ABS / ESP® control module detects malfunction of ISG
control.
Other than above condition FALSE
A/T model:
Any of the following conditions is met.
DTC Condition for A-STOP TRUE
• TCM detects malfunction of engine auto stop control.
Inhibition (TCM) (Page 1A-
51) • TCM detects malfunction of ISG control.
A/T model:
FALSE
Other than above condition
Brake Stroke Sensor Brake stroke sensor learning: Completed TRUE
Learning (Page 1A-51) Other than above condition FALSE
Engine Stop Request During engine auto stop control TRUE
(Page 1A-51) Other than above condition FALSE
Auxiliary power module (lithium-ion battery) is discharged,
Engine Start Request 2 heated or cooled extremely. (inhibits engine auto stop TRUE
(Page 1A-52) control)
Other than above condition FALSE
Auxiliary Power Module Auxiliary power module (lithium-ion battery) is ready for
TRUE
Status (A-STOP) (Page engine auto stop control.
1A-52) Other than above condition FALSE
Auxiliary Power Module Auxiliary power module (lithium-ion battery) is ready for
TRUE
Status (Regeneration) charging current regenerated by deceleration energy.
(Page 1A-52) Other than above condition FALSE
Auxiliary Power Module Auxiliary power module (lithium-ion battery) is ready for
TRUE
Status (Motor Assist) supplying current to ISG to assist engine power.
(Page 1A-52) Other than above condition FALSE
Any of the following conditions is met.
DTC Condition for A-STOP
• ECM detects malfunction of engine auto stop control. TRUE
Inhibition (ECM) (Page 1A-
52) • ECM detects malfunction of ISG control.
Other than above condition FALSE
Battery charged condition is within specified range to
TRUE
Battery Condition (Page execute engine auto stop control.
1A-52) Other than above condition (inhibits engine auto stop
FALSE
control)
Battery temperature is within specified range to execute
TRUE
Battery Temperature engine auto stop control.
Condition (Page 1A-52) Other than above condition (inhibits engine auto stop
FALSE
control)
Engine coolant temperature is within specified range to
TRUE
ECT Condition (Page 1A- execute engine auto stop control.
52) Other than above condition (inhibits engine auto stop
FALSE
control)
 Engine General Information and Diagnosis: K15B 1A-46

Normal condition /
Scan tool data Vehicle condition
Reference value
Brake booster pressure is higher than specified range to
TRUE
Brake Booster Condition execute engine auto stop control.
(Page 1A-52) Other than above condition (inhibits engine auto stop
FALSE
control)
A/T model:
Master cylinder pressure is higher than specified range to TRUE
Master Cylinder Pressure
execute engine auto stop control.
Condition (A-STOP) (Page
A/T model:
1A-52)
Other than above condition (Inhibits engine auto stop FALSE
control)
Brake pedal: Depressed TRUE
Brake Switch Condition
Other than above condition (Inhibits engine auto stop
(Page 1A-52) FALSE
control)
A/T model:
TRUE
Shift position: N or D
Shift Position Condition
A/T model:
(Page 1A-52)
Other than above condition (Inhibits engine auto stop FALSE
control)
Driver seat belt: Fastened
TRUE
Seat Belt/Door Condition Driver door: Closed
(Page 1A-52) Other than above conditions (inhibits engine auto stop
FALSE
control)
Hood is opened in 1 driving cycle. (*1) (inhibits engine auto
Hood Switch Condition TRUE
stop control)
(Page 1A-52)
Other than above condition FALSE
Ignition: “ON”
TRUE
Accel Pedal Condition Accelerator pedal: Depressed
(Page 1A-52) Ignition: “ON”
FALSE
Accelerator pedal: Released
Tilt angle is within specified range to execute engine auto
TRUE
Tilt Angle Condition (A- stop control.
STOP) (Page 1A-52) Other than above condition (Inhibits engine auto stop
FALSE
control)
Speed history is within specified range to execute engine
TRUE
Speed History Condition (A- auto stop control when decelerating.
STOP) (Page 1A-52) Other than above condition (inhibits engine auto stop
FALSE
control when decelerating)
A/T model:
TRUE
TCM Demand Condition (A- Engine auto stop control: Permitted
STOP) (Page 1A-52) A/T model:
FALSE
Engine auto stop control: Inhibited by TCM
Auxiliary Power Module Engine auto stop control: Permitted TRUE
Demand Condition (Page Engine auto stop control: Inhibited by auxiliary power
FALSE
1A-52) module (lithium-ion battery)
Engine auto stop control: Permitted TRUE
ABS/ESP® Demand
Engine auto stop control: Inhibited by ABS / ESP® control
Condition (Page 1A-52) FALSE
module
HVAC Demand Condition Engine auto stop control: Permitted TRUE
(Page 1A-52) Engine auto stop control: Inhibited by BCM FALSE
ENG A-STOP OFF switch: OFF (permits engine auto stop
TRUE
ENG A-STOP OFF Switch control)
Condition (Page 1A-52) Other than above condition (inhibits engine auto stop
FALSE
control)
Starter Inhibition Request Starting motor operation: Inhibited TRUE
(ABS/ESP®) (Page 1A-52) Other than above condition FALSE
1A-47 Engine General Information and Diagnosis: K15B

Normal condition /
Scan tool data Vehicle condition
Reference value
Engine: Running
TRUE
Brake Stroke Sensor (Page Brake pedal: Fully depressed
1A-53) Engine: Running
FALSE
Brake pedal: Released
ISG drive belt slip condition is within specified range to
TRUE
ISG Belt Condition (Page execute engine auto stop control.
1A-53) Other than above condition (inhibits engine auto stop
FALSE
control)
Auxiliary power supply module (lithium-ion battery):
Assist Permit from Auxiliary TRUE
Permits engine power assist control
power module (lithium ion
Other than above condition (inhibits engine power assist
battery) (Page 1A-53) FALSE
control)
ECM: Permits deceleration energy regeneration TRUE
Regeneration Permit Signal
Other than above condition (inhibits deceleration energy
(Page 1A-53) FALSE
regeneration)
Minimum Voltage at Engine
After engine start 6 to 16 V
Start (Page 1A-53)
ISG Adjusting Voltage Engine: Stopped 10 to 11 V
Request Value (Page 1A-
Engine: Idle speed after warming up 12 to 15 V
53)
Engine: Idle speed with no-load after warming up
Battery DOD (Page 1A-53) 0 to 10%
Battery: Fully charged
Auxiliary Power Module
Engine: Idle speed with no-load after warming up 11.3 to 14.3 V
Voltage (Page 1A-53)
Auxiliary Power Module
Engine: Idle speed with no-load after warming up –15 to 70 A
Current 2 (Page 1A-53)
Auxiliary Power Module SOC
Engine: Idle speed with no-load after warming up 30 to 80%
(Page 1A-53)
Auxiliary Power Module
“Pb+” Terminal Voltage Engine: Idle speed with no-load after warming up 11.3 to 14.3 V
(Page 1A-53)
Battery Current Sensor
Engine: Idle speed with no-load after warming up Approx. 3.0 to 4.0 V
Voltage (Page 1A-53)
Generator Field Coil
Operation Rate (Page 1A- Engine: Idle speed with no-load after warming up 0 to 100%
53)
ISG: Generation mode Generation
ISG: Generation mode (Generation is limited.) Generation Limit
ISG: Generation mode (ISG detects malfunction) Generation Failure
ISG: Engine restart mode Restart
ISG: Engine restart mode (Restart is limited.) Restart Limit
ISG: Engine restart mode (ISG detects malfunction) Restart Failure
ISG: Engine power assist mode Assistance
ISG: Engine power assist mode (Power assist is limited.) Assistance Limit
ISG control mode (Page ISG: Engine power assist mode (ISG detects malfunction) Assistance Failure
1A-53) M/T model:
Neutral position switch: ON
Braking
Actual gear shift position: Other than “Neutral”
ISG: Engine restart mode (ISG does not detected DTC.)
M/T model:
Neutral position switch: ON
Braking Failure
Actual gear shift position: Other than “Neutral”
ISG: Engine restart mode (ISG detects DTC.)
Other than above condition Neutral
 Engine General Information and Diagnosis: K15B 1A-48
Scan Tool Data Definitions
Fuel System (Fuel system status)
This parameter indicates state of A/F ratio feedback
loop.
Short Term Fuel Trim (%)
Short term fuel trim value represents short term
corrections to air/fuel mixture. 0 (zero) indicates no
correction, a value greater than 0 indicates enrichment
correction, and a value less than 0 indicates enleanment
correction.
Long Term Fuel Trim (%)
Long term fuel trim value represents long term
corrections to air/fuel mixture. 0 (zero) indicates no
correction, a value greater than 0 indicates enrichment
correction, and a value less than 0 indicates enleanment
correction.
Total Fuel Trim (%)
Total fuel trim is calculated from short term fuel trim and
long term fuel trim. This value indicates how much
correction is necessary to keep the air/fuel mixture
stoichiometrical.
Inj Pulse Width (Fuel injection pulse width, msec)
This parameter indicates the injector drive pulse width
(time) during which the injector valve stays open as
commanded by ECM. (For multipoint fuel injection, the
injector drive time means that of the No.1 cylinder.)
Ignition Advance (Ignition timing advance for No.1
cylinder, ° BTDC)
This parameter indicates the ignition timing of No.1
cylinder commanded by ECM. The actual ignition timing
should be checked using a timing light.
Calculated Load (Calculated load value, %)
This parameter indicates calculated engine load in
percent. The load is calculated based on input signals to
ECM from various engine sensors.
Engine Speed (rpm)
The engine speed is calculated from reference pulses
from the crankshaft position sensor.
Desired Idle (Desired idle speed, rpm)
The desired idle speed is an ECM internal parameter
which indicates the idle speed requested by ECM. If the
engine is not running, this number is not valid.
Vehicle Speed (km/h, MPH)
This parameter indicates the vehicle speed based on
wheel speed signals sent from ABS / ESP® control
module via CAN communication.
MAP (Manifold absolute pressure, kPa, mmHg,
in.Hg, psi, inH2O)
This parameter indicates the calculated manifold
pressure based on MAP sensor signal.
ECT (Engine coolant temperature, °C, °F)
It is detected by engine coolant temperature sensor.
Intake Air Temperature. (°C, °F)
It is detected by intake air temperature sensor.
Barometric Pres (Barometric pressure, kPa, mmHg,
in.Hg, psi, inH2O)
This parameter represents barometric air pressure
measurement and is used for altitude correction of the
fuel injection rate.
Evap Canist Prg Duty (Evap canister purge flow
duty, %)
This parameter indicates valve ON (valve open) time
rate within a certain set cycle of EVAP canister purge
valve which controls the amount of EVAP purge.
VVT Gap (Variable valve timing difference between
target and actual position, °)
This parameter indicates difference between target
camshaft position (intake side) and actual camshaft
position (intake side).
IAC Throttle Opening (Idle air throttle valve opening,
%)
This parameter indicates throttle valve opening of idle air
control in % (100% indicates the maximum idle air flow).
TP Sensor 1 Volt (TP sensor (main) output voltage,
V)
TP sensor (main) data provides throttle valve opening
information in the form of voltage.
TP Sensor 2 Volt (TP sensor (sub) output voltage, V)
TP sensor (sub) data provides throttle valve opening
information in the form of voltage.
APP Sensor 1 Voltage (APP sensor (main) output
voltage, V)
APP sensor (main) data provides accelerator pedal
position information in the form of voltage.
APP Sensor 2 Voltage (APP sensor (sub) output
voltage, V)
APP sensor (sub) data provides accelerator pedal
position information in the form of voltage.
Accel Position (Absolute accelerator pedal position,
%)
This parameter indicates calculated accelerator pedal
position in percent based on input from accelerator pedal
position sensor.
Throttle Position (Absolute throttle position, %)
This parameter indicates calculated throttle opening in
percent based on input from throttle position sensor.
1A-49 Engine General Information and Diagnosis: K15B
Target Throttle Posi (Target throttle valve position,
%)
Target throttle valve position is an ECM internal
parameter which indicates the throttle valve position
requested by ECM.
O2S B1 S1 (HO2S-1, V)
This parameter indicates output voltage of HO2S-1
installed on exhaust manifold (pre-TWC).
O2S B1 S2 (HO2S-2, V)
This parameter indicates output voltage of HO2S-2
installed on exhaust manifold (post-TWC). It is used to
detect catalyst deterioration.
Battery Voltage (V)
This parameter indicates battery voltage inputted from
main relay to ECM.
Fuel Tank Level (%)
This parameter indicates approximate fuel level in the
fuel tank. The fuel level data is provided in percentage
from 0 to 100%.
A/C Pressure (A/C refrigerant absolute pressure,
kPa)
This parameter indicates A/C refrigerant absolute
pressure detected by A/C refrigerant pressure sensor.
Brake Booster Pressure (kPa) (A/T model)
This parameter indicates differential pressure between
atmospheric pressure and brake pressure.
Radiator Fan (Radiator cooling fan control relay,
Low/High/Off)
This parameter indicates state of radiator cooling fan
control relay.
A/C Comp Relay (A/C compressor relay, ON/OFF)
This parameter indicates the state of the A/C
compressor relay.
Fuel Pump (ON/OFF)
ON is displayed when ECM activates the fuel pump via
the fuel pump relay switch.
Starter Switch (Starter switch, ON/OFF)
This parameter indicates state of starting motor control
relay output.
A/C Switch (ON/OFF)
This parameter indicates the output status of A/C
operation command from BCM to ECM.
Blower Fan (ON/OFF)
This parameter indicates the state of the blower speed
selector.
Brake Booster Vacuum Condition (M/T model) (Value
Hi (sufficient) / Value Lo (insufficient))
This parameter indicates the state of brake booster
negative pressure.
Brake Switch (ON/OFF)
This parameter indicates the state of the brake switch.
Electric Load (ON/OFF)
This parameter indicates the state of the electric load of
the vehicle.
PNP Signal (P/N or D range) (A/T model)
Whether the transmission range switch is in P or N range
or in other ranges is displayed. If it is in P or N range, “P/
N” is displayed and if it is in other than P and N ranges,
“D” is displayed.
Fuel Cut (ON/OFF)
This parameter indicates the fuel injection state.
Closed Throttle Pos (Closed throttle position, ON/
OFF)
This parameter is ON when throttle valve is closed to
default position and OFF when the valve is not closed to
default position.
O2S B1 S1 ACT (HO2S-1, Active / Inactive)
This parameter indicates the activation condition of
HO2S-1.
O2S B1 S2 ACT (HO2S-2, Active / Inactive)
This parameter indicates the activation condition of
HO2S-2.
ENG A-STOP (Mon) (Engine auto stop (Monitor), Eng
Stop/Eng Run)
This parameter indicates the state of the engine auto
stop.
ENG A-STOP (Com) (Engine auto stop (Command),
Req/Not Req)
This parameter indicates the state of the engine auto
stop request.
Battery Ambient Temperature (°C, °F)
This parameter indicates battery side and ambient
temperature based on battery temperature sensor.
Battery Voltage (V)
This parameter indicates battery voltage inputted from
main relay to ECM.
Battery Current (A)
This parameter indicates electric load value (current
consumption) detected by electric load current sensor.
Brake Booster (Brake Booster Pressure, kPa)
This parameter indicates brake booster negative
pressure.
 Engine General Information and Diagnosis: K15B 1A-50
Master Cylinder Pressure (kPa)
This parameter indicates brake master cylinder pressure
detected by master cylinder pressure sensor in ESP®
control module.
Brake Stroke (%)
This parameter indicates the depression amount of the
brake pedal detected by the brake stroke sensor as a
percentage.
CVTF Temperature (ATF temperature, °C) (A/T
model)
This parameter indicates the ATF temperature output
from the TCM to the ECM.
Slope Range (%) (A/T model)
This parameter indicates the slope rate of the road
surface detected by the slope sensor in percentage.
Battery Temperature (°C, °F)
This parameter indicates battery inside temperature
estimated by ECM.
ISG Restart Count (Times)
This parameter indicates ISG operation times. 5 times of
engine restarting are counted as one.
Backup Start Count by Starting Motor (Times) (A/T
model)
This parameter indicates restart times by starting motor.
Brake Stroke Sensor Voltage (V)
This parameter indicates brake pedal position
information in voltage from brake stroke sensor.
ISG Belt Slip (Times)
This parameter indicates ISG belt slipping times counted
by ISG.
ISG Equipment (Equipped/Unequipped)
This parameter indicates the vehicle with ISG.
Transmission Type (MT/AT)
This parameter indicates the type of transmission
installed in the vehicle.
Neutral Switch (Neutral Position Switch, ON/OFF) (M/
T model)
This parameter indicates the state of neutral position
switch.
Hood Switch1 (Hood Latch Switch 1, ON/OFF)
This parameter indicates the state of hood latch switch 1.
Hood Switch2 (Hood Latch Switch 2, ON/OFF)
This parameter indicates the state of hood latch switch 2.
Ignition Switch (ON/OFF)
This parameter indicates the state of ignition “ON”.
Starting Switch (ON/OFF)
This parameter indicates the state of ignition “START”.
Half Clutch Switch (CPP No.2 Switch, ON/OFF) (M/T
model)
This parameter indicates the state of CPP No.2 switch.
Clutch Step on Switch (CPP No.1 Switch, ON/OFF)
(M/T model)
This parameter indicates the state of CPP No.1 switch.
Idling Stop Prohibit Switch (ENG A-STOP OFF
Switch, ON/OFF)
This parameter indicates pushed state of ENG A-STOP
OFF switch.
Charge Lamp Switch (ON/OFF)
This parameter indicates the state of electricity
generated by ISG.
Brake Switch (ON/OFF)
This parameter indicates the state of brake light switch.
ENG A-STOP Indicator Light (ON/OFF)
This parameter indicates the state of ENG A-STOP
indicator light for ENG A-STOP system operation.
SHVS Indicator Light (Regeneration) (ON/OFF)
This parameter indicates the state of energy flow of
deceleration energy regeneration on information display
in combination meter.
SHVS Indicator Light (Assist) (ON/OFF)
This parameter indicates the state of energy flow of
engine power assist on information display in
combination meter.
Stop Mode (ON/OFF)
This parameter indicates the state of the engine stop
(Other than engine auto stop control).
Starting Mode (ON/OFF)
This parameter indicates the state of the engine
cranking.
Auto Stop Mode (ON/OFF)
This parameter indicates the state of the engine auto
stop (Engine stop due to engine auto stop control).
Normal Mode (ON/OFF)
This parameter indicates the state of the engine.
Charge Request 1 (ON/OFF)
This parameter indicates the state of ECM charge
request due to the state of discharge of the lead-acid
battery.
1A-51 Engine General Information and Diagnosis: K15B
Charge Request 2 (ON/OFF)
This parameter indicates the state of ECM charge
request due to the state of discharge of the lead-acid
battery.
Charge Request 3 (ON/OFF)
This parameter indicates the state of ECM charge
request due to the state of discharge of the lead-acid
battery.
Charge Request 4 (ON/OFF)
This parameter indicates the state of ECM charge
request due to the state of discharge of the lead-acid
battery.
Charge Request 5 (ON/OFF)
This parameter indicates the state of ECM charge
request due to the state of discharge of the lead-acid
battery.
Charge Request 6 (ON/OFF)
This parameter indicates the state of ECM charge
request due to the state of discharge of the lead-acid
battery.
Charge Request 7 (ON/OFF)
This parameter indicates the state of ECM charge
request due to the state of discharge of the lead-acid
battery.
Charge Request 8 (ON/OFF)
This parameter indicates the state of ECM charge
request due to the state of discharge of the lead-acid
battery.
Auto Stop System Request (No Request/Auto Stop
Inhibit Request/Auto Start Request/Auto Start Inhibit
Request)
This parameter indicates the state of ECM request for
ENG A-STOP system.
Idle Stop Enable (TRUE/FALSE) (A/T model)
This parameter indicates state of permission by TCM for
engine auto stop control.
Shift Position (P/R/N/D/2nd/1st) (A/T model)
Shift position detected by signal fed from transmission
range sensor.
Lithium-Ion Battery High Temperature Status (TRUE/
FALSE)
This parameter indicates the state of auxiliary power
module (lithium-ion battery) temperature.
Li Battery Low Temperature Status (TRUE/FALSE)
This parameter indicates the state of auxiliary power
module (lithium-ion battery) temperature.
Driver Door Switch (ON/OFF)
This parameter indicates the state of driver door switch
sent from BCM through CAN.
Driver Seatbelt Switch (Fasten/Unfasten)
This parameter indicates the state of driver seat belt
switch sent from BCM through CAN.
ABS/ESP Status for ISG (Normal/Backup
Disconnect/Inhibit/Failure)
This parameter indicates the state of control by ABS /
ESP® control module.
Additional charge request (ON/OFF)
This parameter indicates the state of battery charge
request from other control module to ECM.
Air Conditioning Compressor Engine Run request
(ON/OFF)
This parameter indicates the state of engine auto restart
request from BCM during engine auto stop control.
Full Braking (ON/OFF)
This parameter indicates the detected state of full
braking.
DTC Condition for A-STOP Inhibition (Auxiliary
power module) (DTC Condition for A-STOP
Inhibition (Auxiliary power module (lithium-ion
battery)), TRUE/FALSE)
This parameter indicates the state of DTC in engine auto
stop control or ISG control detected by auxiliary power
module (lithium-ion battery).
DTC Condition for A-STOP Inhibition (ISG) (TRUE/
FALSE)
This parameter indicates the state of DTC in engine auto
stop control or ISG control detected by ISG.
DTC Condition for A-STOP Inhibition (ABS / ESP®)
(TRUE/FALSE)
This parameter indicates the state of DTC in engine auto
stop control or ISG control detected by ABS / ESP®
control module.
DTC Condition for A-STOP Inhibition (TCM) (TRUE/
FALSE) (A/T model)
This parameter indicates the state of DTC in engine auto
stop control or ISG control detected by TCM.
Brake Stroke Sensor Learning (TRUE/FALSE)
This parameter indicates the completed state of brake
stroke sensor learning.
Engine Stop Request (TRUE/FALSE)
This parameter indicates the state of engine stop
request from other control module to ECM.
 Engine General Information and Diagnosis: K15B 1A-52
Engine Start Request 2 (TRUE/FALSE)
This parameter indicates the state of engine auto restart
request from auxiliary power module (lithium-ion battery)
when the auxiliary power module (lithium-ion battery)
detects poorly charged state of lithium-ion battery in
auxiliary power module.
Auxiliary Power Module Status (A-STOP) (Auxiliary
Power Module (Lithium-Ion Battery) Status (A-
STOP), TRUE/FALSE)
This parameter indicates the state of permission by
auxiliary power module (lithium-ion battery) for engine
auto stop control.
Auxiliary Power Module Status (Regeneration)
(Auxiliary Power Module (Lithium-Ion Battery) Status
(Regeneration), TRUE/FALSE)
This parameter indicates the state of permission by
auxiliary power module (lithium-ion battery) for
regenerating deceleration energy.
Auxiliary Power Module Status (Motor Assist)
(Auxiliary Power Module (Lithium-Ion Battery) Status
(Motor Assist), TRUE/FALSE)
This parameter indicates the state of permission by
auxiliary power module (lithium-ion battery) for engine
power assist control.
DTC Condition for A-STOP Inhibition (ECM) (TRUE/
FALSE)
This parameter indicates the state of DTC in engine auto
stop control or ISG control detected by ECM.
Battery Condition (TRUE/FALSE)
This parameter indicates the state of battery charge for
execution of engine auto stop control.
Battery Temperature Condition (TRUE/FALSE)
This parameter indicates the state of estimated battery
temperature for execution of engine auto stop control.
ECT Condition (Engine Coolant Temperature
Condition, TRUE/FALSE)
This parameter indicates the state of engine coolant
temperature for execution of engine auto stop control.
Brake Booster Condition (Brake Booster Pressure
Condition, TRUE/FALSE)
This parameter indicates the state of brake booster
negative pressure for execution of engine auto stop
control.
Master Cylinder Pressure Condition (A-STOP)
(TRUE/FALSE) (A/T model)
This parameter indicates the state of master cylinder
pressure for execution of engine auto stop control.
Brake Switch Condition (TRUE/FALSE)
This parameter indicates the state of brake switch for
execution of engine auto stop control.
Shift Position Condition (TRUE/FALSE) (A/T model)
This parameter indicates the state of shift position for
execution of engine auto stop control.
Seat Belt/Door Condition (Seat Belt Buckle Switch /
Front Door Switch (Driver side) Condition, TRUE/
FALSE)
This parameter indicates the state of seat belt buckle
switch and front door switch (driver side) for execution of
engine auto stop control.
Hood Switch Condition (Hood Latch Switch
Condition, TRUE/FALSE)
This parameter indicates the state of hood latch switch
for execution of engine auto stop control.
Accel Pedal Condition (Accelerator Pedal Position
Condition, TRUE/FALSE)
This parameter indicates the state of accelerator pedal
position for execution of engine auto stop control.
Tilt Angle Condition (A-STOP) (TRUE/FALSE)
This parameter indicates the state of tilt angle for
execution of engine auto stop control.
Speed History Condition (A-STOP) (TRUE/FALSE)
This parameter indicates the state of engine auto stop
permission based on vehicle running speed after the
previous engine auto stop.
TCM Demand Condition (A-STOP) (TRUE/FALSE)
This parameter indicates the state of inhibition request
by TCM for engine auto stop control.
Auxiliary Power Module Demand Condition
(Auxiliary Power Module (Lithium-Ion Battery)
Demand Condition, TRUE/FALSE)
This parameter indicates the state of inhibition request
by auxiliary power module (lithium-ion battery) for engine
auto stop control.
ABS/ESP® Demand Condition (TRUE/FALSE)
This parameter indicates the state of inhibition request
by ABS / ESP® control module for engine auto stop
control.
HVAC Demand Condition (TRUE/FALSE)
This parameter indicates the state of inhibition request
by BCM for engine auto stop control.
ENG A-STOP OFF Switch Condition (TRUE/FALSE)
This parameter indicates the state of ENG A-STOP OFF
switch for execution of engine auto stop control.
Starter Inhibition Request (ABS/ESP®) (TRUE/
FALSE)
This parameter indicates the state of starting motor stop
request from ABS / ESP® control module.
1A-53 Engine General Information and Diagnosis: K15B
Brake Stroke Sensor Condition (TRUE/FALSE)
This parameter indicates the state of brake stroke
sensor for execution of engine auto stop control.
ISG Belt Condition (TRUE/FALSE)
This parameter indicates the state of ISG drive belt slip
for execution of engine auto stop control.
Assist Permit from Auxiliary power module (lithium
ion battery) (TRUE/FALSE)
This parameter indicates the state of permission by
lithium-ion battery for engine power assist control.
Regeneration Permit Signal (TRUE/FALSE)
This parameter indicates the state of permission by ECM
for deceleration energy regeneration.
Minimum Voltage at Engine Start (V)
This parameter indicates minimum battery voltage at
engine starting.
ISG Adjusting Voltage Request Value (V)
This parameter indicates regulating voltage requested
from ISG to ECM.
Battery DOD (Battery Depth of Discharge, %)
This parameter indicates the depth of discharge of
battery.
Auxiliary Power Module Voltage (Auxiliary Power
Module (Lithium-Ion Battery) Voltage, V)
This parameter indicates voltage of lithium-ion battery in
auxiliary power module.
Visual Inspection
Visually check the following parts and systems.
Inspection item
• Engine oil – Level, leakage
• Engine coolant – Level, leakage
• Fuel – Level, leakage
• A/T fluid – Level, leakage (A/T model)
• Air cleaner filter – Dirt, clogging
• Battery – Corrosion of terminal
• ISG drive belt – Tension, damage
• Throttle valve – Operating sound
• Vacuum hoses of air intake system – Disconnection,
looseness, deterioration, bend
• Connectors of electric wire harness –
Disconnection, friction, pinch
• Fuses – Blown
• Parts – Installation, deformation
• Bolts and nuts – Looseness
Auxiliary Power Module Current 2 (Auxiliary Power
Module (Lithium-Ion Battery) Current 2, A)
This parameter indicates current of relay “3P” in auxiliary
power module (lithium-ion battery).
Auxiliary Power Module SOC (Auxiliary Power
Module (lithium-ion battery) State of Charge, %)
This parameter indicates the state-of-charge of lithium-
ion battery in auxiliary power module.
Auxiliary Power Module “Pb+” Terminal Voltage
(Auxiliary Power Module (Lithium-Ion Battery) “Pb+”
Terminal Voltage, V)
This parameter indicates output voltage (power supply
side voltage) of auxiliary power module (lithium-ion
battery).
Battery Current Sensor Voltage (V)
This parameter indicates voltage value detected by
electric load current sensor.
Generator Field Coil Operation Rate (%)
This parameter indicates calculated operation rate of
generator field coil based on CAN data from ECM.
ISG control mode (Neutral/Generation/Generation
Limit/Generation Failure/Restart/Restart Limit/
Restart Failure/Assistance/Assistance Limit/
Assistance Failure/Braking/Braking Failure)
This parameter indicates the state of ISG control mode.
AENJHB0B1114008
Referring section
“Engine Oil and Filter Change” in Section 0B (Page 0B-5)
• “Coolant Level Check”: K15B in Section 1F (Page 1F-10)
• “Engine Cooling System Inspection”: K15B in Section 1F
(Page 1F-10)
“Fuel Leakage Check Procedure”: K15B in Section 1G (Page
1G-14)
“ATF Level Check” in Section 5A (Page 5A-117)
“Air Cleaner Filter Inspection and Cleaning”: K15B in Section
1D (Page 1D-9)
“Battery Inspection”: K15B in Section 1J (Page 1J-2)
“ISG Drive Belt Inspection”: K15B in Section 1J (Page 1J-6)
—
—
—
—
—
—
 Engine General Information and Diagnosis: K15B 1A-54

Additionally check the following items at engine start, if possible.

Inspection item Referring section
• MIL – Operation “MIL Check”: K15B (Page 1A-23)
“Generator Symptom Diagnosis”: K15B in Section 1J (Page
• Charging light – Operation
1J-3)
“Oil Pressure Switch On-Vehicle Inspection”: K15B in Section
• Engine oil pressure light – Operation
1E (Page 1E-5)
• Engine coolant temperature meter – Operation “ECT Sensor Inspection”: K15B in Section 1C (Page 1C-9)
“Fuel Level Sensor Inspection”: K15B in Section 1G (Page
• Fuel meter – Operation
1G-26)
• Tachometer – Operation Section 9C
• Exhaust system – Leakage of exhaust gas, noise “Exhaust System Check”: K15B in Section 1K (Page 1K-1)
• Abnormal air being inhaled at air intake system —
• Other parts that can be checked visually —

Engine Basic Inspection

AENJHB0B1114009
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found
in “Visual Inspection”: K15B (Page 1A-53).
Follow the flow carefully.
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 Check battery voltage Go to Step 3. Charge or replace
battery.
Is it 12 V or more?
3 Is engine cranked? Go to Step 4. Go to “Cranking System
Symptom Diagnosis”:
K15B in Section 1I
(Page 1I-2).
4 Does engine start? Go to Step 5. Go to Step 7.
5 Check idle speed Go to Step 6. Go to “Engine Symptom
1) Check engine idle speed. (Page 1A-165) Diagnosis”: K15B (Page
1A-55).
Is check result OK?
6 Check ignition system Go to “Engine Symptom Repair or replace
1) Check ignition system. (Page 1H-4) Diagnosis”: K15B (Page defective parts.
1A-55).
Is check result OK?
7 Check immobilizer system Go to Step 8. Immobilizer control
1) Check immobilizer control system. system malfunction.
• Ignition switch model: (Page 10C-5)
• Keyless push start model: (Page 10C-21)

Is check result OK?

8 Check fuel supply Go to Step 9. Repair or replace
1) Check fuel supply. (Page 1G-24) defective parts.

Is check result OK?

9 Check fuel injector circuit Go to “Engine Symptom Go to “Fuel Injector
1) Check fuel injector circuit. (Page 1G-5) Diagnosis”: K15B (Page Circuit Check”: K15B in
1A-55). Section 1G (Page 1G-
Is check result OK? 5).
1A-55 Engine General Information and Diagnosis: K15B
Engine Symptom Diagnosis
Perform troubleshooting referring to the following points when ECM has detected no DTC and no abnormality has
been found in “Visual Inspection”: K15B (Page 1A-53) and “Engine Basic Inspection”: K15B (Page 1A-54).
Condition Possible cause
Hard starting (Engine can Faulty spark plug
be cranked)
Faulty ignition coil
Dirty or clogged fuel hoses or pipes
Malfunctioning fuel pump
Air drawn in through intake manifold
gasket or throttle body gasket
Faulty electric throttle body assembly
Faulty APP sensor
Faulty ECT sensor or MAP sensor
Faulty ECM
Low compression
Poor spark plug tightening or faulty
gasket
Compression leakage from valve seat
Sticky valve stem
Weak or damaged valve springs
Compression leakage at cylinder head
gasket
Sticky or damaged piston ring
Worn piston, piston ring or cylinder
Malfunctioning PCV valve
VVT system out of order
AENJHB0B1114010
Correction / Reference Item
“Spark Plug Inspection” in Section 1H (Page
1H-7)
“Ignition Coil Assembly Inspection” in Section
1H (Page 1H-8)
“Fuel Pressure Check”: K15B in Section 1G
(Page 1G-9)
“Fuel Pressure Check”: K15B in Section 1G
(Page 1G-9)
Check air intake system.
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K15B in Section 1C (Page 1C-4)
“APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
“ECT Sensor Inspection”: K15B in Section 1C
(Page 1C-9) or “MAP Sensor Inspection”:
K15B in Section 1C (Page 1C-8)
“Inspection of ECM and Its Circuits”: K15B
(Page 1A-150)
“Compression Check”: K15B in Section 1D
(Page 1D-4)
“Spark Plug Removal and Installation” in
Section 1H (Page 1H-7)
“Valve and Valve Guide Inspection”: K15B in
Section 1D (Page 1D-49)
“Valve and Valve Guide Inspection”: K15B in
Section 1D (Page 1D-49)
“Valve Spring Inspection”: K15B in Section 1D
(Page 1D-52)
“Cylinder Head Inspection”: K15B in Section
1D (Page 1D-51)
“Cylinder, Piston and Piston Ring Inspection”:
K15B in Section 1D (Page 1D-57)
“Cylinder, Piston and Piston Ring Inspection”:
K15B in Section 1D (Page 1D-57)
“PCV Valve Inspection”: K15B in Section 1B
(Page 1B-7)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K15B in Section 1D
(Page 1D-22)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K15B in Section 1D
(Page 1D-42)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K15B in Section 1D (Page 1D-
36)
 Engine General Information and Diagnosis: K15B 1A-56

Condition Possible cause Correction / Reference Item

Low oil pressure Improper oil viscosity
Malfunctioning oil pressure switch
Clogged oil strainer
Functional deterioration of oil pump
Worn oil pump relief valve
Excessive clearance in various sliding
parts
Engine noise – Valve Improper valve clearance
noise
Worn valve stem and guide
NOTE
Before checking Weak or broken valve spring
mechanical noise, check
that: Warped or bent valve
• Specified spark plug is
used.
• Specified fuel is used.
“Engine Oil and Filter Change” in Section 0B
(Page 0B-5)
“Oil Pressure Switch On-Vehicle Inspection”:
K15B in Section 1E (Page 1E-5)
Check oil strainer for clog.
“Oil Pump Inspection”: K15B in Section 1E
(Page 1E-12)
“Oil Pump Inspection”: K15B in Section 1E
(Page 1E-12)
—
“Valve Clearance Inspection and Adjustment”:
K15B in Section 1D (Page 1D-6)
“Valve and Valve Guide Inspection”: K15B in
Section 1D (Page 1D-49)
“Valve Spring Inspection”: K15B in Section 1D
(Page 1D-52)
“Valve and Valve Guide Inspection”: K15B in
Section 1D (Page 1D-49)

Engine noise – Piston, Worn piston, piston ring and cylinder “Cylinder, Piston and Piston Ring Inspection”:
piston ring and cylinder bore K15B in Section 1D (Page 1D-57)
noise

NOTE
Before checking
mechanical noise, check
that:
• Specified spark plug is
used.
• Specified fuel is used.

Engine noise – Worn piston, piston ring and cylinder “Cylinder, Piston and Piston Ring Inspection”:
Connecting rod noise bore K15B in Section 1D (Page 1D-57)
Worn connecting rod bearing “Crankshaft Pin and Connecting Rod Bearing
NOTE Inspection”: K15B in Section 1D (Page 1D-60)
Before checking Worn crankshaft pin “Crankshaft Pin and Connecting Rod Bearing
mechanical noise, check Inspection”: K15B in Section 1D (Page 1D-60)
that: Loose connecting rod bolts “Piston, Piston Ring, Connecting Rod and
• Specified spark plug is Cylinder Removal and Installation”: K15B in
used. Section 1D (Page 1D-54)
Low oil pressure Condition “Low oil pressure”
• Specified fuel is used.

Engine noise – Low oil pressure Condition “Low oil pressure”

Crankshaft noise Worn main bearing “Main Bearing Inspection”: K15B in Section 1D
(Page 1D-69)
NOTE Worn crankshaft journal “Crankshaft Inspection”: K15B in Section 1D
Before checking (Page 1D-68)
mechanical noise, check Loose bearing cap bolts “Main Bearing Inspection”: K15B in Section 1D
that: (Page 1D-69)
• Specified spark plug is Excessive crankshaft thrust play “Crankshaft Inspection”: K15B in Section 1D
used. (Page 1D-68)
• Specified fuel is used.
1A-57 Engine General Information and Diagnosis: K15B
Condition Possible cause
Engine overheating Inoperative thermostat
Poor water pump performance
Clogged or leaky radiator
Improper engine oil grade
Clogged oil filter or oil strainer
Poor oil pump performance
Faulty radiator cooling fan control
system
Dragging brakes
Slipping clutch (M/T model)
Blown cylinder head gasket
Air mixed in cooling system
Correction / Reference Item
“Thermostat Inspection”: K15B in Section 1F
(Page 1F-13)
“Water Pump Inspection”: K15B in Section 1F
(Page 1F-18)
“Radiator On-Vehicle Inspection and
Cleaning”: K15B in Section 1F (Page 1F-16)
“Engine Oil and Filter Change” in Section 0B
(Page 0B-5)
“Oil Pressure Check”: K15B in Section 1E
(Page 1E-3)
“Oil Pressure Check”: K15B in Section 1E
(Page 1E-3)
“Radiator Cooling Fan System Check”: K15B
in Section 1F (Page 1F-6)
Condition “Dragging brakes” in “Brake
Symptom Diagnosis” in Section 4A (Page 4A-
2)
Condition “Slipping” in “Clutch System
Symptom Diagnosis” in Section 5C (Page 5C-
2)
“Cylinder Head Inspection”: K15B in Section
1D (Page 1D-51)
“Cooling System Refilling”: K15B in Section 1F
(Page 1F-11)
 Engine General Information and Diagnosis: K15B 1A-58

Condition Possible cause Correction / Reference Item

Poor fuel mileage Faulty spark plug (improper gap, heavy “Spark Plug Inspection” in Section 1H (Page
deposits and burned electrodes, etc.) 1H-7)
High idle speed
Poor performance of ECT sensor or
MAP sensor
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Faulty APP sensor
Faulty fuel injector
Faulty ECM
Low compression
Poor valve seating
Dragging brakes
Slipping clutch (M/T model)
Thermostat out of order
Improper tire pressure
VVT system out of order
Excessive engine oil Broken cylinder head gasket
consumption – Oil
leakage Leaky crankshaft pulley oil seal
Leaky crankshaft rear oil seal
Leaky cylinder head cover gasket
Condition “Improper engine idling or engine
fails to idle”
“ECT Sensor Inspection”: K15B in Section 1C
(Page 1C-9) or “MAP Sensor Inspection”:
K15B in Section 1C (Page 1C-8)
Inspection”: K15B in Section 1C (Page 1C-4)
“APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
“Fuel Injector Circuit Check”: K15B in Section
1G (Page 1G-5)
“Inspection of ECM and Its Circuits”: K15B
(Page 1A-150)
“Compression Check”: K15B in Section 1D
(Page 1D-4)
“Valve and Valve Guide Inspection”: K15B in
Section 1D (Page 1D-49)
Condition “Dragging brakes” in “Brake
Symptom Diagnosis” in Section 4A (Page 4A-
2)
Condition “Slipping” in “Clutch System
Symptom Diagnosis” in Section 5C (Page 5C-
2)
“Thermostat Inspection”: K15B in Section 1F
(Page 1F-13)
“Tire Description” in Section 2D (Page 2D-1)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K15B in Section 1D
(Page 1D-22)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K15B in Section 1D
(Page 1D-42)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K15B in Section 1D (Page 1D-
36)
“Cylinder Head Inspection”: K15B in Section
1D (Page 1D-51)
“Timing Chain Cover Inspection”: K15B in
Section 1D (Page 1D-36)
“Main Bearing, Crankshaft and Cylinder Block
Removal and Installation”: K15B in Section 1D
(Page 1D-64)
“Cylinder Head Cover Components”: K15B in
Section 1D (Page 1D-14)
1A-59 Engine General Information and Diagnosis: K15B

Condition Possible cause Correction / Reference Item

Excessive engine oil Sticky piston ring “Cylinder, Piston and Piston Ring Inspection”:
consumption – Oil K15B in Section 1D (Page 1D-57)
entering combustion Worn piston and cylinder “Cylinder, Piston and Piston Ring Inspection”:
chamber K15B in Section 1D (Page 1D-57)
Worn piston ring groove and ring “Cylinder, Piston and Piston Ring Inspection”:
K15B in Section 1D (Page 1D-57)
Improper location of piston ring gap “Piston, Piston Ring, Connecting Rod and
Cylinder Disassembly and Reassembly”: K15B
in Section 1D (Page 1D-56)
Worn or damaged valve stem seal “Valve and Cylinder Head Disassembly and
Reassembly”: K15B in Section 1D (Page 1D-
46)
Worn valve stem “Valve and Valve Guide Inspection”: K15B in
Section 1D (Page 1D-49)
Engine hesitates – Faulty spark plug or plug gap out of “Spark Plug Inspection” in Section 1H (Page
Momentary lack of adjustment 1H-7)
response as accelerator Fuel pressure out of specification “Fuel Pressure Check”: K15B in Section 1G
is depressed. Can occur (Page 1G-9)
at all vehicle speeds. Poor performance of ECT sensor or “ECT Sensor Inspection”: K15B in Section 1C
Usually severest when MAP sensor (Page 1C-9) or “MAP Sensor Inspection”:
moving out from a stop at K15B in Section 1C (Page 1C-8)
stop signal etc. Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection”: K15B in Section 1C (Page 1C-4)
Faulty APP sensor “APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
Faulty fuel injector “Fuel Injector Circuit Check”: K15B in Section
1G (Page 1G-5)
Faulty ECM “Inspection of ECM and Its Circuits”: K15B
(Page 1A-150)
Engine overheating Condition “Engine overheating”
Low compression “Compression Check”: K15B in Section 1D
(Page 1D-4)
 Engine General Information and Diagnosis: K15B 1A-60

Condition Possible cause Correction / Reference Item

Surge – Engine power Faulty spark plug (excessive carbon
variation under steady deposits, improper gap, burned
throttle. Vehicle speed electrodes, etc.)
changes up and down Variable fuel pressure
with no change in
accelerator pedal Kinky or damaged fuel lines
position.
Faulty fuel pump (clogged fuel filter)
Poor performance of MAP sensor
Faulty fuel injector
Faulty ECM
Faulty electric throttle body assembly
Faulty APP sensor
VVT system out of order
“Spark Plug Inspection” in Section 1H (Page
1H-7)
“Fuel Pressure Check”: K15B in Section 1G
(Page 1G-9)
“Fuel Pressure Check”: K15B in Section 1G
(Page 1G-9)
“Fuel Pump and Its Circuit Check”: K15B in
Section 1G (Page 1G-7)
“MAP Sensor Inspection”: K15B in Section 1C
(Page 1C-8)
“Fuel Injector Circuit Check”: K15B in Section
1G (Page 1G-5)
“Inspection of ECM and Its Circuits”: K15B
(Page 1A-150)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K15B in Section 1C (Page 1C-4)
“APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K15B in Section 1D
(Page 1D-22)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K15B in Section 1D
(Page 1D-42)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K15B in Section 1D (Page 1D-
36)
1A-61 Engine General Information and Diagnosis: K15B

Condition Possible cause Correction / Reference Item

Excessive detonation – Faulty spark plug
Engine continuously
generates sharp, metallic Engine overheating
knocking sound that Clogged fuel filter (faulty fuel pump) or
changes with throttle fuel lines
opening.
Air drawn in through intake manifold or
throttle body gasket
Poor performance of knock sensor, ECT “Knock Sensor On-Vehicle Inspection”: K15B
sensor or MAP sensor
Faulty fuel injector
Faulty ECM
Excessive combustion chamber
deposits
VVT system out of order
“Spark Plug Inspection” in Section 1H (Page
1H-7)
Condition “Engine overheating”
“Fuel Pressure Check”: K15B in Section 1G
(Page 1G-9) or “Fuel Pump and Its Circuit
Check”: K15B in Section 1G (Page 1G-7)
Check air intake system.
in Section 1C (Page 1C-12), “ECT Sensor
Inspection”: K15B in Section 1C (Page 1C-9)
or “MAP Sensor Inspection”: K15B in Section
1C (Page 1C-8)
“Fuel Injector Circuit Check”: K15B in Section
1G (Page 1G-5) or “Fuel Injector Inspection”:
K15B in Section 1G (Page 1G-18)
“Inspection of ECM and Its Circuits”: K15B
(Page 1A-150)
“Cylinder, Piston and Piston Ring Inspection”:
K15B in Section 1D (Page 1D-57) and/or
“Piston Pin and Connecting Rod Inspection”:
K15B in Section 1D (Page 1D-59)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K15B in Section 1D
(Page 1D-22)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K15B in Section 1D
(Page 1D-42)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K15B in Section 1D (Page 1D-
36)
 Engine General Information and Diagnosis: K15B 1A-62

Condition Possible cause Correction / Reference Item

Poor engine power Faulty spark plug “Spark Plug Inspection” in Section 1H (Page
1H-7)
Faulty ignition coil assembly “Ignition Coil Assembly Inspection” in Section
1H (Page 1H-8)
Faulty knock sensor “Knock Sensor On-Vehicle Inspection”: K15B
in Section 1C (Page 1C-12)
Clogged fuel hoses or pipes “Fuel Pressure Check”: K15B in Section 1G
(Page 1G-9)
Malfunctioning fuel pump “Fuel Pump and Its Circuit Check”: K15B in
Section 1G (Page 1G-7)
Air drawn in through intake manifold Check air intake system.
gasket or throttle body gasket
Engine overheating Condition “Engine overheating”
Poor performance of ECT sensor or “ECT Sensor Inspection”: K15B in Section 1C
MAP sensor (Page 1C-9) or “MAP Sensor Inspection”:
K15B in Section 1C (Page 1C-8)
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection”: K15B in Section 1C (Page 1C-4)
Faulty APP sensor “APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
Faulty fuel injector “Fuel Injector Circuit Check”: K15B in Section
1G (Page 1G-5) or “Fuel Injector Inspection”:
K15B in Section 1G (Page 1G-18)
Faulty ECM “Inspection of ECM and Its Circuits”: K15B
(Page 1A-150)
Dragging brakes Condition “Dragging brakes” in “Brake
Symptom Diagnosis” in Section 4A (Page 4A-
2)
Slipping clutch (M/T model) Condition “Slipping” in “Clutch System
Symptom Diagnosis” in Section 5C (Page 5C-
2)
Low compression “Compression Check”: K15B in Section 1D
(Page 1D-4)
VVT system out of order • VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K15B in Section 1D
(Page 1D-22)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K15B in Section 1D
(Page 1D-42)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K15B in Section 1D (Page 1D-
36)
1A-63 Engine General Information and Diagnosis: K15B

Condition Possible cause Correction / Reference Item

Improper engine idling or Faulty spark plug
engine fails to idle
Faulty ignition coil assembly
Fuel pressure out of specification
Leaky manifold, throttle body or cylinder Check air intake system.
head gasket
Faulty evaporative emission control
system
Faulty fuel injector
Poor performance of ECT sensor or
MAP sensor
Faulty electric throttle body assembly
Faulty APP sensor
Faulty ECM
Loose connection or disconnection of
vacuum hoses
Malfunctioning PCV valve
Engine overheating
Low compression
Faulty generator and/or its circuit
VVT system out of order
“Spark Plug Inspection” in Section 1H (Page
1H-7)
“Ignition Coil Assembly Inspection” in Section
1H (Page 1H-8)
“Fuel Pressure Check”: K15B in Section 1G
(Page 1G-9)
“EVAP Canister Purge Valve Inspection”: K15B
in Section 1B (Page 1B-4)
“Fuel Injector Circuit Check”: K15B in Section
1G (Page 1G-5) or “Fuel Injector Inspection”:
K15B in Section 1G (Page 1G-18)
“ECT Sensor Inspection”: K15B in Section 1C
(Page 1C-9) or “MAP Sensor Inspection”:
K15B in Section 1C (Page 1C-8)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K15B in Section 1C (Page 1C-4)
“APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
“Inspection of ECM and Its Circuits”: K15B
(Page 1A-150)
Check connection of vacuum hoses.
“PCV Valve Inspection”: K15B in Section 1B
(Page 1B-7)
Condition “Engine overheating”
“Compression Check”: K15B in Section 1D
(Page 1D-4)
“Generator Test”: K15B in Section 1J (Page
1J-3)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K15B in Section 1D
(Page 1D-22)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K15B in Section 1D
(Page 1D-42)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K15B in Section 1D (Page 1D-
36)
 Engine General Information and Diagnosis: K15B 1A-64
Condition Possible cause
Excessive hydrocarbon Faulty spark plug
(HC) emission or carbon
monoxide (CO) emission Faulty ignition coil assembly
Low compression
Lead contamination of TWC
Faulty evaporative emission control
system
Fuel pressure out of specification
Faulty closed loop system (A/F
feedback compensation) (Poor
performance of ECT sensor or MAP
sensor)
Faulty electric throttle body assembly
Faulty APP sensor
Faulty fuel injector
Faulty ECM
Engine not at normal operating
temperature
Clogged air cleaner
Vacuum leakage
VVT system out of order
Correction / Reference Item
“Spark Plug Inspection” in Section 1H (Page
1H-7)
“Ignition Coil Assembly Inspection” in Section
1H (Page 1H-8)
“Compression Check”: K15B in Section 1D
(Page 1D-4)
Check for absence of filler neck restrictor.
“EVAP Canister Purge System Inspection”:
K15B in Section 1B (Page 1B-1)
“Fuel Pressure Check”: K15B in Section 1G
(Page 1G-9)
“ECT Sensor Inspection”: K15B in Section 1C
(Page 1C-9) or “MAP Sensor Inspection”:
K15B in Section 1C (Page 1C-8)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K15B in Section 1C (Page 1C-4)
“APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
“Fuel Injector Circuit Check”: K15B in Section
1G (Page 1G-5)
“Inspection of ECM and Its Circuits”: K15B
(Page 1A-150)
—
“Air Cleaner Filter Inspection and Cleaning”:
K15B in Section 1D (Page 1D-9)
“Engine Vacuum Check”: K15B in Section 1D
(Page 1D-5)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K15B in Section 1D
(Page 1D-22)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K15B in Section 1D
(Page 1D-42)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K15B in Section 1D (Page 1D-
36)
1A-65 Engine General Information and Diagnosis: K15B

Condition Possible cause Correction / Reference Item

Excessive nitrogen Improper ignition timing
oxides (NOx) emission
Lead contamination of TWC
Fuel pressure out of specification
Faulty closed loop system (A/F
feedback compensation) (Poor
performance of ECT sensor or MAP
sensor)
Faulty electric throttle body assembly
Faulty APP sensor
Faulty fuel injector
Faulty ECM
VVT system out of order
“Ignition Timing Inspection” in Section 1H
(Page 1H-8)
Check for absence of filler neck restrictor.
“Fuel Pressure Check”: K15B in Section 1G
(Page 1G-9)
“ECT Sensor Inspection”: K15B in Section 1C
(Page 1C-9) or “MAP Sensor Inspection”:
K15B in Section 1C (Page 1C-8)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K15B in Section 1C (Page 1C-4)
“APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
“Fuel Injector Circuit Check”: K15B in Section
1G (Page 1G-5) or “Fuel Injector Inspection”:
K15B in Section 1G (Page 1G-18)
“Inspection of ECM and Its Circuits”: K15B
(Page 1A-150)
• VVT actuator: “VVT Actuator, Camshaft and
Tappet Inspection”: K15B in Section 1D
(Page 1D-22)
• Valve timing: “Timing Chain and Chain
Tensioner Inspection”: K15B in Section 1D
(Page 1D-42)
• OCV oil circuit: “Timing Chain Cover
Inspection”: K15B in Section 1D (Page 1D-
36)

MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)
AENJHB0B1114011
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Go to Step 2.
1) Check DTC related to CAN communication. for applicable DTC.

Is there any CAN-DTC(s) detected?

2 DTC check Go to troubleshooting Replace ECM and
1) Check combination meter for DTC. for applicable DTC. recheck MIL operation.
(Page 1C-2)
Is there any DTC(s) detected?

MIL Remains ON after Engine Starts

AENJHB0B1114012
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Substitute a known-
1) Start engine and check DTC of ECM while engine for applicable DTC. good combination meter
running. and recheck MIL
operation. (Page 9C-
Is there any DTC(s)? 34)
If MIL still remains ON,
replace ECM and
recheck MIL operation.
(Page 1C-2)
 Engine General Information and Diagnosis: K15B 1A-66

DTC P0010 / P2088 / P2089

AENJHB0B1114013
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0010: “A” Camshaft Position Actuator Circuit / Open (Bank1) • OCV and/or its circuit
OCV drive circuit is open. • ECM
(3 D/C detection logic)
P2088: “A” Camshaft Position Actuator Control Circuit Low (Bank1)
OCV drive circuit is shorted to ground.
(3 D/C detection logic)
P2089: “A” Camshaft Position Actuator Control Circuit High (Bank1)
OCV drive circuit is shorted to power supply.
(3 D/C detection logic)

Circuit Diagram

1 A1
C01-42 GRN 3
B1

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111011-01

[A]: ECM connector (View: [a]) B1: OCV drive circuit 2. ECM
A1: OCV power supply circuit 1. OCV 3. To main relay

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• Battery voltage is higher than 8.5 V.

1) Run engine at idle speed for 10 sec.

1A-67 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? • If DTC P0010 and Emission Control
P2088 detected, go System Check”: K15B
to Step 2. (Page 1A-21).

• If DTC P2089
detected, go to Step
4.
2 OCV power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect connector from OCV. defective wire harness.
2) Check for proper terminal connection to OCV connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

3 OCV drive circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM.
2) Check for proper terminal connections to “C01” and
“E01” connectors.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and “B1”
circuit terminal at OCV connector: infinity

Is check result OK?

4 OCV drive circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM and OCV connector.
2) Check for proper terminal connections to “C01” and
“E01” connectors and OCV connector.
3) If connections are OK, check the following point.
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 OCV check Go to Step 6. Replace OCV. (Page
1) Check OCV. (Page 1C-14) 1D-36)

Is check result OK?

6 Troubleshooting of other DTC(s) at the same time Go to troubleshooting Replace ECM and
for applicable DTC. recheck DTC. (Page
Is there any DTC(s) detected together? 1C-2)
 Engine General Information and Diagnosis: K15B 1A-68

DTC P0011
AENJHB0B1114014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0011: “A” Camshaft Position Timing Over Advanced or • OCV and/or its circuit
System Performance (Bank1) • CKP sensor and sensor plate
Measured CMP does not reach target CMP for specified time.
• CMP sensor and signal rotor
(3 D/C detection logic)
• OCV oil passage
• VVT actuator
• Valve timing
• ECM

Circuit Diagram

1 A1
C01-42 GRN 3
B1

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111011-01

[A]: ECM connector (View: [a]) B1: OCV drive circuit 2. ECM
A1: OCV power supply circuit 1. OCV 3. To main relay

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following DTCs is not detected in this “DTC Confirmation Procedure”.
– OCV (P0010, P2088 and P2089)

1) Warm up engine and repeat acceleration and deceleration between 30 and 80 km/h (19 and 50 mile/h) more than
10 times.
1A-69 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. for applicable DTC.

Is there any DTC(s) other than P0011?

3 OCV power supply circuit and OCV drive circuit check Go to Step 4. Repair or replace
1) Check “A1” and “B1” circuits according to Step 2 – 4 defective wire harness.
under “DTC P0010 / P2088 / P2089”: K15B (Page 1A-
66).

Is check result OK?

4 Oil pressure check Go to Step 5. Repair or replace
1) Check oil pressure. (Page 1E-3) defective parts.

Is check result OK?

5 OCV oil circuit visual check Go to Step 6. Repair or replace
1) Remove cylinder head cover. (Page 1D-14) defective parts.
2) Check oil pressure leakage from OCV oil circuit.

Is check result OK?

6 CKP sensor and sensor plate check Go to Step 7. Repair or replace
1) Check CKP sensor and sensor plate. (Page 1C-11) defective parts.

Is check result OK?

7 CMP sensor and signal rotor check Go to Step 8. Repair or replace
1) Check CMP sensor and signal rotor. defective parts.
• CMP sensor: (Page 1C-10)
• Signal rotor: (Page 1D-14)

Is check result OK?

8 OCV check Go to Step 9. Replace OCV. (Page
1) Check OCV. (Page 1C-14) 1D-36)

Is check result OK?

9 VVT actuator check Go to Step 10. Replace VVT actuator.
1) Check VVT actuator. (Page 1D-22) (Page 1D-16)

Is check result OK?

10 Valve timing check Replace ECM and Reinstall parts related to
1) Check parts related to timing chain and their installing recheck DTC. (Page timing chain correctly, or
condition. (Page 1D-39) 1C-2) replace defective parts.

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-70

DTC P0016
AENJHB0B1114015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0016: Crankshaft Position – Camshaft Position • OCV
Correlation (Bank1 Sensor A) • OCV oil passage
Difference between camshaft position and crankshaft
• VVT actuator
position is out of specified range.
(3 D/C detection logic) • Valve timing
• Timing chain
• Timing chain tensioner
• Timing chain tensioner adjuster
• ECM

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– OCV (P0010, P2088 and P2089)
– CKP sensor (P0335 and P0336)
– CMP sensor (P0340)

1) Warm up engine and repeat acceleration and deceleration between 30 and 80 km/h (19 and 50 mile/h) more than
10 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. (Page 1A-23) for applicable DTC.

Is there any DTC(s) detected other than P0016?

3 Active test Go to Step 8. Go to Step 4.
1) Set ignition “OFF”, connect SUZUKI scan tool to DLC.
2) Set ignition “ON”.
3) Select “VVT Control” function in “Active Test” mode on
SUZUKI scan tool.
4) Check that parameter “VVT Gap” changes correctly.

Is check result OK?

4 Oil pressure check Go to Step 5. Repair or replace
1) Check oil pressure. (Page 1E-3) defective part.

Is check result OK?

1A-71 Engine General Information and Diagnosis: K15B

Step Action Yes No

5 OCV check Go to Step 6. Replace OCV. (Page
1) Check OCV. (Page 1C-14) 1D-36)

Is check result OK?

6 VVT actuator check Go to Step 7. Replace VVT actuator.
1) Check VVT actuator. (Page 1D-22) (Page 1D-16)

Is check result OK?

7 OCV oil circuit visual check Replace ECM and Clean oil passages and
1) Remove timing chain cover. (Page 1D-33) recheck DTC. (Page filters.
1C-2)
2) Check oil passages and filters. (Page 1D-36)

Is check result OK?

8 Valve timing check Go to Step 9. Adjust valve timing.
1) Check valve timing. (Page 1D-39)

Is check result OK?

9 Engine mechanical system check Replace ECM and Repair or replace
1) Remove timing chain cover. (Page 1D-33) recheck DTC. (Page defective part.
1C-2)
2) Check timing chain, timing chain tensioner and timing
chain tensioner adjuster. (Page 1D-42)

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-72

DTC P0030 / P0031 / P0032

AENJHB0B1114016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0030: HO2S Heater Control Circuit (Bank1 Sensor1) • HO2S-1 heater and/or its circuit
HO2S-1 heater drive circuit is open. • ECM
(3 D/C detection logic)
P0031: HO2S Heater Control Circuit Low (Bank1 Sensor1)
HO2S-1 heater drive circuit is shorted to ground.
(3 D/C detection logic)
P0032: HO2S Heater Control Circuit High (Bank1 Sensor1)
HO2S-1 heater drive circuit is shorted to power supply.
(3 D/C detection logic)

Circuit Diagram

5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111012-01

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• Battery voltage is higher than 8.5 V.

1) Warm up engine to normal operating temperature.

2) Run engine at idle speed for 1 min.
1A-73 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” • If DTC P0030 and Go to “Engine and
performed? P0031 detected, go Emission Control
to Step 2. System Check”: K15B
• If DTC P0032 (Page 1A-21).
detected, go to Step
4.
2 HO2S-1 heater power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect HO2S-1 connector. defective wiring
harness.
2) Check for proper terminal connection to HO2S-1
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

3 HO2S-1 heater drive circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wiring
connectors from ECM. harness.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A4” circuit: less than 1 Ω
• Resistance between “A4” circuit and ground: infinity
• Resistance between “A4” circuit terminal and other
terminal at HO2S-1 connector: infinity

Is check result OK?

4 HO2S-1 heater drive circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wiring
connectors from ECM and HO2S-1 connector. harness.
2) Check for proper terminal connection to “C01” and “E01”
connectors and HO2S-1 connector.
3) If connections are OK, check the following point.
• Voltage of “A4” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 HO2S-1 heater check Replace ECM and Replace HO2S-1.
1) Check HO2S-1 heater. (Page 1C-9) recheck DTC. (Page (Page 1C-9)
1C-2)
Is check result OK?
 Engine General Information and Diagnosis: K15B 1A-74

DTC P0036 / P0037 / P0038

AENJHB0B1114017
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0036: HO2S Heater Control Circuit (Bank1 Sensor2) • HO2S-2 heater and/or its circuit
HO2S-2 heater drive circuit is open. • ECM
(3 D/C detection logic)
P0037: HO2S Heater Control Circuit Low (Bank1 Sensor2)
HO2S-2 heater drive circuit is shorted to ground.
(3 D/C detection logic)
P0038: HO2S Heater Control Circuit High (Bank1 Sensor2)
HO2S-2 heater drive circuit is shorted to power supply.
(3 D/C detection logic)

Circuit Diagram

5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111012-01

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• Battery voltage is higher than 8.5 V.

1) Warm up engine to normal operating temperature.

2) Run engine at idle speed for 1 min.
1A-75 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” • If DTC P0036 and Go to “Engine and
performed? P0037 detected, go Emission Control
to Step 2. System Check”: K15B
• If DTC P0038 (Page 1A-21).
detected, go to Step
4.
2 HO2S-2 heater power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect HO2S-2 connector. defective wiring
harness.
2) Check for proper terminal connection to HO2S-2
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “B1” circuit and ground is
battery voltage.

Is check result OK?

3 HO2S-2 heater drive circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wiring
connectors from ECM. harness.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B4” circuit: less than 1 Ω
• Resistance between “B4” circuit and ground: infinity
• Resistance between “B4” circuit terminal and other
terminal at HO2S-2 connector: infinity

Is check result OK?

4 HO2S-2 heater drive circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wiring
connectors from ECM and HO2S-2 connector. harness.
2) Check for proper terminal connection to “C01” and “E01”
connectors and HO2S-2 connector.
3) If connections are OK, check the following point.
• Voltage of “B4” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 HO2S-2 check Replace ECM and Replace HO2S-2.
1) Check HO2S-2 heater. (Page 1C-9) recheck DTC. (Page (Page 1C-9)
1C-2)
Is check result OK?
 Engine General Information and Diagnosis: K15B 1A-76

DTC P0107 / P0108

AENJHB0B1114018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0107: Manifold Absolute Pressure / Barometric Pressure Circuit Low • MAP sensor and/or its circuit
Output voltage of MAP sensor signal circuit is lower than specified value for • ECM
specified time.
(3 D/C detection logic)
P0108: Manifold Absolute Pressure / Barometric Pressure Circuit High
Output voltage of MAP sensor signal circuit is higher than specified value for
specified time.
(3 D/C detection logic)

Circuit Diagram

1 5V
A1
LT BLU C01-14

A2
BRN C01-27
A3
GRY C01-4

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111013-02

[A]: ECM connector (View: [a]) A3: MAP sensor and ECT sensor ground circuit 3. To ECT sensor ground circuit
A1: MAP sensor power supply circuit 1. MAP sensor
A2: MAP sensor signal circuit 2. ECM

DTC Confirmation Procedure

1) Run engine at idle speed for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 MAP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect MAP sensor connector.
2) Check for proper terminal connection to MAP sensor
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is approx. 5 V.

Is check result OK?

1A-77 Engine General Information and Diagnosis: K15B

Step Action Yes No

3 MAP sensor ground circuit check Repair or replace “A3” Check “A1” circuit.
1) Check that voltage between “A1” and ground is approx. circuit. If defective circuit is
5 V. If this DTC is detected found, repair or replace
again, replace ECM and “A1” circuit.
Is check result OK?
recheck DTC. (Page If circuit is OK, replace
1C-2) ECM and recheck DTC.
(Page 1C-2)
4 MAP sensor signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wiring
connectors from ECM. harness.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at MAP sensor connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 MAP sensor check Replace ECM and Replace MAP sensor.
1) Check MAP sensor. (Page 1C-8) recheck DTC. (Page (Page 1C-7)
1C-2)
Is check result OK?
 Engine General Information and Diagnosis: K15B 1A-78

DTC P0112 / P0113

AENJHB0B1114019
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0112: Intake Air Temperature Sensor1 Circuit Low (Bank1) • IAT sensor and/or its circuit
Output voltage of IAT sensor signal circuit is lower than 0.02 V for 5 sec. • ECM
(3 D/C detection logic)
P0113: Intake Air Temperature Sensor1 Circuit High (Bank1)
Output voltage of IAT sensor signal circuit is higher than 4.9 V for 5 sec.
(3 D/C detection logic)

Circuit Diagram

2
A1 5V
1
YEL C01-22

BEG C01-5
A2

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111014-01

[A]: ECM connector (View: [a]) A2: IAT sensor ground circuit 2. ECM
A1: IAT sensor signal circuit 1. IAT sensor

DTC Confirmation Procedure

NOTE
Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
• ECT sensor (P0116, P0117 and P0118)

1) Run engine at idle speed for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
1A-79 Engine General Information and Diagnosis: K15B

Step Action Yes No

2 IAT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM and IAT sensor connector.
2) Check for proper terminal connection to “C01” and “E01”
connectors and IAT sensor connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and “A2”
circuit terminal at IAT sensor connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 IAT sensor check Replace ECM and Replace IAT sensor.
1) Check IAT sensor. (Page 1C-14) recheck DTC. (Page (Page 1C-13)
1C-2)
Is check result OK?

DTC P0116
AENJHB0B1114020
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0116: Engine Coolant Temperature Sensor1 Circuit Range / Performance • ECT sensor and/or its circuit
Difference between measured ECT and estimated ECT is more than specified • Thermostat
value for specified time with engine running.
• Cooling system
(3 D/C detection logic)
• ECM

Circuit Diagram

2
A1 5V
1
BLU C01-20

GRY C01-4
A2

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111045-01

[A]: ECM connector (View: [a]) A2: MAP sensor and ECT sensor ground circuit 2. ECM
A1: ECT sensor signal circuit 1. ECT sensor 3. To MAP sensor
 Engine General Information and Diagnosis: K15B 1A-80

DTC Confirmation Procedure

NOTE
Check that the following DTC is not detected in this “DTC Confirmation Procedure”.
• ECT sensor (P0118)

1) Warm up engine to normal operating temperature.

2) Run engine at idle speed for 5 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 Coolant level check Go to Step 3. Add coolant and
1) Check coolant level. (Page 1F-10) recheck DTC.

Is check result OK?

3 ECT sensor circuit check Go to Step 4. Repair or replace
1) Check ECT sensor circuits according to Step 2 under defective wire harness.
“DTC P0117 / P0118”: K15B (Page 1A-80).

Is check result OK?

4 ECT sensor check Go to Step 5. Replace ECT sensor.
1) Check ECT sensor. (Page 1C-9) (Page 1C-8)

Is check result OK?

5 Thermostat check Replace ECM and Replace thermostat.
1) Check thermostat. (Page 1F-13) recheck DTC. (Page (Page 1F-12)
1C-2)
Is check result OK?

DTC P0117 / P0118

AENJHB0B1114021
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0117: Engine Coolant Temperature Sensor1 Circuit Low • ECT sensor and/or its circuit
Output voltage of ECT sensor signal circuit is lower than 0.02 V for 5 sec. • ECM
(3 D/C detection logic)
P0118: Engine Coolant Temperature Sensor1 Circuit High
Output voltage of ECT sensor signal circuit is higher than 4.9 V for 5 sec.
(3 D/C detection logic)
1A-81 Engine General Information and Diagnosis: K15B

Circuit Diagram

2
A1 5V
1
BLU C01-20

GRY C01-4
A2

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111045-01

[A]: ECM connector (View: [a]) A2: MAP sensor and ECT sensor ground circuit 2. ECM
A1: ECT sensor signal circuit 1. ECT sensor 3. To MAP sensor ground circuit

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 ECT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM and ECT sensor connector.
2) Check for proper terminal connection to “C01” and “E01”
connectors and ECT sensor connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and “A2”
circuit terminal at ECT sensor connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 ECT sensor check Replace ECM and Replace ECT sensor.
1) Check ECT sensor. (Page 1C-9) recheck DTC. (Page (Page 1C-8)
1C-2)
Is check result OK?
 Engine General Information and Diagnosis: K15B 1A-82

DTC P0122 / P0123

AENJHB0B1114022
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0122: Throttle / Pedal Position Sensor / Switch “A” Circuit Low • TP sensor (main) and/or its circuit
Output voltage of TP sensor (main) signal circuit is lower than 0.2 V. • ECM
(1 D/C detection logic)
P0123: Throttle / Pedal Position Sensor / Switch “A” Circuit High
Output voltage of TP sensor (main) signal circuit is higher than 4.8 V.
(1 D/C detection logic)

Circuit Diagram

5
12V
A1 1
C01-51 LT GRN
4
C01-54 BRN M
5V A2 B1
C01-13 RED
B2 2
C01-26 GRN
B3 3
C01-16 WHT
B4
C01-15 BLK
C01-17 BLK 6

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A110012-01

[A]: ECM connector (View: [a]) B3: TP sensor (sub) signal circuit 4. Throttle actuator
A1: Throttle actuator control circuit (close) B4: TP sensor ground circuit 5. ECM
A2: Throttle actuator control circuit (open) 1. Electric throttle body assembly 6. Shield wire
B1: TP sensor power supply circuit 2. TP sensor (main)
B2: TP sensor (main) signal circuit 3. TP sensor (sub)

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.
2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Release accelerator pedal for 2 sec.
4) Repeat Step 2) – 3) 3 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
1A-83 Engine General Information and Diagnosis: K15B

Step Action Yes No

2 TP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect electric throttle body
assembly connector.
2) Check for proper terminal connection to electric throttle
body assembly connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “B1” and “B4” is approx. 5 V.

Is check result OK?

3 TP sensor ground circuit check Repair or replace “B4” Repair or replace “B1”
1) Check that voltage between “B1” and ground is approx. circuit. circuit.
5 V. If this DTC is detected If this DTC is detected
again, replace ECM and again, replace ECM and
Is check result OK?
recheck DTC. (Page recheck DTC. (Page
1C-2) 1C-2)
4 TP sensor (main) signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at electric throttle body assembly connector:
infinity
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 TP sensor check Replace ECM and Replace electric throttle
1) Check TP sensor referring to “TP Sensor Performance recheck DTC. (Page body assembly. (Page
Check” under “Electric Throttle Body Assembly On- 1C-2) 1D-12)
Vehicle Inspection”: K15B in Section 1C (Page 1C-4).

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-84

DTC P0130
AENJHB0B1114023
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0130: O2 Sensor Circuit (Bank1 Sensor1) • HO2S-1 and/or its circuit
Any of the following conditions is met. • HO2S-2 and/or its circuit
• HO2S-1 signal voltage is between 0.06 V and 0.42 V for • HO2S-1 heater and/or its circuit
30 sec. even if HO2S-2 signal voltage is higher than 0.6 V.
• HO2S-2 heater and/or its circuit
• HO2S-1 signal voltage is between 0.5 V and 1.27 V for 25
• ECM
sec. even if HO2S-2 signal voltage is lower than 0.1 V.
(3 D/C detection logic)

Circuit Diagram

5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111012-01

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.
1A-85 Engine General Information and Diagnosis: K15B

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– A/F feedback (closed loop) control is activated.
– Battery voltage is higher than 11 V.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– HO2S-1 heater (P0030, P0031 and P0032)
– HO2S-2 (P0137, P0138 and P0140)
– Fuel injector (P0201, P0202, P0203, P0204, P0261, P0262, P0264, P0265, P0267, P0268, P0270 and
P0271)

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 50 to 80 km/h (31 to 50 mile/h) constantly for 10 min. or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. (Page 1A-23) for applicable DTC.

Is there any DTC(s) detected other than P0130?

3 HO2S-1 heater, HO2S-1 circuit and HO2S-1 heater circuit Go to Step 4. Repair or replace
check defective parts.
1) Check the following points.
• HO2S-1 heater: (Page 1C-9)
• HO2S-1 circuit: Step 3 under “DTC P0131 / P0132”:
K15B (Page 1A-86)
• HO2S-1 heater circuit: Step 2 – 3 under “DTC P0030 /
P0031 / P0032”: K15B (Page 1A-72)

Is check result OK?

4 HO2S-2 heater, HO2S-2 circuit and HO2S-2 heater circuit Go to Step 5. Repair or replace
check defective parts.
1) Check the following points.
• HO2S-2 heater: (Page 1C-9)
• HO2S-2 circuit: Step 3 under “DTC P0137 / P0138 /
P0140”: K15B (Page 1A-92)
• HO2S-2 heater circuit: Step 2 – 3 under “DTC P0036 /
P0037 / P0038”: K15B (Page 1A-74)

Is check result OK?

5 DTC recheck Go to Step 6. End.
1) Replace HO2S-1. (Page 1C-9)
2) Clear DTC. (Page 1A-24)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is DTC P0130 still detected?

 Engine General Information and Diagnosis: K15B 1A-86

Step Action Yes No

6 DTC recheck Replace ECM and End.
1) Replace HO2S-2. (Page 1C-9) recheck DTC. (Page
1C-2)
2) Clear DTC. (Page 1A-24)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is DTC P0130 still detected?

DTC P0131 / P0132

AENJHB0B1114024
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0131: O2 Sensor Circuit Low Voltage (Bank1 Sensor1) • HO2S-1 and/or its circuit
Output voltage of HO2S-1 circuit is lower than 0.06 V for 30 sec. • ECM
even if output voltage of HO2S-2 circuit is higher than 0.6 V.
(3 D/C detection logic)
P0132: O2 Sensor Circuit High Voltage (Bank1 Sensor1)
Output voltage of HO2S-1 circuit is higher than 1.27 V for 25 sec.
(3 D/C detection logic)

Circuit Diagram

5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111012-01

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
1A-87 Engine General Information and Diagnosis: K15B

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– Battery voltage is higher than 11 V.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– HO2S-1 heater (P0030, P0031 and P0032)
– ECT sensor (P0116, P0117 and P0118)
– HO2S-2 (P0137, P0138 and P0140)
– Fuel injector (P0201, P0202, P0203, P0204, P0261, P0262, P0264, P0265, P0267, P0268, P0270 and
P0271)

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 50 to 80 km/h (31 to 50 mile/h) constantly for 10 min. or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0131 and P0132?
3 HO2S-1 signal and ground circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM and HO2S-1 connector.
2) Check for proper terminal connection to “C01” and “E01”
connectors and HO2S-1 connector.
3) If connections are OK, check the following points.
• Resistance of “A2” and “A3” circuits: less than 1 Ω
• Resistance between each of “A2” and “A3” circuits
and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at HO2S-1 connector: infinity
• Resistance between “A3” circuit terminal and other
terminal at HO2S-1 connector: infinity
• Voltage of “A2” and “A3” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-88

Step Action Yes No

4 DTC recheck Replace ECM and End.
1) Replace HO2S-1. (Page 1C-9) recheck DTC. (Page
1C-2)
2) Clear DTC. (Page 1A-24)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.

Is DTC P0131 and/or P0132 still detected?

DTC P0133
AENJHB0B1114025
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0133: O2 Sensor Circuit Slow Response (Bank1 Sensor1) • HO2S-1 and/ or its circuit
Cycle duration from rich to lean and lean to rich of HO2S-1 is • HO2S-1 heater
longer than specified time.
• Air intake system
(3 D/C detection logic)
• Exhaust system
• Fuel system
• ECM

Circuit Diagram

5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111012-01

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
1A-89 Engine General Information and Diagnosis: K15B

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– A/F feedback (closed loop) control is activated.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– HO2S-1 heater (P0030, P0031 and P0032)
– HO2S-1 (P0130, P0131, P0132 and P0134)
– Fuel trim system (P0171 and P0172)
– Cylinder misfire detected (P0300)
– CKP sensor (P0335)
– CMP sensor (P0340)
– EVAP canister purge valve (P0443, P0458 and P0459)
– System voltage (P0560, P0562 and P0563)

1) Warm up engine to normal operating temperature.

2) With engine speed at 1,600 to 2,500 rpm, drive vehicle at 50 to 80 km/h (31 to 50 mile/h) for 5 min.
3) Check whether O2 sensor readiness / monitoring test has completed or not using scan tool. If O2 sensor
readiness / monitoring test has not completed, check vehicle conditions (environmental) and repeat Step 2) – 3).

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. (Page 1A-23) for applicable DTC.

Is there any DTC(s) other than P0133?

3 Exhaust system and air intake system check Go to Step 4. Repair or replace
1) Check exhaust system and air intake system for defective parts.
clogging or leakage.

Is check result OK?

4 Fuel system inspection Go to Step 5. Repair or replace
1) Check fuel system according to “Fuel System defective parts.
Inspection”: K15B in Section 1G (Page 1G-4).

Is check result OK?

5 HO2S-1 signal circuit check Go to Step 6. Repair or replace
1) Check “A2” and “A3” circuits according to Step 3 under defective wire harness.
“DTC P0131 / P0132”: K15B (Page 1A-86).

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-90

Step Action Yes No

6 HO2S-1 heater check Go to Step 7. Replace HO2S-1.
1) Check HO2S-1 heater. (Page 1C-9) (Page 1C-9)

Is check result OK?

7 DTC recheck Replace ECM and End.
1) Replace HO2S-1. (Page 1C-9) recheck DTC. (Page
1C-2)
2) Clear DTC. (Page 1A-24)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is DTC P0133 still detected?

DTC P0134
AENJHB0B1114026
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0134: O2 Sensor Circuit No Activity Detected (Bank1 Sensor1) • HO2S-1 and/ or its circuit
Output voltage of HO2S-1 circuit stays between 0.42 and 0.5 V for 25 sec. • HO2S-1 heater
(3 D/C detection logic)
• Air intake system
• Exhaust system
• ECM

Circuit Diagram

5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111012-01

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
1A-91 Engine General Information and Diagnosis: K15B

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– Battery voltage is higher than 11 V.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– HO2S-1 heater (P0030, P0031 and P0032)
– Fuel injector (P0201, P0202, P0203, P0204, P0261, P0262, P0264, P0265, P0267, P0268, P0270 and
P0271)

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 50 to 80 km/h (31 to 50 mile/h) constantly for 10 min. or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. (Page 1A-23) for applicable DTC.

Is there any DTC(s) other than P0134?

3 Exhaust system and air intake system check Go to Step 4. Repair or replace
1) Check exhaust system and air intake system for defective part.
clogging or leakage.

Is check result OK?

4 HO2S-1 signal and ground circuit check Go to Step 5. Repair or replace
1) Check “A2” and “A3” circuits according to Step 3 under defective wire harness.
“DTC P0131 / P0132”: K15B (Page 1A-86).

Is check result OK?

5 HO2S-1 heater recheck Go to Step 6. Replace HO2S-1.
1) Check HO2S-1 heater. (Page 1C-9) (Page 1C-9)
2) Clear DTC. (Page 1A-24)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-92

Step Action Yes No

6 DTC recheck Replace ECM and End.
1) Replace HO2S-1. (Page 1C-9) recheck DTC. (Page
1C-2)
2) Clear DTC. (Page 1A-24)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is DTC P0134 still detected?

DTC P0137 / P0138 / P0140

DTC Detecting Condition and Trouble Area
DTC detecting condition
P0137: O2 Sensor Circuit Low Voltage (Bank1 Sensor2)
Output voltage of HO2S-2 circuit is lower than 0.06 V for 30 sec. after warming up. •
(3 D/C detection logic)
P0138: O2 Sensor Circuit High Voltage (Bank1 Sensor2)
Output voltage of HO2S-2 signal circuit is higher than 1.27 V for 25 sec.
(3 D/C detection logic)
P0140: O2 Sensor Circuit No Activity Detected (Bank1 Sensor2)
Output voltage of HO2S-2 circuit stays between 0.42 to 0.50 V for 25 sec.
(3 D/C detection logic)
AENJHB0B1114027
Trouble area
• HO2S-2 and/or its circuit
HO2S-2 heater and/or its circuit
• Exhaust system
• Air intake system
• Fuel system
• ECM

Circuit Diagram

5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111012-01

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
1A-93 Engine General Information and Diagnosis: K15B

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– Battery voltage is higher than 11 V.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– HO2S-2 heater (P0036, P0037 and P0038)

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 50 to 80 km/h (31 to 50 mile/h) constantly for 10 min. or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0137, P0138 and P0140?
3 HO2S-2 signal circuit and ground circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wiring
connectors of ECM and HO2S-2 connector. harness.
2) Check for proper terminal connection to “C01” and “E01”
connectors and HO2S-2 connector.
3) If connections are OK, check the following points.
• Resistance of “B2” and “B3” circuits: less than 1 Ω
• Resistance between each of “B2” and “B3” circuits
and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at HO2S-2 connector: infinity
• Resistance between “B3” circuit terminal and other
terminal at HO2S-2 connector: infinity
• Voltage of “B2” and “B3” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

4 Exhaust system and air intake system check Go to Step 5. Repair or replace
1) Check exhaust system and air intake system for defective part.
clogging or leakage.

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-94

Step Action Yes No

5 HO2S-2 heater circuit check Go to Step 6. Repair or replace
1) Check HO2S-2 heater circuits according to Step 2 – 4 defective part.
under “DTC P0036 / P0037 / P0038”: K15B (Page 1A-
74).

Is check result OK?

6 Fuel injector and its circuit check Go to Step 7. Faulty injector(s) or its
1) Check fuel injector circuit. (Page 1G-5) circuit.
2) Check fuel injectors. (Page 1G-18)

Is check result OK?

7 DTC recheck Replace ECM and End.
1) Replace HO2S-2. (Page 1C-9) recheck DTC. (Page
1C-2)
2) Clear DTC. (Page 1A-24)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is DTC P0137, P0138 or P0140 still detected?

DTC P0171 / P0172

AENJHB0B1114028
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0171: System too Lean (Bank1) • Fuel system
Fuel trim correction is higher than specified value for • Air intake system
specified time under specified vehicle condition.
• Exhaust system
(3 D/C detection logic)
P0172: System too Rich (Bank1) • HO2S-1 and/or its circuit
Fuel trim correction is lower than specified value for • Emission control system
specified time under specified vehicle condition. • ECM
(3 D/C detection logic)
1A-95 Engine General Information and Diagnosis: K15B

Circuit Diagram

5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111012-01

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– A/F feedback (closed loop) control is activated.
– Engine coolant temperature is higher than 70 °C (158 °F).
– Intake air temperature is 75 °C (167 °F) or less.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– IAT sensor (P0112 and P0113)
– ECT sensor (P0116, P0117 and P0118)
– EVAP canister purge valve (P0443, P0458 and P0459)

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 50 to 80 km/h (31 to 50 mile/h) constantly for 10 min. or more.
 Engine General Information and Diagnosis: K15B 1A-96

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. (Page 1A-23) for applicable DTC.

Is there any DTC(s) other than P0171 and P0172?

3 Fuel system and emission control system check Go to Step 4. Repair or replace
1) Check the following points related to fuel and emission defective parts.
control systems.
• Fuel pressure: (Page 1G-9)
• Fuel injector circuit: (Page 1G-5)
• Fuel injector: (Page 1G-18)
• MAP sensor: (Page 1C-8)
• EVAP canister purge valve: (Page 1B-4)
• PCV valve: (Page 1B-7)

Is check result OK?

4 Exhaust system and air intake system check Go to Step 5. Repair or replace
1) Check exhaust system and air intake system for defective parts.
clogging or leakage.

Is check result OK?

5 HO2S-1 signal circuit check Go to Step 6. Repair or replace
1) Check HO2S-1 signal circuits according to Step 3 under defective wire harness.
“DTC P0131 / P0132”: K15B (Page 1A-86).

Is check result OK?

6 DTC recheck Replace ECM and End.
1) Replace HO2S-1. (Page 1C-9) recheck DTC. (Page
1C-2)
2) Clear DTC. (Page 1A-24)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is DTC P0171 or P0172 still detected?

1A-97 Engine General Information and Diagnosis: K15B

DTC P0201 / P0202 / P0203 / P0204 / P0261 / P0262 / P0264 / P0265 / P0267 / P0268 / P0270 / P0271
AENJHB0B1114029
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0201: Injector Circuit / Open – Cylinder1 • Fuel injector and/or its circuit
Fuel injector No.1 and/or its circuit is open with engine running. • ECM
(3 D/C detection logic)
P0202: Injector Circuit / Open – Cylinder2
Fuel injector No.2 and/or its circuit is open with engine running.
(3 D/C detection logic)
P0203: Injector Circuit / Open – Cylinder3
Fuel injector No.3 and/or its circuit is open with engine running.
(3 D/C detection logic)
P0204: Injector Circuit / Open – Cylinder4
Fuel injector No.4 and/or its circuit is open with engine running.
(3 D/C detection logic)
P0261: Cylinder1 Injector Circuit Low
Fuel injector No.1 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P0262: Cylinder1 Injector Circuit High
Fuel injector No.1 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
P0264: Cylinder2 Injector Circuit Low
Fuel injector No.2 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P0265: Cylinder2 Injector Circuit High
Fuel injector No.2 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
P0267: Cylinder3 Injector Circuit Low
Fuel injector No.3 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P0268: Cylinder3 Injector Circuit High
Fuel injector No.3 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
P0270: Cylinder4 Injector Circuit Low
Fuel injector No.4 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P0271: Cylinder4 Injector Circuit High
Fuel injector No.4 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
 Engine General Information and Diagnosis: K15B 1A-98

Circuit Diagram

5 +B

A2 A1 BLU
1
C01-31 PNK

B2 B1
2
C01-11 WHT

C2 C1
3
C01-10 RED

D2 D1
4
C01-12 GRN

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111017-01

[A]: ECM connector (View: [a]) C1: Fuel injector No.3 power supply circuit 2. Fuel injector No.2
A1: Fuel injector No.1 power supply circuit C2: Fuel injector No.3 drive circuit 3. Fuel injector No.3
A2: Fuel injector No.1 drive circuit D1: Fuel injector No.4 power supply circuit 4. Fuel injector No.4
B1: Fuel injector No.2 power supply circuit D2: Fuel injector No.4 drive circuit 5. ECM
B2: Fuel injector No.2 drive circuit 1. Fuel injector No.1

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• Battery voltage is higher than 8.5 V.

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” • If DTC P0201, Go to “Engine and
performed? P0202, P0203, Emission Control
P0204, P0261, System Check”: K15B
P0264, P0267 and (Page 1A-21).
P0270 detected, go
to Step 2.
• If DTC P0262,
P0265, P0268 and
P0271 detected, go
to Step 4.
1A-99 Engine General Information and Diagnosis: K15B

Step Action Yes No

2 Fuel injector power supply circuit check Go to Step 3. Repair or replace
1) When ignition “OFF”, disconnect connector from fuel defective wire harness.
injector related to DTC.
2) Check for proper terminal connection to fuel injector
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1”, “B1”, “C1” or “D1” and
ground is battery voltage.

Is check result OK?

3 Fuel injector drive circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM.
2) Check for proper terminal connections to “C01” and
“E01” connectors.
3) If connections are OK, check the following points.
• Resistance of “A2”, “B2”, “C2” or “D2” circuit: less than
1Ω
• Resistance between each of “A2”, “B2”, “C2” and “D2”
circuit and ground: infinity
• Resistance between “A1” circuit terminal and “A2”
circuit terminal at fuel injector connector: infinity
• Resistance between “B1” circuit terminal and “B2”
circuit terminal at fuel injector connector: infinity
• Resistance between “C1” circuit terminal and “C2”
circuit terminal at fuel injector connector: infinity
• Resistance between “D1” circuit terminal and “D2”
circuit terminal at fuel injector connector: infinity

Is check result OK?

4 Fuel injector drive circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM and fuel injector connector related
to DTC.
2) Check for proper terminal connections to “C01” and
“E01” connectors and fuel injector connector related to
DTC.
3) If connections are OK, check the following point.
• Voltage of “A2”, “B2”, “C2” or “D2” circuit: approx. 0 V
(When ignition is “ON”)

Is check result OK?

5 Fuel injector check Replace ECM and Replace fuel injector
1) Check fuel injector related to DTC. (Page 1G-18) recheck DTC. (Page related to DTC. (Page
1C-2) 1G-16)
Is check result OK?
 Engine General Information and Diagnosis: K15B 1A-100

DTC P0222 / P0223

AENJHB0B1114030
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0222: Throttle / Pedal Position Sensor / Switch “B” Circuit Low • TP sensor (sub) and/or its circuit
Output voltage of TP sensor (sub) signal circuit is lower than 0.2 V. • ECM
(1 D/C detection logic)
P0223: Throttle / Pedal Position Sensor / Switch “B” Circuit High
Output voltage of TP sensor (sub) signal circuit is higher than 4.8 V.
(1 D/C detection logic)

Circuit Diagram

5
12V
A1 1
C01-51 LT GRN
4
C01-54 BRN M
5V A2 B1
C01-13 RED
B2 2
C01-26 GRN
B3 3
C01-16 WHT
B4
C01-15 BLK
C01-17 BLK 6

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A110012-01

[A]: ECM connector (View: [a]) B3: TP sensor (sub) signal circuit 4. Throttle actuator
A1: Throttle actuator control circuit (close) B4: TP sensor ground circuit 5. ECM
A2: Throttle actuator control circuit (open) 1. Electric throttle body assembly 6. Shield wire
B1: TP sensor power supply circuit 2. TP sensor (main)
B2: TP sensor (main) signal circuit 3. TP sensor (sub)

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.
2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Release accelerator pedal for 2 sec.
4) Repeat Step 2) – 3) 3 times.
1A-101 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 TP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect electric throttle body
assembly connector.
2) Check for proper terminal connection to electric throttle
body assembly connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “B1” and “B4” is approx. 5 V.

Is check result OK?

3 TP sensor ground circuit check Repair or replace “B4” Repair or replace “B1”
1) Check that voltage between “B1” and ground is approx. circuit. circuit.
5 V. If this DTC is detected If this DTC is detected
again, replace ECM and again, replace ECM and
Is check result OK?
recheck DTC. (Page recheck DTC. (Page
1C-2) 1C-2)
4 TP sensor (sub) signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B3” circuit: less than 1 Ω
• Resistance between “B3” circuit and ground: infinity
• Resistance between “B3” circuit terminal and other
terminal at electric throttle body assembly connector:
infinity
• Voltage of “B3” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 TP sensor check Replace ECM and Replace electric throttle
1) Check TP sensor referring to “TP Sensor Performance recheck DTC. (Page body assembly. (Page
Check” under “Electric Throttle Body Assembly On- 1C-2) 1D-12)
Vehicle Inspection”: K15B in Section 1C (Page 1C-4).

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-102

DTC P0300 / P0301 / P0302 / P0303 / P0304

AENJHB0B1114031
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0300: Random / Multiple Cylinder Misfire Detected • Exhaust system
Any of the following conditions is met. • Air intake system
• Misfire, which causes catalyst to overheat during 200 engine revolutions, • Ignition system
is detected at 2 or more cylinders. (MIL blinks as long as misfire lasts.)
• Fuel system
• Misfire, which affects exhaust emission adversely during 1,000 engine
• Engine compression
revolutions, is detected at 2 or more cylinders.
(3 D/C detection logic) • Valve clearance
• Valve timing
• ECM
P0301: Cylinder 1 Misfire Detected • Ignition system
P0302: Cylinder 2 Misfire Detected • Engine compression
P0303: Cylinder 3 Misfire Detected
• Valve clearance
P0304: Cylinder 4 Misfire Detected
Any of the following conditions is met. • Fuel injector and/or its circuit
• Misfire, which causes catalyst to overheat during 200 engine revolutions, • ECM
is detected at specific cylinder. (MIL blinks as long as misfire lasts.)
• Misfire, which affects exhaust emission adversely during 1,000 engine
revolutions, is detected at specific cylinder.
(3 D/C detection logic)

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– Engine coolant temperature is higher than –10 °C (14 °F).
– Intake air temperature is –10 °C (14 °F) or more.
– Engine speed is lower than 4,500 rpm.

1) Warm up engine to normal operating temperature.

2) With engine speed at 4,500 rpm or less, drive vehicle at 50 to 80 km/h (31 to 50 mile/h) constantly for 5 min. or
more.
1A-103 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 Fuel level check Add fuel and recheck Go to Step 3.
1) Check fuel level by fuel level meter. DTC.

Does it indicate “E” level (empty)?

3 Fuel quality check Go to Step 4. Replace fuel with
1) Check fuel in fuel tank for smell, color and quality. correct type fuel and
recheck DTC.
Is check result OK?
4 Exhaust system and air intake system check Go to Step 5. Repair or replace
1) Check exhaust system and air intake system for defective parts.
clogging or leakage.

Is check result OK?

5 Ignition system check Go to Step 6. Repair or replace
1) Check ignition system. (Page 1H-4) defective wire harness.

Is check result OK?

6 Fuel system check Go to Step 7. Repair or replace
1) Check the following points related to fuel systems. defective parts.
• Fuel pressure: (Page 1G-9)
• Fuel injector circuit: (Page 1G-5)
• Fuel injector: (Page 1G-18)

Is check result OK?

7 Engine mechanical system check Check ECM power Repair or replace
1) Check the following points which can be cause of rough supply and ground defective parts.
idling or poor performance. circuits. (Page 1A-
162)
• Engine compression: (Page 1D-4)
• Valve clearance: (Page 1D-6) If circuit is OK, replace
ECM and recheck DTC.
• Valve timing: (Page 1D-39) (Page 1C-2)
Is check result OK?
 Engine General Information and Diagnosis: K15B 1A-104

DTC P0327 / P0328

AENJHB0B1114032
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0327: Knock Sensor1 Circuit Low (Bank1 or Single Sensor) • Knock sensor and/or its circuit
Output voltage of knock sensor signal circuit is lower than • ECM
specified value for specified time with engine running.
(3 D/C detection logic)
P0328: Knock Sensor1 Circuit High (Bank1 or Single Sensor)
Output voltage of knock sensor signal circuit is higher than
specified value for specified time with engine running.
(3 D/C detection logic)

Circuit Diagram

2
1 A1
WHT C01-25
B1
BLU C01-37

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111018-01

[A]: ECM connector (View: [a]) B1: Knock sensor signal circuit 2 2. ECM
A1: Knock sensor signal circuit 1 1. Knock sensor

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– Engine coolant temperature is higher than 40 °C (104 °F).

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 80 to 100 km/h (50 to 62 mile/h) or more for 3 min. while engine keeps running at 2,400 rpm or
more. (Keep throttle valve opening constant in this step.)
1A-105 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 Knock sensor signal circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM and knock sensor connector.
2) Check for proper terminal connection to “C01” and “E01”
connectors and knock sensor connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “B1” circuits: less than 1 Ω
• Resistance between each of “A1” and “B1” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and “B1”
circuit terminal at knock sensor connector: infinity
• Voltage of “A1” and “B1” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 Knock sensor check Go to Step 4. Replace knock sensor.
1) Check knock sensor. (Page 1C-12) (Page 1C-12)

Is check result OK?

4 Troubleshooting of other DTC(s) at the same time Go to troubleshooting Replace ECM and
for applicable DTC. recheck DTC. (Page
Is there any DTC(s) detected together? 1C-2)
 Engine General Information and Diagnosis: K15B 1A-106

DTC P0335 / P0336

AENJHB0B1114033
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0335: Crankshaft Position Sensor “A” Circuit • CKP sensor and/or its circuit
CKP sensor signal is not inputted while CMP sensor signal is being inputted. • Sensor plate
(3 D/C detection logic)
• ECM
P0336: Crankshaft Position Sensor “A” Circuit Range / Performance
Any of the following conditions is met.
• Signal detecting time is longer than specification.
• Number of teeth between gaps is more than specification.
• Time between adjacent two teeth is longer than specification.
(3 D/C detection logic)

Circuit Diagram

+B 3
A1 BLU
A2 5V
1
PPL C01-30

A3

B1
B2 5V
2
PNK C01-39
BLK
B3

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHB0A111009-01

[A]: ECM connector (View: [a]) B1: CKP sensor power supply circuit 2. CKP sensor
A1: CMP sensor power supply circuit B2: CKP sensor signal circuit 3. ECM
A2: CMP sensor signal circuit B3: CKP sensor ground circuit
A3: CMP sensor ground circuit 1. CMP sensor

DTC Confirmation Procedure

NOTE
Check that the following DTC is not detected in this “DTC Confirmation Procedure”.
• CMP sensor (P0340)

1) Run engine at idle speed for 5 min.

1A-107 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 CKP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect CKP sensor connector.
2) Check for proper terminal connection to CKP sensor
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “B1” and “B3” is battery
voltage.

Is check result OK?

3 CKP sensor ground circuit check Repair or replace “B3” Repair or replace “B1”
1) Check that voltage between “B1” and ground is battery circuit. circuit.
voltage.

Is check result OK?

4 CKP sensor signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at CKP sensor connector: infinity
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 CKP sensor and sensor plate check Replace ECM and Repair or replace
1) Check CKP sensor and sensor plate. (Page 1C-11) recheck DTC. (Page defective parts.
1C-2)
Is check result OK?
 Engine General Information and Diagnosis: K15B 1A-108

DTC P0340
AENJHB0B1114034
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0340: Camshaft Position Sensor “A” Circuit (Bank1 or Single Sensor) • CMP sensor and/or its circuit
Any of the following conditions is met. • Signal rotor
• CMP sensor signal is not inputted while CKP sensor signal is being inputted. • ECM
• CMP sensor signal pattern is not equal to the expected pattern.
(3 D/C detection logic)

Circuit Diagram

+B 3
A1 BLU
A2 5V
1
PPL C01-30

A3

B1
B2 5V
2
PNK C01-39
BLK
B3

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHB0A111009-01

[A]: ECM connector (View: [a]) B1: CKP sensor power supply circuit 2. CKP sensor
A1: CMP sensor power supply circuit B2: CKP sensor signal circuit 3. ECM
A2: CMP sensor signal circuit B3: CKP sensor ground circuit
A3: CMP sensor ground circuit 1. CMP sensor

DTC Confirmation Procedure

1) Run engine at idle speed for 10 min.
1A-109 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 CMP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect CMP sensor connector.
2) Check for proper terminal connection to CMP sensor
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is battery
voltage.

Is check result OK?

3 CMP sensor ground circuit check Repair or replace “A3” Repair or replace “A1”
1) Check that voltage between “A1” and ground is battery circuit. circuit.
voltage.

Is check result OK?

4 CMP sensor signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at CMP sensor connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 CMP sensor and signal rotor check Replace ECM and Repair or replace
1) Check CMP sensor and signal rotor. recheck DTC. (Page defective parts.
1C-2)
• CMP sensor: (Page 1C-10)
• Signal rotor: (Page 1D-14)

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-110

DTC P0351 / P0352 / P0353 / P0354 / P2300 / P2301 / P2303 / P2304 / P2306 / P2307 / P2309 / P2310
AENJHB0B1114035
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0351: Ignition Coil “A” Primary / Secondary Circuit • Ignition coil assembly and/
Ignition coil assembly No.1 and/or its circuit is open with engine running. or its circuit
(3 D/C detection logic) • ECM
P0352: Ignition Coil “B” Primary / Secondary Circuit
Ignition coil assembly No.2 and/or its circuit is open with engine running.
(3 D/C detection logic)
P0353: Ignition Coil “C” Primary / Secondary Circuit
Ignition coil assembly No.3 and/or its circuit is open with engine running.
(3 D/C detection logic)
P0354: Ignition Coil “D” Primary / Secondary Circuit
Ignition coil assembly No.4 and/or its circuit is open with engine running.
(3 D/C detection logic)
P2300: Ignition Coil “A” Primary Control Circuit Low
Ignition coil assembly No.1 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P2301: Ignition Coil “A” Primary Control Circuit High
Ignition coil assembly No.1 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
P2303: Ignition Coil “B” Primary Control Circuit Low
Ignition coil assembly No.2 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P2304: Ignition Coil “B” Primary Control Circuit High
Ignition coil assembly No.2 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
P2306: Ignition Coil “C” Primary Control Circuit Low
Ignition coil assembly No.3 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P2307: Ignition Coil “C” Primary Control Circuit High
Ignition coil assembly No.3 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
P2309: Ignition Coil “D” Primary Control Circuit Low
Ignition coil assembly No.4 drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P2310: Ignition Coil “D” Primary Control Circuit High
Ignition coil assembly No.4 drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)
1A-111 Engine General Information and Diagnosis: K15B

Circuit Diagram

IG1

5 A1 WHT
1
5V A2
C01-44 BRN
A3 B1
BLK
2
5V B2
C01-33 GRN
B3 C1
BLK 3
5V C2
C01-34 PNK
C3 D1
BLK 4
5V D2
C01-35 LT BLU
D3
BLK

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHB0A111010-01

[A]: ECM connector (View: [a])
A1: Ignition coil assembly No.1 power supply circuit
A2: Ignition coil assembly No.1 drive circuit
A3: Ignition coil assembly No.1 ground circuit
B1: Ignition coil assembly No.2 power supply circuit
B2: Ignition coil assembly No.2 drive circuit
B3: Ignition coil assembly No.2 ground circuit D3: Ignition coil assembly No.4 ground circuit
C1: Ignition coil assembly No.3 power supply circuit 1. Ignition coil assembly No.1
C2: Ignition coil assembly No.3 drive circuit 2. Ignition coil assembly No.2
C3: Ignition coil assembly No.3 ground circuit 3. Ignition coil assembly No.3
D1: Ignition coil assembly No.4 power supply circuit 4. Ignition coil assembly No.4
D2: Ignition coil assembly No.4 drive circuit 5. ECM

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• Battery voltage is higher than 8.5 V.

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” • If DTC P0351, Go to “Engine and
performed? P0352, P0353, Emission Control
P0354, P2300, System Check”: K15B
P2303, P2306 and (Page 1A-21).
P2309 detected, go
to Step 2.
• If DTC P2301,
P2304, P2307 and
P2310 detected, go
to Step 5.
 Engine General Information and Diagnosis: K15B 1A-112

Step Action Yes No

2 Ignition coil assembly power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect connector from ignition
coil assembly related to DTC.
2) Check for proper terminal connection to ignition coil
assembly connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3”, “B1” and
“B3”, “C1” and “C3” or “D1” and “D3” is battery voltage.

Is check result OK?

3 Ignition coil assembly ground circuit check Repair or replace “A3”, Repair or replace “A1”,
1) Check that voltage between “A1”, “B1”, “C1” or “D1” and “B3”, “C3” or “D3” “B1”, “C1” or “D1”
ground is battery voltage. circuit. circuit.

Is check result OK?

4 Ignition coil assembly drive circuit check Go to Step 6. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM.
2) Check for proper terminal connections to “C01” and
“E01” connectors.
3) If connections are OK, check the following points.
• Resistance of “A2”, “B2”, “C2” or “D2” circuit: less than
1Ω
• Resistance between each of “A2”, “B2”, “C2” or “D2”
circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “B2” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “C2” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “D2” circuit terminal and other
terminal at ignition coil connector: infinity

Is check result OK?

5 Ignition coil assembly drive circuit check Go to Step 6. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM and ignition coil assembly
connector related to DTC.
2) Check for proper terminal connections to “C01” and
“E01” connectors and ignition coil assembly connector
related to DTC.
3) If connections are OK, check the following point.
• Voltage of “A2”, “B2”, “C2” or “D2” circuit: approx. 0 V
(When ignition is “ON”)

Is check result OK?

1A-113 Engine General Information and Diagnosis: K15B

Step Action Yes No

6 DTC recheck Replace ECM and End.
1) Replace ignition coil assembly related to DTC with recheck DTC. (Page
normal ignition coil assembly. (Page 1H-8) 1C-2)
2) Clear DTC. (Page 1A-24)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is the same DTC still detected?

DTC P0420
AENJHB0B1114036
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0420: Catalyst System Efficiency Below Threshold (Bank 1) • Fuel system
Average amplitude of HO2S-2 signal is more than specified value • Exhaust system
under specified vehicle condition.
• HO2S-1 and/or its circuit
(3 D/C detection logic)
• HO2S-2 and/or its circuit
• TWC
• ECM

Circuit Diagram

4
5V

RED C01-6
GRN C01-7
1

5V
3

YEL C01-8
BRN C01-19

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0B112017-01

[A]: ECM connector (View: [a]) 2. TWC 4. ECM

1. HO2S-1 3. HO2S-2
 Engine General Information and Diagnosis: K15B 1A-114

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– A/F feedback (closed loop) control is activated.
– Engine coolant temperature at engine start is higher than –9 °C (16 °F).
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– HO2S-1 heater (P0030, P0031 and P0032)
– HO2S-2 heater (P0036, P0037 and P0038)
– TP sensor (P0122, P0123, P0222 and P0223)
– HO2S-1 (P0130, P0131, P0132, P0133 and P0134)
– HO2S-2 (P0137, P0138 and P0140)
– Fuel trim system (P0171 and P0172)
– Cylinder misfire detected (P0300)
– EVAP canister purge valve (P0443, P0458 and P0459)

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 60 to 100 km/h (37 to 62 mile/h) constantly for 10 min. or more at 5th gear (M/T model) or D range
(A/T model). (Keep throttle valve opening constant in this step.)
3) Check whether catalyst readiness / monitoring test has completed or not using scan tool. If catalyst readiness /
monitoring test has not completed, check vehicle conditions (environmental) and repeat Step 2) – 3).

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. (Page 1A-23) for applicable DTC.

Is there any DTC(s) detected other than P0420?

3 Exhaust system check Go to Step 4. Repair or replace
1) Check exhaust system for leakage, damage and defective parts.
looseness.

Is check result OK?

4 HO2S-2 circuit check Go to Step 5. Repair or replace
1) Check HO2S-2 signal and ground circuits according to defective parts.
Step 3 under “DTC P0137 / P0138 / P0140”: K15B
(Page 1A-92).

Is check result OK?

1A-115 Engine General Information and Diagnosis: K15B

Step Action Yes No

5 HO2S-1 signal circuit check Go to Step 6. Repair or replace
1) Check HO2S-1 signal circuits according to Step 3 under defective wire harness.
“DTC P0131 / P0132”: K15B (Page 1A-86).

Is check result OK?

6 DTC recheck Go to Step 7. End.
1) Replace exhaust manifold (incorporating TWC). (Page
1K-3)
2) Clear DTC. (Page 1A-24)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is DTC P0420 still detected?

7 DTC recheck Go to Step 8. End.
1) Replace HO2S-2. (Page 1C-9)
2) Clear DTC. (Page 1A-24)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is DTC P0420 still detected?

8 DTC recheck Replace ECM and End.
1) Replace HO2S-1. (Page 1C-9) recheck DTC. (Page
1C-2)
2) Clear DTC. (Page 1A-24)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is DTC P0420 still detected?

 Engine General Information and Diagnosis: K15B 1A-116

DTC P0443 / P0458 / P0459

AENJHB0B1114037
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0443: Evaporative Emission System Purge Control Valve Circuit • EVAP canister purge valve
EVAP canister purge valve drive circuit is open with engine running. and/or its circuit
(3 D/C detection logic) • ECM
P0458: Evaporative Emission System Purge Control Valve Circuit Low
EVAP canister purge valve drive circuit is shorted to ground with engine running.
(3 D/C detection logic)
P0459: Evaporative Emission System Purge Control Valve Circuit High
EVAP canister purge valve drive circuit is shorted to power supply with engine running.
(3 D/C detection logic)

Circuit Diagram

1 A1
C01-41 GRY 3
B1

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111022-01

[A]: ECM connector (View: [a]) B1: EVAP canister purge valve drive circuit 2. ECM
A1: EVAP canister purge valve power supply circuit 1. EVAP canister purge valve 3. To main relay

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• Battery voltage is higher than 8.5 V.

1) Run engine at idle speed for 10 min.

2) Engine racing more than 3,000 rpm for 5 sec.
1A-117 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” • If DTC P0443 and Go to “Engine and
performed? P0458 detected, go Emission Control
to Step 2. System Check”: K15B
• If DTC P0459 (Page 1A-21).
detected, go to Step
4.
2 EVAP canister purge valve power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect EVAP canister purge defective wire harness.
valve connector.
2) Check for proper terminal connection to EVAP canister
purge valve connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

3 EVAP canister purge valve drive circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and “B1”
circuit terminal at EVAP canister purge valve
connector: infinity

Is check result OK?

4 EVAP canister purge valve drive circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM and EVAP canister purge valve
connector.
2) Check for proper terminal connection to “C01” and “E01”
connectors and EVAP canister purge valve connector.
3) If connections are OK, check the following point.
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 EVAP canister purge valve check Replace ECM and Replace EVAP canister
1) Check EVAP canister purge valve for resistance. recheck DTC. (Page purge valve. (Page
(Page 1B-4) 1C-2) 1B-4)

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-118

DTC P0480 / P0692

AENJHB0B1114038
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0480: Fan1 Control Circuit • Radiator cooling fan relay No.1 and/or
Radiator cooling fan relay No.1 drive circuit is shorted to ground or open. its circuit
(3 D/C detection logic but MIL does not light up) • ECM
P0692: Fan1 Control Circuit High
Radiator cooling fan relay No.1 drive circuit is shorted to power supply.
(3 D/C detection logic but MIL does not light up)

Circuit Diagram

6
7 BLU B1
1
A1
5 LT GRN E01-2
8 GRY
C1 BLU B2
GRN
2 A3 3 GRN E01-27
A2 L+
H+ L-
PNK 4 BLK

C2 H-
LT GRN

C3

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111023-02

[A]: ECM connector (View: [a]) C1: Radiator cooling fan relay No.1 power 4. Radiator cooling fan motor
supply circuit (switch side)
A1: Radiator cooling fan relay No.1 power supply circuit C2: Radiator cooling fan relay No.2 power 5. “RDTR” fuse
(coil side) supply circuit (switch side)
A2: Radiator cooling fan relay No.2 power supply circuit C3: Radiator cooling fan relay No.3 power 6. ECM
(coil side) supply circuit (switch side)
A3: Radiator cooling fan relay No.3 power supply circuit 1. Radiator cooling fan relay No.1 7. To main relay
(coil side)
B1: Radiator cooling fan relay No.1 drive circuit 2. Radiator cooling fan relay No.2 8. To main fuse box
B2: Radiator cooling fan relay No.2 and No.3 drive circuit 3. Radiator cooling fan relay No.3

DTC Confirmation Procedure

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– Battery voltage is higher than 8.5 V.

1) Connect SUZUKI scan tool to DLC.

2) Display “ECT” of “Data List” mode on SUZUKI scan tool.
3) Keep engine at idle speed until engine coolant temperature reaches 97 °C (206.6 °F) or more.
4) Stop engine.
5) Repeat Step 2) – 4) 2 times.
1A-119 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 Radiator cooling fan relay No.1 check • If DTC P0480 Replace radiator cooling
1) Check radiator cooling fan relay No.1. (Page 1F-14) detected, go to Step fan relay No.1.
3.
Is check result OK?
• If DTC P0692
detected, go to Step
5.
3 Radiator cooling fan relay No.1 power supply circuit Go to Step 4. Repair or replace
(coil side) check defective wire harness.
1) With ignition “OFF”, remove radiator cooling fan relay
No.1.
2) Check for proper terminal connection to radiator cooling
fan relay No.1 connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

4 Radiator cooling fan relay No.1 drive circuit check Replace ECM and Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” recheck DTC. (Page defective wire harness.
connectors from ECM. 1C-2)
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at radiator cooling fan relay No.1 connector:
infinity

Is check result OK?

5 Radiator cooling fan relay No.1 drive circuit check Replace ECM and Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” recheck DTC. (Page defective wire harness.
connectors from ECM and remove radiator cooling fan 1C-2)
relay No.1.
2) Check for proper terminal connection to “C01” and “E01”
connectors and radiator cooling fan relay No.1
connector.
3) If connections are OK, check the following point.
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-120

DTC P0481 / P0694

AENJHB0B1114039
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0481: Fan2 Control Circuit • Radiator cooling fan relay No.2 (coil side) and/or its
Radiator cooling fan relay No.2 and/or No.3 drive circuit is circuit
shorted to ground or open. • Radiator cooling fan relay No.3 (coil side) and/or its
(3 D/C detection logic but MIL does not light up) circuit
P0694: Fan2 Control Circuit High
• ECM
Radiator cooling fan relay No.2 and/or No.3 drive circuit is
shorted to power supply.
(3 D/C detection logic but MIL does not light up)

Circuit Diagram

6
7 BLU B1
1
A1
5 LT GRN E01-2
8 GRY
C1 BLU B2
GRN
2 A3 3 GRN E01-27
A2 L+
H+ L-
PNK 4 BLK

C2 H-
LT GRN

C3

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111023-02

[A]: ECM connector (View: [a]) C1: Radiator cooling fan relay No.1 power 4. Radiator cooling fan motor
supply circuit (switch side)
A1: Radiator cooling fan relay No.1 power supply circuit C2: Radiator cooling fan relay No.2 power 5. “RDTR” fuse
(coil side) supply circuit (switch side)
A2: Radiator cooling fan relay No.2 power supply circuit C3: Radiator cooling fan relay No.3 power 6. ECM
(coil side) supply circuit (switch side)
A3: Radiator cooling fan relay No.3 power supply circuit 1. Radiator cooling fan relay No.1 7. To main relay
(coil side)
B1: Radiator cooling fan relay No.1 drive circuit 2. Radiator cooling fan relay No.2 8. To main fuse box
B2: Radiator cooling fan relay No.2 and No.3 drive circuit 3. Radiator cooling fan relay No.3

DTC Confirmation Procedure

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– Battery voltage is higher than 8.5 V.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– Radiator cooling fan relay No.1 (P0480 and P0692)

1) Connect SUZUKI scan tool to DLC.

2) Display “ECT” of “Data List” mode on SUZUKI scan tool.
3) Race engine so that engine coolant temperature reaches 102 °C (215.6 °F) or more.
4) Stop engine.
1A-121 Engine General Information and Diagnosis: K15B

5) Repeat Step 2) – 4) 2 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 Radiator cooling fan relay No.2 and No.3 check • If DTC P0481 Replace radiator cooling
1) Check radiator cooling fan relays No.2 and No.3. detected, go to Step fan relays No.2 and/or
(Page 1F-14) 3. No.3.
• If DTC P0694
Is check result OK?
detected, go to Step
5.
3 Radiator cooling fan relay No.2 and No.3 power supply Go to Step 4. Repair or replace
circuit (coil side) check defective wire harness.
1) With ignition “OFF”, remove radiator cooling fan relays
No.2 and No.3.
2) Check for proper terminal connection to radiator cooling
fan relay No.2 and No.3 connectors.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A2” and “A3”
circuits and ground is battery voltage.

Is check result OK?

4 Radiator cooling fan relay No.2 and No.3 drive circuit Replace ECM and Repair or replace
check recheck DTC. (Page defective wire harness.
1) With ignition “OFF”, disconnect “C01” and “E01” 1C-2)
connectors from ECM.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at drive circuit connector of radiator cooling
fan relay No.2 and No.3: infinity

Is check result OK?

5 Radiator cooling fan relay No.2 and No.3 drive circuit Replace ECM and Repair or replace
check recheck DTC. (Page defective wire harness.
1) With ignition “OFF”, disconnect “C01” and “E01” 1C-2)
connectors from ECM and remove radiator cooling fan
relays No.2 and No.3.
2) Check for proper terminal connection to “C01” and “E01”
connectors and radiator cooling fan relay No.2 and No.3
connectors.
3) If connections are OK, check the following point.
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-122

DTC P0500
AENJHB0B1114040
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0500: Vehicle Speed Sensor “A” • CAN communication line
Any of the following conditions is met. • Wheel speed sensor
• Vehicle speed is slower than 4 km/h (2.5 mile/h) for 13 • ABS / ESP® control module
sec. at fuel cut condition.
• ECM
• Vehicle speed is not inputted by CAN communication.
• Wheel speed sensor error message is received from
ABS / ESP® control module.
(3 D/C detection logic)

Circuit Diagram

3
1

4
7 RED E01-28
WHT E01-29 7
5

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A110014-01

[A]: ECM connector (View: [a]) 3. Left-front wheel speed sensor 6. Right-rear wheel speed sensor
1. ECM 4. Right-front wheel speed sensor 7. CAN driver
2. ABS / ESP® control module 5. Left-rear wheel speed sensor
1A-123 Engine General Information and Diagnosis: K15B

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– Engine coolant temperature is higher than 40 °C (104 °F).
– Engine speed is lower than 4,500 rpm.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– ECT sensor (P0116, P0117 and P0118)
– CKP sensor (P0335)
– CMP sensor (P0340)

1) Warm up engine to normal operating temperature.

2) With engine speed at 4,500 rpm or less, drive vehicle at 60 km/h (37 mile/h) constantly for 1 min. or more at 5th
gear (M/T model) or D range (A/T model). (Keep throttle valve opening constant in this step.)
3) Release accelerator pedal, and keep vehicle coasting for 10 sec. in engine braking condition. (Fuel cut)

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 DTC check Go to troubleshooting Go to Step 3.
for CAN-DTC. (Page
Is there any CAN-DTC detected? 10H-7)
3 DTC check Go to troubleshooting Replace ECM and
1) Check DTC in ABS / ESP® control module. for applicable DTC. recheck DTC. (Page
1C-2)
Is any DTC(s) detected?
 Engine General Information and Diagnosis: K15B 1A-124

DTC P0504
AENJHB0B1114041
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0504: Brake Switch “A”/“B” Correlation • Brake light switch and/or its circuit
Brake light switch signal will not switch to ON or OFF for • ECM
more than specified time.
(1 D/C detection logic)

Circuit Diagram

5 A1 1
A2
PNK
4
2 LT BLU E01-18
B1 3

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHB0A111011-02

[A]: ECM connector (View: [a]) B1: Brake light switch ground circuit 3. Brake light
A1: Brake light switch power supply circuit 1. ECM 4. “STOP” fuse
A2: Brake light switch signal circuit 2. Brake light switch 5. To auxiliary power module (lithium-ion battery)
1A-125 Engine General Information and Diagnosis: K15B

DTC Confirmation Procedure

1) Run engine at idle speed.
2) Depress and release brake pedal 20 times.
3) When depressing or releasing brake pedal, check indication on “Brake Switch” in “Data List” mode on SUZUKI
scan tool.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 Brake light switch power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect brake light switch
connector.
2) Check for proper terminal connection to brake light
switch connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A1” circuit and “B1”
circuit is battery voltage.

Is check result OK?

3 Brake light switch ground circuit check Repair or replace “B1” Check “STOP” fuse has
1) Check that voltage between each of “A1” circuit and circuit. not blown. If check
ground is battery voltage. result is OK, repair or
replace defective wire
Is check result OK? harness.
4 Brake light switch signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between each of “A2” circuit and ground:
infinity
• Resistance between “A2” circuit terminal and other
terminal at brake light switch connector: infinity
• Voltage of “A2” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

5 Brake light switch check Replace ECM and Replace brake light
1) Check brake light switch. (Page 4A-11) recheck DTC. (Page switch. (Page 4A-11)
1C-2)
Is check result OK?
 Engine General Information and Diagnosis: K15B 1A-126

DTC P0530
AENJHB0B1114042
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0530: A/C Refrigerant Pressure Sensor “A” Circuit • A/C refrigerant pressure sensor and/or its circuit
Any of the following conditions is met. • ECM
• Output voltage of A/C refrigerant pressure sensor
signal circuit is lower than 0.15 V.
• Output voltage of A/C refrigerant pressure sensor
signal circuit is higher than 4.93 V.
(3 D/C detection logic but MIL does not light up)

Circuit Diagram

2
A1 5V
BRN E01-14
1 A2 5V

PNK E01-33

A3
BLU E01-9

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A110016-01

[A]: ECM connector (View: [a]) A2: A/C refrigerant pressure sensor signal circuit 1. A/C refrigerant pressure sensor
A1: A/C refrigerant pressure sensor power supply circuit A3: A/C refrigerant pressure sensor ground circuit 2. ECM

DTC Confirmation Procedure

1) Run engine at idle speed for 10 sec.
2) Set A/C ON for 10 sec.
3) Set A/C OFF.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 A/C refrigerant pressure sensor power supply circuit Go to Step 4. Go to Step 3.
check
1) With ignition “OFF”, disconnect A/C refrigerant pressure
sensor connector.
2) Check for proper terminal connection to A/C refrigerant
pressure sensor connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is approx. 5 V.

Is check result OK?

1A-127 Engine General Information and Diagnosis: K15B

Step Action Yes No

3 A/C refrigerant pressure sensor ground circuit check Repair or replace “A3” Repair or replace “A1”
1) Check that voltage between “A1” and ground is approx. circuit. circuit.
5 V. If this DTC is detected If this DTC is detected
again, replace ECM and again, replace ECM and
Is check result OK? recheck DTC. (Page recheck DTC. (Page
1C-2) 1C-2)
4 A/C refrigerant pressure sensor signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at A/C refrigerant pressure sensor connector:
infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 A/C refrigerant pressure sensor check Replace ECM and Replace A/C refrigerant
1) Check A/C refrigerant pressure sensor. recheck DTC. (Page pressure sensor.
1C-2) • Manual single A/C
• Manual single A/C model: (Page 7B-45)
• Manual dual A/C model: (Page 7B-88) model: (Page 7B-
45)
• Auto A/C model: (Page 7B-129)
• Manual dual A/C
Is check result OK? model: (Page 7B-
88)
• Auto A/C model:
(Page 7B-129)

DTC P0560 / P0562 / P0563

AENJHB0B1114043
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0560: System Voltage • ECM power supply circuit and/or ground circuit
Main power supply voltage is lower than 2.54 V for 10 sec. • Charging system
(3 D/C detection logic)
• ECM
P0562: System Voltage Low
Main power supply circuit voltage is lower than 9.8 V for
10 sec. with engine running.
(3 D/C detection logic)
P0563: System Voltage High
Main power supply circuit voltage is higher than 16.5 V for
10 sec. with engine running.
(3 D/C detection logic)
 Engine General Information and Diagnosis: K15B 1A-128

Circuit Diagram

1
A1
2 5V 12V
BRN E01-20 10
3 BEG E01-16 C01-51 LT GRN
BLU E01-19 11
C01-54 BRN M
A2 E1
5V
BLK E01-6 5V
4 C01-13 RED
YEL E01-3 12
WHT E01-5 C01-26 GRN
13
C01-16 WHT
C01-15 BLK
PPL E01-10 12V
5 C01-17 BLK
F1 14 G1 23
5V
B1 E01-49 PNK 15
E01-55 BLU
LT BLU E01-4 F2
3.3V G2
6 BLU E01-48 E01-56 BLU F3
7
PNK E01-47 18
BRN E01-22
19
C1 5V 17
8 5V 16 20
BRN E01-14 E01-1 WHT
PNK E01-33 H1
BLU E01-9 I1 21
D1 5V C01-50 BLK
9 C01-53 BLK 22
LT BLU C01-14 5V I2
BRN C01-27
GRY C01-4

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHB0A111012-01

[A]: ECM connector (View: [a]) I1: ECM ground circuit 1 12. TP sensor (main)
A1: APP sensor (main) power supply circuit I2: ECM ground circuit 2 13. TP sensor (sub)
A2: APP sensor (sub) power supply circuit 1. ECM 14. Main relay
B1: Electric load current sensor and brake stroke sensor 2. APP sensor 15. “FI” fuse
power supply circuit
C1: A/C refrigerant pressure sensor power supply circuit 3. APP sensor (main) 16. “IG” fuse
D1: MAP sensor power supply circuit 4. APP sensor (sub) 17. Ignition switch (ignition switch model)
E1: TP sensor power supply circuit 5. Brake stroke sensor 18. IG12 relay
F1: Main relay drive circuit 6. Electric load current sensor 19. BCM (keyless push start model)
F2: Main power supply circuit 2 7. Battery temperature sensor 20. “KEY” fuse
F3: Main power supply circuit 1 8. A/C refrigerant pressure sensor 21. Main fuse box
G1: Main relay power supply circuit (coil side) 9. MAP sensor 22. Battery
G2: Main relay power supply circuit (switch side) 10. Electric throttle body assembly 23. To auxiliary power module (lithium-ion battery)
H1: Ignition ON signal circuit 11. Throttle actuator

DTC Confirmation Procedure

P0560
1) Set ignition “ON” for 1 min.

P0562 / P0563
1) Run engine at 2,500 rpm or more for 1 min.
1A-129 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 ECM power supply and ground circuit check Go to Step 3. Repair ECM power
1) Check ECM power supply and ground circuits. (Page supply and/or ground
1A-162) circuit.

Is check result OK?

3 Charging system check Replace ECM and Repair or replace
1) Check that charging system is working properly. (Page recheck DTC. (Page defective parts.
1J-3) 1C-2)

Is check result OK?

DTC P0602
AENJHB0B1114044
DTC Detecting Condition and Trouble Area

NOTE
After a reprogramming of ECM is executed, if DTC P0602 is indicated, it is possible that the
reprogramming of ECM is not completed correctly.

DTC detecting condition Trouble area

P0602: Control Module Programming Error • Reprogramming failure of ECM
ECM internal failure (data programming error) • ECM power supply circuit and/or ground circuit
(1 D/C detection logic)
• ECM

DTC Confirmation Procedure

1) Set ignition “ON” for 1 min.

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. (Page 1A-24) trouble. (Page 00-12)
2) Set ignition “OFF”.
3) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is DTC P0602 still detected?

2 ECM reprogramming check Execute reprogramming Go to Step 3.
of ECM correctly again.
Was reprogramming of ECM executed?
3 ECM power and ground circuit check Replace ECM and Repair or replace
1) Check ECM power and ground circuit. (Page 1A-162) recheck DTC. (Page defective wire harness.
1C-2)
Is check result OK?
 Engine General Information and Diagnosis: K15B 1A-130

DTC P0606
AENJHB0B1114045
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0606: Control Module Processor • ECM power supply circuit and/or ground circuit
ECM internal processor failure. • ECM
(3 D/C detection logic)

System Description
Internal control module is installed in ECM.

DTC Confirmation Procedure

NOTE
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– Battery voltage is between 8.5 V and 16.5 V.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– CKP sensor (P0335 and P0336)

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. (Page 1A-24) trouble. (Page 00-12)
2) Set ignition “OFF”.
3) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is DTC P0606 still detected?

2 ECM power and ground circuit check Replace ECM and Repair or replace
1) Check ECM power supply and ground circuits. (Page recheck DTC. (Page defective wire harness.
1A-162) 1C-2)

Is check result OK?

DTC P0607
AENJHB0B1114046
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0607: Control Module Performance • ECM power supply circuit and/or ground circuit
Internal failure in ECM is detected. • ECM
(1 D/C detection logic)

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• Battery voltage is higher than 8 V.

1) Set ignition “ON” for 1 min. or more.

2) Start engine, if possible.
1A-131 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. (Page 1A-24) trouble. (Page 00-12)
2) Set ignition “OFF”.
3) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is DTC P0607 still detected?

2 ECM power supply and ground circuit check Replace ECM and Repair or replace
1) Check ECM power supply circuit and ECM ground recheck DTC. (Page defective wire harness.
circuit. (Page 1A-162) 1C-2)

Is check result OK?

DTC P0645 / P0646 / P0647

AENJHB0B1114047
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0645: A/C Clutch Relay Control Circuit • A/C compressor relay and/or its circuit
A/C compressor relay drive circuit is open. • ECM
(3 D/C detection logic but MIL does not light up)
P0646: A/C Clutch Relay Control Circuit Low
A/C compressor relay drive circuit is shorted to ground.
(3 D/C detection logic but MIL does not light up)
P0647: A/C Clutch Relay Control Circuit High
A/C compressor relay drive circuit is shorted to power supply.
(3 D/C detection logic but MIL does not light up)

Circuit Diagram

B1 1 A1
E01-41 BRN BLU 5

2 4
GRY GRN 6

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A110018-01

[A]: ECM connector (View: [a]) 1. A/C compressor relay 4. “CPRSR” fuse
A1: A/C compressor relay power supply circuit (coil side) 2. A/C compressor 5. To main relay
B1: A/C compressor relay drive circuit 3. ECM 6. To main fuse box
 Engine General Information and Diagnosis: K15B 1A-132

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– Battery voltage is higher than 8.5 V.
– Evaporator temperature is higher than 3 °C (37 °F).
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– ECT sensor (P0117 and P0118)
– A/C refrigerant pressure sensor (P0530)

1) Run engine at idle speed for 10 sec.

2) Set A/C switch ON for 10 sec.
3) Set A/C switch OFF.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 A/C compressor relay check • If DTC P0645 and Replace A/C
1) Check A/C compressor relay. P0646 detected, go compressor relay.
to Step 3.
• Manual single A/C model: (Page 7B-48)
• Manual dual A/C model: (Page 7B-92) • If DTC P0647
detected, go to Step
• Auto A/C model: (Page 7B-134) 5.
Is check result OK?
3 A/C compressor relay power supply circuit (coil side) Go to Step 4. Repair or replace
check defective wire harness.
1) With ignition “OFF”, remove A/C compressor relay.
2) Check for proper terminal connection to A/C compressor
relay connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

4 A/C compressor relay drive circuit check Replace ECM and Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” recheck DTC. (Page defective wire harness.
connectors from ECM. 1C-2)
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at A/C compressor relay connector: infinity

Is check result OK?

1A-133 Engine General Information and Diagnosis: K15B

Step Action Yes No

5 A/C compressor relay drive circuit check Replace ECM and Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” recheck DTC. (Page defective wire harness.
connectors from ECM and remove A/C compressor 1C-2)
relay.
2) Check for proper terminal connection to “C01” and “E01”
connectors and A/C compressor relay connector.
3) If connections are OK, check the following point.
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

DTC P1693
AENJHB0B1114048
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1693: Equipment Information Mismatched • Combination meter
ECM detects incorrect vehicle variant data from ABS / • ABS / ESP® control module
ESP® control module and combination meter.
• ECM
(1 D/C detection logic but MIL does not light up)

DTC Confirmation Procedure

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 DTC check for combination meter Go to Step 3. Go to troubleshooting
1) Check DTC in combination meter. for applicable DTC.

Is check result OK?

3 DTC check for ABS / ESP® control module Go to Step 4. Go to troubleshooting
®
1) Check DTC in ABS / ESP control module. for applicable DTC.
• ABS: (Page 4E-14)
• ESP®: (Page 4F-14)

Is check result OK?

4 Combination meter specification check Go to Step 5. Replace combination
1) Perform “Warning Light Check”. meter and recheck
DTC. (Page 9C-34)
• ABS: (Page 4E-14)
• ESP®: (Page 4F-13)

Is check result OK?

5 ABS / ESP® control module specification check Replace ECM and Replace ABS / ESP®
1) Check that ABS / ESP® control module with the correct recheck DTC. (Page control module and
part number is installed. 1C-2) recheck DTC.
• ABS: (Page 4E-38)
Is check result OK?
• ESP®: (Page 4F-
56)
 Engine General Information and Diagnosis: K15B 1A-134

DTC P2100
AENJHB0B1114049
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2100: Throttle Actuator “A” Control Motor Circuit / Open • Throttle actuator and/or its circuit
Throttle actuator and/or its circuit malfunction (open, short to • ECM
power supply or short to ground) is detected.
(1 D/C detection logic)

Circuit Diagram

5
12V
A1 1
C01-51 LT GRN
4
C01-54 BRN M
5V A2 B1
C01-13 RED
B2 2
C01-26 GRN
B3 3
C01-16 WHT
B4
C01-15 BLK
C01-17 BLK 6

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A110012-01

[A]: ECM connector (View: [a]) B3: TP sensor (sub) signal circuit 4. Throttle actuator
A1: Throttle actuator control circuit (close) B4: TP sensor ground circuit 5. ECM
A2: Throttle actuator control circuit (open) 1. Electric throttle body assembly 6. Shield wire
B1: TP sensor power supply circuit 2. TP sensor (main)
B2: TP sensor (main) signal circuit 3. TP sensor (sub)

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Release accelerator pedal for 2 sec.
4) Repeat Step 2) – 3) 3 times.
1A-135 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 Throttle actuator drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM and electric throttle body assembly
connector.
2) Check for proper terminal connection to “C01” and “E01”
connectors and electric throttle body assembly
connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at electric throttle body assembly connector:
infinity
• Resistance between “A2” circuit terminal and other
terminal at electric throttle body assembly connector:
infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 Electric throttle body assembly check Replace ECM and Replace electric throttle
1) Check electric throttle body assembly for performance. recheck DTC. (Page body assembly. (Page
(Page 1C-4) 1C-2) 1D-12)

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-136

DTC P2101 / P2119

AENJHB0B1114050
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2101: Throttle Actuator “A” Control Motor Circuit Range / Performance • Throttle actuator and/or its circuit
Any of the following conditions is met. • Electric throttle body assembly
• Difference between measured throttle valve position and targeted throttle • ECM
valve position is more than specified value.
• Duty ratio of throttle actuator signal is out of specified range for specified time.
(1 D/C detection logic)
P2119: Throttle Actuator Control Throttle Body Range / Performance
Any of the following conditions is met.
• Time taken by throttle valve to return from partially open position to
mechanical default position is more than specified time during return spring
check process after setting ignition “OFF”.
• Measured default throttle position is out of specified range.
(1 D/C detection logic)

Circuit Diagram

5
12V
A1 1
C01-51 LT GRN
4
C01-54 BRN M
5V A2 B1
C01-13 RED
B2 2
C01-26 GRN
B3 3
C01-16 WHT
B4
C01-15 BLK
C01-17 BLK 6

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A110012-01

[A]: ECM connector (View: [a]) B3: TP sensor (sub) signal circuit 4. Throttle actuator
A1: Throttle actuator control circuit (close) B4: TP sensor ground circuit 5. ECM
A2: Throttle actuator control circuit (open) 1. Electric throttle body assembly 6. Shield wire
B1: TP sensor power supply circuit 2. TP sensor (main)
B2: TP sensor (main) signal circuit 3. TP sensor (sub)
1A-137 Engine General Information and Diagnosis: K15B

DTC Confirmation Procedure

P2101

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• Battery voltage is higher than 8 V.

1) Set ignition “ON”.

2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Release accelerator pedal for 2 sec.
4) Set ignition “OFF” for 1 min. and then set ignition “ON”.

P2119

NOTE
Check that the following conditions are met in this “DTC Confirmation Procedure”.
• Battery voltage is higher than 10 V.
• Engine coolant temperature is higher than 6 °C (43 °F) and lower than 100 °C (212 °F).
• Intake air temperature is higher than 6 °C (43 °F).

1) Set ignition “ON”.

2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Release accelerator pedal for 2 sec.
4) Set ignition “OFF” for 1 min. and then set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 DTC recheck Go to Step 3. End.
1) Clear DTC. (Page 1A-24)
2) Perform electric throttle control system calibration.
(Page 1C-5)
3) Recheck DTC. (Page 1A-23)

Is DTC P2101 / P2119 still detected?

3 Throttle actuator drive circuit check Go to Step 4. Repair or replace
1) Check “A1” and “A2” circuits according to Step 2 under defective wire harness.
“DTC P2100”: K15B (Page 1A-134).

Is check result OK?

4 Electric throttle body assembly check Replace ECM and Replace electric throttle
1) Check electric throttle body assembly for performance. recheck DTC. (Page body assembly. (Page
(Page 1C-4) 1C-2) 1D-12)

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-138

DTC P2122 / P2123

AENJHB0B1114051
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2122: Throttle / Pedal Position Sensor / Switch “D” Circuit Low • APP sensor (main) and/or its circuit
Output voltage of APP sensor (main) signal circuit is lower than 0.4 V. • ECM
(1 D/C detection logic)
P2123: Throttle / Pedal Position Sensor / Switch “D” Circuit High
Output voltage of APP sensor (main) signal circuit is higher than 4.8 V.
(1 D/C detection logic)

Circuit Diagram

4
1
A1 5V
BRN E01-20
A2
2 BEG E01-16
A3
BLU E01-19
B1 5V
BLK E01-6
B2
3 YEL E01-3
B3
WHT E01-5

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111030-01

[A]: ECM connector (View: [a]) B1: APP sensor (sub) power supply circuit 2. APP sensor (main)
A1: APP sensor (main) power supply circuit B2: APP sensor (sub) signal circuit 3. APP sensor (sub)
A2: APP sensor (main) signal circuit B3: APP sensor (sub) ground circuit 4. ECM
A3: APP sensor (main) ground circuit 1. APP sensor

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• Battery voltage is higher than 8 V.

1) Set ignition “ON” for 10 sec.

1A-139 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 Accelerator pedal assembly (incorporating APP sensor) Go to Step 3. Reinstall accelerator
mounting check pedal assembly
1) Check that accelerator pedal assembly (incorporating (incorporating APP
APP sensor) has been mounted to vehicle body properly sensor) properly.
(no pinched floor carpet, etc.). (Page 1C-7)

Is check result OK?

3 APP sensor (main) power supply circuit check Go to Step 5. Go to Step 4.
1) With ignition “OFF”, disconnect APP sensor connector.
2) Check for proper terminal connection to APP sensor
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is approx. 5 V.

Is check result OK?

4 APP sensor (main) ground circuit check Repair or replace “A3” Repair or replace “A1”
1) Check that voltage between “A1” and ground is approx. circuit. circuit.
5 V. If this DTC is detected If this DTC is detected
again, replace ECM and again, replace ECM and
Is check result OK?
recheck DTC. (Page recheck DTC. (Page
1C-2) 1C-2)
5 APP sensor (main) signal circuit check Go to Step 6. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at APP sensor connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

6 APP sensor check Replace ECM and Replace accelerator
1) Check APP sensor. (Page 1C-6) recheck DTC. (Page pedal assembly
1C-2) (incorporating APP
Is check result OK? sensor). (Page 1C-7)
 Engine General Information and Diagnosis: K15B 1A-140

DTC P2127 / P2128

AENJHB0B1114052
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2127: Throttle / Pedal Position Sensor / Switch “E” Circuit Low • APP sensor (sub) and/or its circuit
Output voltage of APP sensor (sub) signal circuit is lower than 0.2 V. • ECM
(1 D/C detection logic)
P2128: Throttle / Pedal Position Sensor / Switch “E” Circuit High
Output voltage of APP sensor (sub) signal circuit is higher than 2.4 V.
(1 D/C detection logic)

Circuit Diagram

4
1
A1 5V
BRN E01-20
A2
2 BEG E01-16
A3
BLU E01-19
B1 5V
BLK E01-6
B2
3 YEL E01-3
B3
WHT E01-5

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111030-01

[A]: ECM connector (View: [a]) B1: APP sensor (sub) power supply circuit 2. APP sensor (main)
A1: APP sensor (main) power supply circuit B2: APP sensor (sub) signal circuit 3. APP sensor (sub)
A2: APP sensor (main) signal circuit B3: APP sensor (sub) ground circuit 4. ECM
A3: APP sensor (main) ground circuit 1. APP sensor

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• Battery voltage is higher than 8 V.

1) Set ignition “ON” for 10 sec.

1A-141 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 Accelerator pedal assembly (incorporating APP sensor) Go to Step 3. Reinstall accelerator
mounting check pedal assembly
1) Check that accelerator pedal assembly (incorporating (incorporating APP
APP sensor) has been mounted to vehicle body properly sensor) properly.
(no pinched floor carpet, etc.). (Page 1C-7)

Is check result OK?

3 APP sensor (sub) power supply circuit check Go to Step 5. Go to Step 4.
1) With ignition “OFF”, disconnect APP sensor connector.
2) Check for proper terminal connection to APP sensor
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “B1” and “B3” is approx. 5 V.

Is check result OK?

4 APP sensor (sub) ground circuit check Repair or replace “B3” Repair or replace “B1”
1) Check that voltage between “B1” and ground is approx. circuit. circuit.
5 V. If this DTC is detected If this DTC is detected
again, replace ECM and again, replace ECM and
Is check result OK?
recheck DTC. (Page recheck DTC. (Page
1C-2) 1C-2)
5 APP sensor (sub) signal circuit check Go to Step 6. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at APP sensor connector: infinity
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

6 APP sensor check Replace ECM and Replace accelerator
1) Check APP sensor. (Page 1C-6) recheck DTC. (Page pedal assembly
1C-2) (incorporating APP
Is check result OK? sensor). (Page 1C-7)
 Engine General Information and Diagnosis: K15B 1A-142

DTC P2135
AENJHB0B1114053
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2135: Throttle / Pedal Position Sensor / Switch “A” / “B” • TP sensor and/or its circuit
Voltage Correlation • Electric throttle body assembly
Difference between TP sensor (main) signal voltage and TP
• ECM
sensor (sub) signal voltage is higher than specified value.
(1 D/C detection logic)

Circuit Diagram

5
12V
A1 1
C01-51 LT GRN
4
C01-54 BRN M
5V A2 B1
C01-13 RED
B2 2
C01-26 GRN
B3 3
C01-16 WHT
B4
C01-15 BLK
C01-17 BLK 6

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A110012-01

[A]: ECM connector (View: [a]) B3: TP sensor (sub) signal circuit 4. Throttle actuator
A1: Throttle actuator control circuit (close) B4: TP sensor ground circuit 5. ECM
A2: Throttle actuator control circuit (open) 1. Electric throttle body assembly 6. Shield wire
B1: TP sensor power supply circuit 2. TP sensor (main)
B2: TP sensor (main) signal circuit 3. TP sensor (sub)

DTC Confirmation Procedure

NOTE
Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
• TP sensor (P0122, P0123, P0222 and P0223)

1) Set ignition “ON” for 10 sec.

2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Release accelerator pedal for 2 sec.
4) Repeat Step 2) – 3) 3 times.
1A-143 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 Wire harness check Go to Step 3. Repair or replace
1) Check the following points. defective wire harness.
• “B1”, “B2” and “B4” circuits: Refer to Step 2 – 4 under
“DTC P0122 / P0123”: K15B (Page 1A-82).
• “B3” circuit: Refer to Step 4 under “DTC P0222 /
P0223”: K15B (Page 1A-100).

Is check result OK?

3 TP sensor check Replace ECM and Replace electric throttle
1) Check TP sensor referring to “TP Sensor Performance recheck DTC. (Page body assembly. (Page
Check” under “Electric Throttle Body Assembly On- 1C-2) 1D-12)
Vehicle Inspection”: K15B in Section 1C (Page 1C-4).

Is check result OK?

DTC P2138
AENJHB0B1114054
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2138: Throttle / Pedal Position Sensor / Switch “D” / “E” Voltage Correlation • APP sensor and/or its circuit
Difference between half of APP (main) sensor signal and APP (sub) sensor signal • ECM
is more than specified value.
(1 D/C detection logic)

Circuit Diagram

4
1
A1 5V
BRN E01-20
A2
2 BEG E01-16
A3
BLU E01-19
B1 5V
BLK E01-6
B2
3 YEL E01-3
B3
WHT E01-5

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111030-01

[A]: ECM connector (View: [a]) B1: APP sensor (sub) power supply circuit 2. APP sensor (main)
A1: APP sensor (main) power supply circuit B2: APP sensor (sub) signal circuit 3. APP sensor (sub)
A2: APP sensor (main) signal circuit B3: APP sensor (sub) ground circuit 4. ECM
A3: APP sensor (main) ground circuit 1. APP sensor
 Engine General Information and Diagnosis: K15B 1A-144

DTC Confirmation Procedure

NOTE
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– System voltage is higher than 8 V.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– APP sensor (P2122, P2123, P2127 and P2128)

1) Set ignition “ON”.

2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Release accelerator pedal for 2 sec.
4) Repeat Step 2) – 3) 3 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 Wire harness check Go to Step 3. Repair or replace
1) Check the following points. defective wire harness.
• “A1”, “A2” and “A3” circuits: Refer to Step 3 – 5 under
“DTC P2122 / P2123”: K15B (Page 1A-138).
• “B1”, “B2” and “B3” circuits: Refer to Step 3 – 5 under
“DTC P2127 / P2128”: K15B (Page 1A-140).

Is check result OK?

3 APP sensor check Replace ECM and Replace accelerator
1) Check APP sensor. (Page 1C-6) recheck DTC. (Page pedal assembly
1C-2) (incorporating APP
Is check result OK? sensor). (Page 1C-7)
1A-145 Engine General Information and Diagnosis: K15B

DTC P2176
AENJHB0B1114055
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2176: Throttle Actuator Control System – Idle Position Not Learned • TP sensor and/or its circuit
Any of the following conditions is met. • Electric throttle body assembly
• TP sensor (main) or TP sensor (sub) signal voltage at default position is • ECM
out of specified range for specified time.
• Electric throttle control system calibration is not completed.
(1 D/C detection logic)

Circuit Diagram

5
12V
A1 1
C01-51 LT GRN
4
C01-54 BRN M
5V A2 B1
C01-13 RED
B2 2
C01-26 GRN
B3 3
C01-16 WHT
B4
C01-15 BLK
C01-17 BLK 6

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A110012-01

[A]: ECM connector (View: [a]) B3: TP sensor (sub) signal circuit 4. Throttle actuator
A1: Throttle actuator control circuit (close) B4: TP sensor ground circuit 5. ECM
A2: Throttle actuator control circuit (open) 1. Electric throttle body assembly 6. Shield wire
B1: TP sensor power supply circuit 2. TP sensor (main)
B2: TP sensor (main) signal circuit 3. TP sensor (sub)
 Engine General Information and Diagnosis: K15B 1A-146

DTC Confirmation Procedure

NOTE
Check that the following conditions are met in this “DTC Confirmation Procedure”.
• Battery voltage is higher than 10 V.
• Engine coolant temperature is higher than 6 °C (43 °F) and lower than 100 °C (212 °F).
• Intake air temperature is higher than 6 °C (43 °F).

1) Set ignition “ON” with accelerator pedal released for 1 min.

2) Set ignition “OFF”.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 Electric throttle control system calibration Go to Step 3. End.
1) Perform electric throttle control system calibration.
(Page 1C-5)
2) Clear DTC. (Page 1A-24)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is DTC P2176 still detected?

3 Wire harness check Go to Step 4. Repair or replace
1) Check the following points. defective wire harness.
• “B1”, “B2” and “B4” circuits: Refer to Step 2 – 4 under
“DTC P0122 / P0123”: K15B (Page 1A-82).
• “B3” circuit: Refer to Step 4 under “DTC P0222 /
P0223”: K15B (Page 1A-100).

Is check result OK?

4 TP sensor check Replace ECM and Replace electric throttle
1) Check TP sensor referring to “TP Sensor Performance recheck DTC. (Page body assembly. (Page
Check” under “Electric Throttle Body Assembly On- 1C-2) 1D-12)
Vehicle Inspection”: K15B in Section 1C (Page 1C-4).

Is check result OK?

1A-147 Engine General Information and Diagnosis: K15B

DTC P2226 / P2227

AENJHB0B1114056
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2226: Barometric Pressure Sensor “A” Circuit Barometric pressure sensor in ECM
Barometric pressure sensor and/or its circuit malfunction (open, short to
power supply or short to ground) is detected.
(3 D/C detection logic)
P2227: Barometric Pressure Sensor “A” Circuit Range / Performance
Any of the following conditions is met.
• Sensor signal is out of specified range.
• Difference between actual and expected ambient pressure is more than
the specified value and the fluctuation of ambient pressure is more than
the specified value.
(3 D/C detection logic)

DTC Confirmation Procedure

P2226
1) Set ignition “ON” for 10 sec.

P2227
1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 ECM power supply and ground circuit check Replace ECM and Repair ECM power
1) Check ECM power supply and ground circuits. (Page recheck DTC. (Page supply and ground
1A-162) 1C-2) circuits.

Is check result OK?

DTC P2271
AENJHB0B1114057
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2271: O2 Sensor Signal Biased / Stuck Rich (Bank 1 • HO2S-2 and/or its circuit
Sensor 2) • Exhaust system
Output voltage of HO2S-2 signal circuit is higher than 0.3
• Air intake system
V for specified time after warming up even when vehicle is
in fuel cut driving condition. • Fuel system
(3 D/C detection logic) • Engine compression
• Ignition system
• Emission control system
• ECM
 Engine General Information and Diagnosis: K15B 1A-148

Circuit Diagram

5V
+B 1 4 A3
RED C01-6
A2
GRN C01-7
A4
BLU PPL C01-49
A1 LT GRN C01-55
5V
2 4 B3
YEL C01-8
B2
BRN C01-19
B4
BLU RED C01-52
B1 BEG C01-56

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IFRA0A111012-01

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– Battery voltage is higher than 10.7 V.
– A/F feedback (closed loop) control is activated.
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– HO2S-2 (P0137, P0138 and P0140)
– Cylinder misfire detected (P0300, P0301, P0302, P0303 and P0304)
– EVAP canister purge valve (P0443, P0458 and P0459)

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 60 to 80 km/h (37 to 50 mile/h) for 10 min. or more.
3) Release accelerator pedal at vehicle speed of 60 km/h (37 mile/h) and let vehicle coast under effect of engine
braking to produce fuel cut condition.
4) Repeat Step 2) – 3) 5 times.
1A-149 Engine General Information and Diagnosis: K15B

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B
(Page 1A-21).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. (Page 1A-23) for applicable DTC.

Is there any DTC(s) other than P2271?

3 Exhaust system and air intake system check Go to Step 4. Repair or replace
1) Check exhaust system and air intake system for defective parts.
clogging or leakage.

Is check result OK?

4 HO2S-2 signal and ground circuit check Go to Step 5. Repair or replace
1) Check “B2” and “B3” circuits according to Step 3 under defective parts.
“DTC P0137 / P0138 / P0140”: K15B (Page 1A-92).

Is check result OK?

5 Engine mechanical system check Go to Step 6. Repair or replace
1) Check the following points related to engine mechanical defective parts.
system.
• Engine compression: (Page 1D-4)
• Spark plug: (Page 1H-6)

Is check result OK?

6 Fuel system and emission control system check Go to Step 7. Repair or replace
1) Check the following points related to fuel and emission defective parts.
control systems.
• Fuel pressure: (Page 1G-9)
• Fuel injector circuit: (Page 1G-5)
• Fuel injector: (Page 1G-18)
• MAP sensor: (Page 1C-8)
• EVAP canister purge valve: (Page 1B-4)
• PCV valve: (Page 1B-7)

Is check result OK?

7 DTC recheck Replace ECM and End.
1) Replace HO2S-2. (Page 1C-9) recheck DTC. (Page
1C-2)
2) Clear DTC. (Page 1A-24)
3) Set ignition “OFF”.
4) Perform “DTC Confirmation Procedure” and check DTC.
(Page 1A-23)

Is DTC P2271 still detected?

DTC U0073 DTC U0121

AENJHB0B1114058 AENJHB0B1114060
Refer to “Troubleshooting for Communication Bus Off”: Refer to “Troubleshooting for Lost Communication”:
K15B Model in Section 10H (Page 10H-17). K15B Model in Section 10H (Page 10H-10).

DTC U0101 DTC U0131

AENJHB0B1114059 AENJHB0B1114061
Refer to “Troubleshooting for Lost Communication”: Refer to “Troubleshooting for Lost Communication”:
K15B Model in Section 10H (Page 10H-10). K15B Model in Section 10H (Page 10H-10).
 Engine General Information and Diagnosis: K15B 1A-150

DTC U0140 DTC U108C

AENJHB0B1114062 AENJHB0B1114064
Refer to “Troubleshooting for Lost Communication”: Refer to “Troubleshooting for Lost Communication”:
K15B Model in Section 10H (Page 10H-10). K15B Model in Section 10H (Page 10H-10).

DTC U0155 DTC U108E

AENJHB0B1114063 AENJHB0B1114065
Refer to “Troubleshooting for Lost Communication”: Refer to “Troubleshooting for Lost Communication”:
K15B Model in Section 10H (Page 10H-10). K15B Model in Section 10H (Page 10H-10).

Inspection of ECM and Its Circuits

AENJHB0B1114066
Voltage Check

NOTE
• As each terminal voltage is affected by battery voltage, check that battery voltage is 12 V or more
when ignition is “ON”.
• Voltage with asterisk (*) cannot be measured with voltmeter because it is pulse signal. Use
oscilloscope for its check.
• Before performing this inspection, read “Precautions for ECM Circuit Inspection” under
“Precautions for Engine (K15B)” in Section 1 (Page 1-1).

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IBP60B110007-01

[A]: ECM connector (View: [a])

“C01” connector
Terminal No. Wire color Circuit Normal voltage Condition
C01-1 — — — —
CAN (low) Refer to reference waveform.
C01-2* WHT
communication circuit “CAN communication signal”: K15B (Page 1A-161)
CAN (high) Refer to reference waveform.
C01-3* RED
communication circuit “CAN communication signal”: K15B (Page 1A-161)
MAP sensor and ECT
C01-4 GRY Below 0.3 V Ignition: “ON”
sensor ground circuit
C01-5 BEG IAT sensor ground circuit Below 0.3 V Ignition: “ON”
C01-6 RED HO2S-1 ground circuit Below 0.3 V Ignition: “ON”
Refer to reference waveform.
C01-7* GRN HO2S-1 signal circuit
“HO2S-1 signal”: K15B (Page 1A-158)
C01-8 YEL HO2S-2 ground circuit Below 0.3 V Ignition: “ON”
C01-9 — — — —
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.3 drive
C01-10* RED • “Fuel injector signal”: K15B (Page 1A-156)
circuit
• “Fuel injector No.3 signal and ignition coil No.3 signal”:
K15B (Page 1A-157)
1A-151 Engine General Information and Diagnosis: K15B

Terminal No. Wire color Circuit Normal voltage Condition

10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.2 drive
C01-11* WHT • “Fuel injector signal”: K15B (Page 1A-156)
circuit
• “Fuel injector No.2 signal and ignition coil No.2 signal”:
K15B (Page 1A-156)
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.4 drive
C01-12* GRN • “Fuel injector signal”: K15B (Page 1A-156)
circuit
• “Fuel injector No.4 signal and ignition coil No.4 signal”:
K15B (Page 1A-157)
TP sensor power supply
C01-13 RED 4.5 to 5.5 V Ignition: “ON”
circuit
MAP sensor power
C01-14 LT BLU 4.5 to 5.5 V Ignition: “ON”
supply circuit
C01-15 BLK TP sensor ground circuit Below 0.3 V Ignition: “ON”
Ignition: “ON”
4.0 to 4.2 V
Accelerator pedal: Released
TP sensor (sub) signal
C01-16 WHT Ignition: “ON”
circuit
0.5 to 0.7 V Accelerator pedal: Fully
depressed
TP sensor shield ground
C01-17 BLK Below 0.3 V Ignition: “ON”
circuit
C01-18 — — — —
Refer to reference waveform.
C01-19* BRN HO2S-2 signal circuit
“HO2S-2 signal”: K15B (Page 1A-158)
Ignition: “ON”
3.2 to 3.6 V
ECT: 0 °C (32 °F)
Ignition: “ON”
C01-20 BLU ECT sensor signal circuit 1.0 to 1.4 V
ECT: 50 °C (122 °F)
Ignition: “ON”
0.2 to 0.5 V
ECT: 100 °C (212 °F)
C01-21 — — — —
Ignition: “ON”
3.2 to 3.6 V
IAT: 0 °C (32 °F)
Ignition: “ON”
C01-22 YEL IAT sensor signal circuit 1.3 to 1.7 V
IAT: 40 °C (104 °F)
Ignition: “ON”
0.4 to 0.8 V
IAT: 80 °C (176 °F)
C01-23 — — — —
C01-24 — — — —
1 to 2 V Engine: Idle speed
Knock sensor signal
C01-25* WHT Refer to reference waveform.
circuit 1
“Knock sensor signal”: K15B (Page 1A-159)
Ignition: “ON”
0.8 to 1.0 V
Accelerator pedal: Released
TP sensor (main) signal
C01-26 GRN Ignition: “ON”
circuit
4.3 to 4.5 V Accelerator pedal: Fully
depressed
4.0 to 4.2 V Ignition: “ON”
Engine: Idle speed after
warming up
1.5 to 1.8 V
C01-27* BRN MAP sensor signal circuit Barometric pressure: 100
kPa, 760 mmHg
Refer to reference waveform.
“MAP sensor signal”: K15B (Page 1A-160)
C01-28 — — — —
C01-29 — — — —
 Engine General Information and Diagnosis: K15B 1A-152

Terminal No. Wire color Circuit Normal voltage Condition

Approx. 0 V or 4 to 5 V Ignition: “ON”
Refer to reference waveform.
C01-30* PPL CMP sensor signal circuit
“CMP sensor signal and CKP sensor signal”: K15B (Page
1A-159)
10 to 14 V Ignition: “ON”
Refer to reference waveform.
Fuel injector No.1 drive
C01-31* PNK • “Fuel injector signal”: K15B (Page 1A-156)
circuit
• “Fuel injector No.1 signal and ignition coil No.1 signal”:
K15B (Page 1A-156)
C01-32 — — — —
Approx. 0 V Ignition: “ON”
Refer to reference waveform.
Ignition coil No.2 drive
C01-33* GRN • “Ignition coil signal”: K15B (Page 1A-158)
circuit
• “Fuel injector No.2 signal and ignition coil No.2 signal”:
K15B (Page 1A-156)
Approx. 0 V Ignition: “ON”
Refer to reference waveform.
Ignition coil No.3 drive
C01-34* PNK • “Ignition coil signal”: K15B (Page 1A-158)
circuit
• “Fuel injector No.3 signal and ignition coil No.3 signal”:
K15B (Page 1A-157)
Approx. 0 V Ignition: “ON”
Refer to reference waveform.
Ignition coil No.4 drive
C01-35* LT BLU • “Ignition coil signal”: K15B (Page 1A-158)
circuit
• “Fuel injector No.4 signal and ignition coil No.4 signal”:
K15B (Page 1A-157)
C01-36 — — — —
1 to 2 V Engine: Idle speed
Knock sensor signal
C01-37* BLU Refer to reference waveform.
circuit 2
“Knock sensor signal”: K15B (Page 1A-159)
C01-38 — — — —
Approx. 0 V or 4 to 5 V Ignition: “ON”
Refer to reference waveform.
C01-39* PNK CKP sensor signal circuit
“CMP sensor signal and CKP sensor signal”: K15B (Page
1A-159)
C01-40 — — — —
10 to 14 V Ignition: “ON”
EVAP canister purge
C01-41* GRY Refer to reference waveform.
valve drive circuit
“EVAP canister purge valve signal”: K15B (Page 1A-158)
10 to 14 V Ignition: “ON”
C01-42* GRN OCV drive circuit Refer to reference waveform.
“OCV signal”: K15B (Page 1A-160)
C01-43 — — — —
Approx. 0 V Ignition: “ON”
Refer to reference waveform.
Ignition coil No.1 drive
C01-44* BRN • “Ignition coil signal”: K15B (Page 1A-158)
circuit
• “Fuel injector No.1 signal and ignition coil No.1 signal”:
K15B (Page 1A-156)
C01-45 — — — —
C01-46 — — — —
C01-47 — — — —
C01-48 — — — —
Refer to reference waveform.
HO2S-1 heater drive
C01-49* PPL “HO2S-1 heater signal and HO2S-2 heater signal”: K15B
circuit
(Page 1A-157)
C01-50 BLK ECM ground circuit 1 Below 0.3 V Ignition: “ON”
1A-153 Engine General Information and Diagnosis: K15B

Terminal No. Wire color Circuit Normal voltage Condition

Throttle actuator drive Refer to reference waveform.
C01-51* LT GRN
circuit (close) “Throttle actuator signal”: K15B (Page 1A-159)
Refer to reference waveform.
HO2S-2 heater drive
C01-52* RED “HO2S-1 heater signal and HO2S-2 heater signal”: K15B
circuit
(Page 1A-157)
C01-53 BLK ECM ground circuit 2 Below 0.3 V Ignition: “ON”
Throttle actuator drive Refer to reference waveform.
C01-54* BRN
circuit (open) “Throttle actuator signal”: K15B (Page 1A-159)
HO2S-1 shield ground
C01-55 LT GRN Below 0.3 V Ignition: “ON”
circuit
HO2S-2 shield ground
C01-56 BEG Below 0.3 V Ignition: “ON”
circuit

“E01” connector
Terminal No. Wire color Circuit Normal voltage Condition
Approx. 0 V Ignition: “OFF” or “ACC”
E01-1 WHT Ignition ON signal circuit
10 to 14 V Ignition: “ON”
Ignition: “ON”
10 to 14 V ECT < 95 °C (203 °F)
Radiator cooling fan relay A/C switch: OFF
E01-2 LT GRN
No.1 drive circuit Ignition: “ON”
Approx. 0 V 97 °C (206.6 °F) < ECT
A/C switch: OFF
Ignition: “ON”
0.325 to 0.425 V
Accelerator pedal: Released
APP sensor (sub) signal
E01-3 YEL Ignition: “ON”
circuit
2.15 to 2.25 V Accelerator pedal: Fully
depressed
Electric load current
sensor and brake stroke
E01-4 LT BLU 4.5 to 5.5 V Ignition: “ON”
sensor power supply
circuit
APP sensor (sub) ground
E01-5 WHT Below 0.3 V Ignition: “ON”
circuit
APP sensor (sub) power
E01-6 BLK 4.5 to 5.5 V Ignition: “ON”
supply circuit
Ignition: “ON”
3 to 5 V
Neutral position switch Gear position: “Neutral”
E01-7 YEL signal circuit (–) (M/T Ignition: “ON”
model) Approx. 0 V Gear position: Other than
“Neutral”
E01-8 — — — —
A/C refrigerant pressure
E01-9 BLU Below 0.3 V Ignition: “ON”
sensor ground circuit
Engine: Idle speed after
0.40 to 1.56 V warming up
Brake stroke sensor signal Brake pedal: Released
E01-10 PPL
circuit Engine: Idle speed after
1.6 to 1.8 V warming up
Brake pedal: Fully depressed
Ignition: “ON”
Approx. 0 V
ST2 relay (–) drive circuit ST2 relay: Operating
E01-11 GRY
(A/T model) Ignition: “ON”
Approx. 2.5 to 4.5 V
ST2 relay: Not operating
E01-12 — — — —
E01-13 — — — —
A/C refrigerant pressure
E01-14 BRN 4.5 to 5.5 V Ignition: “ON”
sensor supply circuit
E01-15 — — — —
 Engine General Information and Diagnosis: K15B 1A-154

Terminal No. Wire color Circuit Normal voltage Condition

Ignition: “ON”
0.70 to 0.80 V
Accelerator pedal: Released
APP sensor (main) signal
E01-16 BEG Ignition: “ON”
circuit
4.35 to 4.45 V Accelerator pedal: Fully
depressed
Ignition: “ON”
Select lever: “P” or “N” (A/T
Approx. 0 V model)
Transmission range switch Clutch pedal: Fully
(A/T model) or CPP No.1 depressed (M/T model)
E01-17 GRN
switch (M/T model) signal Ignition: “ON”
circuit Select lever: Other than “P”
10 to 14 V or “N” position (A/T model)
Clutch pedal: Released (M/T
model)
Brake light switch signal Approx. 0 V Brake pedal: Released
E01-18 LT BLU
circuit 10 to 14 V Brake pedal: Fully depressed
APP sensor (main) ground
E01-19 BLU Below 0.3 V Ignition: “ON”
circuit
APP sensor (main) power
E01-20 BRN 4.5 to 5.5 V Ignition: “ON”
supply circuit
Ignition: “ON”
Approx. 0 V Blower speed switch: 2nd or
higher speed position
Ignition: “ON”
E01-21 YEL Blower motor signal circuit
5 to 7 V Blower speed switch: 1st
position
Ignition: “ON”
10 to 14 V
Blower speed switch: OFF
Electric load current
E01-22 BRN sensor and brake stroke Below 0.3 V Ignition: “ON”
sensor ground circuit
E01-23 — — — —
Fuel pump relay drive Refer to reference waveform.
E01-24 RED
circuit “Fuel pump relay signal”: K15B (Page 1A-160)
E01-25 — — — —
E01-26 — — — —
Ignition: “ON”
10 to 14 V ECT < 100 °C (212 °F)
Radiator cooling fan relay A/C switch: OFF
E01-27 GRN
No.2 and No.3 drive circuit Ignition: “ON”
Approx. 0 V 102 °C (215.6 °F) < ECT
A/C switch: OFF
CAN (high) communication Refer to reference waveform.
E01-28* RED
circuit “CAN communication signal”: K15B (Page 1A-161)
CAN (low) communication Refer to reference waveform.
E01-29* WHT
circuit “CAN communication signal”: K15B (Page 1A-161)
E01-30 — — — —
E01-31 — — — —
E01-32 — — — —
Engine: Running
0.9 to 1.3 V A/C compressor: Not
A/C refrigerant pressure
E01-33 PNK operating
sensor signal circuit
Engine: Running
1.3 to 2.2 V
A/C compressor: Operating
E01-34 — — — —
E01-35 — — — —
1A-155 Engine General Information and Diagnosis: K15B

Terminal No. Wire color Circuit Normal voltage Condition

Ignition: “ON”
Approx. 8 to 13 V
ST2 relay (+) drive circuit ST2 relay: Operating
E01-36 BRN
(A/T model) Ignition: “ON”
Approx. 2.5 to 4.5 V
ST2 relay: Not operating
Refer to reference waveform.
E01-37* WHT ISG cranking signal circuit
“ISG cranking signal”: K15B (Page 1A-161)
E01-38 — — — —
E01-39 — — — —
Ignition: “ON”
3 to 5 V
Neutral position switch Gear position: “Neutral”
E01-40 PNK signal circuit (+) (M/T Ignition: “ON”
model) 10 to 14 V Gear position: Other than
“Neutral”
A/C compressor: Not
A/C compressor relay drive 10 to 14 V
E01-41 BRN operating
circuit
Approx. 0 V A/C compressor: Operating
Ignition: “ON”
10 to 14 V
Clutch pedal: Released
CPP No.2 switch signal
E01-42 PPL Ignition: “ON”
circuit (M/T model)
Approx. 0 V Clutch pedal: Fully
depressed
Starting motor control relay Approx. 0 V Ignition: “ON”
E01-43 LT GRN
signal circuit 6 to 12 V Ignition: “START”
E01-44 — — — —
Battery voltage signal
E01-45 GRY 10 to 14 V Ignition: “ON”
circuit
E01-46 — — — —
Ignition: “ON”
Battery temperature
E01-47 PNK 2.0 to 2.3 V Temperature in the vicinity of
sensor signal circuit
battery: 25 °C (77 °F)
Approx. 2.4 V Ignition: “ON”
Ignition: “ON”
Electric load current
E01-48 BLU Headlight: ON
sensor signal circuit Approx. 1.9 V
Blower speed selector: Max
position
Approx. 0 V Ignition: “ON”
E01-49 PNK Main relay drive circuit Ignition: In 25 sec.
10 to 14 V
after ignition “OFF”
E01-50 — — — —
E01-51 — — — —
E01-52 — — — —
E01-53 — — — —
E01-54 — — — —
E01-55 BLU Main power supply circuit 2 10 to 14 V Ignition: “ON”
E01-56 BLU Main power supply circuit 1 10 to 14 V Ignition: “ON”
 Engine General Information and Diagnosis: K15B 1A-156

Reference Waveform Fuel injector No.1 signal and ignition coil No.1 signal

NOTE Fuel injector No.1 signal (1):

• Display includes the following types of Channel Probe Terminal No.
data: + C01-31
1
– C01-50

Ignition coil No.1 signal (2):

Channel Probe Terminal No.
+ C01-44
2
– C01-50

CMP sensor signal (3):

Channel Probe Terminal No.
+ C01-30
3
– C01-50

CKP sensor signal (4):

Channel Probe Terminal No.
ICP70A110009-01 + C01-39
4
[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel
– C01-50
[B]: Ground level of each channel [D]: TIME/DIV
Measurement condition
• Waveform varies depending on • Engine: Idle speed after warming up
measurement condition and vehicle spec.

Fuel injector signal

Channel Probe Terminal No.
C01-31 (No.1)
C01-11 (No.2)
+
1 C01-10 (No.3)
C01-12 (No.4)
– C01-50

Measurement condition
• Engine: Idle speed after warming up IFRA0A111032-01

5. Camshaft 360° angle 6. Crankshaft 720° angle

Fuel injector No.2 signal and ignition coil No.2 signal

Fuel injector No.2 signal (1):

Channel Probe Terminal No.
+ C01-11
1
– C01-50

Ignition coil No.2 signal (2):

Channel Probe Terminal No.
I7V20A111014-02
+ C01-33
1. Fuel injector signal 2
– C01-50

CMP sensor signal (3):

Channel Probe Terminal No.
+ C01-30
3
– C01-50

CKP sensor signal (4):

Channel Probe Terminal No.
+ C01-39
4
– C01-50
1A-157 Engine General Information and Diagnosis: K15B

Measurement condition Fuel injector No.4 signal and ignition coil No.4 signal
• Engine: Idle speed after warming up
Fuel injector No.4 signal (1):
Channel Probe Terminal No.
+ C01-12
1
– C01-50

Ignition coil No.4 signal (2):

Channel Probe Terminal No.
+ C01-35
2
– C01-50

CMP sensor signal (3):

Channel Probe Terminal No.
IFRA0A111033-01
+ C01-30
3
5. Camshaft 360° angle 6. Crankshaft 720° angle – C01-50

Fuel injector No.3 signal and ignition coil No.3 signal CKP sensor signal (4):
Channel Probe Terminal No.
Fuel injector No.3 signal (1): + C01-39
Channel Probe Terminal No. 4
– C01-50
+ C01-10
1
– C01-50 Measurement condition
• Engine: Idle speed after warming up
Ignition coil No.3 signal (2):
Channel Probe Terminal No.
+ C01-34
2
– C01-50

CMP sensor signal (3):

Channel Probe Terminal No.
+ C01-30
3
– C01-50

CKP sensor signal (4):

Channel Probe Terminal No.
+ C01-39 IFRA0A111035-01
4
– C01-50 5. Camshaft 360° angle 6. Crankshaft 720° angle

Measurement condition HO2S-1 heater signal and HO2S-2 heater signal

• Engine: Idle speed after warming up
HO2S-1 heater signal (1):
Channel Probe Terminal No.
+ C01-49
1
– C01-50

HO2S-2 heater signal (2):

Channel Probe Terminal No.
+ C01-52
2
– C01-50

IJHB0A111013-01

5. Camshaft 360° angle 6. Crankshaft 720° angle

 Engine General Information and Diagnosis: K15B 1A-158

Measurement condition Measurement condition

• Engine: Idle speed after warming up • Engine: Idle speed after warming up

IBP60B110043-01
IFAE0A110043-01 1. Ignition coil signal

HO2S-2 signal HO2S-1 signal

Channel Probe Terminal No. Channel Probe Terminal No.
+ C01-19 + C01-7
1 1
– C01-50 – C01-50
Measurement condition Measurement condition
• Engine: Racing after warming up • Engine: Idle speed after warming up

IFRA0A111046-01
IFAE0A110048-01
1. Engine: Racing 2. Engine: Idle speed
EVAP canister purge valve signal
Ignition coil signal Channel Probe Terminal No.
Channel Probe Terminal No. + C01-41
C01-44 (No.1) 1
– C01-50
C01-33 (No.2)
+
1 C01-34 (No.3) Measurement condition
C01-35 (No.4) • EVAP canister purge valve: 10% open
– C01-50 (using “Active Test” on SUZUKI scan tool)

IFAE0A110038-01
1A-159 Engine General Information and Diagnosis: K15B

Throttle actuator signal Measurement condition

• Ignition: “ON”
Throttle actuator signal (Open) (1):
• Accelerator pedal: Fully depressed position
Channel Probe Terminal No.
+ C01-54
1
– C01-50

Throttle actuator signal (Close) (2):

Channel Probe Terminal No.
+ C01-51
2
– C01-50

Measurement condition
• Ignition: For 10 sec. after ignition “ON”
• Accelerator pedal: Idle position I8C50B111049-01

CMP sensor signal and CKP sensor signal

CMP sensor signal (1):

Channel Probe Terminal No.
+ C01-30
1
– C01-50

CKP sensor signal (2):

Channel Probe Terminal No.
+ C01-39
2
– C01-50
IDAA0A111029-01

Measurement condition
Measurement condition
• Engine: Idle speed after warming up
• Ignition: More than 10 sec. after ignition “ON”
• Accelerator pedal: Idle position

IFAE0A110044-01

IDAA0A111030-01 Knock sensor signal

Channel Probe Terminal No.
C01-25
+
1 C01-37
– C01-50
 Engine General Information and Diagnosis: K15B 1A-160

Measurement condition OCV signal

• Engine: Running at 4,000 rpm after warming up Channel Probe Terminal No.
+ C01-42
1
– C01-50

Measurement condition
• Engine: Racing after warming up
• Accelerator pedal: Fully depressed position

IHL10A111028-01

MAP sensor signal

MAP sensor signal (1):

Channel Probe Terminal No.
IDAA0A111031-01
+ C01-27
1
– C01-50
Fuel pump relay signal
TP sensor (main) signal circuit (2): Channel Probe Terminal No.
Channel Probe Terminal No. + E01-24
1
+ C01-26 – C01-50
2
– C01-50
Measurement condition
Measurement condition • Ignition: “OFF” → “ON” → “START”
• Engine: Racing after warming up

IAW101110042-01

1. Fuel pump relay signal 3. Ignition: “ON”

IFRA0A111039-01
2. Ignition: “OFF” 4. Ignition: “START”
3. Engine: Idle speed 4. Engine: Racing
1A-161 Engine General Information and Diagnosis: K15B

ISG cranking signal CAN communication signal

Channel Probe Terminal No.
+ E01-37 CAN (High) communication signal (1):
1 Channel Probe Terminal No.
– C01-50
C01-3
+
Measurement condition 1 E01-28
• Engine auto stop control → Engine auto start control – C01-50
→ Engine running
CAN (Low) communication signal (2):
Channel Probe Terminal No.
C01-2
+
2 E01-29
– C01-50

Measurement condition
• Engine: Stop
• Ignition: “ON”

IHL10A111035-01

1. Engine auto stop control 3. Engine running

2. Engine auto start control

I8C50B111041-01
 Engine General Information and Diagnosis: K15B 1A-162

ECM Power Supply and Ground Circuit Check

AENJHB0B1114067
Circuit Diagram

1
A1
2 5V 12V
BRN E01-20 10
3 BEG E01-16 C01-51 LT GRN
BLU E01-19 11
C01-54 BRN M
A2 E1
5V
BLK E01-6 5V
4 C01-13 RED
YEL E01-3 12
WHT E01-5 C01-26 GRN
13
C01-16 WHT
C01-15 BLK
PPL E01-10 12V
5 C01-17 BLK
F1 14 G1 23
5V
B1 E01-49 PNK 15
E01-55 BLU
LT BLU E01-4 F2
3.3V G2
6 BLU E01-48 E01-56 BLU F3
7
PNK E01-47 18
BRN E01-22
19
C1 5V 17
8 5V 16 20
BRN E01-14 E01-1 WHT
PNK E01-33 H1
BLU E01-9 I1 21
D1 5V C01-50 BLK
9 C01-53 BLK 22
LT BLU C01-14 5V I2
BRN C01-27
GRY C01-4

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHB0A111012-01

[A]: ECM connector (View: [a]) I1: ECM ground circuit 1 12. TP sensor (main)
A1: APP sensor (main) power supply circuit I2: ECM ground circuit 2 13. TP sensor (sub)
A2: APP sensor (sub) power supply circuit 1. ECM 14. Main relay
B1: Electric load current sensor and brake stroke sensor 2. APP sensor 15. “FI” fuse
power supply circuit
C1: A/C refrigerant pressure sensor power supply circuit 3. APP sensor (main) 16. “IG” fuse
D1: MAP sensor power supply circuit 4. APP sensor (sub) 17. Ignition switch (ignition switch model)
E1: TP sensor power supply circuit 5. Brake stroke sensor 18. IG12 relay
F1: Main relay drive circuit 6. Electric load current sensor 19. BCM (keyless push start model)
F2: Main power supply circuit 2 7. Battery temperature sensor 20. “KEY” fuse
F3: Main power supply circuit 1 8. A/C refrigerant pressure sensor 21. Main fuse box
G1: Main relay power supply circuit (coil side) 9. MAP sensor 22. Battery
G2: Main relay power supply circuit (switch side) 10. Electric throttle body assembly 23. To auxiliary power module (lithium-ion battery)
H1: Ignition ON signal circuit 11. Throttle actuator

Circuit Description
When ignition is set to “ON”, the main relay turns on (contacts close) and the main power is supplied to ECM. ECM
then supplies 5 V power to the following sensors: MAP sensor, A/C refrigerant pressure sensor, APP sensor, TP
sensor, brake stroke sensor and electric load current sensor.
1A-163 Engine General Information and Diagnosis: K15B

Troubleshooting

NOTE
• Before troubleshooting, read “Precautions for ECM Circuit Inspection” under “Precautions for
Engine (K15B)” in Section 1 (Page 1-1).
• Before performing, check that related fuses of ECM power circuit have not blown out.
If any fuse has blown out, replace the fuse and check circuits connected to the blown fuse for short
circuit to ground.

Step Action Yes No

1 Battery check Go to Step 2. Check battery and
1) Check that battery voltage is 12 V or more. charging referring to
“Battery Inspection”:
Is check result OK? K15B in Section 1J
(Page 1J-2) and
“Generator Test”: K15B
in Section 1J (Page 1J-
3).
2 Main relay power supply check Go to Step 3. Check the following
1) With ignition “OFF”, remove main relay (1) from points.
individual circuit fuse box No.1. • “FI” fuse
• Auxiliary power
module (lithium-ion
battery) (Page 10K-
28)
If check result OK,
repair or replace
1 defective wire harness.

IJHA0A110019-01

2) Check for proper terminal connection to main relay

connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between each of “G1” and “G2”
circuit and ground is battery voltage.

Is check result OK?

3 Main relay check Go to Step 4. Replace main relay.
1) Check main relay. (Page 1C-13)

Is check result OK?

4 Ignition signal circuit check Go to Step 5. Check that “KEY” fuse
1) With ignition “OFF”, install main relay to individual circuit has not blown.
fuse box No.1. If check result is OK,
2) Disconnect “C01” and “E01” connectors from ECM. repair or replace
defective wire harness.
3) Check for proper terminal connection to “C01” and “E01”
connectors.
4) If connections are OK, set ignition “ON”.
5) Check that voltage between “H1” and ground is battery
voltage.

Is check result OK?

 Engine General Information and Diagnosis: K15B 1A-164

Step Action Yes No

5 Main relay drive circuit check Go to Step 6. Repair or replace
1) Set ignition “OFF”. defective wire harness.
2) Check that voltage between “F1” and ground is battery
voltage.

Is check result OK?

6 Main power supply circuit check Go to Step 7. Repair or replace
1) Using service wire, ground “F1”. defective wire harness.
2) Set ignition “ON”.
3) Check that voltage between each of “F2” and “F3” circuit
and ground is battery voltage.

Is check result OK?

7 ECM ground circuit check Go to Step 8. Repair or replace
1) Set ignition “OFF”. defective wire harness.
2) Check that resistance between each of “I1” and “I2”
circuit and ground is less than 1 Ω.

Is check result OK?

8 Sensor power supply circuit check ECM power supply and Check wiring harness
1) With ignition “OFF”, connect “C01” and “E01” connectors ground circuits are in for open, short circuit to
to ECM. good condition. battery and short circuit
to ground. If wiring
2) Disconnect connectors from APP sensor, electric load
harness is in good
current sensor, brake stroke sensor, electric throttle body
condition, replace ECM
assembly, MAP sensor and A/C refrigerant pressure
and recheck ECM
sensor.
power supply and
3) Check for proper terminal connection to each sensor ground circuits. (Page
connector. 1C-2)
4) If connections are OK, set ignition “ON”.
5) Check that voltage between each of the following circuits
and ground is approx. 5 V.
• A1
• A2
• B1
• C1
• D1
• E1

Is check result OK?

Fuel Cut Operation Inspection

AENJHB0B1114068 1 2
1) For M/T model, place gear shift lever in neutral
position and apply parking brake.
For A/T model, place select lever in P range and
apply parking brake.
2) Warm up engine to normal operating temperature.
3) While listening to sound of fuel injector (2) using
sound scope (1) or the like, increase engine speed
to higher than 3,000 rpm.

IJHA0A110020-01
1A-165 Engine General Information and Diagnosis: K15B

4) Check that fuel injector operation sound stops when

throttle valve is closed instantly and it resumes when
engine speed decreases to 1,500 rpm.

Repair Instructions
Idle Speed Inspection Special tool
AENJHB0B1116001 (A): SUZUKI scan tool (Suzuki SDT-II)
Before idle speed check, check the following items.
• Lead wires and hoses of electronic fuel injection and
engine and emission control systems are connected
securely.
• Valve clearance is checked according to maintenance
schedule.
• Ignition timing is within specification.
• All electrical systems (wipers, heater, lights, A/C, etc.)
are off. 1

• Air cleaner is properly installed and is in good

condition.
• There is no air abnormally drawn in from air intake
system.
• There is no obstruction in PCV valve or its hose.
• There is no DTC in ECM.
• The following items are turned off as checked using
“Data List” mode on scan tool.
– A/C Comp Relay
– A/C Switch
– Brake Switch (A)

– Electric Load IJHA0A110021-01

– Blower Fan 2) Warm up engine to normal operating temperature.

After checking all items, check idle speed as follows. 3) If check result is not as specified, check engine idle
speed referring to “Improper engine idling or engine
NOTE
fails to idle” under “Engine Symptom Diagnosis”:
Before starting engine, place gear shift lever K15B (Page 1A-55).
in neutral position (M/T model), or select
lever in P range (A/T model), apply parking Engine idle speed
brake and block drive wheels. A/C OFF: 750 to 850 rpm
A/C ON: 750 to 900 rpm
1) With ignition “OFF”, connect SUZUKI scan tool to
DLC (1).

Special Tools and Equipment

Special Tool
AENJHB0B1118001
SUZUKI scan tool (Suzuki
SDT-II)
—
(Page 1A-23) /
(Page 1A-24) /
(Page 1A-165)
 Engine General Information and Diagnosis: D13A 1A-166

D13A
General Description
Engine Diagnosis General Description Driving Cycle
AENJHB0B1121001 A “driving cycle” consists of two parts, engine startup
The engine and emission control system in this vehicle
and engine shutoff.
are controlled by ECM. ECM has an OBD system which
detects a malfunction in this system and abnormality of
1 Driving Cycle Detection Logic
those parts that influence the engine exhaust emission.
The malfunction detected in the first driving cycle is
When diagnosing engine troubles, have full
stored in ECM memory and MIL lights up at the same
understanding of the outline of “OBD System
time.
Description”: D13A (Page 1A-166) and each item in
“Precautions for Diagnosing Trouble” under “Precautions
3 Driving Cycle Detection Logic
for Engine (D13A)” in Section 1 (Page 1-2) and execute
The malfunction detected in the first driving cycle is
diagnosis according to “Engine and Emission Control
stored in ECM memory but the MIL does not light up at
System Check”: D13A (Page 1A-177).
this time.
There is a close relationship between the emission
The MIL does not light up at the second detection of the
system, engine mechanical, engine cooling system,
same malfunction either in the second driving cycle. The
exhaust system, etc. in their structure and operation. In
MIL lights up at the third detection of the same
case of an engine trouble, even when the MIL does not
malfunction in the third driving cycle.
turn on, it should be diagnosed according to “Engine and
Emission Control System Check”: D13A (Page 1A-177).
Freeze Frame Data
ECM stores the engine and driving conditions at the
OBD System Description moment of the detection of a malfunction in its memory.
AENJHB0B1121002
ECM in this vehicle has the following functions. This data is called “Freeze frame data”.
Therefore, it is possible to know engine and driving
• When ignition is “ON” with the engine at a stop, MIL
conditions (e.g. whether the engine was warm or not,
(1) turns on to check the MIL and its circuit.
whether the vehicle was running or stopped, whether air/
fuel mixture was lean or rich) at the moment the
malfunction was detected by checking the freeze frame
data. Also, ECM has a function to store each freeze
1 frame data for three different malfunctions in detecting
order.
Utilizing this function, it is possible to know the detecting
order of the malfunctions, and facilitates recheck and
diagnosis of the trouble.
Freeze frame data (Example)

IJHA0A110010-01

• When ECM detects a malfunction which gives an

adverse effect to vehicle emission while the engine is
running, it makes the MIL in the meter cluster of the
instrument panel turn on and stores the malfunction
area in its memory.
• As a condition for detecting a malfunction in some
areas in the system being monitored by ECM and
turning on MIL due to that malfunction, 1 driving cycle
or 3 driving cycle detection logic is adopted to prevent
erroneous detection.

Warm-Up Cycle
A “warm-up cycle” is defined in the OBD regulations to IDL10A110032-01
be sufficient vehicle operation such that coolant
temperature rises by at least 22 °C (40 °F) from engine Freeze frame data clearance
starting and reaches a minimum temperature of 70 °C The freeze frame data is cleared at the same time as
(158 °F). clearance of DTC.
1A-167 Engine General Information and Diagnosis: D13A

System Readiness Test

The system readiness test is to check if on-board diagnosis of each system related to exhaust emission has been
completed or not using a scan tool (SUZUKI scan tool or OBD generic scan tool).
When the conditions established for each system are met, ECM performs an on-board diagnosis of corresponding
system and changes the status of system readiness test from “Incomplete” to “Complete”. When “Complete” status is
displayed, it is maintained until the “DTC clearance” is performed using scan tool.

NOTE
• The status of system readiness test may be changed as “incomplete” when performing the
following services.
– Disconnection of battery negative (–) cable
– Disconnection of ECM connectors
– Removal of ground cables for ECM
– Disconnection of “ECM” fuse
• By utilizing this system readiness test, it is possible to check that all DTC confirmation procedures
for each system have been completed or not (incompleted). For all DTCs related to each system,
refer to the table below.
• The system readiness test is NOT the result (“Normal” or “Abnormal”) of on-board diagnosis but
the result (“Complete” or “Incomplete”) of on-board diagnosis.

Monitor item of system readiness test table

Monitoring item DTC related to monitoring item
Fuel system P0190 P0201 P0202 P0203 P0204 — —
Comprehensive component P0095 P0115 P0500 — — — —
P0069 P0100 P0101 P0234 P0235 P0401 P0402
EGR system
P0403 P2226 — — — — —
 Engine General Information and Diagnosis: D13A 1A-168

DLC Description Fuel Injection Control Description

AENJHB0B1121003 AENJHB0B1121004
DLC (1) is in compliance with SAE J1962 in the shape of This model is equipped with a common rail type fuel
connector and pin assignment. injection system.
K line (3) of ISO 9141 is used for SUZUKI scan tool For the details of the system, refer to “Fuel System
(SUZUKI-SDT-II) (6) or OBD generic scan tool to Description”: D13A in Section 1G (Page 1G-31).
communicate with ECM. ECM controls fuel injection for optimum fuel combustion
dividing the injection into 3 times in 1 combustion cycle
2 providing each injection volume to fit the driving
condition.
16 15 14 13 12 11 10 9
• Pilot-injection (1): Before pre-injection, fuel is injected
8 7 6 5 4 3 2 1 and mixed with air before the ignition. This pilot-
injection is effective to reduce combustion noise too.
5
3
4 • Pre-injection (2): Before main-injection, a small
1 amount of fuel is injected to create ignition and
prevents combustion chamber from sudden rising of
temperature. This pre-injection restricts abrupt
combustion and it is effective to reduce NOx emission
and diesel engine noise.
• Main-injection (3): This injection generates engine
output.

Example of multiple injection

1
[C]

3
1

[B]
[A]
IJHB0B112001-01

[A]: Top dead center [C]: Injection quantity

[B]: Crank angle
6

IJHB0A113001-01
Electronic Control System Description
2. B + (Continuous battery power) AENJHB0B1121005
4. ECM ground (Signal ground) Fuel Injection Control System
5. Ground (Chassis ground) Refer to “Fuel Injection Control Description”: D13A
(Page 1A-168).

Fuel Injection Timing Control System

Based on signals from sensors (IAT sensor, ECT sensor,
BARO sensor, etc.), ECM controls fuel injection timing to
bring it near to the target fuel injection timing. The target
fuel injection timing is decided on the bases of engine
speed and fuel injection volume.

Fuel cut control

While the vehicle is running, fuel cut is executed for
protection of engine and transaxle when the engine
speed goes up to 5,300 rpm or higher. Furthermore, for
fuel economy, deceleration fuel cut is also executed
under the specified driving conditions.
1A-169 Engine General Information and Diagnosis: D13A

Fuel Pressure Control System A/C Compressor Control System

Based on signal sent from each sensor, ECM controls Based on information from A/C switch, refrigerant
fuel pressure to bring it near to the target fuel pressure. pressure sensor and vehicle driving conditions through
For this purpose, fuel flow actuator in the high pressure CAN communication, the system controls ON/OFF of A/
pump is controlled. C compressor.

Engine Idle Speed Control System CAN Communication System

Based on signal sent from each sensor, ECM controls Using this system, each control module transmits /
fuel injection volume to compensate idle speed to bring it receives data and information with other control
near to the target idle speed. modules.

Glow Plug Control System Brake Override System

Glow plug control module controls operating time of the
glow plugs receiving signal from ECM.
ISG Control System
Based on signals sent from each sensor and controller
through CAN, ECM converts the signals to LIN in central
gateway control module and controls ISG.
ISG generates electricity receiving request from ECM.
And, while the vehicle is decelerating, ISG generates
power intensively regenerating deceleration energy and
improves fuel economy.
Refer to “SHVS System Description”: D13A Model in
Section 11A (Page 11A-40).
When the driver depresses accelerator pedal and brake
pedal at the same time, ECM controls engine output by
restricting fuel injection quantity and prioritizes braking
force.
NOTE
The system may not be activated depending
on the following conditions.
• Depressing amount of accelerator pedal
and brake pedal
• Vehicle speed

Boost Control System

ECM detects actual supercharged pressure and controls
boost pressure control solenoid valve to bring the
pressure near to the target supercharging pressure.

A/F Heater Control System

To quicken startup or maintain activation of A/F sensor,
the system controls A/F sensor heater using duty cycle
pulse signal.

EGR Control System

This system controls of NOx emission by recirculating
exhaust gas into the combustion chamber through intake
manifold. Based on signal from each sensor, ECM
controls EGR valve.

Radiator Cooling Fan Control System

Based on signals of A/C switch, vehicle speed, engine
speed, coolant temperature and refrigerant pressure, the
system controls radiator cooling fan relay No.1, No.2 and
No.3 for operation of LO, HI or stop.

Main Relay Control

• Corresponding to “ON” or “OFF” of ignition mode, the
main relay is controlled for startup or stop of EPI
system.
• The main relay has a self-shutoff function which
supplies power source to internal circuit in ECM for
specified time until the system stops after ignition
“OFF”, and a countercurrent protection feature which
prevents the battery from flowing reverse current
caused by erroneous reverse connection.

Engine and Emission Control Input / Output Table
Function
Fuel injection control Fuel injector
Immobilizer control Fuel injector
Glow plug control
ISG control
Boost pressure control solenoid
Boost control
valve
Engine General Information and Diagnosis: D13A 1A-170
AENJHB0B1121006
Output Input
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• CMP sensor
• APP sensor
• MAF sensor
• IAT sensor-1
• A/F sensor
• Barometric pressure sensor
• A/C refrigerant pressure sensor
• Battery voltage
• Brake light switch / brake switch
• BCM (A/C switch status signal)
• ABS control module (wheel speed signal)
• P/S control module
• Ignition “ON” signal
• BCM
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
Glow plug control module
• CKP sensor
• CMP sensor
• Barometric pressure sensor
• ECT sensor
• CKP sensor
• APP sensor
• MAF sensor
• Electric load current sensor
• Battery temperature sensor
• Brake stroke sensor
ISG • ABS control module (wheel speed signal
and ENG A-STOP status signal)
• BCM (electric load signal and hood
switch status signal)
• BCM (A/C switch status signal)
• ISG (field measured signal)
• Auxiliary power module (lithium-ion
battery) (auxiliary power module (lithium-
ion battery) status signal)
• Ignition “ON” signal
• ECT sensor
• CKP sensor
• APP sensor
• MAF sensor
• Boost pressure sensor
• IAT sensor-1
• ABS control module (wheel speed signal)
1A-171 Engine General Information and Diagnosis: D13A
Function
A/F heater control
EGR control
Radiator cooling fan control
Fuel pump control
Main relay control
A/C compressor control
Output Input
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• MAF sensor
A/F sensor
• IAT sensor-1
• Barometric pressure sensor
• CKP sensor
• Battery voltage
• Ignition “ON” signal
• ECT sensor
• CKP sensor
• MAF sensor
• IAT sensor-1
EGR valve • APP sensor
• A/F sensor
• Barometric pressure sensor
• ABS control module (wheel speed signal)
• BCM (electric load signal and A/C switch
status signal)
• Ignition “ON” signal
• ECT sensor
• CKP sensor
Radiator cooling fan relay • A/C refrigerant pressure sensor
• BCM (electric load signal and A/C switch
status signal)
• ABS control module (wheel speed signal)
• Ignition “ON” signal
Fuel pump relay • Ignition “ST” signal
• CKP sensor
Main relay • Ignition “ON” signal
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• APP sensor
A/C compressor relay • A/C refrigerant pressure sensor
• MAF sensor
• Barometric pressure sensor
• BCM (evaporator temperature signal and
A/C switch status signal)
• ABS control module (wheel speed signal)
 Engine General Information and Diagnosis: D13A 1A-172

Schematic and Routing Diagram

Electronic Control System Diagram
AENJHB0B1122001

3 24
26 1
22
26 2

25

15
26 26

26
9 31
23 4
13 10 8 26
30
27
32
29 26
26

26 11 26 26 26
12
26 18 17 26
5
7 6

16

26

14

: [A]
20
19
: [B]
26
21
28 : [C]

IDL10A110004-01

[A]: Fuel feed line 10. Glow plug 22. A/F sensor
[B]: Fuel return line 11. ECT sensor 23. Oil separator
[C]: Fuel high pressure line 12. CKP sensor 24. Boost pressure control valve actuator
1. Air cleaner 13. Fuel injector 25. Catalytic converter
2. MAF sensor with IAT sensor-1 14. Fuel temperature sensor 26. To ECM
3. Turbocharger 15. Fuel pressure sensor 27. Common rail
4. Intercooler 16. EGR valve 28. Fuel filter water detection sensor
5. APP sensor 17. High pressure pump 29. Boost pressure control solenoid valve
6. Brake light switch / Brake switch 18. Fuel flow actuator 30. To glow plug control module
7. CPP switch 19. Fuel filter 31. Vacuum pump
8. Boost pressure sensor with IAT sensor-2 20. Fuel pump 32. Vacuum tank
9. CMP sensor 21. Fuel tank
1A-173 Engine General Information and Diagnosis: D13A

Electronic Control System Circuit Diagram

AENJHB0B1122002

IG1 1

3 RED E01-54
D01-56 WHT
2 BLU E01-60 38
D01-16 GRY/WHT
WHT YEL E01-29
D01-58 YEL 39
RED/BLK D01-23 D01-17 YEL/BLK
YEL D01-41
4 D01-57 GRN
BLK D01-24 40
WHT D01-37 D01-31 WHT/GRN
PNK D01-25 D01-55 BLU 41
5 PNK/BLK D01-51 D01-1 WHT/BLU
PPL D01-21
D01-4 YEL/BLK
GRY/BLK D01-43 42
6 D01-20 YEL
YEL/RED D01-54
GRN/YEL D01-9 D01-5 BLU/RED
+B +BB
7 YEL/BLK D01-38 D01-6 GRY/RED 43
YEL/RED D01-7
8 D01-30 YEL/GRN YEL 44 BLU IG1
PPL/WHT D01-49 3
9 GRN D01-29 E01-68 BRN 45
10 BRN E01-82 E01-73 LT BLU
BEG E01-63 46 47 48 49
BLU E01-30 50
11 BLK E01-9 E01-1 LT GRN
YEL E01-36 BLU
WHT E01-27 54
GRN
12 BLK E01-42 52
LT GRN E01-39 E01-2 GRN BLU 53 L+ GRY
GRY E01-41 H+
+B WHT E01-40 L-
LT GRN BLK H- 51
PNK E01-6
55
BLU
E01-74 RED BLU
13 BLK PNK WHT
GRY/YEL D01-10 58 57
+BB IG1 56
14 E01-78 BRN BLU
20 19 PPL E01-21 BLK WHT GRN
BLK 60
36 59
15
62
16 BLU E01-66 IG1
61
3
17 LT BLU E01-14 E01-17 WHT
IG2 [A]
18
IG1 63 64
21
22 BRN E01-32 [B] 67 ST 65
E01-49 BRN
IG1 PNK E01-86 68
E01-57 PPL
66
BLU E01-4
3 23
E01-45 YEL
WHT 24 RED E01-89 69 70
BLK E01-79 PNK YEL
25
BEG E01-59
E01-48 GRN BLU RED
GRN E01-7 71
73
E01-71 GRN
26 PNK E01-15
27 E01-72 GRN
75 72
PNK E01-92 74
GRN E01-20 E01-62 RED RED
28 37 77
E01-35 WHT
IG1 LT BLU E01-33
PPL E01-93 76
BRN E01-5 E01-64 GRY
30
29
GRY E01-3
E01-91 GRN
YEL
31
GRY E01-11
E01-13 GRN 79
LT BLU E01-18 81
E01-84 PPL 82
80 78
[C] E01-83 LT GRN
YEL D01-39
32 33 E01-23 BRN
34 83
E01-24 BRN
35
E01-47 BRN
: 84 : 85 : 12V : 5V
IJHB0A113002-01
 Engine General Information and Diagnosis: D13A 1A-174

[A]: Ignition switch model 28. Brake stroke sensor 58. A/C compressor relay
[B]: Keyless push start model 29. ENG A-STOP OFF switch 59. A/C compressor
[C]: Manual A/C model 30. “IG1 SIG2” fuse 60. “CPRSR” fuse
1. ECM 31. Hood latch switch 61. IG11 relay
2. MAF sensor with IAT sensor-1 32. To blower motor 62. “IGN” fuse
3. “IG” fuse 33. Blower speed switch 63. Ignition switch
4. Boost pressure sensor with IAT sensor-2 34. A/C switch 64. “KEY” fuse
5. CMP sensor 35. To BCM 65. “KEY2” fuse
6. CKP sensor 36. Barometric pressure sensor 66. BCM
7. Fuel pressure sensor 37. CAN driver 67. Engine switch
8. ECT sensor 38. Fuel injector No.1 68. ISG
9. APP sensor 39. Fuel injector No.2 69. Main relay
10. APP sensor (main) 40. Fuel injector No.3 70. “ECM” fuse
11. APP sensor (sub) 41. Fuel injector No.4 71. “FI MAIN” fuse
12. A/F sensor 42. Fuel flow actuator 72. “FI” fuse
13. Oil pressure switch 43. EGR valve 73. “INJ” fuse
14. CPP No.2 switch 44. Boost pressure control solenoid valve 74. DLC
15. Brake light switch / Brake switch 45. Glow plug control module 75. To other control module connected by CAN
16. Brake switch 46. Glow plug No.1 76. Starting motor control relay
17. Brake light switch 47. Glow plug No.2 77. “ST” fuse
18. Brake light 48. Glow plug No.3 78. Starting motor
19. “IG1 SIG” fuse 49. Glow plug No.4 79. CPP No.1 switch
20. “STOP” fuse 50. Radiator cooling fan relay No.1 80. “ST SIG2” fuse
21. To other control modules 51. Radiator cooling fan relay No.2 81. DC/DC converter
22. A/C refrigerant pressure sensor 52. Radiator cooling fan relay No.3 82. Main fuse box
23. Water detection sensor with fuel 53. Radiator cooling fan 83. Battery
temperature sensor
24. Fuel filter water detection sensor 54. “RDTR” fuse 84. Engine ground
25. Fuel temperature sensor 55. Fuel pump relay 85. Body ground
26. Brake booster switch 56. Fuel pump
27. Neutral position switch 57. “F/P” fuse

Terminal Arrangement of ECM Connector

NOTE
For circuit names and terminal voltages, refer to “Inspection of ECM and Its Circuits”: D13A (Page 1A-
329).

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113031-01

[A]: ECM connector (View: [a])

1A-175 Engine General Information and Diagnosis: D13A

Component Location
Electronic Control System Component Location
AENJHB0B1123001
Engine Compartment

1
[a]
[c] [d]
[e]
[f]
2
3
[b]

[g]

[1]

[h]

[2]

IJHB0A113003-01
 Engine General Information and Diagnosis: D13A 1A-176

Information sensors Control devices Others

1. Brake booster switch
2. A/C refrigerant pressure sensor
3. Battery sensor
4. MAF sensor with IAT sensor-1
5. Water detection sensor with fuel
temperature sensor
6. Hood latch switch
7. Neutral position switch
[a]: ISG [1]: ECM
[b]: Main relay [2]: Glow plug control module
[c]: Radiator cooling fan relay No.2
[d]: Fuel pump relay
[e]: Radiator cooling fan relay No.3
[f]: A/C compressor relay
[g]: Radiator cooling fan relay No.1
[h]: Boost pressure control solenoid valve

Interior (Around Instrument Panel)

[b] [1]

[a]

[1]

[3]

[2]
1

IJHB0A113004-01

Information sensors Control devices Others

1. Brake light switch / Brake switch [a]: MIL [1]: Combination meter
2. CPP No.1 switch [b]: Glow indicator light [2]: DLC
3. CPP No.2 switch [3]: DC/DC converter
4. APP sensor
5. Brake stroke sensor
1A-177 Engine General Information and Diagnosis: D13A

Engine Assembly

1
[b]
[a] [c]
[k]
[d]
7

2
6

[e]
[f]
[g]
[h]

[i]

4
3

IJHB0A113005-01

Information sensors Control devices

1. Fuel pressure sensor [a]: Fuel injector No.1
2. CMP sensor [b]: Fuel injector No.2
3. A/F sensor [c]: Fuel injector No.3
4. Oil pressure switch [d]: Fuel injector No.4
5. CKP sensor [e]: Glow plug No.1
6. ECT sensor [f]: Glow plug No.2
7. Boost pressure sensor with IAT sensor-2 [g]: Glow plug No.3
[h]: Glow plug No.4
[i]: Fuel flow actuator
[k]: EGR valve

Diagnostic Information and Procedures

Engine and Emission Control System Check
AENJHB0B1124001
Refer to the following items for the details of each step.
Step Action Yes No
1 Customer complaint analysis Go to Step 2. Perform customer
1) Perform “Step 1: Customer Complaint Analysis”: D13A complaint analysis.
(Page 1A-179).

Was customer complaint analysis performed?

2 DTC / freeze frame data check, record and clearance Print DTCs and freeze Go to Step 4.
1) Check for DTCs. (Page 1A-180) frame data or write them
down, clear them
Is there any DTC(s) / freeze frame data? referring to “DTC
Clearance”: D13A
(Page 1A-181) and go
to Step 3.
3 Visual inspection Repair or replace Go to Step 5.
1) Perform “Steps 3 and 4: Visual Inspection”: D13A (Page defective part(s), and go
1A-180). to Step 11.

Is there any faulty condition?

 Engine General Information and Diagnosis: D13A 1A-178

Step Action Yes No

4 Visual inspection Repair or replace Go to Step 8.
1) Perform “Steps 3 and 4: Visual Inspection”: D13A (Page defective part(s), and go
1A-180). to Step 11.

Is there any faulty condition?

5 Trouble symptom confirmation Go to Step 6. Go to Step 7.
1) Check trouble symptom. (Page 1A-180)

Is trouble symptom identified?

6 Rechecking and recording DTC / freeze frame data Go to Step 9. Go to Step 8.
1) Recheck for DTC and freeze frame data. (Page 1A-
180)

Is there any DTC(s)?

7 Rechecking and recording DTC / freeze frame data Go to Step 9. Go to Step 10.
1) Recheck for DTC and freeze frame data. (Page 1A-
180)

Is there any DTC(s)?

8 Engine basic inspection and engine symptom diagnosis Go to Step 11. Check and repair
1) Check and repair. (Page 1A-180) defective part(s), and go
to Step 11.
Are check and repair complete?
9 Troubleshooting for DTC Go to Step 11. Check and repair
1) Check and repair according to applicable DTC defective part(s), and go
troubleshooting. (Page 1A-180) to Step 11.

Are check and repair complete?

10 Intermittent problem check Repair or replace Go to Step 11.
1) Check for intermittent problems. (Page 1A-180) defective part(s), and go
to Step 11.
Is there any faulty condition?
11 Final confirmation test Go to Step 6. End.
1) Clear DTC if any.
2) Perform final confirmation test. (Page 1A-180)

Is there any problem symptom, DTC or abnormal condition?

1A-179 Engine General Information and Diagnosis: D13A

Step 1: Customer Complaint Analysis

Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose,
use of such an inspection form will facilitate collecting information required for proper analysis and diagnosis.
Customer questionnaire form (Example)

I9P60A111042-01
 Engine General Information and Diagnosis: D13A 1A-180

Step 2: DTC / Freeze Frame Data Check, Record and MIL Check
Clearance AENJHB0B1124002

First, check DTC. (Page 1A-180)
If DTC is indicated, print it out or write it down, and then
clear DTC. (Page 1A-181)
Steps 3 and 4: Visual Inspection
As a preliminary step, perform visual check of the items
that support proper function of the engine. (Page 1A-
206)
Step 5: Trouble Symptom Confirmation
Based on information obtained in “Step 1: Customer
Complaint Analysis”: D13A (Page 1A-179) and “Step 2:
DTC / Freeze Frame Data Check, Record and
Clearance”: D13A (Page 1A-180), check trouble
symptoms.
1) Set ignition “ON” and check that MIL (1) lights.
If MIL does not light up (or MIL dims) but engine can
be started, go to “MIL Does Not Come ON with
Ignition “ON” and Engine Stopped (but Engine Can
Be Started)”: D13A (Page 1A-221) for
troubleshooting.
If MIL does not light with ignition “ON” and engine
does not start though it is cranked up, go to
“Inspection of ECM and Its Circuits”: D13A (Page
1A-329).
2) Start engine and check that MIL turns off.
If MIL remains on and no DTC is stored in ECM, go
to “MIL Remains ON after Engine Starts”: D13A
(Page 1A-222) for troubleshooting.

Steps 6 and 7: Rechecking and Recording of DTC

Refer to “DTC Check”: D13A (Page 1A-180) for checking
1
procedure.

Step 8: Engine Basic Inspection and Engine

Symptom Diagnosis
1) Perform “Engine Basic Inspection”: D13A (Page 1A-
207).
2) If there is no faulty part found in inspection
IJHA0A110010-01
procedure of “Engine Basic Inspection”, perform
“Engine Symptom Diagnosis”: D13A (Page 1A-207)
based on symptom found in vehicle inspection in the DTC Check
AENJHB0B1124003
following steps.
1) Set ignition “OFF”.
• Customer complaint analysis
2) Connect SUZUKI scan tool to DLC (1) located on
• Trouble symptom confirmation underside of instrument panel on driver’s seat side.
Step 9: Troubleshooting for DTC (See each DTC Special tool
Troubleshooting) (A): SUZUKI scan tool (Suzuki SDT-II)
Perform applicable DTC troubleshooting and repair or 3) Set ignition “ON”.
replace faulty parts.
4) Read DTC according to instructions displayed on
scan tool and print it out or write it down. Refer to
Step 10: Intermittent Problems Check
Operator's Manual of SUZUKI scan tool for further
If there is no DTC in Step 2:
details.
Check for intermittent problem. (Page 00-12)

If there is any DTC in Step 2:

Check parts related to detected DTC (e.g. wire harness,
connector, etc.).

Step 11: Final Confirmation Test

Check that the problem symptom has gone and the
engine is free from any abnormal conditions. If what has
been repaired is related to a DTC, clear the DTC once,
perform DTC confirmation procedure and check that no
DTC is indicated.
1A-181 Engine General Information and Diagnosis: D13A
NOTE
If communication between SUZUKI scan tool
and ECM is not possible, perform the
following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check serial data line. (Page 1A-222)
• Check ECM power circuit and ground
circuit. (Page 1A-311)
1 1
2 2
(A)
IJHA0A110011-01
5) After completing the check, set ignition “OFF” and
disconnect scan tool from DLC.
DTC Clearance
AENJHB0B1124004
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Clear DTC according to instructions displayed on
SUZUKI scan tool. Refer to Operator's Manual of
SUZUKI scan tool for further details.
NOTE
If communication between SUZUKI scan tool
and ECM is not possible, perform the
following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check serial data line. (Page 1A-222)
• Check ECM power circuit and ground
circuit. (Page 1A-311)
(A)
IJHA0A110011-01
5) After completing DTC clearance, set ignition “OFF”
and disconnect SUZUKI scan tool from DLC.
NOTE
DTC and freeze frame data stored in ECM
memory are also cleared in the following
case. Be careful not to clear them before
recording them.
• When the same malfunction (DTC) is not
detected again for 40 engine warm-up
cycles. (See “Warm-Up Cycle” under “OBD
System Description”: D13A (Page 1A-166).)
 Engine General Information and Diagnosis: D13A 1A-182

DTC Table
AENJHB0B1124005
NOTE
With the generic scan tool, only DTCs with asterisks (*) in the following table can be read.

DTC
DTC DTC name DTC detecting condition detection MIL
logic
Electrical cause:
Measured voltage of fuel flow actuator drive circuit does
*P0001 not match command signal.
Fuel Volume Regulator
(Page Mechanical cause: 1 D/C Lights up
Control Circuit / Open
1A-224) Measured fuel pressure in common rail is higher than
targeted fuel pressure by 30 MPa (305.9 kgf/cm2, 4,350
psi, 300 bar) for 5 sec.
Any of the following conditions is met.
• Measured boost pressure is higher than barometric
*P0069 Manifold Absolute pressure by 23 kPa (0.23 kgf/cm2, 3.34 psi, 225
(Page Pressure-Barometric mbar) for 2 sec. 1 D/C Lights up
1A-225) Pressure Correlation • Measured boost pressure is lower than barometric
pressure by 23 kPa (0.23 kgf/cm2, 3.34 psi, 225
mbar) for 2 sec.
*P0087
Fuel Rail / System Measured fuel pressure in common rail is lower than
(Page 1 D/C Lights up
Pressure-Too Low specified value.
1A-227)
*P0088
Fuel Rail / System Measured fuel pressure in common rail is higher than
(Page 1 D/C Lights up
Pressure-Too High 175 MPa (1,784.5 kgf/cm2, 25,381 psi, 1,750 bar).
1A-229)
*P0089
Fuel Pressure Regulator Measured fuel pressure in common rail is lower than
(Page 1 D/C Lights up
1 Performance targeted fuel pressure by specified value.
1A-230)
Any of the following conditions is met.
*P0095 • Measured voltage of IAT-2 sensor signal circuit is
Intake Air Temperature
(Page higher than 4.6 V for 2 sec. 3 D/C Lights up
Sensor 2 Circuit (Bank1)
1A-232) • Measured voltage of IAT-2 sensor signal circuit is
lower than 0.1 V for 2 sec.
Any of the following conditions is met.
*P0100 • Duty ratio of MAF sensor signal is higher than
Mass or Volume Air Flow
(Page specified value for 2 sec. 3 D/C Lights up
“A” Circuit
1A-233) • Duty ratio of MAF sensor signal is lower than
specified value for 2 sec.
Any of the following conditions is met.
*P0101 Mass or Volume Air Flow • Measured MAF is higher than estimated MAF by
(Page “A” Circuit Range / specified value. 3 D/C Lights up
1A-234) Performance • Measured MAF is lower than estimated MAF by
specified value.
*P0107 Manifold Absolute
(Page Pressure / Barometric Relative boost pressure is lower than specified value. 1 D/C Lights up
1A-225) Pressure Circuit Low
Any of the following conditions is met.
P0110 • Measured voltage of IAT-1 sensor signal is higher
Intake Air Temperature
(Page than 4.9 V for 3 sec. 1 D/C Off
Sensor 1 Circuit (Bank1)
1A-236) • Measured voltage of IAT-1 sensor signal is lower
than 0.2 V for 3 sec.
1A-183 Engine General Information and Diagnosis: D13A

DTC
DTC DTC name DTC detecting condition detection MIL
logic
Any of the following conditions is met.
*P0115 Engine Coolant • Measured voltage of ECT sensor signal circuit is
(Page Temperature Sensor 1 higher than 4.85 V for 2 sec. 1 D/C Lights up
1A-237) Circuit • Measured voltage of ECT sensor signal circuit is
lower than 0.1 V for 2 sec.
Any of the following conditions is met.
• Measured voltage of APP sensor (main) signal circuit
is lower than 0.3 V and output voltage of APP sensor
*P0120 Throttle / Pedal Position (sub) signal circuit is higher than 1.16 V.
(Page Sensor / Switch “A” • Measured voltage of APP sensor (main) signal circuit 1 D/C Lights up
1A-238) Circuit is higher than 4.8 V.
• Both measured voltages of APP sensor (main) and
APP sensor (sub) signal circuits are lower than 0.05
V.
P0130
O2 Sensor Circuit (Bank1 Measured voltages of A/F sensor signal circuits are out
(Page 1 D/C Off
Sensor1) of specified range.
1A-239)
Any of the following conditions is met.
• Measured voltage of A/F sensor heater drive circuit is
P0135 higher than specified value for 3 sec. even when
O2 Sensor Heater Circuit
(Page command signal of A/F sensor heater is ON. 1 D/C Off
(Bank1 Sensor1)
1A-240) • Measured voltage of A/F sensor heater drive circuit is
lower than specified value for 3 sec. even when
command signal of A/F sensor heater is OFF.
P0168
Fuel Temperature Too
(Page Fuel temperature is higher than specified value. 1 D/C Off
High
1A-241)
Any of the following conditions is met.
*P0180 • Measured voltage of fuel temperature sensor signal
Fuel Temperature Sensor
(Page circuit is higher than 4.85 V for 3 sec. 1 D/C Lights up
“A” Circuit
1A-241) • Measured voltage of fuel temperature sensor signal
circuit is lower than 0.1 V for 3 sec.
Any of the following conditions is met.
• Measured voltage of fuel pressure sensor signal
circuit is higher than 4.85 V.
*P0190 • Measured voltage of fuel pressure sensor signal
Fuel Rail Pressure
(Page circuit is lower than 0.15 V. 1 D/C Lights up
Sensor “A” Circuit
1A-243) • Difference between current fuel pressure and
previous fuel pressure at specified vehicle condition
is more than 10 MPa (102.0 kgf/cm2, 1,450 psi, 100
bar).
*P0201
Injector Circuit / Open-
(Page 1 D/C Lights up
Cylinder 1
1A-244)
*P0202 Any of the following conditions is met.
Injector Circuit / Open-
(Page 1 D/C Lights up
Cylinder 2 • Measured voltage of relevant fuel injector drive circuit
1A-244)
(high side) does not match command signal.
*P0203
Injector Circuit / Open- • Measured voltage of relevant fuel injector drive circuit
(Page 1 D/C Lights up
Cylinder 3 (low side) does not match command signal.
1A-244)
*P0204
Injector Circuit / Open-
(Page 1 D/C Lights up
Cylinder 4
1A-244)

DTC DTC name
P0217
Engine Coolant Over
(Page
Temperature Condition
1A-246)
*P0219
Engine Overspeed
(Page
Condition
1A-248)
*P0220 Throttle / Pedal Position
(Page Sensor / Switch “B”
1A-249) Circuit
*P0230
Fuel Pump Primary
(Page
Circuit
1A-251)
*P0234 Turbocharger /
(Page Supercharger “A”
1A-225) Overboost Condition
*P0235 Turbocharger /
(Page Supercharger Boost
1A-252) Sensor “A” Circuit
*P0243 Turbocharger /
(Page Supercharger Wastegate
1A-253) Solenoid “A”
*P0335
Crankshaft Position
(Page
Sensor “A” Circuit
1A-254)
*P0340 Camshaft Position
(Page Sensor “A” Circuit (Bank1
1A-256) or Single Sensor)
P0380
Glow Plug / Heater Circuit Measured voltage of glow plug control module drive
(Page
“A”
1A-258)
*P0401 Exhaust Gas
(Page Recirculation “A” Flow
1A-259) Insufficient Detected
*P0402 Exhaust Gas
(Page Recirculation “A” Flow
1A-259) Excessive Detected
Engine General Information and Diagnosis: D13A 1A-184
DTC
DTC detecting condition detection MIL
logic
ECM limits driving performance by high coolant
1 D/C Off
temperature.
Engine speed exceeds 6,000 rpm for 2 sec. 1 D/C Lights up
Any of the following conditions is met.
• Measured voltage of APP sensor (sub) signal circuit
is lower than 0.3 V and output voltage of APP sensor
(main) signal circuit is higher than 0.86 V.
• Measured voltage of APP sensor (sub) signal circuit 1 D/C Lights up
is higher than 4.9 V.
• Both measured voltages of APP sensor (main) and
APP sensor (sub) signal circuits are lower than 0.05
V.
Any of the following conditions is met.
• Measured voltage of fuel pump relay drive circuit is
higher than specified value even when command
signal of fuel pump relay is ON. 1 D/C Lights up
• Measured voltage of fuel pump relay drive circuit is
lower than specified value even when command
signal of fuel pump relay is OFF.
Boost pressure is higher than barometric pressure by
1 D/C Lights up
200 kPa (2.0 kgf/cm2, 29.0 psi, 2.0 bar) for 1 sec.
Any of the following conditions is met.
• Measured voltage of boost pressure sensor signal
circuit is higher than 4.9 V for 2 sec. 1 D/C Lights up
• Measured voltage of boost pressure sensor signal
circuit is lower than 0.2 V for 2 sec.
Any of the following conditions is met.
• Measured voltage of boost pressure control solenoid
valve drive circuit does not match command signal of
boost pressure control solenoid valve. 1 D/C Lights up
• Difference between actual boost pressure and
estimated boost pressure is more than specified
value when turbocharger is operated.
CKP sensor signal is not input even if CMP sensor
1 D/C Lights up
signal is input.
Any of the following conditions is met.
• Measured voltage of CMP sensor signal circuit is
1 D/C Lights up
higher or lower than specified value.
• CMP sensor signal is not expected value.
1 D/C Off
circuit does not match command signal for 2 sec.
Difference between measured intake air mass and
estimated intake air mass is higher than specified value 3 D/C Lights up
for 10 sec.
Difference between measured intake air mass and
estimated intake air mass is out of specified range for 3 D/C Lights up
10 sec.
1A-185 Engine General Information and Diagnosis: D13A

DTC
DTC DTC name DTC detecting condition detection MIL
logic
*P0403 Exhaust Gas
Measured voltage of EGR valve drive circuit does not
(Page Recirculation “A” Control 3 D/C Lights up
match command signal for 2 sec.
1A-261) Circuit
Any of the following conditions is met.
• Radiator cooling fan relay No.1 drive circuit is open.
P0480
(Page Fan 1 Control Circuit • Radiator cooling fan relay No.1 drive circuit is 1 D/C Off
1A-262) shorted to power supply.
• Radiator cooling fan relay No.1 drive circuit is
shorted to ground.
Any of the following conditions is met.
• Radiator cooling fan relay No.2 and/or No.3 drive
P0481 circuit is open.
(Page Fan 2 Control Circuit • Radiator cooling fan relay No.2 and/or No.3 drive 1 D/C Off
1A-263) circuit is shorted to power supply.
• Radiator cooling fan relay No.2 and/or No.3 drive
circuit is shorted to ground.
*P0500
Invalid vehicle speed signal is received from ABS
(Page Vehicle Speed Sensor “A” 3 D/C Lights up
control module via CAN.
1A-265)
P0520
Engine Oil Pressure Measured voltage of oil pressure switch signal circuit is
(Page 1 D/C Off
Sensor / Switch Circuit higher than specified value when engine is not running.
1A-266)
Any of the following conditions is met.
P0530 • Measured voltage of A/C refrigerant pressure sensor
A/C Refrigerant Pressure
(Page signal circuit is lower than 0.1 V for 2 sec. 1 D/C Off
Sensor “A” Circuit
1A-268) • Measured voltage of A/C refrigerant pressure sensor
signal circuit is higher than 4.9 V for 2 sec.
Brake Booster Pressure Refer to “DTC Table”: D13A Model in Section 11A
P0555 1 D/C Off
Switch Circuit (Page 11A-51).
Any of the following conditions is met.
P0560 • Measured voltage of backup power supply circuit is
(Page System Voltage higher than 16 V. 1 D/C Off
1A-270) • Measured voltage of backup power supply circuit is
lower than 6 V.
Any of the following conditions is met.
• Vehicle speed increases from under 10 km/h (6 mile/
P0571
h) to over 90 km/h (56 mile/h) even through brake
(Page Brake Switch “A” Circuit 1 D/C Off
pedal is depressed.
1A-271)
• Brake light switch signal does not correlate with
brake switch signal.
P0600
Serial Communication
(Page ECM internal failure is detected. 1 D/C Off
Link
1A-273)
*P0601 Internal Control Module
(Page Memory Check Sum ECM internal failure is detected. 1 D/C Lights up
1A-273) Error
*P0604 Internal Control Module
(Page Random Access Memory ECM internal failure is detected. 1 D/C Lights up
1A-273) (RAM) Error
*P060B Internal Control Module
(Page A/D Processing ECM internal failure is detected. 1 D/C Lights up
1A-273) Performance
 Engine General Information and Diagnosis: D13A 1A-186

DTC
DTC DTC name DTC detecting condition detection MIL
logic
*P0641
Sensor Reference Sensor power supply voltage “A” is higher than 5.3 V or
(Page 1 D/C Lights up
Voltage “A” Circuit / Open lower than 4.7 V.
1A-275)
Any of the following conditions is met.
• Measured voltage of A/C compressor relay drive
circuit is higher than specified value for 2 sec. even
P0645 when command signal of A/C compressor relay is
A/C Clutch Relay Control
(Page ON. 1 D/C Off
Circuit
1A-276) • Measured voltage of A/C compressor relay drive
circuit is lower than specified value for 2 sec. even
when command signal of A/C compressor relay is
OFF.
*P0651
Sensor Reference Sensor power supply voltage “B” is higher than 5.3 V or
(Page 1 D/C Lights up
Voltage “B” Circuit / Open lower than 4.7 V.
1A-278)
P0657
Actuator Supply Voltage Measured voltage of main relay drive circuit is lower or
(Page 1 D/C Off
“A” Circuit / Open higher than specified value.
1A-280)
P0683 Glow Plug Control
Measured voltage of glow plug drive circuit does not
(Page Module to PCM 1 D/C Off
match command signal for about 30 sec.
1A-258) Communication Circuit
*P0685
ECM/PCM Power Relay Measured voltage of main relay drive circuit does not
(Page 1 D/C Lights up
Control Circuit / Open match command signal.
1A-280)
*P0697
Sensor Reference Sensor power supply voltage “C” is higher than 5.3 V or
(Page 1 D/C Lights up
Voltage “C” Circuit / Open lower than 4.7 V.
1A-281)
P0704
Clutch Switch Input CPP No.2 switch signal does not change even though
(Page 1 D/C Off
Circuit gear is shifted 40 times.
1A-283)
P081D Neutral Input Circuit 1 D/C Off
Clutch Pedal Switch “A” /
P083F 1 D/C Off
“B” Correlation
ENG A-STOP DC-DC
P1330 Converter “A” 1 D/C Off
Performance
ENG A-STOP DC-DC
P1353 Converter “A” Output 1 D/C Off
Circuit Short to Ground
ENG A-STOP DC-DC Refer to “DTC Table” in Section 10I (Page 10I-11).
P135E Converter “A” Input 1 D/C Off
Circuit
ENG A-STOP DC-DC
P135F 1 D/C Off
Converter “A” Feedback
ENG A-STOP Battery
P1360 1 D/C Off
Performance
P1366 Battery Sensor 1 D/C Off
ENG A-STOP OFF
P13A0 1 D/C Off
Switch Circuit
1A-187 Engine General Information and Diagnosis: D13A

DTC
DTC DTC name DTC detecting condition detection MIL
logic
P13B0 ISG Belt 1 D/C Off
P13B8 ISG Wake-up Command 1 D/C Off
P13B9 ISG Inhibition Command 1 D/C Off
P13BA ISG Performance 1 1 D/C Off
Refer to “DTC Table”: D13A Model in Section 11A
P13BB ISG Performance 2 1 D/C Off
(Page 11A-51).
Brake Stroke Sensor
P13D3 1 D/C Off
Offset
Brake Stroke Sensor
P13D6 1 D/C Off
Performance
Any of the following conditions is met.
• Vehicle speed increases from under 10 km/h (6 mile/
P1571
h) to over 90 km/h (56 mile/h) even through brake
(Page Brake Switch Circuit 1 D/C Off
pedal is depressed.
1A-271)
• Brake switch signal does not correlate with brake
light signal.
Immobilizer ID and/or
P1610 1 D/C Off
Password Not Registered
P1611 Password Not Matched 1 D/C Off
EEPROM Reading /
P1622 Refer to “DTC Table”. 1 D/C Off
Writing Error
Immobilizer • Ignition switch model: (Page 10C-5)
P1642 Communication Line • Keyless push start model: (Page 10C-21) 1 D/C Off
Error
Immobilizer ID
P1644 1 D/C Off
Mismatched
P1646 ID Code Incorrectness 1 D/C Off
P1647
Vehicle Variant Not
(Page Vehicle variant data is not registered in ECM. 1 D/C Off
Programmed
1A-284)
Any of the following conditions is met.
• Measured voltage of APP sensor (main) signal circuit
is higher than output voltage of APP sensor (sub) by
*P2135 Throttle / Pedal Position 0.22 V though output voltage of APP sensor (main) is
(Page Sensor / Switch “A” / “B” lower than 1.27 V. 1 D/C Lights up
1A-285) Voltage Correlation • Measured voltage of APP sensor (main) signal circuit
is higher than output voltage of APP sensor (sub) by
0.32 V though output voltage of APP sensor (main) is
higher than 1.27 V.
Any of the following conditions is met.
P2146 Fuel Injector Group “A” • Measured voltage of fuel injector drive circuit (high
(Page Supply Voltage Circuit / side) is higher than 50 V. 1 D/C Off
1A-244) Open • Measured voltage of fuel injector drive circuit (high
side) is lower than 30 V.
Any of the following conditions is met.
*P2226 • Measured voltage of barometric pressure sensor
Barometric Pressure
(Page signal circuit is higher than 4.8 V for 2 sec. 1 D/C Lights up
Sensor “A” Circuit
1A-273) • Measured voltage of barometric pressure sensor
signal circuit is lower than 0.2 V for 2 sec.
P2237 O2 Sensor Positive
Any one of A/F sensor signal voltage is in abnormal
(Page Current Control Circuit / 1 D/C Off
condition.
1A-286) Open (Bank1 Sensor1)
P2244 O2 Sensor Reference
(Page Voltage Performance A/F power supply voltage is out of specified range. 1 D/C Off
1A-239) (Bank1 Sensor1)
 Engine General Information and Diagnosis: D13A 1A-188

DTC
DTC DTC name DTC detecting condition detection MIL
logic
P2264 Measured voltage of fuel filter water detection sensor is
Water in Fuel Sensor
(Page higher than specified value even though the voltage is 1 D/C Off
Circuit
1A-287) controlled at low level by ECM during self test.
P2297 O2 Sensor Out of Range
(Page During Deceleration A/F value at fuel cut is not as specified. 1 D/C Off
1A-286) (Bank1 Sensor1)
Engine Hood Switch
P254F Refer to “DTC Table” in Section 10I (Page 10I-11). 1 D/C Off
Circuit
P268A Fuel Injector Calibration
(Page Not Learned / Injector calibration code is not registered in ECM. 1 D/C Off
1A-289) Programmed
Control Module
U0073 1 D/C Off
Communication Bus Off
Lost Communication With
*U0121 ABS / ESP® Control 1 D/C Lights up
Module
Lost Communication With
Refer to “Troubleshooting for Lost Communication”:
U0131 Power Steering Control 1 D/C Off
D13A Model in Section 10H (Page 10H-32).
Module
Lost Communication With
U0140 1 D/C Off
Body Control Module
Lost Communication With
U0141 Keyless Start Control 1 D/C Off
Module
LIN Lost Communication
U2006 1 D/C Off
With ISG Refer to “Troubleshooting for Lost Communication”:
LIN Lost Communication D13A Model in Section 10H (Page 10H-32).
U2007 1 D/C Off
With Battery Sensor
U2023 ISG LIN Communication 1 D/C Off
Refer to “DTC Table”: D13A Model in Section 11A
Battery Sensor LIN
U2024 (Page 11A-51). 1 D/C Off
Communication
U2101 CAN Vehicle
CAN vehicle configuration data is not registered in
(Page Configuration List not 1 D/C Off
ECM.
1A-290) Programmed

Fail-Safe Table
AENJHB0B1124006
When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction persists but that mode
is canceled when ECM detects normal condition.
DTC DTC name Fail-safe operation
Electrical cause:
P0001
Fuel Volume Regulator Control Circuit • ECM stops engine.
(Page
/ Open Mechanical cause:
1A-224)
• ECM limits driving performance.
P0069 • ECM stops boost control.
Manifold Absolute Pressure-
(Page
Barometric Pressure Correlation • ECM limits driving performance slightly.
1A-225)
P0087
(Page Fuel Rail / System Pressure-Too Low ECM stops engine.
1A-227)
P0088
(Page Fuel Rail / System Pressure-Too High ECM stops engine.
1A-229)
P0089
Fuel Pressure Regulator1
(Page ECM limits driving performance slightly.
Performance
1A-230)
1A-189 Engine General Information and Diagnosis: D13A

DTC DTC name Fail-safe operation

P0095
Intake Air Temperature Sensor 2
(Page —
Circuit (Bank1)
1A-232)
P0100
(Page Mass or Volume Air Flow “A” Circuit —
1A-233)
P0101
Mass or Volume Air Flow “A” Circuit
(Page —
Range / Performance
1A-234)
P0107 • ECM stops ECM stops boost control.
Manifold Absolute Pressure /
(Page
Barometric Pressure Circuit Low • ECM limits driving performance slightly.
1A-225)
P0110
Intake Air Temperature Sensor 1
(Page —
Circuit (Bank1)
1A-236)
P0115 • ECM stops A/C control.
Engine Coolant Temperature Sensor
(Page • ECM operates radiator cooling fan at high speed.
1 Circuit
1A-237) • ECM inhibits ENG A-STOP system control.
• ECM limits driving performance slightly.
• ECM inhibits ENG A-STOP system control.
• If DTC P0220, P0571, P1571 or P2135 is concurrently present,
P0120
Throttle / Pedal Position Sensor / ECM executes the following fail-safe controls:
(Page
Switch “A” Circuit – When brake pedal is depressed, ECM fixes engine speed at
1A-238)
800 rpm.
– When brake pedal is released, ECM fixes engine speed at
1,000 rpm.
P0130
(Page O2 Sensor Circuit (Bank1 Sensor1) —
1A-239)
P0135
O2 Sensor Heater Circuit (Bank1
(Page —
Sensor1)
1A-240)
P0168
(Page Fuel Temperature Too High —
1A-241)
P0180
(Page Fuel Temperature Sensor “A” Circuit —
1A-241)
P0190
(Page Fuel Rail Pressure Sensor “A” Circuit ECM stops engine.
1A-243)
P0201
(Page Injector Circuit / Open-Cylinder1
1A-244)
P0202
(Page Injector Circuit / Open-Cylinder2
1A-244)
ECM stops control of applicable fuel injector.
P0203
(Page Injector Circuit / Open-Cylinder3
1A-244)
P0204
(Page Injector Circuit / Open-Cylinder4
1A-244)
P0217
Engine Coolant Over Temperature
(Page —
Condition
1A-246)
 Engine General Information and Diagnosis: D13A 1A-190

DTC DTC name Fail-safe operation

P0219
(Page Engine Overspeed Condition —
1A-248)
• ECM limits driving performance slightly.
• ECM inhibits ENG A-STOP system control.
• If DTC P0120, P0571, P1571 or P2135 is concurrently present,
P0220
Throttle / Pedal Position Sensor / ECM executes the following fail-safe controls:
(Page
Switch “B” Circuit – When brake pedal is depressed, ECM fixes engine speed at
1A-249)
800 rpm.
– When brake pedal is released, ECM fixes engine speed at
1,000 rpm.
P0230
(Page Fuel Pump Primary Circuit —
1A-251)
P0234 • ECM stops boost control.
Turbocharger / Supercharger “A”
(Page
Overboost Condition • ECM limits driving performance slightly.
1A-225)
P0235 • ECM stops boost control.
Turbocharger / Supercharger Boost
(Page
Sensor “A” Circuit • ECM limits driving performance slightly.
1A-252)
P0243
Turbocharger / Supercharger
(Page ECM limits driving performance slightly.
Wastegate Solenoid “A”
1A-253)
P0335
(Page Crankshaft Position Sensor “A” Circuit —
1A-254)
P0340
Camshaft Position Sensor “A” Circuit
(Page —
(Bank1 or Single Sensor)
1A-256)
P0380
(Page Glow Plug / Heater Circuit “A” —
1A-258)
P0401
Exhaust Gas Recirculation “A” Flow
(Page —
Insufficient Detected
1A-259)
P0402
Exhaust Gas Recirculation “A” Flow
(Page —
Excessive Detected
1A-259)
P0403
Exhaust Gas Recirculation “A” Control
(Page —
Circuit
1A-261)
P0480
(Page Fan1 Control Circuit ECM operates radiator cooling fan at high mode.
1A-262)
P0481
(Page Fan2 Control Circuit ECM operates radiator cooling fan at high mode.
1A-263)
P0500
(Page Vehicle Speed Sensor “A” ECM inhibits ENG A-STOP system control.
1A-265)
P0520
Engine Oil Pressure Sensor / Switch
(Page —
Circuit
1A-266)
1A-191 Engine General Information and Diagnosis: D13A

DTC DTC name Fail-safe operation

• ECM controls actuators assuming that A/C refrigerant pressure
P0530 is 1,600 kPa (16.3 kgf/cm2, 232 psi, 16 bar).
A/C Refrigerant Pressure Sensor “A”
(Page • ECM stops A/C control.
Circuit
1A-268) • If DTC P0645 is concurrently present, ECM operates radiator
cooling fan at high mode.
• ECM maintains charge amount at specified level.
• ECM inhibits deceleration energy regenerating.
• ECM inhibits ENG A-STOP system control.
P0555 Brake Booster Pressure Switch Circuit • ECM restarts engine immediately when engine auto stop
control is activated.
• ECM inhibits ISG from performing engine power assist.
• ECM inhibits stalling assist control when engine auto stop
control is activated.
P0560
(Page System Voltage ECM inhibits ENG A-STOP system control.
1A-270)
If DTC P0120, P0220, P1571 or P2135 is concurrently present,
ECM executes the following fail-safe controls:
P0571
• When brake pedal is depressed, ECM fixes engine speed at
(Page Brake Switch “A” Circuit
800 rpm.
1A-271)
• When brake pedal is released, ECM fixes engine speed at
1,000 rpm.
P0600
(Page Serial Communication Link —
1A-273)
P0601
Internal Control Module Memory
(Page ECM stops engine.
Check Sum Error
1A-273)
P0604
Internal Control Module Random
(Page ECM stops engine.
Access Memory (RAM) Error
1A-273)
P060B
Internal Control Module A/D
(Page ECM stops engine.
Processing Performance
1A-273)
P0641
Sensor Reference Voltage “A” Circuit /
(Page ECM stops engine.
Open
1A-275)
P0645 • ECM stops idle speed control related to A/C.
(Page A/C Clutch Relay Control Circuit • If DTC P0530 is concurrently present, ECM operates radiator
1A-276) cooling fan at high mode.
P0651
Sensor Reference Voltage “B” Circuit /
(Page ECM limits driving performance slightly.
Open
1A-278)
P0657
Actuator Supply Voltage “A” Circuit /
(Page —
Open
1A-280)
P0683
Glow Plug Control Module to PCM
(Page —
Communication Circuit
1A-258)
P0685
ECM/PCM Power Relay Control
(Page —
Circuit / Open
1A-280)
P0697
Sensor Reference Voltage “C” Circuit /
(Page ECM limits driving performance slightly.
Open
1A-281)
 Engine General Information and Diagnosis: D13A 1A-192

DTC DTC name Fail-safe operation

P0704
(Page Clutch Switch Input Circuit ECM inhibits ENG A-STOP system control.
1A-283)
P081D Neutral Input Circuit • ECM inhibits deceleration energy regenerating.
• ECM inhibits ENG A-STOP system control.
• ECM inhibits engine restart when engine auto stop control is
Clutch Pedal Switch “A” / “B” activated.
P083F
Correlation • ECM inhibits ISG from performing engine power assist.
• ECM inhibits stalling assist control when engine auto stop
control is activated.
ENG A-STOP DC-DC Converter “A” • ECM inhibits deceleration energy regenerating.
P1330
Performance • ECM inhibits ENG A-STOP system control.
ENG A-STOP DC-DC Converter “A”
P1353 • ECM restarts engine immediately when engine auto stop
Output Circuit Short to Ground
control is activated.
ENG A-STOP DC-DC Converter “A”
P135E • ECM inhibits ISG from performing engine power assist.
Input Circuit
ENG A-STOP DC-DC Converter “A” • ECM inhibits stalling assist control when engine auto stop
P135F
Feedback control is activated.
P1360 ENG A-STOP Battery Performance • ECM maintains charge amount at specified level.
• ECM inhibits deceleration energy regenerating.
• ECM inhibits ENG A-STOP system control.
• ECM restarts engine immediately when engine auto stop
P1366 Battery Sensor control is activated.
• ECM inhibits ISG from performing engine power assist.
• ECM inhibits stalling assist control when engine auto stop
control is activated.
• ECM inhibits deceleration energy regenerating.
• ECM inhibits ENG A-STOP system control.
• ECM restarts engine immediately when engine auto stop
P13A0 ENG A-STOP OFF Switch Circuit control is activated.
• ECM inhibits ISG from performing engine power assist.
• ECM inhibits stalling assist control when engine auto stop
control is activated.
P13B0 ISG Belt • ECM maintains charge amount at specified level.
P13B8 ISG Wake-up Command • ECM inhibits deceleration energy regenerating.
P13B9 ISG Inhibition Command
• ECM inhibits ENG A-STOP system control.
P13BA ISG Performance 1
• ECM inhibits engine restart when engine auto stop control is
activated.
P13BB ISG Performance 2 • ECM inhibits ISG from performing engine power assist.
• ECM inhibits stalling assist control when engine auto stop
control is activated.
P13D3 Brake Stroke Sensor Offset
ECM inhibits deceleration energy regenerating.
P13D6 Brake Stroke Sensor Performance
If DTC P0120, P0220, P0571 or P2135 is concurrently present,
ECM executes the following fail-safe controls:
P1571
• When brake pedal is depressed, ECM fixes engine speed at
(Page Brake Switch Circuit
800 rpm.
1A-271)
• When brake pedal is released, ECM fixes engine speed at
1,000 rpm.
1A-193 Engine General Information and Diagnosis: D13A

DTC DTC name Fail-safe operation

Immobilizer ID and/or Password Not
P1610
Registered
P1611 Password Not Matched
P1622 EEPROM Reading / Writing Error
Immobilizer Communication Line
P1642
Error —
P1644 Immobilizer ID Mismatched
P1646 ID Code Incorrectness
P1647
(Page Vehicle Variant Not Programmed
1A-284)
• ECM limits driving performance slightly.
• If DTC P0120, P0220, P0571 or P1571 is concurrently present,
ECM executes the following fail-safe controls:
P2135
Throttle / Pedal Position Sensor / – When brake pedal is depressed, ECM fixes engine speed at
(Page
Switch “A” / “B” Voltage Correlation 800 rpm.
1A-285)
– When brake pedal is released, ECM fixes engine speed at
1,000 rpm.
• ECM inhibits ENG A-STOP system control.
P2146
Fuel Injector Group “A” Supply
(Page —
Voltage Circuit / Open
1A-244)
P2226
Barometric Pressure Sensor “A”
(Page ECM limits driving performance slightly.
Circuit
1A-273)
P2237
O2 Sensor Positive Current Control
(Page —
Circuit / Open (Bank1 Sensor1)
1A-286)
P2244
O2 Sensor Reference Voltage
(Page —
Performance (Bank1 Sensor1)
1A-239)
P2264
(Page Water in Fuel Sensor Circuit —
1A-287)
P2297
O2 Sensor Out of Range During
(Page —
Deceleration (Bank1 Sensor1)
1A-286)
• ECM inhibits deceleration energy regenerating.
• ECM inhibits ENG A-STOP system control.
• ECM inhibits engine restart when engine auto stop control is
P254F Engine Hood Switch Circuit activated.
• ECM inhibits ISG from performing engine power assist.
• ECM inhibits stalling assist control when engine auto stop
control is activated.
P268A
Fuel Injector Calibration Not Learned /
(Page —
Programmed
1A-289)
• ECM maintains charge amount at specified level.
• ECM inhibits deceleration energy regenerating.
• ECM inhibits ENG A-STOP system control.
Control Module Communication Bus • ECM inhibits engine restart when engine auto stop control is
U0073
Off activated.
• ECM inhibits ISG from performing engine power assist.
• ECM inhibits stalling assist control when engine auto stop
control is activated.
 Engine General Information and Diagnosis: D13A 1A-194

DTC DTC name Fail-safe operation

• ECM maintains charge amount at specified level.
• ECM inhibits deceleration energy regenerating.
• ECM inhibits ENG A-STOP system control.
Lost Communication With ABS / • ECM restarts engine immediately when engine auto stop
U0121
ESP® Control Module control is activated.
• ECM inhibits ISG from performing engine power assist.
• ECM inhibits stalling assist control when engine auto stop
control is activated.
Lost Communication With Power
U0131 —
Steering Control Module
• ECM maintains charge amount at specified level.
• ECM inhibits deceleration energy regenerating.
• ECM inhibits ENG A-STOP system control.
Lost Communication With Body • ECM restarts engine immediately when engine auto stop
U0140
Control Module control is activated.
• ECM inhibits ISG from performing engine power assist.
• ECM inhibits stalling assist control when engine auto stop
control is activated.
Lost Communication With Keyless
U0141 —
Start Control Module
• ECM maintains charge amount at specified level.
• ECM inhibits deceleration energy regenerating.
• ECM inhibits ENG A-STOP system control.
U2006 LIN Lost Communication With ISG • ECM inhibits engine restart when engine auto stop control is
activated.
• ECM inhibits ISG from performing engine power assist.
• ECM inhibits stalling assist control when engine auto stop
control is activated.
• ECM maintains charge amount at specified level.
• ECM inhibits deceleration energy regenerating.
• ECM inhibits ENG A-STOP system control.
LIN Lost Communication With Battery • ECM restarts engine immediately when engine auto stop
U2007
Sensor control is activated.
• ECM inhibits ISG from performing engine power assist.
• ECM inhibits stalling assist control when engine auto stop
control is activated.
• ECM maintains charge amount at specified level.
• ECM inhibits deceleration energy regenerating.
• ECM inhibits ENG A-STOP system control.
U2023 ISG LIN Communication Error • ECM inhibits engine restart when engine auto stop control is
activated.
• ECM inhibits ISG from performing engine power assist.
• ECM inhibits stalling assist control when engine auto stop
control is activated.
• ECM maintains charge amount at specified level.
• ECM inhibits deceleration energy regenerating.
• ECM inhibits ENG A-STOP system control.
Battery Sensor LIN Communication • ECM restarts engine immediately when engine auto stop
U2024
Error control is activated.
• ECM inhibits ISG from performing engine power assist.
• ECM inhibits stalling assist control when engine auto stop
control is activated.
1A-195 Engine General Information and Diagnosis: D13A

DTC DTC name Fail-safe operation

U2101
CAN Vehicle Configuration List not
(Page —
Programmed
1A-290)

Scan Tool Data

AENJHB0B1124007
As the data values below are standard values estimated on the basis of values obtained from the normally operating
vehicles using a SUZUKI scan tool, use them as reference values. Even when the vehicle is in good condition, there
may be cases where the checked value does not fall within each specified data range. Therefore, judgment as
abnormal should not be made depending on these data alone. Also, conditions that can be checked by SUZUKI scan
tool are those detected by ECM and output from ECM as commands and there may be cases where the engine or
actuator is not operating (in the condition) as indicated by SUZUKI scan tool.

NOTE
• If communication between SUZUKI scan tool and ECM is not possible, perform the following
checks:
– Check communication condition between PC and VCI using SUZUKI scan tool function.
– Check DLC power circuit and ground circuit.
– Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
– Check serial data line. (Page 1A-222)
– Check ECM power circuit and ground circuit. (Page 1A-311)
• When checking data with engine running at idle or racing, place gear shift lever in neutral position
and apply parking brake fully.

Normal condition /
Scan tool data Vehicle condition Reference item
Reference value
Ignition Switch Ignition: “ON” ON
—
(Page 1A-202) Ignition: “OFF” OFF
Ignition: “ON” ON “Table C-1: Main Relay
Main Relay (Page
Operation Check”: D13A
1A-202) Ignition: “OFF” OFF
(Page 1A-311)
Engine: Running Active “Table A-1: Fuel Pump Relay
Fuel Pump (Page
Operation Check”: D13A
1A-202) Ignition: “ON” Inactive
(Page 1A-291)
Oil Pressure Switch Ignition: “ON” ON
—
(Page 1A-202) Engine: Running OFF
Ignition: “ON”
Closed Throttle ON
Accelerator pedal: Not depressed
Position (Page 1A- —
Ignition: “ON”
202) OFF
Accelerator pedal: Depressed
Engine: Idle speed after warming up ON “Table B-5: EGR Valve
EGR Valve (Page
Operation Check”: D13A
1A-202) Ignition: “ON” OFF
(Page 1A-305)
Ignition: Within a few seconds after setting
Glow Indicator Light ON
ignition “ON” —
(Page 1A-202)
Engine: Idle speed after warming up OFF
Ignition: Within a few seconds after setting “Table C-8: Glow Plug
Glow Plug (Page ON
ignition “ON” Operation Check”: D13A
1A-202)
Ignition: “ON” OFF (Page 1A-323)
Engine: Running without faulty condition OFF “MIL Check”: D13A (Page
MIL (Page 1A-202)
Engine: Running with faulty condition ON 1A-180)
Engine: Idle speed after warming up
A/C Compressor ON
A/C compressor: ON
Relay (Page 1A- —
Engine: Idle speed after warming up
202) OFF
A/C compressor: OFF
 Engine General Information and Diagnosis: D13A 1A-196

Normal condition /
Scan tool data Vehicle condition Reference item
Reference value
Engine: Idle speed after warming up
ON
A/C Switch (Page A/C switch: ON
—
1A-202) Engine: Idle speed after warming up
OFF
A/C switch: OFF
Ignition: “ON”
OFF
Brake Light Switch Brake pedal: Released
—
(Page 1A-202) Ignition: “ON”
ON
Brake pedal: Fully depressed
Ignition: “ON”
OFF
Brake Switch Brake pedal: Released
—
(Page 1A-202) Ignition: “ON”
ON
Brake pedal: Fully depressed
Ignition: “ON”
OFF
Clutch SW (Page Clutch pedal: Released
—
1A-202) Ignition: “ON”
ON
Clutch pedal: Halfway depressed
Battery Voltage
Ignition: “ON” 10 to 14 V —
(Page 1A-202)
Engine: Idle speed after warming up
Approx. 800 rpm “Table C-2: Engine Speed
Engine Speed A/C: Not operating
Check”: D13A (Page 1A-
(Page 1A-202) Engine: Idle speed after warming up
Approx. 900 rpm 313)
A/C: Operating
Engine: Idle speed after warming up
Approx. 800 rpm
Desired Idle (Page A/C: Not operating
—
1A-202) Engine: Idle speed after warming up
Approx. 900 rpm
A/C: Operating
“Table C-7: Speed Signal
Vehicle Speed The same value as
Vehicle: Running Check”: D13A (Page 1A-
(Page 1A-202) Speedometer.
322)
“Table C-3: ECT Sensor
ECT (Page 1A- 80 to 110 °C (176 to
Engine: Idle speed after warming up Check”: D13A (Page 1A-
202) 230 °F)
314)
–5 °C (–9 °F) +
“Table C-4: IAT-1 Sensor
IAT1 (Page 1A- environmental temp.
Engine: Idle speed after warming up Check”: D13A (Page 1A-
203) to 40 °C (72 °F) +
316)
environmental temp.
Ignition: “ON” 0.0 g/sec. “Table B-2: MAF Sensor
MAF (Page 1A-
Check”: D13A (Page 1A-
203) Engine: Idle speed after warming up 3 to 9.5 g/sec.
300)
Barometric pressure “Table B-3: Boost Pressure
MAP (Page 1A- Ignition: “ON”
is displayed. Sensor Check”: D13A (Page
203)
Engine: Idle speed after warming up 75 to 105 kPa 1A-302)
Boost Pressure Ignition: “ON” 50 to 80% “Table B-7: Boost Pressure
Control Solenoid Control Solenoid Valve
Valve Duty (Page Engine: Accelerated to 3,500 rpm 40 to 60% Operation Check”: D13A
1A-203) (Page 1A-309)
Ignition: “ON”
0.70 to 0.80 V “Table C-6: Accelerator
APP Sensor 1 Volt Accelerator pedal: Released
Pedal Check”: D13A (Page
(Page 1A-203) Ignition: “ON”
4.35 to 4.45 V 1A-319)
Accelerator pedal: Fully depressed
Ignition: “ON”
0.325 to 0.425 V “Table C-6: Accelerator
APP Sensor 2 Volt Accelerator pedal: Released
Pedal Check”: D13A (Page
(Page 1A-203) Ignition: “ON”
2.15 to 2.25 V 1A-319)
Accelerator pedal: Fully depressed
Ignition: “ON”
0% “Table C-6: Accelerator
Accel Position Accelerator pedal: Released
Pedal Check”: D13A (Page
(Page 1A-203) Ignition: “ON”
100% 1A-319)
Accelerator pedal: Fully depressed
1A-197 Engine General Information and Diagnosis: D13A

Normal condition /
Scan tool data Vehicle condition Reference item
Reference value
“Table B-5: EGR Valve
EGR Valve Opening
Engine: Idle speed after warming up 0 to 10% Operation Check”: D13A
(Page 1A-203)
(Page 1A-305)
• Manual single A/C model:
“A/C System Performance
Inspection”: Manual A/C
Single Type in Section 7B
(Page 7B-9)
• Manual dual A/C model:
Engine: Idle speed
“A/C System Performance
A/C Pressure A/C switch: ON
1,200 to 1,650 kPa Inspection”: Manual A/C
(Page 1A-203) Blower speed selector: MAX
Dual Type in Section 7B
Ambient temperature: 30 °C (86 °F)
(Page 7B-66)
• Auto A/C model: “A/C
System Performance
Inspection”: Automatic A/
C Dual Type in Section 7B
(Page 7B-100)
“Table A-3: Fuel Temperature
Fuel Temperature Environmental temp.
Engine: Idle speed after warming up Sensor Check”: D13A (Page
(Page 1A-203) to 95 °C (194 °F)
1A-294)
Total Injected Fuel
Engine: Idle speed after warming up 3.0 to 10.0 mm3/str —
(Page 1A-203)
“Table B-4: Barometric
Barometric Pressure Barometric pressure
Ignition: “ON” Pressure Check”: D13A
(Page 1A-203) is displayed.
(Page 1A-304)
“Table A-4: Fuel Pressure
Fuel Rail Pressure 20,000 to 40,000
Engine: Idle speed after warming up Sensor Circuit Check”: D13A
(Page 1A-203) kPa
(Page 1A-296)
Desired Fuel Rail
20,000 to 40,000
Pressure (Page Engine: Idle speed after warming up —
kPa
1A-203)
“Table A-5: Fuel Flow
Fuel Flow Actuator
Engine: Idle speed after warming up 20 to 40% Actuator Operation Check”:
(Page 1A-203)
D13A (Page 1A-298)
At rising ECT: ECT < 98 °C (208 °F)
OFF
At falling ECT: ECT < 95 °C (203 °F)
At rising ECT: 98 °C (208 °F) < ECT < 106
“Table C-9: Radiator Cooling
Radiator Cooling Fan °C (222 °F)
LOW Fan Operation Check”: D13A
(Page 1A-203) At falling ECT: 95 °C (203 °F) < ECT < 103
(Page 1A-326)
°C (217 °F)
At rising ECT: ECT > 106 °C (222 °F)
HIGH
At falling ECT: ECT > 103 °C (217 °F)
Ignition: “ON”
Water in fuel filter: More than specified ON
Fuel Filter Warning
value
Light (Page 1A- —
Ignition: “ON”
203)
Water in fuel filter: Less than specified OFF
value
A/F Sensor Heater Ignition: “ON” 0%
Duty (Page 1A-
Engine: Idle speed after warming up 40 to 70% “Table B-6: A/F Sensor
203)
Check”: D13A (Page 1A-
A/F Sensor Heater
700 to 900 °C (1,292 307)
Temperature Engine: Idle speed after warming up
to 1,652 °F)
(Page 1A-203)
 Engine General Information and Diagnosis: D13A 1A-198

Normal condition /
Scan tool data Vehicle condition Reference item
Reference value
Environmental temp. “Table C-5: IAT-2 Sensor
IAT2 (Page 1A-
Engine: Idle speed after warming up to 60 °C (108 °F) + Check”: D13A (Page 1A-
203)
environmental temp. 318)
Battery Temperature Battery temperature
— —
(Page 1A-203) is displayed
Battery Voltage
Ignition: “ON” 10 to 14 V —
(Page 1A-203)
Ignition: “ON” –8 to 0 A
Ignition: “ON”
–28 to –10 A
Battery Current Headlight: ON
—
(Page 1A-203) Ignition: “ON”
Headlight: ON –33 to –22 A
Blower speed selector: MAX position
Brake Booster
Vacuum Condition Engine: Idle speed after warming up 0 kPa —
(Page 1A-203)
Ignition: “ON”
Approx. 0%
Brake Stroke Brake pedal: Released
—
(Page 1A-203) Engine: Running
20 to 30%
Brake pedal: Fully depressed
Count for ISG
Engine auto start
Restart (Page 1A- Ignition: “ON” —
control counter
203)
Ignition: “ON”
Brake Stroke Sensor Approx. 1.0 V
Brake pedal: Released
Voltage (Page 1A- —
Engine: Running
203) 1.5 to 2.5 V
Brake pedal: fully depressed
ISG Rotation Speed
Engine: Idle speed after warming up Approx. 2,200 rpm —
(Page 1A-204)
Flag used for ISG drive belt: Slipping ON
validation of Belt
—
slipping (Page 1A- Other than above condition OFF
204)
BELT SLIP ISG drive belt: Slipping
JUDGEMENT FUNC Engine power assist or deceleration energy ON
Status for Assist or regeneration: Limit
Generation or —
Regeneration
Other than above condition OFF
strategy (Page 1A-
204)
BELT SLIP ISG drive belt: Slipping
ON
JUDGEMENT 4 IS Engine auto stop control: Prohibit
Status for Idle Stop —
Inhibit Judgement Other than above condition OFF
(Page 1A-204)
BELT SLIP ISG drive belt: Slipping
JUDGEMENT 4 Deceleration energy regeneration: ON
FIXGEN Status for Constant electricity generation
—
Fixed Generation
Mode Judgement Other than above condition OFF
(Page 1A-204)
ISG Equipped
Ignition: “ON” Equipped —
(Page 1A-204)
Ignition: “ON”
ON
Neutral SW (Page Gear position: Neutral
—
1A-204) Ignition: “ON”
OFF
Gear position: Other than neutral
1A-199 Engine General Information and Diagnosis: D13A

Normal condition /
Scan tool data Vehicle condition Reference item
Reference value
Ignition: “ON”
Opened
Hood Switch 1 Engine hood: Open
—
(Page 1A-204) Ignition: “ON”
Closed
Engine hood: Closed
Ignition: “ON”
Closed
Hood Switch 2 Engine hood: Open
—
(Page 1A-204) Ignition: “ON”
Opened
Engine hood: Closed
Starting Switch Starting motor relay: ON ON
—
(Page 1A-204) Other than above condition OFF
Ignition: “ON”
ON
Half Clutch Switch Clutch pedal: Halfway depressed
—
(Page 1A-204) Ignition: “ON”
OFF
Clutch pedal: Released
Ignition: “ON”
ON
Clutch Switch Clutch pedal: Fully depressed
—
(Page 1A-204) Ignition: “ON”
OFF
Clutch pedal: Released
Ignition: “ON”
ENG A-STOP OFF ON
ENG A-STOP OFF switch: Pushed
Switch (Page 1A- —
Ignition: “ON”
204) OFF
ENG A-STOP OFF switch: Released
Ignition: “ON”
Charge Warning Charging system malfunction
ON
Light (Page 1A- ECM detects DTC related to ENG A-STOP —
204) system.
Other than above condition OFF
ENG A-STOP Engine auto stop control: Operating
ON
Warning Light ENG A-STOP OFF switch: Pushed —
(Page 1A-204) Other than above condition OFF
SHVS Indicator Light Deceleration energy regeneration:
ON
(Regeneration) Operating —
(Page 1A-204) Other than above condition OFF
SHVS Indicator Light Engine power assist: Operating ON
(Assist) (Page 1A- —
Other than above condition OFF
204)
ENG A-STOP ECM detects DTC related to ENG A-STOP
ON
Warning Light system.
—
(Flashing) (Page
Other than above condition OFF
1A-204)
Generating Alternator
Engine auto restarting Restart
Preparation status of engine auto start
First Start
Machine Mode control
Status (Page 1A- Preparation status of generating Idle Preflux —
204) Engine stalling assist control is performing. Stalling Help
Engine power assist is performing. Torque Assist 1
Engine power assist is prohibited. Torque Assist 2
Other than above condition Neutral
Generating Alternator
Engine auto restarting Restart
Machine Mode
Engine stalling assist control is performing. Stalling Help
Request (Page 1A- —
Engine power assist is performing. Torque Assist 1
204)
Engine power assist is performing. Torque Assist 2
Other than above condition Neutral
Ignition: “ON” ON
Stop Mode (Page
Engine: Running —
1A-204) OFF
Engine auto stop control: Operating
 Engine General Information and Diagnosis: D13A 1A-200

Normal condition /
Scan tool data Vehicle condition Reference item
Reference value
Cranking Mode Engine: Cranking ON
—
(Page 1A-204) Other than above condition OFF
Auto Stop Mode Engine auto stop control: Operating ON
—
(Page 1A-204) Other than above condition OFF
Normal Mode Engine: Running ON
—
(Page 1A-204) Other than above condition OFF
Auto Start Mode Engine auto start control: Operating ON
—
(Page 1A-204) Other than above condition OFF
On Assist (Page Engine power assist: Operating ON
—
1A-204) Other than above condition OFF
On Generation Generation: Operating ON
—
(Page 1A-204) Other than above condition OFF
Full Charge (PageBattery: Full charge Enable
—
1A-204) Other than above condition Disable
Deceleration energy regeneration:
Regeneration Mode Enable
Operating —
(Page 1A-204)
Other than above condition Disable
Auto Stop Inhibit
Engine auto stop control: Inhibited
Request
Auto Stop System
Engine auto restart control: Permitted Auto Start Request
Request (Page 1A- —
Auto Start Inhibit
205) Engine auto restart control: Inhibited
Request
Other than above condition Not Request
Regeneration Enable Generation: Enable Enable
—
(Page 1A-205) Other than above condition Disable
Assist Enable Deceleration energy regeneration: Enable Enable
—
(Page 1A-205) Other than above condition Disable
Ignition: “OFF” ENG KEY OFF SAS
Ignition: “ON” ENG OFF SAS OFF
ENG A-STOP system is inactive while
ENG ON SAS OFF
engine is running.
ENG A-STOP system is active while
ENG ON SAS ON
engine is running.
Engine revolution: Decreasing ENG SAS
Engine auto stop control: Active STOPPING
Engine: Stopped ENG SAS
ENG A-STOP
Engine auto stop control: Active STOPPED
System Status —
Engine: Cranking
(Page 1A-205) ENG SAS CRK
Engine auto start control: Active
Engine restart by ISG is enable when ENG SAS STOP
engine is stalled. DRV
Engine restart by ISG is disable and
ENG SAS BUZ
warning buzzer sounds.
Engine stalls immediately when engine is ENG STOP SAS
restarted. OFF
Engine restart is performed before engine ENG SAS
stops completely. CHOFMIND
Auto Stop Request ECM requests engine auto stop control True
—
(Page 1A-205) Other than above condition False
Auto Start Request ECM requests engine auto start control True
—
(Page 1A-205) Other than above condition False
Driver Door Status Driver door: Closed Close
—
(Page 1A-205) Other than above condition Open
Driver Seatbelt Driver seatbelt: Fastened Fasten
Switch (Page 1A- —
Other than above condition Unfasten
205)
ABS Active (Page ABS: Operating True
—
1A-205) Other than above condition False
1A-201 Engine General Information and Diagnosis: D13A

Normal condition /
Scan tool data Vehicle condition Reference item
Reference value
Ignition: “ON”
Front Wiper Active Front wiper switch: “INT”, “LO” or “HI” Active
—
(Page 1A-205) position
Other than above condition Not Active
Air Conditioning Engine auto stop control: Operating Engine Run
Compressor Engine A/C switch: ON Requested
—
Run Request
Other than above condition No Action
(Page 1A-205)
ISG Error Flag ISG malfunction is detected. True
—
(Page 1A-205) Other than above condition False
ECM Error Flag ECM detects malfunction True
—
(Page 1A-205) Other than above condition False
ABS control module detects malfunction
ABS Error Flag True
related to ISG control —
(Page 1A-205)
Other than above condition False
Brake Stroke Sensor Brake stroke sensor calibration: Completed False
Not Calibrated —
Other than above condition True
(Page 1A-205)
All Status for A- All of ENG A-STOP execution condition are
True
STOP (Page 1A- satisfied. —
205) Other than above condition False
Diagnostic Status for DTC related to ENG A-STOP system is
False
A-STOP (Page 1A- detected. —
205) Other than above condition True
Battery Status Battery: Normal condition True
(Voltage, Discharge,
—
Charge) for A-STOP Other than above condition False
(Page 1A-205)
Battery Status Battery temperature: In specified value True
(Temperature) for A-
—
STOP (Page 1A- Other than above condition False
205)
Engine Coolant Engine coolant temperature: In specified
True
Temperature Status value
—
for A-STOP (Page
Other than above condition False
1A-205)
Brake Booster Status Brake booster switch: ON True
for A-STOP (Page —
Other than above condition False
1A-205)
Neutral Switch Status Gear position: Neutral True
for A-STOP (Page —
Other than above condition False
1A-205)
Hood Switch Status Engine hood: Closed True
for A-STOP (Page —
Other than above condition False
1A-205)
Accelerator Pedal Accelerator pedal: Released True
Status for A-STOP —
Other than above condition False
(Page 1A-205)
Clutch Pedal Status Clutch pedal: Released True
for A-STOP (Page —
Other than above condition False
1A-205)
Vehicle Speed After vehicle running under specified
True
History Status for A- condition
—
STOP (Page 1A-
Other than above condition False
206)
ABS Status for A- ABS: Operating False
STOP (Page 1A- —
Other than above condition True
206)
 Engine General Information and Diagnosis: D13A 1A-202

Normal condition /
Scan tool data Vehicle condition Reference item
Reference value
A/C Status for A- A/C: OFF True
STOP (Page 1A- —
A/C: ON False
206)
ENG A-STOP OFF ENG A-STOP system is not inhibited by
True
Switch Status for A- ENG A-STOP OFF switch.
—
STOP (Page 1A-
Other than above condition False
206)
ISG Belt Status for A- ISG belt: Normal condition True
STOP (Page 1A- —
Other than above condition False
206)
ISG Regulated Ignition: “ON” 10 to 14 V
Voltage (Page 1A- —
Engine: Idle speed after warming up 12 to 15 V
206)
Pb Battery SOC
Ignition: “ON” 50 to 100% —
(Page 1A-206)
Battery Voltage at
Last Cranking Peak Engine: Idle speed after warming up 3 to 15 V —
(Page 1A-206)

Scan Tool Data Definitions A/C Switch (ON/OFF)

Ignition Switch (ON/OFF) This parameter indicates the state that ECM operates A/
This parameter indicates operating state of ignition C by request from BCM.
switch. “ON” is displayed when the ignition mode is
“ON”. Brake Light Switch (ON/OFF)
This parameter indicates the state of the brake light
Main Relay (ON/OFF) switch signal inputted into ECM.
This parameter indicates operating state of main relay.
Brake Switch (ON/OFF)
Fuel Pump (Active / Inactive) This parameter indicates operating state of brake switch.
This parameter indicates operating state of the fuel
pump relay requested by ECM. Clutch SW (Clutch pedal position switch, ON/OFF)
This parameter indicates operating state of CPP No.2
Oil Pressure Switch (ON/OFF) switch.
This parameter indicates the state of the oil pressure
switch. Battery Voltage (V)
This parameter indicates battery positive voltage
Closed Throttle Position (ON/OFF) inputted from main relay to ECM.
This parameter indicates operating state of accelerator
pedal. Engine Speed (rpm)
This parameter indicates revolutions per minute of
EGR Valve (ON/OFF) engine. It is calculated based on the input signal of CKP
This parameter indicates operating state of EGR valve. sensor.

Glow Indicator Light (ON/OFF) Desired Idle (Desired idle speed) (rpm)
This parameter indicates operating state of glow The desired idle speed is an ECM internal parameter
indicator light. which indicates idle speed requested by ECM. If the
engine is not running this number is not valid.
Glow Plug (ON/OFF)
This parameter indicates the state of glow plug signal Vehicle Speed (km/h, MPH)
from ECM to glow plug control module. This parameter indicates the vehicle speed based on
wheel speed signals sent from ABS control module via
MIL (ON/OFF) CAN communication.
This parameter indicates operating state of MIL.
ECT (Engine coolant temperature, °C, °F)
A/C Compressor Relay (ON/OFF) This parameter indicates the calculated ECT based on
This parameter indicates operating state of A/C ECT sensor voltage.
compressor relay.
1A-203 Engine General Information and Diagnosis: D13A
IAT1 (Intake Air Temperature-1, °C, °F)
This parameter indicates the calculated IAT-1 based on
IAT-1 sensor voltage.
MAF (Mass air flow rate) (g/sec., Lb/min)
This parameter indicates mass air flow rate calculated by
ECM based on input voltage of MAF sensor.
MAP (Manifold Absolute Pressure, kPa, mmHg,
in.Hg, psi, inH2O)
This parameter indicates boost pressure calculated by
ECM based on input voltage of boost pressure sensor.
Boost Pressure Control Solenoid Valve Duty (%)
This parameter indicates the valve ON (valve open) time
ratio of signal for controlling boost pressure control
solenoid valve which controls the boost pressure.
APP Sensor 1 Volt (APP sensor (main) output
voltage, V)
This parameter indicates the input voltage of APP
sensor (main) installed in the accelerator pedal.
APP Sensor 2 Volt (APP sensor (sub) output voltage,
V)
This parameter indicates the input voltage of APP
sensor (sub) installed in the accelerator pedal.
Accel Position (Accelerator pedal position) (%)
This parameter indicates the depressing amount of
accelerator pedal calculated by ECM based on the input
signals of the APP sensor (main and sub) in percentage.
EGR Valve Opening (%)
This parameter indicates EGR valve control duty
percentage.
A/C Pressure (A/C refrigerant pressure) (kPa)
This parameter indicates the calculated A/C refrigerant
absolute pressure based on A/C refrigerant pressure
sensor voltage.
Fuel Temperature (°C, °F)
This parameter indicates fuel temperature calculated by
ECM based on input voltage of fuel temperature sensor.
Total Injected Fuel (mm3/str)
This parameter indicates quantity of fuel injection when
crankshaft is rotated two times (720°).
Barometric Pressure (kPa, mmHg, in.Hg, psi, inH2O)
This parameter indicates barometric air pressure
calculated by barometric pressure sensor in ECM.
Fuel Rail Pressure (Fuel pressure in common rail,
kPa, mmHg, in.Hg, psi, inH2O)
This parameter indicates fuel pressure in common rail
calculated by fuel pressure sensor signals.
Desired Fuel Rail Pressure (Fuel pressure in
common rail (target)) (kPa, mmHg, in.Hg, psi, inH2O)
This parameter indicates the target fuel pressure in
common rail calculated by ECM based on various input
signals.
Fuel Flow Actuator (%)
This parameter indicates duty ratio of the signal that
controls opening time of fuel flow actuator.
Radiator Cooling Fan (OFF/LOW/HIGH)
This parameter indicates the state of radiator cooling fan
control relay.
Fuel Filter Warning Light (ON / OFF)
This parameter indicates operating state of fuel filter
warning light.
A/F Sensor Heater Duty (%)
This parameter indicates ON time ratio of control signal
for A/F sensor heater.
A/F Sensor Heater Temperature (°C, °F)
This parameter indicates A/F sensor heater temperature
calculated by ECM based on input signal of A/F sensor
heater circuit.
IAT2 (Intake Air Temperature-2, °C, °F)
This parameter indicates the calculated IAT-2 based on
IAT-2 sensor voltage.
Battery Temperature (°C, °F)
This parameter indicates battery temperature calculated
by ECM based on battery sensor signal.
Battery Voltage (V)
This parameter indicates battery positive voltage
inputted from main relay to ECM.
Battery Current (A)
This parameter indicates battery current calculated by
ECM based on battery sensor signal.
Brake Booster Vacuum Condition (kPa)
This parameter indicates the state of brake booster
negative pressure.
Brake Stroke (%)
This parameter indicates the depression amount of the
brake pedal detected by the brake stroke sensor as a
percentage.
Count for ISG Restart (Times)
This parameter indicates number of times the engine is
restarted by ISG. This parameter is renewed when the
engine is restarted 5 times by ISG.
Brake Stroke Sensor Voltage (V)
This parameter indicates brake pedal position
information in voltage from brake stroke sensor.
 Engine General Information and Diagnosis: D13A 1A-204
ISG Rotation Speed (rpm)
This parameter indicates ISG rotation speed measured
by ISG.
Flag used for validation of Belt slipping (ON/OFF)
This parameter indicates the state of ISG belt slipping.
BELT SLIP JUDGEMENT FUNC Status for Assist or
Generation or Regeneration strategy (ON/OFF)
This parameter indicates restriction of engine power
assist and power generation by ISG when slippage of
the belt occurs.
BELT SLIP JUDGEMENT 4 IS Status for Idle Stop
Inhibit Judgement (ON/OFF)
This parameter indicates inhibition of engine auto stop
control when slippage of the belt occurs.
BELT SLIP JUDGEMENT 4 FIXGEN Status for Fixed
Generation Mode Judgement (ON/OFF)
This parameter indicates fixed power generation when
slippage of the belt occurs.
ISG Equipped (Equipped / Unequipped)
This parameter indicates whether this vehicle is
equipped with ISG.
Neutral SW (Neutral Switch, ON/OFF)
This parameter indicates operating state of neutral
position switch.
Hood Switch1 (Opened/Closed)
This parameter indicates operating state of hood latch
switch 1.
Hood Switch2 (Opened/Closed)
This parameter indicates operating state of hood latch
switch 2.
Starting Switch (ON/OFF)
This parameter indicates operating state of starting
motor control relay.
Half Clutch Switch (ON/OFF)
This parameter indicates operating state of CPP No.2
switch.
Clutch Switch (ON/OFF)
This parameter indicates operating state of CPP No.1
switch.
ENG A-STOP OFF Switch (ON/OFF)
This parameter indicates operating state of ENG A-
STOP OFF switch.
Charge Warning Light (ON/OFF)
This parameter indicates the state of charge warning
light.
ENG A-STOP Warning Light (ON/OFF)
This parameter indicates operating of ENG A-STOP
warning light for ENG A-STOP system.
SHVS Indicator Light (Regeneration) (ON/OFF)
This parameter indicates operating state of SHVS
indicator light. “ON” shows deceleration energy
regeneration by ISG.
SHVS Indicator Light (Assist) (ON/OFF)
This parameter indicates operating state of SHVS
indicator light. “ON” shows engine power assist by ISG.
ENG A-STOP Warning Light (Flashing) (ON/OFF)
This parameter indicates malfunction of ENG A-STOP
system.
Machine Mode Status (Neutral / Alternator / Restart /
First Start / Idle Preflux / Stalling Help / Torque Assist
1 / Torque Assist 2)
This parameter indicates actual control state of ISG.
Machine Mode Request (Neutral / Alternator / Restart
/ Stalling Help / Torque Assist 1 / Torque Assist 2)
This parameter indicates requested control of ISG.
Stop Mode (ON/OFF)
This parameter indicates the state of the engine stopping
with ignition “ON”.
Cranking Mode (ON/OFF)
This parameter indicates the state of the first engine
cranking by using starting motor.
Auto Stop Mode (ON/OFF)
This parameter indicates operating state of engine auto
stop control.
Normal Mode (ON/OFF)
This parameter indicates the state of the engine running
normally.
Auto Start Mode (ON/OFF)
This parameter indicates the state that ECM requires
restart to ISG.
On Assist (ON/OFF)
This parameter indicates operating state of engine
power assist.
On Generation (ON/OFF)
This parameter indicates the state of generation.
Full Charge (Enable / Disable)
This parameter indicates whether battery is fully charged
or not.
Regeneration Mode (Enable / Disable)
This parameter indicates whether deceleration energy
regeneration is performed or not.
1A-205 Engine General Information and Diagnosis: D13A
Auto Stop System Request (No Request / Auto Stop
Inhibit Request / Auto Start Request / Auto Start
Inhibit Request)
This parameter indicates requested state of ENG A-
STOP system.
Regeneration Enable (Enable / Disable)
This parameter indicates enabled state of deceleration
energy regeneration.
Assist Enable (Enable / Disable)
This parameter indicates enabled state of engine power
assist.
ENG A-STOP System Status (ENG KEY OFF SAS/
ENG OFF SAS OFF/ENG ON SAS OFF/ENG ON SAS
ON/ENG SAS STOPPING/ENG SAS STOPPED/ENG
SAS CRK/ENG SAS STOP DRV/ENG SAS BUZ/ENG
STOP SAS OFF/ENG SAS CHOFMIND)
This parameter indicates operating state of ENG A-
STOP system.
Auto Stop Request (True / False)
This parameter indicates whether engine auto stop
control is requested from ECM or not.
Auto Start Request (True / False)
This parameter indicates whether engine auto start
control is requested from ECM or not.
Driver Door Status (Open / Close)
This parameter indicates operating state of driver door
switch.
Driver Seatbelt Switch (Unfasten / Fasten)
This parameter indicates operating state of driver
seatbelt switch.
ABS Active (True / False)
This parameter indicates operating state of ABS.
Front Wiper Active (Active / Not Active)
This parameter indicates operating state of windshield
wiper.
Air Conditioning Compressor Engine Run Request
(Engine Run Requested / No Action)
This parameter indicates the state of “Engine start
request” with air conditioner.
ISG Error Flag (True / False)
This parameter indicates whether malfunction due to
ISG is detected or not.
ECM Error Flag (True / False)
This parameter indicates whether malfunction is
detected by ECM or not.
ABS Error Flag (True / False)
This parameter indicates whether malfunction of ABS
control module related to ISG control is detected or not.
Brake Stroke Sensor Not Calibrated (True / False)
This parameter indicates whether brake stroke sensor
calibration is completed or not.
All Status for A-STOP (True / False)
This parameter indicates whether requirements for ENG
A-STOP system activation are satisfied or not.
Diagnostic Status for A-STOP (True / False)
This parameter indicates whether DTC detecting
conditions for ENG A-STOP system activation are
satisfied or not.
Battery Status (Voltage, Discharge, Charge) for A-
STOP (True / False)
This parameter indicates whether battery voltage
requirements for ENG A-STOP system activation are
satisfied or not.
Battery Status (Temperature) for A-STOP (True /
False)
This parameter indicates whether battery temperature
requirements for ENG A-STOP system activation are
satisfied or not.
Engine Coolant Temperature Status for A-STOP
(True / False)
This parameter indicates whether ECT requirements for
ENG A-STOP system activation are satisfied or not.
Brake Booster Status for A-STOP (True / False)
This parameter indicates whether requirements of brake
booster negative pressure for ENG A-STOP system
activation are satisfied or not.
Neutral Switch Status for A-STOP (True / False)
This parameter indicates whether requirements of
neutral position switch operating state for ENG A-STOP
system activation are satisfied or not.
Hood Switch Status for A-STOP (True / False)
This parameter indicates whether hood switch
requirements for ENG A-STOP system activation are
satisfied or not.
Accelerator Pedal Status for A-STOP (True / False)
This parameter indicates whether accelerator pedal
requirement for ENG A-STOP system activation is
satisfied or not.
Clutch Pedal Status for A-STOP (True / False)
This parameter indicates whether clutch pedal
requirements for ENG A-STOP system activation are
satisfied or not.
 Engine General Information and Diagnosis: D13A 1A-206

Vehicle Speed History Status for A-STOP (True /
False)
This parameter indicates whether requirement of vehicle
speed history for ENG A-STOP system activation is
satisfied or not.
ABS Status for A-STOP (True / False)
This parameter indicates whether requirement of ABS
status for ENG A-STOP system activation is satisfied or
not.
A/C Status for A-STOP (True / False)
This parameter indicates whether requirement of A/C
status for ENG A-STOP system activation is satisfied or
not.
ISG Belt Status for A-STOP (True / False)
This parameter indicates whether requirement of ISG
belt status (belt slip) for ENG A-STOP system activation
is satisfied or not.
ISG Regulated Voltage (V)
This parameter indicates voltage of ISG regulator
inputted into ECM via central gateway control module.
Pb Battery SOC (%)
This parameter indicates battery SOC (State of Charge).
Battery Voltage at Last Cranking Peak (V)
This parameter indicates minimum voltage at the latest
cranking.

ENG A-STOP OFF Switch Status for A-STOP (True /

False)
This parameter indicates enabled state of ENG A-STOP
system activation based on ENG A-STOP OFF switch
operating state.

Visual Inspection
AENJHB0B1124008
Visually check the following parts and systems.
Inspection item Referring section
• Engine oil-level, leakage “Engine Oil and Filter Change”: D13A in Section 1E
(Page 1E-16)
• Engine coolant-level, leakage “Coolant Level Check”: D13A in Section 1F (Page 1F-
24)
• Fuel-level, leakage “Fuel Leakage Check Procedure”: D13A in Section 1G
(Page 1G-41)
• Air cleaner filter-dirt, clogging “Air Cleaner Filter Inspection and Cleaning”: D13A in
Section 1D (Page 1D-82)
• Battery-corrosion of terminal “Battery Description”: D13A in Section 1J (Page 1J-
12)
• ISG drive belt-tension, damage “ISG Drive Belt Inspection”: D13A in Section 1J (Page
1J-18)
• Water pump drive belt-tension, damage “Water Pump Drive Belt Inspection”: D13A in Section
1F (Page 1F-31)
• Vacuum hoses of air intake system-disconnection,
—
looseness, deterioration, bend
• Connectors of electric wire harness-disconnection, friction —
• Fuses-blown —
• Parts-installation, bolts-looseness —
• Parts-deformation —
• Other parts that can be checked visually —
Also check the following items at engine start, if possible
• MIL-Operation “MIL Check”: D13A (Page 1A-180)
• Charging light-Operation “Generator Symptom Diagnosis”: D13A in Section 1J
(Page 1J-14)
• Oil pressure light-Operation “Oil Pressure Switch On-Vehicle Inspection”: D13A in
Section 1E (Page 1E-17)
• Engine coolant temperature meter-Operation —
• Fuel level meter-Operation “Fuel Level Sensor Inspection”: D13A in Section 1G
(Page 1G-58)
• Tachometer-Operation —
• Abnormal air being inhaled from air intake system —
• Exhaust system-leakage of exhaust gas, noise —
• Other parts that can be checked visually —
1A-207 Engine General Information and Diagnosis: D13A

Engine Basic Inspection

AENJHB0B1124009
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found
in “Visual Inspection”: D13A (Page 1A-206).
Follow the flow carefully.
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Battery voltage check Go to Step 3. Charge or replace
1) Check battery voltage. battery.

Is it 12 V or more?
3 Can engine be cranked? Go to Step 4. Go to “Cranking System
Symptom Diagnosis”:
D13A in Section 1I
(Page 1I-17).
4 Does engine start? Go to “Engine Symptom Go to Step 5.
Diagnosis”: D13A (Page
1A-207).
5 Immobilizer system check Go to Step 6. Repair or replace
1) Check immobilizer control system. defective part(s).
• Ignition switch model: (Page 10C-5)
• Keyless push start model: (Page 10C-21)

Is check result OK?

6 Low fuel pressure circuit check Go to Step 7. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

7 High fuel pressure circuit check Go to “Hard Starting Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) (Engine Can Be defective part(s).
Cranked)” under
Is check result OK? “Engine Symptom
Diagnosis”: D13A (Page
1A-207).

Engine Symptom Diagnosis

AENJHB0B1124010
Perform troubleshooting referring to the following table when ECM has detected no DTC and no abnormality has been
found in “Visual Inspection”: D13A (Page 1A-206) and “Engine Basic Inspection”: D13A (Page 1A-207).
Condition Referring section
Hard starting (Engine can be cranked) Refer to “Hard Starting (Engine Can Be Cranked)”: D13A
(Page 1A-208).
Engine not running smoothly Refer to “Engine Not Running Smoothly”: D13A (Page 1A-
209).
Engine does not produce best performance Refer to “Engine Does Not Produce Best Performance”:
D13A (Page 1A-210).
Engine hesitation-momentary lack of response as Refer to “Engine Hesitation – Momentary Lack of
accelerator is depressed Response as Accelerator Is Depressed”: D13A (Page 1A-
212).
Improper engine idle or engine stops at idle speed Refer to “Improper Engine Idling or Engine Stops at Idle”:
D13A (Page 1A-213).
Engine cuts out whilst driving Refer to “Engine Cuts Out whilst Driving”: D13A (Page 1A-
214).
Engine knocking Refer to “Engine Knocking”: D13A (Page 1A-215).
White exhaust fumes Refer to “White Exhaust Fumes”: D13A (Page 1A-215).
Black exhaust fumes Refer to “Black Exhaust Fumes”: D13A (Page 1A-217).
 Engine General Information and Diagnosis: D13A 1A-208

Condition Referring section

Excessive exhaust fumes Refer to “Excessive Exhaust Fumes”: D13A (Page 1A-
218).
Excessive engine oil level Refer to “Engine Oil Excessive Level”: D13A (Page 1A-
219).
Poor fuel mileage Refer to “Poor Fuel Mileage”: D13A (Page 1A-219).
Excessive engine oil consumption Refer to “Engine Oil Excessive Consumption”: D13A
(Page 1A-220).

Hard Starting (Engine Can Be Cranked)

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. (Page 1E-16)
• Check that air intake / turbocharger circuit is working
properly. (Page 1A-299)
• Check that main and circuit fuses have not blown.
• Wiring on engine correctly connected to ground.
• Battery correctly connected to ground.
• Battery positive (+) cable and all leads are firmly
connected.

Is check result OK?

2 Parameter check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check the values of the following parameters. (Page
1A-195)
• Battery Voltage
• Accel Position
• APP Sensor 1 Volt
• APP Sensor 2 Volt
• Barometric Pressure
• Fuel Temperature
• Fuel Rail Pressure
• EGR Valve Opening

Is check result OK?

3 Glow plug control module and its circuit check Go to Step 4. Repair or replace
1) Check that glow plugs are working properly. (Page 1A- defective part(s).
323)

Is check result OK?

4 Low fuel pressure circuit check Go to Step 5. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

5 High fuel pressure circuit check Go to Step 6. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part(s).

Is check result OK?

6 Lubrication system check Go to Step 7. Repair or replace
1) Check lubrication system is working properly. (Page defective part(s).
1E-15)

Is check result OK?

1A-209 Engine General Information and Diagnosis: D13A

Step Action Yes No

7 Cylinder compression check Go to Step 8. Cylinder compression is
1) Carry out cylinder compression check. (Page 1D-79) insufficient. Repair or
replace defective
Is check result OK? part(s).
8 Timing check Go to Step 9. Adjust valve timing.
1) Check that valve timing is correct. (Page 1D-79) (Page 1D-105)

Is check result OK?

9 Combustion chamber check Go to Step 10. Repair or replace
1) Check combustion chamber for excessive deposits. defective part(s).
• Valve: (Page 1D-125)
• Cylinder head: (Page 1D-126)
• Piston: (Page 1D-132)

Is check result OK?

10 Valve spring and hydraulic valve adjuster check End. Repair or replace
1) Check valve spring and hydraulic valve adjuster. defective part(s).
(Page 1D-127)

Is check result OK?

Engine Not Running Smoothly

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. (Page 1E-16)
• Check that air intake / turbocharger circuit is working
properly. (Page 1A-299)
• Check that main and circuit fuses have not blown.

Is check result OK?

2 Parameter check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check the values of the following parameters. (Page
1A-195)
• Battery Voltage
• Accel Position
• APP Sensor 1 Volt
• APP Sensor 2 Volt
• Barometric Pressure
• Fuel Temperature
• Fuel Rail Pressure
• EGR Valve Opening

Is check result OK?

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part(s).

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-210

Step Action Yes No

5 Vehicle speed signal check Go to Step 6. Repair or replace
1) Check that vehicle speed signal is correct. (Page 1A- defective part(s).
322)

Is check result OK?

6 A/C system check Go to Step 7. Repair or replace
1) Check that A/C system is working properly. defective part(s).
• Manual single A/C model: (Page 7B-9)
• Manual dual A/C model: (Page 7B-66)
• Auto A/C model: (Page 7B-100)

Is check result OK?

7 Glow plug control module and its circuit check Go to Step 8. Repair or replace
1) Check that glow plugs are working properly. (Page 1A- defective part(s).
323)

Is check result OK?

8 EGR valve check Go to Step 9. Repair or replace
1) Check EGR valve operation. (Page 1A-305) defective part(s).

Is check result OK?

9 Turbocharger system check Go to Step 10. Repair or replace
1) Check turbocharger system is working properly. (Page defective part(s).
1A-299)

Is check result OK?

10 Timing check Go to Step 11. Adjust valve timing.
1) Check that valve timing is correct. (Page 1D-79) (Page 1D-105)

Is check result OK?

11 Cylinder compression check Go to Step 12. Cylinder compression is
1) Carry out cylinder compression check. (Page 1D-79) insufficient. Repair or
replace defective
Is check result OK? part(s).
12 Lubrication system check End. Repair or replace
1) Check lubrication system is working properly. (Page defective part(s).
1E-15)

Is check result OK?

Engine Does Not Produce Best Performance

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. (Page 1E-16)
• Check that air intake / turbocharger circuit is working
properly. (Page 1A-299)
• Check that main and circuit fuses have not blown.

Is check result OK?

1A-211 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 Parameter check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check the values of the following parameters. (Page
1A-195)
• Battery Voltage
• Accel Position
• APP Sensor 1 Volt
• APP Sensor 2 Volt
• Barometric Pressure
• IAT 1
• IAT 2
• Fuel Temperature
• Fuel Rail Pressure
• EGR Valve Opening

Is check result OK?

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part(s).

Is check result OK?

5 Glow plug control module and its circuit check Go to Step 6. Repair or replace
1) Check that glow plugs are working properly. (Page 1A- defective part(s).
323)

Is check result OK?

6 EGR valve check Go to Step 7. Repair or replace
1) Check EGR valve operation. (Page 1A-305) defective part(s).

Is check result OK?

7 Brake light switch check Go to Step 8. Brake pedal does not
1) Check that brake light switch is working properly. return. Eliminate cause
(Page 4A-11) of sticking.
Switch stuck closed or
Is check result OK?
wiring short circuit.
Repair circuit or replace
brake light switch.
8 Turbocharger system check Go to Step 9. Repair or replace
1) Check turbocharger system is working properly. (Page defective part(s).
1A-299)

Is check result OK?

9 Timing check Go to Step 10. Adjust valve timing.
1) Check that valve timing is correct. (Page 1D-79). (Page 1D-105)

Is check result OK?

10 Cylinder compression check Go to Step 11. Cylinder compression is
1) Carry out cylinder compression check. (Page 1D-79) insufficient. Repair or
replace defective
Is check result OK? part(s).
 Engine General Information and Diagnosis: D13A 1A-212

Step Action Yes No

11 Brake system check Go to Step 12. Repair or replace
1) Check brake system for dragging. (Page 4A-2) defective part(s).

Is check result OK?

12 Clutch system check End. Repair or replace
1) Check clutch system for slipping. (Page 5C-2) defective part(s).

Is check result OK?

Engine Hesitation – Momentary Lack of Response as Accelerator Is Depressed

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. (Page 1E-16)
• Check that intake air / vacuum circuit is working
properly. (Page 1A-299)
• Check that main and circuit fuses have not blown.

Is check result OK?

2 Parameter check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check the values of the following parameters. (Page
1A-195)
• Battery Voltage
• Accel Position
• APP Sensor 1 Volt
• APP Sensor 2 Volt
• Barometric Pressure
• IAT 1
• IAT 2
• Fuel Temperature
• EGR Valve Opening
• Fuel Rail Pressure

Is check result OK?

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part(s).

Is check result OK?

5 Glow plug control module and its circuit check Go to Step 6. Repair or replace
1) Check that glow plugs are working properly. (Page 1A- defective part(s).
323)

Is check result OK?

6 Cylinder compression check End. Cylinder compression is
1) Carry out cylinder compression check. (Page 1D-79) insufficient. Repair or
replace defective
Is check result OK? part(s).
1A-213 Engine General Information and Diagnosis: D13A

Improper Engine Idling or Engine Stops at Idle

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. (Page 1E-16)
• Check that air intake / turbocharger circuit is working
properly. (Page 1A-299)
• Check main and circuit fuses have blown.

Is check result OK?

2 Configuration test Go to Step 3. Register data of
1) If symptom is occurs after replacing fuel pressure replacing component(s)
sensor, MAF sensor, A/F sensor, flywheel, fuel injector in ECM described in
or ECM, it is necessary to register data into ECM. “Description of ECM
(Page 1C-18) Registration”: D13A in
Section 1C (Page 1C-
• Injector calibration code
18).
• Vehicle variant data (including CAN vehicle
configuration data)
• A/F sensor data
• MAF sensor data
• Rail pressure sensor data
• Flywheel data

Is check result OK?

3 Parameter check Go to Step 4. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check the values of the following parameters. (Page
1A-195)
• Battery Voltage
• Accel Position
• APP Sensor 1 Volt
• APP Sensor 2 Volt
• Barometric Pressure
• IAT 1
• IAT 2
• A/C Pressure
• Fuel Temperature
• EGR Valve Opening
• Fuel Rail Pressure

Is check result OK?

4 Low fuel pressure circuit check Go to Step 5. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

5 High fuel pressure circuit check Go to Step 6. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part(s).

Is check result OK?

6 Glow plug control module and its circuit check Go to Step 7. Repair or replace
1) Check that glow plugs are working properly. (Page 1A- defective part(s).
323)

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-214

Step Action Yes No

7 EGR valve check Go to Step 8. Repair or replace
1) Check EGR valve operation. (Page 1A-305) defective part(s).

Is check result OK?

8 A/C compressor magnet clutch check Go to Step 9. Repair or replace
1) Check magnet clutch operation for being stuck on and defective part(s).
chattering.

Is check result OK?

9 Cylinder compression check Go to Step 10. Cylinder compression is
1) Carry out cylinder compression check. (Page 1D-79) insufficient. Repair or
replace defective
Is check result OK? part(s).
10 Lubrication system check End. Repair or replace
1) Check lubrication system is working properly. (Page defective part(s).
1E-15)

Is check result OK?

Engine Cuts Out whilst Driving

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. (Page 1E-16)
• Check that air intake / turbocharger circuit is working
properly. (Page 1A-299)
• Check that main and circuit fuses have not blown.
• Wiring on engine correctly connected to ground.
• Battery correctly connected to ground.
• Battery positive (+) cable and all leads are firmly
connected.

Is check result OK?

2 Parameter check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check the value of the following parameter. (Page 1A-
195)
• Battery Voltage

Is check result OK?

3 Glow plug control module and its circuit check Go to Step 4. Repair or replace
1) Check that glow plugs are working properly. (Page 1A- defective part(s).
323)

Is check result OK?

4 Low fuel pressure circuit check Go to Step 5. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

5 High fuel pressure circuit check End. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part(s).

Is check result OK?

1A-215 Engine General Information and Diagnosis: D13A

Engine Knocking
Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. (Page 1E-16)
• Check that air intake / turbocharger circuit is working
properly. (Page 1A-299)

Is check result OK?

2 Parameter check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check the values of the following parameters. (Page
1A-195)
• Battery Voltage
• Barometric Pressure
• IAT 1
• IAT 2
• Fuel Temperature

Is check result OK?

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part(s).

Is check result OK?

5 Glow plug control module and its circuit check Go to Step 6. Repair or replace
1) Check that glow plugs are working properly. (Page 1A- defective part(s).
323)

Is check result OK?

6 Combustion chamber check End. Repair or replace
1) Check combustion chamber for excessive deposits. defective part(s).
• Valve: (Page 1D-125)
• Cylinder head: (Page 1D-126)
• Piston: (Page 1D-132)

Is check result OK?

White Exhaust Fumes

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. (Page 1E-16)
• Check that air intake / turbocharger circuit is working
properly. (Page 1A-299)
• Check that main and circuit fuses have not blown.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-216

Step Action Yes No

2 Parameter check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check the values of the following parameters. (Page
1A-195)
• Battery Voltage
• Barometric Pressure
• Fuel Temperature
• IAT 1
• IAT 2

Is check result OK?

3 Glow plug control module and its circuit check Go to Step 4. Repair or replace
1) Check that glow plugs are working properly. (Page 1A- defective part(s).
323)

Is check result OK?

4 Cylinder compression check Go to Step 5. Cylinder compressions
1) Carry out cylinder compression check. (Page 1D-79) is insufficient. Repair or
replace defective
Is check result OK? part(s).
5 Cylinder head gasket and valve oil seal check Go to Step 6. • Cylinder head
1) Check the following points. tightening incorrect:
• Check that cylinder head is correctly tightened. – Proceed with
• Check seal of cylinder head gasket. removing-refitting
of cylinder head to
• Check seal of valve oil seals. correctly retighten
Is check result OK? cylinder head.
(Page 1D-120)
• Cylinder head gasket
damaged:
– Replace cylinder
head gasket.
(Page 1D-120)
• Valve oil seal
missing:
– Replace valve oil
seals. (Page 1D-
123)
6 Blow-by gas intake circuit check Go to Step 7. • Fault in hose
1) Check condition of blow-by gas intake circuit, especially between oil separator
for obstructions in separator or hoses. and intake manifold:
– Restore circuit to
Is check result OK? working order.
– Replace pipe if
necessary.
• Fault in oil separator:
– Restore circuit to
working order.
– If necessary,
replace oil
separator. (Page
1B-16)
1A-217 Engine General Information and Diagnosis: D13A

Step Action Yes No

7 Turbocharger seal check End. Gasket seal insufficient:
1) Check that there is no engine oil leakage from • Replace
turbocharger impeller shaft. turbocharger.
(Page 1D-88)
Is check result OK?

Black Exhaust Fumes

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. (Page 1E-16)
• Check that intake air / vacuum circuit is working
properly. (Page 1A-299)
• Check that main and circuit fuses have not blown.

Is check result OK?

2 Parameter check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check the values of the following parameters. (Page
1A-195)
• Battery Voltage
• Barometric Pressure
• Fuel Temperature
• EGR Valve Opening

Is check result OK?

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part(s).

Is check result OK?

5 EGR valve check Go to Step 6. Repair or replace
1) Check EGR valve operation. (Page 1A-305) defective part(s).

Is check result OK?

6 Glow plug control module and its circuit check Go to Step 7. Repair or replace
1) Check that glow plugs are working properly. (Page 1A- defective part(s).
323)

Is check result OK?

7 A/F sensor check Go to Step 8. Repair or replace
1) Check A/F sensor operation. (Page 1A-307) defective part(s).

Is check result OK?

8 Timing check Go to Step 9. Adjust valve timing.
1) Check that valve timing is correct. (Page 1D-79) (Page 1D-105)

Is check result OK?

9 Turbocharger system check End. Repair or replace
1) Check turbocharger system is working properly. (Page defective part(s).
1A-302)

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-218

Excessive Exhaust Fumes

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. (Page 1E-16)
• Check that air intake / turbocharger circuit is working
properly. (Page 1A-299)
• Check that main and circuit fuses have not blown.

Is check result OK?

2 Parameter check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check the values of the following parameters. (Page
1A-195)
• Battery Voltage
• Barometric Pressure
• ECT

Is check result OK?

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part(s).

Is check result OK?

5 Glow plug control module and its circuit check Go to Step 6. Repair or replace
1) Check that glow plugs are working properly. (Page 1A- defective part(s).
323)

Is check result OK?

6 Cylinder compression check Go to Step 7. Cylinder compression is
1) Carry out cylinder compression check. (Page 1D-79) insufficient. Repair or
replace defective
Is check result OK? part(s).
7 A/F sensor check Go to Step 8. Repair or replace
1) Check A/F sensor operation. (Page 1A-307) defective part(s).

Is check result OK?

8 Timing check Go to Step 9. Adjust valve timing.
1) Check that valve timing is correct. (Page 1D-79) (Page 1D-105)

Is check result OK?

9 Turbocharger system check End. Repair or replace
1) Check turbocharger system is working properly. (Page defective part(s).
1A-302)

Is check result OK?

1A-219 Engine General Information and Diagnosis: D13A

Engine Oil Excessive Level

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. (Page 1E-16)
• Check condition of fuel circuit and check that it is
working properly. (Page 1A-291)

Is check result OK?

2 Cylinder compression check Go to Step 3. Cylinder compression is
1) Carry out cylinder compression check. (Page 1D-79) insufficient. Repair or
replace defective
Is check result OK? part(s).
3 Timing check Go to Step 4. Adjust valve timing.
1) Check that valve timing is correct. (Page 1D-79) (Page 1D-105)

Is check result OK?

4 Low fuel pressure circuit check Go to Step 5. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

5 High fuel pressure circuit check End. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part(s).

Is check result OK?

Poor Fuel Mileage

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. (Page 1E-16)
• Check that air intake / turbocharger circuit is working
properly. (Page 1A-299)
• Check tire pressure. (Page 2D-1)

Is check result OK?

2 Parameter check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check the values of the following parameters. (Page
1A-195)
• Battery Voltage
• Accel Position
• APP Sensor 1 Volt
• APP Sensor 2 Volt
• Barometric Pressure
• Fuel Rail Pressure
• EGR Valve Opening

Is check result OK?

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-220

Step Action Yes No

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part(s).

Is check result OK?

5 Cylinder compression check Go to Step 6. Cylinder compression is
1) Carry out cylinder compression check. (Page 1D-79) insufficient. Repair or
replace defective
Is check result OK? part(s).
6 Turbocharger system check Go to Step 7. Repair or replace
1) Check turbocharger system is working properly. (Page defective part(s).
1A-302)

Is check result OK?

7 Timing check Go to Step 8. Adjust valve timing.
1) Check that valve timing is correct. (Page 1D-79) (Page 1D-105)

Is check result OK?

8 A/F sensor check Go to Step 9. Repair or replace
1) Check A/F sensor operation. (Page 1A-307) defective part(s).

Is check result OK?

9 Lubrication system check Go to Step 10. Repair or replace
1) Check lubrication system is working properly. (Page defective part(s).
1E-15)

Is check result OK?

10 A/C compressor magnet clutch check Go to Step 11. Repair or replace
1) Check magnet clutch operation for stuck on and defective part(s).
chattering.

Is check result OK?

11 Brake system check Go to Step 12. Repair or replace
1) Check brake system for dragging. (Page 4A-2) defective part(s).

Is check result OK?

12 Clutch system check Go to Step 13. Repair or replace
1) Check clutch system for slipping. (Page 5C-2) defective part(s).

Is check result OK?

13 Combustion chamber check End. Repair or replace
1) Check combustion chamber for excessive deposits. defective part(s).
• Valve: (Page 1D-125)
• Cylinder head: (Page 1D-126)
• Piston: (Page 1D-132)

Is check result OK?

Engine Oil Excessive Consumption

Step Action Yes No
1 Preliminary check Go to Step 2. Refill or replace
1) Check that engine oil level is correct. (Page 1E-16) defective part(s).

Is check result OK?

2 Cylinder compression check Go to Step 3. Cylinder compression is
1) Carry out cylinder compression check. (Page 1D-79) insufficient. Repair or
replace defective
Is check result OK? part(s).
1A-221 Engine General Information and Diagnosis: D13A

Step Action Yes No

3 Cylinder head gasket and valve oil seal check Go to Step 4. • Cylinder head
1) Check the following points. tightening incorrect:
• Check that cylinder head is correctly tightened. – Proceed with
• Check seal of cylinder head gasket. removing-refitting
of cylinder head to
• Check seal of stem seals. correctly retighten
Is check result OK? cylinder head.
(Page 1D-120)
• Cylinder head gasket
damaged:
– Replace cylinder
head gasket.
(Page 1D-120)
• Valve oil seal
missing:
– Replace stem
seals. (Page 1D-
120)
4 Blow-by gas intake circuit check Go to Step 5. • Fault in hose
1) Check condition of blow-by gas intake circuit, especially between oil separator
for obstructions in separator or hoses. and intake manifold:
– Restore circuit to
Is check result OK?
working order.
– Replace pipe if
necessary.
• Fault in oil separator:
– Restore circuit to
working order.
– If necessary,
replace cylinder
head cover.
5 Turbocharger seal check End. Gasket seal insufficient:
1) Check that there is no engine oil leakage from • Replace
turbocharger impeller shaft. turbocharger.
(Page 1D-88)
Is check result OK?

MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)
AENJHB0B1124011
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Go to Step 2.
1) Check combination meter for DTC. for applicable DTC.

Is there any DTC(s) detected?

2 Combination meter operation check Replace ECM and Replace combination
1) Set ignition “ON”. recheck MIL operation. meter and recheck MIL
(Page 1C-20) operation. (Page 9C-
2) Check warning / indicator lights other than MIL in
34)
combination meter light up.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-222

MIL Remains ON after Engine Starts

AENJHB0B1124012
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Substitute a known-
1) Start engine and recheck DTC of ECM while engine for applicable DTC. good combination meter
running. and recheck MIL
operation. (Page 9C-
Is there any DTC(s)? 34)
If MIL still remains on,
replace ECM and
recheck MIL operation.
(Page 1C-20)

Serial Data Link Circuit Check

AENJHB0B1124013
Circuit Diagram

+B

4 5

1 3
B1

E01-64 GRY

A1

C1 C2

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0B112002-01

[A]: ECM connector (View: [a]) C2: Ground circuit 4. “B/U” fuse
A1: Serial communication circuit 1. ECM 5. “DOME2” fuse
B1: DLC power supply circuit 2. DLC
C1: ECM ground circuit 3. To combination meter

Troubleshooting
Step Action Yes No
1 MIL check Go to Step 2. Go to applicable
1) Perform “MIL Check”: D13A (Page 1A-180). troubleshooting.

Is check result OK?

1A-223 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 Scan tool condition check Go to Step 3. Repair or replace
1) Check that SUZUKI scan tool is as follows. defective part.
• There are no deformation and wear for DLC cable,
USB cable and VCI terminals.
• Connection for DLC cable, USB cable and VCI
terminals are in good condition.
• Communication between VCI and PC is possible.
• Correct software is used.

Is check result OK?

3 Scan tool operation check Go to Step 4. Go to “Troubleshooting
1) Check DLC terminal for deformation and wear. for Lost
Communication”: D13A
2) If it is in good condition, connect SUZUKI scan tool to
Model in Section 10H
DLC with ignition “OFF”.
(Page 10H-32).
3) Check if communication is possible with other control
modules (BCM, ABS control module, combination meter,
SDM, or P/S control module).

Can SUZUKI scan tool communicate with other control

modules?
4 Serial communication circuit check Go to Step 5. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at DLC: infinity
• Voltage of “A1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 ECM power and ground circuit check Go to Step 6. Repair or replace
1) Check ECM power supply and ground circuits according defective wire harness.
to Step 3 – 4 of “Table C-1: Main Relay Operation
Check”: D13A (Page 1A-311).

Is check result OK?

6 DLC power and ground circuit check Go to Step 7. Repair or replace
1) Check DLC power supply and ground circuits as follows. defective wire harness.
• Voltage of “B1” circuit: 10 to 14 V
• Resistance between each of “C1” and “C2” circuits
and ground: less than 1 Ω

Is check result OK?

7 Scan tool operation check Scan tool is in good Replace VCI and
1) Check if communication is possible with other vehicles. condition, check recheck scan tool
intermittent trouble operation.
Is check result OK? referring to “Intermittent
Connection and Poor
Contact Inspection” in
Section 00 (Page 00-
12).
 Engine General Information and Diagnosis: D13A 1A-224

DTC P0001
AENJHB0B1124014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0001: Fuel Volume Regulator Control Circuit / Open Electric cause:
Electrical cause: • Fuel flow actuator and/or its circuit
Measured voltage of fuel flow actuator drive circuit does not match
• ECM
command signal.
Mechanical cause:
Mechanical cause:
Measured fuel pressure in common rail is higher than targeted fuel • High fuel pressure circuit (high pressure
pressure by 30 MPa (305.9 kgf/cm2, 4,350 psi, 300 bar) for 5 sec. pump, common rail and high pressure line)
(1 D/C detection logic) • Fuel return line
• Fuel pressure sensor

Circuit Diagram

A1
YEL/BLK D01-4
2 A2
YEL D01-20

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113007-01

[A]: ECM connector (View: [a]) A2: Fuel flow actuator drive circuit 2. Fuel flow actuator
A1: Fuel flow actuator power supply circuit 1. ECM

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Does engine start? Go to Step 5. Go to Step 3.
3 Fuel flow actuator circuit check Go to Step 4. Repair or replace
1) Check “A1” and “A2” circuits according to Step 1 of defective wire harness.
“Table A-5: Fuel Flow Actuator Operation Check”: D13A
(Page 1A-298).

Is check result OK?

1A-225 Engine General Information and Diagnosis: D13A

Step Action Yes No

4 Fuel flow actuator check Replace ECM and Replace fuel flow
1) Check fuel flow actuator. (Page 1G-50) recheck DTC. (Page actuator. (Page 1G-
1C-20) 49)
Is check result OK?
5 Fuel return line Go to Step 6. Repair or replace
1) Check fuel return line for bending. defective part(s).

Is check result OK?

6 Fuel pressure sensor power supply circuit, signal Go to Step 7. Repair or replace
circuit and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Step 3 –
6 of “Table A-4: Fuel Pressure Sensor Circuit Check”:
D13A (Page 1A-296).

Is check result OK?

7 High fuel pressure circuit check Replace fuel pressure Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) sensor and recheck defective part(s).
DTC. (Page 1G-50)
Is check result OK?

DTC P0069 / P0107 / P0234

AENJHB0B1124015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0069: Manifold Absolute Pressure-Barometric Pressure • Boost pressure sensor and/or its circuit
Correlation • Air intake circuit
Any of the following conditions is met.
• Turbocharger
• Measured boost pressure is higher than barometric pressure by 23
• Vacuum system
kPa (0.23 kgf/cm2, 3.34 psi, 225 mbar) for 2 sec.
• Barometric pressure sensor (in ECM)
• Measured boost pressure is lower than barometric pressure by 23 kPa
(0.23 kgf/cm2, 3.34 psi, 225 mbar) for 2 sec. • ECM
(1 D/C detection logic)
P0107: Manifold Absolute Pressure / Barometric Pressure Circuit
Low
Relative boost pressure is lower than specified value.
(1 D/C detection logic)
P0234: Turbocharger / Supercharger “A” Overboost Condition
Boost pressure is higher than barometric pressure by 200 kPa (2.0 kgf/
cm2, 29.0 psi, 2.0 bar) for 1 sec.
(1 D/C detection logic)
 Engine General Information and Diagnosis: D13A 1A-226

Circuit Diagram

A1
RED/BLK D01-23
A2
2 YEL D01-41
A3
BLK D01-24

3 B1
WHT D01-37

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113008-01

[A]: ECM connector (View: [a]) A3: Boost pressure sensor ground circuit 1. ECM
A1: Boost pressure sensor power supply circuit B1: IAT-2 sensor signal circuit 2. Boost pressure sensor
A2: Boost pressure sensor signal circuit 1. ECM 3. IAT-2 sensor

DTC Confirmation Procedure

P0069 / P0234

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Run engine at idle speed for 1 min.

P0107

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Run engine at 2,000 rpm and keep the speed for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Boost pressure sensor power supply circuit, signal Go to Step 3. Repair or replace
circuit and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Step 5 –
9 of “Table B-3: Boost Pressure Sensor Check”: D13A
(Page 1A-302).

Is check result OK?

3 Boost pressure sensor check Go to Step 4. Replace boost pressure
1) Check boost pressure sensor. (Page 1C-29) sensor with IAT sensor-
2. (Page 1C-28)
Is check result OK?
1A-227 Engine General Information and Diagnosis: D13A

Step Action Yes No

4 Air intake / turbocharger circuit check Go to Step 5. Repair or replace
1) Check that air intake / turbocharger circuit is working defective part(s).
properly. (Page 1A-299)

Is check result OK?

5 Vacuum system check Replace ECM and Repair or replace
1) Check the following parts: recheck DTC. (Page defective part(s).
1C-20)
• Check vacuum hoses and pipes.
• Check vacuum pump. (Page 1D-86)

Is check result OK?

DTC P0087
AENJHB0B1124016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0087: Fuel Rail / System Pressure-Too Low • Lack of fuel
Measured fuel pressure in common rail is lower than specified • Fuel pressure sensor and/or its circuit
value.
• Low fuel pressure circuit (fuel pressure regulator in
(1 D/C detection logic)
fuel pump, fuel pump and/or its circuit, fuel hose,
fuel pipe)
• High fuel pressure circuit (high pressure pump,
common rail, high pressure pipe, fuel injector)
• Clog of fuel filter
• ECM

Circuit Diagram

A1
GRN/YEL D01-9
A2
2 YEL/BLK D01-38
A3
YEL/RED D01-7

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113009-01

[A]: ECM connector (View: [a]) A2: Fuel pressure sensor signal circuit 1. ECM
A1: Fuel pressure sensor power supply circuit A3: Fuel pressure sensor ground circuit 2. Fuel pressure sensor

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Run engine at idle speed for 1 min.

 Engine General Information and Diagnosis: D13A 1A-228

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Fuel level check Add fuel and recheck Go to Step 3.
1) Check fuel level by fuel gauge. DTC.

Does fuel gauge indicate “E” level (empty)?

3 Fuel pressure sensor power supply circuit, signal Go to Step 4. Repair or replace
circuit and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Step 3 –
6 of “Table A-4: Fuel Pressure Sensor Circuit Check”:
D13A (Page 1A-296).

Is check result OK?

4 Low fuel pressure circuit check Go to Step 5. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

5 High fuel pressure circuit check Go to Step 6. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part(s).

Is check result OK?

6 Fuel filter replacement Go to Step 7. End.
1) Replace fuel filter. (Page 1G-59)
2) Clear DTC. (Page 1A-181)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure, and check DTC.
(Page 1A-180)

Is DTC P0087 still detected?

7 Fuel pressure sensor replacement Replace ECM and End.
1) Replace fuel pressure sensor. (Page 1G-50) recheck DTC. (Page
1C-20)
2) Clear DTC. (Page 1A-181)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure, and check DTC.
(Page 1A-180)

Is DTC P0087 still detected?

1A-229 Engine General Information and Diagnosis: D13A

DTC P0088
DTC Detecting Condition and Trouble Area
DTC detecting condition
P0088: Fuel Rail / System Pressure-Too High
Measured fuel pressure in common rail is higher than 175 • Low fuel pressure circuit (fuel pressure regulator in fuel
MPa (1,784.5 kgf/cm2, 25,381 psi, 1,750 bar).
(1 D/C detection logic)
AENJHB0B1124017
Trouble area
• Fuel pressure sensor and/or its circuit
pump, fuel pump and/or its circuit, fuel filter clogging,
fuel hose bending, fuel pipe, fuel flow actuator)
• High fuel pressure circuit (high pressure pump,
common rail, high pressure pipe, fuel injector)
• ECM

Circuit Diagram

A1
GRN/YEL D01-9
A2
2 YEL/BLK D01-38
A3
YEL/RED D01-7

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113009-01

[A]: ECM connector (View: [a]) A2: Fuel pressure sensor signal circuit 1. ECM
A1: Fuel pressure sensor power supply circuit A3: Fuel pressure sensor ground circuit 2. Fuel pressure sensor

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Fuel pressure sensor power supply circuit, signal Go to Step 3. Repair or replace
circuit and ground circuit check defective wire harness
1) Check “A1”, “A2” and “A3” circuits according to Step 3 – and go to Step 3.
6 of “Table A-4: Fuel Pressure Sensor Circuit Check”:
D13A (Page 1A-296).

Is check result OK?

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s) and go
to Step 5.
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-230

Step Action Yes No

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part and go to
Step 5.
Is check result OK?
5 Fuel pressure sensor replacement Replace ECM and End.
1) Replace fuel pressure sensor. (Page 1G-50) recheck DTC. (Page
1C-20)
2) Clear DTC. (Page 1A-181)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
(Page 1A-180)

Is DTC P0088 still detected?

DTC P0089
AENJHB0B1124018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0089: Fuel Pressure Regulator 1 Performance • Lack of fuel
Measured fuel pressure in common rail is lower than targeted • Fuel pressure sensor and/or its circuit
fuel pressure by specified value.
• Low fuel pressure circuit (fuel pressure regulator in
(1 D/C detection logic)
fuel pump, fuel pump and/or its circuit, fuel filter
clogging, fuel hose bending, fuel pipe, fuel flow
actuator)
• High fuel pressure circuit (high pressure pump,
common rail, high pressure pipe, fuel injector)
• ECM

Circuit Diagram

A1
GRN/YEL D01-9
A2
2 YEL/BLK D01-38
A3
YEL/RED D01-7

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113009-01

[A]: ECM connector (View: [a]) A2: Fuel pressure sensor signal circuit 1. ECM
A1: Fuel pressure sensor power supply circuit A3: Fuel pressure sensor ground circuit 2. Fuel pressure sensor

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Run engine at idle speed for 1 min.

1A-231 Engine General Information and Diagnosis: D13A

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Fuel level check Add fuel and recheck Go to Step 3.
1) Check fuel level by fuel gauge. DTC.

Does fuel gauge indicate “E” level (empty)?

3 Fuel pressure sensor power supply circuit, signal Go to Step 4. Repair or replace
circuit and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Step 3 –
6 of “Table A-4: Fuel Pressure Sensor Circuit Check”:
D13A (Page 1A-296).

Is check result OK?

4 Low fuel pressure circuit check Go to Step 5. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

5 High fuel pressure circuit check Go to Step 6. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part(s).

Is check result OK?

6 Fuel pressure sensor replacement Replace ECM and End.
1) Replace fuel pressure sensor. (Page 1G-50) recheck DTC. (Page
1C-20)
2) Clear DTC. (Page 1A-181)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure, and check DTC.
(Page 1A-180)

Is DTC P0089 still detected?

 Engine General Information and Diagnosis: D13A 1A-232

DTC P0095
AENJHB0B1124019
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0095: Intake Air Temperature Sensor 2 Circuit (Bank1) • IAT-2 sensor and/or its circuit
Any of the following conditions is met. • ECM
• Measured voltage of IAT-2 sensor signal circuit is higher
than 4.6 V for 2 sec.
• Measured voltage of IAT-2 sensor signal circuit is lower
than 0.1 V for 2 sec.
(3 D/C detection logic)

Circuit Diagram

A1
RED/BLK D01-23
A2
2 YEL D01-41
A3
BLK D01-24

3 B1
WHT D01-37

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113008-01

[A]: ECM connector (View: [a]) A3: Boost pressure sensor ground circuit 2. Boost pressure sensor
A1: Boost pressure sensor power supply circuit B1: IAT-2 sensor signal circuit 3. IAT-2 sensor
A2: Boost pressure sensor signal circuit 1. ECM

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 IAT-2 sensor signal circuit and boost pressure sensor Go to Step 3. Repair or replace
ground circuit check defective wire harness.
1) Check “B1” and “A3” circuits according to Step 2 of
“Table C-5: IAT-2 Sensor Check”: D13A (Page 1A-318).

Is check result OK?

3 IAT-2 sensor check Replace ECM and Replace boost pressure
1) Check IAT-2 sensor. (Page 1C-29) recheck DTC. (Page sensor with IAT sensor-
1C-20) 2. (Page 1C-28)
Is check result OK?
1A-233 Engine General Information and Diagnosis: D13A

DTC P0100
AENJHB0B1124020
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0100: Mass or Volume Air Flow “A” Circuit • MAF sensor and/or its circuit
Any of the following conditions is met. • ECM
• Duty ratio of MAF sensor signal is higher than specified value for 2 sec.
• Duty ratio of MAF sensor signal is lower than specified value for 2 sec.
(3 D/C detection logic)

Circuit Diagram

IG1 1

A1
WHT
A2
2 RED E01-54
A3
YEL E01-29

3 B1
BLU E01-60

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113010-01

[A]: ECM connector (View: [a]) A3: MAF sensor ground circuit 2. MAF sensor
A1: MAF sensor power supply circuit B1: IAT-1 sensor signal circuit 3. IAT-1 sensor
A2: MAF sensor signal circuit 1. ECM

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 MAF sensor power supply circuit, signal circuit and Go to Step 3. Repair or replace
ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Step 5 –
8 of “Table B-2: MAF Sensor Check”: D13A (Page 1A-
300).

Is check result OK?

3 MAF sensor check Replace ECM and Replace MAF sensor
1) Check MAF sensor. (Page 1C-23) recheck DTC. (Page with IAT sensor-1.
1C-20) (Page 1C-23)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-234

DTC P0101
AENJHB0B1124021
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0101: Mass or Volume Air Flow “A” Circuit Range / Performance • MAF sensor and/or its circuit
Any of the following conditions is met. • EGR valve and/or its circuit
• Measured MAF is higher than estimated MAF by specified value. • Air intake circuit
• Measured MAF is lower than estimated MAF by specified value. • ECM
(3 D/C detection logic)

Circuit Diagram

IG1 1

A1
WHT
A2
2 RED E01-54
A3
YEL E01-29

3 B1
BLU E01-60

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113010-01

[A]: ECM connector (View: [a]) A3: MAF sensor ground circuit 2. MAF sensor
A1: MAF sensor power supply circuit B1: IAT-1 sensor signal circuit 3. IAT-1 sensor
A2: MAF sensor signal circuit 1. ECM

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and an assistant.

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– Fuel cut < 50 times

1) Warm up engine to normal operating temperature.

2) Drive vehicle (with engine speed at 2,500 rpm or more) and gear at 4th for 10 sec.
3) Release accelerator pedal, and let vehicle coast to 1,500 rpm with engine brakes applied.
4) Repeat Step 2) – 3) 20 times.
1A-235 Engine General Information and Diagnosis: D13A

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 MAF sensor power supply circuit, signal circuit and Go to Step 3. Repair or replace
ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Step 5 –
8 of “Table B-2: MAF Sensor Check”: D13A (Page 1A-
300).

Is check result OK?

3 MAF sensor check Go to Step 4. Replace MAF sensor
1) Check MAF sensor. (Page 1C-23) with IAT sensor-1.
(Page 1C-23)
Is check result OK?
4 EGR valve operation check Go to Step 5. Repair or replace
1) Check EGR valve operation. (Page 1A-305) defective part(s).

Is check result OK?

5 Air intake / turbocharger circuit check Replace ECM and Repair or replace
1) Check that air intake / turbocharger circuit is working recheck DTC. (Page defective part(s).
properly. (Page 1A-299) 1C-20)

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-236

DTC P0110
AENJHB0B1124022
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0110: Intake Air Temperature Sensor 1 Circuit (Bank1) • IAT-1 sensor and/or its circuit
Any of the following conditions is met. • ECM
• Measured voltage of IAT-1 sensor signal is higher than 4.9 V for 3 sec.
• Measured voltage of IAT-1 sensor signal is lower than 0.2 V for 3 sec.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

IG1 1

A1
WHT
A2
2 RED E01-54
A3
YEL E01-29

3 B1
BLU E01-60

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113010-01

[A]: ECM connector (View: [a]) A3: MAF sensor ground circuit 2. MAF sensor
A1: MAF sensor power supply circuit B1: IAT-1 sensor signal circuit 3. IAT-1 sensor
A2: MAF sensor signal circuit 1. ECM

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 IAT-1 sensor signal circuit and MAF sensor ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) Check “B1” and “A3” circuits according to Step 2 of
“Table C-4: IAT-1 Sensor Check”: D13A (Page 1A-316).

Is check result OK?

3 IAT-1 sensor check Replace ECM and Replace MAF sensor
1) Check IAT-1 sensor. (Page 1C-23) recheck DTC. (Page with IAT sensor-1.
1C-20) (Page 1C-23)
Is check result OK?
1A-237 Engine General Information and Diagnosis: D13A

DTC P0115
AENJHB0B1124023
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0115: Engine Coolant Temperature Sensor 1 Circuit • ECT sensor and/or its circuit
Any of the following conditions is met. • ECM
• Measured voltage of ECT sensor signal circuit is higher than 4.85 V for 2 sec.
• Measured voltage of ECT sensor signal circuit is lower than 0.1 V for 2 sec.
(1 D/C detection logic)

Circuit Diagram

1
A1
2
PPL/WHT D01-49
A2
GRN D01-29

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113011-01

[A]: ECM connector (View: [a]) A2: ECT sensor ground circuit 2. ECT sensor
A1: ECT sensor signal circuit 1. ECM

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 ECT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
1) Check “A1” and “A2” circuits according to Step 2 of defective wire harness.
“Table C-3: ECT Sensor Check”: D13A (Page 1A-314).

Is check result OK?

3 ECT sensor check Replace ECM and Replace ECT sensor.
1) Check ECT sensor. (Page 1C-26) recheck DTC. (Page (Page 1C-25)
1C-20)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-238

DTC P0120
AENJHB0B1124024
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0120: Throttle / Pedal Position Sensor / Switch “A” Circuit • APP sensor and/or its circuit
Any of the following conditions is met. • ECM
• Measured voltage of APP sensor (main) signal circuit is lower than 0.3 V and
output voltage of APP sensor (sub) signal circuit is higher than 1.16 V.
• Measured voltage of APP sensor (main) signal circuit is higher than 4.8 V.
• Both measured voltages of APP sensor (main) and APP sensor (sub) signal
circuits are lower than 0.05 V.
(1 D/C detection logic)

Circuit Diagram

1
A1
2 BRN E01-82
A2
BEG E01-63
A3
BLU E01-30
B1
3 BLK E01-9
B2
YEL E01-36
B3
WHT E01-27

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113012-01

[A]: ECM connector (View: [a]) B1: APP sensor (sub) power supply circuit 2. APP sensor (main)
A1: APP sensor (main) power supply circuit B2: APP sensor (sub) signal circuit 3. APP sensor (sub)
A2: APP sensor (main) signal circuit B3: APP sensor (sub) ground circuit
A3: APP sensor (main) ground circuit 1. ECM

DTC Confirmation Procedure

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 APP sensor (main) power supply circuit, signal circuit Go to Step 3. Repair or replace
and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Step 3 –
7 of “Table C-6: Accelerator Pedal Check”: D13A (Page
1A-319).

Is check result OK?

1A-239 Engine General Information and Diagnosis: D13A

Step Action Yes No

3 APP sensor (main) check Replace ECM and Replace APP sensor.
1) Check APP sensor (main). (Page 1C-25) recheck DTC. (Page (Page 1C-25)
1C-20)
Is check result OK?

DTC P0130 / P2244

AENJHB0B1124025
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0130: O2 Sensor Circuit (Bank1 Sensor1) • A/F sensor and/or its circuit
Measured voltages of A/F sensor signal circuits are out of specified range. • ECM
(1 D/C detection logic but MIL does not light up)
P2244: O2 Sensor Reference Voltage Performance (Bank1 Sensor1)
A/F power supply voltage is out of specified range.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

2 1
A1
BLK E01-42
A2
LT GRN E01-39
A3
GRY E01-41
A4
+B
WHT E01-40
B1 B2
PINK E01-6
BLU

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113013-01

[A]: ECM connector (View: [a]) A3: A/F sensor signal circuit (VSIP) B2: A/F sensor heater drive circuit
A1: A/F sensor signal circuit (RC) A4: A/F sensor signal circuit (IP) 1. ECM
A2: A/F sensor signal circuit (VS) B1: A/F sensor heater power supply circuit 2. A/F sensor

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 A/F sensor signal circuit check Go to Step 3. Repair or replace
1) Check “A1”, “A2”, “A3” and “A4” circuits according to defective wire harness.
Step 6 of “Table B-6: A/F Sensor Check”: D13A (Page
1A-307).

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-240

Step Action Yes No

3 A/F sensor replacement Replace ECM and End.
1) Replace A/F sensor. (Page 1B-14) recheck DTC. (Page
1C-20)
2) Clear DTC. (Page 1A-181)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTCs.
(Page 1A-180)

Is DTC P0130 or P2244 still detected?

DTC P0135
AENJHB0B1124026
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0135: O2 Sensor Heater Circuit (Bank1 Sensor1) • A/F sensor heater and/or its
Any of the following conditions is met. circuit
• Measured voltage of A/F sensor heater drive circuit is higher than specified value • ECM
for 3 sec. even when command signal of A/F sensor heater is ON.
• Measured voltage of A/F sensor heater drive circuit is lower than specified value
for 3 sec. even when command signal of A/F sensor heater is OFF.
(1 D/C detection logic but does not light up)

Circuit Diagram

2 1
A1
BLK E01-42
A2
LT GRN E01-39
A3
GRY E01-41
A4
+B
WHT E01-40
B1 B2
PINK E01-6
BLU

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113013-01

[A]: ECM connector (View: [a]) A3: A/F sensor signal circuit (VSIP) B2: A/F sensor heater drive circuit
A1: A/F sensor signal circuit (RC) A4: A/F sensor signal circuit (IP) 1. ECM
A2: A/F sensor signal circuit (VS) B1: A/F sensor heater power supply circuit 2. A/F sensor

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Run engine at idle speed for 1 min.

1A-241 Engine General Information and Diagnosis: D13A

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 A/F sensor heater power supply circuit and drive circuit Go to Step 3 Repair or replace
check defective wire harness.
1) Check “B1” and “B2” circuits according to Step 3 – 4 of
“Table B-6: A/F Sensor Check”: D13A (Page 1A-307).

Is check result OK?

3 A/F sensor heater check Replace ECM and Replace A/F sensor.
1) Check A/F sensor heater for resistance. (Page 1B-14) recheck DTC. (Page (Page 1B-14)
1C-20)
Is check result OK?

DTC P0168 / P0180

AENJHB0B1124027
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0168: Fuel Temperature Too High • Fuel temperature sensor and/or its circuit
Fuel temperature is higher than specified value. • ECM
(1 D/C detection logic but MIL does not light up)
P0180: Fuel Temperature Sensor “A” Circuit
Any of the following conditions is met.
• Measured voltage of fuel temperature sensor signal
circuit is higher than 4.85 V for 3 sec.
• Measured voltage of fuel temperature sensor signal
circuit is lower than 0.1 V for 3 sec.
(1 D/C detection logic)

Circuit Diagram

IG1 1
2
A1
A2
WHT
3 RED E01-89
BLK
A3 B1
4
BEG E01-59
B2
GRN E01-7

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113014-01

[A]: ECM connector (View: [a]) B1: Fuel temperature sensor signal circuit 3. Fuel filter water detection sensor
A1: Fuel filter water detection sensor power supply circuit B2: Fuel temperature sensor ground circuit 4. Fuel temperature sensor
A2: Fuel filter water detection sensor signal circuit 1. ECM
A3: Fuel filter water detection sensor ground circuit 2. Water detection sensor with fuel temperature sensor
 Engine General Information and Diagnosis: D13A 1A-242

DTC Confirmation Procedure

P0168

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and an assistant.

1) Warm up engine to normal operating temperature.

2) Drive vehicle for 1 min.

P0180
1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Fuel temperature sensor signal circuit and ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) Check “B1” and “B2” circuits according to Step 2 of
“Table A-3: Fuel Temperature Sensor Check”: D13A
(Page 1A-294).

Is check result OK?

3 Fuel temperature sensor check Replace ECM and Replace fuel filter
1) Check fuel temperature sensor. (Page 1G-59) recheck DTC. (Page assembly. (Page 1G-
1C-20) 59)
Is check result OK?
1A-243 Engine General Information and Diagnosis: D13A

DTC P0190
AENJHB0B1124028
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0190: Fuel Rail Pressure Sensor “A” Circuit • Lack of fuel
Any of the following conditions is met. • Fuel pressure sensor and/or its circuit
• Measured voltage of fuel pressure sensor signal circuit is higher than • Low fuel pressure circuit (fuel pressure
4.85 V. regulator in fuel pump, fuel pump and/
• Measured voltage of fuel pressure sensor signal circuit is lower than or its circuit, fuel hose, fuel pipe)
0.15 V. • High fuel pressure circuit (high
• Difference between current fuel pressure and previous fuel pressure at pressure pump, common rail, high
specified vehicle condition is more than 10 MPa (102.0 kgf/cm2, 1,450 pressure pipe, fuel injector)
psi, 100 bar). • ECM
(1 D/C detection logic)

Circuit Diagram

A1
GRN/YEL D01-9
A2
2 YEL/BLK D01-38
A3
YEL/RED D01-7

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113009-01

[A]: ECM connector (View: [a]) A2: Fuel pressure sensor signal circuit 1. ECM
A1: Fuel pressure sensor power supply circuit A3: Fuel pressure sensor ground circuit 2. Fuel pressure sensor

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Fuel level check Add fuel and recheck Go to Step 3.
1) Check fuel level by fuel gauge. DTC.

Does fuel gauge indicate “E” level (empty)?

3 Fuel pressure sensor power supply circuit, signal Go to Step 4. Repair or replace
circuit and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Step 3 –
6 of “Table A-4: Fuel Pressure Sensor Circuit Check”:
D13A (Page 1A-296).

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-244

Step Action Yes No

4 Low fuel pressure circuit check Go to Step 5. Repair or replace
1) Check low fuel pressure circuit. (Page 1G-32) defective part(s).

Is check result OK?

5 High fuel pressure circuit check Go to Step 6. Repair or replace
1) Check high fuel pressure circuit. (Page 1G-36) defective part(s).

Is check result OK?

6 Fuel pressure sensor replacement Replace ECM and End.
1) Replace fuel pressure sensor. (Page 1G-50) recheck DTC. (Page
1C-20)
2) Clear DTC. (Page 1A-181)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
(Page 1A-180)

Is DTC P0190 still detected?

DTC P0201 / P0202 / P0203 / P0204 / P2146

AENJHB0B1124029
NOTE
For identification of each cylinder, refer to “Electronic Control System Component Location”: D13A
(Page 1A-175).

DTC Detecting Condition and Trouble Area

DTC detecting condition Trouble area
P0201: Injector Circuit / Open-Cylinder 1 • Fuel injector and/or its
P0202: Injector Circuit / Open-Cylinder 2 circuit
P0203: Injector Circuit / Open-Cylinder 3 • ECM
P0204: Injector Circuit / Open-Cylinder 4
Any of the following conditions is met.
• Measured voltage of relevant fuel injector drive circuit (high side) does not match
command signal.
• Measured voltage of relevant fuel injector drive circuit (low side) does not match
command signal.
(1 D/C detection logic)
P2146: Fuel Injector Group “A” Supply Voltage Circuit / Open
Any of the following conditions is met.
• Measured voltage of fuel injector drive circuit (high side) is higher than 50 V.
• Measured voltage of fuel injector drive circuit (high side) is lower than 30 V.
(1 D/C detection logic but MIL does not light up)
1A-245 Engine General Information and Diagnosis: D13A

Circuit Diagram

A1
WHT D01-56
2 A2
GRY/WHT D01-16

B1
YEL D01-58
3 B2
YEL/BLK D01-17

C1
GRN D01-57
4 C2
WHT/GRN D01-31

D1
BLU D01-55
5 D2
WHT/BLU D01-1

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113015-01

[A]: ECM connector (View: [a]) C1: Fuel injector No.3 drive circuit (high side) 2. Fuel injector No.1
A1: Fuel injector No.1 drive circuit (high side) C2: Fuel injector No.3 drive circuit (low side) 3. Fuel injector No.2
A2: Fuel injector No.1 drive circuit (low side) D1: Fuel injector No.4 drive circuit (high side) 4. Fuel injector No.3
B1: Fuel injector No.2 drive circuit (high side) D2: Fuel injector No.4 drive circuit (low side) 5. Fuel injector No.4
B2: Fuel injector No.2 drive circuit (low side) 1. ECM

DTC Confirmation Procedure

P0201 / P0202 / P0203 / P0204

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– Battery voltage > 10 V

1) Warm up engine to normal operating temperature.

2) Run engine at 3,000 rpm and keep the speed for 10 sec.

P2146

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– Battery voltage > 7 V

1) Run engine at idle speed for 1 min.

 Engine General Information and Diagnosis: D13A 1A-246

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Fuel injector drive circuit (high side) and (low side) Go to Step 3. Repair or replace
check defective wire harness.
1) Check of “A1”, “A2”, “B1”, “B2”, “C1”, “C2”, “D1” and “D2”
circuits according to Step 1 of “Table A-2: Fuel Injector
Circuit Check”: D13A (Page 1A-293).

Is check result OK?

3 Fuel injector check Replace ECM and Replace fuel injector.
1) Check fuel injector. (Page 1G-46) recheck DTC. (Page (Page 1G-47)
1C-20)
Is check result OK?

DTC P0217
AENJHB0B1124030
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0217: Engine Coolant Over Temperature Condition • ECT sensor and/or its circuit
ECM limits driving performance by high coolant temperature. • Engine cooling system
(1 D/C detection logic but MIL does not light up)
• Engine oil insufficient
• ECM

Circuit Diagram

1
A1
2
PPL/WHT D01-49
A2
GRN D01-29

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113011-01

[A]: ECM connector (View: [a]) A2: ECT sensor ground circuit 2. ECT sensor
A1: ECT sensor signal circuit 1. ECM
1A-247 Engine General Information and Diagnosis: D13A

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and an assistant.

1) Warm up engine to normal operating temperature.

2) Drive vehicle for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 ECT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
1) Check “A1” and “A2” circuits according to Step 2 of defective wire harness.
“Table C-3: ECT Sensor Check”: D13A (Page 1A-314).

Is check result OK?

3 ECT sensor check Go to Step 4. Replace ECT sensor.
1) Check ECT sensor. (Page 1C-26) (Page 1C-25)

Is check result OK?

4 Cooling system check Go to Step 5. Repair or replace
1) Check cooling system. defective part(s).
• Radiator cooling fan operation: (Page 1A-326)
• Coolant level: (Page 1F-24)
• Engine cooling system: (Page 1F-24)

Is check result OK?

5 Engine lubrication system check Go to Step 6. Repair or replace
1) Check that there is no engine oil leakage and check defective part(s).
engine oil level. (Page 1E-16)

Is check result OK?

6 Thermostat replacement Replace ECM and End.
1) Replace thermostat. (Page 1F-26) recheck DTC. (Page
1C-20)
2) Check DTC. (Page 1A-180)

Is DTC P0217 still detected?

 Engine General Information and Diagnosis: D13A 1A-248

DTC P0219
AENJHB0B1124031
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0219: Engine Overspeed Condition • CKP sensor and/or its circuit
Engine speed exceeds 6,000 rpm for 2 sec. • ECM
(1 D/C detection logic)

Circuit Diagram

3 1
A1
GRY/BLK D01-43
2 A2
YEL/RED D01-54

B1
5 PNK D01-25
B2
4 PNK/BLK D01-51
B3
PPL D01-21

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113016-01

[A]: ECM connector (View: [a]) B2: CMP sensor signal circuit 3. CKP sensor teeth
A1: CKP sensor signal circuit (+) B3: CMP sensor ground circuit 4. CMP sensor
A2: CKP sensor signal circuit (–) 1. ECM 5. CMP sensor teeth
B1: CMP sensor power supply circuit 2. CKP sensor

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and an assistant.

1) Warm up engine to normal operating temperature.

2) Drive vehicle for 5 min. (Engine speed at lower than 4,000 rpm.)
1A-249 Engine General Information and Diagnosis: D13A

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Customer’s driving condition check Go to Step 3. Inform customer that
1) Check engine speed is higher than 6,000 rpm for 2 this high engine speed
seconds in customer’s driving condition. may cause mechanical
damage.
Is check result OK?
3 CKP sensor signal circuit check Go to Step 4. Repair or replace
1) Check “A1” and “A2” circuits according to Step 3 of defective wire harness.
“Table C-2: Engine Speed Check”: D13A (Page 1A-313).

Is check result OK?

4 CKP sensor check Go to Step 5. Replace CKP sensor.
1) Check CKP sensor. (Page 1C-28) (Page 1C-27)

Is check result OK?

5 CKP sensor teeth check Replace ECM and Replace flywheel.
1) Check CKP sensor teeth. (Page 1D-112) recheck DTC. (Page (Page 1D-105)
1C-20)
Is check result OK?

DTC P0220
AENJHB0B1124032
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0220: Throttle / Pedal Position Sensor / Switch “B” Circuit • APP sensor and/or its circuit
Any of the following conditions is met. • ECM
• Measured voltage of APP sensor (sub) signal circuit is lower than 0.3 V and output
voltage of APP sensor (main) signal circuit is higher than 0.86 V.
• Measured voltage of APP sensor (sub) signal circuit is higher than 4.9 V.
• Both measured voltages of APP sensor (main) and APP sensor (sub) signal circuits
are lower than 0.05 V.
(1 D/C detection logic)
 Engine General Information and Diagnosis: D13A 1A-250

Circuit Diagram

1
A1
2 BRN E01-82
A2
BEG E01-63
A3
BLU E01-30
B1
3 BLK E01-9
B2
YEL E01-36
B3
WHT E01-27

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113012-01

[A]: ECM connector (View: [a]) B1: APP sensor (sub) power supply circuit 2. APP sensor (main)
A1: APP sensor (main) power supply circuit B2: APP sensor (sub) signal circuit 3. APP sensor (sub)
A2: APP sensor (main) signal circuit B3: APP sensor (sub) ground circuit
A3: APP sensor (main) ground circuit 1. ECM

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Keep accelerator pedal at released position for 2 sec.
4) Repeat Step 2) – 3) 3 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 APP sensor (sub) power supply circuit, signal circuit Go to Step 3. Repair or replace
and ground circuit check defective wire harness.
1) Check “B1”, “B2” and “B3” circuits according to Step 3 –
7 of “Table C-6: Accelerator Pedal Check”: D13A (Page
1A-319).

Is check result OK?

3 APP sensor (sub) check Replace ECM and Replace APP sensor.
1) Check APP sensor (sub). (Page 1C-25) recheck DTC. (Page (Page 1C-25)
1C-20)
Is check result OK?
1A-251 Engine General Information and Diagnosis: D13A

DTC P0230
AENJHB0B1124033
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0230: Fuel Pump Primary Circuit • Fuel pump relay (coil side) and/or its
Any of the following conditions is met. circuit
• Measured voltage of fuel pump relay drive circuit is higher than specified • ECM
value even when command signal of fuel pump relay is ON.
• Measured voltage of fuel pump relay drive circuit is lower than specified
value even when command signal of fuel pump relay is OFF.
(1 D/C detection logic)

Circuit Diagram

+B 1

A1 2 A3

BLU RED E01-74

WHT PNK B1
4 B2
3
A2 BLK

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113017-01

[A]: ECM connector (View: [a]) B1: Fuel pump power supply circuit 3. Fuel pump
A1: Fuel pump relay power supply circuit (coil side) B2: Fuel pump ground circuit 4. “F/P” fuse
A2: Fuel pump relay power supply circuit (switch side) 1. ECM
A3: Fuel pump relay drive circuit 2. Fuel pump relay

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Fuel pump relay (coil side) power supply circuit and Go to Step 3. Repair or replace
drive circuit check defective wire harness.
1) Check “A1” and “A3” circuits according to Step 2 – 3 of
“Table A-1: Fuel Pump Relay Operation Check”: D13A
(Page 1A-291).

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-252

Step Action Yes No

3 Fuel pump relay check Replace ECM and Replace fuel pump
1) Check fuel pump relay for resistance. (Page 1C-30) recheck DTC. (Page relay. (Page 10B-14)
1C-20)
Is check result OK?

DTC P0235
AENJHB0B1124034
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0235: Turbocharger / Supercharger Boost Sensor “A” Circuit • Boost pressure sensor and/or its circuit
Any of the following conditions is met. • ECM
• Measured voltage of boost pressure sensor signal circuit is higher
than 4,9 V for 2 sec.
• Measured voltage of boost pressure sensor signal circuit is lower
than 0.2 V for 2 sec.
(1 D/C detection logic)

Circuit Diagram

A1
RED/BLK D01-23
A2
2 YEL D01-41
A3
BLK D01-24

3 B1
WHT D01-37

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113008-01

[A]: ECM connector (View: [a]) A3: Boost pressure sensor ground circuit 2. Boost pressure sensor
A1: Boost pressure sensor power supply circuit B1: IAT-2 sensor signal circuit 3. IAT-2 sensor
A2: Boost pressure sensor signal circuit 1. ECM

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
1A-253 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 Boost pressure sensor power supply circuit, signal Go to Step 3. Repair or replace
circuit and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Step 5 –
9 of “Table B-3: Boost Pressure Sensor Check”: D13A
(Page 1A-302).

Is check result OK?

3 Boost pressure sensor check Replace ECM and Replace boost pressure
1) Check boost pressure sensor. (Page 1C-29) recheck DTC. (Page sensor with IAT sensor-
1C-20) 2. (Page 1C-28)
Is check result OK?

DTC P0243
AENJHB0B1124035
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0243: Turbocharger / Supercharger Wastegate Solenoid “A” • Boost pressure control solenoid valve
Any of the following conditions is met. and/or its circuit
• Measured voltage of boost pressure control solenoid valve drive • Boost pressure sensor with IAT sensor-2
circuit does not match command signal of boost pressure control and/or its circuit
solenoid valve. • Air intake system
• Difference between actual boost pressure and estimated boost • Turbocharger
pressure is more than specified value when turbocharger is
• Vacuum system
operated.
(1 D/C detection logic) • ECM

Circuit Diagram

BLU/RED D01-5

A1 A2
2 GRY/RED D01-6

B1 B2
BLU 3 YEL YEL/GRN D01-30

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113018-01

[A]: ECM connector (View: [a]) B1: Boost pressure control solenoid valve power supply 2. EGR valve
circuit
A1: EGR valve power supply circuit B2: Boost pressure control solenoid valve drive circuit 3. Boost pressure control solenoid valve
A2: EGR valve drive circuit 1. ECM
 Engine General Information and Diagnosis: D13A 1A-254

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Run engine at 2,500 rpm or more for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Boost pressure control solenoid valve operation check Go to Step 3. Repair or replace
1) Check that boost pressure control solenoid valve is defective part(s).
working properly. (Page 1A-309)

Is check result OK?

3 Boost pressure sensor check Go to Step 4. Repair or replace
1) Check boost pressure sensor. (Page 1A-302) defective part(s).

Is check result OK?

4 Air intake / turbocharger circuit check Go to Step 5. Repair or replace
1) Check that air intake / turbocharger circuit is working defective part(s).
properly. (Page 1A-299)

Is check result OK?

5 Vacuum system check Replace ECM and Repair or replace
1) Check the following parts: recheck DTC. (Page defective part(s).
1C-20)
• Vacuum hose and pipe
• Vacuum pump (Page 1D-86)

Is check result OK?

DTC P0335
AENJHB0B1124036
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0335: Crankshaft Position Sensor “A” Circuit • CKP sensor and/or its circuit
CKP sensor signal is not input even if CMP sensor signal • CKP sensor rotor
is input.
• ECM
(1 D/C detection logic)
1A-255 Engine General Information and Diagnosis: D13A

Circuit Diagram

3 1
A1
GRY/BLK D01-43
2 A2
YEL/RED D01-54

B1
5 PNK D01-25
B2
4 PNK/BLK D01-51
B3
PPL D01-21

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113016-01

[A]: ECM connector (View: [a]) B2: CMP sensor signal circuit 3. CKP sensor teeth
A1: CKP sensor signal circuit (+) B3: CMP sensor ground circuit 4. CMP sensor
A2: CKP sensor signal circuit (–) 1. ECM 5. CMP sensor teeth
B1: CMP sensor power supply circuit 2. CKP sensor

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Crank engine for 5 sec.

2) Run engine at 2,000 rpm or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 CKP sensor signal circuit check Go to Step 3. Repair or replace
1) Check “A1” and “A2” circuits according to Step 3 of defective wire harness.
“Table C-2: Engine Speed Check”: D13A (Page 1A-313).

Is check result OK?

3 CKP sensor check Go to Step 4. Replace CKP sensor.
1) Check CKP sensor. (Page 1C-28) (Page 1C-27)

Is check result OK?

4 CKP sensor teeth check Replace ECM and Replace flywheel.
1) Check CKP sensor teeth. (Page 1D-112) recheck DTC. (Page (Page 1D-105)
1C-20)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-256

DTC P0340
AENJHB0B1124037
NOTE
For identification of each cylinder, refer to “Electronic Control System Component Location”: D13A
(Page 1A-175).

DTC Detecting Condition and Trouble Area

DTC detecting condition Trouble area
P0340: Camshaft Position Sensor “A” Circuit (Bank1 or Single Sensor) • CMP sensor and/or its circuit
Any of the following conditions is met. • CMP sensor rotor
• Measured voltage of CMP sensor signal circuit is higher or lower than • ECM
specified value.
• CMP sensor signal is not expected value.
(1 D/C detection logic)

Circuit Diagram

3 1
A1
GRY/BLK D01-43
2 A2
YEL/RED D01-54

B1
5 PNK D01-25
B2
4 PNK/BLK D01-51
B3
PPL D01-21

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113016-01

[A]: ECM connector (View: [a]) B2: CMP sensor signal circuit 3. CKP sensor teeth
A1: CKP sensor signal circuit (+) B3: CMP sensor ground circuit 4. CMP sensor
A2: CKP sensor signal circuit (–) 1. ECM 5. CMP sensor teeth
B1: CMP sensor power supply circuit 2. CKP sensor

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
1A-257 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 CMP sensor power supply circuit and ground circuit Go to Step 5. Go to Step 3.
check
1) When ignition is “OFF”, disconnect CMP sensor
connector.
2) Check for proper terminal connection to CMP sensor
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1” and “B3” circuits is
approx. 5 V.

Is check result OK?

3 CMP sensor ground circuit check Repair “B3” circuit. Go to Step 4.
1) Check that voltage between “B1” circuit and ground is If DTC is detected
approx. 5 V. again, replace ECM and
recheck DTC. (Page
Is check result OK?
1C-20)
4 CMP sensor power supply circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “D01” connector from recheck DTC. (Page defective wire harness.
ECM. 1C-20)
2) Check for proper terminal connection to “D01”
connector.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at CMP sensor connector: infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 CMP sensor signal circuit check Go to Step 6. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at CMP sensor connector: infinity
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

6 CMP sensor check Go to Step 7. Replace CMP sensor.
1) Check CMP sensor. (Page 1C-27) (Page 1C-26)

Is check result OK?

7 CMP sensor teeth check Replace ECM and Replace exhaust
1) Check CMP sensor teeth. (Page 1D-117) recheck DTC. (Page manifold side camshaft.
1C-20) (Page 1D-115)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-258

DTC P0380 / P0683

AENJHB0B1124038
NOTE
For identification of each cylinder, refer to “Electronic Control System Component Location”: D13A
(Page 1A-175).

DTC Detecting Condition and Trouble Area

DTC detecting condition Trouble area
P0380: Glow Plug / Heater Circuit “A” • Glow plug and/or its circuit
Measured voltage of glow plug control module drive circuit does not • Glow plug control module and/or its circuit
match command signal for 2 sec.
• ECM
(1 D/C detection logic but MIL does not light up)
P0683: Glow Plug Control Module to PCM Communication
Circuit
Measured voltage of glow plug drive circuit does not match
command signal for about 30 sec.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

+BB IG1 1

A2 A1
7 B1
WHT BRN E01-68
B2
RED 2
LT BLU E01-73
A3
BLK
C1 C2 C3 C4
BLU RED YEL GRN
3 4 5 6

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113019-01

[A]: ECM connector (View: [a]) C1: Glow plug No.1 drive circuit 3. Glow Plug No.1
A1: Glow plug control module power supply circuit C2: Glow plug No.2 drive circuit 4. Glow Plug No.2
A2: Glow plug control module power supply circuit C3: Glow plug No.3 drive circuit 5. Glow Plug No.3
A3: Glow plug control module ground circuit C4: Glow plug No.4 drive circuit 6. Glow Plug No.4
B1: Glow plug control module drive circuit 1. ECM 7. “IG” fuse
B2: Glow plug control module communication circuit 2. Glow plug control module

DTC Confirmation Procedure

P0380

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

1A-259 Engine General Information and Diagnosis: D13A

P0683

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 30 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Glow plug control module power supply circuit, ground Go to Step 3. Repair or replace
circuit and drive circuit check defective wire harness.
1) Check “A1”, “A2”, “A3” and “B1” circuits according to
Step 2 – 5 of “Table C-8: Glow Plug Operation Check”:
D13A (Page 1A-323).

Is check result OK?

3 Glow plug check Go to Step 4. Replace faulty glow
1) Check glow plugs. (Page 1C-25) plug. (Page 1C-24)

Is check result OK?

4 Glow plug circuit check Go to Step 5. Repair or replace
1) Check “C1”, “C2”, “C3” and “C4” circuits according to defective wire harness.
Step 7 of “Table C-8: Glow Plug Operation Check”: D13A
(Page 1A-323).

Is check result OK?

5 Glow plug control module replacement Replace ECM and End.
1) Replace glow plug control module. (Page 1C-30) recheck DTC. (Page
1C-20)
2) Clear DTC. (Page 1A-181)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTCs.
(Page 1A-180)

Is DTC P0380 or P0683 still detected?

DTC P0401 / P0402

AENJHB0B1124039
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0401: Exhaust Gas Recirculation “A” Flow Insufficient Detected • MAF sensor and/or its circuit
Difference between measured intake air mass and estimated intake air • EGR valve and/or its circuit
mass is higher than specified value for 10 sec.
• Air intake circuit leakage or clog
(3 D/C detection logic)
P0402: Exhaust Gas Recirculation “A” Flow Excessive Detected • Turbocharger
Difference between measured intake air mass and estimated intake air • ECM
mass is out of specified range for 10 sec.
(3 D/C detection logic)
 Engine General Information and Diagnosis: D13A 1A-260

Circuit Diagram

IG1 1

A1
WHT
A2
2 RED E01-54
A3
YEL E01-29

3 B1
BLU E01-60

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113010-01

[A]: ECM connector (View: [a]) A3: MAF sensor ground circuit 2. MAF sensor
A1: MAF sensor power supply circuit B1: IAT-1 sensor signal circuit 3. IAT-1 sensor
A2: MAF sensor signal circuit 1. ECM

DTC Confirmation Procedure

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– Barometric pressure > 90 kPa (675 mmHg, 26.6 in.Hg, 0.90 bar)
– IAT > 15 °C (59 °F)

1) Warm up engine to normal operating temperature.

2) Run engine at 1,400 to 3,000 rpm for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 MAF sensor power supply circuit, signal circuit and Go to Step 3. Repair or replace
ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuit according to Step 5 – 8
of “Table B-2: MAF Sensor Check”: D13A (Page 1A-
300).

Is check result OK?

3 MAF sensor check Go to Step 4. Replace MAF sensor
1) Check MAF sensor. (Page 1C-23) with IAT sensor-1.
(Page 1C-23)
Is check result OK?
4 EGR valve operation check Go to Step 5. Repair or replace
1) Check EGR valve operation. (Page 1A-305) defective part(s).

Is check result OK?

1A-261 Engine General Information and Diagnosis: D13A

Step Action Yes No

5 Air intake / turbocharger circuit check Replace ECM and Repair or replace
1) Check that air intake / turbocharger circuit is working recheck DTC. (Page defective part(s).
properly. (Page 1A-299) 1C-20)

Is check result OK?

DTC P0403
AENJHB0B1124040
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0403: Exhaust Gas Recirculation “A” Control Circuit • EGR valve and/or its circuit
Measured voltage of EGR valve drive circuit does not match command signal for 2 • ECM
sec.
(3 D/C detection logic)

Circuit Diagram

BLU/RED D01-5

A1 A2
2 GRY/RED D01-6

B1 B2
BLU 3 YEL YEL/GRN D01-30

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113018-01

[A]: ECM connector (View: [a]) B1: Boost pressure control solenoid valve power supply circuit 2. EGR valve
A1: EGR valve power supply circuit B2: Boost pressure control solenoid valve drive circuit 3. Boost pressure control solenoid valve
A2: EGR valve drive circuit 1. ECM

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

2) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
 Engine General Information and Diagnosis: D13A 1A-262

Step Action Yes No

2 EGR valve power supply circuit and drive circuit check Go to Step 3. Repair or replace
1) Check “A1” and “A2” circuits according to Step 2 and 4 of defective wire harness.
“Table B-5: EGR Valve Operation Check”: D13A (Page
1A-305).

Is check result OK?

3 EGR valve check Replace ECM and Replace EGR valve.
1) Check EGR valve. (Page 1B-12) recheck DTC. (Page (Page 1B-10)
1C-20)
Is check result OK?

DTC P0480
AENJHB0B1124041
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0480: Fan 1 Control Circuit • Radiator cooling fan relay No.1 (coil side)
Any of the following conditions is met. and/or its circuit
• Radiator cooling fan relay No.1 drive circuit is open. • ECM
• Radiator cooling fan relay No.1 drive circuit is shorted to power
supply.
• Radiator cooling fan relay No.1 drive circuit is shorted to ground.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

1
+BB +B
A3
A1 3 LT GRN E01-1
D1
BLU
6 B1 4 B3 2
A2

GRY PNK
B2 D3 BLK
C1 5 C3
D2
GRN E01-2
BLK LT GRN
C2 D4
[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113020-01

[A]: ECM connector (View: [a]) D1: Radiator cooling fan power supply circuit (low speed side)
A1: Radiator cooling fan relay No.1 power supply circuit (coil side) D2: Radiator cooling fan ground circuit (low speed side)
A2: Radiator cooling fan relay No.1 power supply circuit (switch side) D1: Radiator cooling fan power supply circuit (high speed side)
A3: Radiator cooling fan relay No.1 drive circuit D2: Radiator cooling fan ground circuit (high speed side)
B1: Radiator cooling fan relay No.2 power supply circuit (coil side) 1. ECM
B2: Radiator cooling fan relay No.2 power supply circuit (switch side) 2. Radiator cooling fan
B3: Radiator cooling fan relay No.2 drive circuit 3. Radiator cooling fan relay No.1
C1: Radiator cooling fan relay No.3 power supply circuit (coil side) 4. Radiator cooling fan relay No.2
C2: Radiator cooling fan relay No.3 ground circuit 5. Radiator cooling fan relay No.3
C3: Radiator cooling fan relay No.3 drive circuit 6. “RDTR” fuse
1A-263 Engine General Information and Diagnosis: D13A

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Connect SUZUKI scan tool to DLC.

2) Display “ECT” of “Data List” mode on SUZUKI scan tool.
3) Keep engine at idle speed until engine coolant temperature reaches 98 °C (208 °F) or more.
4) Stop engine.
5) Repeat Step 2) – 4) 2 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Radiator cooling fan relay No.1 power supply circuit Go to Step 3. Repair or replace
(coil side) and radiator cooling fan relay No.1 drive defective wire harness.
circuit check
1) Check “A1” and “A3” circuits according to Step 3 – 4 of
“Table C-9: Radiator Cooling Fan Operation Check”:
D13A (Page 1A-326).

Is check result OK?

3 Radiator cooling fan relay No.1 check Replace ECM and Replace radiator cooling
1) Check radiator cooling fan relay No.1. (Page 1F-28) recheck DTC. (Page fan relay No.1. (Page
1C-20) 10B-14)
Is check result OK?

DTC P0481
AENJHB0B1124042
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0481: Fan 2 Control Circuit • Radiator cooling fan relay No.2 (coil side)
Any of the following conditions is met. and/or its circuit
• Radiator cooling fan relay No.2 and/or No.3 drive circuit is open. • Radiator cooling fan relay No.3 (coil side)
• Radiator cooling fan relay No.2 and/or No.3 drive circuit is shorted to and/or its circuit
power supply. • ECM
• Radiator cooling fan relay No.2 and/or No.3 drive circuit is shorted to
ground.
(1 D/C detection logic but MIL does not light up)
 Engine General Information and Diagnosis: D13A 1A-264

Circuit Diagram

1
+BB +B
A3
A1 3 LT GRN E01-1
D1
BLU
6 B1 4 B3 2
A2

GRY PNK
B2 D3 BLK
C1 5 C3
D2
GRN E01-2
BLK LT GRN
C2 D4
[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113020-01

[A]: ECM connector (View: [a]) D1: Radiator cooling fan power supply circuit (low speed side)
A1: Radiator cooling fan relay No.1 power supply circuit (coil side) D2: Radiator cooling fan ground circuit (low speed side)
A2: Radiator cooling fan relay No.1 power supply circuit (switch side) D1: Radiator cooling fan power supply circuit (high speed side)
A3: Radiator cooling fan relay No.1 drive circuit D2: Radiator cooling fan ground circuit (high speed side)
B1: Radiator cooling fan relay No.2 power supply circuit (coil side) 1. ECM
B2: Radiator cooling fan relay No.2 power supply circuit (switch side) 2. Radiator cooling fan
B3: Radiator cooling fan relay No.2 drive circuit 3. Radiator cooling fan relay No.1
C1: Radiator cooling fan relay No.3 power supply circuit (coil side) 4. Radiator cooling fan relay No.2
C2: Radiator cooling fan relay No.3 ground circuit 5. Radiator cooling fan relay No.3
C3: Radiator cooling fan relay No.3 drive circuit 6. “RDTR” fuse

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Connect SUZUKI scan tool to DLC.

2) Display “ECT” of “Data List” mode on SUZUKI scan tool.
3) Race engine so that engine coolant temperature reaches 103 °C (217 °F) or more.
4) Stop engine.
5) Repeat Step 2) – 4) 2 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
1A-265 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 Radiator cooling fan relay No.2 power supply circuit Go to Step 3. Repair or replace
(coil side), radiator cooling fan relay No.3 power supply defective wire harness.
circuit (coil side), radiator cooling fan relay No.2 and
radiator cooling fan relay No.3 drive circuit check
1) Check “B1”, “B3”, “C1” and “C3” circuits according to
Step 8 – 10 of “Table C-9: Radiator Cooling Fan
Operation Check”: D13A (Page 1A-326).

Is check result OK?

3 Radiator cooling fan relay No.2 and No.3 check Replace ECM and Replace radiator cooling
1) Check radiator cooling fan relay No.2 and No.3. (Page recheck DTC. (Page fan relay No.2 or No.3.
1F-28) 1C-20) (Page 10B-14)

Is check result OK?

DTC P0500
AENJHB0B1124043
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0500: Vehicle Speed Sensor “A” • Wheel speed sensor and/or its circuit
Invalid vehicle speed signal is received from ABS control • CAN communication line
module via CAN.
• ABS control module
(3 D/C detection logic)
• No vehicle variant data (including CAN vehicle
configuration data)
• ECM

Circuit Diagram

3
1

4
7 RED E01-62
WHT E01-35 7
5

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113021-01

[A]: ECM connector (View: [a]) 3. Left-front wheel speed sensor 6. Right-rear wheel speed sensor
1. ECM 4. Right-front wheel speed sensor 7. CAN driver
2. ABS control module 5. Left-rear wheel speed sensor
 Engine General Information and Diagnosis: D13A 1A-266

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and an assistant.

1) Warm up engine to normal operating temperature.

2) Drive vehicle at engine speed of 2,000 to 3,000 rpm for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Wheel speed sensor check Go to Step 3. Repair or replace
1) Check that wheel speed sensor is working properly. defective part(s).
(Page 1A-322)

Is check result OK?

3 Vehicle variant data (including CAN vehicle Replace ECM and End.
configuration data) check recheck DTC. (Page
1) Check registered vehicle variant data (including CAN 1C-20)
vehicle configuration data). (Page 1C-22)
2) Perform DTC confirmation procedure, and check for
DTCs. (Page 1A-180)

Is DTC P0500 still detected?

DTC P0520
AENJHB0B1124044
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0520: Engine Oil Pressure Sensor / Switch Circuit • Oil pressure switch and/or its circuit
Measured voltage of oil pressure switch signal circuit is • ECM
higher than specified value when engine is not running.
(1 D/C detection logic but MIL does not light up)
1A-267 Engine General Information and Diagnosis: D13A

Circuit Diagram

1
A1
2
GRY/YEL D01-10

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113022-01

[A]: ECM connector (View: [a]) 1. ECM

A1: Oil pressure switch signal circuit 2. Oil pressure switch

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Set ignition “OFF” and wait for more than 30 sec.
3) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Oil pressure switch signal circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect “D01” connector from defective wire harness.
ECM and oil pressure switch connector.
2) Check for proper terminal connection to “D01” connector
and oil pressure switch connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Voltage of “A1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

3 Oil pressure switch check Replace ECM and Replace oil pressure
1) Check oil pressure switch. (Page 1E-17) recheck DTC. (Page switch. (Page 1E-17)
1C-20)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-268

DTC P0530
AENJHB0B1124045
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0530: A/C Refrigerant Pressure Sensor “A” Circuit • A/C refrigerant pressure sensor and/or
Any of the following conditions is met. its circuit
• Measured voltage of A/C refrigerant pressure sensor signal circuit is • No vehicle variant data (including CAN
lower than 0.1 V for 2 sec. vehicle configuration data)
• Measured voltage of A/C refrigerant pressure sensor signal circuit is • ECM
higher than 4.9 V for 2 sec.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

1
A1
2 BRN E01-32
A2
PNK E01-86
A3
BLU E01-4

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113023-01

[A]: ECM connector (View: [a]) A2: A/C refrigerant pressure sensor signal circuit 1. ECM
A1: A/C refrigerant pressure sensor power supply circuit A3: A/C refrigerant pressure sensor ground circuit 2. A/C refrigerant pressure sensor

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 A/C refrigerant pressure sensor power supply circuit Go to Step 5. Go to Step 3.
check
1) When ignition is “OFF”, disconnect A/C refrigerant
pressure sensor connector.
2) Check for proper terminal connection to A/C refrigerant
pressure sensor connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” circuits is
approx. 5 V.

Is check result OK?

1A-269 Engine General Information and Diagnosis: D13A

Step Action Yes No

3 A/C refrigerant pressure sensor ground circuit check Repair “A3” circuit. Go to Step 4.
1) Check that voltage between “A1” circuit and ground is If DTC P0530 is
approx. 5 V. detected again, replace
ECM and recheck DTC.
Is check result OK?
(Page 1C-20)
4 A/C refrigerant pressure sensor power supply circuit Replace ECM and Repair or replace
check recheck DTC. (Page defective wire harness.
1) When ignition is “OFF”, disconnect “E01” connector from 1C-20)
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at A/C refrigerant pressure sensor connector:
infinity
• Voltage of “A1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 A/C refrigerant pressure sensor signal circuit check Go to Step 6. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at A/C refrigerant pressure sensor connector:
infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

6 A/C refrigerant pressure sensor check Go to Step 7. Replace A/C refrigerant
1) Check A/C refrigerant pressure sensor. pressure sensor.
• Manual single A/C model: (Page 7B-45) • Manual single A/C
• Manual dual A/C model: (Page 7B-88) model: (Page 7B-
45)
• Auto A/C model: (Page 7B-129)
• Manual dual A/C
Is check result OK? model: (Page 7B-
88)
• Auto A/C model:
(Page 7B-129)
7 Vehicle variant data (including CAN vehicle Replace ECM and End.
configuration data) check recheck DTC. (Page
1) Check registered vehicle variant data (including CAN 1C-20)
vehicle configuration data). (Page 1C-22)
2) Perform DTC confirmation procedure, and check for
DTCs. (Page 1A-180)

Is DTC P0530 still detected?

 Engine General Information and Diagnosis: D13A 1A-270

DTC P0560
AENJHB0B1124046
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0560: System Voltage • ECM backup power supply
Any of the following conditions is met. circuit
• Measured voltage of backup power supply circuit is higher than 16 V. • ECM ground circuit
• Measured voltage of backup power supply circuit is lower than 6 V. • Charging system
(1 D/C detection logic but MIL does not light up) • ECM

Circuit Diagram

1
D1
YEL E01-45

A1 2 A3
YEL PNK E01-79
RED BLU B1
A2 GRN E01-48
B2
GRN E01-71
B3
GRN E01-72
C1
BRN E01-23
C2
BRN E01-24
C3
BRN E01-47

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113024-01

[A]: ECM connector (View: [a]) B2: ECM power supply circuit D1: ECM backup power supply circuit
A1: Main relay power supply circuit (coil side) B3: ECM power supply circuit 1. ECM
A2: Main relay power supply circuit (switch side) C1: ECM ground circuit 2. Main relay
A3: Main relay drive circuit C2: ECM ground circuit
B1: ECM power supply circuit C3: ECM ground circuit

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
1A-271 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 ECM backup power supply circuit and ground circuit Go to Step 3. Repair or replace
check defective wire harness.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM and “ECM” fuse.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check that ECM backup power
supply circuit and ground circuit (“D1”, “C1”, “C2” and
“C3”) is as follows.
• Resistance of “D1”, “C1”, “C2” and “C3” circuits: less
than 1 Ω
• Resistance between each of “D1”, “C1”, “C2” and “C3”
circuits and ground: infinity
• Resistance between “D1” circuit terminal and other
terminal at ECM connector: infinity
• Resistance between “C1” circuit terminal and other
terminal at ECM connector: infinity
• Resistance between “C2” circuit terminal and other
terminal at ECM connector: infinity
• Resistance between “C3” circuit terminal and other
terminal at ECM connector: infinity
• Voltage of “D1”, “C1”, “C2” and “C3” circuits: approx. 0
V (When ignition is “ON”)

Is check result OK?

3 Charging system check Go to Step 4. Repair or replace
1) Check that charging system is working properly. (Page defective part(s).
1J-15)

Is check result OK?

4 DTC check Replace ECM and End.
1) Clear DTC. (Page 1A-181) recheck DTC. (Page
1C-20)
2) Set ignition “OFF”.
3) Perform DTC confirmation procedure to check for DTC.
(Page 1A-180)

Is DTC P0560 still detected?

DTC P0571 / P1571

AENJHB0B1124047
DTC Detecting Condition and Table Area
DTC detecting condition Trouble area
P0571: Brake Switch “A” Circuit • Brake light switch and/or its circuit
Any of the following conditions is met. • Brake switch and/or its circuit
• Vehicle speed increases from under 10 km/h (6 mile/h) to over 90 km/h • ECM
(56 mile/h) even though brake pedal is depressed.
• Brake light switch signal does not correlate with brake switch signal.
(1 D/C detection logic but MIL does not light up)
P1571: Brake Switch Circuit
Any of the following conditions is met.
• Vehicle speed increases from under 10 km/h (6 mile/h) to over 90 km/h
(56 mile/h) even though brake pedal is depressed.
• Brake switch signal does not correlate with brake light signal.
(1 D/C detection logic but MIL does not light up)
 Engine General Information and Diagnosis: D13A 1A-272

Circuit Diagram

IG1 1
A1 A2
+BB 5
LT GRN
6 2 BLU E01-66
PNK
3 LT BLU E01-14
B1 4
B2

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113025-01

[A]: ECM connector (View: [a]) B2: Brake light switch signal circuit 4. Brake light
A1: Brake switch power supply circuit 1. ECM 5. “IG1 SIG” fuse
A2: Brake switch signal circuit 2. Brake switch 6. “STOP” fuse
B1: Brake light switch power supply circuit 3. Brake light switch

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and an assistant.

1) Drive vehicle at 90 km/h (56 mile/h) or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Brake switch power supply circuit and brake light Go to Step 3. Check “IG1 SIG” fuse
switch power supply circuit check and “STOP” fuse for
1) When ignition is “OFF”, disconnect brake light switch / blowout. If fuse is not
brake switch connector. blown, repair or replace
defective wire harness.
2) Check for proper terminal connection to brake light
switch / brake switch connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A1” and “B1”
circuits and ground is battery voltage.

Is check result OK?

1A-273 Engine General Information and Diagnosis: D13A

Step Action Yes No

3 Brake switch signal circuit and brake light switch signal Go to Step 4. Repair or replace
circuit check defective wire harness.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A2” and “B2” circuits: less than 1 Ω
• Resistance between each of “A2” and “B2” circuits
and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at brake light switch / brake switch connector:
infinity
• Resistance between “B2” circuit terminal and other
terminal at brake light switch / brake switch connector:
infinity
• Voltage of “A2” and “B2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

4 Brake light switch and brake switch check Replace ECM and Replace brake light
1) Check brake light switch / brake switch. (Page 4A-11) recheck DTC. (Page switch / brake switch.
1C-20) (Page 4A-11)
Is check result OK?

DTC P0600 / P0601 / P0604 / P060B / P2226

AENJHB0B1124048
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0600: Serial Communication Link • ECM power supply circuit and/or
ECM internal failure is detected. ground circuit
(1 D/C detection logic but MIL does not light up) • ECM
P0601: Internal Control Module Memory Check Sum Error
ECM internal failure is detected.
(1 D/C detection logic)
P0604: Internal Control Module Random Access Memory (RAM) Error
ECM internal failure is detected.
(1 D/C detection logic)
P060B: Internal Control Module A/D Processing Performance
ECM internal failure is detected.
(1 D/C detection logic)
P2226: Barometric Pressure Sensor “A” Circuit • Barometric pressure sensor (in ECM)
Any of the following conditions is met. • ECM
• Measured voltage of barometric pressure sensor signal circuit is higher
than 4.8 V for 2 sec.
• Measured voltage of barometric pressure sensor signal circuit is lower
than 0.2 V for 2 sec.
(1 D/C detection logic)
 Engine General Information and Diagnosis: D13A 1A-274

Circuit Diagram

1
D1
YEL E01-45

A1 2 A3
YEL PNK E01-79
RED BLU B1
A2 GRN E01-48
B2
GRN E01-71
B3
GRN E01-72
C1
BRN E01-23
C2
BRN E01-24
C3
BRN E01-47

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113024-01

[A]: ECM connector (View: [a]) B2: ECM power supply circuit D1: ECM backup power supply circuit
A1: Main relay power supply circuit (coil side) B3: ECM power supply circuit 1. ECM
A2: Main relay power supply circuit (switch side) C1: ECM ground circuit 2. Main relay
A3: Main relay drive circuit C2: ECM ground circuit
B1: ECM power supply circuit C3: ECM ground circuit

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177)
2 DTC recheck Go to Step 3. Check for intermittent
1) Clear DTC. (Page 1A-181) trouble. (Page 00-12)
2) Set ignition “OFF”.
3) Perform DTC confirmation procedure to check for DTCs.
(Page 1A-180)

Is DTC P0600, P0601, P0604, P060B or P2226 still

detected?
3 ECM power supply circuit and ground circuit check Replace ECM and Repair or replace
1) Check “B1”, “B2”, “B3”, “C1”, “C2” and “C3” circuits recheck DTC. (Page defective wire harness.
according to Step 3 – 4 of “Table C-1: Main Relay 1C-20)
Operation Check”: D13A (Page 1A-311).

Is check result OK?

1A-275 Engine General Information and Diagnosis: D13A

DTC P0641
AENJHB0B1124049
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0641: Sensor Reference Voltage “A” Circuit / Open • Fuel pressure sensor and/or its circuit
Sensor power supply voltage “A” is higher than 5.3 V or • Boost pressure sensor and/or its circuit
lower than 4.7 V.
• ECM
(1 D/C detection logic)

Circuit Diagram

GRN/YEL D01-9

2 YEL/BLK D01-38

YEL/RED D01-7

RED/BLK D01-23

3 YEL D01-41

BLK D01-24

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113026-01

[A]: ECM connector (View: [a]) 2. Fuel pressure sensor

1. ECM 3. Boost pressure sensor

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
 Engine General Information and Diagnosis: D13A 1A-276

Step Action Yes No

2 Sensor power supply circuit, signal circuit and ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) Check power supply circuit, signal circuit and ground
circuit of the following sensors.
• Fuel pressure sensor: According to Step 3 – 6 of
“Table A-4: Fuel Pressure Sensor Circuit Check”:
D13A (Page 1A-296).
• Boost pressure sensor: According to Step 5 – 9 of
“Table B-3: Boost Pressure Sensor Check”: D13A
(Page 1A-302).

Is check result OK?

3 DTC check Go to Step 4. Replace fuel pressure
1) When ignition is “OFF”, disconnect connector from fuel sensor. (Page 1G-50)
pressure sensor.
2) Clear DTC. (Page 1A-181)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
(Page 1A-180)

Is DTC P0641 still detected?

4 DTC check Replace ECM and Replace boost pressure
1) When ignition is “OFF”, disconnect connector from boost recheck DTC. (Page sensor with IAT sensor-
pressure sensor with IAT sensor-2. 1C-20) 2. (Page 1C-28)
2) Clear DTC. (Page 1A-181)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
(Page 1A-180)

Is DTC P0641 still detected?

DTC P0645
AENJHB0B1124050
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0645: A/C Clutch Relay Control Circuit • A/C compressor relay (coil side) and/or its
Any of the following conditions is met. circuit
• Measured voltage of A/C compressor relay drive circuit is higher • No vehicle variant data (including CAN
than specified value for 2 sec. even when command signal of A/C vehicle configuration data)
compressor relay is ON. • ECM
• Measured voltage of A/C compressor relay drive circuit is lower
than specified value for 2 sec. even when command signal of A/C
compressor relay is OFF.
(1 D/C detection logic but MIL does not light up)
1A-277 Engine General Information and Diagnosis: D13A

Circuit Diagram

+BB +B 1

A1 2 A2

BLU BRN E01-78

GRN 3
WHT BLK

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113027-01

[A]: ECM connector (View: [a]) A2: A/C compressor relay drive circuit 2. A/C compressor relay
A1: A/C compressor relay power supply circuit (coil side) 1. ECM 3. A/C compressor

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Check that the following conditions are met.
• Blower speed selector: Maximum position
• A/C switch: ON
3) Run engine at idle speed for 1 min. and check that the following conditions are met.
• Blower speed selector: OFF
• A/C switch: OFF
4) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 A/C compressor relay power supply circuit (coil side) Go to Step 3. Repair or replace
check defective wire harness.
1) When ignition is “OFF”, remove A/C compressor relay.
(Page 10B-14)
2) Check for proper terminal connection to A/C compressor
relay connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-278

Step Action Yes No

3 A/C compressor relay drive circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and each
terminal at A/C compressor relay connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

4 A/C compressor relay check Go to Step 5. Replace A/C
1) Check A/C compressor relay for resistance. compressor relay.
(Page 10B-14)
• Manual single A/C model: (Page 7B-48)
• Manual dual A/C model: (Page 7B-92)
• Auto A/C model: (Page 7B-134)

Is check result OK?

5 Vehicle variant data (including CAN vehicle Replace ECM and End.
configuration data) check recheck DTC. (Page
1) Check registered vehicle variant data (including CAN 1C-20)
vehicle configuration data). (Page 1C-22)
2) Perform DTC confirmation procedure, and check for
DTCs. (Page 1A-180)

Is DTC P0645 still detected?

DTC P0651
AENJHB0B1124051
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0651: Sensor Reference Voltage “B” Circuit / Open • APP sensor (main) and/or its circuit
Sensor power supply voltage “B” is higher than 5.3 V or • CMP sensor and/or its circuit
lower than 4.7 V.
• ECM
(1 D/C detection logic)
1A-279 Engine General Information and Diagnosis: D13A

Circuit Diagram

2 BRN E01-82
BEG E01-63
BLU E01-30

PNK D01-25
3 PNK/BLK D01-51
PPL D01-21

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113028-01

[A]: ECM connector (View: [a]) 2. APP sensor (main)

1. ECM 3. CMP sensor

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Sensor power supply circuit, signal circuit and ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) Check power supply circuit, signal circuit and ground
circuit of the following sensors.
• APP sensor (main) according to Step 3 – 7 of “Table
C-6: Accelerator Pedal Check”: D13A (Page 1A-319).
• CMP sensor according to Step 2 – 5 of “DTC P0340”:
D13A (Page 1A-256).

Are they in good condition?

3 DTC check Go to Step 4. Replace APP sensor.
1) When ignition is “OFF”, disconnect connector from APP (Page 1C-25)
sensor.
2) Clear DTC. (Page 1A-181)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
(Page 1A-180)

Is DTC P0651 still detected?

 Engine General Information and Diagnosis: D13A 1A-280

Step Action Yes No

4 DTC check Replace ECM and Replace CMP sensor.
1) When ignition is “OFF”, disconnect connector CMP recheck DTC. (Page (Page 1C-26)
sensor. 1C-20)
2) Clear DTC. (Page 1A-181)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
(Page 1A-180)

Is DTC P0651 still detected?

DTC P0657 / P0685

AENJHB0B1124052
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0657: Actuator Supply Voltage “A” Circuit / Open • Main relay (coil side) and/or its
Measured voltage of main relay drive circuit is lower or higher than specified value. circuit
(1 D/C detection logic but MIL does not light up) • ECM
P0685: ECM/PCM Power Relay Control Circuit / Open
Measured voltage of main relay drive circuit does not match command signal.
(1 D/C detection logic)

Circuit Diagram

1
D1
YEL E01-45

A1 2 A3
YEL PNK E01-79
RED BLU B1
A2 GRN E01-48
B2
GRN E01-71
B3
GRN E01-72
C1
BRN E01-23
C2
BRN E01-24
C3
BRN E01-47

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113024-01

[A]: ECM connector (View: [a]) B2: ECM power supply circuit D1: ECM backup power supply circuit
A1: Main relay power supply circuit (coil side) B3: ECM power supply circuit 1. ECM
A2: Main relay power supply circuit (switch side) C1: ECM ground circuit 2. Main relay
A3: Main relay drive circuit C2: ECM ground circuit
B1: ECM power supply circuit C3: ECM ground circuit
1A-281 Engine General Information and Diagnosis: D13A

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Main relay power supply circuit (coil side) and main Go to Step 3. Repair or replace
relay drive circuit check defective wire harness.
1) Check “A1” and “A3” circuits according to Step 1 – 2 of
“Table C-1: Main Relay Operation Check”: D13A (Page
1A-311).

Is check result OK?

3 Main relay check Replace ECM and Replace main relay.
1) Check main relay. (Page 1C-30) recheck DTC. (Page (Page 10B-14)
1C-20)
Is check result OK?

DTC P0697
AENJHB0B1124053
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0697: Sensor Reference Voltage “C” Circuit / Open • A/C refrigerant pressure sensor and/or its circuit
Sensor power supply voltage “C” is higher than 5.3 V or • APP sensor (sub) and/or its circuit
lower than 4.7 V.
• ECM
(1 D/C detection logic)

Circuit Diagram

2 BRN E01-32

PNK E01-86
BLU E01-4

3
BLK E01-9
YEL E01-36
WHT E01-27

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113029-01

[A]: ECM connector (View: [a]) 2. A/C refrigerant pressure sensor

1. ECM 3. APP sensor (sub)
 Engine General Information and Diagnosis: D13A 1A-282

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Sensor power supply circuit, signal circuit and ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) Check power supply circuit, signal circuit and ground
circuit of the following sensors.
• A/C refrigerant pressure sensor according to Step 2 –
5 of “DTC P0530”: D13A (Page 1A-268).
• APP sensor (sub) according to Step 3 – 7 of “Table C-
6: Accelerator Pedal Check”: D13A (Page 1A-319).

Is check result OK?

3 DTC check Go to Step 4. Replace A/C refrigerant
1) When ignition is “OFF”, disconnect connector from A/C pressure sensor.
refrigerant pressure sensor. • Manual single A/C
2) Clear DTC. (Page 1A-181) model: (Page 7B-
45)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC. • Manual dual A/C
(Page 1A-180) model: (Page 7B-
88)
Is DTC P0697 still detected? • Auto A/C model:
(Page 7B-129)
4 DTC check Replace ECM and Replace APP sensor.
1) When ignition is “OFF”, disconnect connector from APP recheck DTC. (Page (Page 1C-25)
sensor. 1C-20)
2) Clear DTC. (Page 1A-181)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
(Page 1A-180)

Is DTC P0697 still detected?

1A-283 Engine General Information and Diagnosis: D13A

DTC P0704
AENJHB0B1124054
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0704: Clutch Switch Input Circuit • CPP No.2 switch and/or its circuit
CPP No.2 switch signal does not change even though gear is shifted • ECM
40 times.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

A2 A1
2
BLK PPL E01-21

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113030-01

[A]: ECM connector (View: [a]) A2: CPP No.2 switch power supply circuit 2. CPP No.2 switch
A1: CPP No.2 switch signal circuit 1. ECM

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and an assistant.

1) Drive vehicle at 10 km/h (6 mile/h) or higher while engine keeps running at 1,000 rpm or higher.
2) In state of Step 1), repeat gear shift 60 times or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 CPP No.2 switch power supply circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect CPP No.2 switch defective wire harness.
connector.
2) Check for proper terminal connection to CPP No.2
switch connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A2” circuit and ground is
battery voltage.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-284

Step Action Yes No

3 CPP No.2 switch signal circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and each
terminal at CPP switch connector: infinity
• Voltage of “A1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

4 CPP No.2 switch check Replace ECM and Replace CPP No.2
Check CPP No.2 switch. (Page 5C-4) recheck DTC. (Page switch. (Page 5C-4)
1C-20)
Is check result OK?

DTC P1647
AENJHB0B1124055
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1647: Vehicle Variant Not Programmed • No vehicle variant data
Vehicle variant data is not registered in ECM. • ECM
(1 D/C detection logic but MIL does not light up)

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Registration data check Go to Step 3. Register correct vehicle
1) When ignition is “OFF”, connect SUZUKI scan tool to variant data to ECM,
DLC. referring to “Vehicle
Variant Data (Including
2) Set ignition “ON”.
CAN Vehicle
3) Check registered vehicle variant data. (Page 1C-22) Configuration Data)
Is registered vehicle variant data correct? Registration”: D13A in
Section 1C (Page 1C-
22).
3 DTC recheck Replace ECM and End.
1) Clear DTC. (Page 1A-181) recheck DTC. (Page
1C-20)
2) Set ignition “ON”.
3) Perform DTC confirmation procedure, and check for
DTCs. (Page 1A-180)

Is DTC P1647 still detected?

1A-285 Engine General Information and Diagnosis: D13A

DTC P2135
AENJHB0B1124056
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2135: Throttle / Pedal Position Sensor / Switch “A” / “B” Voltage Correlation • APP sensor and/or its circuit
Any of the following conditions is met. • ECM
• Measured voltage of APP sensor (main) signal circuit is higher than output voltage
of APP sensor (sub) by 0.22 V though output voltage of APP sensor (main) is
lower than 1.27 V.
• Measured voltage of APP sensor (main) signal circuit is higher than output voltage
of APP sensor (sub) by 0.32 V though output voltage of APP sensor (main) is
higher than 1.27 V.
(1 D/C detection logic)

Circuit Diagram

1
A1
2 BRN E01-82
A2
BEG E01-63
A3
BLU E01-30
B1
3 BLK E01-9
B2
YEL E01-36
B3
WHT E01-27

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113012-01

[A]: ECM connector (View: [a]) B1: APP sensor (sub) power supply circuit 2. APP sensor (main)
A1: APP sensor (main) power supply circuit B2: APP sensor (sub) signal circuit 3. APP sensor (sub)
A2: APP sensor (main) signal circuit B3: APP sensor (sub) ground circuit
A3: APP sensor (main) ground circuit 1. ECM

DTC Confirmation Procedure

NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON”.

2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Keep accelerator pedal at released position for 2 sec.
4) Repeat Step 2) – 3) 3 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
 Engine General Information and Diagnosis: D13A 1A-286

Step Action Yes No

2 APP sensor (main) power supply circuit, signal circuit Go to Step 3. Repair or replace
and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Step 3 –
7 of “Table C-6: Accelerator Pedal Check”: D13A (Page
1A-319).

Is check result OK?

3 APP sensor (sub) power supply circuit, signal circuit Go to Step 4. Repair or replace
and ground circuit check defective wire harness.
1) Check “B1”, “B2” and “B3” circuits according to Step 3 –
7 of “Table C-6: Accelerator Pedal Check”: D13A (Page
1A-319).

Is check result OK?

4 APP sensor check Replace ECM and Replace APP sensor.
1) Check APP sensor. (Page 1C-25) recheck DTC. (Page (Page 1C-25)
1C-20)
Is check result OK?

DTC P2237 / P2297

AENJHB0B1124057
DTC Detecting Condition and Table Area
DTC detecting condition Trouble area
P2237: O2 Sensor Positive Current Control Circuit / • A/F sensor and/or its circuit
Open (Bank1 Sensor1) • ECM
Any one of A/F sensor signal voltage is in abnormal
condition.
(1 D/C detection logic but MIL does not light up)
P2297: O2 Sensor Out of Range During Deceleration
(Bank1 Sensor1)
A/F value at fuel cut is not as specified.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

2 1
A1
BLK E01-42
A2
LT GRN E01-39
A3
GRY E01-41
A4
+B
WHT E01-40
B1 B2
PINK E01-6
BLU

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113013-01

[A]: ECM connector (View: [a]) A3: A/F sensor signal circuit (VSIP) B2: A/F heater drive circuit
A1: A/F sensor signal circuit (RC) A4: A/F sensor signal circuit (IP) 1. ECM
A2: A/F sensor signal circuit (VS) B1: A/F heater power supply circuit 2. A/F sensor
1A-287 Engine General Information and Diagnosis: D13A

DTC Confirmation Procedure

P2237
1) Run engine at idle speed for 3 min.

P2297

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and an assistant.

NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 50 °C (122 °F) < ECT < 100 °C (212 °F)
– –44 °C (–47 °F) < IAT < 100 °C (212 °F)
– Barometric pressure >= 50 kPa (375 mmHg, 14.8 in.Hg, 0.5 bar)

1) Drive vehicle at 40 km/h (25 mile/h) or more for 5 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 A/F sensor signal circuit check Go to Step 3. Repair or replace
1) Check “A1”, “A2”, “A3” and “A4” circuits according to defective wire harness.
Step 6 of “Table B-6: A/F Sensor Check”: D13A (Page
1A-307).

Is check result OK?

3 A/F sensor replacement Replace ECM and Repair or replace
1) Replace A/F sensor. (Page 1B-14) recheck DTC. (Page defective wire harness.
1C-20)
2) Clear DTC. (Page 1A-181)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
(Page 1A-180)

Is DTC P2237 or P2297 still detected?

DTC P2264
AENJHB0B1124058
DTC Detecting Condition and Table Area
DTC detecting condition Trouble area
P2264: Water in Fuel Sensor Circuit • Fuel filter water detection sensor and/or its circuit
Measured voltage of fuel filter water detection sensor is • ECM
higher than specified value even though the voltage is
controlled at low level by ECM during self test.
(1 D/C detection logic but MIL does not light up)
 Engine General Information and Diagnosis: D13A 1A-288

Circuit Diagram

IG1 1
2
A1
A2
WHT
3 RED E01-89
BLK
A3 B1
4
BEG E01-59
B2
GRN E01-7

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113014-01

[A]: ECM connector (View: [a]) B1: Fuel temperature sensor signal circuit 3. Fuel filter water detection sensor
A1: Fuel filter water detection sensor power supply circuit B2: Fuel temperature sensor ground circuit 4. Fuel temperature sensor
A2: Fuel filter water detection sensor signal circuit 1. ECM
A3: Fuel filter water detection sensor ground circuit 2. Water detection sensor with fuel temperature sensor

DTC Confirmation Procedure

1) Warm up engine to normal operating temperature.
2) Set ignition “OFF” and wait for more than 30 sec.
3) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177)
2 Drain water from fuel filter End. Go to Step 3.
1) Drain water. (Page 1G-41)
2) Clear DTC. (Page 1A-181)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
(Page 1A-180)

Is check result OK?

3 Fuel filter water detection sensor power supply circuit Go to Step 5. Go to Step 4.
and ground circuit check
1) When ignition is “OFF”, disconnect water detection
sensor with fuel temperature sensor connector.
2) Check for proper terminal connection to water detection
sensor with fuel temperature sensor connector.
3) If connections are OK, set ignition “ON”.
4) Check voltage between “A1” and “A3” circuit is battery
voltage.

Is check result OK?

1A-289 Engine General Information and Diagnosis: D13A

Step Action Yes No

4 Fuel filter water detection sensor ground circuit check Repair “A3” circuit. Repair “A1” circuit.
1) Check voltage between “A1” circuit and ground is battery
voltage.

Is check result OK?

5 Fuel filter water detection sensor signal circuit check Go to Step 6. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at water detection sensor with fuel
temperature sensor connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

6 Fuel filter water detection sensor check Replace ECM and Replace fuel filter
1) Check fuel filter water detection sensor. (Page 1G-59) recheck DTC. (Page assembly. (Page 1G-
1C-20) 59)
Is check result OK?

DTC P268A
AENJHB0B1124059
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P268A: Fuel Injector Calibration Not Learned / Programmed • NO injector calibration code
Injector calibration code is not registered in ECM. • ECM
(1 D/C detection logic but MIL does not light up)

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Injector calibration code check Go to Step 3. Register correct injector
1) When ignition is “OFF”, connect SUZUKI scan tool to calibration code to
DLC. ECM. (Page 1C-22)
2) Set ignition “ON”.
3) Check registered injector calibration code with that of the
code mentioned on the injector with the help of SDT.
(Page 1C-22)

Is registered injector calibration code correct?

 Engine General Information and Diagnosis: D13A 1A-290

Step Action Yes No

3 DTC recheck Replace ECM and End.
1) Clear DTC. (Page 1A-181) recheck DTC. (Page
1C-20)
2) Set ignition “ON”.
3) Perform DTC confirmation procedure to check for DTC.
(Page 1A-180)

Is DTC P268A still detected?

DTC U0073 DTC U0141

AENJHB0B1124060 AENJHB0B1124064
Refer to “Troubleshooting for Communication Bus Off”: Refer to “Troubleshooting for Lost Communication”:
D13A Model in Section 10H (Page 10H-38). D13A Model in Section 10H (Page 10H-32).

DTC U0121 DTC U2006

AENJHB0B1124061 AENJHB0B1124065
Refer to “Troubleshooting for Lost Communication”: Refer to “Troubleshooting for Lost Communication”:
D13A Model in Section 10H (Page 10H-32). D13A Model in Section 10H (Page 10H-32).

DTC U0131 DTC U2007

AENJHB0B1124062 AENJHB0B1124066
Refer to “Troubleshooting for Lost Communication”: Refer to “Troubleshooting for Lost Communication”:
D13A Model in Section 10H (Page 10H-32). D13A Model in Section 10H (Page 10H-32).

DTC U0140 DTC U2023

AENJHB0B1124063 AENJHB0B1124067
Refer to “Troubleshooting for Lost Communication”: Refer to “Troubleshooting for Lost Communication”:
D13A Model in Section 10H (Page 10H-32). D13A Model in Section 10H (Page 10H-32).

DTC U2024
AENJHB0B1124068
Refer to “Troubleshooting for Lost Communication”:
D13A Model in Section 10H (Page 10H-32).

DTC U2101
AENJHB0B1124069
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
U2101: CAN Vehicle Configuration List not Programmed • No Vehicle variant data
CAN vehicle configuration data is not registered in ECM. • ECM
(1 D/C detection logic but MIL does not light up)

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-177).
2 Registration data check Go to Step 3. Register correct CAN
1) When ignition is “OFF”, connect SUZUKI scan tool to vehicle configuration
DLC. data to ECM, referring
to “Vehicle Variant Data
2) Set ignition “ON”.
(Including CAN Vehicle
3) Check Vehicle variant data. (Page 1C-22) Configuration Data)
Registration”: D13A in
Is registered Vehicle variant data correct?
Section 1C (Page 1C-
22).
1A-291 Engine General Information and Diagnosis: D13A

Step Action Yes No

3 DTC recheck Replace ECM and End.
1) Clear DTC. (Page 1A-181) recheck DTC. (Page
1C-20)
2) Set ignition “ON”.
3) Perform DTC confirmation procedure, and check for
DTCs. (Page 1A-180)

Is DTC U2101 still detected?

Table A-1: Fuel Pump Relay Operation Check

AENJHB0B1124070
Circuit Diagram

+B 1

A1 2 A3

BLU RED E01-74

WHT PNK B1
4 B2
3
A2 BLK

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113017-01

[A]: ECM connector (View: [a]) B1: Fuel pump power supply circuit 3. Fuel pump
A1: Fuel pump relay power supply circuit (coil side) B2: Fuel pump ground circuit 4. “F/P” fuse
A2: Fuel pump relay power supply circuit (switch side) 1. ECM
A3: Fuel pump relay drive circuit 2. Fuel pump relay

Troubleshooting
Step Action Yes No
1 Fuel pump operation check End. Go to Step 2.
1) Check fuel pump operation. (Page 1G-56)

Is check result OK?

2 Fuel pump relay power supply circuit check Go to Step 3. Repair “A1” and/or “A2”
1) When ignition is “OFF”, remove fuel pump relay. (Page circuit.
10B-14)
2) Check for proper terminal connection to fuel pump relay.
3) If connections are OK, check that voltage between each
of “A1” and “A2” circuits and ground is battery voltage.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-292

Step Action Yes No

3 Fuel pump relay drive circuit check Go to Step 4. Repair “A3” circuit.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A3” circuit: less than 1 Ω
• Resistance between “A3” circuit and ground: infinity
• Resistance between “A3” circuit terminal and each
terminal at fuel pump relay connector: infinity
• Voltage of “A3” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

4 Fuel pump relay check Go to Step 5. Replace fuel pump
1) Check fuel pump relay. (Page 1C-30) relay. (Page 10B-14)

Is check result OK?

5 Fuel pump relay drive signal check Go to Step 6. Replace ECM and
1) When ignition is “OFF”, connect “E01” connector to recheck fuel pump
ECM. operation. (Page 1C-
20)
2) Check that voltage between “A3” circuit and ground is
approx. 0 V for about 20 sec. after setting ignition “ON”.

Is check result OK?

6 Fuel pump power supply circuit and ground circuit Replace fuel pump. Go to Step 7.
check (Page 1G-56)
1) When ignition is “OFF”, install fuel pump relay.
2) Disconnect connector from fuel pump.
3) Check for proper connection to fuel pump.
4) If connections are OK, check that voltage between “B1”
and “B2” circuits is battery voltage for about 20 sec. after
setting ignition “ON”.

Is check result OK?

7 Fuel pump ground circuit check Repair “B2” circuit. Repair “B1” circuit.
1) Check that voltage between “B1” circuit and ground is
battery voltage for about 20 sec. after setting ignition
“ON”.

Is check result OK?

1A-293 Engine General Information and Diagnosis: D13A

Table A-2: Fuel Injector Circuit Check

AENJHB0B1124071
NOTE
• This procedure is to troubleshoot only open, short to ground circuit and short to power supply
circuit of fuel injector circuit. If it is necessary to troubleshoot for injector operation, perform “High-
Pressure Fuel Supply Circuit Check”: D13A in Section 1G (Page 1G-36).
• For identification of each cylinder, refer to “Electronic Control System Component Location”: D13A
(Page 1A-175).

Circuit Diagram

A1
WHT D01-56
2 A2
GRY/WHT D01-16

B1
YEL D01-58
3 B2
YEL/BLK D01-17

C1
GRN D01-57
4 C2
WHT/GRN D01-31

D1
BLU D01-55
5 D2
WHT/BLU D01-1

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113015-01

[A]: ECM connector (View: [a]) C1: Fuel injector No.3 drive circuit (high side) 2. Fuel injector No.1
A1: Fuel injector No.1 drive circuit (high side) C2: Fuel injector No.3 drive circuit (low side) 3. Fuel injector No.2
A2: Fuel injector No.1 drive circuit (low side) D1: Fuel injector No.4 drive circuit (high side) 4. Fuel injector No.3
B1: Fuel injector No.2 drive circuit (high side) D2: Fuel injector No.4 drive circuit (low side) 5. Fuel injector No.4
B2: Fuel injector No.2 drive circuit (low side) 1. ECM
 Engine General Information and Diagnosis: D13A 1A-294

Troubleshooting
Step Action Yes No
1 Fuel injector drive circuit (high side) and (low side) Go to Step 2. Repair defective circuit.
check
1) When ignition is “OFF”, disconnect “D01” connector from
ECM and all fuel injector connectors.
2) Check for proper terminal connection to “D01” connector
and all fuel injector connectors.
3) If connections are OK, check the following points.
• Resistance of “A1”, “A2”, “B1”, “B2”, “C1”, “C2”, “D1”
and “D2” circuits: less than 1 Ω
• Resistance between each of “A1”, “A2”, “B1”, “B2”,
“C1”, “C2”, “D1” and “D2” circuits and ground: infinity
• Resistance between “A1” circuit terminal and each
terminal at fuel injector connector: infinity
• Resistance between “B1” circuit terminal and each
terminal at fuel injector connector: infinity
• Resistance between “C1” circuit terminal and each
terminal at fuel injector connector: infinity
• Resistance between “D1” circuit terminal and each
terminal at fuel injector connector: infinity
• Voltage of “A1”, “A2”, “B1”, “B2”, “C1”, “C2”, “D1” and
“D2” circuits: approx. 0 V (when ignition is “ON”.)

Is check result OK?

2 Fuel injector check End. Replace fuel injector.
1) Check fuel injector. (Page 1G-46) (Page 1G-47)

Is check result OK?

Table A-3: Fuel Temperature Sensor Check

AENJHB0B1124072
Circuit Diagram

IG1 1
2
A1
A2
WHT
3 RED E01-89
BLK
A3 B1
4
BEG E01-59
B2
GRN E01-7

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113014-01

[A]: ECM connector (View: [a]) B1: Fuel temperature sensor signal circuit 3. Fuel filter water detection sensor
A1: Fuel filter water detection sensor power supply circuit B2: Fuel temperature sensor ground circuit 4. Fuel temperature sensor
A2: Fuel filter water detection sensor signal circuit 1. ECM
A3: Fuel filter water detection sensor ground circuit 2. Water detection sensor with fuel temperature sensor
1A-295 Engine General Information and Diagnosis: D13A

Troubleshooting
Step Action Yes No
1 Parameter check End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Start engine and warm it up to normal operating
temperature, then check that “Fuel Temperature”
displayed on SUZUKI scan tool is within environmental
temp. to 95 °C (203 °F).

Is check result OK?

2 Fuel temperature sensor signal circuit and ground Go to Step 3. Repair defective wire
circuit check harness.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM and water detection sensor with fuel temperature
sensor connector.
2) Check for proper terminal connection to “E01” connector
and water detection sensor with fuel temperature sensor
connector.
3) If connections are OK, check the following points.
• Resistance of “B1” and “B2” circuits: less than 1 Ω
• Resistance between each of “B1” and “B2” circuit and
ground: infinity
• Resistance between “B1” circuit terminal and each
terminal at water detection sensor with fuel
temperature sensor connector: infinity
• Resistance between “B2” circuit terminal and each
terminal at water detection sensor with fuel
temperature sensor connector: infinity
• Voltage of “B1” and “B2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 Fuel temperature sensor check Replace ECM and Replace fuel filter
1) Check fuel temperature sensor. (Page 1G-59) recheck parameter. assembly. (Page 1G-
(Page 1C-20) 59)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-296

Table A-4: Fuel Pressure Sensor Circuit Check

AENJHB0B1124073
Circuit Diagram

A1
GRN/YEL D01-9
A2
2 YEL/BLK D01-38
A3
YEL/RED D01-7

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113009-01

[A]: ECM connector (View: [a]) A2: Fuel pressure sensor signal circuit 1. ECM
A1: Fuel pressure sensor power supply circuit A3: Fuel pressure sensor ground circuit 2. Fuel pressure sensor

Troubleshooting
Step Action Yes No
1 Parameter check End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Start engine and warm it up to normal operating
temperature.
3) With engine running at specified idle speed and
accelerator pedal not depressed, check that “Fuel Rail
Pressure” displayed on SUZUKI scan tool is 20 to 40
MPa.

Is check result OK?

2 Parameter check End. Go to Step 3.
1) With accelerator pedal depressed and engine speed at
3,500 rpm, check that “Fuel Rail Pressure” displayed on
SUZUKI scan tool is more than 60 MPa.

Is check result OK?

3 Fuel pressure sensor power supply circuit and ground Go to Step 6. Go to Step 4.
circuit check
1) When ignition is “OFF”, disconnect fuel presser sensor
connector.
2) Check for proper terminal connection to fuel presser
sensor connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” circuits is
approx. 5 V.

Is check result OK?

1A-297 Engine General Information and Diagnosis: D13A

Step Action Yes No

4 Fuel pressure sensor ground circuit check Repair “A3” circuit. Go to Step 5.
1) Check that voltage between “A1” circuit and ground is
approx. 5 V.

Is check result OK?

5 Fuel pressure sensor power supply circuit check Replace ECM and Repair “A1” circuit.
1) When ignition is “OFF”, disconnect “D01” connector from recheck parameter.
ECM. (Page 1C-20)
2) Check for proper terminal connection to “D01”
connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at fuel pressure sensor connector: infinity
• Voltage of “A1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

6 Fuel pressure sensor signal circuit check Replace fuel pressure Repair “A2” circuit.
1) When ignition is “OFF”, disconnect “D01” connector from sensor and recheck
ECM. parameter. (Page 1G-
50)
2) Check for proper terminal connection to “D01”
connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at fuel pressure sensor connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-298

Table A-5: Fuel Flow Actuator Operation Check

AENJHB0B1124074
Circuit Diagram

A1
YEL/BLK D01-4
2 A2
YEL D01-20

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113007-01

[A]: ECM connector (View: [a]) A2: Fuel flow actuator drive circuit 2. Fuel flow actuator
A1: Fuel flow actuator power supply circuit 1. ECM

Troubleshooting
Step Action Yes No
1 Fuel flow actuator power supply circuit and drive circuit Go to Step 2. Repair defective wire
check harness.
1) When ignition is “OFF”, disconnect “D01” connector from
ECM and fuel flow actuator connector.
2) Check for proper terminal connection to “D01” connector
and fuel flow actuator connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A1” circuit terminal and each
terminal at fuel flow actuator connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (when
ignition is “ON”.)

Is check result OK?

2 Fuel flow actuator check Replace ECM and Replace fuel flow
1) Check fuel flow actuator. (Page 1G-50) recheck parameter. actuator. (Page 1G-
(Page 1C-20) 49)
Is check result OK?
1A-299 Engine General Information and Diagnosis: D13A

Table B-1: Air Intake / Turbocharger Circuit Check

AENJHB0B1124075
Troubleshooting
Step Action Yes No
1 Preliminary check Go to Step 2. Repair replace defective
1) Check the following points. part(s).
• Check seal of turbocharger system hoses.
• Check intercooler for leakage.
• Check that hose clamps in air intake system are
correctly fitted and tightened.
• Check air intake hoses and pipes for obstructions,
damage, etc.
• Check that MAF sensor with IAT sensor-1 is not
contaminated.
• Visually check turbocharger for oil leakage and
damage.

Is check result OK?

2 Air cleaner filter condition check Go to Step 3. Replace air cleaner
1) Check that air cleaner filter is not contaminated. filter. (Page 1D-82)

Is check result OK?

3 Air cleaner filter condition check Go to Step 4. Refit air cleaner filter
1) Check that air cleaner filter is correctly fitted. correctly.

Is check result OK?

4 Turbocharger check Go to Step 5. Repair or replace
1) Check turbocharger. (Page 1D-91) defective part(s).

Is check result OK?

5 MAF sensor operation check End. Repair or replace
1) Check that MAF sensor is working properly. (Page 1A- defective part(s).
300)

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-300

Table B-2: MAF Sensor Check

AENJHB0B1124076
Circuit Diagram

IG1 1

A1
WHT
A2
2 RED E01-54
A3
YEL E01-29

3 B1
BLU E01-60

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113010-01

[A]: ECM connector (View: [a]) A3: MAF sensor ground circuit 2. MAF sensor
A1: MAF sensor power supply circuit B1: IAT-1 sensor signal circuit 3. IAT-1 sensor
A2: MAF sensor signal circuit 1. ECM

Troubleshooting
Step Action Yes No
1 Parameter check Go to Step 2. Go to Step 5.
1) When ignition “OFF”, connect SUZUKI scan tool to DLC.
2) Set ignition “ON”.
3) Check that engine stops and all electrical loads are
turned off.
4) Check that “MAF” parameter displayed on SUZUKI scan
tool is 0.0 g/sec. (0.0 Lb/min).

Is check result OK?

2 Parameter check Go to Step 3. Go to Step 5.
1) Start engine and warm it up to normal operating
temperature.
2) Check that “MAF” parameter displayed on SUZUKI scan
tool is 3 to 9.5 g/sec. (0.40 to 1.19 Lb/min).

Is check result OK?

3 Parameter check Go to Step 4. Go to Step 5.
1) With all electrical loads turned off, depress accelerator
pedal several times and check that “MAF” parameter
displayed on SUZUKI scan tool is changed in a short
time.

Is check result OK?

4 Parameter check End. Go to Step 5.
1) Check that “MAF” parameter displayed on SUZUKI scan
tool is 40.0 g/sec. (5.29 Lb/min) or more with engine
speed at 3,500 rpm.

Is check result OK?

1A-301 Engine General Information and Diagnosis: D13A

Step Action Yes No

5 MAF sensor power supply circuit and ground circuit Go to Step 8. Go to Step 6.
check
1) When ignition is “OFF”, disconnect MAF sensor with IAT
sensor-1 connector.
2) Check for proper terminal connection to MAF sensor
with IAT sensor-1 connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” circuits is
battery voltage.

Is check result OK?

6 MAF sensor power supply circuit check Go to Step 7. Repair “A1” circuit.
1) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

7 MAF sensor ground circuit check Replace ECM and Repair “A3” circuit.
1) When ignition is “OFF”, disconnect “E01” connector from recheck parameter.
ECM. (Page 1C-20)
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A3” circuit: less than 1 Ω
• Resistance between “A3” circuit and ground: infinity
• Resistance between “A3” circuit terminal and other
terminal at MAF with IAT sensor-1 connector: infinity
• Voltage of “A3” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

8 MAF sensor signal circuit check Go to Step 9. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at MAF sensor with IAT sensor-1 connector:
infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

9 MAF sensor check Replace ECM and Replace MAF sensor
1) Check MAF sensor. (Page 1C-23) recheck parameter. with IAT sensor-1.
(Page 1C-20) (Page 1C-23)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-302

Table B-3: Boost Pressure Sensor Check

AENJHB0B1124077
Circuit Diagram

A1
RED/BLK D01-23
A2
2 YEL D01-41
A3
BLK D01-24

3 B1
WHT D01-37

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113008-01

[A]: ECM connector (View: [a]) A3: Boost pressure sensor ground circuit 2. Boost pressure sensor
A1: Boost pressure sensor power supply circuit B1: IAT-2 sensor signal circuit 3. IAT-2 sensor
A2: Boost pressure sensor signal circuit 1. ECM

Troubleshooting
Step Action Yes No
1 Air intake system check Go to Step 2. Repair or replace
1) Check that air intake system is working properly. defective part(s).
(Page 1A-299)

Is check result OK?

2 Parameter check Go to Step 3. Go to Step 5.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Set ignition “ON”.
3) Check that engine stops and all electrical loads are
turned off.
4) Check that “MAP” displayed on SUZUKI scan tool is
approximately equal to “Barometric Pressure”.

Is check result OK?

3 Parameter check Go to Step 4. Go to Step 5.
1) With engine running at specified idle speed and
accelerator pedal not depressed, check that “MAP” is 75
to 105 kPa (0.8 to 1.1 kgf/cm2, 10.8 to 15.2 psi).

Is check result OK?

4 Parameter check End. Go to Step 5.
1) With accelerator pedal depressed and engine speed at
3,500 rpm, check that “MAP” is 123 kPa (1.25 kgf/cm2,
17.8 psi) or more.

Is check result OK?

1A-303 Engine General Information and Diagnosis: D13A

Step Action Yes No

5 Boost pressure sensor power supply circuit and ground Go to Step 9. Go to Step 6.
circuit check
1) When ignition is “OFF”, disconnect connector of boost
pressure sensor with IAT sensor-2.
2) Check for proper terminal connection to connector of
boost pressure sensor with IAT sensor-2.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” circuits is
approx. 5 V.

Is check result OK?

6 Boost pressure sensor ground circuit check 1 Go to Step 8. Go to Step 7.
1) Check that voltage between “A1” circuit and ground is
approx. 5 V.

Is check result OK?

7 Boost pressure sensor power supply circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “D01” connector from recheck parameter. defective wire harness.
ECM. (Page 1C-20)
2) Check for proper terminal connection to “D01”
connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at boost pressure sensor with IAT sensor-2
connector: infinity
• Voltage of “A1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

8 Boost pressure sensor ground circuit check 2 Replace ECM and Replace “A3” circuit.
1) When ignition is “OFF”, disconnect “D01” connector from recheck parameter.
ECM. (Page 1C-20)
2) Check for proper terminal connection to “D01”
connector.
3) If connections are OK, check the following points.
• Resistance of “A3” circuit: less than 1 Ω
• Resistance between “A3” circuit and ground: infinity
• Resistance between “A3” circuit terminal and other
terminal at boost pressure with IAT sensor-2
connector: infinity
• Voltage of “A3” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-304

Step Action Yes No

9 Boost pressure sensor signal circuit check Go to Step 10. Repair or replace
1) When ignition is “OFF”, disconnect “D01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “D01”
connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at boost pressure sensor with IAT sensor-2
connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

10 Boost pressure sensor check Replace ECM and Replace boost pressure
1) Check boost pressure sensor. (Page 1C-29) recheck parameter. sensor with IAT sensor-
(Page 1C-20) 2. (Page 1C-28)
Is check result OK?

Table B-4: Barometric Pressure Check

AENJHB0B1124078
Troubleshooting
Step Action Yes No
1 Parameter check End. Replace ECM and
1) When ignition is “OFF”, connect SUZUKI scan tool to recheck parameter.
DLC. (Page 1C-20)
2) Set ignition “ON”.
3) Check that engine stops and all electrical loads are
turned off.
4) Check that “Barometric Pressure” displayed on SUZUKI
scan tool is approximately equal to barometric pressure.

Is check result OK?

1A-305 Engine General Information and Diagnosis: D13A

Table B-5: EGR Valve Operation Check

AENJHB0B1124079
Circuit Diagram

BLU/RED D01-5

A1 A2
2 GRY/RED D01-6

B1 B2
BLU 3 YEL YEL/GRN D01-30

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113018-01

[A]: ECM connector (View: [a]) B1: Boost pressure control solenoid valve power supply circuit 2. EGR valve
A1: EGR valve power supply circuit B2: Boost pressure control solenoid valve drive circuit 3. Boost pressure control solenoid valve
A2: EGR valve drive circuit 1. ECM

Troubleshooting
Step Action Yes No
1 Active test End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Set ignition “ON”.
3) Select “EGR Valve” function in “Active Test” mode on
SUZUKI scan tool.
4) Check EGR valve operation sound.

Is check result OK?

2 EGR valve power supply circuit check 1 Go to Step 4. Go to Step 3.
1) When ignition is “OFF”, disconnect EGR valve
connector.
2) Check for proper terminal connection to EGR valve
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-306

Step Action Yes No

3 EGR valve power supply circuit check 2 Replace ECM and Replace “A1” circuit.
1) When ignition is “OFF”, disconnect “D01” connector from recheck EGR valve
ECM. operation. (Page 1C-
20)
2) Check for proper terminal connection to “D01”
connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and each
terminal at EGR valve connector: infinity
• Voltage of “A1” circuit: approx. 0 V (when ignition is
“ON”.)

Is check result OK?

4 EGR valve drive circuit check Go to Step 5. Repair or replace
1) When ignition is “OFF”, disconnect “D01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “D01”
connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and each
terminal at EGR valve connector: infinity
• Voltage of “A2” circuit: approx. 0 V (when ignition is
“ON”.)

Is check result OK?

5 EGR valve check Replace ECM and Replace EGR valve.
1) Check EGR valve. (Page 1B-12) recheck EGR valve (Page 1B-10)
operation. (Page 1C-
Is check result OK? 20)
1A-307 Engine General Information and Diagnosis: D13A

Table B-6: A/F Sensor Check

AENJHB0B1124080
Circuit Diagram

2 1
A1
BLK E01-42
A2
LT GRN E01-39
A3
GRY E01-41
A4
+B
WHT E01-40
B1 B2
PINK E01-6
BLU

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113013-01

[A]: ECM connector (View: [a]) A3: A/F sensor signal circuit (VSIP) B2: A/F sensor heater drive circuit
A1: A/F sensor signal circuit (RC) A4: A/F sensor signal circuit (IP) 1. ECM
A2: A/F sensor signal circuit (VS) B1: A/F sensor heater power supply circuit 2. A/F sensor

Troubleshooting
Step Action Yes No
1 Parameter check Go to Step 2. Go to Step 3.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Start engine and warm it up normal operating
temperature.
3) With engine running at specified idle speed, check that
“A/F Sensor Heater Duty” displayed on SUZUKI scan
tool is 40 to 70%.

Is check result OK?

2 A/F sensor signal voltage check End. Go to Step 6.
1) With engine running at specified idle speed, check that
voltage between each of “A1”, “A2”, “A3” and “A4”
circuits and ground is 2 to 6 V. (Page 1A-329)

Is check result OK?

3 A/F sensor heater power supply circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect A/F sensor defective wire harness.
connector.
2) Check for proper terminal connection to A/F sensor
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1” circuit and ground is
battery voltage.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-308

Step Action Yes No

4 A/F sensor heater drive circuit check Go to Step 5. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and each
terminal at A/F sensor connector: infinity
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 A/F sensor heater check Replace ECM and Replace A/F sensor.
1) Check A/F sensor heater for resistance. (Page 1B-14) recheck parameter. (Page 1B-14)
(Page 1C-20)
Is check result OK?
6 A/F sensor signal circuit check Go to Step 7. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM and A/F sensor connector.
2) Check for proper terminal connection to “E01” connector
and A/F sensor connector.
3) If connections are OK, check the following points.
• Resistance of “A1, “A2”, “A3” and “A4” circuits: less
than 1 Ω
• Resistance between each of “A1, “A2”, “A3” and “A4”
circuits and ground: infinity
• Resistance between “A1” circuit terminal and each
terminal at A/F sensor connector: infinity
• Resistance between “A2” circuit terminal and each
terminal at A/F sensor connector: infinity
• Resistance between “A3” circuit terminal and each
terminal at A/F sensor connector: infinity
• Resistance between “A4” circuit terminal and each
terminal at A/F sensor connector: infinity
• Voltage of “A1, “A2”, “A3” and “A4” circuits: approx. 0
V (When ignition is “ON”)

Is check result OK?

7 A/F sensor replacement End. Replace ECM. (Page
1) Replace A/F sensor. (Page 1B-14) 1C-20)
2) With engine running at specified idle speed, check that
voltage between each of “A1”, “A2”, “A3” and “A4”
circuits and ground is 2 to 6 V.

Is check result OK?

1A-309 Engine General Information and Diagnosis: D13A

Table B-7: Boost Pressure Control Solenoid Valve Operation Check

AENJHB0B1124081
Circuit Diagram

BLU/RED D01-5

A1 A2
2 GRY/RED D01-6

B1 B2
BLU 3 YEL YEL/GRN D01-30

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113018-01

[A]: ECM connector (View: [a]) B1: Boost pressure control solenoid valve power 2. EGR valve
supply circuit
A1: EGR valve power supply circuit B2: Boost pressure control solenoid valve drive circuit 3. Boost pressure control solenoid valve
A2: EGR valve drive circuit 1. ECM

Troubleshooting
Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following parts. defective part(s).
• Check vacuum tank, hoses and pipes.
• Check vacuum pump. (Page 1D-86)

Is check result OK?

2 Active check End. Go to Step 3.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Set ignition “ON”.
3) Select “Boost Pressure Control Solenoid Valve” function
in “Active Test” mode on SUZUKI scan tool.
4) Check boost pressure control solenoid valve for
operation sound.

Is check result OK?

3 Boost pressure control solenoid valve power supply Go to Step 5. Go to Step 4.
circuit check 1
1) When ignition is “OFF”, disconnect boost pressure
control solenoid valve connector.
2) Check for proper terminal connection to boost pressure
control solenoid valve connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1” circuit and ground is
battery voltage.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-310

Step Action Yes No

4 Boost pressure control solenoid valve power supply Replace ECM and Replace “B1” circuit.
circuit check 2 recheck boost pressure
1) When ignition is “OFF”, disconnect “D01” connector from control solenoid valve
ECM. operation. (Page 1C-
20)
2) Check for proper terminal connection to “D01”
connector.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and each
terminal at boost pressure control solenoid valve
connector: infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 Boost pressure control solenoid valve drive circuit Go to Step 6. Repair or replace
check defective wire harness.
1) When ignition is “OFF”, disconnect “D01” connector from
ECM.
2) Check for proper terminal connection to “D01”
connector.
3) If connections are OK, check the following points.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and each
terminal at boost pressure control solenoid valve
connector: infinity
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

6 Boost pressure control solenoid valve check Replace ECM and Replace boost pressure
1) Check boost pressure control solenoid valve. (Page recheck boost pressure control solenoid valve.
1C-31) control solenoid valve (Page 1C-31)
operation. (Page 1C-
Is check result OK? 20)
1A-311 Engine General Information and Diagnosis: D13A

Table C-1: Main Relay Operation Check

AENJHB0B1124082
Circuit Diagram

1
D1
YEL E01-45

A1 2 A3
YEL PNK E01-79
RED BLU B1
A2 GRN E01-48
B2
GRN E01-71
B3
GRN E01-72
C1
BRN E01-23
C2
BRN E01-24
C3
BRN E01-47

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113024-01

[A]: ECM connector (View: [a]) B2: ECM power supply circuit D1: ECM backup power supply circuit
A1: Main relay power supply circuit (coil side) B3: ECM power supply circuit 1. ECM
A2: Main relay power supply circuit (switch side) C1: ECM ground circuit 2. Main relay
A3: Main relay drive circuit C2: ECM ground circuit
B1: ECM power supply circuit C3: ECM ground circuit

Troubleshooting
Step Action Yes No
1 Main relay power supply circuit check Go to Step 2. Repair or replace
1) When ignition is “OFF”, remove main relay. defective wire harness.
2) Check for proper terminal connection to main relay
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A1” and “A2”
circuits and ground is battery voltage.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-312

Step Action Yes No

2 Main relay drive circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A3” circuit: less than 1 Ω
• Resistance between “A3” circuit and ground: infinity
• Resistance between “A3” circuit terminal and each
terminal at main relay connector: infinity
• Voltage of “A3” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

3 ECM power supply circuit Go to Step 4. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “B1”, “B2” and “B3” circuits: less than 1
Ω
• Resistance between each of “B1”, “B2” and “B3”
circuits and ground: infinity
• Resistance between “B1” circuit terminal and each
terminal at “E01” connector: infinity
• Resistance between “B2” circuit terminal and each
terminal at “E01” connector: infinity
• Resistance between “B3” circuit terminal and each
terminal at “E01” connector: infinity
• Voltage of “B1”, “B2” and “B3” circuits: approx. 0 V
(When ignition is “ON”)

Is check result OK?

4 ECM ground circuit check Go to Step 5. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “C1”, “C2” and “C3” circuits: less than 1
Ω
• Resistance between “C1” circuit terminal and each
terminal at “E01” connector: infinity
• Resistance between “C2” circuit terminal and each
terminal at “E01” connector: infinity
• Resistance between “C3” circuit terminal and each
terminal at “E01” connector: infinity
• Voltage of “C1”, “C2” and “C3” circuits: approx. 0 V
(When ignition is “ON”)

Is check result OK?

5 Main relay check End. Replace main relay.
1) Check main relay. (Page 1C-30) (Page 10B-14)

Is check result OK?

1A-313 Engine General Information and Diagnosis: D13A

Table C-2: Engine Speed Check

AENJHB0B1124083
Circuit Diagram

3 1
A1
GRY/BLK D01-43
2 A2
YEL/RED D01-54

B1
5 PNK D01-25
B2
4 PNK/BLK D01-51
B3
PPL D01-21

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113016-01

[A]: ECM connector (View: [a]) B2: CMP sensor signal circuit 3. CKP sensor teeth
A1: CKP sensor signal circuit (+) B3: CMP sensor ground circuit 4. CMP sensor
A2: CKP sensor signal circuit (–) 1. ECM 5. CMP sensor teeth
B1: CMP sensor power supply circuit 2. CKP sensor

Troubleshooting
Step Action Yes No
1 Parameter check Go to Step 2. Go to Step 3.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Set ignition “ON”.
3) Check that “Engine Speed” is approx. 0 rpm with engine
stopped.

Is check result OK?

2 Idle speed check End. Go to Step 3.
1) Start engine and warm it up to normal operating
temperature.
2) With engine running at specified idle speed, all electrical
loads turned off and accelerator pedal released, check
that “Engine Speed” is approx. 800 rpm.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-314

Step Action Yes No

3 CKP sensor signal circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect “D01” connector from defective wire harness.
ECM and CKP sensor connector.
2) Check for proper terminal connection to “D01” connector
and CKP sensor connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and each
terminal at CKP sensor connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

4 CKP sensor check Go to Step 5. Replace CKP sensor.
1) Check CKP sensor. (Page 1C-28) (Page 1C-27)

Is check result OK?

5 CKP sensor teeth check Replace ECM and Replace flywheel.
1) Check CKP sensor teeth. (Page 1D-112) recheck parameter. (Page 1D-112)
(Page 1C-20)
Is check result OK?

Table C-3: ECT Sensor Check

AENJHB0B1124084
Circuit Diagram

1
A1
2
PPL/WHT D01-49
A2
GRN D01-29

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113011-01

[A]: ECM connector (View: [a]) A2: ECT sensor ground circuit 2. ECT sensor
A1: ECT sensor signal circuit 1. ECM
1A-315 Engine General Information and Diagnosis: D13A

Troubleshooting
Step Action Yes No
1 Parameter check End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Start engine and warm it up normal operating
temperature.
3) Turn off all electrical loads.
4) Check that “ECT” displayed on SUZUKI scan tool is 80
to 110 °C (176 to 230 °F).

Is check result OK?

2 ECT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect “D01” connector from defective wire harness.
ECM and ECT sensor connector.
2) Check for proper terminal connection to “D01” connector
and ECT sensor connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and each
terminal at ECT sensor connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 ECT sensor check Replace ECM and Replace ECT sensor.
1) Check ECT sensor. (Page 1C-26) recheck parameter. (Page 1C-25)
(Page 1C-20)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-316

Table C-4: IAT-1 Sensor Check

AENJHB0B1124085
Circuit Diagram

IG1 1

A1
WHT
A2
2 RED E01-54
A3
YEL E01-29

3 B1
BLU E01-60

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113010-01

[A]: ECM connector (View: [a]) A3: MAF sensor ground circuit 2. MAF sensor
A1: MAF sensor power supply circuit B1: IAT-1 sensor signal circuit 3. IAT-1 sensor
A2: MAF sensor signal circuit 1. ECM

Troubleshooting
Step Action Yes No
1 Parameter check End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Start engine and warm it up to normal operating
temperature.
3) With engine running at specified idle speed, all electrical
loads turned off and accelerator pedal not depressed,
check that “IAT1” is under –5 °C (–9 °F) + environmental
temp. and over 40 °C (72 °F) + environmental temp.

Is check result OK?

1A-317 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 IAT-1 sensor signal circuit and MAF sensor ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM and MAF sensor with IAT sensor-1 connector.
2) Check for proper terminal connection to “E01” connector
and MAF sensor with IAT sensor-1 connector.
3) If connections are OK, check the following points.
• Resistance of “B1” and “A3” circuits: less than 1 Ω
• Resistance between each of “B1” and “A3” circuits
and ground: infinity
• Resistance between “B1” circuit terminal and each
terminal at MAF sensor with IAT sensor-1 connector:
infinity
• Resistance between “A3” circuit terminal and each
terminal at MAF sensor with IAT sensor-1 connector:
infinity
• Voltage of “B1” and “A3” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 IAT-1 sensor check Replace ECM and Replace MAF sensor
1) Check IAT-1 sensor. (Page 1C-23) recheck parameter. with IAT sensor-1.
(Page 1C-20) (Page 1C-23)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-318

Table C-5: IAT-2 Sensor Check

AENJHB0B1124086
Circuit Diagram

A1
RED/BLK D01-23
A2
2 YEL D01-41
A3
BLK D01-24

3 B1
WHT D01-37

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113008-01

[A]: ECM connector (View: [a]) A3: Boost pressure sensor ground circuit 2. Boost pressure sensor
A1: Boost pressure sensor power supply circuit B1: IAT-2 sensor signal circuit 3. IAT-2 sensor
A2: Boost pressure sensor signal circuit 1. ECM

Troubleshooting
Step Action Yes No
1 Parameter check End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Start engine and warm it up to normal operating
temperature.
3) With engine running at specified idle speed, all electrical
loads turned off and accelerator pedal not depressed,
check that “IAT2” is between environmental temp. and
60 °C (108 °F) + environmental temp.

Is check result OK?

1A-319 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 IAT-2 sensor signal circuit and boost pressure sensor Go to Step 3. Repair or replace
ground circuit check defective wire harness.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM and boost pressure sensor with IAT sensor-2
connector.
2) Check for proper terminal connection to “E01” connector
and boost pressure sensor with IAT sensor-2 connector.
3) If connections are OK, check the following points.
• Resistance of “B1” and “A3” circuits: less than 1 Ω
• Resistance between each of “B1” and “A3” circuits
ground: infinity
• Resistance between “B1” circuit terminal and each
terminal at boost pressure sensor with IAT sensor-2
connector: infinity
• Resistance between “A3” circuit terminal and each
terminal at boost pressure sensor with IAT sensor-2
connector: infinity
• Voltage of “B1” and “A3” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 IAT-2 sensor check Replace ECM and Replace boost pressure
1) Check IAT-2 sensor. (Page 1C-29) recheck parameter. sensor with IAT sensor-
(Page 1C-20) 2. (Page 1C-28)
Is check result OK?

Table C-6: Accelerator Pedal Check

AENJHB0B1124087
Circuit Diagram

1
A1
2 BRN E01-82
A2
BEG E01-63
A3
BLU E01-30
B1
3 BLK E01-9
B2
YEL E01-36
B3
WHT E01-27

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113012-01

[A]: ECM connector (View: [a]) B1: APP sensor (sub) power supply circuit 2. APP sensor (main)
A1: APP sensor (main) power supply circuit B2: APP sensor (sub) signal circuit 3. APP sensor (sub)
A2: APP sensor (main) signal circuit B3: APP sensor (sub) ground circuit
A3: APP sensor (main) ground circuit 1. ECM
 Engine General Information and Diagnosis: D13A 1A-320

Troubleshooting
Step Action Yes No
1 Parameter check Go to Step 2. Go to Step 3.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Set ignition “ON”.
3) With all electrical loads turned off and accelerator pedal
not depressed, check that the following parameters
displayed on SUZUKI scan tool are as specified below.
• “Accel Position”: 0%
• “APP Sensor 1 Volt”: 0.70 to 0.80 V
• “APP Sensor 2 Volt”: 0.325 to 0.425 V

Is check result OK?

2 Parameter check End. Go to Step 3.
1) With accelerator pedal depressed fully, check that the
following parameters displayed on SUZUKI scan tool are
as specified below.
• “Accel Position”: 100%
• “APP sensor 1 volt”: 4.35 to 4.45 V
• “APP sensor 2 volt”: 2.15 to 2.25 V

Is check result OK?

3 APP sensor power supply circuit and ground circuit Go to Step 6. Go to Step 4.
check
1) When ignition is “OFF”, disconnect APP sensor
connector.
2) Check for proper terminal connection to APP sensor
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A1” to “A3” circuits
and “B1” to “B3” circuits is approx. 5 V.

Is check result OK?

4 APP sensor ground circuit check 1 Go to Step 6. Go to Step 5.
1) Check that voltage between each of “A1” and “B1”
circuits and ground is approx. 5 V.

Is check result OK?

5 APP sensor power supply circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from recheck parameter. defective wire harness.
ECM. (Page 1C-20)
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “B1” circuits: less than 1 Ω
• Resistance between each of “A1” and “B1” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at APP sensor connector: infinity
• Resistance between “B1” circuit terminal and other
terminal at APP sensor connector: infinity
• Voltage of “A1” and “B1” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

1A-321 Engine General Information and Diagnosis: D13A

Step Action Yes No

6 APP sensor ground circuit check 2 Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from recheck parameter. defective wire harness.
ECM. (Page 1C-20)
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A3” and “B3” circuits: less than 1 Ω
• Resistance between each of “A3” and “B3” circuits
and ground: infinity
• Resistance between “A3” circuit terminal and other
terminal at APP sensor connector: infinity
• Resistance between “B3” circuit terminal and other
terminal at APP sensor connector: infinity
• Voltage of “A3” and “B3” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

7 APP sensor signal circuit check Go to Step 8. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A2” and “B2” circuits: less than 1 Ω
• Resistance between each of “A2” and “B2” circuits
and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at APP sensor connector: infinity
• Resistance between “B2” circuit terminal and other
terminal at APP sensor connector: infinity
• Voltage of “A2” and “B2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

8 APP sensor check Replace ECM and Replace APP sensor.
1) Check APP sensor. (Page 1C-25) recheck parameter. (Page 1C-25)
(Page 1C-20)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-322

Table C-7: Speed Signal Check

AENJHB0B1124088
Circuit Diagram

3
1

4
7 RED E01-62
WHT E01-35 7
5

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113021-01

[A]: ECM connector (View: [a]) 3. Left-front wheel speed sensor 6. Right-rear wheel speed sensor
1. ECM 4. Right-front wheel speed sensor 7. CAN driver
2. ABS control module 5. Left-rear wheel speed sensor

Troubleshooting
Step Action Yes No
1 Parameter check End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Perform a road test and drive vehicle at constant speed
of 30 km/h (19 mile/h).
3) Check that “Vehicle Speed” displayed on SUZUKI scan
tool is approx. 30 km/h (19 mile/h).

Is check result OK?

2 DTC check Go to troubleshooting Go to Step 3.
1) Check ABS control module for DTC. for applicable DTC.

Is there any DTC related to wheel speed sensor?

3 DTC check Go to troubleshooting Go to Step 4.
1) Check ECM and ABS control module for DTC. for applicable DTC.

Is there any DTC related to CAN?

4 ECM replacement End. Replace ABS control
1) Replace ECM. (Page 1C-20) module. (Page 4E-38)
2) Recheck parameter referring to “Step 1”.

Is check result OK?

1A-323 Engine General Information and Diagnosis: D13A

Table C-8: Glow Plug Operation Check

AENJHB0B1124089
NOTE
For identification of each cylinder, refer to “Electronic Control System Component Location”: D13A
(Page 1A-175).

Circuit Diagram

+BB IG1 1
A2 A1
7 B1
WHT BRN E01-68
B2
RED 2
LT BLU E01-73
A3
BLK
C1 C2 C3 C4
BLU RED YEL GRN
3 4 5 6

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113019-01

[A]: ECM connector (View: [a]) C1: Glow plug No.1 drive circuit 3. Glow plug No.1
A1: Glow plug control module power supply circuit C2: Glow plug No.2 drive circuit 4. Glow plug No.2
A2: Glow plug control module power supply circuit C3: Glow plug No.3 drive circuit 5. Glow plug No.3
A3: Glow plug control module ground circuit C4: Glow plug No.4 drive circuit 6. Glow plug No.4
B1: Glow plug control module drive circuit 1. ECM 7. “IG” fuse
B2: Glow plug control module communication circuit 2. Glow plug control module

Troubleshooting
Step Action Yes No
1 Active test End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Disconnect glow plug connector from glow plugs.
3) Set ignition “ON”.
4) Select “Glow Plug” function in “Active Test” mode on
SUZUKI scan tool.
5) Check that voltage between each of glow plug connector
terminal and vehicle ground is higher than 12 V.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-324

Step Action Yes No

2 Glow plug control module power supply circuit and Go to Step 5. Go to Step 3.
ground circuit check
1) When ignition is “OFF”, disconnect “E07” connector from
glow plug control module.
2) Check for proper terminal connection to “E07” connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A1” and “A2”
circuits and “A3” circuit is battery voltage.

Is check result OK?

3 Glow plug control module ground circuit check Repair “A3” circuit. Go to Step 4.
1) Check that voltage between each of “A1” and “A2”
circuits and ground is battery voltage.

Is check result OK?

4 Glow plug control module power supply circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “D01” connector from recheck glow plug defective wire harness.
ECM. operation. (Page 1C-
20)
2) Check for proper terminal connection to “D01”
connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at glow plug control module connector:
infinity
• Resistance between “A2” circuit terminal and other
terminal at glow plug control module connector:
infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

5 Glow plug control module drive circuit check Go to Step 6. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and each
terminal at glow plug control module connector:
infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

1A-325 Engine General Information and Diagnosis: D13A

Step Action Yes No

6 Glow plug control module communication circuit check Go to Step 7. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and each
terminal at glow plug control module connector:
infinity
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

7 Glow plug drive circuit check Go to Step 8. Repair or replace
1) When ignition is “OFF”, disconnect “D02” connector from defective wire harness.
glow plug control module and all glow plug connectors.
2) Check for proper terminal connection to “D02” connector
and all glow plug connectors.
3) If connections are OK, check that glow plug drive circuit
(“C1”, “C2”, “C3” and “C4”) is as follows.
• Resistance of “C1”, “C2”, “C3” and “C4” circuits: less
than 1 Ω
• Resistance between each of “C1”, “C2”, “C3” and “C4”
circuits and ground: infinity
• Resistance between “C1” circuit terminal and other
terminal at glow plug control module connector:
infinity
• Resistance between “C2” circuit terminal and other
terminal at glow plug control module connector:
infinity
• Resistance between “C3” circuit terminal and other
terminal at glow plug control module connector:
infinity
• Resistance between “C4” circuit terminal and other
terminal at glow plug control module connector:
infinity
• Voltage of “C1”, “C2”, “C3” and “C4” circuits: approx. 0
V (When ignition is “ON”)

Is check result OK?

8 Glow plug check Go to Step 9. Replace glow plugs.
1) Check all glow plugs. (Page 1C-25) (Page 1C-24)

Is check result OK?

9 Glow plug control module replacement End. Replace ECM. (Page
1) Replace glow plug control module. (Page 1C-30) 1C-20)
2) Check glow plug operation

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-326

Table C-9: Radiator Cooling Fan Operation Check

AENJHB0B1124090
! WARNING
The radiator cooling fan can come on whenever the ignition is “ON”. This electric fan starts
automatically anytime the ECT sensor senses a coolant temperature higher than a predetermined level
even when the engine is not running.
When the ignition is “ON”, keep hands, tools, clothing, and other items away from the radiator cooling
fan.

Circuit Diagram

1
+BB +B
A3
A1 3 LT GRN E01-1
D1
BLU
6 B1 4 B3 2
A2

GRY PNK
B2 D3 BLK
C1 5 C3
D2
GRN E01-2
BLK LT GRN
C2 D4
[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113020-01

[A]: ECM connector (View: [a]) D1: Radiator cooling fan power supply circuit (low speed side)
A1: Radiator cooling fan relay No.1 power supply circuit (coil side) D2: Radiator cooling fan ground circuit (low speed side)
A2: Radiator cooling fan relay No.1 power supply circuit (switch side) D1: Radiator cooling fan power supply circuit (high speed side)
A3: Radiator cooling fan relay No.1 drive circuit D2: Radiator cooling fan ground circuit (high speed side)
B1: Radiator cooling fan relay No.2 power supply circuit (coil side) 1. ECM
B2: Radiator cooling fan relay No.2 power supply circuit (switch side) 2. Radiator cooling fan
B3: Radiator cooling fan relay No.2 drive circuit 3. Radiator cooling fan relay No.1
C1: Radiator cooling fan relay No.3 power supply circuit (coil side) 4. Radiator cooling fan relay No.2
C2: Radiator cooling fan relay No.3 ground circuit 5. Radiator cooling fan relay No.3
C3: Radiator cooling fan relay No.3 drive circuit 6. “RDTR” fuse

Troubleshooting
Step Action Yes No
1 Active test Go to Step 2. Go to Step 3.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Set ignition “ON”.
3) Select “Radiator Fan” function in “Active Test” mode on
SUZUKI scan tool.
4) Check that radiator cooling fan operates at low mode.

Is check result OK?

2 Active test End. Go to Step 8.
1) Check that radiator cooling fan operates at high mode.

Is check result OK?

1A-327 Engine General Information and Diagnosis: D13A

Step Action Yes No

3 Radiator cooling fan relay No.1 power supply circuit Go to Step 4. Repair or replace
check defective wire harness.
1) When ignition is “OFF”, remove radiator cooling fan relay
No.1. (Page 10B-14)
2) Check for proper terminal connection to radiator cooling
fan relay No.1 connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A1” and “A2”
circuits and ground is battery voltage.

Is check result OK?

4 Radiator cooling fan relay No.1 drive circuit check Go to Step 5. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A3” circuit: less than 1 Ω
• Resistance between “A3” circuit and ground: infinity
• Resistance between “A3” circuit terminal and each
terminal at radiator cooling fan relay No.1 connector:
infinity
• Voltage of “A3” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 Radiator cooling fan relay No.1 check Go to Step 6. Replace radiator cooling
1) Check radiator cooling fan relay No.1. (Page 1F-28) fan relay No.1. (Page
10B-14)
Is check result OK?
6 Radiator cooling fan power supply circuit (low speed Go to Step 7. Repair or replace
side) defective wire harness.
1) When ignition is “OFF”, disconnect radiator cooling fan
connector.
2) Check for proper terminal connection to radiator cooling
fan connector.
3) If connections are OK, check the following points.
• Resistance of “D1” circuit: less than 1 Ω
• Resistance between “D1” circuit and ground: infinity
• Resistance between “D1” circuit terminal and each
terminal at radiator cooling fan connector: infinity
• Voltage of “D1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

7 Radiator cooling fan ground circuit (low speed side) Go to Step 14. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “D2” circuit: less than 1 Ω
• Resistance between “D2” circuit terminal and each
terminal at radiator cooling fan connector: infinity
• Voltage of “D2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-328

Step Action Yes No

8 Radiator cooling fan relay No.2 and No.3 power supply Go to Step 9. Repair or replace
circuit check defective wire harness.
1) When ignition is “OFF”, remove radiator cooling fan relay
No.2 and No.3. (Page 10B-14)
2) Check for proper terminal connection to radiator cooling
fan relay No.2 and No.3 connectors.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “B1”, “B2” and “C1”
circuits and ground is battery voltage.

Is check result OK?

9 Radiator cooling fan relay No.3 ground circuit check Go to Step 10. Repair or replace
1) Check that resistance “C2” circuit and ground is less defective wire harness.
than 1 Ω.

Is check result OK?

10 Radiator cooling fan relay No.2 and No.3 drive circuit Go to Step 11. Repair or replace
check defective wire harness.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “B3” and “C3” circuits: less than 1 Ω
• Resistance between “B3” and “C3” circuits and
ground: infinity
• Resistance between “B3” circuit terminal and each
terminal at radiator cooling fan relay No.2 connector:
infinity
• Resistance between “C3” circuit terminal and each
terminal at radiator cooling fan relay No.3 connector:
infinity
• Voltage of “B3” and “C3” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

11 Radiator cooling fan power supply circuit (high speed Go to Step 12. Repair or replace
side) defective wire harness.
1) When ignition is “OFF”, disconnect radiator cooling fan
connector.
2) Check for proper terminal connection to radiator cooling
fan connector.
3) If connections are OK, check the following points.
• Resistance of “D3” circuit: less than 1 Ω
• Resistance between “D3” circuit and ground: infinity
• Resistance between “D3” circuit terminal and each
terminal at radiator cooling fan connector: infinity
• Voltage of “D3” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

1A-329 Engine General Information and Diagnosis: D13A

Step Action Yes No

12 Radiator cooling fan ground circuit (high speed side) Go to Step 13. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “D4” circuit: less than 1 Ω
• Resistance between “D4” circuit and ground: less than
1Ω
• Resistance between “D4” circuit terminal and each
terminal at radiator cooling fan connector: infinity
• Voltage of “D4” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

13 Radiator cooling fan relay No.2 and No.3 check Go to Step 14. Replace radiator cooling
1) Check radiator cooling fan relay No.2 and No.3. (Page fan relay No.2 and No.3.
1F-28) (Page 10B-14)

Is check result OK?

14 Radiator cooling fan check Replace ECM and Replace radiator cooling
1) Check radiator cooling fan. (Page 1F-28) recheck radiator cooling fan motor. (Page 1F-
fan operation. (Page 29)
Is check result OK? 1C-20)

Inspection of ECM and Its Circuits

AENJHB0B1124091
NOTE
• As each terminal voltage is affected by battery voltage, check that battery voltage is 12 V or more
when ignition is “ON”.
• Voltage with asterisk (*) cannot be measured with voltmeter because it is pulse signal.
Use oscilloscope for its check.
• Before performing this inspection, read “Precautions of ECM Circuit Inspection” under
“Precautions for Engine (D13A)” in Section 1 (Page 1-2).

Terminal Arrangement of ECM Connector

[A]
E01 D01

6 15 14 13 12 11 10 9 8 7 5 4 3 2 1
[a]
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
48 47

70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71 60 54 53 52 51 50 49 48 47 46 59 58 57 56 55

IJHB0A113031-01

[A]: ECM connector (View: [a])

“D01” connector
Terminal No. Wire color Circuit Normal voltage Condition
Fuel injector No.4 drive circuit Refer to reference waveform.
D01-1* WHT/BLU
(low side) “Fuel injector signal”: D13A (Page 1A-335)
D01-2 — — — —
D01-3 — — — —
Fuel flow actuator power
D01-4 YEL/BLK 10 to 14 V Ignition: “ON”
supply circuit
D01-5 BLU/RED ECM power supply circuit 10 to 14 V Ignition: “ON”
Refer to reference waveform.
D01-6* GRY/RED EGR valve drive circuit
“EGR valve signal”: D13A (Page 1A-336)
 Engine General Information and Diagnosis: D13A 1A-330

Terminal No. Wire color Circuit Normal voltage Condition

Fuel pressure sensor ground
D01-7 YEL/RED Below 0.3 V Ignition: “ON”
circuit
D01-8 — — — —
Fuel pressure sensor power
D01-9 GRN/YEL 4 to 6 V Ignition: “ON”
supply circuit
Oil pressure switch signal 0 to 1 V Ignition: “ON”
D01-10 GRY/YEL
circuit 10 to 14 V Engine: Idle speed after warming up
D01-11 — — — —
D01-12 — — — —
D01-13 — — — —
D01-14 — — — —
D01-15 — — — —
Fuel injector No.1 drive circuit Refer to reference waveform.
D01-16* GRY/WHT
(low side) “Fuel injector signal”: D13A (Page 1A-335)
Fuel injector No.2 drive circuit Refer to reference waveform.
D01-17* YEL/BLK
(low side) “Fuel injector signal”: D13A (Page 1A-335)
D01-18 — — — —
D01-19 — — — —
Refer to reference waveform.
D01-20* YEL Fuel flow actuator drive circuit
“Fuel flow actuator signal”: D13A (Page 1A-337)
D01-21 PPL CMP sensor ground circuit Below 0.3 V Ignition: “ON”
D01-22 — — — —
Boost pressure sensor power
D01-23 RED/BLK 4 to 6 V Engine: Idle speed after warming up
supply circuit
Boost pressure sensor ground
D01-24 BLK Below 0.3 V Ignition: “ON”
circuit
CMP sensor power supply
D01-25 PNK 4 to 6 V Engine: Idle speed after warming up
circuit
D01-26 — — — —
D01-27 — — — —
D01-28 — — — —
D01-29 GRN ECT sensor ground circuit Below 0.3 V Ignition: “ON”
Refer to reference waveform.
Boost pressure control
D01-30* YEL/GRN “Boost pressure control solenoid valve signal”: D13A
solenoid valve drive circuit
(Page 1A-337)
Fuel injector No.3 drive circuit Refer to reference waveform.
D01-31* WHT/GRN
(low side) “Fuel injector signal”: D13A (Page 1A-335)
D01-32 — — — —
D01-33 — — — —
D01-34 — — — —
D01-35 — — — —
D01-36 — — — —
Ignition: “ON”
Approx. 1.7 V
Intake air temperature: 20 °C (68 °F)
Ignition: “ON”
D01-37 WHT IAT-2 sensor signal circuit Approx. 1.0 V
Intake air temperature: 40 °C (105 °F)
Ignition: “ON”
Approx. 0.5 V
Intake air temperature: 60 °C (140 °F)
Engine: Idle speed after warming up
Approx. 1.1 V Reference rail pressure: 30 MPa (305.9
kgf/cm2, 4,350 psi, 300 bar)
Fuel pressure sensor signal
D01-38 YEL/BLK Engine: Running at 3,000 rpm after
circuit
warming up
Approx. 2.2 V
Reference rail pressure: 71 MPa (724.0
kgf/cm2, 10,298 psi, 710 bar)
1A-331 Engine General Information and Diagnosis: D13A

Terminal No. Wire color Circuit Normal voltage Condition

Ignition: “ON”
Approx. 0 V
Blower speed switch: 2nd or more
Blower motor signal circuit Ignition: “ON”
D01-39 YEL 5 to 7 V
(Manual A/C model) Blower speed switch: 1st
Ignition: “ON”
10 to 14 V
Blower speed switch: OFF
D01-40 — — — —
Engine: Idle speed after warming up
Approx. 1.6 V Reference boost pressure: 99 kPa
(1.01 kgf/cm2, 14.4 psi, 0.99 bar)
Boost pressure sensor signal
D01-41 YEL Engine: Running at 3,500 rpm after
circuit
warming up
Approx. 2.0 V
Reference boost pressure: 123 kPa
(1.25 kgf/cm2, 17.8 psi, 1.23 bar)
D01-42 — — — —
Refer to reference waveform.
D01-43* GRY/BLK CKP sensor signal circuit (+) “CMP sensor signal and CKP sensor signal”: D13A
(Page 1A-338)
D01-44 — — — —
D01-45 — — — —
D01-46 — — — —
D01-47 — — — —
D01-48 — — — —
Ignition: “ON”
Approx. 2.8 V
ECT: Approx. 20 °C (68 °F)
Ignition: “ON”
D01-49 PPL/WHT ECT sensor signal circuit Approx. 1.8 V
ECT: Approx. 40 °C (104 °F)
Ignition: “ON”
Approx. 0.7 V
ECT: Approx. 80 °C (176 °F)
D01-50 — — — —
Refer to reference waveform.
D01-51* PNK/BLK CMP sensor signal circuit “CMP sensor signal and CKP sensor signal”: D13A
(Page 1A-338)
D01-52 — — — —
D01-53 — — — —
Refer to reference waveform.
D01-54* YEL/RED CKP sensor signal circuit (–) “CMP sensor signal and CKP sensor signal”: D13A
(Page 1A-338)
Fuel injector No.4 drive circuit Refer to reference waveform.
D01-55* BLU
(high side) “Fuel injector signal”: D13A (Page 1A-335)
Fuel injector No.1 drive circuit Refer to reference waveform.
D01-56* WHT
(high side) “Fuel injector signal”: D13A (Page 1A-335)
Fuel injector No.3 drive circuit Refer to reference waveform.
D01-57* GRN
(high side) “Fuel injector signal”: D13A (Page 1A-335)
Fuel injector No.2 drive circuit Refer to reference waveform.
D01-58* YEL
(high side) “Fuel injector signal”: D13A (Page 1A-335)
D01-59 — — — —
D01-60 — — — —

“E01” connector
Terminal No. Wire color Circuit Normal voltage Condition
Ignition: “ON”
10 to 14 V ECT < 95 °C (203 °F)
Radiator cooling fan relay A/C switch: OFF
E01-1 LT GRN
No.1 drive circuit Ignition: “ON”
Approx. 0 V 98 °C (208 °F) < ECT
A/C switch: OFF
 Engine General Information and Diagnosis: D13A 1A-332

Terminal No. Wire color Circuit Normal voltage Condition

Ignition: “ON”
10 to 14 V ECT < 103 °C (217 °F)
Radiator cooling fan relay A/C switch: OFF
E01-2 GRN
No.2 and No.3 drive circuit Ignition: “ON”
Approx. 0 V 106 °C (222 °F) < ECT
A/C switch: OFF
Ignition: “ON”
10 to 14 V
ENG A-STOP OFF switch ENG A-STOP OFF switch: Pushed
E01-3 GRY
signal circuit Ignition: “ON”
Approx. 0 V
ENG A-STOP OFF switch: Released
A/C refrigerant pressure
E01-4 BLU Below 0.3 V Ignition: “ON”
sensor ground circuit
Brake stroke sensor ground
E01-5 BRN Approx. 0 V Ignition: “ON”
circuit
Refer to reference waveform.
E01-6* PNK A/F sensor heater drive circuit “A/F sensor heater relay drive signal”: D13A (Page 1A-
338)
Fuel temperature sensor
E01-7 GRN Below 0.3 V Ignition: “ON”
ground circuit
E01-8 — — — —
APP sensor (sub) power
E01-9 BLK 4 to 6 V Ignition: “ON”
supply circuit
E01-10 — — — —
Ignition: “ON”
Approx. 0 V
Hood latch switch 2 signal Hood latch: Latch released
E01-11* GRY
circuit Ignition: “ON”
10 to 14 V
Hood latch: Fully latched
E01-12 — — — —
DC/DC converter diagnosis 10 to 14 V Ignition: ACC
E01-13 GRN
output signal circuit Approx. 0 V Ignition: “ON”
Ignition: “ON”
0 to 1 V
Brake light switch signal Brake pedal: Not depressed
E01-14 LT BLU
circuit Ignition: “ON”
10 to 14 V
Brake pedal: Fully depressed
Ignition: “ON”
Approx. 0 V Brake pedal: Fully depressed after
Brake booster switch signal
E01-15 PNK depressing several times
circuit
Engine: Running
10 to 14 V
Brake pedal: Not depressed
E01-16 — — — —
E01-17 WHT Ignition signal circuit 10 to 14 V Ignition: “ON”
Ignition: “ON”
10 to 14 V
Hood latch switch 1 signal Hood latch: Latch released
E01-18 LT BLU
circuit Ignition: “ON”
Approx. 0 V
Hood latch: Fully latched
E01-19 — — — —
Ignition: “ON”
Approx. 0 V
Neutral position switch signal Gear position: Other than Neutral
E01-20 GRN
circuit (–) Ignition: “ON”
Approx. 3 V
Gear position: Neutral
Ignition: “ON”
10 to 14 V
Clutch pedal: Not depressed
E01-21 PPL CPP No.2 switch signal circuit
Ignition: “ON”
0 to 1 V
Clutch pedal: Fully depressed
E01-22 — — — —
E01-23 BRN ECM ground circuit Below 0.3 V Ignition: “ON”
E01-24 BRN ECM ground circuit Below 0.3 V Ignition: “ON”
E01-25 — — — —
E01-26 — — — —
1A-333 Engine General Information and Diagnosis: D13A

Terminal No. Wire color Circuit Normal voltage Condition

APP sensor (sub) ground
E01-27 WHT Below 0.3 V Ignition: “ON”
circuit
E01-28 — — — —
E01-29 YEL MAF sensor ground circuit Below 0.3 V Ignition: “ON”
APP sensor (main) ground
E01-30 BLU Below 0.3 V Ignition: “ON”
circuit
E01-31 — — — —
A/C refrigerant pressure
E01-32 BRN 4 to 6 V Ignition: “ON”
sensor power supply circuit
Brake stroke sensor power
E01-33 LT BLU 4 to 6 V Ignition: “ON”
supply circuit
E01-34 — — — —
CAN (low) communication Refer to reference waveform.
E01-35* WHT
circuit “CAN communication signal”: D13A (Page 1A-338)
Ignition: “ON”
1.70 to 2.30 V
APP sensor (sub) signal Accelerator pedal: Fully depressed
E01-36 YEL
circuit Ignition: “ON”
0.20 to 0.60 V
Accelerator pedal: Not depressed
E01-37 — — — —
E01-38 — — — —
E01-39 LT GRN A/F sensor signal circuit (VS) 2 to 6 V Engine: Idle speed after warming up
E01-40 WHT A/F sensor signal circuit (IP) 2 to 6 V Engine: Idle speed after warming up
A/F sensor signal circuit
E01-41 GRY 2 to 6 V Engine: Idle speed after warming up
(VSIP)
E01-42 BLK A/F sensor signal circuit (RC) 2 to 6 V Engine: Idle speed after warming up
E01-43 — — — —
E01-44 — — — —
ECM backup power supply
E01-45 YEL 10 to 14 V —
circuit
E01-46 — — — —
E01-47 BRN ECM ground circuit Below 0.3 V Ignition: “ON”
E01-48 GRN ECM power supply circuit 10 to 14 V Ignition: “ON”
14 to 18 V Ignition: “ON”
Refer to reference waveform.
• “ISG wake-up signal and ISG inhibitor signal”: D13A
E01-49 BRN ISG inhibition signal circuit
(Page 1A-339)
• “ISG wake-up signal, ISG inhibition signal and DC/DC
converter activation signal”: D13A (Page 1A-339)
E01-50 — — — —
E01-51 — — — —
E01-52 — — — —
E01-53 — — — —
Refer to reference waveform.
E01-54* RED MAF sensor signal circuit
“MAF sensor signal”: D13A (Page 1A-339)
E01-55 — — — —
E01-56 — — — —
Refer to reference waveform.
• “ISG wake-up signal and ISG inhibitor signal”: D13A
E01-57 PPL ISG wake-up signal circuit (Page 1A-339)
• “ISG wake-up signal, ISG inhibition signal and DC/DC
converter activation signal”: D13A (Page 1A-339)
E01-58 — — — —
Engine: Idle speed after warming up
Approx. 2.54 V
Fuel temperature: 25 °C (77 °F)
Fuel temperature sensor Engine: Idle speed after warming up
E01-59 BEG Approx. 1.14 V
signal circuit Fuel temperature: 60 °C (140 °F)
Engine: Idle speed after warming up
Approx. 0.43 V
Fuel temperature: 100 °C (212 °F)
 Engine General Information and Diagnosis: D13A 1A-334

Terminal No. Wire color Circuit Normal voltage Condition

Ignition: “ON”
Approx. 1.7 V
Intake air temperature: 20 °C (68 °F)
Ignition: “ON”
E01-60* BLU IAT-1 sensor signal circuit Approx. 1.0 V
Intake air temperature: 40 °C (105 °F)
Ignition: “ON”
Approx. 0.5 V
Intake air temperature: 60 °C (140 °F)
E01-61 — — — —
CAN (high) communication Refer to reference waveform.
E01-62* RED
circuit “CAN communication signal”: D13A (Page 1A-338)
Ignition: “ON”
3.60 to 4.20 V
APP sensor (main) signal Accelerator pedal: Fully depressed
E01-63 BEG
circuit Ignition: “ON”
0.50 to 0.90 V
Accelerator pedal: Not depressed
Refer to reference waveform.
E01-64* GRY Serial communication circuit
“Serial communication signal”: D13A (Page 1A-340)
E01-65 — — — —
Ignition: “ON”
10 to 14 V
Brake pedal: Not depressed
E01-66 BLU Brake switch signal circuit
Ignition: “ON”
0 to 1 V
Brake pedal: Fully depressed
E01-67 — — — —
Ignition: Within 20 sec. after setting
Glow plug control module 10 to 14 V
E01-68 BRN ignition “ON”
communication circuit
0 to 1 V Ignition: After 20 sec. from ignition “ON”
E01-69 — — — —
E01-70 — — — —
E01-71 GRN ECM power supply circuit 10 to 14 V Ignition: “ON”
E01-72 GRN ECM power supply circuit 10 to 14 V Ignition: “ON”
Ignition: Within 20 sec. after setting
Glow plug control module 0 to 1 V
E01-73 LT BLU ignition “ON”
drive circuit
10 to 14 V Ignition: After 20 sec. from ignition “ON”
Ignition: Within 20 sec. after setting
0 to 1 V
ignition “ON”
E01-74 RED Fuel pump relay drive circuit
Engine: Idle speed after warming up
10 to 14 V Ignition: After 20 sec. from ignition “ON”
E01-75 — — — —
E01-76 — — — —
E01-77 — — — —
Engine: Idle speed after warming up
0 to 1 V
A/C compressor relay drive A/C compressor: ON
E01-78 BRN
circuit Engine: Idle speed after warming up
10 to 14 V
A/C compressor: OFF
0 to 1 V Ignition: “ON”
E01-79 PNK Main relay drive circuit
10 to 14 V Ignition: “OFF”
E01-80 — — — —
E01-81 — — — —
APP sensor (main) power
E01-82 BRN 4 to 6 V Ignition: “ON”
supply circuit
Starting motor control relay Approx. 0 V Ignition: “ON”
E01-83 LT GRN
signal circuit 6 to 12 V Ignition: “Start”
Refer to reference waveform.
DC/DC converter activation
E01-84 PPL “ISG wake-up signal, ISG inhibition signal and DC/DC
signal circuit
converter activation signal”: D13A (Page 1A-339)
E01-85 — — — —
1A-335 Engine General Information and Diagnosis: D13A

Terminal No. Wire color Circuit Normal voltage Condition

Engine: Idle speed after warming up
A/C switch: OFF
0.9 to 1.3 V
A/C refrigerant pressure: 600 kPa (6.1
A/C refrigerant pressure kgf/cm2, 87 psi, 6.0 bar)
E01-86 PNK
sensor signal circuit Engine: Idle speed after warming up
A/C switch: ON
1.3 to 2.2 V
A/C refrigerant pressure: 1,200 kPa
(12.2 kgf/cm2, 174 psi, 12 bar)
E01-87 — — — —
E01-88 — — — —
Ignition: After 5 sec. from ignition “ON”
10 to 14 V Amount of water in fuel filter: Below
Fuel filter water detection
E01-89 RED specified level
sensor signal circuit
Amount of water in fuel filter: Specified
0 to 1 V
level or more
E01-90 — — — —
Ignition: “ON”
Approx. 0 V
Clutch pedal: Fully depressed
E01-91 GRN CPP No.1 switch signal circuit
Ignition: “ON”
10 to 14 V
Clutch pedal: Released
Ignition: “ON”
10 to 14 V
Neutral position switch signal Gear position: Other than Neutral
E01-92 PNK
circuit (+) Ignition: “ON”
Approx. 3 V
Gear position: Neutral
Ignition: “ON”
Approx. 1.0 V
Brake stroke sensor signal Brake pedal: Released
E01-93 PPL
circuit Ignition: “ON”
1.5 to 2.5 V
Brake pedal: Fully depressed
E01-94 — — — —

Reference Waveform • Waveform varies depending on

measurement condition and vehicle spec.
NOTE
• Display includes the following types of Fuel injector signal
data:
Fuel injector No.1 signal (high side) (1):
Channel Probe Terminal No.
+ D01-56
1
– E01-23

Fuel injector No.1 signal (low side) (2):

Channel Probe Terminal No.
+ D01-16
2
– E01-23

Fuel injector No.4 signal (high side) (3):

Channel Probe Terminal No.
+ D01-55
3
– E01-23
I8T401111066-01
Fuel injector No.4 signal (low side) (4):
[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel
Channel Probe Terminal No.
[B]: Ground level of each channel [D]: TIME/DIV
+ D01-1
4
– E01-23

Fuel injector No.2 signal (high side) (1):

Channel Probe Terminal No.
+ D01-58
1
– E01-23
 Engine General Information and Diagnosis: D13A 1A-336

Fuel injector No.2 signal (low side) (2): EGR valve signal
Channel Probe Terminal No. Channel Probe Terminal No.
+ D01-17 + D01-6
2 1
– E01-23 – E01-23

Fuel injector No.3 signal (high side) (3): Measurement condition

Channel Probe Terminal No. • Engine: Running after warming up
+ D01-57 EGR valve duty: 50%
3
– E01-23

Fuel injector No.3 signal (low side) (4):

Channel Probe Terminal No.
+ D01-31
4
– E01-23

Measurement condition
Engine: Idle speed after warming up

I7N20A112003-02

Measurement condition
• Engine: Running after warming up
• EGR valve duty: 2.0%

IAY40A110011-02

5. Signal is outputted, but fuel is not injected. 7. Crankshaft angle at 360°

6. Fuel is injected.

I7N20A112004-02

IAY40A110019-01

5. Signal is outputted, but fuel is not injected. 6. Fuel is injected.

1A-337 Engine General Information and Diagnosis: D13A

Fuel flow actuator signal Boost pressure control solenoid valve signal
Channel Probe Terminal No. Channel Probe Terminal No.
+ D01-20 + D01-30
1 1
– E01-23 – E01-23

Measurement condition Measurement condition

Ignition: “ON” Ignition: “ON”

IAY40A110034-01 IAY40A110036-01

Measurement condition Measurement condition

Engine: Idle speed after warming up Engine: Idle speed after warming up

IAY40A110035-01 IAY40A110037-01
 Engine General Information and Diagnosis: D13A 1A-338

CMP sensor signal and CKP sensor signal A/F sensor heater relay drive signal
Channel Probe Terminal No.
CMP sensor signal (1): + E01-6
Channel Probe Terminal No. 1
– E01-23
+ D01-51
1
– E01-23 Measurement condition
Engine: Idle speed after warming up
CKP sensor signal (+) (2):
Channel Probe Terminal No.
+ D01-43
2
– E01-23

CKP sensor signal (–) (3):

Channel Probe Terminal No.
+ D01-54
3
– E01-23

Measurement condition
• Engine: Idle speed after warming up

I7V10A112001-01

CAN communication signal

CAN (high) communication (1):

Channel Probe Terminal No.
+ E01-35
1
– E01-23

CAN (low) communication (2):

Channel Probe Terminal No.
+ E01-62
2
I9P60A112043-01
– E01-23

Measurement condition
Engine: Idle speed after warming up

I9P60A112044-01

4. Camshaft 360° angle 5. Crankshaft 360° angle

I7N20A112011-03
1A-339 Engine General Information and Diagnosis: D13A

ISG wake-up signal and ISG inhibitor signal Measurement condition

Engine auto stop control → Engine auto start control →
ISG wake-up signal (1): Engine running
Channel Probe Terminal No.
+ E01-57
1
– E01-23

ISG inhibition signal (2):

Channel Probe Terminal No.
+ E01-49
2
– E01-23

Measurement condition
• Vehicle: Running
• Engine power assist: OFF → ON → OFF

IFL10A110006-01

4. Engine auto stop control 6. Engine running

5. Engine auto start control

MAF sensor signal

Channel Probe Terminal No.
+ E01-54
1
– E01-23

Measurement condition
Engine: Idle speed after warming up

IFL10A110005-01

3. Engine power assist: ON

ISG wake-up signal, ISG inhibition signal and DC/DC

converter activation signal

ISG wake-up signal (1):

Channel Probe Terminal No.
+ E01-57
1
– E01-23

ISG inhibition signal (2):

Channel Probe Terminal No. I7N20A112012-02
+ E01-49
2
– E01-23

DC/DC converter activation signal (3):

Channel Probe Terminal No.
+ E01-85
3
– E01-23
 Engine General Information and Diagnosis: D13A 1A-340

Serial communication signal

Channel Probe Terminal No.
+ E01-64
1
– E01-23

Measurement condition
Ignition: “ON”

I7N20A112014-02

Repair Instructions
Idle Speed Inspection Special tool
AENJHB0B1126001 : SUZUKI scan tool (Suzuki SDT-II)
1) Shift transaxle into neutral.
Engine idle speed
2) Start engine and warm it up to normal operating
A/C OFF: Approx. 800 rpm
temperature.
A/C ON: Approx. 900 rpm
3) Turn all electrical loads off.
5) If engine idle speeds are not as specified, go to
4) Using SUZUKI scan tool, check that idle speed is
“Improper Engine Idling or Engine Stops at Idle”
within specification.
under “Engine Symptom Diagnosis”: D13A (Page
1A-207).

Special Tools and Equipment

Special Tool
AENJHB0B1128001
SUZUKI scan tool (Suzuki
SDT-II)
—
(Page 1A-180) /
(Page 1A-181) /
(Page 1A-340)
1B-1 Aux. Emission Control Devices: K15B

Aux. Emission Control Devices

Engine

K15B
Diagnostic Information and Procedures
EVAP Canister Purge System Inspection NOTE
AENJHB0B1214001
EVAP canister purge valve is operated using
! WARNING
scan tool as follows.
If you suck at the nipple on the EVAP canister • EVAP canister purge valve is OFF: 0%
purge valve, you will inhale harmful fuel • EVAP canister purge valve is ON: 100%
vapor that may be present inside the EVAP
canister purge valve.
Never suck the nipple on the EVAP canister
purge valve.

NOTICE
If excessive negative pressure is applied, the
EVAP canister purge valve may be damaged.
Do not exceed negative pressure of –66 kPa
(–0.67 kgf/cm2, –9.57 psi, –0.66 bar). 1

Using SUZUKI Scan Tool

1) Prepare to operate EVAP canister purge valve as
follows.
a) Connect SUZUKI scan tool to DLC (1) with
ignition “OFF”.
b) With ignition “ON”, clear DTC and select “Active
Test” mode on SUZUKI scan tool.
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)

(A)

IJHA0A110021-01

2) Set ignition “OFF”.

3) Disconnect vacuum hose (2) from intake manifold
and purge hose from EVAP canister purge valve (1).
4) Install special tool to vacuum hose.
Special tool
(A): 09917M47011
5) Set ignition “ON”.
6) Check EVAP canister purge valve operation as
follows.
a) Check that negative pressure of –60 kPa (–0.61
kgf/cm2, –8.70 psi, –0.60 bar) can be applied
when EVAP canister purge valve is turned off [A].
b) Check that no negative pressure can be applied
when EVAP canister purge valve is turned on [B].
 Aux. Emission Control Devices: K15B 1B-2

7) If faulty condition is found, check the following items. 2) Set ignition “OFF”.
• Wire harness and connections 3) Disconnect vacuum hose (2) from intake manifold
• EVAP canister purge valve: (Page 1B-4) and purge hose from EVAP canister purge valve (1).
• Vacuum hose: (Page 1B-7) 4) Install special tool to vacuum hose.
Special tool
[A] [B]
(A): 09917M47011
5) Set ignition “ON”.
1 1
(A)
6) Check EVAP canister purge valve operation as
(A) follows.
a) Check that negative pressure of –60 kPa (–0.61
kgf/cm2, –8.70 psi, –0.60 bar) can be applied
when EVAP canister purge valve is turned off [A].
2 2
b) Check that no negative pressure can be applied
when EVAP canister purge valve is turned on [B].
IFRA0A121002-01 7) If faulty condition is found, check the following items.
• Wire harness and connections
Without Using SUZUKI Scan Tool
• EVAP canister purge valve: (Page 1B-4)
1) Prepare to operate EVAP canister purge valve as
follows. • Vacuum hose: (Page 1B-7)
a) Connect service wire (2) between EVAP canister [A] [B]
purge valve and EVAP canister purge valve
connector with ignition “OFF”.
b) Set ignition “ON”. 1 1
(A)
(A)
NOTE
EVAP canister purge valve (1) is operated
using service wire as follows.
2 2
• EVAP canister purge valve is OFF:
[a]: Unground “GRY” harness side
terminal of EVAP canister purge valve.
IFRA0A121002-01
• EVAP canister purge valve is ON:
[b]: Ground “GRY” harness side terminal
of EVAP canister purge valve.

[a]

[b]

1
I8C50B120002-01
1B-3 Aux. Emission Control Devices: K15B

Repair Instructions
EVAP System Components
AENJHB0B1216001

(b)

(b)
5 6
[a]

4
3

(a)
[a]

IJHA0A120001-01

1. EVAP canister 4. Engine harness bracket 7. To fuel filler neck

2. EVAP canister bracket 5. To intake manifold : 7.0 Nm (0.71 kgf-m, 5.5 lbf-ft)
3. EVAP canister purge valve 6. To fuel tank : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
 Aux. Emission Control Devices: K15B 1B-4

EVAP Canister Purge Valve Removal and
Installation
AENJHB0B1216002
Removal
1) Disconnect EVAP canister purge valve connector.
2) Remove EVAP canister purge valve (1) from engine
harness bracket (2).
3) Disconnect purge hose No.1 (3) and purge hose
No.2 (4) from EVAP canister purge valve.
EVAP Canister Purge Valve Inspection
AENJHB0B1216003
! WARNING
If you suck at the nipple on the EVAP canister
purge valve, you will inhale harmful fuel
vapor that may be present inside the EVAP
canister purge valve.
Never suck at any of the nipples on the EVAP
canister purge valve.

3
2 NOTICE
If excessive negative pressure is applied, the
EVAP canister purge valve may be damaged.
Do not exceed negative pressure of –66 kPa
(–0.67 kgf/cm2, –9.57 psi, –0.66 bar).

1) With ignition “OFF”, disconnect connector and hoses

from EVAP canister purge valve (1).
4
2) Remove purge valve from engine harness bracket.
1 3) Check resistance between two terminals of purge
valve.
IJHA0A120002-01 If faulty condition is found, replace purge valve.

Installation EVAP canister purge valve resistance

Reverse removal procedure noting the following point. 22 – 26 Ω at 20 °C (68 °F)
• Tighten EVAP canister purge valve nut (1) to specified
torque.
Tightening torque
EVAP canister purge valve nut (a): 7.0 N·m (0.71
kgf-m, 5.5 lbf-ft)

1
I8T401122005-01

1, (a)

IJHA0A120003-01
1B-5 Aux. Emission Control Devices: K15B

4) Check purge valve operation as follows. EVAP Canister Removal and Installation
If faulty condition is found, replace purge valve. AENJHB0B1216004
Removal
a) Install special tool and vacuum hose (2) to purge
1) Hoist vehicle.
valve (1).
2) Disconnect air suction hose (1), fuel EVAP hose (2)
Special tool and purge hose (3) from EVAP canister.
(A): 09917M47011
b) When connecting 12 V battery to purge valve
terminals, check that negative pressure (–60
kPa, –0.61 kgf/cm2, –8.70 psi, –0.60 bar) cannot
be applied to purge valve.
c) When not connecting 12 V battery to purge valve 1
terminals, check that negative pressure (–60 3
kPa, –0.61 kgf/cm2, –8.70 psi, –0.60 bar) can be
2
applied to purge valve.

[A]

2
IJHB0A121001-01
1 (A)
3) Remove EVAP canister (1) with EVAP canister
bracket.

[B]

1
2

(A)
1

IDAA0A121003-01

[A]: Purge valve ON [B]: Purge valve OFF

IJHB0A121002-01

4) Remove EVAP canister (1) from EVAP canister

bracket (2), if necessary.

2
IJHB0A121003-01
 Aux. Emission Control Devices: K15B 1B-6

Installation EVAP Canister Inspection

Reverse removal procedure noting the following points. AENJHB0B1216005

• Tighten EVAP canister bolts to specified torque, if ! WARNING

removed. If you suck at the nozzle on the EVAP
Tightening torque canister, you will inhale harmful fuel vapor
EVAP canister bolt (a): 9.0 N·m (0.92 kgf-m, 7.0 that may be present inside the canister.
lbf-ft) Never suck at any of the nozzles on the EVAP
canister.

1) Remove EVAP canister. (Page 1B-5)

(a)
2) Check outside of EVAP canister visually.
3) Check that there is no restriction of flow through
purge port (1) and air port (2) when air is blown (4)
into tank port (3).

(a) 3

IJHB0A121004-01 2

• Tighten EVAP canister bracket bolts to specified

1
torque.
Tightening torque
EVAP canister bracket bolt (a): 9.0 N·m (0.92 kgf-
m, 7.0 lbf-ft)

IJHB0A121006-01

(a)

(a)

IJHB0A121005-01
1B-7 Aux. Emission Control Devices: K15B

4) Check EVAP canister for air leakage according to
the following procedure.
a) Plug purge port (1) and air port (2) using rubber
plug (3).
b) Install hose (4) and special tool to tank port (5).
Special tool
(A): 09917M47011
c) Using special tool, apply specified negative
pressure to EVAP canister for one minute.
EVAP canister holding negative pressure
–20.0 kPa (-0.20 kgf/cm2, –2.90 psi, –0.20 bar)
PCV Valve Inspection
AENJHB0B1216008
1) Disconnect PCV valve from cylinder head cover and
install plug to head cover hole.
2) Run engine at idle speed.
3) Place finger over end of PCV valve (1) to check for
negative pressure.
If no negative pressure is felt, check valve for
clogging. Replace PCV valve if defective.
1

(A) 4

5 3

2
3
I7V20A121009-01

1 4) Stop engine and remove PCV valve (1).

Install clean hose to valve and check that there is air
flow when blowing air into hose from “a” to “b” and
that there is no air flow when blowing air into hose
from “b” to “a” as shown in figure.
If faulty condition is found, replace PCV valve.

1 a
IJHB0A121007-01

If faulty condition is found, replace EVAP canister.

EVAP Connection Hose Inspection

AENJHB0B1216006
Check hoses for connection, leakage, clogging and
deterioration. I7V10A121002-01
Replace hose if defective.

PCV Hose Inspection

AENJHB0B1216007
Check hoses for connection, leakage, clogging and
deterioration.
Replace hose if defective.
 Aux. Emission Control Devices: K15B 1B-8

Fuel Cut Valve Inspection

AENJHB0B1216009
1) Disconnect fuel EVAP hose (1).

1 1

[B]
1
(A)
(A)

IJHB0A121008-01
2
2) Check fuel cut valve for operation as follows. 3

a) Connect fuel EVAP hose (1) to vacuum port (2)

of special tool. [A]

Special tool 1
(A): 09917M47011
b) Check that air can be sucked when negative
pressure is applied to fuel cut valve. IJHA0A120011-01

c) Disconnect hose from special tool. [A]: Air flow to vacuum port [B]: Air flow from pressure port

d) Connect hose to pressure port (3) of special tool.

3) If faulty condition is found, replace fuel tank. (Page
e) Check that air flows into tank when pressure is
1G-21)
applied to fuel cut valve.

Specifications
Tightening Torque Specifications
AENJHB0B1217001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
EVAP canister purge valve nut 7.0 0.71 5.5 (Page 1B-4)
EVAP canister bolt 9.0 0.92 7.0 (Page 1B-6)
EVAP canister bracket bolt 9.0 0.92 7.0 (Page 1B-6)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“EVAP System Components”: K15B (Page 1B-3)
“Fasteners Information” in Section 0A (Page 0A-5)
1B-9 Aux. Emission Control Devices: K15B

Special Tools and Equipment

Special Tool
AENJHB0B1218001
09917M47011 SUZUKI scan tool (Suzuki
SDT-II)
Vacuum pump gauge —
(Page 1B-1) / (Page 1B-1)
(Page 1B-2) /
(Page 1B-5) /
(Page 1B-7) /
(Page 1B-8)
 Aux. Emission Control Devices: D13A 1B-10

D13A
Repair Instructions
EGR Valve and EGR Cooler Components
AENJHB0B1226001

1
7 (c)
9
6
(a)

6
3

10 2

(b)

4
(b)
IJHB0A123001-01

1. EGR valve 5. Clamp 9. To intake manifold : 1.2 Nm (0.12 kgf-m, 1.0 lbf-ft)
2. EGR cooler 6. Gasket 10. To thermostat : Do not reuse.
3. EGR cooler hose 7. EGR pipe clamp : 22 Nm (2.2 kgf-m, 16.5 lbf-ft)
4. EGR cooler pipe 8. To heater inlet hose : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)

EGR Valve and EGR Cooler Removal and 5) Remove cable bracket. (Page 5B-55)
Installation 6) Remove intake air joint, intercooler outlet pipe No.3,
AENJHB0B1226002
inter cooler outlet hose No.3 and No.4. (Page 1D-
83)
Removal
7) Move harness bracket by removing harness bracket
1) Remove battery and battery tray. (Page 1J-16)
bolts. (Page 1C-28)
2) Drain coolant. (Page 1F-25)
8) Remove breather pipe (1) and heater outlet hose (2).
3) Remove air cleaner assembly. (Page 1D-82)
4) Remove degassing tank (1).

IJHB0A123003-01

IJHB0A123002-01
1B-11 Aux. Emission Control Devices: D13A

9) Disconnect EGR cooler inlet hose (1) and heater Installation

inlet hose (2). Reverse removal procedure noting the following points.
10) Disconnect EGR pipe (3) from intake manifold. • Clean mating surface of EGR valve and cylinder
11) Disconnect connector (4) from EGR valve. head.
12) Remove EGR valve (5) and EGR cooler together • Use new gaskets.
from cylinder head. • Tighten EGR cooler bolts and EGR cooler pipe bolt to
specified torque, if removed.
Tightening torque
4
EGR cooler bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)
5 EGR cooler pipe bolt (b): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)
3

(a)

1
2

IJHB0A123004-01

13) Remove EGR cooler hoses (1), EGR cooler pipe (2)
and heater inlet hose (3) from EGR cooler, if
necessary.
14) Remove EGR cooler (4) from EGR valve (5), if (b)
necessary. IJHB0A123006-01

• Tighten EGR valve bolts and EGR pipe clamp bolt to

specified torque.
5
Tightening torque
EGR valve bolt (a): 22 N·m (2.2 kgf-m, 16.5 lbf-ft)
1
EGR pipe clamp bolt (b): 1.2 N·m (0.12 kgf-m, 1.0
lbf-ft)
3

(b)

1
4
2

IJHB0A123005-01

(a)

IJHB0A123007-01

• Tighten breather pipe bolt and breather pipe clamp

bolt to specified torque. (Page 1D-81)
• Refill cooling system with coolant. (Page 1F-25)
• Check cooling system for leakage. (Page 1F-24)
 Aux. Emission Control Devices: D13A 1B-12

EGR Valve Inspection Cleaning Procedure for EGR Valve

AENJHB0B1226003
Visual Check
Check EGR valve for damage on valve and valve seat. If
faulty condition is found, replace EGR valve.
Operation Check
1) Connect battery positive terminal to “Power supply”
terminal (2) and negative terminal to “Ground”
terminal (3) of EGR valve (4).
2) Check valve (1) operation as shown in figure. If it
does not operate, replace EGR valve.
3 2
AENJHB0B1226004
! WARNING
When performing the following procedure,
wear gloves and safety glasses to prevent
any possible irritation of skin or eyes.
1) Remove EGR valve assembly referring to “EGR
Valve and EGR Cooler Removal and Installation”:
D13A (Page 1B-10).
2) Remove EGR valve assembly referring to “EGR
Valve and EGR Cooler Components”: D13A (Page
1B-10).
3) Remove EGR solenoid (1) from EGR valve housing
(2).

! CAUTION
4 Keep EGR solenoid (1) away from cleaning
area to prevent it from corrosion caused by
diesel fuel and any damage.

I7V20A122002-01
IAY40A120001-01
Resistance Check 4) Clean EGR valve housing (EGR cooler side) as
Check resistance between terminals of EGR valve. follows.
If resistance is not as specified, replace EGR valve.
a) Place EGR valve housing on a tray (1) so that
EGR valve resistance EGR cooler side (2) is facing up.
7.5 to 8.1 Ω at 20 °C (68 °F) b) Fill up diesel fuel (3) into EGR valve housing
(EGR cooler side). and leave it for 30 min.

3
2

IAY40A120002-01

IBL80A122006-01
1B-13 Aux. Emission Control Devices: D13A

c) Clean deposited soot from side wall and valve

plate of EGR valve housing (shaded area in 2
figure below) by using fine grain water proof
abrasive paper (1) which is wet with diesel fuel.

! CAUTION 3

Do not damage edges of valve plate (2) and

valve stem (3)

IAY40A120005-01

6) Drain diesel fuel from EGR valve housing and dry it

as follows.

! CAUTION

• Use care not to drop EGR valve housing

IAY40A120003-01 when shaking.
• Do not damage edges of valve plate and
d) Pour fresh diesel fuel into EGR valve housing stem when cleaning.
(EGR cooler side) and rinse to clean lose
deposited soot remaining in it. a) Shake EGR valve housing while pushing valve
5) Clean EGR valve housing (inside) as follows. stem from EGR solenoid side by hand to drain
diesel fuel remaining.
a) While pouring diesel fuel (3) from EGR cooler
side (2), move valve plate up and down 50 times b) Using a clean cloth, wipe off any diesel fuel from
by pushing valve stem (1) by hand from EGR EGR valve housing.
solenoid side to flush internal carbon. c) Dry EGR valve housing completely.
7) Install EGR solenoid (1) with new gasket to EGR
valve housing (2).
8) Tighten EGR solenoid valve bolts to specified
3 torque.
2 Tightening torque
EGR valve solenoid bolt (a): 6.5 N·m (0.65 kgf-
m, 4.5 lbf-ft)

IAY40A120004-01

b) While pouring diesel fuel EGR cooler side, rotate

valve stem (1) 3 revolutions by hand from EGR
solenoid side to clean EGR valve plate (2) and
valve seat (3) IAY40A120006-01

9) Install EGR cooler to EGR valve referring to “EGR

Valve and EGR Cooler Removal and Installation”:
D13A (Page 1B-10).
10) Install EGR valve assembly referring to “EGR Valve
and EGR Cooler Components”: D13A (Page 1B-10).
 Aux. Emission Control Devices: D13A 1B-14

A/F Sensor On-Vehicle Inspection Removal

AENJHB0B1226005
A/F Sensor Heater 1) Disconnect negative (–) cable at battery.
1) Disconnect negative (–) cable at battery. 2) Remove air cleaner suction pipe. (Page 1D-81)
2) Disconnect A/F sensor connector. (Page 1B-14) 3) Detach connector (1) of A/F sensor from its bracket
(2).
3) Using ohmmeter, measure resistance between
terminals “Heater +” and “Heater –” at sensor 4) Disconnect connector from A/F sensor.
connector (1). a) Move connector lock pin (3) in arrow direction as
If resistance is not as specified, replace A/F sensor. shown in figure.
(Page 1B-14) b) Push connector lock lever (4) and disconnect
connector from A/F sensor (5).
NOTE
5) Remove A/F sensor.
Ambient temperature of sensor affects
resistance largely. Check that sensor heater
1
is at reference temperature.
5
A/F sensor heater resistance
2.40 to 3.05 Ω at 25 °C (77 °F) 2

4
1

3
I9P60A122014-01 IJHB0A123008-01

A/F Sensor Removal and Installation Installation

AENJHB0B1226006 Reverse removal procedure noting the following points.
! CAUTION • Check gasket (1) for deterioration and damage. If
gasket is defective, replace A/F sensor.
Touching a hot exhaust system component
will cause a burn.
Do not perform any service work on the
exhaust system until the exhaust system has
cooled.

NOTE
If A/F sensor is replaced, initialize A/F data in
ECM.
For details, refer to “Description of ECM
Registration”: D13A in Section 1C (Page 1C-
I7V20A122014-01
18).
• Tighten A/F sensor and A/F sensor bracket bolt to
specified torque. (Page 1K-7)
• When replacing A/F sensor, initialize A/F sensor data
in ECM. (Page 1C-22)
1B-15 Aux. Emission Control Devices: D13A

Crankcase Ventilation System Components

AENJHB0B1226007

2
8 2

13 2
(a)

(a)

10

5 11

(a)

2 12

9
4

(a)
IDL10A120004-02

1. Oil separator 6. Ventilation connector 11. To timing chain cover

2. Clamp 7. O-ring 12. To cylinder block
3. Ventilation No.1 hose 8. Hose bracket 13. To breather pipe
4. Crankcase ventilation cover 9. Gasket : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
5. Ventilation No.2 hose 10. Breather hose : Do not reuse.
 Aux. Emission Control Devices: D13A 1B-16

Oil Separator and Crankcase Ventilation Cover Tightening torque

Removal and Installation Oil separator mounting bolt (a): 9.0 N·m (0.92 kgf-
AENJHB0B1226008 m, 7.0 lbf-ft)
Ventilation connector bolt (b): 9.0 N·m (0.92 kgf-m,
Removal 7.0 lbf-ft)
1) Disconnect negative (–) cable at battery.
2) Remove ISG. (Page 1J-20)
3) Disconnect ventilation No.2 hose (1) from ventilation
connector.
4) Disconnect ventilation No.2 hose from hose bracket
(2).

(a)

(b)
1

2
IDL10A120005-01
5) Remove vacuum tank and vacuum tank bracket, if
necessary. (Page 1I-19)
6) Remove oil separator (1), hoses (2) and crankcase
ventilation cover (3) together from cylinder block.
IJHB0A123010-01
Oil Separator Inspection
AENJHB0B1226009
• Check oil separator for wear or damage. If
malfunction is found, replace oil separator.
• Check hoses for connection, leakage, clogging and
deterioration. If malfunction is found, replace oil
separator.

IJHB0A123009-01

7) Remove hoses from oil separator and crankcase

ventilation cover, if necessary.

Installation
Reverse removal procedure noting the following points.
• Clean mating surfaces of crankcase ventilation cover
and cylinder block.
• Use new crankcase ventilation cover gasket and
ventilation hose clamps.
• Tighten each bolt to specified torque.
1B-17 Aux. Emission Control Devices: D13A

Specifications
Tightening Torque Specifications
AENJHB0B1227001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
EGR cooler bolt 25 2.5 18.5 (Page 1B-11)
EGR cooler pipe bolt 25 2.5 18.5 (Page 1B-11)
EGR valve bolt 22 2.2 16.5 (Page 1B-11)
EGR pipe clamp bolt 1.2 0.12 1.0 (Page 1B-11)
EGR valve solenoid bolt 6.5 0.65 4.5 (Page 1B-13)
Oil separator mounting bolt 9.0 0.92 7.0 (Page 1B-16)
Ventilation connector bolt 9.0 0.92 7.0 (Page 1B-16)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“EGR Valve and EGR Cooler Components”: D13A (Page 1B-10)
“Crankcase Ventilation System Components”: D13A (Page 1B-15)
“Fasteners Information” in Section 0A (Page 0A-5)

Engine Electrical Devices
Engine
K15B
General Description
Engine Electrical Devices Description
AENJHB0B1311001
Various sensors for the engine control in this model are
outlined as follows.
TP Sensor (Main / Sub)
• The sensor is mounted on electric throttle body.
• A noncontact type sensor with Hall IC generates dual
voltage signals in response to throttle valve opening
and these signals, main and sub, are inputted to ECM.
Based on the signals, ECM calculates opening degree
of the throttle valve.
APP Sensor (Main / Sub)
• The sensor is mounted on accelerator pedal.
• A noncontact type sensor applying electromagnetic
induction detects depressing degree of accelerator
pedal.
• Dual voltage signals, main and sub, are inputted to
ECM. Based on the signals, ECM controls throttle
valve opening activating throttle motor.
MAP Sensor
• The sensor is mounted on intake manifold.
• A pressure responsive silicon membrane incorporated
in diaphragm generates voltage signal corresponding
to intake pressure (absolute pressure) and the signal
is inputted to ECM. Based on the signal, ECM
calculates manifold absolute pressure.
ECT Sensor
• The sensor is mounted on thermostat case.
• A thermistor incorporated in the sensor changes
electrical resistance corresponding to temperature
and the resistance converted to voltage is inputted to
ECM. Based on the voltage signal, ECM calculates
coolant temperature.
HO2S-1
• HO2S-1 is mounted on exhaust manifold.
• The sensor is composed of a platinum coated zirconia
element which generates electromotive force sensing
difference of oxygen concentration. Voltage signal
corresponding to variation of oxygen concentration in
exhaust gas before flowing into catalyst is inputted to
ECM.
Engine Electrical Devices: K15B 1C-1
• Judging from signals from HO2S-1 and HO2S-2, ECM
controls A/F (air fuel ratio) to maintain purification rate
of exhaust gas in high level for stabile emissions. A
heater is incorporated in oxygen sensor for quick
startup and maintenance of activation.
HO2S-2
• HO2S-2 is mounted on exhaust manifold.
• The sensor is composed of a platinum coated zirconia
element which generates electromotive force sensing
difference of oxygen concentration. Voltage signal
corresponding to variation of oxygen concentration in
exhaust gas after flowing out of catalyst is inputted to
ECM.
• Judging from signals from HO2S-1 and HO2S-2, ECM
controls A/F (air fuel ratio) to maintain purification rate
of exhaust gas in high level for stabile emissions. A
heater is incorporated in oxygen sensor for quick
startup and maintenance of activation.
CMP Sensor
• The sensor is mounted on the end of cylinder head at
intake manifold side.
• Magnetic variation induced by a signal rotor press-
fitted on camshaft end is converted to voltage signal in
the sensor and the signal is inputted to ECM.
• Based on CMP signal and CKP signal, ECM reads
each piston position in cylinder and controls fuel
injection and ignition timing. Further, detecting open/
close timing of intake valves, ECM controls VVT
operation.
CKP Sensor
• The sensor is mounted on cylinder block near the
crank pulley at intake manifold side.
• Magnetic variation induced by a sensor plate installed
on crankshaft is converted to voltage signal in the
sensor and the signal is inputted to ECM. Using the
signal, ECM calculates engine speed.
• Based on CMP signal and CKP signal, ECM reads
each piston position in cylinder and controls fuel
injection and ignition timing.
1C-2 Engine Electrical Devices: K15B

Knock Sensor Electric Load Current Sensor

• The sensor is mounted on cylinder block.
• A piezoelectric ceramic element incorporated in the
sensor generates electromotive force in proportion to
degree of shock and the generated voltage signal is
inputted to ECM. Using the signal, ECM detects
piston knocking.
• The sensor is unified with battery temperature sensor
and installed in negative (–) cable terminal.
• A noncontact sensor incorporating Hall IC converts
current value in response to electrical load to voltage
signal and then the signal is inputted to ECM. Using
this signal as a judgement factor, ECM controls ISG.

IAT Sensor Battery Temperature Sensor

• The sensor is mounted on air cleaner inlet pipe.
• A thermistor incorporated in the sensor generates
voltage signal corresponding to intake air temperature
and the signal is inputted to ECM. Using the signal,
ECM calculates intake air temperature.
A/C Refrigerant Pressure Sensor
• The sensor is mounted on high pressure piping in A/C
system.
• A pressure transductor (semiconductor chip) is
incorporated in the sensor and variation of refrigerant
pressure is converted to voltage signal and then the
signal is inputted to ECM. Using the signal, ECM
calculates refrigerant pressure.
• The sensor is unified with electric load current sensor
and installed in negative (–) cable terminal.
• A thermistor in the sensor changes resistance in
response to temperature and peripheral temperature
of the battery is converted to voltage signal and then
the signal is inputted to ECM. Using this signal as a
judgement factor, ECM controls ISG.
Barometric Pressure Sensor
The sensor is incorporated in ECM and detects
atmospheric pressure.

Component Location
Electronic Control System Component Location
AENJHB0B1313001
Refer to “Electronic Control System Component Location”: K15B in Section 1A (Page 1A-18).

Repair Instructions
ECM Removal and Installation Removal
AENJHB0B1316001
NOTICE 1) Disconnect negative (–) cable at battery.
2) Turn lock lever (1) in arrow direction until it stops.
The ECM is a precision unit and can be easily
Then, disconnect connectors from ECM.
damaged.
Handle the ECM carefully and do not expose 1
it to large shock. 1

NOTE
After ECM is replaced with new one, perform
“Procedure after ECM Replacement”: K15B
(Page 1C-3).
IFRA0A131001-01
 Engine Electrical Devices: K15B 1C-3

3) Remove ECM (1) from ECM bracket by removing • Connect connectors to ECM as follows:
mounting bolts (2). a. Check that lock lever of ECM connectors is in
unlocked position.

IFRA0A131003-01

b. Insert ECM connectors to ECM until they stop with

lock lever in unlocked position.
1
2 2

IJHA0A130001-01

4) Remove ECM bracket (1), if necessary.

IFRA0A131004-01

c. Pull lock lever down to lock ECM connectors

securely.

1 IFRA0A131005-01

IJHA0A130002-01
Procedure after ECM Replacement
AENJHB0B1316002
Installation NOTE
Reverse removal procedure noting the following points.
When ECM and BCM are replaced with new
• Tighten ECM bracket nuts (1) to specified torque, if
ones at the same time, perform “Immobilizer
removed.
Key Registration” instead of “ECM
Tightening torque Registration” using SUZUKI scan tool and
ECM bracket nut (a): 8.8 N·m (0.90 kgf-m, 6.5 lbf- security device.
ft) Refer to Operator’s Manual of SUZUKI scan
tool for the immobilizer registration.

After ECM is replaced with new one, perform the

following procedure:
1) Perform “Immobilizer key Registration” mode of
SUZUKI scan tool.
Refer to “SUZUKI Immobilizer Control System
Operator’s Manual”.
2) Perform electric throttle control system calibration.
(Page 1C-5)
1, (a)

1, (a)
IJHA0A130003-01
1C-4 Engine Electrical Devices: K15B
Electric Throttle Body Assembly On-Vehicle
Inspection
AENJHB0B1316003
! CAUTION
If you touch the throttle valve with your finger
when the ignition is “ON” and the accelerator
pedal is depressed, your finger may be
pinched in the gap between the throttle valve
and throttle body housing when the
accelerator pedal is released.
Never touch the throttle valve with your
finger when the ignition is “ON” and the
accelerator pedal is depressed.
NOTICE
Failure to take proper precautions when
handling the electric throttle body assembly
may lead to malfunction of the electric
throttle body assembly or damage to its
components.
• Do not disassemble the electric throttle
body assembly.
• Do not drop or otherwise expose the
electric throttle body assembly to large
shock. Any electric throttle body assembly
that has received large shock should be
replaced.
• Keep the throttle body housing and/or
throttle valve free of dust, metallic particles
or other foreign materials.
• Do not apply undue forces to the throttle
valve when checking operation of the
throttle valve or performance of the TP
sensor; otherwise the plastic gears in the
throttle valve actuator will be damaged.
NOTE
After replacing or cleaning electric throttle
body assembly, calibration of throttle valve
position is required. (Page 1C-5)
Throttle Valve Visual Check
1) Set ignition “OFF”.
2) Remove air cleaner outlet hose. (Page 1D-9)
3) Check that there is no foreign material caught
between throttle valve and throttle body housing. If
foreign materials are present, remove electric throttle
body assembly and clean its inside thoroughly.
(Page 1D-12)
Throttle Valve Operation Check
1) Set ignition “OFF”.
2) Remove air cleaner outlet hose. (Page 1D-9)
3) Check throttle valve operation as follows.
If faulty condition is found, replace electric throttle
body assembly. (Page 1D-12)
a) Check that throttle valve (1) moves smoothly to
both fully closed position and fully open position
when pressed manually.
1
IFKA0P130007-01
b) Check throttle valve returns to default position
when finger pressure on throttle valve is
released at both fully closed position and fully
open position.
Throttle valve default position
“a”: A slight opening from fully closed
position (1)
1
“a”
I7V20A131002-04
Electric Throttle Body System Operation Check
1) Check that engine idle speed is specified value.
(Page 1A-165)
2) Check that engine speed increases smoothly in
response to depressing of accelerator pedal, and
engine speed decreases to specified idle speed
when accelerator pedal is released.
3) Stop engine and with ignition is “ON”.
4) Select “Target Throttle Posi” and “Throttle Position”
in “Data List” mode on SUZUKI scan tool. And check
the following points. (Page 1A-39)
• “Throttle Position” value when accelerator pedal is
released.
• “Throttle Position” value when accelerator pedal is
fully depressed.
• “Throttle Position” follows “Target Throttle Posi”
when accelerator pedal is opened fully from fully
closed position.
5) If faulty condition is found in Step 1) – 4), check the
following points.
• Wire harness and connections
• APP sensor: (Page 1C-6)
• TP sensor: (Page 1C-5)
• Throttle motor: (Page 1C-5)
 Engine Electrical Devices: K15B 1C-5

6) If check result is OK in Step 5), replace ECM. c) Check that voltage varies depending on throttle
(Page 1C-2) opening angle as shown in the following graph
while throttle valve is opened and closed
Throttle Motor Check manually.
1) Set ignition “OFF”.
[c]
2) Disconnect connector from electric throttle body 4.4 - 4.6 4.4 - 4.7
4.3 - 4.5
assembly. 4.0 - 4.2 [a]

3) Measure resistance between terminals “5” and “6” of

electric throttle body assembly. [b]
If faulty condition is found, replace electric throttle
0.8 - 1.0 0.5 - 0.7
body assembly. (Page 1D-12) 0.4 - 0.6 0.3 - 0.6
[e] [d]
Throttle motor resistance
0.3 to 100 Ω at 20 °C (68 °F) [f]
[g]
IDLA0A130003-02
6 5 4 32 1 [a]: TP sensor (main) voltage
[b]: TP sensor (sub) voltage
[c]: Voltage (V)
[d]: Throttle valve opening
[e]: Position where throttle valve is a slight opening from fully closed
position (default position)
IFKA0P130008-01 [f]: Angle obtained when accelerator pedal is depressed fully
[g]: Angle obtained when throttle valve is fully opened manually
TP Sensor Performance Check
1) Set ignition “OFF”. Electric Throttle Control System Calibration
AENJHB0B1316004
2) Disconnect connector from electric throttle body
assembly. 1) After performing any one of the following services, it
is necessary to calibrate electric throttle control
3) Check output voltage of TP sensor main and sub
system.
signals as follows.
If faulty condition is found, replace electric throttle • Replacement of ECM
body assembly. (Page 1D-12) • Clearance of DTC related to ECM
a) Arrange 3 new 1.5 V batteries (1) in series, and • Removal and installation of electric throttle body
check that total voltage is 4.5 to 5.0 V. assembly (cleaning or replacement)
b) Connect voltmeter (2) and the batteries to TP 2) Check that the following conditions are satisfied
sensor as shown in figure. when performing this calibration procedure.
• DTC is not detected in ECM.
[A]
• Vehicle is stationary.
6 5 4 32 1 • Engine is stopped.
• Engine coolant temperature between 6 °C (43 °F)
and 100 °C (212 °F).
2
• Intake air temperature is higher than 6 °C (43 °F).
• Accelerator pedal is released.
• Battery voltage is higher than 10 V.
1
3) Perform this calibration procedure as follows.
a) Clear DTC. (Page 1A-24)
[B]
NOTE
6 5 4 32 1
Perform “DTC clear” although DTC is not
detected.
2
b) Set ignition “ON” and leave it for 40 sec. or more.
c) Set ignition “OFF” and leave it for 10 sec. or
more.
1 4) Perform “ECM Learning Procedure of Engine
IFKA0P130009-01 Torque”: K15B (Page 1C-6).
[A]: TP sensor (main) [B]: TP sensor (sub)
1C-6 Engine Electrical Devices: K15B

ECM Learning Procedure of Engine Torque Without Using Suzuki Scan Tool
AENJHB0B1316005
1) Check APP sensor output voltage as follows.
1) Check that the following conditions are satisfied
If faulty condition is found, replace accelerator pedal
when performing this procedure.
assembly. (Page 1C-7)
• DTC is not detected in ECM.
a) Arrange 3 new 1.5 V batteries (1) in series, and
• Vehicle is stationary. check that total voltage is 4.5 – 5.0 V.
• Engine is stopped. b) Connect voltmeter (2) and batteries to APP
• Engine coolant temperature between 6 °C (43 °F) sensor as shown in figure.
and 100 °C (212 °F).
[A]
• Intake air temperature is higher than 6 °C (43 °F).
6 5 4 3 21
• Accelerator pedal is released.
• Battery voltage is higher than 10 V.
2) Start engine.
2
3) Warm up engine at idle speed to normal operating
temperature.

APP Sensor On-Vehicle Inspection 1

AENJHB0B1316006
Using SUZUKI Scan Tool
1) Check that accelerator pedal assembly has been [B]

mounted to vehicle body properly (no pinched floor 6 5 4 3 21

carpet, etc.).
If mounting is improper, reinstall accelerator pedal
assembly. (Page 1C-7)
2
2) Connect SUZUKI scan tool to DLC with ignition
“OFF”.
3) Display “Data List” mode.
4) Check that voltage varies depending on accelerator 1
position as shown in the following graph. IE3J0P130009-01

If faulty condition is found, check the following items. [A]: APP sensor (main) [B]: APP sensor (sub)
• Wire harness and connections
• APP sensor c) Check that voltage varies depending on
accelerator pedal stroke as shown in the
[c] following graph.
4.350 - 4.450
[c]
4.350 - 4.450
[a]

2.150 - 2.250 [a]

2.150 - 2.250
[b]
0.700 - 0.800
0.325 - 0.425 [b]
0.700 - 0.800
[d] [e]
IA1J0P130056-01
0.325 - 0.425

[a]: APP sensor (main) voltage [d] [e]

IA1J0P130056-01
[b]: APP sensor (sub) voltage
[c]: Voltage (V) [a]: APP sensor (main) voltage
[d]: Idle position of accelerator pedal [b]: APP sensor (sub) voltage
[e]: Fully depressed position of accelerator pedal [c]: Voltage (V)
[d]: Idle position of accelerator pedal
[e]: Fully depressed position of accelerator pedal
 Engine Electrical Devices: K15B 1C-7

Accelerator Pedal Assembly (Incorporating MAP Sensor Removal and Installation

AENJHB0B1316008
APP Sensor) Removal and Installation Removal
AENJHB0B1316007
1) Remove electric throttle body assembly. (Page
NOTICE
1D-12)
Failure to take proper precautions when 2) Disconnect connector of MAP sensor (1).
handling the APP sensor assembly may lead
to malfunction of the APP sensor. 3) Remove MAP sensor from intake manifold (2).
• Do not drop or otherwise expose the APP
sensor assembly to large shock. Any APP
sensor assembly that has received large
1
shock must be replaced.
• Keep the sensor section of the APP sensor
assembly away from water.

Removal 2
1) Disconnect connector from accelerator pedal
assembly (1).
2) Remove accelerator pedal assembly.

IJHA0A130005-01
Installation
Reverse removal procedure noting the following point.
Installation
• Tighten accelerator pedal assembly nuts (2) to Reverse removal procedure noting the following points.
specified torque.
• Check that O-ring is free from damage.
Tightening torque • Tighten MAP sensor bolt (1) to specified torque.
Accelerator pedal assembly nut (a): 13 N·m (1.3
kgf-m, 9.5 lbf-ft) Tightening torque
MAP sensor bolt (a): 4.0 N·m (0.41 kgf-m, 3.0 lbf-
ft)

2, (a)

1,(a)

IJHA0A130004-01

IJHA0A130006-01

• After installing electric throttle body assembly, perform

“Electric Throttle Control System Calibration”: K15B
(Page 1C-5).
1C-8 Engine Electrical Devices: K15B

MAP Sensor Inspection ECT Sensor On-Vehicle Inspection

AENJHB0B1316009 AENJHB0B1316010
NOTICE Check that ECT sensor signal is outputted properly.
If excessive negative pressure is applied, the (Page 1A-150)
MAP sensor may be damaged. If faulty condition is found, check the following points.
Do not exceed negative pressure of –70 kPa • Wire harness and connections
(–0.7 kgf/cm2, –10.2 psi, –0.7 bar). • ECT sensor: (Page 1C-9)

1) Remove MAP sensor. (Page 1C-7)

ECT Sensor Removal and Installation
2) Check MAP sensor output voltage as follows. If AENJHB0B1316011
faulty condition is found, replace MAP sensor. Removal
(Page 1C-7) 1) Drain coolant. (Page 1F-11)
a) Arrange 3 new 1.5 V batteries (1) in series, and 2) Disconnect connector from ECT sensor.
check that total voltage is 4.5 to 5.0 V. 3) Remove ECT sensor (1).
b) Connect voltmeter (2), special tool and batteries
to MAP sensor (3) as shown in figure.
Special tool
(A): 09917M47011

3
3 2 1

(A)

2 IJHA0A130007-01

Installation
Reverse removal procedure noting the following points.
• Check O-ring for damage and replace ECT sensor.
1 • Tighten ECT sensor (1) to specified torque.
IDLA0A130007-01
Tightening torque
4. Adapter included in special tool. ECT sensor (a): 12 N·m (1.2 kgf-m, 9.0 lbf-ft)

c) Check that voltage drops gradually when

negative pressure is gradually applied with
special tool.

NOTE
Environmental condition affects output
voltage largely.
The sensor voltage below is reference value
when measuring under the following
1, (a)
conditions.
• Power supply voltage: 5 V
• Ambient temperature: 20 °C (68 °F)
IJHA0A130008-01
• Atmospheric pressure: 101.3 kPa (1.01 kgf/
• Connect connector to ECT sensor.
cm2, 14.7 psi, 1.01 bar)
• Refill cooling system. (Page 1F-11)
MAP sensor reference voltage • Check cooling system for leakage. (Page 1F-10)
Atmospheric pressure: Approx. 4.1 V
Negative pressure of –30 kPa (–0.3 kgf/cm2, –
4.35 psi, –0.3 bar): Approx. 2.9 V
Negative pressure of –60 kPa (–0.6 kgf/cm2, –
8.70 psi, –0.6 bar): Approx. 1.7 V
 Engine Electrical Devices: K15B 1C-9

ECT Sensor Inspection HO2S On-Vehicle Inspection

AENJHB0B1316012 AENJHB0B1316013
HO2S Heater
NOTE
1) Disconnect HO2S-1 or HO2S-2 connector with
Do not measure resistance with terminal of ignition “OFF”.
the ECT sensor soaked in water. As for the
2) Using ohmmeter, measure heater resistance of
measurement in the soaked state, an
HO2S-1 or HO2S-2 connector (sensor side).
accurate measurement cannot be done.
If faulty condition is found, replace HO2S-1 or
Check resistance between terminal “1” and terminal “2” HO2S-2. (Page 1C-9)
varies depending on coolant temperature as shown in NOTE
the following graph.
If faulty condition is found, replace ECT sensor (1). Temperature of sensor affects resistance
(Page 1C-8) largely. Check that sensor heater is at
specified temperature.
2
HO2S-1 heater resistance
3
Between terminal “3” and “4”: 5.0 to 6.4 Ω at 20
°C (68 °F)

1
2 1
IBV10A131003-01

1. HO2S-1 connector (viewed from terminal side)

4

HO2S-2 heater resistance

IAW101130017-01
Between terminals “1” and “2”: 5.0 to 6.4 Ω at 20
2. Ohmmeter 4. Heater °C (68 °F)
3. Temperature gauge

[a]

(5.74)
I7V20A131012-01

1. HO2S-2 connector (viewed from terminal side)

HO2S Removal and Installation

2.29 - 2.62 AENJHB0B1316014

(1.16)
(0.59)
Removal
0.31 - 0.33
! CAUTION
20 40 60 80 [b]

I9P60A131005-04
Touching exhaust system components when
they are still hot may cause burns.
[a]: Resistance [b]: Temperature
Check that the exhaust system has cooled
down before removing the HO2S.

1) Disconnect connector of HO2S-1 or HO2S-2 and

release its wire harness from clamps.
2) Remove HO2S-1 (1) or HO2S-2 (2) from exhaust
manifold.
1C-10 Engine Electrical Devices: K15B

Installation CMP Sensor Inspection

Reverse removal procedure noting the following points.
• Tighten HO2S-1 or HO2S-2 to specified torque.
Tightening torque
HO2S-1 (a): 45 N·m (4.6 kgf-m, 33.5 lbf-ft)
HO2S-2 (b): 45 N·m (4.6 kgf-m, 33.5 lbf-ft)
AENJHB0B1316015
1) With ignition “OFF”, disconnect CMP sensor
connector.
2) Connect service wires (1) between CMP sensor and
CMP sensor connector as shown in figure.
3) With ignition “ON”, check that output voltage varies
depending on position of signal rotor as follows.

1
3 2 1

1, (a) [A]

[B]
2, (b)
IJHA0A130009-01

• After installation, check exhaust leakage from sensor

with engine running.

IFAE0A130018-01

[A]: Approx. 0 V
CMP sensor is facing to projection of signal rotor.
[B]: Approx. 5 V
CMP sensor is not facing to projection of signal rotor.

4) If faulty condition is found, replace CMP sensor.


CMP Sensor Removal and Installation
AENJHB0B1316016
NOTICE
Reinstallation of CMP sensor may cause oil
leakage.
Once CMP sensor is removed, replace it with
new one
Removal
1) Remove electric throttle body assembly. (Page
1D-12)
2) Disconnect connector from CMP sensor (1).
3) Remove CMP sensor from cylinder head.
IJHA0A130010-01
Installation
Reverse removal procedure noting the following points.
• Apply engine oil to O-ring of sensor.
• After installing electric throttle body assembly, perform
“Electric Throttle Control System Calibration”: K15B
(Page 1C-5).
• Start engine and check CMP sensor for oil leakage.
If oil leakage is found, replace CMP sensor.
Engine Electrical Devices: K15B 1C-11
CKP Sensor Removal and Installation
AENJHB0B1316017
NOTICE
The CKP sensor bolt is pre-coated with
adhesive. If the bolt is reused, it may work
loose.
Replace the CKP sensor bolt with a new one.
Removal
1) Remove ISG. (Page 1J-7)
2) Disconnect connector from CKP sensor.
3) Remove CKP sensor (1) from cylinder block.
IJHA0A130012-01
Installation
Reverse removal procedure noting the following points.
• Apply engine oil to O-ring of sensor.
• Start engine and check CKP sensor for oil leakage.
If oil leakage is found, replace CKP sensor.
CKP Sensor Inspection
AENJHB0B1316018
1) Remove CKP sensor. (Page 1C-11)
2) Check the following points.
• O-ring (1) is free from damage.
• End face of sensor and sensor plate teeth are free
from any metal particles and damage.
I7N301132020-01
1C-12 Engine Electrical Devices: K15B

3) Check CKP sensor as follows. Knock Sensor On-Vehicle Inspection

If faulty condition is found, replace CKP sensor. AENJHB0B1316019

(Page 1C-11) 1) Disconnect connector from knock sensor.

a) Connect battery (1) and ohmmeter (3) to CKP 2) Connect oscilloscope (1) to knock sensor connector
sensor as shown in figure. (2) as shown in figure.
b) Check that CKP sensor resistance varies as 3) Check that oscilloscope displays waveform like a
specified below by passing ferromagnetic one shown below when cylinder block is given a
material (iron) (2). shock by plastic hammer.
If faulty condition is found, replace knock sensor.
NOTE (Page 1C-12)
Keep approximately 1 mm (0.03 in) gap “a”
between ferromagnetic material (iron) and
2 1
end face of CKP sensor.
2
CKP sensor resistance
Resistance alternates between 220 Ω or
smaller (ON) and infinity (OFF)
1
IFRA0B132015-01
“a”
3 2 1

2
1

IBV10A131008-01

I9P60A131019-02

Knock Sensor Removal and Installation

AENJHB0B1316020

Removal
1) Remove intake manifold. (Page 1D-13)
2) Remove knock sensor (1) from cylinder block.

IJHA0A130015-01
 Engine Electrical Devices: K15B 1C-13

Installation IAT Sensor Removal and Installation

Reverse removal procedure noting the following point. AENJHB0B1316023

• Install knock sensor as shown in figure, and tighten NOTICE

knock sensor bolt (1) to specified torque. The IAT sensor is a precision component and
Tightening torque can be easily damaged.
Knock sensor bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf- Handle the IAT sensor carefully and do not
ft) expose it to large shock.

Removal
1) Disconnect IAT sensor connector.
1, (a)
2) Remove IAT sensor (1) from air cleaner outlet hose
(2).

“a”

IJHA0A130011-01

“a”: 0 – 20°

IJHA0A130013-01
Engine and Emission Control System Relay
Inspection Installation
AENJHB0B1316021 Reverse removal procedure noting the following point.
Refer to “Control Relay Inspection” in Section 10B (Page
• Install IAT sensor (1) as shown in figure.
10B-61).

IAT Sensor On-Vehicle Inspection

AENJHB0B1316022
Check that IAT sensor signal is outputted properly.
(Page 1A-150) 1
If faulty condition is found, check the following points.
• Wire harness and connections
• IAT sensor: (Page 1C-14)

“a”

IJHA0A130014-01

“a”: 90°
1C-14 Engine Electrical Devices: K15B

IAT Sensor Inspection OCV Inspection

AENJHB0B1316024 AENJHB0B1316025
1) Remove IAT sensor. (Page 1C-13) 1) Remove OCV. (Page 1D-36)
2) Check that resistance between sensor terminals 2) Check OCV as follows.
varies depending on temperature while blowing hot • Check resistance between terminals of OCV
air to temperature sensing part (1) of IAT sensor (2) connector (1).
using hot air drier (3). If measured resistance is out of specified range,
If faulty condition is found, replace IAT sensor. replace OCV. (Page 1D-36)
(Page 1C-13)
OCV resistance
2 6.7 to 7.7 Ω at 20 °C (68 °F)

2 1

1
3

IBV10A131012-01

[a] 1

I9T401132006-02

• Connect battery to OCV connector (1) as shown in

figure, and check operating sound caused by
movement of spool valve (2).
If check result is not as specified, replace OCV.
2.21 - 2.69
(Page 1D-36)

(0.322)
0 20 40 60 80 [b]

IBV10A131013-01

[a]: Resistance 4. Temperature gauge

[b]: Temperature

I9T401132007-02
 Engine Electrical Devices: K15B 1C-15

Electric Load Current Sensor On-Vehicle Without using SUZUKI scan tool
Inspection 1) When ignition is “OFF”, disconnect electric load
AENJHB0B1316026
current sensor connector.
Battery Current
Using SUZUKI scan tool 2) Using service wire (1), connect electric load current
sensor (2) and electric load current sensor connector
1) When ignition is “OFF”, connect SUZUKI scan tool to
(3).
DLC.
3) With ignition “ON”, check that voltage varies
Special tool depending on electric load. Refer to “Inspection of
: SUZUKI scan tool (Suzuki SDT-II) ECM and Its Circuits”: K15B in Section 1A (Page 1A-
2) Check that battery current value displayed on 150).
SUZUKI scan tool changes to values indicated
2
below as electric load increases.
3
1
Battery current (Reference)
Ignition “ON”: 2 to 8 A
Ignition “ON”, headlight ON: 14 to 24 A
Ignition “ON”, headlight ON and blower speed
selector in MAX position: 22 to 35 A
If check result is not as specified, check the following
points.
• Electric load current sensor circuits (power,
ground and output)
I9P60A131022-01
• Battery negative (–) cable
If check result is not as specified, check the following
• The following charging system components
parts and circuit.
– Battery: (Page 1J-2)
• Battery negative (–) cable
– ISG: (Page 1J-3)
• The following charging system components
– ISG output circuit
– Battery: (Page 1J-2)
– ISG CAN communication circuit
– ISG: (Page 1J-3)
If electric load current sensor circuits and charging
system are in good condition, replace electric load – ISG output circuit
current sensor (1). – ISG CAN communication circuit
If electric load current sensor circuit and charging
system are in good condition, replace electric load
1
current sensor.

Temperature
1) When ignition is “OFF”, disconnect electric load
current sensor connector.
2) Connect ohmmeter to electric load current sensor (1)
as shown in figure.

IJHA0A130016-01

2 1
4 3

IJHA0A130017-01
1C-16 Engine Electrical Devices: K15B

3) Check that resistance varies depending on battery Installation

temperature as shown in graph below. Reverse removal procedure noting the following point.
If check result is not as specified, replace electric • Tighten electric load current sensor nut (1) to
load current sensor. specified torque.
[a] Tightening torque
Electric load current sensor nut (a): 14 N·m (1.4
kgf-m, 10.5 lbf-ft)

(0.25)
0 20 40 60 80 90 [b]
68 104 140 176 194
IFRA0A131025-01
1, (a)
[a]: Resistance [b]: Temperature

IJHA0A130019-01
Electric Load Current Sensor Removal and
Installation Brake Stroke Sensor On-Vehicle Inspection
AENJHB0B1316027 AENJHB0B1316028
Removal Refer to “Brake Stroke Sensor On-Vehicle Inspection”:
1) Disconnect negative (–) cable at battery. K15B Model in Section 11A (Page 11A-36).
2) Disconnect connector from electric load current
sensor. Brake Stroke Sensor Removal and Installation
AENJHB0B1316029
3) Remove electric load current sensor (1). Refer to “Brake Stroke Sensor Removal and
Installation”: K15B Model in Section 11A (Page 11A-37).

Brake Stroke Sensor Inspection and

Adjustment
AENJHB0B1316030
Refer to “Brake Stroke Sensor Inspection and
Adjustment”: K15B Model in Section 11A (Page 11A-38).
1

Brake Stroke Sensor Zero Point Reset

AENJHB0B1316031
Refer to “Brake Stroke Sensor Zero Point Reset”: K15B
Model in Section 11A (Page 11A-39).

IJHA0A130018-01
 Engine Electrical Devices: K15B 1C-17

Specifications
Tightening Torque Specifications
AENJHB0B1317001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
ECM bracket nut 8.8 0.90 6.5 (Page 1C-3)
Accelerator pedal assembly nut 13 1.3 9.5 (Page 1C-7)
MAP sensor bolt 4.0 0.41 3.0 (Page 1C-7)
ECT sensor 12 1.2 9.0 (Page 1C-8)
HO2S-1 45 4.6 33.5 (Page 1C-10)
HO2S-2 45 4.6 33.5 (Page 1C-10)
Knock sensor bolt 23 2.3 17.0 (Page 1C-13)
Electric load current sensor nut 14 1.4 10.5 (Page 1C-16)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Special Tool
AENJHB0B1318001
09917M47011 SUZUKI scan tool (Suzuki
SDT-II)
Vacuum pump gauge —
(Page 1C-8) (Page 1C-15)
1C-18 Engine Electrical Devices: D13A

D13A
General Description
Description of ECM Registration
AENJHB0B1321001
The following vehicle information are registered in ECM.
• Injector calibration code
• Vehicle variant data (including CAN vehicle configuration data)
• Flywheel data
• A/F sensor data
• MAF sensor data
• Rail pressure sensor data
• Immobilizer ID code
• Brake stroke sensor zero point
If any one of the following parts is replaced, register / initialize the necessary information in ECM as table below.
Part Registered / initialized data Reference
• Injector calibration code
• Vehicle variant data (including
CAN vehicle configuration data)
• Flywheel data Go to “Registration for ECM
ECM
• A/F sensor data Replacement”: D13A (Page 1C-21).
• MAF sensor data
• Rail pressure sensor data
• Immobilizer ID code
Go to “Injector Calibration Code
Fuel injector(s) Injector calibration code
Registration”: D13A (Page 1C-22).
Go to “Flywheel Data Initialization”: D13A
Flywheel Flywheel data
(Page 1C-22).
Go to “A/F Sensor Data Initialization”:
A/F sensor A/F sensor data
D13A (Page 1C-22).
Go to “MAF Sensor Data Initialization”:
MAF sensor MAF sensor data
D13A (Page 1C-22).
• Common rail Go to “Rail Pressure Sensor
Rail pressure sensor data
• Rail pressure sensor Initialization”: D13A (Page 1C-22).
Go to “ECM Registration”.
• Ignition switch model: (Page 10C-
BCM Immobilizer ID code 16)
• Keyless push start model: (Page
10C-30)
Go to “Brake Stroke Sensor Zero Point
Brake stroke sensor Brake stroke sensor zero point
Reset”: D13A (Page 1C-25).

Engine Electrical Devices Description
AENJHB0B1321003
Various sensors for the engine control in this model are
outlined as follows.
APP Sensor (Main / Sub)
• The sensor is mounted on accelerator pedal.
• A noncontact type sensor applying electromagnetic
induction detects depressing degree of accelerator
pedal.
• Dual voltage signals, main and sub, are inputted to
ECM. Based on the signals, ECM controls fuel
injection timing.
MAF Sensor with IAT Sensor-1
• The sensor is located between air cleaner case and
air cleaner outlet hose.
• A hot film type MAF sensor is adopted. Intake air
passing through electrically heated film (platinum
wire) cools the film and the cooling ratio is detected as
current value and then calculated to intake air volume.
Further, IAT sensor-1 compensates intake air volume.

Boost Pressure Sensor with IAT Sensor-2
• The sensor is unified with IAT sensor-2 and installed
on intake manifold.
• A pressure responsive silicon membrane incorporated
in diaphragm generates voltage signal corresponding
to intake pressure (absolute pressure) and the signal
is inputted to ECM. Based on the signal, ECM
calculates manifold absolute pressure.
ECT Sensor
• The sensor is mounted on thermostat case.
• A thermistor incorporated in the sensor changes
electrical resistance corresponding to temperature
and the resistance converted to voltage is inputted to
ECM. Based on the voltage signal, ECM calculates
coolant temperature.
CMP Sensor
• The sensor is mounted on camshaft housing.
• Magnetic variation generated by rotation of exhaust
camshaft projection (signal rotor) is converted to
voltage signal and imputed to ECM.
CKP Sensor
• The sensor is mounted on cylinder block near the
flywheel at exhaust manifold side.
• Magnetic variation generated by rotation of angle gear
positioned flywheel front side is converted to voltage
signal and imputed to ECM. Based on this voltage
signal, ECM calculates engine speed and crank
position.
Brake Stroke Sensor
A noncontact type sensor incorporating Hall IC is
mounted on brake pedal. Voltage signal corresponding
to depressing degree of brake pedal is outputted to
ECM. Based on the signal, ECM detects operating
conditions of brake pedal.
Barometric Pressure Sensor
The sensor is incorporated in ECM and detects
atmospheric pressure.
A/F Sensor
• The sensor is installed at inlet portion of catalytic
converter.
• The sensor is equipped with a zirconia element which
detects oxygen concentration in exhaust gas linearly
from lean to rich. And, incorporated heater in the
sensor is duty controlled by ECM.
Fuel Pressure Sensor
• The sensor is mounted on common rail.
• Fuel pressure in the common rail is converted to
voltage signal and inputted to ECM. Based on this
signal, ECM controls fuel pressure to bring it near to
the target fuel pressure.
Engine Electrical Devices: D13A 1C-19
A/C Refrigerant Pressure Sensor
• The sensor is mounted on high pressure piping in A/C
system.
• A pressure transductor (semiconductor chip) is
incorporated in the sensor and variation of refrigerant
pressure is converted to voltage signal and then the
signal is inputted to ECM. Using the signal, ECM
calculates refrigerant pressure.
Water Detection Sensor with Fuel Temperature
Sensor
• The sensor is mounted on top of the fuel filter located
in engine compartment.
• The sensor is equipped with a thermistor which
generates voltage signal according to the fuel
temperature and this voltage signal is inputted to
ECM. Based on this signal, ECM controls fuel
injection volume.
• The water detection sensor detects accumulation of
water in the fuel filter.
Battery Sensor
• The sensor is installed on negative (–) terminal of
battery cable.
• Variation of battery current which changes according
to electrical loading is converted to voltage signal and
inputted to ECM. Based on this signal, ECM controls
generator.
ECM
• Based on signal from each sensor and corresponding
to vehicle running conditions, ECM controls actuators
optimally. Refer to “Electronic Control System
Description”: D13A in Section 1A (Page 1A-168).
• ECM is equipped with self-diagnosis function and,
when malfunction is detected, it makes MIL turn on to
warn the driver of the trouble.
Glow Plug Control Module
• The module is mounted on front under frame left side
near the front bumper behind the fender liner.
• Based on signal from ECM, the module controls
operating time of glow plugs.
Glow Plug
Glow plug is installed in each cylinder and heat
combustion chamber controlled by glow plug control
module.
Oil Pressure Switch
The switch monitors pressure of engine oil for
lubrication.
1C-20 Engine Electrical Devices: D13A

Component Location
Electronic Control System Component Location
AENJHB0B1323001
Refer to “Electronic Control System Component Location”: D13A in Section 1A (Page 1A-175).

Repair Instructions
ECM Removal and Installation 7) Remove ECM with ECM box (1).
AENJHB0B1326001
NOTICE
1
The ECM is a precision unit and can be easily
damaged.
Handle the ECM carefully and do not expose
it to large shock.

Removal
1) When replacing ECM with new one, perform “Vehicle
Information Upload” under “Registration for ECM
Replacement”: D13A (Page 1C-21).
2) Disconnect negative (–) cable at battery.
3) Disconnect connectors from ECM as follows.
IJHB0A133003-01
a) Pull out lock slider (1) to release locking of lock
lever. 8) Remove ECM (1) with ECM brackets (2) from ECM
box (3).
b) Pull up the lock lever (2).
9) Remove ECM brackets from ECM.
2
1

1
I9P60A132001-02

4) Remove cowl top garnish. (Page 9H-13) 2

5) Detach harness clamps (1) from cowl upper panel.
6) Turn over cowl front silencer after removing clips (2).
IJHB0A133004-01

IJHB0A133002-01
 Engine Electrical Devices: D13A 1C-21

Installation Vehicle Information Download

Reverse removal procedure noting the following points. 1) When ignition is “OFF”, connect SUZUKI scan tool to
• Tighten ECM box bolts and nuts in numerical order DLC.
(“1” – “6”) and tighten ECM box nuts to specified
Special tool
torque.
: SUZUKI scan tool (Suzuki SDT-II)
Tightening torque
2) Set ignition “ON”.
ECM box nut* (a): 8.8 N·m (0.90 kgf-m, 6.5 lbf-ft)
3) Select “ECM Replacement” under “Utility” mode of
SUZUKI scan tool.
4) Select “Replace ECM with upload”.
(a), “5” 5) Select “Download Inj Code to ECU” according to
instructions displayed on SUZUKI scan tool.
(a), “6” 6) Register vehicle variant data (including CAN vehicle
configuration data). (Page 1C-22)
“4”
7) Register immobilizer ID code.
• Ignition switch model: (Page 10C-16)
“2”
• Keyless push start model: (Page 10C-30)
“3” 8) Set ignition “OFF” and wait for 30 sec. or more.
“1”

IJHB0A133005-01 Vehicle Information Manual Input

• When replacing ECM with new one, register vehicle
NOTE
information in ECM.
– Vehicle information upload is completed: Use the “Vehicle Information Manual Input”
“Vehicle Information Download” under “Registration procedure only when the “Replace ECM with
for ECM Replacement”: D13A (Page 1C-21). Upload” procedure cannot be completed
normally.
– Vehicle information upload is not completed:
“Vehicle Information Manual Input” under 1) When ignition is “OFF”, connect SUZUKI scan tool to
“Registration for ECM Replacement”: D13A (Page DLC.
1C-21).
Special tool
: SUZUKI scan tool (Suzuki SDT-II)
Registration for ECM Replacement
AENJHB0B1326002
2) Set ignition “ON”.
NOTE
3) Select “ECM Replacement” under “Utility” mode of
• For details of SUZUKI scan tool, refer to its SUZUKI scan tool.
Operator’s Manual. 4) Select “Replace ECM with direct input” according to
• If the vehicle information cannot be instructions displayed on SUZUKI scan tool.
uploaded from the replaced ECM using 5) Register vehicle variant data (including CAN vehicle
SUZUKI scan tool, refer to “Precautions for configuration data). (Page 1C-22)
Replacing ECM” under “Precautions for
Engine (D13A)” in Section 1 (Page 1-2). 6) Register immobilizer ID code.
• Ignition switch model: (Page 10C-16)
Vehicle Information Upload • Keyless push start model: (Page 10C-30)
1) When ignition is “OFF”, connect SUZUKI scan tool to 7) Set ignition “OFF” and wait for 30 sec. or more.
DLC.
8) Clear DTC. (Page 1A-181)
Special tool
: SUZUKI scan tool (Suzuki SDT-II)
2) Set ignition “ON”.
3) Select “ECM Replacement” under “Utility” mode of
SUZUKI scan tool.
4) Select “Replace ECM with upload”.
5) Select “Upload Inj Code from ECU” according to
instructions displayed on SUZUKI scan tool.
1C-22 Engine Electrical Devices: D13A
Vehicle Variant Data (Including CAN Vehicle
Configuration Data) Registration
AENJHB0B1326003
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
Special tool
: SUZUKI scan tool (Suzuki SDT-II)
2) Set ignition “ON”.
3) Select “Vehicle variant registration” in “Utility” menu.
4) Select “Registration” and follow instructions
displayed on SUZUKI scan tool.
Injector Calibration Code Registration
AENJHB0B1326004
After replacing one or more fuel injector(s) with new one,
perform the following procedure.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
Special tool
: SUZUKI scan tool (Suzuki SDT-II)
2) Record injector calibration codes stamped on top of
fuel injector. (Page 1G-47)
3) Select “Injector calibration code” in “Utility” menu.
4) Select “Registration” and input injector calibration
codes manually according to instructions displayed
on SUZUKI scan tool.
5) Check that injector calibration codes have been
correctly input in ECM.
6) When ignition is “OFF”, disconnect SUZUKI scan
tool from DLC.
Flywheel Data Initialization
AENJHB0B1326005
After replacing flywheel with new one, perform the
following procedure.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
Special tool
: SUZUKI scan tool (Suzuki SDT-II)
2) Execute “Initialize Flywheel Data” in “Utility” mode
according to instructions displayed on SUZUKI scan
tool.
3) When ignition is “OFF”, disconnect SUZUKI scan
tool from DLC.
A/F Sensor Data Initialization
AENJHB0B1326006
After replacing A/F sensor with new one, perform the
following procedure.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
Special tool
: SUZUKI scan tool (Suzuki SDT-II)
2) Execute “Initialize A/F Sensor Data” in “Utility” mode
according to instructions displayed on SUZUKI scan
tool.
3) When ignition is “OFF”, disconnect SUZUKI scan
tool from DLC.
MAF Sensor Data Initialization
AENJHB0B1326007
After replacing MAF sensor with IAT sensor-1 with new
one, perform the following procedure.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
Special tool
: SUZUKI scan tool (Suzuki SDT-II)
2) Execute “Initialize MAF Sensor Data” in “Utility”
mode according to instructions displayed on SUZUKI
scan tool.
3) When ignition is “OFF”, disconnect SUZUKI scan
tool from DLC.
Rail Pressure Sensor Initialization
AENJHB0B1326008
After replacing rail pressure sensor with new one,
perform the following procedure.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
Special tool
: SUZUKI scan tool (Suzuki SDT-II)
2) Execute “Initialize rail pressure sensor Data” in
“Utility” mode according to instructions displayed on
SUZUKI scan tool.
3) When ignition is “OFF”, disconnect SUZUKI scan
tool from DLC.
 Engine Electrical Devices: D13A 1C-23

MAF Sensor with IAT Sensor-1 Removal and Installation

Installation
AENJHB0B1326009
NOTICE
Failure to take proper precautions when
handling the MAF sensor with IAT sensor-1
may lead to malfunction of the sensor.
• Do not disassemble the sensor.
• Do not drop or expose the sensors to
shock. Any MAF sensor with IAT sensor-1
that has been dropped must be replaced.
• Do not clean the sensor.
• Do not direct compressed air from an air
blow gun or the like to the sensor.
• Do not put a finger or any other object into
the sensor.
NOTE
If MAF sensor with IAT sensor-1 is replaced,
initialize MAF data in ECM.
For details, refer to “Description of ECM
Registration”: D13A (Page 1C-18).
Removal
1) Disconnect connector from MAF sensor with IAT
sensor-1.
2) Disconnect air cleaner outlet hose No.1 (1) from
MAF sensor with IAT sensor-1 (2).
3) Disconnect connector from MAF sensor with IAT
Reverse removal procedure noting the following points.
• Check O-ring for damage and replace it if defective.
• Tighten MAF sensor with IAT sensor-1 bolts and air
cleaner outlet hose No.1 clamp to specified torque.
(Page 1D-81)
• When replacing MAF sensor, initialize MAF sensor
data in ECM. (Page 1C-22)
MAF Sensor with IAT Sensor-1 Inspection
AENJHB0B1326010
NOTICE
The MAF sensor with IAT sensor-1 will be
damaged if exposed to a temperature higher
than 100 °C (212 °F).
Do not heat the MAF sensor with IAT sensor-
1 to a temperature higher than 100 °C (212
°F).
MAF Sensor
1) Arrange 3 new 1.5 V batteries (2) in series, and
check that total voltage is 4.5 to 5.0 V.
2) Connect 12 V battery (1), 1.5 V batteries, 1.2 kΩ
resistance (3) and oscilloscope (4) to MAF sensor
with IAT sensor-1 (5) as shown in figure.
3
2

sensor-1 as follows.
a) Move connector lock pin (3) in arrow direction as 4
shown in figure.
b) Push connector lock lever (4) and disconnect 5
connector from MAF sensor with IAT sensor-1.
1
4) Remove MAF sensor with IAT sensor-1 from air
cleaner case (5). IDAA0A132025-01

3) Check that signal waveform changes depending on

3 amount of blowing air as shown in figures. If faulty
4
condition is found, replace MAF sensor with IAT
5 sensor-1. (Page 1C-23)
Blowing air: Small
2

IJHB0A133006-01

I9P60A132010-02
1C-24 Engine Electrical Devices: D13A

Blowing air: Large Glow Plug Removal and Installation

AENJHB0B1326011
Removal
1) Remove air cleaner outlet hose No.1, if necessary.
2) Pull off glow plug wires.
3) Loosen glow plugs using special tool.
4) Remove glow plugs from cylinder head by hand.
Special tool
(A): 09911M78610

(A)
I9P60A132011-01

IAT Sensor-1
Measure resistance between sensor terminals (1) and
(2) while blowing hot air against temperature sensing
part of MAF sensor with IAT sensor-1 (3) using hot air
drier (4). If check result is not as specified, replace MAF
sensor with IAT sensor-1.
IAT sensor-1 resistance
IJHB0A133007-01
20 °C (68 °F): 2 to 3 kΩ
60 °C (140 °F): 0.5 to 0.7 kΩ
Installation
Reverse removal procedure noting the following point.
• Tighten glow plug to specified torque.
4
5 Special tool
1 2 (A): 09911M78610
Tightening torque
Glow plug (a): 8.0 N·m (0.82 kgf-m, 6.0 lbf-ft)

3 (a)

IDAA0A132026-01

5. Thermometer

(A)

IJHB0A133021-01

• Tighten air cleaner outlet hose No.1 clamps to

specified torque. (Page 1D-81)
 Engine Electrical Devices: D13A 1C-25

Glow Plug Inspection ECT Sensor Removal and Installation

AENJHB0B1326012 AENJHB0B1326019
Measure glow plug resistance as shown below. Removal
If resistance is not as specified, replace glow plug. 1) Remove battery and battery tray from vehicle.
Glow plug resistance 2) Drain coolant. (Page 1F-25)
Approx. 0.9 Ω at 20 °C (68 °F) 3) Remove degassing tank. (Page 1F-23)
4) Pull up connector lock lever (1) and disconnect
connector from ECT sensor (2).

I5RW0D130003-01
2
1

APP Sensor Assembly On-Vehicle Inspection

AENJHB0B1326013
2
Refer to “APP Sensor On-Vehicle Inspection”: K15B
(Page 1C-6).

Accelerator Pedal Assembly (Incorporating IJHB0A133019-01

APP Sensor) Removal and Installation 5) Remove clip (1) and then remove ECT sensor (2)
AENJHB0B1326014
Refer to “Accelerator Pedal Assembly (Incorporating from thermostat case.
APP Sensor) Removal and Installation”: K15B (Page
1C-7).

Brake Stroke Sensor On-Vehicle Inspection

AENJHB0B1326015
Refer to “Brake Stroke Sensor On-Vehicle Inspection”:
D13A Model in Section 11A (Page 11A-78).
2
Brake Stroke Sensor Removal and Installation
AENJHB0B1326016
1
Refer to “Brake Stroke Sensor Removal and
Installation”: D13A Model in Section 11A (Page 11A-78).
IFRA0A132018-01

Brake Stroke Sensor Inspection

AENJHB0B1326017
Refer to “Brake Stroke Sensor Inspection”: D13A Model
in Section 11A (Page 11A-78).

Brake Stroke Sensor Zero Point Reset

AENJHB0B1326018
Refer to “Brake Stroke Sensor Zero Point Reset”: D13A
Model in Section 11A (Page 11A-78).
1C-26 Engine Electrical Devices: D13A

Installation CMP Sensor Removal and Installation

Reverse removal procedure noting the following points.
Removal
• Use new O-ring (1) and clip (2).
NOTE
Clip (2) can be inserted from either top or
bottom. However, it is necessary to align
straight side of groove [c] on ECT sensor
with strait side [b] of clip.
[a]
AENJHB0B1326021
1) Remove air cleaner assembly. (Page 1D-82)
2) Disconnect connector from CMP sensor as follows:
a) Move connector lock pin (1) in arrow direction as
shown in figure.
b) Push connector lock lever (2) and disconnect
connector from CMP sensor (3).
3) Remove CMP sensor from camshaft housing (4).

[a] [b]
3
2
4
[c]

2
1
1

IJHB0B132001-01

• After installation, check that clip does not come off the IJHB0A133009-01

ECT sensor and thermostat case.

Installation
• Refill cooling system with coolant. (Page 1F-25)
Reverse removal procedure noting the following points.
• Check cooling system for leakage. (Page 1F-24)
• Check O-ring (1) for deterioration and damage. If
check result is not OK, replace CMP sensor.
ECT Sensor Inspection
AENJHB0B1326020 • Tighten CMP sensor bolt to specified torque.
Immerse temperature sensing part of ECT sensor in
Tightening torque
water and measure resistance between sensor terminals
CMP sensor bolt (a): 8.0 N·m (0.82 kgf-m, 6.0 lbf-
while heating water gradually.
ft)
If measured resistance is not as specified, replace ECT
sensor.
Reference resistance of ECT sensor
Temperature Resistance
10 °C (50 °F) Approx. 3.8 kΩ
1
20 °C (68 °F) Approx. 2.5 kΩ (a)

30 °C (86 °F) Approx. 1.7 kΩ

40 °C (104 °F) Approx. 1.1 kΩ
60 °C (140 °F) Approx. 0.6 kΩ
80 °C (176 °F) Approx. 0.3 kΩ

IJHB0A133010-01

• Tighten engine cover bolts to specified torque.

(Page 1D-83)

I6RS0E130003-01
 Engine Electrical Devices: D13A 1C-27

CMP Sensor Inspection CKP Sensor Removal and Installation

AENJHB0B1326022
1) Check CMP sensor power supply circuit, signal
circuit and ground circuit according to Step 2 – 5 of
“DTC P0340”: D13A in Section 1A (Page 1A-256).
2) Set ignition “OFF” and connect ECM connector to
ECM.
3) Connect service wires (1) between CMP sensor (2)
and CMP sensor connector (3).
4) Set ignition “ON”.
5) Check that CMP sensor signal voltage is as
specified below for both cases when iron (4) is
brought in front of and away from CMP sensor.
If voltage is not as specified, replace CMP sensor.
AENJHB0B1326023
Removal
1) Disconnect connector from CKP sensor as follows.
a) Move connector lock pin (1) in arrow direction as
shown in figure.
b) Push connector lock lever (2) and disconnect
connector from CKP sensor (3).
2) Remove CKP sensor from cylinder block.

NOTE
3
Keep approximately 1 mm (0.03 in.) gap “a”
between magnetic substance (iron) and end
1
face of CMP sensor. 2

CMP sensor signal voltage

When iron is brought in front of CMP sensor: 0 to
0.5 V IJHB0A133011-01
When iron is brought away from CMP sensor:
Approx. 5.0 V Installation
Reverse removal procedure noting the following points.
• Clean CKP sensor and sensor rotor teeth before
installation.
3
2 • Tighten CKP sensor bolt to specified torque.
Tightening torque
CKP sensor bolt (a): 8.0 N·m (0.82 kgf-m, 6.0 lbf-
ft)

4
1
“a”
(a)
I9P60A132023-03

IJHB0A133012-01
1C-28 Engine Electrical Devices: D13A

CKP Sensor Inspection 3) Disconnect connector from boost pressure sensor

AENJHB0B1326024
1) Check that CKP sensor and sensor rotor teeth are
free from any metal particles and damage.
2) Check that resistance between terminals of CKP
sensor is within specified range.
If resistance is not as specified, replace CKP sensor.
CKP sensor resistance
632 to 948 Ω at 20 °C (68 °F)
with IAT sensor-2 (1) as follows.
a) Move connector lock pin (2) in arrow direction as
shown in figure.
b) Push connector lock lever (3) and disconnect
connector from boost pressure sensor with IAT
sensor-2.
4) More harness bracket (4) by removing harness
bracket bolts (5).
5) Remove boost pressure sensor with IAT sensor-2
from intake manifold.

5 3

I5RW0D130011-01

Boost Pressure Sensor with IAT Sensor-2

Removal and Installation
AENJHB0B1326025 5
Removal 4
1) Remove air cleaner assembly. (Page 1D-82) 1

2) Disconnect engine harness clamp (1) from harness

bracket (2).
IJHB0A133013-01

1 Installation
Reverse removal procedure noting the following points.
• Check O-ring (2) of boost pressure sensor with IAT
sensor-2 (1) for deformation or damage.
If defect is found, replace boost pressure sensor with
IAT sensor-2.
• Tighten boost pressure sensor with IAT sensor-2
2
screw to specified torque.
Tightening torque
Boost pressure sensor with IAT sensor-2 screw
IJHB0A133020-01
(a): 2.0 N·m (0.20 kgf-m, 1.5 lbf-ft)

1
1
2

(a)

IJHB0A133014-01
 Engine Electrical Devices: D13A 1C-29

Boost Pressure Sensor with IAT Sensor-2 f) Check that voltage varies gradually when
Inspection pressure is gradually applied with special tool.
AENJHB0B1326026
Boost pressure sensor output voltage
Boost Pressure Sensor Atmospheric pressure: Approx. 1.6 V
Vacuum –30 kPa (–0.3 kgf/cm2, –4.35 psi, –0.3
NOTICE bar): Approx. 1.2 V
Failure to take proper precautions when Positive pressure 30 kPa (0.3 kgf/cm2, 4.35
checking the boost pressure sensor with IAT psi, 0.3 bar): Approx. 2.1 V
sensor-2 will damage the sensor.
Take the following precautions to reduce the 2
risk of the damage to the sensor.
• Do not heat the boost pressure sensor
with IAT sensor-2 to a temperature higher
than 100 °C (212 °F).
• Do not apply vacuum more than –60 kPa (– (A)
0.6 kgf/cm2, –8.7 psi, –0.6 bar) to boost
pressure sensor with IAT sensor-2. 1
• Do not apply pressure more than 100 kPa
(1.0 kgf/cm2, 14.5 psi, 1.0 bar) to boost
pressure sensor with IAT sensor-2.

1) Check boost pressure sensor output voltage as (B)

follows. If check result is not as specified, replace
boost pressure sensor with IAT sensor-2. 3

NOTE
Environmental condition affects output
I9P60A132028-03
voltage largely.
The sensor voltage below is reference value 3. Compressed air
when measuring under the following
condition. IAT Sensor-2
• Atmospheric pressure: 101.3 kPa (1.01 kgf/ Measure resistance between sensor terminals while
cm2, 14.7 psi, 1.01 bar) blowing hot air against temperature sensing part of boost
pressure sensor with IAT sensor-2 (1) using hot air drier
a) Arrange 3 new 1.5 V batteries (1) in series, and (2). If faulty condition is found, replace boost pressure
check that total voltage is 4.5 to 5.0 V. sensor with IAT sensor-2.
b) Connect voltmeter (2), special tool, hose and IAT sensor-2 resistance
batteries to boost pressure sensor with IAT 20 °C (68 °F): 2.40 to 2.61 kΩ
sensor-2 as shown in figure. 60 °C (140 °F): 0.59 to 0.63 kΩ
Special tool
(A): 09917M47011
c) Check that voltage varies gradually when
vacuum is gradually applied with special tool.
d) Disconnect special tool. 3 2

e) Connect special tool and hose to boost pressure

1
sensor with IAT sensor-2 as shown in figure.
Special tool
(B): 09918M18111
I9P60A132029-02

3. Temperature gouge
1C-30 Engine Electrical Devices: D13A

Fuel Pump Relay, Starting Motor Control Relay Installation

and Main Relay Inspection Reverse removal procedure noting the following points.
AENJHB0B1326027
• Tighten glow plug control module nut to specified
Refer to “Control Relay Inspection” in Section 10B (Page
torque.
10B-61).
Tightening torque
Glow Plug Control Module Removal and Glow plug control module nut (a): 7.0 N·m (0.71
Installation kgf-m, 5.5 lbf-ft)
AENJHB0B1326028
Removal
1) Disconnect negative (–) cable at battery. (a)

2) Remove left side front fender lining. (Page 9J-3)

3) Disconnect connectors (1) from glow plug control
module.
4) Disconnect glow control wire (2) from glow plug
control module.
5) Remove glow plug control module (3).
6) Remove glow plug control module bracket (4), if
necessary.
7) Remove clamps (5) from glow plug control module
bracket, if necessary. IJHB0A133016-01

• Connect glow control wire as follows and tighten glow

control wire nut to specified torque.
4
Tightening torque
5
Glow control wire nut (a): 6.3 N·m (0.64 kgf-m, 5.0
lbf-ft)
3

2
[a]

[a]

(a)

IJHB0A133015-01 IJHB0A133017-01
 Engine Electrical Devices: D13A 1C-31

Boost Pressure Control Solenoid Valve Installation

Removal and Installation Reverse removal procedure.
AENJHB0B1326029
Removal
Boost Pressure Control Solenoid Valve
1) Disconnect vacuum hoses (1) from boost pressure Inspection
control solenoid valve (2). AENJHB0B1326030
2) Disconnect connector (3) from boost pressure Check resistance between two terminals of boost
control solenoid valve. pressure control solenoid valve. If resistance is not as
specified, replace boost pressure control solenoid valve.
3) Remove boost pressure control solenoid valve from
bracket (4). Resistance of boost pressure control solenoid valve
4) Remove boost control solenoid valve bracket, if : 14.8 to 16.2 Ω at 20 °C (68 °F)
necessary.

3
I7V20A132016-01
1

IJHB0A133018-01

Specifications
Tightening Torque Specifications
AENJHB0B1327001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
ECM box nut* 8.8 0.90 6.5 (Page 1C-21)
Glow plug 8.0 0.82 6.0 (Page 1C-24)
CMP sensor bolt 8.0 0.82 6.0 (Page 1C-26)
CKP sensor bolt 8.0 0.82 6.0 (Page 1C-27)
Boost pressure sensor with IAT sensor-2 screw 2.0 0.20 1.5 (Page 1C-28)
Glow plug control module nut 7.0 0.71 5.5 (Page 1C-30)
Glow control wire nut 6.3 0.64 5.0 (Page 1C-30)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0A (Page 0A-5)
1C-32 Engine Electrical Devices: D13A

Special Tools and Equipment

Special Tool
AENJHB0B1328001
09911M78610 09917M47011
Glow plug wrench Vacuum pump gauge
(Page 1C-24) / (Page 1C-29)
(Page 1C-24)

09918M18111 SUZUKI scan tool (Suzuki

SDT-II)
Air pressure regulator —
(Page 1C-29) (Page 1C-21) /
(Page 1C-21) /
(Page 1C-21) /
(Page 1C-22) /
(Page 1C-22) /
(Page 1C-22) /
(Page 1C-22) /
(Page 1C-22) /
(Page 1C-22)
 Engine Mechanical: K15B 1D-1

Engine Mechanical
Engine

K15B
General Description
Engine Construction Description
AENJHB0B1411001
The engine is a water-cooled, in-line 4-cylinder, 4-stroke-cycle gasoline unit with a DOHC valve mechanism arranged
in a “V” type valve configuration and has 16 valves. The intake camshaft is equipped with a VVT actuator and the
actuator improves engine performance changing intake valve timing continuously.
1D-2 Engine Mechanical: K15B

VVT System Description

AENJHB0B1411002
System Description
The VVT system continuously varies the intake valve timing in response to the engine operating condition and
optimizes it.
The optimized intake valve timing produces such an air intake with high efficiency that both the higher power
generation and lower fuel consumption can be attained in the whole engine speed range from low to high. In the area
of the average engine load, low emission of nitrogen oxides (NOx) and high fuel efficiency can also be attained by
making the valve opening overlap between the intake and exhaust valves longer.
The intake valve timing is varied by the VVT actuator (1) which varies the rotational phase between the intake
camshaft (3) and sprocket. The rotor (2) in the VVT actuator is actuated by switching or adjusting the hydraulic
pressure applied to the chambers for the timing advancing (7) and/or retarding (6). To switch or adjust the hydraulic
pressure appropriately, ECM operates the OCV (12) according to the engine speed, throttle opening, engine coolant
temperature and camshaft position (angle).

1
7 2

6
3

8 9
12

11

10
Most advanced timing 50° (variable angle)

Intake valve
Valve lift

Exhaust valve

Most retarded timing

Crank angle

Overlap of valves
IFRA0A141001-01

4. Oil passage to chamber for timing retarding 8. Oil filter 10. Oil pan
5. Oil passage to chamber for timing advancing 9. Oil pump 11. Control signal from ECM

Operation Description
OCV
The OCV switches and adjusts the hydraulic pressure
applied to the VVT actuator by moving the valve spool
(1) according to the duty cycle pulses from ECM.
Through this control, the valve timing is varied
continuously. ECM outputs duty signal of about 240 Hz
to the OCV.
1 3
I5RW0C140034-01
VVT actuator
The VVT actuator has chambers for timing advancing (2)
and retarding (3) which are separated by the rotor (5).
The rotor turns according to change in balance between
the hydraulic pressures applied to both chambers. The
sprocket (1) is installed on the housing (4) and the rotor
is secured on the camshaft by bolts. Therefore, the
rotation of the rotor changes the phase between the
sprocket and camshaft.
5
1 3
6 4
IBP80A141002-01
6. Seal
Engine Mechanical: K15B 1D-3
Timing advancing
When the duty ratio of the signal from the ECM to the
intake OCV is high, the valve spool (4) of the OCV
moves to the left. By this valve spool movement, the
pressurized oil (1) is led into the timing advancing
chamber and the oil in the timing retarding chamber is
drained. As a result, the rotor (3) turns in the timing
advancing direction.
4 1 2
IBP60B140088-01
2. Drain
Timing holding
When ECM keeps the duty ratio of the signal sent to the
OCV constant, the valve spool of the OCV is held in the
same position. Because this condition creates no oil
pressure change in both chambers, the rotor is fixed at a
target position.
I5RW0C140036-01
Timing retarding
When the duty ratio of the signal from the ECM to the
intake OCV is low, the valve spool of the OCV moves to
the right. By this valve spool movement, the pressurized
oil is led into the timing retarding chamber and the oil in
the timing advancing chamber is drained. As a result, the
rotor turns in the timing retarding direction.
I5RW0C140037-01
1D-4 Engine Mechanical: K15B

VVT Operation
Driving condition Valve timing Target of control Effect
To shorten the valve opening overlap
Engine running at idle Stabilization of the engine
Most retarded to prevent the exhaust gas counterflow
speed rotation at idle speed.
to intake manifold.
To lengthen the valve opening overlap Improvement of the fuel
Average engine load To the advanced to enhance the internal exhaust gas efficiency.
range side recirculation and reduce the pumping Lowering of the exhaust
loss. emission.
To shorten the valve opening overlap
Light engine load
To the retarded side to prevent the exhaust gas counterflow Keeping of the engine stability.
range
to intake manifold.
Low or average
To advance the closing timing of the Improvement of generating the
engine speed range To the advanced
intake valve to improve the volumetric engine torque at low and
with heavy engine side
efficiency. average engine speed.
load
High engine speed To retard the closing timing of the
Improvement of generating the
range with heavy To the retarded side intake valve to improve the volumetric
engine power.
engine load efficiency.
To shorten the valve opening overlap
to prevent the exhaust gas counterflow
Stabilization of engine speed at
to intake manifold and reduce the fuel
Low engine coolant fast idle.
Most retarded increasing.
temperature Improvement of the fuel
To slow the fast idle speed of the
efficiency.
engine as a result of stabilizing the
engine idling.
To shorten the valve opening overlap
At engine starting and Improvement of engine start
Most retarded to prevent the exhaust gas counterflow
stopping ability.
to intake manifold.

Diagnostic Information and Procedures

Compression Check
AENJHB0B1414001
(A)
1) Warm up engine to normal operating temperature.
2) Stop engine after warming up. (B)
3) For M/T model, place gear shift lever in “Neutral” and
apply parking brake.
For A/T model, place select lever in P range and
apply parking brake.
4) Remove all ignition coil assemblies and all spark
plugs. (Page 1H-7)
(C)
5) Disconnect fuel pump relay. (Page 10B-14)
IFRA0A141002-01
6) Install special tools into spark plug hole.
Special tool
(A): 09915M64512
(B): 09915M64530
(C): 09915M64550
 Engine Mechanical: K15B 1D-5

7) Disengage clutch (1) (to lighten starting load on Engine Vacuum Check
engine) for M/T model, and depress accelerator AENJHB0B1414002
Using SUZUKI Scan Tool
pedal (2) all the way to make throttle fully open.
1) Warm up engine to normal operating temperature.
2) For M/T model, place gear shift lever in “Neutral” and
apply parking brake.
For A/T model, place select lever in P range and
apply parking brake.
3) Stop engine and turn off all electric switches.
4) When ignition is “OFF”, connect SUZUKI scan tool to
DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)

IGJA0A141031-02

8) Crank engine with fully charged battery, and read the

highest pressure on special tool.

NOTE
• For measuring compression pressure,
crank engine at least 200 rpm with fully
charged battery. 1
• Check installation condition of special tool
if measured compression pressure is
lower than the limit.
• If the measured compression pressure of
particular cylinder is lower than the limit,
add a bit of engine oil into the cylinder
through the spark plug hole, and then
repeat the compression check.
– If the compression pressure increases
after adding engine oil, the following
may be the cause:
– Pressure leakage due to worn piston (A)
rings or worn cylinder
IJHA0A110021-01
– If the compression pressure does not
5) Run engine at specified idle speed.
increase, one of the following may be
the cause: 6) Select “MAP” under “Data List” mode on scan tool.
Manifold absolute pressure should be within
– Incorrect valve timing
specification.
– Pressure leakage from the valve or
valve seats Manifold absolute pressure specification (at sea
level)
– Pressure leakage from the cylinder
50 kPa (0.50 kgf/cm2, 7.25 psi, 0.5 bar) or less at
head gasket
specified idle speed
Compression pressure
Standard: 1,600 kPa (16.3 kgf/cm2, 232 psi, 16
bar)
Limit: 1,300 kPa (13.3 kgf/cm2, 189 psi, 13 bar)
Max. difference between any two cylinders: 100
kPa (1.0 kgf/cm2, 14.5 psi, 1 bar)
9) Carry out Step 6) – 8) on each cylinder to obtain 4
readings.
10) Install spark plugs and ignition coil assemblies.
(Page 1H-7)
11) Connect fuel pump relay.
1D-6 Engine Mechanical: K15B
Not Using SUZUKI Scan Tool
1) Warm up engine to normal operating temperature.
2) For M/T model, place gear shift lever in “Neutral” and
apply parking brake.
For A/T model, place select lever in P range and
apply parking brake.
3) Stop engine and turn off all electric switches.
4) Remove air cleaner assembly. (Page 1D-9)
5) Remove PCV hose (1) from PCV valve (2).
1 b) Turn camshafts by 90° (by turning crankshaft
2 by turning crankshaft. Check valve clearances.
IHL10A141077-02
6) Connect special tool to PCV hose (1).
Special tool
(A): 09915M67311
7) Close PCV valve (2) using tape (3) or the like.
8) Install air cleaner assembly. (Page 1D-9)
(A)
3
2
IHL10A141078-02
9) Run engine at specified idle speed. (Page 1A-165)
10) Read vacuum gauge. Vacuum should be within
specification.
Vacuum specification (at sea level)
–50 kPa (–0.50 kgf/cm2, –7.25 psi, –0.5 bar) or
less at specified idle speed
11) Remove air cleaner assembly. (Page 1D-9)
12) Disconnect special tool from PCV hose.
13) Pull off tape from PCV valve.
14) Install PCV hose to PCV valve.
15) Install air cleaner assembly. (Page 1D-9)
Valve Clearance Inspection and Adjustment
AENJHB0B1414003
Inspection
1) Remove cylinder head cover. (Page 1D-14)
2) Hoist vehicle and remove right side engine under
side cover.
3) Using wrench, turn crankshaft pulley (1) clockwise
until cam lobes (2) become perpendicular to tappet
faces (3) at valves “1” and “7” as shown in figure.
4) Check valve clearance with feeler gauge (4) as
follows.
a) Check valve clearance at valves “1” and “7”.
with wrench).
c) Check that cam lobes are perpendicular to
tappet faces at valves to be checked (in this
case, “3” and “8”). If not, adjust cam lob position
d) In the same manner as in Step b) – c), check
valve clearances at valves “4” and “6”.
e) In the same manner as in Step b) – c) again,
check valve clearances at valves “2” and “5”.
If valve clearance is not as specified, record valve
clearance and adjust it to specification. (Page 1D-7)
Valve clearance specification
When cold (ECT: 15 – 25 °C (59 – 77 °F)):
• Intake: 0.14 – 0.23 mm (0.0056 – 0.0090 in.)
• Exhaust: 0.30 – 0.40 mm (0.0119 – 0.0157 in.)
2
“a”
4
3
IFRA0A141006-01
“a”: 90°
 Engine Mechanical: K15B 1D-7

c) Select new tappet closest to calculated value

from available size of spare part.
Available tappets No.
Thickness Thickness
Tappet No. Tappet No.
mm (in.) mm (in.)
3.88 (0.1528) 388 3.48 (0.1370) 348
3.86 (0.1520) 386 3.46 (0.1362) 346
3.84 (0.1512) 384 3.44 (0.1354) 344
3.82 (0.1504) 382 3.42 (0.1346) 342
3.80 (0.1496) 380 3.40 (0.1339) 340
IBP60B140003-02 3.78 (0.1488) 378 3.38 (0.1331) 338
3.76 (0.1480) 376 3.36 (0.1323) 336
Adjustment 3.74 (0.1472) 374 3.34 (0.1315) 334
1) Remove tappet to be replaced. (Page 1D-16) 3.72 (0.1465) 372 3.32 (0.1307) 332
2) Select proper size of tappet as follows to adjust valve 3.70 (0.1457) 370 3.30 (0.1299) 330
clearance to specified valve. 3.68 (0.1449) 368 3.28 (0.1291) 328
a) Using a micrometer, measure the thickness of 3.66 (0.1441) 366 3.26 (0.1283) 326
the removed tappet (1). 3.64 (0.1433) 364 3.24 (0.1276) 324
3.62 (0.1425) 362 3.22 (0.1268) 322
b) Calculate the thickness of new tappet by the 3.60 (0.1417) 360 3.20 (0.1260) 320
following formula. 3.58 (0.1409) 358 3.18 (0.1252) 318
NOTE 3.56 (0.1402) 356 3.16 (0.1244) 316
3.54 (0.1394) 354 3.14 (0.1236) 314
If the number in the second decimal place is 3.52 (0.1386) 352 3.12 (0.1228) 312
odd, use (A – 0.01) tappet. 3.50 (0.1378) 350 3.10 (0.1220) 310
Intake:
3) Install camshafts and tappets. (Page 1D-16)
A = B + C – 0.19 mm (0.0075 in.)
Exhaust: 4) Recheck valve clearance.
A = B + C – 0.35 mm (0.0138 in.)
A: Thickness “a” of new tappet
B: Thickness “a” of removed tappet
C: Measured valve clearance

"a"
1

I7V20A141015-01
1D-8 Engine Mechanical: K15B

Repair Instructions
Air Cleaner Components
AENJHB0B1416001

2
1

(a)

8 6
5
9
10

(a)

IJHA0A140002-01

1. Air cleaner assembly 5. Air intake shroud 9. To cylinder head cover

2. Air cleaner suction hose
3. Air cleaner suction pipe
4. Air cleaner outlet hose
6. Breather hose pipe 10. To electric throttle body assembly
7. IAT sensor : 1.3 Nm (0.13 kgf-m, 1.0 lbf-ft)
: For installation, refer to “IAT Sensor
Removal and Installation”: K15B in Section
1C (Page 1C-13).
8. Breather hose

Air Cleaner Filter Removal and Installation Installation

AENJHB0B1416002
1) Install air cleaner filter to air cleaner case.
Removal
1) Unhook air cleaner case clamps (1).
2) Open air cleaner cap (2), and then remove air
cleaner filter.

IHL10A141054-02

1
1

IGSB0A143004-01
 Engine Mechanical: K15B 1D-9

2) Fit tabs (1) of the cap with the case hooks, and join Air Cleaner Assembly Removal and Installation
air cleaner cap (2) with air cleaner case (3). AENJHB0B1416004

3) Hook air cleaner case clamps (4). Removal

1) Remove air cleaner bolt (1).
1
2) Disconnect air cleaner suction hose (2) from air
cleaner assembly (3).
3) Loosen air cleaner outlet hose clamp (4) and remove
air cleaner assembly.

1 3
2

3 4
4
IJHA0A140004-01

IJHA0A140058-01 4) Remove air cleaner suction hose (1) and air cleaner
suction pipe (2), if necessary.
Air Cleaner Filter Inspection and Cleaning
AENJHB0B1416003

Inspection
Check air cleaner filter for dirt. Replace excessively dirty
filter. 1

Cleaning
Blow off dust by compressed air from air outlet side of
filter. 2

IJHA0A140005-01

5) Remove air cleaner outlet hose (1) according to the

procedure, if necessary.
a) Loosen air cleaner outlet hose clamp (2).
b) Remove air cleaner outlet hose from electric
throttle body assembly.
c) Remove IAT sensor (3) from air cleaner outlet
hose.
d) Remove breather hose pipe (4) from air cleaner
IHL10A141056-02
outlet hose.

3
4

IJHA0A140006-01
1D-10 Engine Mechanical: K15B

Installation
Reverse removal procedure noting the following points.
• Tighten air cleaner outlet hose clamps to specified
torque. (Page 1D-8)
• Insert protrusions (1) of air cleaner assembly (2) into
grommets (3) on intake manifold.

1
3

IJHA0A140007-01
 Engine Mechanical: K15B 1D-11

Throttle Body and Intake Manifold Components

AENJHB0B1416005

10

6
(a) 1
7

11

IHL10A141003-06

1. Intake manifold 6. Vacuum pipe intake hose 11. To brake booster

2. Intake manifold gasket
3. Electric throttle body assembly
: Do not disassemble.
4. Electric throttle body gasket
5. PCV hose
7. MAP sensor : 4.0 Nm (0.41 kgf - m, 3.0 lbf-ft)
: For tightening order, refer to “MAP Sensor Removal and
Installation”: K15B in Section 1C (Page 1C-7).
8. EVAP canister purge valve hose : Do not reuse.
9. To PCV valve
10. To EVAP canister purge valve
1D-12 Engine Mechanical: K15B

Throttle Body On-Vehicle Inspection Installation

AENJHB0B1416006
Check electric throttle body assembly. (Page 1C-4) 1) Clean mating surfaces and install new electric
throttle body gasket (1) to intake manifold.
Electric Throttle Body Assembly Removal and
Installation
AENJHB0B1416007

NOTICE 1

The electric throttle body will lose its original

performance if it is disassembled.
Do not disassemble the electric throttle body.
If any faulty condition is found, replace it with
a new one.

NOTE
After replacing electric throttle body IJHA0A140010-01
assembly, calibration of throttle valve
2) Install electric throttle body assembly (1) to intake
position is required. (Page 1C-5)
manifold.
Removal 3) Connect electric throttle body connector (2) to
1) Disconnect negative (–) cable at battery. electric throttle body assembly.
2) Remove air cleaner assembly and air cleaner outlet
hose. (Page 1D-9)
1
3) Disconnect electric throttle body connector (2) from
electric throttle body assembly (1).
2

IJHA0A140009-01

4) Install air cleaner assembly and air cleaner outlet

hose. (Page 1D-9)
5) Connect negative (–) cable at battery.
IJHA0A140009-01

4) Remove electric throttle body assembly from intake
manifold.
5) Remove electric throttle body gasket.
Throttle Body Cleaning
AENJHB0B1416008
Clean electric throttle body assembly referring to
“Throttle Valve Visual Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection”: K15B in Section
1C (Page 1C-4).
 Engine Mechanical: K15B 1D-13

Intake Manifold Removal and Installation

AENJHB0B1416009

Removal
1) Remove electric throttle body assembly. (Page
1D-12)
2) Disconnect MAP sensor connector. (Page 1C-7)
3) Disconnect the following hoses.
• Vacuum pipe intake hose (1) from intake manifold
• EVAP canister purge valve hose (2) from intake
manifold
• PCV hose (3) from intake manifold
4) Disconnect fuel hose clamp (4) from intake manifold.

4 1

IJHA0A140011-01

5) Disconnect engine harness clamps (1) from intake

manifold (2).
6) Remove intake manifold and its gaskets.

[A]

1
2
IJHA0A140059-01

[A]: M/T model

7) Remove MAP sensor, if necessary.

Installation
Reverse removal procedure noting the following points.
• Use new gaskets.
• Check that all removed parts are back in place.
1D-14 Engine Mechanical: K15B

Cylinder Head Cover Components

AENJHB0B1416010

5
6

3 (a)

2 1217G
IJHA0A140012-01

1. Cylinder head cover 4. PCV valve : 3.0 Nm → 5.0 Nm → 7.5 Nm (0.31 kgf-m → 0.51 kgf-m
→ 0.76 kgf-m, 2.5 lbf-ft → 4.0 lbf-ft → 5.5 lbf-ft)
2. Cylinder head cover gasket 5. Oil filler cap : Do not reuse.
: Apply sealant 99000-31260 referring to “Cylinder
Head Cover Removal and Installation”: K15B (Page
1D-14).
3. Cylinder head cover bolt 6. PCV valve seal
: For tightening order, refer to “Cylinder Head Cover
Removal and Installation”: K15B (Page 1D-14).

Cylinder Head Cover Removal and Installation

AENJHB0B1416011 3
4
Removal
1) Remove air cleaner assembly. (Page 1D-9)
2) Remove ignition coil assemblies. (Page 1H-8)
3) Disconnect engine harness clamps.
2
4) Remove HO2S bracket (1).
5) Remove oil level gauge (2). 1
6) Disconnect PCV hose (3) from PCV valve.
7) Disconnect breather hose (4) from cylinder head
cover. IHL10A141061-04
 Engine Mechanical: K15B 1D-15

8) Remove PCV valve and PCV valve seal from 5) Install cylinder head cover to cylinder head.
cylinder head cover, if necessary.
NOTE
9) Loosen cylinder head cover mounting bolts in
numerical order (“1” – “14”) evenly and gradually. When installing cylinder head cover, use care
so that cylinder head cover gasket will not
“3” “7” “10” “13” “12” “5” get out of place or fall off.

6) Tighten cylinder head cover bolts according to the

following procedure:
“1” “2”
a) Tighten cylinder head cover bolts to 3.0 Nm
(0.31 kgf-m, 2.5 lbf-ft) in numerical order (“1” –
“14”) evenly and gradually.
b) Retighten them to 5.0 Nm (0.51 kgf-m, 4.0 lbf-ft)
in the same manner as in Step a).
“4” “6” “11” “14” “9” “8” c) Retighten them to 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)
IHL10A141062-03 in the same manner as in Step a).
10) Remove cylinder head cover with gasket.
Tightening torque
Cylinder head cover bolt* (a): 3.0 Nm → 5.0
Installation
Nm → 7.5 Nm (0.31 kgf-m → 0.51 kgf-m →
1) Remove oil, old sealant and dust from sealing 0.76 kgf-m, 2.5 lbf-ft → 4.0 lbf-ft → 5.5 lbf-ft)
surfaces on cylinder head and cover.
2) Install new gasket (2) to cylinder head cover (1). “12”, (a) “8”, (a) “5”, (a) “2”, (a) “3”, (a) “10”, (a)
3) Apply engine oil to inside surface of ignition coil
gaskets (3).
“14”, (a) “13”, (a)
3 3

“11”, (a) “9”, (a) “4”, (a) “1”, (a) “6”, (a) “7”, (a)
IHL10A141063-03

7) Install PCV valve seal and PCV valve, if removed.

2 1 8) Connect PCV hose (3) to PCV valve.
IGSB0A143018-01
9) Connect breather hose (4) to cylinder head cover.
4) Apply sealant “A” to the mating surface as shown.
10) Install oil level gauge (2).
“A”: Sealant 99000–31260 (SUZUKI Bond
11) Install HO2S bracket (1).
No.1217G)
3
“A”
4

“A” IHL10A141061-04
IFRA0A141027-01
12) Install ignition coil assemblies. (Page 1H-8)
13) Connect engine harness clamps.
14) Install air cleaner assembly. (Page 1D-9)
1D-16 Engine Mechanical: K15B

Camshaft and Tappet Components

AENJHB0B1416012

OIL
3

OIL
7

OIL
8 5

OIL
5 4

9
6 (b) 5

9
1 9

9
OIL

7 5
9

OIL
8

(a)
9
(a)
2
IHL10A141005-02

1. VVT actuator 5. Camshaft housing 9. Dowel pin

: Do not disassemble.
2. Exhaust camshaft timing sprocket 6. Camshaft housing bolt : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
: For tightening order, refer to “Camshaft and
Tappet Removal and Installation”: K15B (Page
1D-16).
3. Intake camshaft 7. Camshaft bearing : 5.0 Nm → 8.0 Nm → 11 Nm (0.51
: Apply engine oil to sliding surface. : For applying engine oil, refer to “Camshaft and kgf-m → 0.82 kgf-m → 1.1 kgf-m,
Tappet Removal and Installation”: K15B (Page 4.0 lbf-ft → 6.0 lbf-ft → 8.5 lbf-ft)
1D-16).
4. Exhaust camshaft 8. Tappet
: Apply engine oil to sliding surface. : Apply engine oil to sliding surface.

Camshaft and Tappet Removal and Installation NOTE

AENJHB0B1416013
When the lines are aligned with cylinder head
NOTICE surface as shown, each sprocket timing mark
If engine oil contacts to compressor drive at the chain cover side points the top.
belt and water pump / generator drive belt,
problems such as belt squeal could occur.
1 1
Do not allow engine oil to contact
compressor drive belt and water pump /
generator drive belt. If engine oil contacts
them, wash it off with water.

Removal
1) Hoist vehicle and remove right side engine under
side cover.
2) Remove cylinder head cover. (Page 1D-14) 2 2
I7V20A141006-01
3) Turn crankshaft clockwise and position piston No.1
to TDC as follows.
a) Align marks (lines) (1) on VVT actuator
(sprocket) and exhaust camshaft timing sprocket
with surface of cylinder head (2).
 Engine Mechanical: K15B 1D-17

b) Check that notch (1) on crankshaft pulley is b) Tighten fixing bolt (2) by hand and push timing
aligned with “0” line (2) (TDC) on timing chain chain tensioner (1) at upper part of the pivot.
cover. c) Turn crankshaft 20° (3) counterclockwise and
tighten the bolt by hand again.
2 d) Turn crankshaft 20° clockwise and tighten the
bolt more by hand.

IJHB0A141001-01 1

4) Remove timing chain cover plug (1) and gasket (2).

I7V20A141010-01

1 2
I7V20A141008-01

5) Release tension of timing chain by fixing timing chain 3

tensioner (1) as follows.

NOTICE
Tightening fixing bolt with wrench may
damage timing chain tensioner.
Tighten the bolt only by hand.

NOTE
If this step to slacken timing chain is omitted, IJHB0B141006-01
reinstallation of the exhaust camshaft timing
sprocket will become difficult.

a) Prepare an M8 bolt of the following dimensions.

• Thread pitch: 1.25 mm (0.049 in.)
• Length “a”: 35 mm (1.4 in.) or longer

“a”

I7V20A141009-02
1D-18 Engine Mechanical: K15B

6) Put matchmarks (2) on timing chain links aligned 8) Loosen camshaft housing bolts in numerical order
with timing marks (1) on intake sprocket (4) and (“1” – “21”) evenly and gradually.
exhaust sprocket (3).
“2” “12” “13” “20” “21” “16” “17” “8” “9”
NOTE
If colored chain links are aligned with timing
“5”
marks on intake sprocket and exhaust
sprocket respectively with success, it is not “3”
necessary to put matchmarks.
In this case, use the colored chain links as “4”
matchmarks for installation.
“1” “10” “11” “18” “19” “14” “15” “6” “7”

2 2 IFRA0A141033-01

9) Remove exhaust camshaft and intake camshaft.

1
1 NOTE
Because a guide to prevent coming off of
3
4 timing chain from crankshaft timing sprocket
is provided at the lower part of oil pump,
timing chain will not be disengaged from
crankshaft timing sprocket even when
camshafts are removed.

10) Remove camshaft bearings.

IJHA0A140060-01
11) Remove tappets, if necessary.
7) With hexagonal section of exhaust camshaft held
12) Remove VVT actuator from intake camshaft as
stationary using spanner or adjustable wrench,
follows, if necessary.
remove sprocket bolt and then remove exhaust
camshaft timing sprocket (1). a) Hold hexagonal section of camshaft using vice.
b) Remove VVT actuator bolt and remove VVT
NOTE actuator (1).
Do not turn camshaft after removing exhaust
camshaft timing sprocket.

I7V20A141013-01 I9P60A141035-01

Installation
1) Install VVT actuator (1) to camshaft as follows, if
removed.
a) Hold hexagonal section of camshaft using vice.
b) Install VVT actuator and tighten VVT actuator
bolt to specified torque.
Tightening torque
VVT actuator bolt (a): 60 N·m (6.1 kgf-m, 44.5
lbf-ft)
(a)
I9P60A141076-01
2) Apply engine oil to contact surfaces of each tappet
(hatched area), if removed, and install tappets (1) to
cylinder head.
1 5 camshaft housings. And, their positioning
I7V20A141016-01
3) Install camshaft bearings as follows.
a) Check mating surfaces of bearing backside and
corresponding cylinder head and camshaft
housing are clean and dry.
b) Fit tab (1) of camshaft bearing half to groove (2)
of cylinder head and other half to camshaft
housing.
c) Press bearing end (3) until it becomes flush with
cylinder head and other half with camshaft
housing mating surface.
1 3
I7V20A141088-01
4) Apply engine oil to bearing portions of cylinder head.
Engine Mechanical: K15B 1D-19
5) Set camshafts to cylinder head as follows.
a) Align matchmark (1) on VVT actuator with
matchmark marked before removal (or colored
link) (2) on timing chain.
b) Put exhaust camshaft so that pin (3) is located
as shown in figure.
2
1 “a”
3
IFRA0A141034-01
“a”: Approx. 11° from vertical line
c) Apply engine oil to sliding surfaces of camshafts.
6) Check that all dowel pins are fitted to cylinder head.
7) Install camshaft housings (1) to proper places
distinguished by letter (2), number (3) and arrow (4)
on each camshaft housing.
NOTE
Shapes and functions of No.1 and No.2
camshaft housings are different from No.3 –
is restricted by their shape.
3
1
2
4
IHL10A141006-01
2. I: For intake camshaft
E: For exhaust camshaft
3. Position from timing chain side
4. Point arrow to timing chain side
1D-20 Engine Mechanical: K15B

8) Tighten camshaft housing bolts according to the NOTICE

following procedure. If the exhaust camshaft timing sprocket bolt
a) Tighten camshaft housing bolts to 5.0 Nm (0.51 is tightened using the special tool (offset
kgf-m, 4.0 lbf-ft) in numerical order (“1” – “21”) adapter) until the torque wrench reads the
evenly and gradually. specified torque below, the bolt will be
b) In the same manner as in Step a), tighten them tightened too much.
to 8.0 Nm (0.82 kgf-m, 6.0 lbf-ft). Follow the steps below to tighten the bolt
c) In the same manner as in Step b), tighten them using the special tool appropriately.
to 11 Nm (1.1 kgf-m, 8.5 lbf-ft).
a) Measure length (L) of torque wrench (1).
Tightening torque b) Calculate reading value (M) of the torque wrench
Camshaft housing bolt* (a): 5.0 Nm → 8.0 using the following formula.
Nm → 11 Nm (0.51 kgf-m → 0.82 kgf-m → 1.1
kgf-m, 4.0 lbf-ft → 6.0 lbf-ft → 8.5 lbf-ft) NOTE
If offset adapter other than the special tool is
“10”, (a) “2”, (a) “6”, (a) “14”, (a)
“20”, (a) “9”, (a) “1”, (a) “5”, (a) “13”, (a)
used, measure the center distance
corresponding to “a” and apply the
dimension to the formula.
“17”, (a)
Formula for torque wrench reading value
“19”, (a) when using special tool
M = T x L / (L + “a”)
“18”, (a) • M: Torque wrench reading value when using
special tool
“21”, (a) “11”, (a) “3”, (a) “7”, (a) “15”, (a) • T: Specified torque
“12”, (a) “4”, (a) “8”, (a) “16”, (a)
IFRA0A141035-01 • L: Torque wrench length
9) Install exhaust camshaft timing sprocket to camshaft • “a”: Dimension of special tool (18 mm (0.71
as follows. in.))
a) Engage timing chain with exhaust camshaft Special tool
timing sprocket aligning its matchmark marked (A): 09911M05120
before removal (or colored link) (2) with timing
mark (3) on the sprocket. (A) 1
b) With timing chain engaged, install exhaust
sprocket to camshaft and tighten exhaust
camshaft timing sprocket bolt (1) temporarily.
L
NOTE “a”
IBP70A140024-01
Slight turning the exhaust camshaft by a c) Tighten exhaust camshaft timing sprocket bolt
wrench will facilitate fitting the sprocket. (1) until torque wrench reads the value obtained
in the above Step b).

2
Tightening torque
3 Exhaust camshaft timing sprocket bolt (a):
60 N·m (6.1 kgf-m, 44.5 lbf-ft)

IJHA0A140020-01

10) Tighten exhaust camshaft timing sprocket bolt to

specified torque using special tool as follows.

1, (a)

IFRA0A141036-01
 Engine Mechanical: K15B 1D-21

11) Check that timing marks (1) on VVT actuator (4) and b) Check that notch (1) on crankshaft pulley is
exhaust camshaft timing sprocket (3) are aligned aligned with “0” line (2) (TDC) on timing chain
with matchmarks marked before removal (or colored cover.
links) (2) on timing chain.
2
2 2

1
1

1
3
4

IJHB0A141001-01

c) Turn crankshaft clockwise 720° and check again

IJHA0A140060-01
12) Remove fixing bolt from timing chain cover.
13) Install timing chain cover plug (1) with new gasket (2)
and tighten it to specified torque.
Tightening torque
Timing chain cover plug (a): 25 N·m (2.5 kgf-m,
18.5 lbf-ft)
that sprocket marks (lines) (1) are aligned with
top face of cylinder head (2).
NOTE
If crankshaft is turned only 360°, the timing
marks (lines) on VVT actuator and exhaust
camshaft timing sprocket will not meet top
face of cylinder head.

1 1

2 2
I7V20A141006-01
1,(a) 2
I7V20A141023-01
15) Check valve clearance. (Page 1D-6)
14) Check that timing chain is installed properly as
16) Install cylinder head cover. (Page 1D-14)
follows.
17) Run engine and check for oil leakage.
a) Check that VVT actuator and exhaust camshaft
timing sprocket marks (lines) (1) are aligned with 18) Install right side engine under side cover.
top face of cylinder head (2). If not, align exhaust
camshaft timing sprocket with timing chain again
repeating the installation from step 9).

NOTE
Check of exact alignment is necessary.

1 1

2 2
I7V20A141006-01
1D-22 Engine Mechanical: K15B

VVT Actuator, Camshaft and Tappet Inspection Camshaft Runout

AENJHB0B1416014 Set camshaft between two “V” blocks and measure its
runout using a dial gauge.
VVT Actuator If measured runout exceeds limit, replace camshaft.
Fit VVT actuator to camshaft and hold hexagonal section
of camshaft using spanner or adjustable wrench. Camshaft runout
Check if VVT actuator (1) is not turned by hand. Limit: 0.015 mm (0.00059 in.)
If moved, replace VVT actuator.

I2RH0B140081-01

Camshaft Journal Wear

Check camshaft journals and camshaft housings for
pitting, scratches, wear or damage.
IAP70B140015-01
If any defect is found, replace camshaft and/or cylinder
head with camshaft housings as assembly.
Signal Rotor
Check signal rotor (1) for crack and damage. If any NOTICE
defect is found, replace camshaft. Attempting to repair sliding surface of
1
camshaft housing by scraping etc. will
adversely affect lubrication.
Do not repair sliding surface of camshaft
housing.

IFRA0A141084-01

Cam Wear
Using a micrometer, measure cam height “a”. If I2RH0B140082-01
measured height is below its limit, replace camshaft. Check clearance using gauging plastic according to the
Cam height “a” of camshaft following procedure.
Standard Limit 1) Clean housings and camshaft journals.
45.024 – 45.184 mm 44.924 mm 2) Remove all tappets.
Intake cam
(1.7726 – 1.7788 in.) (1.7686 in.) 3) Install camshafts to cylinder head.
44.659 – 44.819 mm 44.559 mm
Exhaust cam 4) Place a piece of gauging plastic to full width of
(1.7583 – 1.7645 in.) (1.7543 in.)
camshaft journal parallel to camshaft.
5) Without applying engine oil, install camshaft
housings referring to Step 1) – 8) in “installation”
under “Camshaft and Tappet Removal and
Installation”: K15B (Page 1D-16).

I2RH0B140080-01
 Engine Mechanical: K15B 1D-23

6) Remove housings, and using scale (2) on gauging

plastic envelope, measure gauging plastic (1) width [A]
at the widest point.
Camshaft journal clearance
Standard Limit
Intake side 0.031 – 0.087 mm 0.10 mm
No.1 housing (0.0013 – 0.0034 in.) (0.0039 in.)
Exhaust side 0.045 – 0.087 mm 0.10 mm
No.1 housing (0.0018 – 0.0034 in.) (0.0039 in.)
0.045 – 0.087 mm 0.10 mm [B]
Others
(0.0018 – 0.0034 in.) (0.0039 in.)

I8C50A140033-01

7) Install intake and exhaust camshafts without tappet,

and then measure intake and exhaust camshaft
housing thrust play using a dial gauge.
I2RH0B140083-01 If measured play exceeds limit, replace camshaft
If measured camshaft journal clearance exceeds and/or cylinder head with camshaft housings as
limit, measure camshaft journal diameter and assembly.
camshaft journal housing bore diameter. Replace Camshaft housing thrust play
camshaft or cylinder head assembly whichever the Standard: 0.10 – 0.35 mm (0.0040 – 0.0137 in.)
difference from specification is greater. Limit: 0.50 mm (0.020 in.)
Camshaft journal diameter [A]
Item Standard
29.440 – 29.455 mm
Intake side No.1 housing
(1.1591 – 1.1596 in.)
Exhaust side No.1 26.934 – 26.955 mm
housing (1.0604 – 1.0612 in.)
22.934 – 22.955 mm
Others
(0.9030 – 0.9037 in.)

Camshaft journal housing bore diameter [B]

Item Standard
I7V20A141074-01
32.500 – 32.515 mm
Intake side No.1 housing
(1.2796 – 1.2801 in.) Wear of Tappet
Exhaust side No.1 27.000 – 27.021 mm Check tappet for pitting, scratches or damage.
housing (1.0630 – 1.0638 in.) If any defect is found, replace tappet.
23.000 – 23.021 mm
Others
(0.9056 – 0.9063 in.)

Intake side No.1 camshaft bearing thickness

1.513 – 1.519 mm (0.0596 – 0.0598 in.)

I7V20A141075-01
1D-24 Engine Mechanical: K15B
Measure cylinder head bore and tappet outside diameter
to determine cylinder head-to-tappet clearance. If
clearance exceeds limit, replace tappet or cylinder head.
Cylinder head to tappet clearance
Standard: 0.025 – 0.062 mm (0.0099 – 0.024 in.)
Limit: 0.10 mm (0.0039 in.)
Tappet outside diameter [A]
Standard: 27.959 – 27.975 mm (1.1008 – 1.1013 in.)
Cylinder head tappet bore [B]
Standard: 28.000 – 28.021 mm (1.1024 – 1.1031 in.)
I2RH0B140086-01
Crankshaft Front Oil Seal Removal and
Installation
AENJHB0B1416015
Removal
1) Hoist vehicle and remove right side engine under
side cover.
2) Remove compressor drive belt.
• Manual A/C single model: (Page 7B-49)
• Manual A/C dual model: (Page 7B-92)
• Automatic A/C model: (Page 7B-135)
3) Remove ISG drive belt. (Page 1J-7)
4) Remove crankshaft pulley referring to Step 3) – 4) in
“Removal” under “Timing Chain Cover Removal and
Installation”: K15B (Page 1D-33).
5) Using a flat-bladed screwdriver or the like wrapped
with protective tape, remove crankshaft front oil seal
(1) slowly.
NOTICE
• If tip of screwdriver scratches timing chain
cover, it may cause oil leakage.
Carefully remove oil seal not to damage
timing chain cover.
• If crankshaft edge is dented, it may disturb
smooth installation of crankshaft pulley.
Carefully remove oil seal not to damage
crankshaft edge.
1
IJHB0A141002-01

Installation
1) Using special tool and hammer, install new
crankshaft front oil seal (1) into timing chain cover.
Depth
“a”: 0.35 – 2.15 mm (0.0137 – 0.0864 in.)
Special tool
(A): 09913M70123
“a”
1 4) Remove flywheel (M/T model) or drive plate (A/T
(A)
IJHB0A141003-01
2) Install crankshaft pulley referring to Step 17) – 19) in
“Installation” under “Timing Chain Cover Removal
and Installation”: K15B (Page 1D-33).
3) Install ISG drive belt. (Page 1J-7)
4) Install compressor drive belt.
• Manual A/C single model: (Page 7B-49)
• Manual A/C dual model: (Page 7B-92)
• Automatic A/C model: (Page 7B-135)
5) Install right side engine under side cover.
Engine Mechanical: K15B 1D-25
Crankshaft Rear Oil Seal Removal and
Installation
AENJHB0B1416016
Removal
1) Dismount transaxle assembly.
• M/T model: (Page 5B-15)
• A/T model: (Page 5A-149)
2) Remove oil pan. (Page 1E-7)
3) For M/T model, remove clutch cover and clutch disc.
(Page 5C-11)
model) from crankshaft. (Page 1D-37)
5) Remove oil seal housing and crankshaft rear oil seal
referring to Step 5) – 6) in “Removal” under “Main
Bearing, Crankshaft and Cylinder Block Removal
and Installation”: K15B (Page 1D-64).
Installation
1) Check smoothness of crankshaft flange and apply
engine oil to the sealing surface.
2) Install crankshaft rear oil seal and oil seal housing
referring to Step 12) – 16) in “Installation” under
“Main Bearing, Crankshaft and Cylinder Block
Removal and Installation”: K15B (Page 1D-64).
3) Install flywheel (M/T model) or drive plate (A/T
model) to crankshaft. (Page 1D-37)
4) For M/T model, install clutch cover and clutch disc.
(Page 5C-11)
5) Install oil pan. (Page 1E-7)
6) Mount transaxle assembly.
• M/T model: (Page 5B-15)
• A/T model: (Page 5A-149)
1D-26 Engine Mechanical: K15B

Engine Mounting Components

AENJHB0B1416017

[A]

(e) (e)

(e) (e)

(e)

(c)
1

(e)
(e)

[B] [A]
(a)
(e)
(a)
(e)

2
(a)
(e)
(a)
(e) 4

3 (a)

5
(b)
(a)
(e)

(a)

[B]

(d)

(b)

(c)
(a)

IJHA0A140026-01

[A]: M/T model 4. Engine rear torque rod bracket : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
[B]: A/T model 5. Engine rear torque rod : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
1. Engine right mounting : 93 Nm (9.5 kgf-m, 68.5 lbf-ft) : Do not reuse.
2. Engine left mounting : 85 Nm (8.7 kgf-m, 63.0 lbf-ft)
3. Engine left mounting bracket : 80 Nm (8.25.6 kgf-m, 59.0 lbf-ft)
 Engine Mechanical: K15B 1D-27

Engine Assembly Removal and Installation 11) Disconnect the following hoses.
AENJHB0B1416018
Removal • Vacuum pipe intake hose (1)
1) Relieve fuel pressure. (Page 1G-14) • Radiator inlet hose (2)
2) Disconnect steering lower shaft from pinion shaft. • Radiator outlet hose (3)
(Page 6B-14) • Heater inlet hose (4)
3) Remove battery and battery tray. (Page 1J-5) • Heater outlet hose (5)
4) Disconnect ECM connectors. (Page 1C-2) • Fuel feed hose (6)
5) Hoist vehicle and remove engine under side covers. • EVAP canister purge hose (7)
6) Drain the following oils and fluid, if necessary. • ATF cooler hoses (8) (A/T model)
• Engine oil: (Page 1E-4)
• Manual transaxle oil (M/T model): (Page 5B-8)
1
• ATF (A/T model): (Page 5A-119)
6
7) Drain coolant. (Page 1F-11)
8) Remove air cleaner assembly. (Page 1D-9)
9) Disconnect the following connectors and cable
including the related clamps.
• Connectors (1) in main fuse box
4
• Connector (2) in individual circuit fuse box No.1
7
• Battery ground cable (3)
5
• Electric load current sensor connector (4) IJHB0A141004-01

2
3 3
4
8

IJHB0A141005-01

12) With hoses connected, detach A/C compressor from

1 cylinder block.
• Manual A/C single model: (Page 7B-50)
1
IJHA0A140027-02 • Manual A/C dual model: (Page 7B-92)
10) Disconnect the following cables and pipe. • Automatic A/C model: (Page 7B-135)
• M/T model: NOTICE
– Gear shift and select control cables: (Page
When A/C compressor is detached, the A/C
5B-11)
hoses could be damaged receiving weight of
– Clutch fluid pipe: (Page 5C-7) the compressor.
• A/T model: Select cable (Page 5A-129) Suspend the removed A/C compressor to the
vehicle body while the compressor is
detached.
1D-28 Engine Mechanical: K15B

13) Remove engine harness from auxiliary power
module (lithium-ion battery) as follows.
a) Remove “Pb +” terminal and “ISG +” terminal
from auxiliary power module (lithium-ion battery).
(Page 10K-30)
20) Support front suspension frame (1), transaxle case
(2) and oil pan (3) using jack.
21) Remove front suspension frame bolts (4).
3 2

b) Remove harness protector cover (1).

1
4 4

IJHA0A140030-01

22) Remove engine right mounting bolts (1) and nuts (2).

IGSB0A142026-01

c) Remove grommet (1) and pull out engine

harness (2) to underbody.
d) Disconnect clamp (3).
2
1

3
1 2

IJHA0A140031-01

23) Remove engine left mounting bolts (1) and nuts (2).
3
[A]
IFRA0B142023-01

14) Remove stabilizer bar joints from stabilizer bar.

(Page 2B-12) 2 1
15) Disconnect tie-rod end from steering knuckle at each
of right and left sides. (Page 6B-17)
16) Disconnect suspension arm joint from steering
knuckle at each of right and left sides. (Page 2B-8)
17) Disconnect right and left drive shaft joints from
steering knuckle. (Page 3A-3)
18) Remove apron lower member bracket. (Page 9H- IJHA0A140032-01
5)
19) Remove exhaust pipe and exhaust center pipe. [B]
(Page 1K-4)

2 1

IJHA0A140033-01

[A]: M/T model [B]: A/T model

 Engine Mechanical: K15B 1D-29

24) Before removing engine, check that all hoses,
electric wires and cables are disconnected from
engine.
25) Lower engine assembly with transaxle, front
suspension frame, drive shafts, steering gear case
all together.
NOTICE
30) Check that a suitable hook (1) with bolt and nut is
installed as shown in figure. Install special tool
(engine hook) on stud bolts of exhaust manifold with
nuts (08316- 1010A) (2), and then using these hooks
lift engine assembly.
Special tool
(A): 09910M66820

When A/C compressor is detached, the A/C

hoses could be damaged receiving weight of
the compressor.
Suspend the removed A/C compressor to the
1
vehicle body while the compressor is
detached.

26) Install a suitable hook (1) with bolt and nut as shown
in figure and, using this hook and another hook (2)
on transaxle, lift engine with transaxle and
suspension frame assembled, if necessary.

IFRA0A141045-01

(A)

IFRA0A141045-01

[A] [B]
2

IJHA0A140035-01

31) Remove the following components from engine

2
assembly, if necessary.
2
• Engine harness
• Transaxle
IJHA0A140034-01
– M/T model: (Page 5B-15)
[A]: M/T model [B]: A/T model
– A/T model: (Page 5A-149)
27) Remove front drive shaft assemblies, if necessary. • Clutch cover and disc (M/T model): (Page 5C-
(Page 3A-3) 11)
28) Remove drive intermediate shaft assembly, if • Flywheel (M/T model): (Page 1D-37)
necessary. (Page 3A-11) • Drive plate (A/T model): (Page 1D-37)
29) Remove front suspension frame, if necessary.
(Page 2B-13)
1D-30 Engine Mechanical: K15B

Installation Tightening torque

1) Install the following components to engine, if Engine left mounting nut (a): 55 N·m (5.6 kgf-m,
removed. 40.5 lbf-ft)
Engine left mounting bolt (b): 55 N·m (5.6 kgf-
• Flywheel (M/T model): (Page 1D-37)
m, 40.5 lbf-ft)
• Drive plate (A/T model): (Page 1D-37)
• Clutch disc and cover (M/T model): (Page 5C- [A]
11)
• Transaxle
– M/T model: (Page 5B-15) 1, (a) 2, (b)
– A/T model: (Page 5A-149)
• Engine harness
2) Positioning ground cable to specified angle as
shown, tighten engine harness ground bolt (1) to
specified torque, if removed.
Position range for ground cable
“a”: 45° IJHA0A140036-01

Tightening torque
Engine harness ground bolt (a): 11 N·m (1.1 kgf- [B]

m, 8.5 lbf-ft)

1, (a) 2, (b)

“a”

“a”

IJHA0A140037-01
1, (a)
[A]: M/T model [B]: A/T model

8) Tighten new engine right mounting nuts (1) and bolt

IJHB0A141006-01
(2) to specified torque.
3) Install front suspension frame, if removed. (Page
2B-13) NOTICE
4) Install drive intermediate shaft assembly, if removed. The engine right mounting bolt is pre-coated
(Page 3A-11) with friction stabilizer. If the bolt is reused, it
5) Install front drive shaft assemblies, if removed. may work loose.
(Page 3A-3) Never reuse the engine right mounting bolt.
6) Lift up engine assembly with transaxle, front
Tightening torque
suspension frame, drive shafts and steering gear
Engine right mounting nut (a): 80 N·m (8.2 kgf-
case all together.
m, 59.0 lbf-ft)
NOTICE Engine right mounting bolt (b): 80 N·m (8.2 kgf-
m, 59.0 lbf-ft)
When A/C compressor is detached, the A/C
hoses could be damaged receiving weight of
the compressor.
Suspend the removed A/C compressor to the
vehicle body while the compressor is
detached.

7) Tighten engine left mounting nuts (1) and bolt (2) to 1, (a)

specified torque. 2, (b)

IJHA0A140038-01

9) Tighten front suspension frame bolts to specified
torque. (Page 2B-12)
10) Remove jack.
11) Install exhaust pipe and exhaust center pipe.
(Page 1K-4)
12) Install apron lower member bracket. (Page 9H-5)
13) Connect right and left drive shaft joints to steering
knuckle. (Page 3A-3)
14) Connect suspension arm joint to steering knuckle at
each of right and left sides. (Page 2B-8)
15) Connect tie-rod end to steering knuckle at each of
right and left sides. (Page 6B-17)
16) Install stabilizer bar joints to stabilizer bar. (Page
2B-12)
17) Install engine harness to auxiliary power module
(lithium-ion battery) as follows.
a) Put engine harness (1) to floor panel and
connect clamp.
b) Insert end of engine harness into floor hole.
c) Fit grommet (2) directing arrow mark (3) to
vehicle forward.
d) Install harness protector cover (4).
4 1
3
2
[f]
IGSB0A142031-01
[f]: Forward
e) Install “Pb +” terminal and “ISG +” terminal to
auxiliary power module (lithium-ion battery).
(Page 10K-30)
Engine Mechanical: K15B 1D-31
18) Install all other removed electric wires, connectors
and hoses to original positions.
19) Install A/C compressor to cylinder block.
• Manual A/C single model: (Page 7B-50)
• Manual A/C dual model: (Page 7B-92)
• Automatic A/C model: (Page 7B-135)
20) Connect the following cables and pipe.
• M/T model:
– Gear shift and select control cables (Page
5B-11)
– Clutch fluid pipe (Page 5C-7)
• A/T model: Select cable (Page 5A-129)
21) Check that removed parts are back in place.
Reinstall any necessary parts which have not been
reinstalled.
22) Refill engine and transaxle with oil or fluid.
• Engine oil: (Page 1E-4)
• Manual transaxle oil (M/T model): (Page 5B-8)
• ATF (A/T model): (Page 5A-119)
23) Install air cleaner assembly. (Page 1D-9)
24) Refill cooling system with coolant. (Page 1F-11)
25) Install battery tray and connect ECM connectors,
and then install battery. (Page 1J-5)
26) Connect steering lower shaft to pinion shaft. (Page
6B-14)
27) Check for leakage of fuel, coolant, oil and exhaust
gas.
• Fuel leakage: (Page 1G-14)
• Coolant leakage: (Page 1F-10)
28) Install engine under side covers.
1D-32 Engine Mechanical: K15B

Timing Chain Cover Components

AENJHB0B1416019

OIL
5 (c)

6
8 (b)

7
11 (b)

1 1217G

OIL
4
17

16 (b)

17

14 (b)
10
9

15 (d)
12 (b)
2
OIL

13 (a)
IJHB0B141001-01

1. Timing chain cover 13. Crankshaft pulley bolt

: Apply sealant 99000-31260.
: For details, refer to “Timing Chain Cover Removal and Installation”: K15B (Page
1D-33).
2. Crankshaft pulley 14. ISG drive belt auto tensioner upper bolt
3. Crankshaft front oil seal 15. ISG drive belt auto tensioner lower bolt
: Apply engine oil to oil seal lip.
4. OCV 16. ISG drive belt auto tensioner bracket bolt
: Apply engine oil to O-ring.
5. Gasket 17. Dowel pin
: Apply engine oil.
6. Filter : 19 Nm → +75° (1.9 kgf-m → +75°, 14.0 lbf-ft → +75°)
7. Timing chain cover plug gasket : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
8. Timing chain cover plug : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
9. ISG drive belt auto tensioner : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
10. ISG drive belt auto tensioner bracket : 93 Nm (9.5 kgf-m, 68.5 lbf-ft)
11. Timing chain cover bolt No.1 : Do not reuse.
: For tightening order, refer to “Timing Chain Cover Removal and Installation”: K15B
(Page 1D-33).
12. Timing chain cover bolt No.2
: For tightening order, refer to “Timing Chain Cover Removal and Installation”: K15B
(Page 1D-33).
 Engine Mechanical: K15B 1D-33

Timing Chain Cover Removal and Installation 10) Remove O-ring (1) and gasket (2).
AENJHB0B1416020
11) Remove filters (3) from timing chain cover, if
Removal necessary.
1) Remove engine assembly from vehicle. (Page 1D- 3
2
27)
2) Remove ISG drive belt auto tensioner, auto
tensioner bracket and idler pulley. (Page 1J-9)
3) Remove crankshaft pulley bolt (1).
To lock crankshaft pulley (2), use special tool as
shown in figure.
Special tool
(A): 09917M68222

2 1

IFRA0A141054-01
(A)
12) Remove OCV from timing chain cover. (Page 1D-
36)
13) Remove oil pump from timing chain cover. (Page
1E-11)

Installation
1
IJHB0A141008-01 1) Install oil pump to timing chain cover. (Page 1E-11)
4) Remove crankshaft pulley (1). 2) Press-fit new crankshaft front oil seal (1) into timing
If it is hard to remove, use special tools. chain cover (2) using special tool (A) as shown in
Special tool figure.
(A): 09926M58010 Depth
(B): 09913M66710 “a”: 0.35 – 2.15 mm (0.0138 – 0.0846 in.)
Special tool
(A): 09913M70123

(A)

1
(A)
(B)
2

1
IHL10A141067-02

5) Remove cylinder head cover. (Page 1D-14)

“a”
6) Remove oil pan. (Page 1E-7)
7) Remove water pump pulley. (Page 1F-17) IFRA0A141055-02

8) Remove timing chain cover. 3) Install OCV to timing chain cover. (Page 1D-36)
9) Remove crankshaft front oil seal from timing chain
cover. (Page 1D-24)
1D-34 Engine Mechanical: K15B

4) Check cleanliness of filters (3) and install them to 9) Clean mating portions (1) of cylinder block and
timing chain cover. cylinder head particularly.
5) Apply engine oil to new gasket (2) and install it to 10) Apply sealant “A” to mating surface of cylinder and
timing chain cover. cylinder head, and surface of timing chain cover as
6) Apply engine oil to new O-ring (1) and install it to oil shown in figure.
pump. “A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
3
2
Sealant amount for timing chain cover
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)

1, “A” 1, “A”
1 “A” “A”

IFRA0A141054-01
“a”
7) Check that dowel pins (1) are installed to cylinder “A” “b”
block.
IHL10A141076-01

11) Install timing chain cover noting the following points.

• Apply engine oil to oil seal lip.
• Align straight lines (1) of oil pump inner rotor with
straight lines (2) of crankshaft sprocket.
• Install timing chain cover within 2 minutes after
applying sealant.
• Check O-ring and gasket for proper fit.
• Use care so that oil seal lip is not damaged and oil
seal spring is not coming off.
1
IJHB0B141002-01

8) Clean mating surfaces of timing chain cover, cylinder

block and cylinder head.

2 1
IFRA0A141057-01
 Engine Mechanical: K15B 1D-35

12) Tighten timing chain cover bolts No.1 and No.2 in 18) Insert crankshaft pulley (1) aligning key groove (2)
numerical order (“1” – “15”) evenly and gradually to with key (3) on crankshaft.
specified torque.
NOTICE
Tightening torque
Turning over of oil seal lip or coming off of
Timing chain cover bolt No.1* (a): 25 N·m (2.5
the inside spring will cause oil leakage.
kgf-m, 18.5 lbf-ft)
While inserting crankshaft pulley, pay
Timing chain cover bolt No.2* (b): 25 N·m (2.5
attention not to damage oil seal lip nor
kgf-m, 18.5 lbf-ft)
disengage the inside spring.
“1”, (a)
“10”, (b) “8”, (b)

“6”, (a)

“4”, (b) “3”, (b) 3

2
“2”, (b)
“5”, (b)
“9”, (b)

“11”, (b) “7”, (b)

1

“12”, (b)
“13”, (b) IJHB0A141010-01

19) Hold crankshaft pulley (1) with special tool and

“15”, (b) tighten crankshaft pulley bolt (2) according to the
“14”, (b)
IFRA0A141058-01 following procedure.
13) Wipe off excessive sealant squeezed out from timing
NOTE
chain cover at the lower end.
For accurate angle tightening of the bolt, use
14) Install water pump pulley. (Page 1F-17)
tightening angle gauge available in the
15) Install cylinder head cover. (Page 1D-14) market.
16) Install oil pan. (Page 1E-7)
17) Clean crankshaft pulley and apply engine oil to
sealing surface (1).

IJHA0A140061-01

1 Special tool
(A): 09917M68222
IJHB0A141009-01
1D-36 Engine Mechanical: K15B

a) Tighten crankshaft pulley bolt to 19 Nm (1.9 kgf- OCV Removal and Installation
m, 14.0 lbf-ft). AENJHB0B1416022

b) Retighten the bolt to 75°. Removal

Tightening torque 1) Disconnect OCV connector from OCV (1).
Crankshaft pulley bolt* (a): 19 Nm → +75° 2) Remove OCV.
(1.9 kgf-m → +75°, 14.0 lbf-ft → +75°)

(A)
1

IJHA0A140042-01

2, (a)
IJHB0A141011-01
20) Install ISG drive belt auto tensioner, auto tensioner
bracket and idler pulley. (Page 1J-9)
21) Install engine assembly to vehicle. (Page 1D-27)
Timing Chain Cover Inspection
AENJHB0B1416021
Check oil passages for VVT actuator and filters (1).
Clean oil passages and filters if clogging or foreign
material exists.
Installation
Reverse removal procedure noting the following points.
• Check cleanliness of oil gallery in oil pump and OCV.
• Apply engine oil to O-ring and carefully insert OCV to
timing chain cover.
• Tighten OCV bolt (1) to specified toque.
Tightening torque
OCV bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)

1, (a)
1

IFRA0A141060-01
IJHA0A140043-01
 Engine Mechanical: K15B 1D-37

Flywheel / Drive Plate Removal and Installation Installation

AENJHB0B1416023 Reverse removal procedure noting the following points.
Removal
• For M/T model, press-fit input shaft bearing (1) using
1) For M/T model, remove clutch cover and clutch disc.
special tool and hydraulic press (2).
(Page 5C-11)
2) For A/T model, remove transaxle assembly. (Page Depth
5A-149) “a”: 0 – 0.5 mm (0 – 0.01 in.)
3) Lock flywheel (M/T model) or drive plate assembly Special tool
(A/T model) using special tool as shown in figure. (A): 09913M75821
Special tool
(A): 09924M17811 1 2
“a”

(A)

I8C50A140045-01
IGSB0A141019-01
4) Remove flywheel (M/T model) or drive plate (A/T • Install special tool in ring gear teeth to lock flywheel
model) from crankshaft. (M/T model) or drive plate (A/T model) as shown in
5) Remove input shaft bearing (1) from flywheel, if figure.
necessary, using special tool as shown in figure.
Special tool
Special tool (A): 09924M17811
(A): 09921–20210
(B): 09930M30104 • Tighten new flywheel bolts or drive plate bolts to
specified torque.

NOTICE
The flywheel bolts (M/T model) or drive plate
bolts (A/T model) are pre-coated with
(B) adhesive. If these bolts are reused, they may
work loose.
Replace the flywheel bolts (M/T model) or
(A)
drive plate bolts (A/T model) with new ones
whenever they are removed.
1

Tightening torque
IHL10A141086-01 Flywheel bolt (a): 83 N·m (8.5 kgf-m, 61.5 lbf-ft)
Drive plate bolt (a): 83 N·m (8.5 kgf-m, 61.5 lbf-ft)

I8C50A140046-01
1D-38 Engine Mechanical: K15B

Flywheel / Drive Plate Inspection Flywheel / drive plate face runout

AENJHB0B1416024 Limit: 0.2 mm (0.0079 in.)

Visual Inspection
• If ring gear is damaged, cracked or worn, replace
flywheel (M/T model) or drive plate (A/T model).
• If the surface contacting clutch disc is damaged or
excessively worn, replace flywheel (M/T model).
• If input shaft bearing is damaged or does not rotate
smoothly, replace input shaft bearing (M/T model).

Flywheel / Drive Plate Face Runout

Check flywheel (M/T model) or drive plate (A/T model)
face runout with a dial gauge.
If runout exceeds its limit, replace flywheel (M/T model) IDX00P140054-01

or drive plate (A/T model).

Timing Chain and Chain Tensioner Components

AENJHB0B1416025
OIL

2
OIL

(a)

(b)

5
OIL

3
(b)

(b)
IHL10A141087-01

1. Crankshaft timing sprocket 4. Timing chain tensioner : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: Apply engine oil to sliding surface.
2. Timing chain 5. Timing chain tensioner adjuster
: Apply engine oil. : For installation, refer to “Timing Chain and Chain
Tensioner Removal and Installation”: K15B (Page
1D-39).
3. Timing chain guide : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: Apply engine oil to sliding surface.
 Engine Mechanical: K15B 1D-39

Timing Chain and Chain Tensioner Removal NOTE

and Installation If it is necessary to rotate the camshaft with
AENJHB0B1416026
the timing chain removed, rotate the
Removal camshaft after turning crankshaft
counterclockwise 30 – 90° as shown in figure.
NOTICE
After the timing chain has been removed,
independently turning the camshaft or
crankshaft beyond the allowable angle “a”
ranges shown in figure will cause
interference between pistons and valves or “b”
between the valves themselves, which will
cause damage to these parts and/or related
parts. 1
I7V20A141058-01
Avoid turning each of the camshaft or
crankshaft alone beyond the angle ranges “a”: 30° 1. Camshaft sprocket key
shown in figure. “b”: 90°

1 1) Remove timing chain cover. (Page 1D-33)

2) By turning crankshaft, align camshafts and
“b”
crankshaft at specific position as follows.
“b” a) Align timing mark (1) on VVT actuator with
surface of cylinder head (2).
b) Align timing mark (3) on exhaust camshaft timing
“b” “b”
2 sprocket with matchmark (4) on cylinder head.
c) Check crankshaft sprocket key (5) is aligned with
3
matchmark (6) on cylinder block.
3) Remove timing chain tensioner adjuster (7).
5 4) Remove timing chain tensioner (8).
5) Remove timing chain guide (9).
6) Remove timing chain (10), crankshaft timing
4 sprocket (11) and crankshaft sprocket key.
“a” “a”

2
1 10

IAP70B140027-01

“a”: 90° 3. Matchmark on cylinder head

“b”: 15° 4. Crankshaft sprocket key
1. Timing mark on VVT actuator 5. Matchmark on cylinder block
2. Timing mark on exhaust 8
camshaft timing sprocket 4

6
7

11
IJHB0B141003-01
1D-40 Engine Mechanical: K15B
Installation
1) Position crankshaft sprocket key (1) within a 30° –
90° range (2) counterclockwise from matchmark (3)
on cylinder block.
2) Align timing mark (4) on VVT actuator with surface of
cylinder head (5).
3) Align timing mark (6) on exhaust camshaft timing
sprocket with matchmark (7) on cylinder head.
NOTE
Camshaft may rotate a little pushed by valve
springs and does not remain in the aligned
position. Hold the camshaft in the position
using a wrench carefully.
4 5
7
3
2
1
IGSB0A143041-01
4) Set crankshaft sprocket key and align it with
matchmark on cylinder block by turning crankshaft.
5) Set crankshaft sprocket key and align it with
matchmark on cylinder block by turning crankshaft.
6) Engage timing chain with crankshaft timing sprocket
aligning its colored link (3) with groove (4) of the
sprocket.
7) With timing chain engaged, install crankshaft timing
sprocket to crankshaft aligning the keyway with
crankshaft key.
1 1
2 2
4
3
IFRA0A141066-01
8) Apply engine oil to sliding surfaces of timing chain
guide (1) and timing chain tensioner (2).
9) Install timing chain guide and tighten timing chain
guide bolts (3) to specified torque.
Tightening torque
Timing chain guide bolt (a): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)
10) Tighten timing chain tensioner bolt (4) to specified
torque.
Tightening torque
Timing chain tensioner bolt (b): 25 N·m (2.5 kgf-
m, 18.5 lbf-ft)
4, (b) 3, (a)
2 3, (a)
IFRA0A141067-01
 Engine Mechanical: K15B 1D-41

11) Check that all colored links (1) of timing chain are
aligned with timing marks (2) on VVT actuator and
exhaust camshaft timing sprocket, and groove (3) of
timing sprocket.
1 1
2 2
c) Install timing chain tensioner adjuster (1) with the
retainer (2) inserted.
Tighten timing chain tensioner adjuster bolts (3)
to specified torque, and then remove the
retainer.
Tightening torque
Timing chain tensioner adjuster bolt (a): 11
N·m (1.1 kgf-m, 8.5 lbf-ft)

3,(a)

2
IELA0A142071-02

13) Apply engine oil to timing chain, turn crankshaft

clockwise 720°, and check that the following
3 conditions are satisfied:
• Timing mark (1) on VVT actuator is aligned with
1 surface of cylinder head (2).
IFRA0A141068-01

12) Install timing chain tensioner adjuster (1) as follows. • Timing mark (3) on exhaust camshaft timing
sprocket is aligned with matchmark (4) on cylinder
a) Release lock cam moving link plate (2) in arrow head.
direction and push in plunger (3) fully.
• Crankshaft sprocket key (5) is aligned with
b) Insert a retainer (1.0 – 1.2 mm (0.039 – 0.047 in.) matchmark (6) on cylinder block.
diameter wire or the like) to hole (4) and hold
plunger in place. 2
1

3
1
3

4
IJAA0A142003-01

IJHB0B141004-01

14) Install timing chain cover. (Page 1D-33)

1D-42 Engine Mechanical: K15B

Timing Chain and Chain Tensioner Inspection Crankshaft Timing Sprocket

AENJHB0B1416027 Check teeth of sprocket for wear or damage.
If abnormality is found, replace crankshaft timing
Timing Chain Guide
sprocket.
Check sliding surface of timing chain guide (1) for wear
or damage.
If abnormality is found, replace timing chain guide.

1
I2RH0B140070-01

Timing Chain
I7V20A141066-01
Check timing chain for wear or damage.
Timing Chain Tensioner If abnormality is found, replace timing chain.
Check sliding surface of timing chain tensioner (1) for
wear or damage.
If abnormality is found, replace timing chain tensioner.

I2RH01140077-01

Timing Chain Tensioner Adjuster

Check that teeth (1) is free from damage.
If abnormality is found, replace timing chain tensioner
adjuster.

I7V20A141067-01
1

IELA0A142075-02
 Engine Mechanical: K15B 1D-43

Valve and Cylinder Head Components

AENJHB0B1416028

OIL
9 (a)

10

1
1

3
2

2 13 (b)
3

5
OIL

4 12 11
OIL

4
OIL

6
OIL

7
12

IGSB0A143038-01

1. Valve cotter 9. Cylinder head bolt

: Check cylinder head bolt for deformation to reusing. (Page 1D-52)
: Apply engine oil to bolt thread.
: For tightening order, refer to “Valve and Cylinder Head Removal and Installation”: K15B
(Page 1D-44).
2. Valve spring retainer 10. Cylinder head
3. Valve spring 11. Cylinder head gasket
: For installation, refer to “Valve and
Cylinder Head Disassembly and
Reassembly”: K15B (Page 1D-46).
4. Valve stem seal 12. Dowel pin
: Apply engine oil to valve stem seal lip.
5. Valve spring seat 13. Venturi plug
6. Intake valve : 20 Nm → 40 Nm → +60° → +60° (2.0 kgf-m → 4.1 kgf-m → +60° → +60°, 15.0 lbf-ft → 29.5
: Apply engine oil to sliding surface. lbf-ft → +60° → +60°)
7. Exhaust valve : 3.5 Nm (0.36 kgf-m, 2.5 lbf-ft)
: Apply engine oil to sliding surface.
8. Valve guide : Do not reuse.
1D-44 Engine Mechanical: K15B

Valve and Cylinder Head Removal and 16) Remove the following components from cylinder
Installation head, if necessary.
AENJHB0B1416029
• Fuel injector: (Page 1G-16)
Removal • CMP sensor: (Page 1C-11)
1) Remove engine assembly from vehicle. (Page 1D- • Thermostat case: (Page 1F-9)
27) • EVAP canister purge valve: (Page 1B-3)
2) Remove intake manifold. (Page 1D-13)
Installation
3) Remove exhaust manifold. (Page 1K-3)
1) Clean mating surfaces of cylinder head and cylinder
4) Remove water inlet pipe. (Page 1F-9)
block. Remove oil, old gasket and dust from mating
5) Remove oil pan. (Page 1E-7) surfaces.
6) Remove cylinder head cover. (Page 1D-14) 2) Install dowel pins (1) to cylinder block, if removed.
7) Remove timing chain cover. (Page 1D-33) 3) Set new cylinder head gasket (2) to cylinder block.
8) Remove timing chain. (Page 1D-39)
9) Remove spark plugs. (Page 1H-7)
2
1
10) Remove intake camshaft, exhaust camshaft,
camshaft bearings and tappets. (Page 1D-16)
11) Remove cylinder head bolts in numerical order (“1” –
1
“10”) evenly and gradually.

“5” “10” “8” “2”

1

“3”

IFRA0A141071-01

“1”

“7” “9” “6” “4”

I9P60A141002-01

12) Check all around cylinder head for any other parts
required to be removed or disconnected and remove
or disconnect them if any.
13) Remove cylinder head (1) from cylinder block.
14) Remove dowel pins (2) from cylinder block, if
necessary.
15) Remove cylinder head gasket (3) from cylinder
block.

2
3

2
IFRA0A141070-01
 Engine Mechanical: K15B 1D-45

4) Install cylinder head to cylinder block according to
the following procedure.
NOTE
• Before installing the cylinder head to the
cylinder block, turn crankshaft
counterclockwise and position the
crankshaft sprocket key (1) within an angle
of 30° – 90° from TDC as shown in figure
and keep the valves from coming in
contact with the piston.
“a”
“b”
a) Apply engine oil to thread for 4 mm (0.16 in.)
from lower end of cylinder head bolts.
b) Tighten cylinder head bolts to 20 Nm (2.0 kgf-m,
15.0 lbf-ft) in numerical order (“1” – “10”) as
shown.
c) In the same manner as in Step b), tighten them
to 40 Nm (4.1 kgf-m, 29.5 lbf-ft).
d) Retighten all cylinder head bolts 60° in numerical
order as shown in figure.
e) Retighten all cylinder head bolts 60° again in
numerical order as shown in figure.
Tightening torque
Cylinder head bolt* (a): 20 Nm → 40 Nm →
+60° → +60° (2.0 kgf-m → 4.1 kgf-m → +60° →
+60°, 15.0 lbf-ft → 29.5 lbf-ft → +60° → +60°)

“8”,(a) “6”,(a) “1”,(a) “3”,(a) “9”,(a)

1
I7V20A141058-01

“a”: 30° “b”: 90°

• If cylinder head bolt is reused, check bolt

for deformation. (Page 1D-52)
• For accurate angle tightening of the bolt,
use tightening angle gauge available in the
market. “10”,(a) “4”,(a) “2”,(a) “5”,(a) “7”,(a)
I9P60A141005-02

5) Install EVAP canister purge valve, if removed.

(Page 1B-3)
6) Install thermostat case, if removed. (Page 1F-9)
7) Install CMP sensor, if removed. (Page 1C-11)
8) Install fuel injector, if removed. (Page 1G-16)
9) Install camshafts, camshaft bearings and tappets.
(Page 1D-16)
10) Install spark plugs. (Page 1H-7)
11) Install timing chain. (Page 1D-39)
IJHA0A140061-01
12) Install timing chain cover. (Page 1D-33)
13) Install cylinder head cover. (Page 1D-14)
14) Install oil pan. (Page 1E-7)
15) Install water inlet pipe. (Page 1F-9)
16) Install exhaust manifold. (Page 1K-3)
17) Install intake manifold. (Page 1D-13)
18) Install engine assembly to vehicle. (Page 1D-27)
1D-46 Engine Mechanical: K15B

Valve and Cylinder Head Disassembly and 4) Release special tools, and remove spring retainer
Reassembly and valve spring.
AENJHB0B1416030
5) Remove valve to combustion chamber side.
Disassembly 6) Remove valve stem seal (1) and valve spring seat
(2).
1) Remove venturi plug (1).

I2RH0B140094-01

7) Using special tool (A), remove valve guide from

1 combustion chamber side to valve spring side.
I9P60A141070-01 Special tool
2) Place disassembled parts except valve stem seal (A): 09916M44310
and valve guide in order so that they can be installed
in their original positions.
3) Using special tools (A) and (B), compress valve
spring and then remove valve cotters (1) also using
special tool (C).
Special tool
(A): 09916M14510
(B): 09916M14522
(C): 09916M84511

I2RH0B140095-01

I2RH0B140093-01
 Engine Mechanical: K15B 1D-47

Reassembly 2) Using special tools, install new valve guide to

cylinder head as follows.
NOTICE
Special tool
The engine could be damaged if shavings
(A): 09916M57330
remain inside the valve guide hole after
(B): 09916M56011
reaming it.
Thoroughly remove shavings from the a) Uniformly heat cylinder head to a temperature of
reamed hole. 80 to 100 °C (176 to 212 °F) so that it will not be
distorted, and drive new valve guide into its hole
1) Before installing valve guide into cylinder head, ream with special tools.
guide hole with special tools to remove burrs and b) Install new valve guide until special tool (B)
make the hole truly round. contacts cylinder head.
Special tool After installation, check that valve guide
(A): 09916M34542 protrudes from cylinder head by specified
(B): 09916M37320 dimension “a”.
Valve guide protrusion (In and Ex)
“a”: 11.0 – 11.5 mm (0.434 – 0.452 in.)

I2RH0B140096-01

I2RH0B140097-01

3) Ream valve guide bore with special tools.

After reaming, clean bore.
Special tool
(A): 09916M34542
(B): 09916M34570

I2RH0B140096-01

4) Install valve spring seat to cylinder head.

1D-48 Engine Mechanical: K15B

5) After applying engine oil to valve stem seal (1) and NOTICE
spindle of special tool (B), fit valve stem seal to Insufficient seating of valve cotters between
spindle, and then install valve stem seal to valve retainer and valve stem neck may cause
guide by pushing special tool by hand. coming off of the cotters after engine start.
After installation, check that valve stem seal is Check seating position of the cotters
properly fixed to valve guide. carefully when fitting them. Tapping of stem
NOTICE end with plastic hammer after fitting cotters
will help confirmation of their seating.
If the valve stem seal is installed by striking
the special tool with a hammer or other NOTE
similar tool, the valve stem seal may be
damaged, causing oil to get down past the Applying small amount of grease to valve
seal. cotters may facilitate the fitting.
Push the special tool only by hand to force
Special tool
the valve stem seal into position.
(A): 09916M14510
Special tool (B): 09916M14522
(A): 09917M98221 (C): 09916M84511
(B): 09916M57330

I2RH0B140101-01

10) Install venturi plug (1) and tighten it to specified

torque.
Tightening torque
Venturi plug (a): 3.5 N·m (0.36 kgf-m, 2.5 lbf-ft)

I2RH0B140098-01

6) Apply engine oil to valve stem seal lip and valve

stem.
7) Install valve to valve guide.
8) Install valve spring and spring retainer.
Each valve spring has top end (large-pitch end (1))
and bottom end (small-pitch end (2)). Position spring
in place with its bottom end (small-pitch end) facing
the bottom (valve spring seat side).

[a] 3

1
1, (a)

I9P60A141003-01

2
[b]
IDAA0A141035-01

[a]: Valve spring retainer side 3. Paint mark

[b]: Valve spring seat side

9) Use special tools to compress valve spring and fit

two valve cotters (1) into groove in valve stem.
 Engine Mechanical: K15B 1D-49

Valve and Valve Guide Inspection

AENJHB0B1416031

Valve Guide
Valve stem-to-valve guide clearance
Using a micrometer and bore gauge, take diameter readings on valve stems and valve guides to check valve stem-to-
valve guide clearance.
Take reading at more than one place along the length of each valve stem and valve guide.
If clearance exceeds limit, replace valve and valve guide.
Valve stem and valve guide specification
Item Standard Limit
In 4.965 – 4.980 mm (0.1955 – 0.1960 in.) —
Valve stem outside diameter [A]
Ex 4.940 – 4.955 mm (0.1945 – 0.1950 in.) —
Valve guide inside diameter [B] In & Ex 5.000 – 5.012 mm (0.1969 – 0.1973 in.) —
Valve stem-to-valve guide In 0.020 – 0.047 mm (0.0008 – 0.0018 in.) 0.070 mm (0.0028 in.)
clearance Ex 0.045 – 0.072 mm (0.0018 – 0.0028 in.) 0.090 mm (0.0035 in.)

I4RS0B140016-01

Valve stem end deflection • Measure valve protrusion “a”.

If bore gauge is not available, check end deflection of If measured length is out of standard value, replace
valve stem with a dial gauge instead. valve.
Move valve stem end in directions (1) and (2) to
Valve protrusion “a” standard
measure end deflection.
IN: 34.6 – 35.4 mm (1.37 – 1.39 in.)
If deflection exceeds its limit, replace valve and valve
EX: 34.5 – 35.3 mm (1.36 – 1.38 in.)
guide.
Valve stem end deflection limit
In: 0.14 mm (0.0055 in.)
Ex: 0.18 mm (0.0071 in.) 1
“a”

IYSQ01141096-01
3

Valve
I9T401142024-01
Visual inspection
2. Valve guide 3. Valve seat
• Remove all carbon deposits from valve (1).
• Check each valve for wear, burn or distortion at its
face and valve stem and, if necessary, replace it.
1D-50 Engine Mechanical: K15B

Valve head radial runout Valve seat repair

Check each valve for radial runout with a dial gauge and If a valve seat does not contact its valve uniformly or
“V” block. To check runout, rotate valve slowly. If runout shows width of seating contact out of specified range,
exceeds its limit, replace valve. repair it by cutting, if necessary, and regrinding and then
finish it by lapping.
Valve head radial runout
1) Intake valve seat:
Standard Limit
Use valve seat cutters (1) to make three cuts as
Intake valve 0 – 0.05 mm 0.08 mm
shown in figure. Three cutters must be used: the 1st
(0 – 0.0019 in.) (0.0031 in.)
for making 30° angle, the 2nd for making 70° angle,
Exhaust valve 0 – 0.03 mm 0.08 mm
and 3rd for making 45° angle. The 3rd cut (45°) must
(0 – 0.0011 in.) (0.0031 in.)
be made to produce desired seat width.
Seat width for intake valve seat
“a”: 1.0 – 1.4 mm (0.0394 – 0.0551 in.)
2) Exhaust valve seat:
Use valve seat cutters (1) to make two cuts as
shown in figure. Two cutters must be used: the 1st
for making 15° angle, and the 2nd for making 45°
angle. The second cut must be made to produce
desired seat width.
Seat width for exhaust valve seat
I2RH01140136-01 “b”: 1.0 – 1.4 mm (0.0394 – 0.0551 in.)

Seating contact width

Create contact pattern on each valve in the usual
manner, i.e., by giving uniform coat of marking
compound to valve seat and by rotating and tapping seat
with valve head. Valve lapper (tool used in valve lapping)
must be used. 1

Pattern produced on seating face of valve must be a

continuous ring without any break, and the width of
pattern must be within specified range.
Standard seating width “a” revealed by contact
[A] [B]
pattern on valve face
Intake and Exhaust: 1.0 – 1.4 mm (0.0394 – 0.0551
in.) “a” “b”
“f”
“e” “e”
“d”
“c”
I9P60A141078-01

[A]: Intake “c”: 15° “e”: 45°

[B]: Exhaust “d”: 30° “f”: 70°

3) Valve lapping:
Lap valve on seat in two steps, first with coarse size
lapping compound applied to face and the second
with fine-size compound, each time using valve
lapper according to usual lapping method.

I2RH0B140103-01 Venturi Plug Inspection

AENJHB0B1416032
Check that venturi is not clogged.
If clogged, clean or replace.

I7V20A141083-03
 Engine Mechanical: K15B 1D-51

Cylinder Head Inspection

AENJHB0B1416033
• Remove all carbon deposits from combustion
chambers.

NOTICE
Metal surfaces can be scuffed or nicked
when removing carbon deposits with sharp-
edged tool.
Do not use any sharp-edged tool to scrape
off carbon deposits from engine parts.

I2RH0B140106-01

Distortion of seating faces intake manifold and

I2RH0B140105-01
exhaust manifold on cylinder head
• Check cylinder head for crack on intake and exhaust Limit: 0.05 mm (0.0020 in.)
ports, combustion chambers and head surface.
[A]
Cylinder Head Flatness
Use a straightedge and feeler gauge to check flatness of
gasket surface at a total of 6 positions.
If any measured value exceeds its limit, correct gasket
surface with a surface plate and abrasive paper #400
(waterproof silicon carbide abrasive paper) by placing [B]
abrasive paper on surface plate and rubbing gasket
surface against paper to grind high spots.
If it is impossible to correct cylinder head distortion,
replace cylinder head.

NOTE IFRA0A141072-01

Distorted mating surface of cylinder head [A]: Intake side [B]: Exhaust side
causes combustion gas and/or coolant
leakage, overheating and reduced power
output.

Distortion of cylinder head mating surface

Limit: 0.03 mm (0.0012 in.)
1D-52 Engine Mechanical: K15B

Cylinder Head Bolt Inspection Valve spring preload when compressed to 28.9 mm
AENJHB0B1416034 (1.138 in.)
NOTE Standard: 104 – 120 N (10.6 – 12.2 kgf, 23.4 – 27.0 lbf)
If cylinder head bolt is reused, check thread Limit: 94 N (9.6 kgf, 21.1 lbf)
diameter of cylinder head bolt (1) for
deformation as follows and replace it with
new one if thread diameter difference
exceeds limit.

Measure each thread diameter of cylinder head bolt “c”

at “a” and “d” at “b” using micrometer (3).
Then calculate difference in diameters (“c” – “d”).
If it exceeds limit, replace cylinder head bolt with new “a”
I9T401142034-01
one.
Cylinder head bolt diameter measurement points
“a”: 70 mm (2.76 in.)
“b”: 105 mm (4.13 in.)
Cylinder head bolt diameter difference (deformation)
Limit (“c” – “d”): 0.2 mm (0.008 in.)

1
“c” “d”

I9T401142035-01

“a”
Spring Squareness
“b”
I9P60A141079-01
Use a square and surface plate to check each spring for
squareness in terms of clearance between the third turn
from top of valve spring and square as shown. If
3 clearance exceeds limit, replace valve springs.
Valve spring squareness “a”
2 Limit: 1.9 mm (0.075 in.)

“a”

I9T401142032-01

2. Thread

Valve Spring Inspection

AENJHB0B1416035
IFRA0A141073-01
Valve Spring Free Length and Preload
• Check each valve spring for breakage or weakening.
• Measure valve spring free length and preload.
If measured value is less than limit, replace valve
spring.

NOTE
Weakened valve spring can cause chatter,
not to mention possibility of reducing power
output due to gas leakage caused by
decreased seating pressure.

Valve spring free length “a”

Standard: 42.87 mm (1.688 in.)
 Engine Mechanical: K15B 1D-53

Piston, Piston Ring, Connecting Rod and Cylinder Components

AENJHB0B1416036

OIL
1

OIL
2

OIL
3

OIL
4

OIL
8

OIL
5

11
11
OIL

OIL
10 (a)
6

IHL10A141032-03

1. 1st ring 8. Piston pin

: For assembly, refer to “Piston, Piston Ring, Connecting Rod and : Apply engine oil to sliding surface.
Cylinder Disassembly and Reassembly”: K15B (Page 1D-56).
: Apply engine oil to sliding surface.
2. 2nd ring 9. Piston pin circlip
: For assembly, refer to “Piston, Piston Ring, Connecting Rod and
Cylinder Disassembly and Reassembly”: K15B (Page 1D-56).
: Apply engine oil to sliding surface.
3. Oil ring 10. Connecting rod bolt
: For assembly, refer to “Piston, Piston Ring, Connecting Rod and : Check connecting rod bolt for deformation to reuse. (Page
Cylinder Disassembly and Reassembly”: K15B (Page 1D-56). 1D-59)
: Apply engine oil to sliding surface. : Apply engine oil to bolt thread and seat.
: For tightening order, refer to “Piston, Piston Ring, Connecting
Rod and Cylinder Removal and Installation”: K15B (Page 1D-
54).
4. Piston 11. Dowel pin
: For assembly, refer to “Piston, Piston Ring, Connecting Rod and
Cylinder Removal and Installation”: K15B (Page 1D-54).
: Apply engine oil to sliding surface.
5. Connecting rod : 15 Nm → +65° (1.5 kgf-m → +65°, 11.0 lbf-ft → +65°)
: Do not apply engine oil to mating surface between connecting rod
bearing and connecting rod.
: Apply engine oil to sliding surface.
6. Connecting rod bearing cap : Do not reuse.
: To install connecting rod cap, direct arrow on it to crank pulley.
: Do not apply engine oil to mating surface between connecting rod
bearing and connecting rod cap.
7. Connecting rod bearing
: For applying engine oil, refer to “Piston, Piston Ring, Connecting
Rod and Cylinder Removal and Installation”: K15B (Page 1D-54).
1D-54 Engine Mechanical: K15B

Piston, Piston Ring, Connecting Rod and
Cylinder Removal and Installation
AENJHB0B1416037
NOTICE
If any of the parts listed below is reinstalled
into a position different from the original
position, engine problems could occur.
If these parts are to be reused, keep them in
numerical order so that they can be
reinstalled in their original positions.
• Connecting rods
• Connecting rod bearing caps
• Connecting rod bearings
• Pistons
Removal
1) Remove engine assembly from vehicle. (Page 1D-
27)
2) Remove cylinder head. (Page 1D-44)
3) Mark cylinder numbers on all pistons, connecting
rods and connecting rod caps using silver pencil or
quick drying paint.
4) Remove connecting rod bearing caps.
5) Remove carbon deposits from top of cylinder bore
before removing piston from cylinder.
6) Push piston and connecting rod assembly out from
the top of cylinder bore.
7) Remove connecting rod bearings from connecting
rod and connecting rod bearing cap, if necessary.
Installation
NOTICE
The engine will seize up if it is operated when
the parts listed below are not properly
lubricated.
Lubricate all the friction surfaces of these
parts with engine oil before installing them.
• Crankshaft pins
• Connecting rod bearings
• Pistons
• Piston rings
• Cylinder walls
2) Install connecting rod bearing to connecting rod
bearing cap and connecting rod as follows.
a) Check mating surfaces of bearing backside and
corresponding connecting rod are clean and dry.
b) Fit tab (1) of connecting rod bearing to groove (2)
of connecting rod and bearing cap.
c) Press bearing end (3) until it becomes flush with
connecting rod or connecting rod bearing cap
mating surface.
NOTICE
If oil is present between the bearing backside
and connecting rod surface, the bearing
could heat up to very high temperature,
resulting in seizure.
Thoroughly wipe off any trace of oil that is
present between the bearing backside and
connecting rod surface.
1 3
2
I7V20A141088-01
3) Apply engine oil to pistons, piston rings, cylinder
walls, connecting rod bearings and crankshaft pins.
4) Position crankshaft pin corresponding to piston and
connecting rod assembly to be installed to the
bottom dead center.
5) Install piston and connecting rod assembly into
cylinder bore as follows.
a) Point front mark (1) on piston head to crankshaft
pulley side (2) and carefully insert piston and
connecting rod assembly.
2
1

1) Check that dowel pins (1) are installed to connecting IHL10A141033-01

rod bearing cap.

1
IELA0A142163-02
 Engine Mechanical: K15B 1D-55

b) Compress piston rings with special tool. 6) Install connecting rod bearing cap as follows.
c) Holding special tool firmly against cylinder block,
NOTICE
tap piston head with a hammer handle.
Using connecting rod bolts that are deformed
d) If oil ring catches cylinder edge, do not push
exceeding the service limit could lead to
piston by force. Draw out piston a little and
engine problems.
repeat Step b) – c).
Before installing connecting rod bearing cap,
e) After piston rings enter cylinder bore, continue check that connecting rod bolts are not
pushing piston and connecting rod assembly deformed exceeding the service limit
until big end bearing meets crankshaft pin. referring to “Connecting rod bolt
NOTICE deformation” under “Piston Pin and
Connecting Rod Inspection”: K15B (Page 1D-
• With oil ring got stuck in the cylinder edge, 59).
forced pushing the piston will break the oil
ring rail and spoil the engine performance NOTE
if the ring is installed as it is.
For accurate angle tightening of the bolt, use
If breakage of oil ring is noted, replace the
tightening angle gauge available in the
piston ring as a set.
market.
• While inserting piston and connecting rod
assembly into cylinder bore, connecting
rod big end may hit crankshaft pin and
damage the pin surface.
Carefully insert piston and connecting rod
assembly not to hit crankshaft pin with the
big end.

Special tool
(A): 09916M77310

IJHA0A140061-01

(A) a) Point front mark (protrusion) (2) on connecting

rod bearing cap (1) to crankshaft pulley side.
b) Apply engine oil to thread and seat of connecting
rod bolt (3).
c) Tighten a pair of connecting rod bolts evenly and
gradually to 15 Nm (1.5 kgf-m, 11.0 lbf-ft).
I8T401142095-01
d) Retighten them 65°.
e) In the same manner as in Step c) – d), tighten
connecting rod bolts of other cylinders.
f) Apply engine oil to all of connecting rod big ends.
Tightening torque
Connecting rod bolt* (a): 15 Nm → +65° (1.5
kgf-m → +65°, 11.0 lbf-ft → +65°)

3, (a)
2
1

3, (a)
IAP70P140031-01

7) Install cylinder head. (Page 1D-44)

8) Install engine assembly. (Page 1D-27)
1D-56 Engine Mechanical: K15B

Piston, Piston Ring, Connecting Rod and Reassembly

Cylinder Disassembly and Reassembly
AENJHB0B1416038 NOTICE

NOTICE The engine will seize up if it is operated when

the parts listed below are not properly
If any of the parts listed below is reinstalled lubricated.
into a position different from the original Lubricate all the friction surfaces of these
position, engine problems could occur. parts with engine oil before installing them.
If these parts are to be reused, keep them in
• Pistons
numerical order so that they can be
reinstalled in their original positions. • Piston pins
• Pistons • Piston rings
• Piston pins • Connecting rods
• Piston rings • Connecting rod bearings
• Connecting rods
1) Remove carbon deposits from piston head and ring
• Connecting rod bearings grooves using a suitable tool.
2) Install piston pin to piston (1) and connecting rod (2)
Disassembly
as follows.
1) Using a piston ring expander, remove 1st ring, 2nd
a) Apply engine oil to piston pin, piston pin hole in
ring and oil ring from piston.
piston and connecting rod.
2) Remove piston pin from piston and connecting rod
b) Fit connecting rod positioning oil hole (5) on
as follows.
connecting rod and front mark (4) on piston as
a) Remove piston pin circlips (1), as shown. shown in figure.
c) Insert piston pin into piston and connecting rod.
d) Install new piston pin circlips (3) so that each
opening comes within the range indicated by
arrow (6) as shown in figure.

6 4
“a”

6
3 “a”

I2RH0B140113-01
2 3
1
b) Remove piston pin. 5

IHL10A141034-01

“a”: 45°

I2RH0B140114-01
 Engine Mechanical: K15B 1D-57

3) Install piston rings to piston noting the following • Difference of measurements at two positions exceeds
points. taper limit.
• As shown in figure, 1st and 2nd rings have top • Difference between thrust and axial measurements
mark (1) respectively. When installing them, face exceeds out-of-round limit.
each top mark upward.
Cylinder bore diameter
• 1st ring (2) differs from 2nd ring (3) in thickness Standard: 74.000 – 74.014 mm (2.9134 – 2.9139 in.)
and shape of surface contacting cylinder wall. Limit: 74.050 mm (2.9153 in.)
• When installing oil ring (4), install spacer first and
Cylinder taper and out-of-round
then two rails.
Limit: 0.010 mm (0.0004 in.)

3
I7V20A141095-01

“e” “f”
I8C50A140063-01

4) After installing three rings (1st, 2nd and oil rings), “c”
distribute their end gaps as shown in figure.
“d”
“b”
“a”
I9P60A141081-01

“e”: 50 mm (1.97 in.) “f”: 100 mm (3.94 in.)

Piston
Visual inspection
IFAE0A140127-01
Check piston for faults, crack or other damages.
“a”: 45° 3. 1st ring end gap
Damaged or faulty piston should be replaced.
1. Front mark 4. 2nd ring end gap and oil ring spacer gap
2. Oil ring upper rail gap 5. Oil ring lower rail gap
Piston diameter
As shown in figure, piston diameter should be measured
Cylinder, Piston and Piston Ring Inspection at specified position “a” 12 mm (0.47 in.) from piston skirt
AENJHB0B1416039
end in the direction perpendicular to piston pin.
Cylinder If measured diameter is less than its limit, replace piston.
Visual inspection Piston diameter specification
Check cylinder walls for scratches, roughness or ridges Standard size (used piston): 73.978 – 73.990 mm
which indicate excessive wear. (2.9126 – 2.9129 in.)
If cylinder bore is very rough, deeply scratched or ridged, Standard size (new piston with coating): 73.984 –
replace cylinder block, piston rings and/or pistons. 74.016 mm (2.9127 – 2.9140 in.)

Cylinder bore diameter, taper and out-of-round

Using a cylinder gauge, measure cylinder bore in thrust
and axial directions at two positions (“a” and “b”) and
cylinder taper (“c” and “d”) as shown in figure.
If any of the following conditions is found, replace
cylinder block. “a”

• Cylinder bore diameter exceeds limit. IHL10A141052-01

“a”: 12 mm (0.47 in.)

1D-58 Engine Mechanical: K15B

Piston clearance 2) Fit new piston ring (1) into piston groove, and
Measure cylinder bore diameter and piston diameter to measure clearance between ring and ring land using
find their difference which is piston clearance. Piston feeler gauge (2). If clearance is out of limit, replace
clearance should be within specification. If it is not as piston.
specified, replace cylinder block, piston rings and/or
Ring groove clearance
pistons.
Standard Limit
NOTE 0.03 – 0.07 mm
1st ring 0.12 mm (0.0047 in.)
Cylinder bore diameters used here are (0.0012 – 0.0027 in.)
measured in thrust direction at two positions. 0.02 – 0.06 mm
2nd ring 0.10 mm (0.0039 in.)
(0.0008 – 0.0023 in.)
Piston clearance 0.04 – 0.12 mm
Oil ring —
Standard (used piston): 0.010 to 0.036 mm (0.00040 (0.0158 – 0.0472 in.)
to 0.00141 in.)
Standard (new piston with coating): –0.016 to 0.030
mm (–0.00063 to 0.00118 in.)
Limit: 0.072 mm (0.0028 in.)
1

IHL10A141036-01

Piston Ring
Piston ring end gap
I7V20A141095-01
To measure end gap, insert piston ring (1) into cylinder
bore and then measure the gap using feeler gauge (2).
If measured gap exceeds limit, replace piston ring.

NOTE
Remove carbon deposit from top of cylinder
bore before inserting piston ring.
“a”

IHL10A141035-01 Piston ring end gap

“a”: 12 mm (0.47 in.) Item Standard Limit
0.15 – 0.25 mm
Ring groove clearance Top ring 0.7 mm (0.0276 in.)
(0.0060 – 0.0098 in.)
1) Before checking, piston grooves must be clean, dry 0.25 – 0.38 mm
2nd ring 1.0 mm (0.0394 in.)
and free from carbon deposits. (0.0099 – 0.0149 in.)
0.10 – 0.40 mm
Oil ring 1.2 mm (0.0472 in.)
(0.0040 – 0.0157 in.)

"a"

1
I7V20A141096-02

“a”. 50 mm (2.0 in.)

 Engine Mechanical: K15B 1D-59

Piston Pin and Connecting Rod Inspection Connecting Rod

AENJHB0B1416040
Piston Pin
Visual inspection
Check piston pin, connecting rod small-end bore and
piston pin hole in piston for wear or damage, paying
particular attention to condition of small-end bore
bushing. If piston pin, connecting rod small end bore or
piston pin hole in piston is badly worn or damaged,
replace piston pin, connecting rod and/or piston.
Big-end side clearance
Check big-end of connecting rod for side clearance, with
rod fitted and connected to its crankshaft pin in a normal
manner. If measured clearance exceeds its limit, replace
connecting rod.
Big-end side clearance
Standard: 0.10 – 0.30 mm (0.0040 – 0.0118 in.)
Limit: 0.55 mm (0.0217 in.)

Piston pin clearance

Check piston pin clearance in small-end and piston.
Replace connecting rod and/or piston, if its small-end is
badly worn or damaged or if measured clearance
exceeds limit.
Piston pin clearance in connecting rod small-end
Standard: 0.003 – 0.018 mm (0.0002 – 0.0007 in.)
Limit: 0.0018 mm (0.0007 in.)
Piston pin clearance in piston
Standard: 0.004 – 0.013 mm (0.0002 – 0.0005 in.) IEL70B140192-01

Limit: 0.013 mm (0.0005 in.)

Small-end bore
18.003 – 18.013 mm (0.7088 – 0.7091 in.)
Piston pin outside diameter
17.995 – 18.000 mm (0.7085 – 0.7086 in.)
Diameter of piston pin hole in piston
18.004 – 18.008 mm (0.7088 – 0.7089 in.)
Connecting rod alignment
Mount connecting rod on aligner to check it for bow and
twist. If measured value exceeds the limit, replace
connecting rod.
Connecting rod alignment
Limit on bow: 0.05 mm (0.0020 in.)
Limit on twist: 0.10 mm (0.0039 in.)

I4RH01140053-01

I4RS0A140023-01
1D-60 Engine Mechanical: K15B

Connecting rod bolt deformation Crankshaft pin taper ([a] – [b]) and out-of-roundness
Measure each thread diameter of connecting rod bolt (1) ([1] – [2])
at “c” on 12 mm (0.47 in.) from bolt mounting surface Limit: 0.005 mm (0.0002 in.)
and “d” on 32 mm (1.26 in.) from bolt mounting surface
using a micrometer (3).
Calculate difference in diameters (“c” – “d”). If it exceeds
limit, replace connecting rod bolt.
Connecting rod bolt measurement points
“a”: 12 mm (0.47 in.)
“b”: 32 mm (1.26 in.)
Connecting rod bolt diameter difference
Limit (“c” – “d”): 0.05 mm (0.002 in.)

1 “c” “d” [1] [a] [b]

[2]

“a”

I8T401142103-01
“b”

Connecting Rod Bearing General Information

3 • Service connecting rod bearings are available in
standard size and 0.25 mm (0.0098 in.) undersize
bearing, and standard size bearing has five kinds of
2
bearings differing in tolerance.
• For identification of undersize bearing, it is painted red
at the position as shown in figure, undersize bearing
thickness is 1.605 – 1.615 mm (0.0632 – 0.0635 in.)
I9P60A141082-01 at its center.
2. Thread

Crankshaft Pin and Connecting Rod Bearing

Inspection
AENJHB0B1416041

Crankshaft Pin Diameter

Check crankshaft pin for uneven wear or damage.
Measure crankshaft pin for out-of-round or its taper with 1
a micrometer. If crankshaft pin is damaged or out-of IHL10A141037-01
round or taper is out of limit, replace crankshaft or 1. Painting
regrind crankshaft pin to undersize and use undersize
bearing. Connecting Rod Bearing Visual Inspection
NOTE Check bearing shells for signs of fusion, pitting, burn or
flaking and observe contact pattern. Defective bearing
When regrinding crankpin to undersize, use shells must be replaced.
undersize connecting rod bearing.

Crankshaft pin diameter

Connecting rod bearing
Crankshaft pin diameter
size
37.982 – 38.000 mm
Standard
(1.4954 – 1.4960 in.)
0.25 mm (0.0098 in.) 37.732 – 37.750 mm
undersize (1.4855 – 1.4862 in.)
 Engine Mechanical: K15B 1D-61

Connecting Rod Bearing Clearance 5) If clearance cannot be brought to its limit even by a
new standard size bearing, use next thicker bearing
NOTICE and recheck clearance or regrind crankshaft pin to
Using connecting rod bolts that are deformed undersize and use 0.25 mm (0.0098 in.) undersize
exceeding the service limit could lead to bearing.
engine problems.
After checking connecting rod bearing Selection of Connecting Rod Bearing
clearance, check that connecting rod bolts If engine is under the following conditions, select a new
are not deformed exceeding the service limit standard bearing as follows, and install it.
referring to “Connecting rod bolt • Bearing is defective.
deformation” under “Piston Pin and
• Bearing clearance is out of specification.
Connecting Rod Inspection”: K15B (Page 1D-
59). • Crankshaft or connecting rod is replaced.
1) Check stamped numbers on connecting rod and its
1) Clean connecting rod bearings and crankshaft pin. cap as shown.
2) Place a piece of gauging plastic (1) to full width of Three kinds of numbers (“1”, “2” and “3”) represent
crankshaft pin as contacted by bearing (parallel to the following connecting rod big-end inside
crankshaft), avoiding oil hole. diameters.
For example, stamped number “1” indicates that
corresponding connecting rod big-end inside
1 diameter is 41.0000 – 41.0060 mm (1.61418 –
1.61440 in.).
Connecting rod big-end inside diameter
Stamped
Connecting rod big-end inside diameter
number
41.0000 – 41.0060 mm
1
(1.61418 – 1.61440 in.)
41.0061 – 41.0120 mm
2
I7V20A141100-01 (1.61442 – 1.61464 in.)
3) Without applying engine oil, install connecting rod 41.0121 – 41.0180 mm
3
bearings and its cap referring to Step 1) – 6) (1.61466 – 1.61488 in.)
“Installation” under “Piston, Piston Ring, Connecting
Rod and Cylinder Removal and Installation”: K15B
(Page 1D-54).
4) After three minutes, remove cap and measure
gauging plastic (1) width (clearance) at the widest
point using a scale (2) on gauging plastic envelope.
2
If clearance exceeds its limit, select a new standard
size connecting rod bearing. (Page 1D-61)
After selecting new connecting rod bearing, recheck 1
clearance.
Connecting rod bearing clearance
IHL10A141074-01
Standard: 0.031 – 0.049 mm (0.0013 – 0.0019 in.)
Limit: 0.065 mm (0.0026 in.) 1. Connecting rod big-end inside diameter number
2. Weight indication mark

2
1

I7V20A141101-01
1D-62 Engine Mechanical: K15B

2) Check crankshaft pin diameter. On crank web No.5, 4) From number stamped on connecting rod and its cap
four alphabets are stamped as shown in figure. and alphabets stamped on crank web No.5,
Three kinds of alphabet (“A”, “B” and “C”) represent determine new standard bearing to be installed to
the following crankshaft pin diameter respectively. connecting rod big-end inside, referring to the
For example, stamped “A” indicates that following table.
corresponding crankshaft pin diameter is 37.9940 – For example, if number stamped on connecting rod
38.0000 mm (1.49583 – 1.49606 in.). and its cap is “1” and alphabet stamped on crank
web No.5 is “B”, install a new standard bearing
Crankshaft pin outer diameter
painted in “Black” to its connecting rod big-end
Stamped alphabet Crankshaft pin diameter inside.
37.9940 – 38.0000 mm
A Connecting rod bearing cross-reference
(1.49583 – 1.49606 in.)
37.9880 – 37.9939 mm selection table (standard size)
B
(1.49560 – 1.49581 in.) Stamped number for
37.9820 – 37.9879 mm connecting rod big end
C
(1.49536 – 1.49558 in.) inside diameter
1 2 3
Stamped alphabet A Green Black Nothing
for crankshaft pin B Black Nothing Yellow
diameter C Nothing Yellow Blue

5) Check bearing clearance with newly selected

standard bearing referring to “Connecting Rod
Bearing Clearance”: K15B (Page 1D-61).
If clearance still exceeds its limit, use next thicker
bearing and recheck clearance.

1 2 3 4
I9P60A141010-01

1. Crankshaft pin No.1 3. Crankshaft pin No.3

2. Crankshaft pin No.2 4. Crankshaft pin No.4

3) There are five kinds of standard bearing thickness

and they are painted in the following colors.
Each color indicates the following thickness at the
center of bearing.
Standard size connecting rod bearing thickness
Color
Bearing thickness
painted
Blue 1.498 – 1.501 mm (0.05898 – 0.05909 in.)
Yellow 1.495 – 1.498 mm (0.05886 – 0.05897 in.)
Nothing 1.492 – 1.495 mm (0.05875 – 0.05885 in.)
Black 1.489 – 1.492 mm (0.05863 – 0.05874 in.)
Green 1.486 – 1.489 mm (0.05851 – 0.05862 in.)

1
IFAE0A140128-01

1. Paint
 Engine Mechanical: K15B 1D-63

Main Bearing, Crankshaft and Cylinder Block Components

AENJHB0B1416042

(c) 2

OIL
4

(e)

22 1

(e)
OIL

11

3 1322 (d) 15
21 (a)
OIL

10 16

6
5 7

20
18
19
17 (a)
7

14 1217G

(e)
OIL

7 12
OIL

10
13
OIL

8
OIL

9 (b)
IJHB0B141005-01
1D-64 Engine Mechanical: K15B

1. CKP sensor 15. Flywheel

2. Knock sensor 16. Input shaft bearing
: For removal and installation, refer to “Knock Sensor Removal
and Installation”: K15B in Section 1C (Page 1C-12).
3. Oil pressure switch 17. Flywheel bolt
: Apply sealant 99000-32150 to thread.
4. Cylinder block 18. Drive plate front flange
: Do not apply engine oil to main bearing seating face.
: Apply engine oil to sliding surface.
5. Sensor plate 19. Drive plate
6. Crankshaft timing sprocket key 20. Drive rear plate
7. Dowel pin 21. Drive plate bolt
8. Main bearing cap 22. Timing chain oil jet
9. Main bearing cap bolt : 83 Nm (8.5 kgf-m, 61.5 lbf-ft)
: Apply engine oil to bolt thread and seat.
: For tightening order, refer to “Main Bearing, Crankshaft and
Cylinder Block Removal and Installation”: K15B (Page 1D-64).
10. Main bearing : 20 Nm → 40 Nm → +60° (2.0 kgf-m → 4.1 kgf-m → +60°, 15.0
: For applying engine oil, refer to “Main Bearing, Crankshaft and lbf-ft → 29.5 lbf-ft → +60°)
Cylinder Block Removal and Installation”: K15B (Page 1D-64).
11. Thrust bearing : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: Install thrust bearing with oil grooves facing out.
: Apply engine oil to sliding surface.
12. Crankshaft : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
: Apply engine oil to sliding surface.
13. Crankshaft rear oil seal : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: Apply engine oil to seal lip.
: For installation, refer to “Main Bearing, Crankshaft and Cylinder
Block Removal and Installation”: K15B (Page 1D-64).
14. Oil seal housing : Do not reuse.
: Apply sealant 99000-31260 referring to “Main Bearing,
Crankshaft and Cylinder Block Removal and Installation”: K15B
(Page 1D-64).

Main Bearing, Crankshaft and Cylinder Block 8) Remove main bearing caps.
Removal and Installation
AENJHB0B1416043 “7” “9” “5”

Removal “3” “1”

1) Remove engine assembly from vehicle. (Page 1D-
27)
2) Remove flywheel (M/T model) or drive plate (A/T
model). (Page 1D-37) “4” “2”

3) Remove pistons and connecting rods. (Page 1D-

54) “8” “10” “6”
I9P60A141012-01
4) Remove CKP sensor. (Page 1C-11) 9) Remove crankshaft from cylinder block.
5) Remove oil seal housing (1). 10) Remove sensor plate from crankshaft, if necessary.
11) Remove ISG, if necessary. (Page 1J-7)
12) Remove water pump, if necessary. (Page 1F-17)
13) Remove knock sensor, if necessary. (Page 1C-12)
14) Remove oil pressure switch, if necessary. (Page
1E-5)

I7V20A141105-01

6) Remove crankshaft rear oil seal from oil seal

housing.
7) Remove main bearing cap bolts in numerical order
(“1” – “10”) evenly and gradually.
 Engine Mechanical: K15B 1D-65

Installation b) Align hole (4) in sensor plate with hole (5) in

crankshaft (2), and then install sensor plate to
NOTICE crankshaft.
• The engine will seize up if it is operated c) Tighten sensor plate screws to specified torque.
when the parts listed below are not
Tightening torque
properly lubricated.
Sensor plate screw (a): 11 N·m (1.1 kgf-m, 8.5
Lubricate all the friction surfaces of these
lbf-ft)
parts with engine oil before installing them.
– Crankshaft journals
3
– Main bearings (sliding surface) 2
– Thrust bearings 1 1
(a)
• Using main bearing cap bolts that are
deformed exceeding the service limit could
lead to engine problems.
When main bearing cap bolts are reused,
check that main bearing cap bolts are not
deformed exceeding the service limit (a)
referring to “Main Bearing Cap Bolt” under (a) 5
4
“Main Bearing Inspection”: K15B (Page IHL10A141039-03
1D-69). 6) Install main bearings to cylinder block and main
bearing caps as follows.
NOTE
NOTICE
Properly use main bearings checking their
width and oil hole. If oil is present between the bearing backside
and cylinder block or main bearing cap
“a” “a” surface, the bearing could heat up to very
high temperature, resulting in seizure.
Thoroughly wipe off any trace of oil that is
2
present between the bearing backside and
1
cylinder block or main bearing cap surface.

NOTE
• Install main bearing halves (1) with oil
groove (2) to cylinder block.

3 4

2
2
“b” “b”
IJHA0A140051-02
2
“a”: Width (wider than “b”)
“b”: Width (narrower than “a”)
1
1. Main bearing No.1 upper half with oil groove and 2 holes
2. Main bearing No.1 lower half 1
3. Main bearing No.2 – 5 upper halves with oil groove and 1 hole
4. Main bearing No.2 – 5 lower halves
1

IFRA0A141081-01

1) Install oil pressure switch, if removed. (Page 1E-5)
2) Install knock sensor, if removed. (Page 1C-12)
3) Install water pump, if removed. (Page 1F-17)
4) Install ISG, if removed. (Page 1J-7)
5) Install sensor plate (1) as follows, if removed.
a) Face flat side of sensor plate toward crankshaft
(3).
• Install other main bearing halves without
oil groove to main bearing caps.
a) Check mating surfaces (5) of bearing backside
and corresponding cylinder block and main
bearing cap are clean and dry.
b) Fit the tab (1) on each bearing into groove (2) in
cylinder block and main bearing cap.
1D-66 Engine Mechanical: K15B

c) Press bearing end (3) until it fully seats in NOTICE

cylinder block and main bearing cap. Using main bearing cap bolts that are
d) Apply engine oil to sliding surface (4) of main deformed exceeding the service limit could
bearing halves at cylinder block side. lead to engine problems.
Before installing main bearing cap, check
that main bearing cap bolts are not deformed
exceeding the service limit referring to “Main
1 3 Bearing Cap Bolt” under “Main Bearing
4 Inspection”: K15B (Page 1D-69).

2 NOTE

5
For accurate angle tightening of the bolt, use
I8T401142036-01 tightening angle gauge available in the
7) Check that dowel pins (1) are installed to each main market.
bearing cap.

IHL10A141040-04

8) Apply engine oil to thrust bearings (1) and install IJHA0A140061-01

them to cylinder block between No.2 and No.3
cylinders with oil grooves (2) facing outward.
2 c) Tighten main bearing cap bolts to 20 Nm (2.0
1
IHL10A141041-01
9) Check cleanliness of crankshaft journal and place
crankshaft on cylinder block and then apply engine
oil to crankshaft journal.
10) Install main bearing caps according to the following
a) Point arrow mark on cap to crankshaft pulley
side and set main bearing caps to cylinder block.
b) Apply engine oil to bolt thread and seat of main
bearing cap bolts.
kgf-m, 15.0 lbf-ft) in numerical order (“1” – “10”)
as shown.
d) In the same manner as in Step c), tighten them
to 40 Nm (4.1 kgf-m, 29.5 lbf-ft).
e) Retighten all main bearing cap bolts 60° in
numerical order as shown in figure.
Tightening torque
Main bearing cap bolt* (a): 20 Nm → 40 Nm
→ +60° (2.0 kgf-m → 4.1 kgf-m → +60°, 15.0
lbf-ft → 29.5 lbf-ft → +60°)
“4”, (a) “2”, (a) “6”, (a)

procedure.
“8”, (a) “10”, (a)

“7”, (a) “9”, (a)

“3”, (a) “1”, (a) “5”, (a)

IFRA0A141082-01
 Engine Mechanical: K15B 1D-67

11) Check that crankshaft rotates smoothly when turning 16) Install oil seal housing (1) according to the following
it by hand. procedure.
12) Install new crankshaft rear oil seal (1) to oil seal a) Apply engine oil to oil seal lip.
housing (2) using special tool. b) Within 2 minutes after applying sealant, install oil
Special tool seal housing applying special tool to crankshaft.
(A): 09911M16300 NOTICE
Rear oil seal installing position (depth)
• Turning over of oil seal lip or coming off of
“a”: 2 mm (0.079 in.)
the inside spring will cause oil leakage.
(A)
While installing oil seal housing, pay
attention not to turn over oil seal lip nor
disengage the inside spring.
• The oil seal housing bolts are pre-coated
with adhesive. If the bolts are reused, they
(A) 1
“a”
may work loose.
Replace the oil seal housing bolts with new
2
ones whenever they are removed.

c) Tighten new oil seal housing bolts (2) to

2 1
specified torque.
I7V20A141110-01 Special tool
13) Check that dowel pins (2) are installed to oil seal (A): 09911M97720
housing (1) as shown in figure. Tightening torque
14) Clean mating surfaces of cylinder block and oil seal Oil seal housing bolt (a): 11 N·m (1.1 kgf-m,
housing. 8.5 lbf-ft)
15) Apply sealant to mating surface of oil seal housing.
(A)
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G) 3

Sealant amount for rear oil seal housing

Width: “a”: 3 mm (0.12 in.)
1
Height “b”: 2 mm (0.08 in.)

“a” (A)
“A” “b”
2,(a)

I7V20A141112-01
“A”
3. Crankshaft side

1
17) Install CKP sensor. (Page 1C-11)
18) Install pistons and connecting rods. (Page 1D-54)
2 2
19) Install flywheel (M/T model) or drive plate (A/T
model). (Page 1D-37)
20) Install cylinder head. (Page 1D-44)
IFRA0A141083-01
21) Install camshafts and tappets. (Page 1D-16)
22) Install timing chain. (Page 1D-39)
23) Install timing chain cover. (Page 1D-33)
24) Install cylinder head cover. (Page 1D-14)
25) Install oil pan. (Page 1E-7)
26) Install engine assembly to vehicle. (Page 1D-27)
1D-68 Engine Mechanical: K15B

Crankshaft Inspection Out-of-Roundness and Taper (Uneven Wear) of

AENJHB0B1416044 Journal
An unevenly worn crankshaft journal shows up as a
Crankshaft Runout
difference in diameter at a cross section or along its
Using a dial gauge, measure runout at center journal.
length (or both). This difference, if any, is determined by
Rotate crankshaft slowly. If runout exceeds its limit,
taking micrometer readings. If any one of journals is
replace crankshaft.
badly damaged or uneven wear exceeds its limit, regrind
Crankshaft runout or replace crankshaft.
Limit: 0.02 mm (0.0008 in.)
Crankshaft journal outside diameter
Standard: 45.000 – 45.018 mm (1.7717 – 1.7723 in.)
Limit: 44.99 mm (1.7713 in.)
Crankshaft out-of-roundness ([1] – [2]) and taper ([a]
– [b])
Limit: 0.01 mm (0.0004 in.)

[a] [b]

I7V20A141113-01

Crankshaft Thrust Play

1) Assemble crankshaft, main bearings, thrust bearings [1]

and main bearing caps. (Page 1D-64)

2) Using dial gauge (1), measure crankshaft thrust play
(2) as shown in figure. [2]

If measured thrust play exceeds limit, replace thrust

bearing with new one (standard size or oversize) to
obtain standard thrust play. I8C50A140075-01

Recheck crankshaft thrust play.

Crankshaft thrust play
Standard: 0.11 – 0.31 mm (0.0044 – 0.0122 in.)
Limit: 0.35 mm (0.0138 in.)
Thrust bearing thickness
Standard size: 2.470 – 2.520 mm (0.9725 – 0.9921
in.)
Oversize (0.125 mm, 0.00492 in.): 2.533 – 2.583
mm (0.0998 – 0.1016 in.)

1 2

I8C50A140074-01
 Engine Mechanical: K15B 1D-69

Main Bearing Inspection Visual Inspection

AENJHB0B1416045 Check bearings for pitting, scratches, wear or damage.
NOTE If any defect is found, replace both upper and lower
halves. Never replace either half without replacing the
Properly use main bearings checking their other half.
width and oil hole.
Main Bearing Clearance
“a” “a”

NOTE
Do not rotate crankshaft while gauging
1 2 plastic is fitted.

Check clearance using gauging plastic according to the

following procedure.
1) Remove main bearing caps.
2) Clean bearings and main journals.
3) Place a piece of gauging plastic (1) to full width of
3 4 bearing (parallel to crankshaft) on journal, avoiding
oil hole.

1
“b” “b”
IJHA0A140051-02

“a”: Width (wider than “b”)

“b”: Width (narrower than “a”)
1. Main bearing No.1 upper half with oil groove and 2 holes
2. Main bearing No.1 lower half
3. Main bearing No.2 – 5 upper halves with oil groove and 1 hole
4. Main bearing No.2 – 5 lower halves

I7V20A141118-01

General Information 4) Without applying engine oil, install main bearing cap
referring to Step 10) – 11) in “installation” under
• Service main bearings are available in standard size
“Main Bearing, Crankshaft and Cylinder Block
and 0.25 mm (0.0098 in.) undersize, and each of them
Removal and Installation”: K15B (Page 1D-64).
has five kinds of bearings differing in tolerance.
• Upper bearing half (1) has oil groove (2) as shown in
figure.
Install this half with oil groove to cylinder block (3).
• Lower bearing half does not have oil groove.

I7V20A141117-01
1D-70 Engine Mechanical: K15B

5) After three minutes, remove main bearing cap and Selection of Main Bearing
using scale (2) on gauging plastic envelope, Standard size bearing
measure gauging plastic (1) width at the widest If engine is under one of the following conditions, select
point. a new standard bearing as follows, and install it.
Main bearing No.1 clearance • Bearing is defective.
Standard: 0.014 – 0.032 mm (0.00055 – 0.00125 • Bearing clearance is out of specification.
in.) • Crankshaft or cylinder block is replaced.
Limit: 0.055 mm (0.00216 in.)
1) Check journal diameter. As shown in figure, crank
Main bearing No.2 – 5 clearance web No.4 has stamped numbers.
Standard: 0.016 – 0.034 mm (0.00063 – 0.00133 Six kinds of numbers (“1” – “6”) represent the
in.) following journal diameters.
Limit: 0.050 mm (0.00197 in.) Stamped numbers on crank web No.4 represent
diameters of journal indicated with an arrow in figure
1 respectively.
2 For example stamped number “1” indicates that
corresponding journal diameter is 45.0150 – 45.0180
mm (1.77226 – 1.77236 in.).
Crankshaft journal diameter
Stamped numbers Journal diameter
45.0150 – 45.0180 mm
1
(1.77225 – 1.77236 in.)
45.0120 – 45.0149 mm
2
I7V20A141119-01 (1.77213 – 1.77224 in.)
If measured clearance is less than standard or more 45.0090 – 45.0119 mm
3
than service limit, replace main bearings with new (1.77201 – 1.77212 in.)
ones referring to “Selection of Main Bearing”: K15B 45.0060 – 45.0089 mm
4
(Page 1D-70) and recheck main bearing clearance. (1.77189 – 1.77200 in.)
If measured clearance with new bearing is out of 45.0030 – 45.0059 mm
5
standard, select other bearing according to the (1.77178 – 1.77188 in.)
following procedure and recheck main bearing 45.0000 – 45.0029 mm
6
clearance. (1.77166 – 1.77176 in.)
• More than standard:
Replace bearing with one size thicker or regrind
crankshaft journal to undersize and use 0.25 mm
(0.0098 in.) undersize bearing.
• Less than standard:
Replace bearing with one size thinner or regrind
crankshaft journal to undersize and use 0.25 mm 1
(0.0098 in.) undersize bearing.

IHL10A141042-01

1. Crankshaft pulley side

 Engine Mechanical: K15B 1D-71

2) Check bearing cap bore diameter without bearing. 3) There are five kinds of standard bearing thickness
On mating surface of cylinder block, six alphabets or and they are painted in the following colors.
numbers are stamped as shown in figure (1). Each color indicates the following thickness at the
Six kinds of alphabets (“A” – “F”) or numbers (“1” – center of bearing.
“6”) represent the following cap bore diameters.
Standard size crankshaft main bearing No.1
Stamped alphabets or numbers on cylinder block
thickness
represent bearing cap bore diameter marked with an
arrow in figure respectively. Color
Bearing thickness
For example, stamped “A” or “1” indicates that painted
corresponding bearing cap bore diameter is 49.0000 Pink 1.991 – 1.994 mm (0.07838 – 0.07950 in.)
– 49.0030 mm (1.92914 – 1.92925 in.). Purple 1.994 – 1.997 mm (0.07950 – 0.07862 in.)
Brown 1.997 – 2.000 mm (0.07862 – 0.07874 in.)
Crankshaft bearing cap bore Green 2.000 – 2.003 mm (0.07874 – 0.07885 in.)
Stamped alphabets Bearing cap bore diameter Black 2.003 – 2.006 mm (0.07885 – 0.07897 in.)
(numbers) (without bearing)
49.0000 – 49.0030 mm Standard size crankshaft main bearing No.2 – 5
A or 1
(1.92914 – 1.92925 in.) thickness
49.0031 – 49.0060 mm Color
B or 2 Bearing thickness
(1.92926 – 1.92937 in.) painted
49.0061 – 49.0090 mm Pink 1.990 – 1.993 mm (0.07835 – 0.07846 in.)
C or 3
(1.92938 – 1.92948 in.) Purple 1.993 – 1.996 mm (0.07846 – 0.07858 in.)
49.0091 – 49.0120 mm Brown 1.996 – 1.999 mm (0.07858 – 0.07870 in.)
D or 4
(1.92950 – 1.92960 in.) Green 1.999 – 2.002 mm (0.07870 – 0.07881 in.)
49.0121 – 49.0150 mm Black 2.002 – 2.005 mm (0.07881 – 0.07893 in.)
E or 5
(1.92962 – 1.92972 in.)
49.0151 – 49.0180 mm
F or 6
(1.92973 – 1.92984 in.)

2 1
IHL10A141037-01

1. Paint

1
IHL10A141043-01

2. Crankshaft pulley side

1D-72 Engine Mechanical: K15B

4) From number stamped on crank web No.4 and alphabets or numbers stamped on cylinder block, determine new
standard bearing to be installed to journal, referring to the following table.
For example, if number stamped on crank web No.4 is “1” and alphabet stamped on cylinder block is “B”, install a
new standard bearing painted in “Pink” to its journal.
Main bearing cross-reference selection table (standard size)
Number stamped on crank web No.4
1 2 3 4 5 6
Upper Pink Pink Pink Purple Purple Brown
A or 1
Lower Pink Pink Purple Purple Brown Brown
Upper Pink Pink Purple Purple Brown Brown
B or 2
Lower Pink Purple Purple Brown Brown Green
Alphabet or Upper Pink Purple Purple Brown Brown Green
C or 3
number Lower Purple Purple Brown Brown Green Green
stamped on Upper Purple Purple Brown Brown Green Green
D or 4
cylinder block Lower Purple Brown Brown Green Green Black
Upper Purple Brown Brown Green Green Black
E or 5
Lower Brown Brown Green Green Black Black
Upper Brown Brown Green Green Black Black
F or 6
Lower Brown Green Green Black Black Black

5) Using scale (2) and gauging plastic (1), check bearing clearance with newly selected standard bearing.
If clearance still exceeds its limit, use next thicker bearing and recheck clearance, referring to “Main Bearing
Clearance”: K15B (Page 1D-69).

1
2

I7V20A141119-01

Undersize bearing (0.25 mm)

• There are five kinds of undersize bearing thickness and they are painted in the following colors.
Each color indicates the following thickness at the center of bearing.
Undersize crankshaft main bearing No.1 thickness
Color painted Bearing thickness
Red & Pink 2.116 – 2.119 mm (0.08330 – 0.08342 in.)
Red & Purple 2.119 – 2.122 mm (0.08342 – 0.08354 in.)
Red & Brown 2.122 – 2.125 mm (0.08354 – 0.08366 in.)
Red & Green 2.125 – 2.128 mm (0.08366 – 0.08377 in.)
Red & Black 2.128 – 2.131 mm (0.08377 – 0.08389 in.)

Undersize crankshaft main bearing No.2 – 5 thickness

Color painted Bearing thickness
Red & Pink 2.115 – 2.118 mm (0.08327 – 0.08338 in.)
Red & Purple 2.118 – 2.121 mm (0.08338 – 0.08350 in.)
Red & Brown 2.121 – 2.124 mm (0.08350 – 0.08362 in.)
Red & Green 2.124 – 2.127 mm (0.08362 – 0.08374 in.)
Red & Black 2.127 – 2.130 mm (0.08374 – 0.08385 in.)
 Engine Mechanical: K15B 1D-73

1
IHL10A141044-01

1. Paint

• If necessary, regrind crankshaft journal and select undersize bearing to use with crankshaft as follows.
1) Regrind journal to the following finished diameter.
Finished journal diameter
44.7500 – 44.7680 mm (1.76182 – 1.76251 in.)
2) Using micrometer, measure reground journal diameter.
Measurement should be taken in two directions perpendicular to each other to check for out-of-roundness.
3) Using journal diameter measured above and alphabets or numbers stamped on cylinder block, select an undersize
bearing referring to the following table.
Check bearing clearance with newly selected undersize bearing.

I2RH0B140144-01

Main bearing cross–reference table (undersize)

Measured journal diameter
44.7650 – 44.7620 – 44.7590 – 44.7560 – 44.7530 – 44.7500 –
44.7680 mm 44.7649 mm 44.7619 mm 44.7589 mm 44.7559 mm 44.7529 mm
(1.76241 – (1.76229 – (1.76217 – (1.76205 – (1.76193 – (1.76182 –
1.76251 in.) 1.76239 in.) 1.76227 in.) 1.76216 in.) 1.76204 in.) 1.76192 in.)
Upper Red & Pink Red & Pink Red & Pink Red & Purple Red & Purple Red & Brown
A or 1
Lower Red & Pink Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown
Upper Red & Pink Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown
Alphabet B or 2
Lower Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown Red & Green
or
Upper Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown Red & Green
number C or 3
Lower Red & Purple Red & Purple Red & Brown Red & Brown Red & Green Red & Green
stamped
Upper Red & Purple Red & Purple Red & Brown Red & Brown Red & Green Red & Green
on D or 4
Lower Red & Purple Red & Brown Red & Brown Red & Green Red & Green Red & Black
cylinder
Upper Red & Purple Red & Brown Red & Brown Red & Green Red & Green Red & Black
block E or 5
Lower Red & Brown Red & Brown Red & Green Red & Green Red & Black Red & Black
Upper Red & Brown Red & Brown Red & Green Red & Green Red & Black Red & Black
F or 6
Lower Red & Brown Red & Green Red & Green Red & Black Red & Black Red & Black
1D-74 Engine Mechanical: K15B

Main Bearing Cap Bolt Sensor Plate Inspection

Measure each thread diameter at specified points on AENJHB0B1416046

main bearing cap bolts (1) using a micrometer (3). Check sensor plate for crack and damage.
Calculate difference in diameters (“c” – “d”). If any defect is found, replace it.
If it exceeds limit, replace main bearing cap bolt with new
one.
Main bearing cap bolt diameter measurement points
“a”: 40 mm (1.6 in.)
“b”: 64 mm (2.5 in.)
Main bearing cap bolt diameter difference
Limit (“c” – “d”): 0.2 mm (0.0079 in.)

1
“c” “d”

“a”

“b”
I9P60A141079-01 IHL10A141045-01

Cylinder Block Inspection

3 AENJHB0B1416047

Distortion of Gasket Surface

2 Using straightedge and feeler gauge, check gasket
surface for distortion. If distortion exceeds its limit, repair
it.
If repair is not possible, replace cylinder block.
Cylinder block flatness
I9T401142032-01
Limit: 0.03 mm (0.0012 in.)
2. Thread

I7V20A141125-01

I7V20A141126-01
 Engine Mechanical: K15B 1D-75

Specifications
Tightening Torque Specifications
AENJHB0B1417001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Cylinder head cover bolt* 3.0 Nm → 5.0 Nm → 7.5 Nm (0.31 kgf-m (Page 1D-15)
→ 0.51 kgf-m → 0.76 kgf-m, 2.5 lbf-ft → 4.0
lbf-ft → 5.5 lbf-ft)
VVT actuator bolt 60 6.1 44.5 (Page 1D-19)
Camshaft housing bolt* 5.0 Nm → 8.0 Nm → 11 Nm (0.51 kgf-m (Page 1D-20)
→ 0.82 kgf-m → 1.1 kgf-m, 4.0 lbf-ft → 6.0
lbf-ft → 8.5 lbf-ft)
Exhaust camshaft timing sprocket bolt 60 6.1 44.5 (Page 1D-20)
Timing chain cover plug 25 2.5 18.5 (Page 1D-21)
Engine harness ground bolt 11 1.1 8.5 (Page 1D-30)
Engine left mounting nut 55 5.6 40.5 (Page 1D-30)
Engine left mounting bolt 55 5.6 40.5 (Page 1D-30)
Engine right mounting nut 80 8.2 59.0 (Page 1D-30)
Engine right mounting bolt 80 8.2 59.0 (Page 1D-30)
Timing chain cover bolt No.1* 25 2.5 18.5 (Page 1D-35)
Timing chain cover bolt No.2* 25 2.5 18.5 (Page 1D-35)
Crankshaft pulley bolt* 19 Nm → +75° (1.9 kgf-m → +75°, 14.0 lbf- (Page 1D-36)
ft → +75°)
OCV bolt 11 1.1 8.5 (Page 1D-36)
Flywheel bolt 83 8.5 61.5 (Page 1D-37)
Drive plate bolt 83 8.5 61.5 (Page 1D-37)
Timing chain guide bolt 11 1.1 8.5 (Page 1D-40)
Timing chain tensioner bolt 25 2.5 18.5 (Page 1D-40)
Timing chain tensioner adjuster bolt 11 1.1 8.5 (Page 1D-41)
Cylinder head bolt* 20 Nm → 40 Nm → +60° → +60° (2.0 kgf- (Page 1D-45)
m → 4.1 kgf-m → +60° → +60°, 15.0 lbf-ft
→ 29.5 lbf-ft → +60° → +60°)
Venturi plug 3.5 0.36 2.5 (Page 1D-48)
Connecting rod bolt* 15 Nm → +65° (1.5 kgf-m → +65°, 11.0 lbf- (Page 1D-55)
ft → +65°)
Sensor plate screw 11 1.1 8.5 (Page 1D-65)
Main bearing cap bolt* 20 Nm → 40 Nm → +60° (2.0 kgf-m → 4.1 (Page 1D-66)
kgf-m → +60°, 15.0 lbf-ft → 29.5 lbf-ft →
+60°)
Oil seal housing bolt 11 1.1 8.5 (Page 1D-67)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Air Cleaner Components”: K15B (Page 1D-8)
“Throttle Body and Intake Manifold Components”: K15B (Page 1D-11)
“Cylinder Head Cover Components”: K15B (Page 1D-14)
“Camshaft and Tappet Components”: K15B (Page 1D-16)
“Engine Mounting Components”: K15B (Page 1D-26)
“Timing Chain Cover Components”: K15B (Page 1D-32)
“Timing Chain and Chain Tensioner Components”: K15B (Page 1D-38)
“Valve and Cylinder Head Components”: K15B (Page 1D-43)
“Piston, Piston Ring, Connecting Rod and Cylinder Components”: K15B (Page 1D-53)
“Main Bearing, Crankshaft and Cylinder Block Components”: K15B (Page 1D-63)
“Fasteners Information” in Section 0A (Page 0A-5)
1D-76 Engine Mechanical: K15B

Special Tools and Equipment

Recommended Service Material
AENJHB0B1418001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 (Page 1D-15) / (Page
1D-34) / (Page 1D-67)

NOTE
Required service material(s) is also described in:
“Cylinder Head Cover Components”: K15B (Page 1D-14)
“Camshaft and Tappet Components”: K15B (Page 1D-16)
“Timing Chain Cover Components”: K15B (Page 1D-32)
“Timing Chain and Chain Tensioner Components”: K15B (Page 1D-38)
“Valve and Cylinder Head Components”: K15B (Page 1D-43)
“Piston, Piston Ring, Connecting Rod and Cylinder Components”: K15B (Page 1D-53)
“Main Bearing, Crankshaft and Cylinder Block Components”: K15B (Page 1D-63)

Special Tool
AENJHB0B1418002
09910M66820 09911M05120
Engine hook Box end wrench (14 mm)
(Page 1D-29) (Page 1D-20)

09911M16300 09911M97720
Oil seal installer Oil seal installer
(Page 1D-67) (Page 1D-67)

09913M66710 09913M70123
Bearing puller Bearing installer
(Page 1D-33) (Page 1D-25) /
(Page 1D-33)

09913M75821 09915M64512
Bearing installer attachment Compression gauge
(Page 1D-37) (Page 1D-4)

09915M64530 09915M64550
Compression gauge hose Compression gauge
attachment (B)
(Page 1D-4) (Page 1D-4)
 Engine Mechanical: K15B 1D-77

09915M67311 09916M14510
Vacuum gauge Valve lifter
(Page 1D-6) (Page 1D-46) /
(Page 1D-48)

09916M14522 09916M34542
Valve spring compressor Reamer handle
attachment
(Page 1D-46) / (Page 1D-47) /
(Page 1D-48) (Page 1D-47)

09916M34570 09916M37320
Valve guide reamer (5 mm) Valve guide outer reamer
(10.5 mm)
(Page 1D-47) (Page 1D-47)

09916M44310 09916M56011
Valve guide remover (5 mm) Valve guide installer
attachment (protrusion: 11.5
mm)
(Page 1D-46) (Page 1D-47)

09916M57330 09916M77310
Valve guide installer handle Piston ring compressor (50 -
125 mm)
(Page 1D-47) / (Page 1D-55)
(Page 1D-48)

09916M84511 09917M68222
Forceps Crankshaft pulley holder
(Page 1D-46) / (Page 1D-33) /
(Page 1D-48) (Page 1D-35)

09917M98221 09921–20210
Valve guide stem Bearing remover (12 mm)
attachment
(Page 1D-48) (Page 1D-37)

09924M17811 09926M58010
Flywheel holder Bearing remover attachment
(Page 1D-37) / (Page 1D-33)
(Page 1D-37)
1D-78 Engine Mechanical: K15B

09930M30104 SUZUKI scan tool (Suzuki

SDT-II)
Sliding shaft —
(Page 1D-37) (Page 1D-5)
 Engine Mechanical: D13A 1D-79

D13A
Diagnostic Information and Procedures
Compression Check NOTE
AENJHB0B1424001
Check compression pressure on all 4 cylinders as For measuring compression pressure, crank
follows. engine at 200 rpm or higher with fully
charged battery.
1) Warm up engine to normal operating temperature.
2) Stop engine after warming up. Compression pressure
3) Place shift lever in “Neutral” position, apply parking Limit: 1,650 kPa (16.8 kgf/cm2, 239.3 psi, 16.5 bar)
brake and block drive wheels. Max. difference between any two cylinders: 150
4) Disconnect glow plug control module connector. kPa (1.5 kgf/cm2, 21.8 psi, 1.5 bar)
(Page 1C-30) 10) Remove special tools.
5) Remove all glow plugs. (Page 1C-24) 11) Carry out Step 7) – 10) on each cylinder to obtain 4
6) Remove fuel pump relay. (Page 1A-175) readings.
7) Install special tools into glow plug hole. 12) Install glow plugs. (Page 1C-24)
Special tool 13) Install fuel pump relay.
(A): 09915M68610 14) Connect glow plug control module connector.
(B): 09912M57822 (Page 1C-30)

(B) Timing Check

AENJHB0B1424002
(A)
Check timing between camshafts and crankshaft as
follows.
1) Remove common rail. (Page 1G-48)
2) Remove engine hook (1) and common rail bracket
(2) from camshaft housing.

(A)
2

(B)

I3RB0A143007-01
IJHB0A143001-01
3) Disconnect wiring harness connectors of injectors,
8) Disengage clutch to lighten starting load on engine. CMP sensor and glow plugs.
9) Crank engine with fully charged battery, and read the
highest pressure on special tool.
If measured compression pressure is lower than
specified value, check installation condition of
special tools.
If they are properly installed, compression leakage at
piston ring contact position or valve contact position
is suspected.
1D-80 Engine Mechanical: D13A

4) Remove camshaft housing plugs (1). 8) After checking, remove special tools inserted in Step
5) Turn crankshaft pulley and align camshaft housing 6) – 7).
plug hole (2) with camshaft gap (3) as shown in 9) Apply thread lock compound to thread part of
figure. camshaft housing plugs (1), and tighten camshaft
6) Lock camshafts (4) by inserting special tools (A) to housing plugs to specified torque.
plug holes. “A”: Thread lock cement (Loctite omnifit 100M
Special tool spezial®)
(A): 09917M68610 Tightening torque
Camshaft housing plug (a): 18 N·m (1.8 kgf-m,
2 13.5 lbf-ft)
(A)

1, “A”, (a)

4
3
1 (A)
(A)

1, “A”, (a)

I3RB0A143010-01

7) Insert special tool to hole of transaxle case (1) while I3RB0A143031-03

lightly swing crankshaft pulley by hand. 10) Connect wiring harness connectors to injectors,
Check that special tool can be inserted in proper CMP sensor and glow plugs.
position as shown in figure.
11) Install common rail bracket (2) and engine hook (1)
Special tool to camshaft housing. Tighten common rail bracket
(A): 09912M46310 bolts to specified torque.
If not, adjust timing by reinstalling timing chain. Tightening torque
(Page 1D-105) Common rail bracket bolt (a): 22 N·m (2.2 kgf-
m, 16.5 lbf-ft)

1 (a)

(a)

I3RB0A143034-01

(A) 12) Install common rail. (Page 1G-48)

I9P60A142001-01 13) Check for fuel leakage. (Page 1G-41)

[A] [B]

“a” 2 2
“b”
1 1

(A)
(A)

I7V20A142002-01

[A]: Proper position “a”: 4 mm (0.16 in.)

[B]: Improper position “b”: 12 mm (0.47 in.)
2. Flywheel
 Engine Mechanical: D13A 1D-81

Repair Instructions
Air Cleaner Components
AENJHB0B1426001

11

12

1
4 (c)

(a)
3
2
9
(a)
5

10

(b)

4 (c)
13 8
7
4 (c)

4 (d)
4 (d)
14

(a)

6
IJHB0A143002-01

1. Air cleaner assembly 8. Breather pipe : 8.5 Nm (0.87 kgf-m, 6.5 lbf-ft)
2. O-ring 9. Air suction hose : 6.0 Nm (0.61 kgf-m, 4.5 lbf-ft)
3. MAF sensor with IAT sensor-1 10. Air cleaner suction pipe : 3.5 Nm (0.36 kgf-m, 2.5 lbf-ft)
4. Hose clamp 11. Vacuum hose : 1.5 Nm (0.15 kgf-m, 1.5 lbf-ft)
: Position clamp screw in specified place as shown in figure.
5. Air cleaner outlet hose No.1 12. To boost control solenoid valve : Do not reuse.
6. Air cleaner outlet hose No.2 13. To oil separator
7. Air cleaner outlet pipe 14. To Turbocharger
1D-82 Engine Mechanical: D13A

Air Cleaner Filter Removal and Installation Air Cleaner Assembly Removal and Installation
AENJHB0B1426002 AENJHB0B1426004
Removal
1) Unhook air cleaner case clamps (1). Removal
2) Open air cleaner cap (2), and then remove air 1) Disconnect MAF sensor with IAT sensor-1 connector
cleaner filter. (1).
2) Disconnect air cleaner outlet hose No.1 (2) from
MAF sensor with IAT sensor-1.
2 3) Disconnect air suction hose (3) and vacuum hose (4)
from air cleaner assembly.
4) Remove air cleaner assembly (5).

1 4
IJHB0A143004-01

1
Installation
Reverse removal procedure. 3
2

Air Cleaner Filter Inspection and Cleaning IJHB0A143088-01

AENJHB0B1426003

Inspection Installation
Check air cleaner filter for dirt. Replace excessively dirty Reverse removal procedure noting the following points.
filter. • Connect each hose securely.
• Tighten air cleaner outlet hose No.1 clamp and air
Cleaning suction hose clamp to specified torque. (Page 1D-
Blow off dust by compressed air from air outlet side of 81)
filter.

IJHB0A143006-01
 Engine Mechanical: D13A 1D-83

Intercooler Components
AENJHB0B1426005

5 17 (b)
17 (b)

9
17 (b)
8
6

17 (b)

22
12
15
16
13
4
11

17 (b)

7
17 (b)
(a)
2

18
14
20

3 10

17 (b)
11

19
21

17 (b)

20

20

20 1

14
IJHB0B142001-01

1. Intercooler 10. Turbo outlet air pipe 19. Intercooler shroud

2. Intercooler inlet hose 11. Gasket 20. Seal
3. Intercooler outlet hose No.1 12. Air intake joint 21. To turbocharger
4. Intercooler outlet hose No.2 13. Intake throttle spacer 22. To intake manifold
5. Intercooler outlet hose No.3 14. Grommet : 8.5 Nm (0.87 kgf-m, 6.5 lbf-ft)
6. Intercooler outlet hose No.4 15. Intercooler outlet pipe No.2 bracket : 4.5 Nm (0.46 kgf-m, 3.5 lbf-ft)
7. Intercooler outlet pipe No.1 16. Intercooler outlet pipe No.3 bracket : Do not reuse.
8. Intercooler outlet pipe No.2 17. Clamp
: Position clamp screw in specified place as
shown in figure.
9. Intercooler outlet pipe No.3 18. Intercooler upper bracket
1D-84 Engine Mechanical: D13A

Intercooler Removal and Installation 6) Disconnect intercooler outlet hose (1) from
AENJHB0B1426006 intercooler.
Removal
1) Remove front bumper. (Page 9H-2)
2) Remove front end lower cover. (Page 9H-5)
3) Remove intercooler shroud (1).

IJHB0A143011-01

7) Remove intercooler upper bracket (1).

8) Remove intercooler (2).

IJHB0A143008-01 1
4) Remove intercooler inlet hose (1).

1 2
IJHB0A143012-01

Installation
Reverse removal procedure noting the following points.
IJHB0A143009-01 • Use new intercooler inlet hose and new intercooler
5) Remove intercooler outlet pipe No.1 (1) from inlet hose clamps.
intercooler (2). • Tighten intercooler upper bracket bolts (1) to specified
torque.
Tightening torque
Intercooler upper bracket bolt (a): 8.5 N·m (0.87
kgf-m, 6.5 lbf-ft)

1
1, (a)

IJHB0A143010-01

IJHB0A143013-01

• Tighten hose clamps to specified torque. (Page 1D-

83)
 Engine Mechanical: D13A 1D-85

Vacuum Pump Removal and Installation
AENJHB0B1426007
NOTICE
The vacuum pump will lose its original
performance if it is disassembled.
Do not disassemble and repair the vacuum
pump. If any faulty condition is found,
replace the vacuum pump with a new one.
7) Disconnect brake booster hose (1) from vacuum
pump.
8) Disconnect EGR valve connector (3).
9) Disconnect vacuum hose (2).
10) Remove vacuum pump (4) and gasket from
camshaft housing.

Removal
1) Release fuel pressure. (Page 1G-41)
1
2) Remove battery from vehicle. (Page 1J-16)
3) With hose connected, move degassing tank (1) in
arrow direction to release it from stay. 4

2
1

IJHB0A143017-01

Installation
Reverse removal procedure noting the following points.
• Put new gasket on vacuum pump.
• Install vacuum pump (1) to camshaft housing.
Fit protrusion of vacuum pump coupling (2) into slot
(3) of camshaft.
IJHB0A143014-01

4) Remove air cleaner assembly. (Page 1D-82)

5) Remove high pressure pipe (1) between common
rail and high pressure pump. (Page 1G-45) 3
6) Remove fuel dumper bolt (2).

2 1
I7V20A142010-02
2

IJHB0A143016-01
1D-86 Engine Mechanical: D13A

• Tighten vacuum pump bolts (1) to specified torque.

Tightening torque
Vacuum pump bolt (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)

1, (a)

IJHB0A143019-01

• Tighten fuel damper bolt to specified torque. (Page

1G-42)
• Install new high pressure pipe between common rail
and high pressure pump. (Page 1G-45)
• Check for fuel leakage. (Page 1G-41)

Vacuum Pump Inspection

AENJHB0B1426008
1) Warm up engine to normal operating temperature.
2) Stop engine.
3) Disconnect vacuum hose from vacuum pipe and
connect special tool to the hose (1).
Special tool
(A): 09915M67311

(A)

IJHB0A143020-01

4) Check negative pressure with engine idling. If

negative pressure is not as specified, replace
vacuum pump.
Negative pressure specification
More than –50 kPa (–0.5 kgf/cm2, –7.25 psi, –0.5
bar) within 5 seconds at idle speed
 Engine Mechanical: D13A 1D-87

Turbocharger and Exhaust Manifold Components

AENJHB0B1426009

(a)

(c)
5

(d)
12 1

11
3
13 8
14
(a)
4

(b) 2 (c)
9 (c)
10 (c)
IJHB0B142002-01

1. Turbocharger 8. Spacer : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)

: Do not disassemble.
2. Gasket 9. Oil drain pipe bolt No.1 : 22 Nm (2.2 kgf-m, 16.5 lbf-ft)
3. Turbocharger oil intake pipe 10. Oil drain pipe bolt No.2 : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
4. Oil drain pipe 11. To oil cooler assembly : 15 Nm → +30° (1.5 kgf-m → +30°, 11.0 lbf-
ft → +30°)
5. Exhaust manifold 12. To catalytic converter : Do not reuse.
6. Exhaust manifold gasket 13. To air cleaner outlet hose No.2
7. Exhaust manifold cover 14. To cylinder block
1D-88 Engine Mechanical: D13A

Turbocharger Removal and Installation 3) Remove intercooler inlet hose (1).

AENJHB0B1426010

Removal

! CAUTION 1

Touching a hot exhaust system component

will cause a burn.
Do not perform any service work on the
exhaust system until the exhaust system is
cool.

NOTICE
The turbocharger will lose its original IJHB0A143024-01
performance if it is disassembled.
4) Disconnect vacuum hose (1) from turbocharger (2).
Do not disassemble the turbocharger. If any
faulty condition is found, replace the 5) Remove turbo outlet air pipe (3) and gasket.
turbocharger with a new one.
1
1) Remove air suction hose (1) and air cleaner suction
pipe (2).

3
2

IJHB0A143025-01

6) Remove exhaust manifold side engine hanger.

(Page 1D-87)
7) Disconnect glow plug connectors. (Page 1C-24)
IJHB0A143022-01
8) Remove turbocharger oil intake pipe (1) and
2) Remove air cleaner outlet hose No.1 (1) and No.2 gaskets.
(2) with air cleaner outlet pipe (3).

1
3

2
IJHB0A143026-01
IJHB0A143023-01
9) Disconnect A/F sensor connector and clamp.
(Page 1B-14)
10) Remove exhaust manifold cover. (Page 1D-87)
 Engine Mechanical: D13A 1D-89

11) Remove oil drain pipe bolts No.2 (1). 16) Remove oil drain pipe (1) and gaskets, if necessary.

1
1

IJHB0A143030-01
IJHB0A143027-01

12) Remove exhaust No.1 pipe. (Page 1K-8) Installation

13) Remove catalytic converter brace bolt. (Page 1K- Reverse removal procedure noting the following points.
7) • Clean mating surfaces of turbocharger, catalytic
14) Remove turbocharger (1) with catalytic converter (2) converter and exhaust manifold.
from exhaust manifold.
NOTICE
If the turbocharger is to be reused, check the
threaded holes in the flange and the mating
1
surfaces for rust which may cause loosening
of the bolts and nuts.
If rusted, remove the rust by grinding the
surfaces and tapping the threaded holes.

• Use new all gaskets.

• Tighten oil drain pipe bolts No.1 (1) to specified
torque, if removed.
2
Tightening torque
IJHB0A143028-01 Oil drain pipe bolt No.1 (a): 9.0 N·m (0.92 kgf-m,
15) Release lock plate (1) and remove turbocharger 7.0 lbf-ft)
bolts (2), and then remove turbocharger and gasket
from catalytic converter.
1, (a)

2 IJHB0A143031-01

IJHB0A143029-01
1D-90 Engine Mechanical: D13A

• Use new lock plate (1) and tighten new turbocharger • Tighten oil drain pipe bolts No.2 (1) to specified
bolts (2) to specified torque. torque.
• After tightening turbocharger bolt to specified torque, Tightening torque
caulk lock plate securely. Oil drain pipe bolt No.2 (a): 9.0 N·m (0.92 kgf-m,
Tightening torque 7.0 lbf-ft)
Turbocharger bolt (a): 30 N·m (3.1 kgf-m, 22.5 lbf-
ft)

1, (a)

2, (a)
IJHB0A143034-01

• Tighten exhaust manifold cover nuts and new engine

IJHB0A143032-01
hook bolt to specified torque. (Page 1D-87)
• Use new turbocharger stud bolt (1).
• Tighten turbocharger oil intake pipe bolts (1) to
• Tighten new turbocharger nuts (2) to specified torque. specified torque.
Tightening torque Tightening torque
Turbocharger nut (a): 25 N·m (2.5 kgf-m, 18.5 lbf- Turbocharger oil intake pipe bolt (a): 22 N·m (2.2
ft) kgf-m, 16.5 lbf-ft)

1
1, (a)

2, (a)

IJHB0A143033-01
IJHB0A143035-01
• Use new oil drain pipe gasket.
• Install new intercooler inlet hose and tighten new
intercooler inlet hose clamps to specified torque.
(Page 1D-83)
• Tighten air cleaner outlet hose No.1 and No.2 clamps
to specified torque. (Page 1D-81)
• Tighten air suction hose clamp and air cleaner suction
hose bolts to specified torque. (Page 1D-81)
• Check any leakage of oil and exhaust gas.
 Engine Mechanical: D13A 1D-91

• If turbocharger is replaced with new one, perform the 4) Measure stroke of boost pressure control valve rod
following procedure. “a” (3) when applying negative pressure of –60 kPa
Otherwise, remaining oil in turbine housing may leak (–0.61 kgf/cm2, –8.70 psi, –0.60 bar).
from turbocharger.
Boost pressure control valve rod stroke:
a. Check the following points. “a”: 6.7 to 7.7 mm (0.264 to 0.303 in.) when
– Parking brake is applied. pressure is changed from –30 kPa (–0.31 kgf/
– Drive wheels are blocked. cm2, –4.35 psi, –0.30 bar) to –60 kPa (–0.61 kgf/
cm2, –8.70 psi, –0.60 bar)
– Gear shift lever is in “Neutral” position.
b. Warm up engine.
2
c. After warming up engine, keep the engine speed 3
around 3,000 rpm for 10 min.
While engine is running, check turbocharger for 1

abnormal noise.
d. After stopping engine, check turbocharger for oil
leakage.

Turbocharger Inspection
AENJHB0B1426011

Visual Inspection
[a]
Check gasket surfaces and housings for trace of
leakage.
[b]
If any abnormality is found, replace turbocharger.
“a”

Moving Part IJHB0A143036-01

Check moving part as follows. [a]: Boost pressure control valve rod position at –30 kPa (–0.31 kgf/cm2, –
4.35 psi, –0.30 bar)
• Visually check compressor and turbine blades for [b]: Boost pressure control valve rod position at –60 kPa (–0.61 kgf/cm2, –
deformation and damage. 8.70 psi, –0.60 bar)

• Wobble shaft with finger and check that compressor

blades do not touch the housing. Exhaust Manifold Removal and Installation
AENJHB0B1426012
• Blow compressed air on compressor and check the Removal
shaft for smooth rotation.
1) Drain engine coolant. (Page 1F-25)
If any abnormality is found replace turbocharger.
2) Remove turbocharger. (Page 1D-88)
Boost Pressure Control Valve 3) Remove oil cooler. (Page 1E-19)
1) Set magnetic base with dial gauge (1) as shown in 4) Remove exhaust manifold (1) and exhaust manifold
figure. gasket.
2) Connect special tool to boost pressure control valve
(2).
Special tool
(A): 09917M47011
3) Apply negative pressure of –30 kPa (–0.31 kgf/cm2,
–4.35 psi, –0.30 bar).

IJHB0A143037-01

Installation
Reverse removal procedure noting the following points.
• Use new gasket.
• Tighten new exhaust manifold nuts (1) as follows.
1D-92 Engine Mechanical: D13A

NOTE Tightening torque

For accurate angle tightening of the bolt, use Exhaust manifold nut* (a): 15 Nm → +30° (1.5 kgf-m
tightening angle gauge available in the → +30°, 11.0 lbf-ft → +30°)
market.
1, (a)
1, (a)

1, (a) 1, (a)

IJHB0A143038-01

IJHA0A140061-01 • Refill cooling system with coolant. (Page 1F-25)

• Refill engine with engine oil. (Page 1E-16)
a. Tighten exhaust manifold nuts to 15 Nm (1.5 kgf-
m, 11.0 lbf-ft). • Check any leakage of oil, coolant and exhaust.
b. Retighten them 30°. – Coolant leakage: (Page 1F-24)

Intake Manifold Components

AENJHB0B1426013

2
5
(b)

6
6

10

7 (a)

8 (a)
IJHB0A143039-01

1. Intake manifold 6. Intake manifold gasket : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
2. Boost pressure sensor with IAT sensor-2 7. Intake manifold bolt No.1 : 2.0 Nm (0.20 kgf-m, 1.5 lbf-ft)
: For tightening order, refer to “Intake Manifold Removal
and Installation”: D13A (Page 1D-93).
3. EGR pipe 8. Intake manifold bolt No.2 : Do not reuse.
: For tightening order, refer to “Intake Manifold Removal
and Installation”: D13A (Page 1D-93)
4. EGR pipe gasket 9. Intake throttle spacer gasket
5. Harness bracket 10. To intake throttle spacer
 Engine Mechanical: D13A 1D-93

Intake Manifold Removal and Installation 10) Remove harness bracket (1).
AENJHB0B1426014
11) Disconnect boost pressure sensor with IAT sensor-2
Removal connector (2).
1) Remove engine assembly. (Page 1D-99)
2) Remove ISG. (Page 1J-20)
3) Remove oil separator. (Page 1B-16)
2
4) Remove intercooler outlet pipe No.3 (1).
5) Remove intercooler outlet pipe No.3 bracket (2).

1 1

IJHB0A143043-01

2 12) Remove hose bracket. (Page 1B-15)

13) Remove intake manifold (1) and gaskets from
cylinder head.

IJHB0B142003-01
1
6) Remove air intake joint (1) and its gasket.
7) Remove intake throttle spacer (2) and its gasket.

IJHB0A143044-01

14) Remove EGR pipe, if necessary. (Page 1D-92)

1 15) Remove boost pressure sensor, if necessary.
(Page 1C-28)
IJHB0A143041-01

8) Remove EGR valve and EGR cooler. (Page 1B-

10)
9) Remove oil level gauge guide mounting bolt (1).

IJHB0A143042-01
1D-94 Engine Mechanical: D13A

Installation Crankshaft Front Oil Seal Removal and

Reverse removal procedure noting the following points. Installation
AENJHB0B1426015
• Clean mating surfaces of intake manifold and cylinder
Removal
head.
1) Remove front-right wheel. (Page 2D-3)
• Use new gaskets for intake manifold, intake throttle
spacer, air intake joint and EGR pipe. 2) Remove right side engine under side cover.
• Tighten intake manifold bolts in numerical order 3) Remove right side apron lower member. (Page
evenly and gradually to specified torque. 9H-5)
4) Remove ISG drive belt. (Page 1J-18)
Tightening torque
Intake manifold bolt* (a): 25 N·m (2.5 kgf-m, 18.5 5) Remove crank pulley (1).
lbf-ft)

“9”, (a) “5”, (a) “1”, (a) “4”, (a) “8”, (a)

“7”, (a) “3”, (a) “2”, (a) “6”, (a) IJHB0A143047-01

IJHB0A143045-01 6) To lock crankshaft, set special tool to oil pump drive
• Tighten oil level gauge guide mounting bolt to flange.
specified torque.
NOTE
Tightening torque
Oil level gauge guide mounting bolt (a): 9.0 N·m ( Use bolts (1) included fitted on special tool.
0.92 kgf-m, 7.0 lbf-ft)
Special tool
(A): 09910M95020

(a)

IJHB0A143046-01 (A)

• Tighten intercooler outlet hose No.3 and No.4 clamps

to specified torque. (Page 1D-83)
• Check that all removed parts are back in place. IJHB0A143048-01

Reinstall any necessary parts which have not been

reinstalled.
 Engine Mechanical: D13A 1D-95

7) Loosen oil pump drive flange bolt (1) by turning it Installation

clockwise, and then remove oil pump drive flange. 1) Install new oil seal (1) using special tool.
NOTE Special tool
Turn oil pump drive flange bolt clockwise to (A): 09913M75510
loosen it.

(A)

IEL10A142005-01

2) Apply engine oil to oil seal lip.

IJHB0A143049-01

8) Using flat-bladed screwdriver (1) or the like, remove 3) Install oil pump drive flange and set special tool.
crankshaft front oil seal (2). Special tool
(A): 09910M95020
NOTICE
Damage to timing chain cover may result in 4) Tighten new oil pump drive flange bolt (1) as follows.
oil leakage. NOTE
When removing the crankshaft front oil seal,
wrap the tip of flat-bladed screwdriver or the For accurate angle tightening of the bolt, use
like with protective tape (3) to prevent the tightening angle gauge available in the
timing chain cover from being damaged. market.

3 2

IJHA0A140061-01
IEL10A142004-02

4. Wood piece or the like

1D-96 Engine Mechanical: D13A

a) Tighten oil pump drive flange bolt to 50 Nm (5.1 9) Start engine and check for oil leakage. If leakage is
kgf-m, 37.0 lbf-ft). found, repair leaky point.
b) Retighten the bolt to 90°. 10) Install right side engine under side cover.
Tightening torque 11) Install front-right wheel. (Page 2D-3)
Oil pump drive flange bolt* (a): 50 Nm → +90°
(5.1 kgf-m → +90°, 37.0 lbf-ft → +90°)
Crankshaft Rear Oil Seal Removal and
Installation
AENJHB0B1426016
1, (a) Removal
1) Dismount transaxle assembly. (Page 5B-58)
2) Remove clutch cover and clutch disc. (Page 5C-
(A) 11)
3) Remove flywheel referring to Step 12) and 14) in
“Removal” under “Timing Chain Cover and Timing
Chain Removal and Installation”: D13A (Page 1D-
105).
4) Using a flat-bladed screwdriver or the like wrapped
with protective tape, remove crankshaft rear oil seal
(1) slowly.

NOTICE
• If tip of screwdriver scratches cylinder
IJHB0A143050-01 block, lower crankcase or crankshaft
5) Remove special tool from oil pump drive flange. sealing surface, it may cause oil leakage.
Carefully remove oil seal not to damage
NOTE cylinder block, lower crankcase and
Install removed bolts (1) to special tool. crankshaft sealing surface.
• If crankshaft edge is dented or shaved, it
may adversely affect new oil seal lip when
installing.
Carefully remove oil seal not to damage
crankshaft edge.
1

IEL10A142007-01

6) Install crankshaft pulley (1) and tighten crankshaft 1

pulley bolts (2) to specified torque.

Tightening torque
Crankshaft pulley bolt (a): 30 N·m (3.1 kgf-m,
22.5 lbf-ft)

1 IJHB0A143051-01
2, (a)

IFL10A140010-01

7) Install ISG drive belt. (Page 1J-18)

8) Install right side apron lower member. (Page 9H-5)
 Engine Mechanical: D13A 1D-97

Installation
1) Check smoothness of crankshaft flange and apply
engine oil to the sealing surface.
2) Using special tools, install new crankshaft rear oil
seal (1) as follows.
Special tool
(A): 09913M58620
(B): 09924M74510
Crankshaft rear oil seal Installing position
(depth)
“a”: 1.0 mm (0.04 in.)
a) Fit crankshaft oil seal to special tool (A).
b) Install special tool (B) to special tool (A), and
install crankshaft rear oil seal by tapping special
tool (B) lightly with a plastic hammer.
c) Remove special tools (A) and (B).

“a” 3
1

(B)

(A)

IJHB0A143052-01

2. Crankshaft 3. Cylinder block

3) Install flywheel referring to Step 17) in “Installation”

under “Timing Chain Cover and Timing Chain
Removal and Installation”: D13A (Page 1D-105).
4) Install clutch cover and clutch disc. (Page 5C-11)
5) Mount transaxle assembly. (Page 5B-58)
1D-98 Engine Mechanical: D13A

Engine Mounting Components

AENJHB0B1426017

(e)
(e)
(e)
(e)

(e)

(e)
4
(c)
(e)

(e)

(e)
5
(e)

6 3 (d)

(f)
(d)

(d)
7

(b)

(d)

(a)
IJHB0A143053-01

1. Engine right mounting
2. Engine right mounting bracket
3. Engine hook
4. Engine left mounting
5. Engine left mounting bracket
6. Engine rear torque rod bracket
7. Engine rear torque rod
: 93 Nm (9.5 kgf-m, 68.5 lbf-ft)
: 85 Nm (8.7 kgf-m, 63.0 lbf-ft)
: 65 Nm (6.6 kgf-m, 48.0 lbf-ft)
: 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
: 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
: 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: Do not reuse.
 Engine Mechanical: D13A 1D-99

Engine Assembly Removal and Installation 16) Disconnect the following hoses.
AENJHB0B1426018
Removal • Brake booster hose (1)
1) Relieve fuel pressure. (Page 1G-41) • Fuel feed hose (2)
2) Disconnect steering lower shaft from pinion shaft. • Fuel return hose (3)
(Page 6B-14) • Radiator inlet hose (4) and outlet hose (5)
3) Remove battery and battery tray from vehicle. • Heater inlet hose (6) and outlet hose (7)
(Page 1J-16) • Vacuum hoses (8)
4) Remove air cleaner assembly with MAF sensor with
IAT sensor-1. (Page 1D-82)
2
5) Remove air cleaner suction pipe. (Page 1D-81) 3
6) Drain the following oils, if necessary.
6
• Engine oil: (Page 1E-16)
• Manual transaxle oil: (Page 5B-53)
7) Drain coolant. (Page 1F-25)
8) Hoist vehicle and remove engine under side covers.
1
9) Remove front bumper. (Page 9H-2)
10) Remove intercooler. (Page 1D-84) 7
11) Remove intercooler inlet hose (1). IJHB0A143055-01

12) Remove intercooler outlet pipe No.1 (2).

8

IJHB0A143054-01

13) Remove water pump drive belt. (Page 1F-32)

14) With A/C hose connected, detach A/C compressor 4
from its bracket. Using a rope, hold A/C compressor
in a place where no damage will be caused. 5

• Manual A/C single model: (Page 7B-50)

IJHB0A143056-01
• Manual A/C dual model: (Page 7B-92)
17) Disconnect gear shift and gear control cables from
• Automatic A/C dual model: (Page 7B-135) transaxle. (Page 5B-56)
15) Remove degassing tank. (Page 1F-23)
1D-100 Engine Mechanical: D13A

18) Disconnect the following connectors and cable
including the related clamps.
• Ground cable (1)
• Individual circuit fuse box No.1 connector (2)
• Main fuse box connectors (3)
• ECM connector (engine harness side) (4) (Page
1C-20)
• Main harness connectors (5)
• A/F sensor connector (6)
• Glow plug control module connector (engine
harness side) (Page 1C-30)
5 steering knuckle. (Page 3A-3)
4
5 2
19) Disconnect clutch fluid pipe from clutch pipe joint.
(Page 5C-7)
20) Remove apron lower members. (Page 9H-5)
21) Remove exhaust No.1 pipe. And using a rope, hold
exhaust center pipe. (Page 1K-8)
22) Remove stabilizer joints from stabilizer bar. (Page
2B-12)
23) Disconnect tie-rod end from steering knuckle at each
of right and left sides. (Page 6B-17)
24) Disconnect suspension arm joint from steering
knuckle at each of right and left sides. (Page 2B-8)
25) Disconnect right and left drive shaft joints from
26) Support front suspension frame (1), transaxle case
(2) and oil pan (3) using jack.
27) Remove front suspension frame bolts (4).

3 2
1

3 4
IJHB0A143057-01
4

1
6

IJHB0A143059-01

28) Remove engine left mounting nuts (1) and bolt (2).

IJHB0A143058-01

IJHB0A143060-01
 Engine Mechanical: D13A 1D-101

29) Remove engine right mounting nuts (1) and bolt (2). • Remove ventilation connector (1) and O-ring.
• Remove oil level gauge guide mounting bolt (2).

IJHB0A143061-01
2
30) Before removing engine, check that all hoses,
electric wires and cables are disconnected from IJHB0A143063-01

engine. • Disconnect fuel pressure sensor connector (1).

31) Lower engine with transaxle, front suspension frame, • Remove engine harness bracket bolts (2).
drive shafts and steering gear case assembly all
together.

NOTICE 1
The A/C compressor may be damaged if it
hits against or interferes with other parts.
Suspend the removed A/C compressor in a
place where no damage will be caused during
removal of the engine assembly.

32) For removal of drive shafts, front suspension frame 2

and steering gear case, lift engine assembly with

transaxle connecting a chain to hooks as follows, if
necessary. IJHB0A143064-01

• Remove air cleaner outlet hose No.1 (1).
• Remove intercooler outlet pipe No.2 (2).
• Remove intercooler outlet pipe No.3 (3).
• Moving obstacles such as engine harness and oil
level gauge guide aside, connect a chain to
engine hook (1) and transaxle hook (2).

IJHB0A143065-01
1
IJHB0B142004-01
1D-102 Engine Mechanical: D13A

33) Remove right and left drive shafts and intermediate 9) Tighten oil level gauge guide mounting bolt (1) to
shaft, if necessary. (Page 3A-3) specified torque, if removed.
34) Remove front suspension frame, if necessary. Tightening torque
35) Remove or move parts shown in Step 32) aside, Oil level gauge guide mounting bolt (a): 9.0 N·m
connect a chain to engine hooks (1) and lift engine (0.92 kgf-m, 7.0 lbf-ft)
assembly, if necessary.

1
1

1, (a)
IJHB0A143068-01

10) Install intercooler outlet pipe No.2 and No.3 and

tighten these clamps to specified torque, if removed.
IJHB0A143066-01 (Page 1D-83)
36) Remove transaxle from engine, if necessary. 11) Install air cleaner outlet hose No.1 and tighten its
(Page 5B-58) clamps to specified torque, if removed. (Page 1D-
37) Remove clutch cover and clutch disc, if necessary. 81)
(Page 5C-11) 12) Lift up engine with transaxle, front suspension frame,
38) Remove engine harness, if necessary. (Page 9A- drive shafts and steering gear case assembly all
142) together.

NOTICE
Installation
The A/C compressor may be damaged if it
1) Install engine harness, if removed. (Page 9A-142)
hits against or interferes with other parts.
2) Install clutch cover and clutch disc, if removed. Suspend the removed A/C compressor in a
(Page 5C-11) place where no damage will be caused during
3) Install transaxle to engine, if removed. (Page 5B- installation of the engine assembly.
58)
4) Install front suspension frame, if removed. (Page
2B-13)
5) Install right and left drive shafts and intermediate
shaft, if removed. (Page 3A-3)
6) Install engine harness bracket bolts (2), if removed.
7) Connect fuel pressure sensor connector (1), if
disconnected.

IJHB0A143067-01

8) Install ventilation connector and new O-ring, if

removed. (Page 1B-15)
 Engine Mechanical: D13A 1D-103

13) Tighten engine right mounting bolt (1) and nuts (2) to 24) Insert the claw (1) into the body hole, and then
specified torque. tighten the ground terminal bolt.
Tightening torque
Engine right mounting bolt (a): 65 N·m (6.6 kgf-
m, 48.0 lbf-ft)
Engine right mounting nut (b): 65 N·m (6.6 kgf-
m, 48.0 lbf-ft)

1, (a)

2, (b)

IJHB0A143069-02
14) Tighten engine left mounting bolt (1) and nuts (2) to
specified torque.
Tightening torque
Engine left mounting bolt (a): 55 N·m (5.6 kgf-
m, 40.5 lbf-ft)
Engine left mounting nut (b): 55 N·m (5.6 kgf-m,
40.5 lbf-ft)
1, (a)
2, (b)
IJHB0A143070-01
15) Tighten suspension frame bolts to specified torque.
(Page 2B-13)
16) Connect right and left drive shaft joints to steering
knuckle. (Page 3A-3)
17) Connect suspension arm joint to steering knuckle at
each of right and left sides. (Page 2B-8)
18) Connect tie-rod end to steering knuckle at each of
right and left sides. (Page 6B-17)
19) Install stabilizer joints to stabilizer bar. (Page 2B-
12)
20) Install exhaust No.1 pipe. (Page 1K-8)
21) Install apron lower members. (Page 9H-5)
22) Connect clutch fluid pipe from clutch pipe joint.
(Page 5C-7)
23) Install all other removed electric wires, connectors
and hoses to original positions.
IJHB0A143071-01
25) Connect gear shift and gear select control cables to
transaxle. (Page 5B-56)
26) Install degassing tank. (Page 1F-23)
27) Install A/C compressor to its bracket.
• Manual A/C single model: (Page 7B-34)
• Manual A/C dual model: (Page 7B-87)
• Automatic A/C dual model: (Page 7B-126)
28) Install water pump drive belt. (Page 1F-32)
29) Install intercooler outlet pipe No.1, new intercooler
inlet hose and new intercooler inlet hose clamps and
tighten these clamps to specified torque. (Page
1D-83)
30) Install intercooler. (Page 1D-84)
31) Install front bumper. (Page 9H-2)
32) Install air cleaner suction pipe. (Page 1D-81)
33) Install air cleaner assembly with MAF sensor with
IAT sensor-1. (Page 1D-82)
34) Refill engine with engine oil. (Page 1E-16)
35) Refill transaxle with transaxle oil. (Page 5B-53)
36) Refill cooling system with coolant. (Page 1F-25)
37) Refill clutch system with clutch fluid and bleed the
system. (Page 5C-5)
38) Install battery tray and battery. (Page 1J-16)
39) Connect positive (+) and negative (–) cables at
battery.
40) Connect steering lower shaft to pinion shaft. (Page
6B-14)
41) Check any leakage of fuel, coolant, oil and exhaust.
• Fuel leakage: (Page 1G-41)
• Coolant leakage: (Page 1F-24)
42) Check front wheel alignment. (Page 2B-2)
43) Install engine under side covers.
1D-104 Engine Mechanical: D13A

Timing Chain Cover and Timing Chain Components

AENJHB0B1426019

13 (b)
(e)

OIL
7 (a)
(a)

16
3
11

(a)

10
OIL
(d) 12

OIL
9

4 14
6
4 8
2
OIL

5 (c)
1
(a)
15 (f)
IJHB0A143072-01

1. Crankshaft pulley
2. Crankshaft front oil seal
: Apply engine oil to oil seal lip.
3. Timing chain cover
4. Crankshaft sprocket shim
5. Oil pump drive flange
6. Timing chain cover gasket
7. Timing chain
: Apply engine oil.
8. Crankshaft timing sprocket
9. Timing chain guide : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
: Apply engine oil to sliding surface.
10. Timing chain tensioner : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
: Apply engine oil to sliding surface.
11. Timing chain tensioner adjuster : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
12. Flywheel : 30 Nm (3.1 kgf-m, 22.5 lbf-ft)
13. Camshaft housing plug : 15 Nm → +35° (1.5 kgf-m → +35°,
: Apply Loctite omnifit 100M spezial® to thread parts. 11.0 lbf-ft → +35°)
14. Camshaft housing / cylinder head / cylinder block : 50 Nm → +90° (5.1 kgf-m → +90°,
: Apply sealant 99000-85E11 to mating surfaces. 37.0 lbf-ft → +90°)
15. Oil pump drive flange bolt : Do not reuse.
:Turn oil pump drive flange bolt clockwise to loosen it.
16. Camshaft timing sprocket
 Engine Mechanical: D13A 1D-105

Timing Chain Cover and Timing Chain Removal 9) Remove water pump. (Page 1F-34)
and Installation 10) Remove engine right mounting bracket (1).
AENJHB0B1426020

Removal
1) Remove engine assembly. (Page 1D-99)
2) Remove oil pan. (Page 1E-20)
3) Remove ventilation connector (1) and O-ring (2)
from timing chain cover (3).

2
1

3 IJHB0A143074-01

11) Remove crankshaft pulley (1).

1
I7V20A142036-01

4) Remove common rail. (Page 1G-48)

5) Remove engine hook (1) and common rail bracket
(2) from camshaft housing.

IFL10A140015-01

12) Lock flywheel (1) using special tool (A).

2 Special tool
(A): 09916M98610

I3RB0A143007-01

6) Remove ISG. (Page 1J-20)

7) Remove ISG drive belt idler pulley. (Page 1J-19)
8) Remove ISG drive belt idler bracket (1).

(A)
1

IJHB0A143075-01

IJHB0A143073-01
1D-106 Engine Mechanical: D13A

13) Loosen oil pump drive flange bolt (1) by turning it
clockwise and remove oil pump drive flange (2).
NOTE
Turn oil pump drive flange bolt clockwise to
loosen it.
18) Lock crankshaft (1) by installing special tool (A) as
follows.
a) Set special tool to crankshaft aligning its hole (2)
with crankshaft dowel pin.
b) Tighten special tool to crankshaft using removed
flywheel bolts.
c) Insert locating pin of special tool to cylinder block
hole.

2 NOTE
When special tool is set and locating pin is
1 inserted, pistons are positioned just between
TDC and BDC. In this position, valves are
kept from contact with pistons.

Special tool
I3RB0A143012-01
(A): 09912M38300
14) Remove flywheel (1), and then special tool (A)
installed in Step 12).
Special tool
(A): 09916M98610
(A)

2 1

IJHB0A143090-01

19) Remove timing chain cover (1) and its gasket.

(A)

1
IJHB0A143089-01

15) Remove camshaft housing plugs (1).

16) Align camshaft housing plug holes (2) with camshaft
gap (3) by turning crankshaft clockwise as shown in
figure.
17) Lock camshafts (4) by inserting special tools (A) into
plug holes.
Special tool
(A): 09917M68610

2 I3RB0A143015-01
(A)

4
3
1 (A)
(A)

I3RB0A143010-01
 Engine Mechanical: D13A 1D-107

20) Remove crankshaft front oil seal (1) from timing Installation
chain cover (2) using flat-bladed screwdriver (3) or
the like, if necessary.
3 1
1) Clean mating surfaces of timing chain cover, cylinder
block, cylinder head, camshaft housing and flywheel.
2) Check that special tools (A) and (B) are installed. If
special tool(s) is removed, install special tool(s)
referring to Step 17) – 18) of “Removal” in this
procedure.
Special tool
(A): 09917M68610
(B): 09912M38300

2
(A)

I3RB0A143016-01

21) Remove timing chain tensioner adjuster (1).

22) Remove timing chain tensioner (2).
23) Remove timing chain guide (3). (A)
(A)
24) Remove timing chain (4) with crankshaft timing
sprocket (5).

4
1
(B)

I3RB0A143018-01
3
3) Install crankshaft sprocket shim, if removed.
2 4) Engage timing chain (1) to camshaft timing sprocket
(2).
5) Engage crankshaft timing sprocket (5) to timing
chain with its long taper side (3) facing outside (4) as
shown in figure.
5 2

I3RB0A143017-01

25) Remove crankshaft sprocket shim, if necessary.

1

5
4

5
I3RB0A143019-01
1D-108 Engine Mechanical: D13A

6) Insert crankshaft timing sprocket with timing chain
into crankshaft.
7) Apply engine oil to sliding surface of timing chain
guide (1) and tighten chain guide mounting bolts to
specified torque.
Tightening torque
Chain guide mounting bolt (a): 9.0 N·m (0.92
kgf-m, 7.0 lbf-ft)
10) Install timing chain tensioner adjuster (1) as follows.
a) Tighten upper chain tensioner adjuster mounting
bolt (2) by hand.
b) Push tensioner adjuster assembly in arrow
direction as shown in figure, and then tighten
tensioner adjuster bolts to specified torque.
Tightening torque
Chain tensioner adjuster bolt (a): 9.0 N·m (
0.92 kgf-m, 7.0 lbf-ft)

1 2,(a)

(a)
1

I3RB0A143020-01
(a)
8) Apply engine oil to sliding surface of timing chain I3RB0A143025-01
tensioner (1) and tighten chain tensioner mounting
11) Apply engine oil to timing chain.
bolts to specified torque.
12) Remove special tools (A) and (B) and turn
Tightening torque crankshaft counterclockwise 720° for stable fitting of
Chain tensioner mounting bolt (a): 25 N·m (2.5 chain in guide.
kgf-m, 18.5 lbf-ft)
Special tool
(A): 09917M68610
(B): 09912M38300
1

(A)

(A)
(a) (A)

I3RB0A143021-01

9) Push plunger (1) into timing chain tensioner adjuster

body (2) till plunger is held in place as shown in
figure.

(B)

I3RB0A143018-01

2 1

I3RB0A143022-01
 Engine Mechanical: D13A 1D-109

13) Install new crankshaft front oil seal (1) to timing chain 15) Install timing chain cover (1) as follows.
cover (2) using special tool (C) as shown in figure, if a) Fit timing chain cover and new timing chain
removed. cover gasket (2).
Special tool b) Install oil pump drive flange (3).
(C): 09913M75510 c) Tighten timing chain cover bolts and nuts to
specified torque.
(C)
Tightening torque
Timing chain cover bolt (a): 9.0 N·m (0.92
kgf-m, 7.0 lbf-ft)
1 Timing chain cover nut (b): 9.0 N·m (0.92
2
kgf-m, 7.0 lbf-ft)

1
I3RB0A143023-01
2
14) Apply sealant to crankcase side of timing chain
cover gasket as shown in figure.
“A”: Sealant 99000–85E11 (Three Bond TB
1227®)
(a)
Sealant amount for timing chain cover
Width “a”: 3 – 4 mm (0.12 – 0.15 in.)
Height “b”: 1.5 – 2 mm (0.06 – 0.07 in.) (b)

3 4

1
I9P60A142051-01

“a” 4. Oil seal

“b”
16) Check dowel pin (1) is installed to crankshaft (2).
“A”

IDL10A140048-01

“a”: 3 – 4 mm (0.12 – 0.15 in.) “b”: 1.5 – 2 mm (0.06 – 0.07 in.)

1D-110 Engine Mechanical: D13A

17) Install flywheel (3) as follows.
NOTE
• If flywheel is replaced, initialize flywheel
data in ECM.
For details, refer to “Flywheel Data
Initialization”: D13A in Section 1C (Page
1C-22).
• For accurate angle tightening of the bolt,
use tightening angle gauge available in the
market.
18) Using special tool, tighten new oil pump drive flange
bolt (1) to specified torque by turning it
counterclockwise.
NOTE
For accurate angle tightening of the bolt, use
tightening angle gauge available in the
market.

IJHA0A140061-01

Tightening torque
Oil pump drive flange bolt* (a): 50 Nm → +90°
IJHA0A140061-01
(5.1 kgf-m → +90°, 37.0 lbf-ft → +90°)
a) Tighten new flywheel bolts (4) by hand.
b) Lock flywheel using special tool (A).
Special tool
(A): 09916M98610 1, (a)

c) Tighten the bolts to 15 Nm (1.5 kgf-m, 11.0 lbf-

ft).
d) Retighten the bolts to 35°.
Tightening torque I3RB0A143028-01
Flywheel bolt* (a): 15 Nm → +35° (1.5 kgf-m 19) Install crankshaft pulley (1) and tighten crankshaft
→ +35°, 11.0 lbf-ft → +35°) pulley bolts (2) to specified torque.
Tightening torque
2 Crankshaft pulley bolt (a): 30 N·m (3.1 kgf-m,
22.5 lbf-ft)
3

1
2, (a)

4, (a)
1 (A)
IJHB0A143076-01

IFL10A140010-01
 Engine Mechanical: D13A 1D-111

20) Remove special tool installed in Step 17).
21) Turn crankshaft clockwise two revolutions.
22) Lock camshafts (3) by inserting special tools (A) to
camshaft housing plug holes aligning the holes (1)
with camshaft gaps (2) as shown in figure.
Special tool
(A): 09917M68610
26) Install engine right mounting bracket (1) and tighten
engine right mounting bracket bolts to specified
torque.
Tightening torque
Engine right mounting bracket bolt (a): 60 N·m (
6.1 kgf-m, 44.5 lbf-ft)

1
(A)

3
2
(a)
(A)
(A) (a)

I3RB0A143029-01 IJHB0A143078-01

23) Check that locating pin of special tool (A) can be 27) Install water pump. (Page 1F-34)
inserted to cylinder block hole through flywheel hole 28) Install ISG drive belt idler bracket (1) and tighten ISG
smoothly. drive belt idler bracket bolts to specified torque.
If not, remove timing chain and flywheel and repeat
Step 2) – 22). Tightening torque
ISG drive belt idler bracket bolt (a): 55 N·m (5.6
Special tool kgf-m, 40.5 lbf-ft)
(A): 09912M38300

(A)

(a)
IJHB0A143077-01

24) Remove special tools installed in Step 22) and 23).

IJHB0A143079-01
25) Apply thread lock cement to thread part of camshaft
29) Install ISG drive belt idler pulley. (Page 1J-19)
housing plugs (1) and tighten them to specified
torque. 30) Install ISG. (Page 1J-20)
31) Install oil pan. (Page 1E-20)
“A”: Thread lock cement (Loctite omnifit 100M
spezial®)
Tightening torque
Camshaft housing plug (a): 18 N·m (1.8 kgf-m,
13.5 lbf-ft)

1, “A”, (a)

1, “A”, (a)

I3RB0A143031-03
1D-112 Engine Mechanical: D13A

32) Install common rail bracket (2) and engine hook (1) Timing Chain
to camshaft housing and tighten common rail bracket Check timing chain for wear or damage.
bolts to specified torque. If any defect is found, replace timing chain.
Tightening torque
Common rail bracket bolt (a): 22 N·m (2.2 kgf-
m, 16.5 lbf-ft)

1 (a)
I3RB0A143038-01
2
Timing Chain Tensioner Adjuster
(a) Check that sliding surfaces are free from damage.
If any defect is found, replace timing chain tensioner
adjuster.

I3RB0A143034-01

33) Install common rail. (Page 1G-48)

34) Install ventilation connector with new O-ring.
(Page 1B-15) I3RB0A143039-01
35) Install engine assembly. (Page 1D-99)
Timing Chain Guide
Timing Chain Cover and Timing Chain Check shoe (1) for wear or damage.
Inspection If any defect is found, replace timing chain guide.
AENJHB0B1426021

Timing Chain Tensioner

Check shoe (1) for wear or damage.
If any defect is found, replace timing chain tensioner.

I3RB0A143040-01

1
Flywheel
• Check sensor teeth for missing, damage or
I3RB0A143036-01 deformation.
If any defect is found, replace flywheel.
Crankshaft Timing Sprocket • Check gear for crack or wear.
Check teeth of sprocket for wear or damage. If any defect is found, replace flywheel.
If any defect is found, replace crankshaft timing • Check surface for damage or excessive wear.
sprocket. If any defect is found, replace flywheel.

I3RB0A143037-01

IBP80A142007-01

Camshaft Housing Components
12
(c)
1. Camshaft housing
2. Camshaft timing sprocket
3. Washer
4. Camshaft housing gasket
: “TOP” mark provided on gasket facing upward.
5. Intake camshaft
: Apply engine oil to sliding surface.
6. Exhaust camshaft
: Apply engine oil to sliding surface.
Engine Mechanical: D13A 1D-113
AENJHB0B1426022
(d)
OIL
11 (a) 7
(b)
OIL
5
OIL
8
OIL
6
10
IDL10A140057-01
7. Intake camshaft gear : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
: Apply engine oil to gear.
8. Exhaust camshaft gear : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: Apply engine oil to gear.
9. Cylinder head : 150 Nm (15.3 kgf-m, 111.0 lbf-ft)
10. Dowel pin : 15 Nm → 150 Nm (1.5 kgf-m →
15.3 kgf-m, 11.0 lbf-ft → 111.0 lbf-ft)
11. Camshaft housing bolt : Do not reuse.
: For tightening order, refer to “Camshaft
Housing Assembly Removal and
Installation”: D13A (Page 1D-114).
12. Camshaft housing stud bolt
: For tightening order, refer to “Camshaft
Housing Assembly Removal and
Installation”: D13A (Page 1D-114).
1D-114 Engine Mechanical: D13A

Camshaft Housing Assembly Removal and Installation

Installation 1) Clean mating surfaces of camshaft housing
AENJHB0B1426023
assembly and cylinder head.
Removal 2) Install dowel pins (1) to cylinder head, if removed.
1) Remove engine assembly. (Page 1D-99) 3) Put new camshaft housing gasket (2) on cylinder
head. “TOP” mark (3) on gasket should face upward.
2) Remove timing chain. (Page 1D-105)
3) Remove fuel injectors. (Page 1G-47)
4) Loosen camshaft housing bolts (1) and camshaft
housing stud bolts (2) in numerical order evenly and
gradually as shown in figure, and remove them.
3
1, “1”
1, “13” 1, “7” 1
1, “18”
1, “12”
1, “2” 2
1, “6”
2, “8”

2, “17”

1, “14”

1, “5” 1, “11” 1, “3”

1, “9” 1
1, “15”
1, “16”
1, “10” I7V20A142039-01
1, “4”
IJHB0B142005-01

5) Remove camshaft housing assembly (1) and

camshaft housing gasket (2).

IJHB0A143080-01
 Engine Mechanical: D13A 1D-115

4) Install camshaft housing assembly (1) to cylinder 5) Measure step (flatness) “a” between camshaft
head (2) as follows. housing (1) and cylinder head (2) using dial gauge
a) Put camshaft housing assembly on cylinder (3) and special tool (A) as shown in figure.
head, and tighten camshaft housing bolts (3) and If it is not as specified, reinstall camshaft housing
camshaft housing stud bolts (4) by hand. assembly.
b) Align end faces of camshaft housing with Special tool
cylinder head using straightedge (5). (A): 09910M26550
c) Tighten camshaft housing bolts and camshaft Step (flatness) between camshaft housing
housing stud bolts to specified torque in assembly and cylinder head
numerical order as shown in figure. “a”: –0.1 to 0.1 mm (–0.0039 to 0.0039 in.)
Tightening torque
Camshaft housing bolt* (a): 18 N·m (1.8 kgf-
m, 13.5 lbf-ft)
1
Camshaft housing stud bolt* (b): 25 N·m (2.5
kgf-m, 18.5 lbf-ft)
“a”
5
1
2

2
(A)
I7V20A142040-01

6) Install fuel injectors. (Page 1G-47)

7) Install timing chain and timing chain cover. (Page
1D-105)
3, “18”, (a)
8) Install engine assembly. (Page 1D-99)
3, “6”, (a) 3, “12”, (a)
3, “1”, (a)
3, “7”, (a) Camshaft Housing Assembly Disassembly and
3, “13”, (a) 3, “17”, (a) Reassembly
AENJHB0B1426024
4, “11”, (b)

4, “2”, (b) Disassembly

1) Remove camshaft housing assembly. (Page 1D-
3, “5”, (a) 114)
3, “14”, (a) 3, “8”, (a) 2) Remove vacuum pump. (Page 1D-85)
3, “16”, (a)
3) Remove high pressure pump. (Page 1G-49)
3, “4”, (a)
3, “3”, (a) 3, “10”, (a) 4) Remove CMP sensor. (Page 1C-26)
3, “9”, (a)
3, “15”, (a) 5) Remove special tools from camshaft housing.
IJHB0B142006-01

Special tool
(A): 09917M68610

(A)

(A)

I3RB0A143049-01
1D-116 Engine Mechanical: D13A

6) Remove camshaft timing sprocket, camshaft gears NOTE

and camshafts from camshaft housing as follows. Identify intake camshaft by letters “LH” and
a) Lock camshaft timing sprocket (1) using special exhaust camshaft by letters “RH” as shown
tool. in the figure.
Special tool
(A): 09917M68222 1
b) Remove camshaft gear bolt (2) from intake
camshaft.
c) Remove camshaft gear bolt (3) from exhaust
camshaft.
d) Remove camshaft timing sprocket bolt (4) and
then camshaft timing sprocket (1).
7 2 3
6
1 4
1

4
5

(A) 2
I3RB0A143052-01

4. “LH” mark 6. Crankshaft pulley side

5. “RH” mark 7. Flywheel side

2) Install special tools (A) as follows.

a) Turning each camshaft, align camshaft housing
plug hole (1) with camshaft gap (2) as shown in
figure.
b) Lock both camshafts (3) by inserting special
3 2 tools (A) into plug holes.
I3RB0A143051-01
Special tool
e) Remove camshafts (1) and camshaft gears (2).
(A): 09917M68610

1
(A)

3
1 2

1
2
(A)
I3RB0A143050-01

3
Reassembly (A)

1) Apply engine oil to sliding surface of each camshaft

and camshaft housing, and then insert intake 3
camshaft (1) and exhaust camshaft (2) to camshaft
housing (3). I3RB0A143053-01
 Engine Mechanical: D13A 1D-117

3) Install intake camshaft gear (1) and exhaust e) Retighten each camshaft gear bolt to 150 Nm
camshaft gear (2) to camshaft housing and tighten (15.3 kgf-m, 111.0 lbf-ft).
camshaft gear bolts (3) by hand.
Tightening torque
NOTE Camshaft gear bolt* (b): 15 Nm → 150 Nm
(1.5 kgf-m → 15.3 kgf-m, 11.0 lbf-ft → 111.0
Identify intake camshaft gear by punch mark
lbf-ft)
“IN” and exhaust camshaft gear by punch
mark “EX” as shown in figure.

1
4 5

1 2, (a)

(A)

1 3, (b) 4, (b)
IDL10A140049-02 I3RB0A143055-01

4. “IN” mark 5. “EX” mark 5) Install CMP sensor. (Page 1C-26)

6) Install high pressure pump. (Page 1G-49)
4) Tighten camshaft timing sprocket bolt and camshaft
gear bolts as follows. 7) Install vacuum pump. (Page 1D-85)
a) Set camshaft timing sprocket (1) to camshaft and 8) Install camshaft housing assembly. (Page 1D-114)
tighten bolt (2) lightly.
b) Lock timing sprocket using special tool.
Camshaft Inspection
AENJHB0B1426025

Special tool
(A): 09917M68222 Camshaft
• Check journals and cam faces for wear or damage.
c) Tighten camshaft timing sprocket bolt to If any defect is found, replace camshaft.
specified torque.
• Check CMP sensor pickup for missing, damage or
Tightening torque deformation.
Camshaft timing sprocket bolt (a): 150 N·m ( If any defect is found, replace camshaft.
15.3 kgf-m, 111.0 lbf-ft)
d) Tighten exhaust camshaft gear bolt (3) and
intake camshaft gear bolt (4) to 15 Nm (1.5 kgf-
m, 11.0 lbf-ft).

I3RB0A143056-01
1D-118 Engine Mechanical: D13A

Camshaft Journal • Check camshaft housing bore diameter using bore

Check camshaft journal diameter using micrometer.
If measured diameter is not as specified, replace
camshaft.
Camshaft journal diameter
No.1: 38.500 – 38.515 mm (1.5158 – 1.5163 in.)
No.2: 38.000 – 38.015 mm (1.4961 – 1.4966 in.)
No.3: 30.000 – 30.015 mm (1.1812 – 1.1816 in.)
gauge.
If measured diameter is not as specified, replace
camshaft housing.
Camshaft housing bore diameter
No.1: 38.545 – 38.570 mm (1.5176 – 1.5185 in.)
No.2: 38.045 – 38.070 mm (1.4979 – 1.4988 in.)
No.3: 30.045 – 30.070 mm (1.1829 – 1.1838 in.)

3 2 1

I3RB0A143127-02

1. Camshaft journal No.1 4. Intake camshaft

2. Camshaft journal No.2 5. Exhaust camshaft
3. Camshaft journal No.3 6. Crankshaft pulley side I3RB0A143059-01

1. Camshaft housing bore No.1 3. Camshaft housing bore No.3

Camshaft Housing 2. Camshaft housing bore No.2 4. Crankshaft pulley side
• Check camshaft housing for pitting, scratch, wear or
damage. Camshaft Timing Sprocket
If any defect is found, replace camshaft housing. Check camshaft timing sprocket for pitting, scratch or
damage.
If any defect is found, replace camshaft timing sprocket.

I3RB0A143058-01

I3RB0A143060-01

Intake Camshaft Gear and Exhaust Camshaft Gear

Check intake and exhaust camshaft gears for pitting,
scratch or damage.
If any defect is found, replace camshaft gear.

I3RB0A143061-01
 Engine Mechanical: D13A 1D-119

Valve and Cylinder Head Components

AENJHB0B1426026

OIL
3

OIL
2

OIL
4
10 (a) 15
5

OIL
6

OIL
7

15

11

OIL
8

15

OIL
9

12 13

13

14

IDL10A140058-01

1. Valve rocker arm 7. Valve stem seal 13. Dowel pin

2. Hydraulic valve lash adjuster
: Apply engine oil to sliding
surface.
3. Valve cotter
: Apply engine oil to sliding
surface.
4. Valve spring retainer
: Apply engine oil to sliding
surface.
5. Valve spring
6. Valve spring seat
: Apply engine oil to sliding
surface.
: Apply engine oil to sliding surface.
8. Intake valve 14. Cylinder block
: Apply engine oil to sliding surface.
9. Exhaust valve 15. Plug
: Apply engine oil to sliding surface. : Apply sealant 99000-85E00 to all around
thread part.
10. Cylinder head bolt : 40 Nm → +90° → +90° (4.1 kgf-m → +90°
: For tightening order, refer to “Valve and → +90°, 29.5 lbf-ft → +90° → +90°)
Cylinder Head Assembly Removal and
Installation”: D13A (Page 1D-120).
11. Cylinder head : Do not reuse.
12. Cylinder head gasket
: “TOP” mark on gasket comes crankshaft
pulley side, facing up.
1D-120 Engine Mechanical: D13A

Valve and Cylinder Head Assembly Removal 10) Loosen cylinder head bolts (1) in numerical order
and Installation evenly and gradually as shown in figure, and remove
AENJHB0B1426027 them.
11) Remove cylinder head (2) and cylinder head gasket
Removal
(3).
1) Remove engine assembly. (Page 1D-99)
12) Remove dowel pins (4), if necessary.
2) Remove camshaft housing assembly. (Page 1D-
114) 1, “1”
3) Remove exhaust manifold. (Page 1D-91) “7” “4”
4) Remove thermostat assembly. (Page 1F-26) “9”
5) Remove oil separator. (Page 1B-15) “5

6) Remove intake manifold. (Page 1D-93) “3”

7) Remove oil pressure switch. (Page 1E-17)

8) Remove glow plugs. (Page 1C-24) “6”
9) Remove hydraulic valve lash adjusters (1) with valve “10”
2
rocker arms (2). “8”
“2”
NOTE 3

Immerse removed hydraulic valve lash

adjusters in clean engine oil and keep them
there until their reinstallation to prevent
entering of air in the adjusters. 4
I7V20A142042-01

13) Check all around cylinder head for any other parts
2 required to be removed or disconnected.
1
Installation
1) Clean mating surfaces of cylinder head and cylinder
block.
2) Install dowel pins (1) to cylinder block (2), if
removed.

1
IJHB0A143081-01

I3RB0A143065-01
 Engine Mechanical: D13A 1D-121

3) Select and install new cylinder head gasket as c) Lock crankshaft (1) inserting locating pin (3) of
follows. special tool.
a) For turning crankshaft, install special tool (A) and
NOTE
disconnect locating pin (1).
When special tool (A) is set and locating pin
Special tool is inserted, pistons are positioned just
(A): 09912M38300 between TDC and BDC.

Special tool
1
(A): 09912M38300

3
(A)

(A)

IJHB0A143091-01

b) Using special tool and dial gauge, measure 1

2
piston protrusion “a” at specified measurement
positions (2) when piston is at TDC as shown in IJHB0A143092-01
figure. Record the maximum measured value in 2. Dowel pin
each point and repeat this procedure in all
pistons (1). d) Select cylinder head gasket according to
Special tool average value of the maximum protrusions “a” in
(A): 09910M26550 8 positions measured in Step b).
Piston
Gasket thickness
1 1 “a”
protrusion
2 0.67 – 0.77 mm 0.028 – 0.127 mm
Type A
(0.0264 – 0.0303 in.) (0.00111 – 0.00500 in.)
0.77 – 0.87 mm 0.128 – 0.227 mm
Type B
4 3 (0.0304 – 0.0342 in.) (0.00503 – 0.00893 in.)
0.87 – 0.97 mm 0.228 – 0.327 mm
(A) Type C
(0.0343 – 0.0381 in.) (0.00898 – 0.0128 in.)
1
e) Measure cylinder head height.
When cylinder head height is less than the
specified value, cylinder head could have been
ground.
Checking value of the cylinder head height,
change cylinder head gasket selected in Step d)
according to the following table or replace
IJHB0A143082-01 cylinder head.
3. Cylinder block 4. Crankshaft pulley side Cylinder head height “a”
Standard: 105.45 – 105.55 mm (4.152 – 4.155
in.)

I5RS0B140025-02
1D-122 Engine Mechanical: D13A

Selected cylinder Cylinder head b) Make end faces of cylinder head (1) and cylinder
Cylinder head block (2) flush using straightedge (3).
head gasket in gasket to be
height
Step d) installed c) Tighten all bolts to 40 Nm (4.1 kgf-m, 29.5 lbf-ft)
Type A Type B in numerical order as shown in figure.
105.35 – 105.45 mm Type B Type C d) Retighten all bolts 90° in numerical order as
(4.147 – 4.151 in.) Replace shown in figure.
Type C
cylinder head.
e) Repeat Step d).
Type A Type C
Replace Tightening torque
105.25 – 105.35 mm Type B
cylinder head. Cylinder head bolt* (a): 40 Nm → +90° →
(4.143 – 4.147 in.)
Replace +90°, (4.1 kgf-m → +90° → +90°, 29.5 lbf-ft →
Type C
cylinder head. +90° → +90°)
105.25 mm
Replace cylinder head.
(4.143 in.) or less

f) Put new cylinder head gasket (1) on cylinder

block.

1 [A]

[B]

[C]

I3RB0A143069-02

[A]: Type A (without hole) [C]: Type C (with two holes)

[B]: Type B (with one hole)

4) Install cylinder head to cylinder block as follows. I7V20A142044-01

NOTE
For accurate angle tightening of the bolt, use
tightening angle gauge available in the
market.

IJHA0A140061-01

a) Install cylinder head, and tighten new cylinder

head bolts by hand.
 Engine Mechanical: D13A 1D-123

5) Measure step (flatness) “a” between cylinder head Valve and Cylinder Head Assembly
(1) and cylinder block (2) using dial gauge and Disassembly and Reassembly
special tool as shown in figure. AENJHB0B1426028

If measured step is not as specified, remove cylinder

head and return to Step 4). Disassembly
1) Using special tools (A) and (B), compress valve
Special tool spring and then remove valve cotters (1) using
(A): 09910M26550 special tool (C).
Step (flatness) between cylinder head and Special tool
cylinder block (A): 09916M14510
“a”: –0.1 to 0.1 mm (–0.0039 to 0.0039 in.) (B): 09916M14522
(C): 09916M84511
1

“a”

(A)

I3RB0A143071-01

6) Apply engine oil around hydraulic valve lash

I3RB0A143073-01
adjusters (1) and valve rocker arms (2), and install
2) Release special tools, and remove valve spring
them to cylinder head.
retainer and valve spring.
3) Remove valve from combustion chamber side.
1 2
4) Remove valve stem seal (1) from valve guide using
special tool, and then remove valve spring seat (2).
Special tool
(A): 09917M98610

2
I3RB0A143072-01

7) Install glow plugs. (Page 1C-24)

8) Install oil pressure switch. (Page 1E-17)
(A)
9) Install intake manifold. (Page 1D-93)
10) Install oil separator. (Page 1B-16)
11) Install thermostat assembly. (Page 1F-26)
12) Install exhaust manifold. (Page 1D-91) I3RB0A143074-01

13) Install camshaft housing assembly. (Page 1D-114)

14) Install engine assembly. (Page 1D-99)
1D-124 Engine Mechanical: D13A
Reassembly
1) Install valve spring seats to cylinder head.
2) Install new valve stem seal (1) to valve guide.
After applying engine oil to seal and spindle of
special tool (valve guide installer handle), fit stem
seal to spindle, and then install seal to valve guide
by pushing special tool by hand.
After installation, check that seal is properly installed
to valve guide.
NOTICE
If the valve stem seal is installed by striking
the special tool with a hammer or other
similar tool, the valve stem seal may be
damaged, causing oil to leak passing the
seal.
Push the special tool only by hand to force
the valve stem seal into position.
Special tool
(A): 09916M58210
(B): 09917M98221
(A)
(B)
I3RB0A143075-01
3) Apply engine oil to valve stem seal, valve guide bore
and valve stem, and then install valve to valve guide.
I3RB0A143076-01
4) Install valve spring and valve spring retainer.
5) Using special tools (A) and (B), compress valve
spring. Then, fit two valve cotters (1) into groove in
valve stem using special tool (C).
NOTICE
Insufficient seating of valve cotters between
retainer and valve stem neck may cause
coming off of the cotters after engine start.
Check seating position of the cotters
carefully when fitting them. Tapping of stem
end with plastic hammer after fitting cotters
will help confirmation of their seating.
NOTE
Applying small amount of grease to valve
cotters may facilitate the fitting.
Special tool
(A): 09916M14510
(B): 09916M14522
(C): 09916M84511
I3RB0A143077-01
 Engine Mechanical: D13A 1D-125

Valve and Valve Guide Inspection Valve

AENJHB0B1426029
Visual inspection
Valve Guide • Remove all carbon deposits from valves.
Valve stem-to-guide clearance • Check each valve for wear, burn or distortion at its
Using micrometer and bore gauge, measure diameter of face and stem end.
valve stems and guides to check stem-to-guide Replace valve, if necessary.
clearance. • Check valve stem end face for pitting and wear.
Measure diameter at more than one place along the If pitting or wear is found, resurface valve stem end,
length of each stem and guide. but not too much as to grind.
If clearance is not as specified, replace valve and/or When it is worn out, replace valve.
cylinder head.
Valve stem diameter [A]
In and EX: 5.977 – 5.992 mm (0.2353 – 0.2359 in.)
Valve guide bore [B]
In and EX: 6.020 – 6.038 mm (0.2371 – 0.2377 in.)
Stem-to-guide clearance
In and EX: 0.028 – 0.061 mm (0.0012 – 0.0024 in.)

I2RH01140135-01

Valve seat repair

A valve seat not producing a uniform contact with its
valve or showing width of seating contact that is not
within specified range must be repaired by regrinding or
by cutting and regrinding and finishing by lapping.
1) Valve seat:
Use valve seat cutters (1) to make three cuts as
shown in figure. Three cutters must be used: the 1st
for making 20° angle, the 2nd for making 60° angle,
and 3rd for making 45° angle.
Seat width for valve seat
“a”: 1.35 – 1.62 mm (0.0532 – 0.0637 in.)

I7V20A142058-01
1D-126 Engine Mechanical: D13A
2) Valve lapping:
Lap valve on seat in two steps, first with coarse size
lapping compound applied to face and the second
with fine-size compound, each time using valve
lapper according to usual lapping method.
I7V20A142045-01
Cylinder Head Inspection
AENJHB0B1426030
• Remove all carbon deposits from combustion
chambers.
NOTICE
Metal surfaces can be scuffed or nicked
when removing carbon deposits with sharp-
edged tool.
Do not use any sharp-edged tool to scrape
off carbon deposits from engine parts.
I3RB0A143078-01
• Check cylinder head for crack on intake and exhaust
ports, combustion chambers and head surface.
Using straightedge and feeler gauge, check flatness
of gasket surface at 2 positions.
If distortion exceeds its limit, replace or regrind
cylinder head.
Limit of distortion for piston side surface of
cylinder head:
0.10 mm (0.00394 in.)
I3RB0A143079-01
NOTE
When cylinder head had been ground, it is
necessary to replace gasket referring to Step
3) of “Installation” under “Valve and Cylinder
Head Assembly Removal and Installation”:
D13A (Page 1D-120).
 Engine Mechanical: D13A 1D-127

Valve Spring Inspection

AENJHB0B1426031
Valve Spring Free Length and Preload
Referring to data given below, check that each spring is
in good condition, free of any evidence of breakage or
weakening.
Remember, weakened valve springs can cause chatter,
not to mention possibility of reducing power output due
to gas leakage caused by decreased seating pressure.
Valve spring free length (In and Ex) “a”:
37.9 mm (1.492 in.)
Valve spring preload when compressed to 31.0 mm
(1.220 in.) (In and Ex):
162 – 180 N (16.6 – 18.4 kgf, 36.5 – 40.4 lbf)
Valve spring preload when compressed to 23.5 mm
(0.925 in.) (In and Ex):
361 – 395 N (36.9 – 40.2 kgf, 81.2 – 88.7 lbf)

I3RB0A143080-01

Hydraulic Valve Lash Adjuster and Valve Rocker

Arm
Check hydraulic valve lash adjuster (1) and valve rocker
arm (2) for pitting, scratches, wear or damage.
If any defect is found, replace them.

I3RB0A143081-01
1D-128 Engine Mechanical: D13A

Piston, Piston Ring, Connecting Rod and Cylinder Components

AENJHB0B1426032

OIL
1

OIL
7

OIL
2

OIL
3

OIL
8
OIL
4 6
OIL

OIL
10 (a)
9
6

IJHB0A143083-01

1. 1st ring 7. Connecting rod

: For assembly, refer to “Piston, Piston Ring, Connecting Rod
and Cylinder Disassembly and Reassembly”: D13A (Page 1D-
131).
: Apply engine oil to sliding surface.
2. 2nd ring
: For assembly, refer to “Piston, Piston Ring, Connecting Rod
and Cylinder Disassembly and Reassembly”: D13A (Page 1D-
131).
: Apply engine oil to sliding surface.
3. Oil ring
: For assembly, refer to “Piston, Piston Ring, Connecting Rod
and Cylinder Disassembly and Reassembly”: D13A (Page 1D-
131).
: Apply engine oil to sliding surface.
4. Piston
: For assembly, refer to “Piston, Piston Ring, Connecting Rod
and Cylinder Removal and Installation”: D13A (Page 1D-128).
: Apply engine oil to sliding surface.
5. Piston pin
: Apply engine oil to sliding surface.
6. Piston pin circlip
: Do not apply oil to mating surface between connecting rod
and connecting rod bearing.
: Apply engine oil to sliding surface.
8. Connecting rod bearing
: For applying engine oil, refer to “Piston, Piston Ring,
Connecting Rod and Cylinder Removal and Installation”: D13A
(Page 1D-128).
9. Connecting rod bearing cap
: Do not apply oil to mating surface between connecting rod
bearing and connecting rod bearing cap.
10. Connecting rod bearing cap bolt
: For tightening order, refer to “Piston, Piston Ring, Connecting
Rod and Cylinder Removal and Installation”: D13A (Page 1D-
128).
: Apply engine oil to bolt thread and seat.
: 20 Nm → +40° (2.0 kgf-m → +40°, 15.0 lbf-ft → +40°)
: Do not reuse.

Piston, Piston Ring, Connecting Rod and

Cylinder Removal and Installation 1
AENJHB0B1426033

Removal
1) Remove engine assembly. (Page 1D-99)
2) Remove cylinder head. (Page 1D-120)
3) Remove oil pan. (Page 1E-20)
4) Remove oil pan baffle plate (1) from lower
crankcase.

I3RB0A143083-01

5) Remove special tool.
Special tool
(A): 09912M38300
(A)
I3RB0A143084-01
6) Mark cylinder numbers on all pistons using silver
pencil or quick drying paint.
7) Remove connecting rod bearing caps (1).
1
I3RB0A143085-01
8) Remove carbon deposits from top of each cylinder
bore before removing piston from cylinder.
9) Push piston and connecting rod assembly out from
the top of cylinder bore.
10) Remove connecting rod bearings from connecting
rod and connecting rod bearing cap.
Installation
1) Install connecting rod bearing to connecting rod
bearing cap and connecting rod as follows.
a) Check mating surfaces of bearing backside and
corresponding connecting rod are clean and dry.
b) Fit bearing half without hole to connecting rod
and the other bearing half with hole to bearing
cap.
c) Press each bearing half until it is closely fitted to
connecting rod or connecting rod bearing cap.
2) Apply engine oil to pistons, rings, cylinder walls,
connecting rod bearings and crankshaft pins.
Engine Mechanical: D13A 1D-129
NOTICE
If oil is present between the bearing’s outside
surface and the connecting rod surface, the
bearing could heat up to very high
temperature, resulting in seizure.
Thoroughly wipe off any trace of oil that is
present between the bearing’s outside
surface and the connecting rod surface.
3) Position crankshaft pin corresponding to piston and
connecting rod assembly to be installed to the BDC.
4) Install piston and connecting rod assembly into
cylinder bore matching cylinder number marked in
removal as follows.
a) Point front mark (1) on piston head to crankshaft
pulley side (2) and carefully insert piston and
connecting rod assembly.
1
2
I3RB0A143086-01
b) Compress piston rings with special tool (A).
c) Holding special tool firmly against cylinder block,
tap piston head with a hammer handle.
d) After piston rings enter cylinder bore, continue
pushing piston and connecting rod assembly
until big end bearing meets crankshaft pin.
NOTICE
While inserting piston and connecting rod
assembly into cylinder bore, connecting rod
big end may hit crankshaft pin and damage
the pin surface.
Carefully insert piston and connecting rod
assembly not to hit crankshaft pin with the
big end.
Special tool
(A): 09916M77310
(A)
I3RB0A143087-01
1D-130 Engine Mechanical: D13A

5) Install connecting rod bearing cap (1) matching 6) Lock crankshaft (1) installing special tool.
inscribed numbers (2) on bearing cap and
connecting rod, and then tighten new connecting rod NOTE
bearing cap bolts as follows. When special tool (A) is set and locating pin
is inserted, pistons are positioned just
NOTE between TDC and BDC.
For accurate angle tightening of the bolt, use
tightening angle gauge available in the Special tool
market. (A): 09912M38300

(A)

1
2

I3RB0A143089-01
IJHA0A140061-01
2. Dowel pin

a) Apply engine oil to thread and seat of connecting

7) Install oil pan baffle plate (1) to lower crankcase and
rod bolt.
tighten oil pan baffle plate bolts to specified torque.
b) Tighten a pair of connecting rod bearing cap
bolts (3) evenly and gradually to 20 Nm (2.0 kgf- Tightening torque
m, 15.0 lbf-ft). Oil pan baffle plate bolt (a): 9.0 N·m (0.92 kgf-m,
7.0 lbf-ft)
c) Retighten them 40°.
Tightening torque 1
Connecting rod bearing cap bolt* (a): 20 Nm
→ +40° (2.0 kgf-m → +40°, 15.0 lbf-ft → +40°)

3, (a) 3, (a) (a)

I3RB0A143090-02

8) Install oil pan. (Page 1E-20)

9) Install cylinder head. (Page 1D-120)
1 10) Install camshaft housing assembly. (Page 1D-114)
11) Install timing chain and timing chain cover. (Page
1D-105)
2 12) Install engine assembly. (Page 1D-99)

I3RB0A143088-01

d) In the same manner as in Step b) – c), tighten

connecting rod bearing cap bolts of other
cylinders.
e) Apply engine oil to all of connecting rod big ends.
 Engine Mechanical: D13A 1D-131

Piston, Piston Ring, Connecting Rod and

Cylinder Disassembly and Reassembly
AENJHB0B1426034

Disassembly
4
1) Using piston ring expander, remove 1st and 2nd
compression rings and oil ring from piston.
2) Remove piston pin from piston and connecting rod 1
as follows. 2
5
3
a) Using a flat-bladed screwdriver (2) or the like,
remove piston pin circlips (1).
I3RB0A143093-01

3) Install piston rings to piston.

NOTE
• As shown in figure, each piston ring has a
“TOP” mark. When installing these piston
rings to piston, face marked side of each
ring toward top of piston.
• 1st ring (1) differs from 2nd ring (2) in
thickness and shape.
Distinguish 1st ring from 2nd ring,
I3RB0A143091-01
referring to figure.
b) Remove piston pin (1) from piston (2) and
connecting rod. • When installing oil ring, install spiral ring
(3) first and then rail (4).

I3RB0A143092-01 1

2 3
Reassembly
1) Remove carbon deposits from piston head and ring 4
grooves using a suitable tool.
I9P60A142053-03
2) Install piston pin to piston and connecting rod as
4) After installing three rings (1st, 2nd and oil rings),
follows.
distribute their end gaps as shown in figure.
a) After applying engine oil to piston pin, piston pin
holes in piston and connecting rod, fit connecting 2
rod to piston so that inscribed number (2) on 1

connecting rod and cutout of piston skirt (1)

come on the opposite side, and insert piston pin
to piston and connecting rod. “a”

b) Install new piston pin circlips (5).

c) Position opening (4) of piston pin circlip to
“a”
opposite side of cutout (3).
2 2

I7V20A142047-01

“a”: 120° 2. Ring end gap

1. Arrow mark
1D-132 Engine Mechanical: D13A

Cylinder, Piston and Piston Ring Inspection Cylinder bore diameter

AENJHB0B1426035
Cylinder bore diameter specification
Cylinder Category (2) Cylinder bore diameter
Visual inspection 69.600 – 69.610 mm
A
Check cylinder walls for scratches, roughness or ridges (2.74016 – 2.74054 in.)
which indicate excessive wear. 69.610 – 69.620 mm
B
If cylinder bore is very rough, deeply scratched or ridged, (2.74055 – 2.74093 in.)
replace cylinder block with new one. 69.620 – 69.630 mm
C
(2.74094 – 2.74133 in.)
Cylinder bore diameter, taper and out-of-roundness
Using a cylinder gauge (1), measure cylinder bore in Cylinder taper difference
thrust and axial directions at any positions as shown in Limit: 0.01 mm (0.00040 in.)
figure.
Out-of-roundness difference
If any of the following conditions is found, replace
Limit: 0.005 mm (0.00020 in.)
cylinder block.
• Cylinder bore diameter exceeds specification. 2
• Difference of measurements at two positions exceeds
taper limit.
• Difference between thrust and axial measurements
exceeds out-of-roundness limit.
1

I7V20A142048-02

3. Crankshaft pulley side

 Engine Mechanical: D13A 1D-133

Piston Piston clearance

Visual inspection Measure cylinder bore diameter and piston diameter to
Check piston for crack or other damages. find their difference which is piston clearance. If it is not
Damaged or faulty piston should be replaced. as specified, rebore cylinder and use oversize piston.

NOTE
Piston diameter
As shown in figure, piston diameter should be measured Cylinder bore diameters used here are
at a position 7.00 mm (0.28 in.) (“a”) from piston skirt end measured in thrust direction at two positions.
in the direction perpendicular to piston pin.
Piston clearance:
Piston diameter specification Standard: 0 – 0.036 mm (0 – 0.0014 in.)
Index (1) on piston Limit: 0.064 mm (0.0025 in.)
Piston diameter with coating
head
69.574 – 69.600 mm Ring groove clearance
A
(2.7391 – 2.7401 in.) Before checking, piston grooves must be clean, dry and
69.584 – 69.610 mm free of carbon deposits.
B
(2.7395 – 2.7405 in.) Fit new piston ring (1) into piston groove, and measure
69.594 – 69.620 mm clearance between ring and ring land using feeler gauge
C
(2.7399 – 2.7409 in.) (2). If clearance is not as specified, replace piston ring
and/or piston.
Ring groove clearance
1st ring: 0.105 – 0.150 mm (0.0042 – 0.0059 in.)
2nd ring: 0.075 – 0.120 mm (0.0030 – 0.0047 in.)
Oil ring: 0.025 – 0.070 mm (0.0010 – 0.0028 in.)

I7V20A142049-01

I3RB0A143097-01
1D-134 Engine Mechanical: D13A

Piston Ring 3) Using micrometer, measure piston diameter.

Piston ring end gap
To measure end gap, insert piston ring (1) into cylinder
bore and then measure the gap using feeler gauge (2).
If measured gap is not as specified, replace piston ring.
NOTE
Remove all carbon deposits from top of
cylinder bore before inserting piston ring.
Piston ring end gap
1st ring: 0.18 – 0.30 mm (0.0071 – 0.0118 in.)
2nd ring: 1.00 – 1.50 mm (0.0394 – 0.0590 in.)
Oil ring: 0.25 – 0.50 mm (0.0099 – 0.0196 in.)
4) Rebore and hone cylinder to the following
dimension.
Cylinder bore diameter to be rebored:
70.000 – 70.010 mm (2.75590 – 2.75629 in.)
NOTE
Before reboring, install lower crankcase and
tighten to specification to avoid distortion of
cylinder bores while reboring.
5) Measure piston clearance after honing. If clearance
is out of specification, replace cylinder block and all
pistons.
Piston clearance:
0.054 mm (0.00212 in.)

Piston Pin and Connecting Rod Inspection

AENJHB0B1426036
Piston Pin Visual Inspection
Check piston pin, connecting rod small-end bore and
piston pin hole in piston for wear or damage, paying
particular attention to condition of small-end bushing. If
piston pin, connecting rod small-end, pin hole in piston is
badly worn or damaged, replace pin, connecting rod
and/or piston.

I3RB0A143099-01

Honing or Reboring Cylinder

1) When any of the cylinders needs reboring, all other
cylinders must also be rebored at the same time.
2) Use oversized piston according to amount of
cylinder wear.
Oversize piston diameter
Size Piston diameter with coating
Oversize 0.40 69.974 – 70.000 mm
(2.7548 – 2.7559 in.)

I2RH01140157-01

“a”: 7 mm (0.276 in.)

 Engine Mechanical: D13A 1D-135

Piston Pin Clearance

Check piston pin clearance in small-end and piston.
Replace connecting rod and/or piston, if its small-end is
badly worn or damage.
Piston pin clearance in connecting rod small-end:
0.019 – 0.030 mm (0.00075 – 0.00118 in.)
Piston pin clearance in piston: 3
0.004 – 0.014 mm (0.00016 – 0.00055 in.)
Piston pin diameter:
1
22.982 – 22.987 mm (0.90481 – 0.90500 in.)
Connecting rod small-end bore:
23.006 – 23.012 mm (0.90575 – 0.90598 in.) 2
I3RB0A143100-01
Piston pin hole bore in piston:
22.991 – 22.996 mm (0.90516 – 0.90535 in.) Crankshaft Pin and Connecting Rod Bearing
Inspection
AENJHB0B1426037
Connecting Rod Bearing General Information
• Cap side connecting rod bearing half (1) has a hole
(2) as shown in figure.
Install this half with hole to connecting rod bearing
cap.
• Connecting rod side connecting rod bearing half (3)
does not have hole.

3
I3RB0A143101-01
I3RB0A143098-01

Connecting Rod Crankshaft Pin Diameter

Check connecting rod big-end bore.
1) Install connecting rod bearing cap (2) to connecting
rod (1).
2) Measure connecting rod big-end bore using bore
gauge (3).
If measured bore is not as specified, replace
connecting rod and bearing cap as a set.
Check crankshaft pin for uneven wear or damage.
Measure crankshaft pin for out-of-roundness or taper
with a micrometer (1).
If crankshaft pin is damaged or out-of-roundness or
taper is not as specified, regrind or replace crankshaft.
Crankshaft pin diameter:
42.582 – 42.600 mm (1.6765 – 1.6771 in.)

Big-end bore:
45.734 – 45.744 mm (1.8006 – 1.8009 in.)

I5RS0B140032-01
1D-136 Engine Mechanical: D13A

Big-End Side Clearance NOTE

Check big-end of connecting rod for side clearance, with
rod fitted and connected to its crankshaft pin in normal
manner.
If measured clearance is not as specified, replace
connecting rod.
Big-end side clearance:
0.12 – 0.45 mm (0.0048 – 0.0177 in.)
It is not necessary to use new bearing cap
bolts for measuring procedure.
5) Using scale (1) on gauging plastic (2) envelope,
measure gauging plastic width (clearance) at the
widest point after removing connecting rod bearing
cap.
If clearance exceeds its specification, use a new
standard size bearing and/or crankshaft.
After selecting new connecting rod bearing, recheck
clearance.
Connecting rod bearing clearance:
0.030 – 0.062 mm (0.0012 – 0.0024 in.)

2
1

I2RH0B140148-01

Connecting Rod Bearing Visual Inspection

Check bearing shells for signs of fusion, pitting, burn or
flaking and observe contact pattern. Defective bearing
shells must be replaced.
I3RB0A143103-01

Connecting rod bearing clearance

Selection of Connecting Rod Bearing
NOTE
Do not rotate crankshaft while gauging
plastic is fitted.
1) Before checking bearing clearance, clean bearing
and crankshaft pin.
2) Install bearing in connecting rod and bearing cap.
3) Place a piece of gauging plastic (1) to full width of
crankshaft pin (parallel to crankshaft), avoiding oil
hole.
NOTE
• If bearing is defective or bearing clearance
is not as specified, select a new standard
bearing according to the following
procedure and install it.
• When replacing crankshaft or connecting
rod and its bearings due to any reason,
select new standard bearings to be
installed referring to alphabets stamped on
crank web No.1.

Standard size of connecting rod bearing

1
1) Check connecting rod big-end inside diameter.
If measured big-end inside diameter is not as
specified, replace connecting rod assembly.
Connecting rod big-end inside diameter:
45.734 – 45.744 mm (1.8006 – 1.8009 in.)

I3RB0A143102-01

4) Install connecting rod and connecting rod bearing

cap. (Page 1D-128)
 Engine Mechanical: D13A 1D-137

2) Next, check crankshaft pin diameter. As shown in 3) There are two kinds of standard bearings differing in
figure, crank web No.1 has stamped alphabets. thickness. To distinguish them, they are painted in
Two kinds of alphabet “A” and “B” represent the the following colors at the position shown in figure.
following crankshaft pin diameter respectively. Each color indicates the following thickness at the
For example, stamped “A” indicates that center of bearing.
corresponding crankshaft pin diameter is 42.591 –
Standard size of connecting rod bearing
42.600 mm (1.6769 – 1.66771 in.).
thickness
Crankshaft pin diameter Color painted Bearing thickness
Class Crankshaft pin diameter 1.546 – 1.552 mm
Red
42.591 – 42.600 mm (0.06087 – 0.06110 in.)
A
(1.6769 – 1.6771 in.) 1.550 – 1.556 mm
Blue
42.582 – 42.591 mm (0.06103 – 0.06125 in.)
B
(1.6765 – 1.6768 in.)

I5RS0B140031-01

1. Paint

4) From alphabet stamped on crank web No.1,

determine new standard bearing to be installed to
connecting rod big-end inside, referring to the table.
For example, if number stamped on crank web No.1
is “A“, install a new standard bearing painted in
IJHB0A143084-01
“Red” to its connecting rod big-end inside.
1. Crankshaft pulley side Specification of new standard connecting rod
bearing size
Alphabet stamped on crank web
Color painted
No.1 (Crankshaft pin diameter)
A Red
B Blue

5) Check bearing clearance with newly selected

standard bearing referring to “Connecting Rod
Bearing Visual Inspection”: D13A (Page 1D-136).
If clearance is not as specified, use next thicker
bearing and recheck clearance.

2
1

I5RS0B140033-01

1. Scale 2. Gauging plastic

1D-138 Engine Mechanical: D13A

Undersize bearing (0.127 mm (0.0050 in.)) • If necessary, regrind crankshaft pin and select
• 0.127 mm (0.00500 in.) undersize bearing is available undersize bearing to use with it as follows.
in two kinds varying in thickness. To distinguish them, 1) Regrind crankshaft pin to the following finished
each bearing is painted in the following colors at the diameter.
position shown in figure. Each color indicates the
Finished diameter
following thickness at the center of bearing.
42.455 – 42.473 mm (1.6715 – 1.6721 in.)
Undersize connecting rod bearing thickness
2) Using micrometer (1), measure reground crankshaft
Color painted Bearing thickness pin diameter. Measurement should be taken in two
1.609 – 1.615 mm directions perpendicular to each other to check for
Brown
(0.06335 – 0.06358 in.) out-of-roundness.
1.613 – 1.619 mm
Green 3) Using crankshaft pin diameter measured above,
(0.06351 – 0.06374 in.)
select an undersize bearing, referring to table given
below. Check bearing clearance with newly selected
undersize bearing.
Specification of new undersize connecting rod
bearing
Measured crankshaft
Color painted
pin diameter
42.464 – 42.473 mm
Brown
(1.6719 – 1.6721 in.)
42.455 – 42.464 mm
Green
(1.6715 – 1.6718 in.)

I5RS0B140031-01

1. Paint

I5RS0B140032-01
 Engine Mechanical: D13A 1D-139

Main Bearing, Crankshaft and Cylinder Block Components

AENJHB0B1426038

OIL
1 3

OIL
11
5

OIL
2

(a)

OIL
4

OIL
10 5

OIL
6 5

8 (d)

(b)

11

7 (c)
IJHB0A143085-01

1. Cylinder block 9. Oil jet

: Apply sealant 99000-85E11. (Page 1D-140)
: Do not apply oil to main bearing seating face.
2. Crankshaft 10. Timing chain oil jet
: Apply engine oil to sliding surface.
3. Main bearing (with thrust bearings) 11. Dowel pin
: Apply engine oil to sliding surface.
4. Crankshaft rear oil seal : 6.0 Nm (0.61 kgf-m, 4.5 lbf-ft)
: Apply engine oil-to-oil seal lip.
5. Main bearing : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
: Apply engine oil to bearing inside surfaces.
6. Lower crankcase : 20 Nm → +80° (2.0 kgf-m → +80°, 15.0 lbf-ft → +80°)
: Do not apply oil to main bearing seating face.
7. Crankcase bolt No.1 : 15 Nm → 30 Nm (1.5 kgf-m → 3.1 kgf-m, 11.0 lbf-ft →
: For tightening order, refer to “Main Bearing, Crankshaft and Cylinder Block 22.5 lbf-ft)
Removal and Installation”: D13A (Page 1D-140).
8. Crankcase bolt No.2 : Do not reuse.
: For tightening order, refer to “Main Bearing, Crankshaft and Cylinder Block
Removal and Installation”: D13A (Page 1D-140).
1D-140 Engine Mechanical: D13A

Main Bearing, Crankshaft and Cylinder Block 6) Remove ISG bracket (1) from cylinder block.
Removal and Installation
AENJHB0B1426039

NOTE
• All parts to be installed must be perfectly
clean.
• Apply oil to crankshaft journals, main
bearings, main bearing (with thrust
bearings), crankpins, connecting rod
1
bearings, pistons, piston rings and
cylinder bores.

Removal
1) Remove engine assembly. (Page 1D-99)
2) Remove cylinder head assembly. (Page 1D-120)
3) Remove CKP sensor. (Page 1C-27)
4) Remove A/C compressor bracket (1).
IFL10A140019-01
7) Remove crank ventilation cover from cylinder block.
8) Remove piston and connecting rod. (Page 1D-
128)
9) Loosen crankcase bolt No.1 and crankcase bolt
No.2 in numerical order evenly and gradually as
shown in figure, and remove them.

“1” “3”
“6”
“10” “7”

“15” “12” “14”

“17” “20”

IFL10A140018-01
“19” “18”
5) Remove timing chain oil jet (1) from cylinder block.

“13” “11” “16”

“8”
“4” “5” “9”
1 “2”
I3RB0A143108-01

10) Remove lower crankcase (1) from cylinder block

using special tool.
Special tool
(A): 09921M96510
I3RB0A143106-01

(A)
I3RB0A143109-01
 Engine Mechanical: D13A 1D-141

11) Remove crankshaft (1) and flywheel side crankshaft Installation

oil seal (2) from cylinder block. 1) Install dowel pins (1) to cylinder block, if removed.
12) Remove main bearings (3) and main bearing (with 2) Install oil jets (2) to cylinder block and tighten new oil
thrust bearings) (4) from cylinder block and lower jet bolts to specified torque, if removed.
crankcase.
Tightening torque
2 Oil jet bolt (a): 9.0 N·m (0.92 kgf-m, 7.0 lbf-ft)

(a)
1

3 2 1

I3RB0A143112-01
4
3) Install main bearings (3) and main bearing (with
3
I3RB0A143110-01 thrust bearings) (4) to cylinder block and lower
13) Remove oil jets (1) from cylinder block, if necessary. crankcase as follows.
14) Remove dowel pins (2) from cylinder block, if NOTICE
necessary.
• The engine will seize up if it is operated
when the parts listed below are not
2
properly lubricated.
Lubricate all the friction surfaces of these
parts with engine oil before installing them.
– Crankshaft journals
1 2 – Main bearings
– Thrust bearings
• If oil is present between the bearing’s
outside surface and the cylinder block /
I3RB0A143111-01 lower crankcase surface, the bearing could
heat up to very high temperature, resulting
in seizure.
Thoroughly wipe off any trace of oil that is
present between the bearing’s outside
surface and the cylinder block / lower
crankcase surface.

NOTE
One of two main bearing halves has an oil
groove (5).
Install the one half to cylinder block, and the
other half without oil groove to lower
crankcase.
Check that two halves are painted in the
same color.
1D-142 Engine Mechanical: D13A

a) Check mating surfaces of bearing backside and 6) Clean mating surface of cylinder block and lower
corresponding cylinder block and lower crankcase.
crankcase are clean and dry. 7) Apply sealant to lower crankcase (1) as shown in
b) Fit tab (1) on each bearing to cutout (2) in figure.
cylinder block and lower crankcase.
“A”: Sealant 99000–85E11 (Three Bond TB
c) Press bearing end until it seats closely in cylinder 1227®)
block and lower crankcase.
d) Apply engine oil to sliding surface of main 1
bearing halves at cylinder block side.

“A” “A”
1
2

“a”
5
“A”

I3RB0A143116-01
3
“a”: 3.0 mm (0.118 in.)

3 8) Install lower crankcase to cylinder block.

9) Tighten new crankcase bolts No.1 (“1” – “10”) and
new crankcase bolts No.2 (“11” – “20”) in numerical
order as follows.

NOTE
4
For accurate angle tightening of the bolt, use
I3RB0A143113-01
tightening angle gauge available in the
4) Install dowel pin (1) to crankshaft, if removed. market.

I3RB0A143114-01

5) Check cleanliness of crankshaft journal and place IJHA0A140061-01

crankshaft (1) on cylinder block and then apply
engine oil to crankshaft journal. a) Tighten crankcase bolts No.1 to 20 Nm (2.0 kgf-
m, 15.0 lbf-ft).
b) Retighten them 80°.
c) Tighten crankcase bolts No.2 to 15 Nm (1.5 kgf-
m, 11.0 lbf-ft).
d) Retighten them to 30 Nm (3.1 kgf-m, 22.5 lbf-ft).
1
Tightening torque
Crankcase bolt No.1* (a): 20 Nm → +80° (2.0
kgf-m → +80°, 15.0 lbf-ft → +80°)
Crankcase bolt No.2* (b): 15 Nm → 30 Nm
I3RB0A143115-01 (1.5 kgf-m → 3.1 kgf-m, 11.0 lbf-ft → 22.5 lbf-
ft)
 Engine Mechanical: D13A 1D-143

NOTE 11) Install timing chain oil jet (1) to cylinder block and
After tightening lower crankcase bolts, check tighten oil jet union bolts to specified torque.
that crankshaft rotates smoothly. Tightening torque
Oil jet union bolt (a): 6.0 N·m (0.61 kgf-m, 4.5 lbf-
ft)
“15”, (b) “20”, (b) “18”, (b)
“11”, (b) “14”, (b)

“6”, (a) “9”, (a) “7”, (a)

1
“4”, (a) “1”, (a)

(a)

“2”, (a) “3”, (a)

I3RB0A143119-01

12) Install pistons and connecting rods. (Page 1D-128)

“8”, (a) “10”, (a) “5”, (a)
13) Install crank ventilation cover to cylinder block.
“13”, (b) 14) Install ISG bracket (1) to cylinder block and tighten
“17”, (b) “16”, (b) “12”, (b)
“19”, (b) ISG bracket bolts to specified torque.
IJHB0A143086-01

10) Using special tools, install new crankshaft rear oil Tightening torque
seal (1) as follows. ISG bracket bolt (a): 22 N·m (2.2 kgf-m, 16.5 lbf-
ft)
Special tool
(A): 09913M58620
(B): 09924M74510
Crankshaft rear oil seal Installing position
(depth)
“a”: 1.0 mm (0.04 in.)
a) Fit crankshaft rear oil seal to special tool (A). (a)
b) Install special tool (B) to special tool (A), and
1
install crankshaft rear oil seal by tapping special
tool (B) lightly with a plastic hammer.
c) Remove special tools (A) and (B).

“a” 3
1
IFL10A140020-01

15) Install A/C compressor bracket (1) and tighten A/C

2 compressor bracket bolts in numerical order (“1” –
“4”), if removed.

(A) “3” “4”

(B)

IDL10A140050-01

2. Crankshaft 3. Cylinder block

“1” “2”
IFL10A140021-01
1D-144 Engine Mechanical: D13A

16) Install CKP sensor. (Page 1C-27) Crankshaft Thrust Play

17) Install cylinder head assembly. (Page 1D-120)
18) Install engine assembly. (Page 1D-99)
Main Bearing, Crankshaft and Cylinder Block
Inspection
AENJHB0B1426040
1) Install main bearings, main bearing (with thrust
bearings), crankshaft and lower crankcase. (Page
1D-140)
2) Using a dial gauge, measure crankshaft thrust play.
If measured value is not as specified, replace main
bearing (with thrust bearings).

Thrust Bearing Inspection Crankshaft thrust play:

0.06 – 0.26 mm (0.0022 – 0.0104 in.)
1) There are standard and oversize bearings differing in
thickness. To distinguish them, they are painted in
the following colors at the position shown in figure.
2) If measured value is not as specified, replace thrust
bearing.
Thickness of crankshaft thrust bearing
Color painted Bearing thickness
Yellow
Blue
Red 2.310 – 2.360 mm
Standard
Black (0.0909 – 0.0929 in.)
I7V20A142053-02
Green
Brown Cylinder Block Bore
Yellow / Black
Measure cylinder block bore and check the bore for
Blue / Black
uneven wear or damage. If it is damaged or diameter is
Red / Black 2.437 – 2.487 mm
Oversize not as specified, replace cylinder block.
Black / Black (0.0959 – 0.0979 in.)
Green / Black Cylinder block bore diameter
Brown / Black Class 1 54.710 – 54.714 mm (2.1540 – 2.1540 in.)
Class 2 54.714 – 54.718 mm (2.1541 – 2.1542 in.)
Class 3 54.718 – 54.722 mm (2.1543 – 2.1544 in.)

I7V20A142052-02
I5RS0B140029-01
1. Paint
 Engine Mechanical: D13A 1D-145

Main Bearing Inspection Main bearing clearance

AENJHB0B1426041
General Information
• Service main bearings are available in standard size
and 0.127 mm (0.00500 in.) undersize, and both
standard size and undersize bearings have three
kinds varying in thickness.
• Bearing upper half (1) has oil groove (2) as shown in
figure.
Install bearing halves with oil groove to cylinder block.
• Bearing lower half does not have oil groove.
1
NOTE
Do not rotate crankshaft while gauging
plastic is placed.
1) Before checking bearing clearance, clean bearing
and crankshaft journal.
2) Install bearings to cylinder block and lower
crankcase. (Page 1D-140)
3) Put crankshaft and place a piece of gauging plastic
(1) to full width of crankshaft journal (parallel to
crankshaft), avoiding oil hole.

1
I3RB0A143123-01

I3RB0A143124-01
Visual inspection
4) Install lower crankcase. (Page 1D-140)
Check bearings for pitting, scratches, wear or damage.
If any defect is found, replace both upper and lower NOTE
halves.
It is not necessary to use new crankcase
Never replace either half without replacing the other half.
bolts for measuring procedure.

5) Remove lower crankcase and using a scale (1) on

gauging plastic (2) envelope, measure gauging
plastic width (clearance) at the widest point.
If clearance is not as specified, replace bearing.
Always replace both upper and lower halves as a
set.
Main bearing clearance:
0.026 – 0.050 mm (0.0011 – 0.0019 in.)

2
I3RB0A143125-01
1D-146 Engine Mechanical: D13A

Selection of Main Bearing 2) Check cylinder block bore diameter. On rear end of
Standard bearing cylinder block, three numbers are stamped as shown
If bearing is defective, or bearing clearance is not as in figure.
specified, select a new standard bearing according to Three kinds of numbers (“1”, “2” and “3”) represent
the following procedure and install it. the following cylinder block bore diameters.
1) Check journal diameter. As shown in figure, crank Stamped numbers on cylinder block represent
web No.1 has stamped alphabets. cylinder block bore diameter marked with an arrow in
Three kinds of alphabets (“A”, “B” and “C”) represent figure respectively.
the following journal diameters. For example, stamped “1” indicates that
Stamped alphabets on crank web No.1 represent corresponding cylinder block bore diameter is
journal diameters marked with an arrow in figure 54.710 – 54.714 mm (2.15394 – 2.15409 in.).
respectively. For example, stamped alphabet “A” Cylinder block bore
indicates that corresponding journal diameter is Stamped number Bore diameter
50.994 – 51.000 mm (2.0077 – 2.0078 in.). 54.710 – 54.714 mm
1
Crankshaft journal diameter (2.15394 – 2.15409 in.)
Stamped alphabet Journal diameter 54.714 – 54.718 mm
2
50.994 – 51.000 mm (2.15410 – 2.15425 in.)
A 54.718 – 54.722 mm
(2.0077 – 2.0078 in.) 3
50.988 – 50.994 mm (2.15426 – 2.15440 in.)
B
(2.0074 – 2.0076 in.)
50.982 – 50.988 mm
C
(2.0072 – 2.0074 in.)

IJHB0A143087-01

1. Crankshaft pulley side

I7V20A142055-01

1. Crankshaft pulley side

 Engine Mechanical: D13A 1D-147

3) There are 3 kinds of standard bearings differing in

thickness. To distinguish them, they are painted in
the following colors at the position shown in figure.
Each color indicates the following thickness at the
center of bearing.
Standard size of crankshaft main bearing without
thrust bearing thickness
Color painted Bearing thickness
1.836 – 1.841 mm
Red
(0.07229 – 0.07248 in.)
1.841 – 1.846 mm
Blue
(0.07249 – 0.07267 in.)
1.846 – 1.851 mm
Yellow
(0.07268 – 0.07287 in.)

Standard size of crankshaft main bearing with

thrust bearing thickness
Color painted
With standard
With oversize Bearing thickness
size thrust
thrust bearing
bearing I7V20A142056-02

1.836 – 1.841 mm [A]: Without thrust bearing 1. Paint

Red Red / Black (0.07229 – 0.07248 [B]: With thrust bearings
in.)
1.841 – 1.846 mm
Blue Blue / Black (0.07249 – 0.07267
in.)
1.846 – 1.851 mm
Yellow Yellow / Black (0.07268 – 0.07287
in.)

4) From alphabet stamped on crank web No.1 and numbers stamped on cylinder block, determine new standard
bearing to be installed, referring to the table below.
For example, if alphabet stamped on crank web No.1 is “A” and number stamped on cylinder block is “1”, install a
new standard bearing painted in “Red” or “Red / Black” for upper and “Red” for lower to its journal.
Main bearing cross-reference table (standard size)
Alphabet stamped on crank web No.1 (Journal diameter)
A B C
Upper Red or Red / Black Red or Red / Black Blue or Blue / Black
1
Lower Red Blue Blue
Number stamped on
Upper Red or Red / Black Blue or Blue / Black Blue or Blue / Black
cylinder block (Bore 2
Lower Blue Blue Yellow
diameter)
Upper Blue or Blue / Black Blue or Blue / Black Yellow or Yellow / Black
3
Lower Blue Yellow Yellow

2
I5RS0B140036-01

1. Scale 2. Gauging plastic

1D-148 Engine Mechanical: D13A

Undersize bearing 0.127 mm (0.0050 in.)

• 0.127 mm (0.00500 in.) undersize bearing is available
in three kinds varying in thickness. To distinguish
them, each bearing is painted in the following colors at
the position shown in figure. Each color represents
the following thickness at the center of bearing.
Undersize of crankshaft main bearing without
thrust bearing thickness
Color painted Bearing thickness
1.899 – 1.904 mm
Brown
(0.07477 – 0.07496 in.)
1.904 – 1.909 mm
Green
(0.07497 – 0.07515 in.)
1.909 – 1.914 mm
Black
(0.07516 – 0.07535 in.)

Undersize of crankshaft main bearing with thrust

bearing thickness
Color painted
With
I7V20A142056-02
standard With oversize Bearing thickness
size thrust thrust bearing [A]: Without thrust bearing 1. Paint
[B]: With thrust bearings
bearing
1.899 – 1.904 mm
Brown Brown / Black • If necessary, regrind crankshaft journal and select
(0.07477 – 0.07496 in.)
1.904 – 1.909 mm undersize bearing to use with crankshaft as follows.
Green Green / Black
(0.07497 – 0.07515 in.)
1.909 – 1.914 mm
Black Black / Black
(0.07516 – 0.07535 in.)
1) Regrind journal to the following finished diameter.
Finished diameter
50.855 – 50.873 mm (2.00216 – 2.00287 in.)
2) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions
perpendicular to each other to check for out-of-roundness.
3) Using journal diameter measured above, select an undersize bearing referring to table below. Check bearing
clearance with newly selected undersize bearing.
Main bearing cross-reference table (undersize)
Alphabet stamped on crank web No.1 (Journal diameter)
50.867 – 50.873 mm 50.861 – 50.867 mm 50.855 – 50.861 mm
(2.0027 – 2.0028 in.) (2.0024 – 2.0026 in.) (2.0022 – 2.0024 in.)
Brown or Brown / Brown or Brown /
Upper Green or Green / Black
1 Black Black
Lower Brown Green Green
Number stamped on Brown or Brown / Green or Green /
Upper Green or Green / Black
cylinder block (Bore 2 Black Black
diameter) Lower Green Green Black
Green or Green / Green or Green /
Upper Black or Black / Black
3 Black Black
Lower Green Black Black
 Engine Mechanical: D13A 1D-149

Cylinder Block Inspection

AENJHB0B1426042

Distortion of Gasket Surface

Using straightedge and feeler gauge, check gasket
surface for distortion. If distortion exceeds specified limit,
repair it.
If repair is not possible, replace cylinder block.
Cylinder block flatness
Limit: 0.03 mm (0.0012 in.)

IDL10A140052-01

IDL10A140053-01
1D-150 Engine Mechanical: D13A

Specifications
Tightening Torque Specifications
AENJHB0B1427001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Camshaft housing plug (Page 1D-80) /
18 1.8 13.5
(Page 1D-111)
Common rail bracket bolt (Page 1D-80) /
22 2.2 16.5
(Page 1D-112)
Intercooler upper bracket bolt 8.5 0.87 6.5 (Page 1D-84)
Vacuum pump bolt 23 2.3 17.0 (Page 1D-86)
Oil drain pipe bolt No.1 9.0 0.92 7.0 (Page 1D-89)
Turbocharger bolt 30 3.1 22.5 (Page 1D-90)
Turbocharger nut 25 2.5 18.5 (Page 1D-90)
Oil drain pipe bolt No.2 9.0 0.92 7.0 (Page 1D-90)
Turbocharger oil intake pipe bolt 22 2.2 16.5 (Page 1D-90)
Exhaust manifold nut* 15 Nm → +30° (1.5 kgf-m → +30°, 11.0 lbf- (Page 1D-92)
ft → +30°)
Intake manifold bolt* 25 2.5 18.5 (Page 1D-94)
Oil level gauge guide mounting bolt (Page 1D-94) /
9.0 0.92 7.0
(Page 1D-102)
Oil pump drive flange bolt* 50 Nm → +90° (5.1 kgf-m → +90°, 37.0 lbf- (Page 1D-96) /
ft → +90°) (Page 1D-110)
Crankshaft pulley bolt (Page 1D-96) /
30 3.1 22.5
(Page 1D-110)
Engine right mounting bolt 65 6.6 48.0 (Page 1D-103)
Engine right mounting nut 65 6.6 48.0 (Page 1D-103)
Engine left mounting bolt 55 5.6 40.5 (Page 1D-103)
Engine left mounting nut 55 5.6 40.5 (Page 1D-103)
Chain guide mounting bolt 9.0 0.92 7.0 (Page 1D-108)
Chain tensioner mounting bolt 25 2.5 18.5 (Page 1D-108)
Chain tensioner adjuster bolt 9.0 0.92 7.0 (Page 1D-108)
Timing chain cover bolt 9.0 0.92 7.0 (Page 1D-109)
Timing chain cover nut 9.0 0.92 7.0 (Page 1D-109)
Flywheel bolt* 15 Nm → +35° (1.5 kgf-m → +35°, 11.0 lbf- (Page 1D-110)
ft → +35°)
Engine right mounting bracket bolt 60 6.1 44.5 (Page 1D-111)
ISG drive belt idler bracket bolt 55 5.6 40.5 (Page 1D-111)
Camshaft housing bolt* 18 1.8 13.5 (Page 1D-115)
Camshaft housing stud bolt* 25 2.5 18.5 (Page 1D-115)
Camshaft timing sprocket bolt 150 15.3 111.0 (Page 1D-117)
Camshaft gear bolt* 15 Nm → 150 Nm (1.5 kgf-m → 15.3 kgf- (Page 1D-117)
m, 11.0 lbf-ft → 111.0 lbf-ft)
Cylinder head bolt* 40 Nm → +90° → +90°, (4.1 kgf-m → +90° (Page 1D-122)
→ +90°, 29.5 lbf-ft → +90° → +90°)
Connecting rod bearing cap bolt* 20 Nm → +40° (2.0 kgf-m → +40°, 15.0 lbf- (Page 1D-130)
ft → +40°)
Oil pan baffle plate bolt 9.0 0.92 7.0 (Page 1D-130)
Oil jet bolt 9.0 0.92 7.0 (Page 1D-141)
Crankcase bolt No.1* (a) 20 Nm → +80° (2.0 kgf-m → +80°, 15.0 lbf- (Page 1D-142)
ft → +80°)
Crankcase bolt No.2* (b) 15 Nm → 30 Nm (1.5 kgf-m → 3.1 kgf-m, (Page 1D-142)
11.0 lbf-ft → 22.5 lbf-ft)
Oil jet union bolt 6.0 0.61 4.5 (Page 1D-143)
ISG bracket bolt 22 2.2 16.5 (Page 1D-143)
 Engine Mechanical: D13A 1D-151

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Air Cleaner Components”: D13A (Page 1D-81)
“Intercooler Components”: D13A (Page 1D-83)
“Turbocharger and Exhaust Manifold Components”: D13A (Page 1D-87)
“Intake Manifold Components”: D13A (Page 1D-92)
“Engine Mounting Components”: D13A (Page 1D-98)
“Timing Chain Cover and Timing Chain Components”: D13A (Page 1D-104)
“Camshaft Housing Components”: D13A (Page 1D-113)
“Valve and Cylinder Head Components”: D13A (Page 1D-119)
“Piston, Piston Ring, Connecting Rod and Cylinder Components”: D13A (Page 1D-128)
“Main Bearing, Crankshaft and Cylinder Block Components”: D13A (Page 1D-139)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Recommended Service Material
AENJHB0B1428001
Material SUZUKI recommended product or Specification Note
Sealant Three Bond TB 1227® P/No.: 99000–85E11 (Page 1D-109) / (Page
1D-142)
Thread lock cement Loctite omnifit 100M spezial® — (Page 1D-80) / (Page
1D-111)

NOTE
Required service material(s) is also described in:
“Timing Chain Cover and Timing Chain Components”: D13A (Page 1D-104)
“Camshaft Housing Components”: D13A (Page 1D-113)
“Valve and Cylinder Head Components”: D13A (Page 1D-119)
“Piston, Piston Ring, Connecting Rod and Cylinder Components”: D13A (Page 1D-128)
“Main Bearing, Crankshaft and Cylinder Block Components”: D13A (Page 1D-139)

Special Tool
AENJHB0B1428002
09910M26550 09910M95020
Dial gauge support Oil pump drive flange holder
(Page 1D-115) / (Page 1D-94) /
(Page 1D-121) / (Page 1D-95)
(Page 1D-123)

09912M38300 09912M46310
Crankshaft locking tool TDP definition pin
(Page 1D-106) / EN-46785
(Page 1D-107) / (Page 1D-80)
(Page 1D-108) /
(Page 1D-111) /
(Page 1D-121) /
(Page 1D-121) /
(Page 1D-129) /
(Page 1D-130)
1D-152 Engine Mechanical: D13A

09912M57822 09913M58620
Compression gauge Oil seal installer
(Page 1D-79) (Page 1D-97) /
(Page 1D-143)

09913M75510 09915M67311
Bearing installer Vacuum gauge
(Page 1D-95) / (Page 1D-86)
(Page 1D-109)

09915M68610 09916M14510
Dummy heater plug Valve lifter
(Page 1D-79) (Page 1D-123) /
(Page 1D-124)

09916M14522 09916M58210
Valve spring compressor Valve guide installer handle
attachment
(Page 1D-123) / (Page 1D-124)
(Page 1D-124)

09916M77310 09916M84511
Piston ring compressor (50 - Forceps
125 mm)
(Page 1D-129) (Page 1D-123) /
(Page 1D-124)

09916M98610 09917M47011
Flywheel locking tool Vacuum pump gauge
KM-652 (Page 1D-91)
(Page 1D-105) /
(Page 1D-106) /
(Page 1D-110)

09917M68222 09917M68610
Crankshaft pulley holder Camshaft locking tool
(Page 1D-116) / EN-46781
(Page 1D-117) (Page 1D-80) /
(Page 1D-106) /
(Page 1D-107) /
(Page 1D-108) /
(Page 1D-111) /
(Page 1D-115) /
(Page 1D-116)
 Engine Mechanical: D13A 1D-153

09917M98221 09917M98610
Valve guide stem Valve stem seal pliers
attachment
(Page 1D-124) KM-840
(Page 1D-123)

09921M96510 09924M74510
Oil pan seal cutter Bearing and oil seal handle
(Page 1D-140) (Page 1D-97) /
(Page 1D-143)
1E-1 Engine Lubrication System: K15B

Engine Lubrication System

Engine

K15B
General Description
Engine Lubrication Description
AENJHB0B1511001
The oil pump is of a trochoid type.
Oil is drawn up through the oil pump strainer and passes through the pump to the oil filter. The filtered oil flows into the
main oil gallery in the cylinder block. Oil from the main gallery is supplied to the crankshaft main bearings and cylinder
head. An oil passage is connected to the sub gallery via backside of crankshaft main bearing. The following devices
are lubricated or pressurized by delivered oil as follows.
• Crankshaft journal
Main bearings supporting crankshaft journals are lubricated and the oil is supplied to the connecting rod bearings by
means of intersecting passages drilled in the crankshaft, and then splashed from the big end of each connecting rod
to lubricate cylinder wall, piston pin, piston and piston rings.
• Timing chain oil jet
Oil from an oil passage between the main gallery and main bearing is supplied to the jet and injected for lubrication
of the timing chain, timing sprockets, timing chain tensioner and timing chain guide.
• Tensioner adjuster
Oil from an oil passage connected to the main bearing provides pressure to the tensioner adjuster for adjustment of
the chain tension.
• Cylinder head
Oil from the main gallery is supplied to OCV through the timing chain cover, and then sent to camshaft No.1 housing
to activate the VVT. The rest of oil is supplied to intake No.2 bearing through the orifice and sent to the intake
camshaft and exhaust camshaft journals.
– Intake VVT actuator
Oil is supplied to VVT through the timing chain cover, intake OCV, cylinder head, camshaft No.1 housing and
intake camshaft and it is used for the intake camshaft timing control.
– Camshaft journal
For journals other than intake No.1 journal, oil is supplied to the intake and exhaust camshaft journals through the
passages inside the camshafts. For intake No.1 journal, oil is supplied from the intake OCV through the cylinder
head and the camshaft No.1 housing.
The oil pump is equipped with an oil relief valve. This valve relieves oil pressure when the pressure exceeds specified
value.
The oil filter provides a relief valve to bypass oil when oil pressure exceeds the filter’s specification caused by clogging
of the filter element due to poor maintenance (without changing the filter as scheduled). In this situation, dusty oil will
circulate in the engine without filtration and causes the engine damage.
 Engine Lubrication System: K15B 1E-2

Cam surface & Tappet Pressurized oil

Splashed oil
Return oil
VVT actuator Bypass line

Intake camshaft Exhaust camshaft Piston ring Piston pin

Camshaft
Cylinder wall Piston
No.1 housing

OCV Crankshaft pin - Connecting rod

Chain cover Camshaft No.2 housing

Crankshaft journal

Cylinder head
Tensioner adjuster

Timing chain oil jet Timing chain - Chain

tensioner - Chain guide

Cylinder block (main gallery)

Oil filter
Oil filter
relief valve

Cylinder block

Oil pump
Oil pump
relief valve

Oil strainer

Oil pan
IGJA0A151001-02
1E-3 Engine Lubrication System: K15B

Diagnostic Information and Procedures

Oil Pressure Check 3) Install special tools to threaded hole where oil
AENJHB0B1514001 pressure switch was removed.
! CAUTION
Special tool
Touching a hot exhaust system component (A): 09915M77311
will cause a burn. (B): 09915M78211
Do not perform any service work on and
around the exhaust system until the exhaust (B)
system is cool. (A)

NOTE
Before checking oil pressure, check the
following points.
• Oil level in oil pan
If oil level is low, add oil up to FULL level
mark (hole) (1) on oil level gauge. (Page
1E-4)
I7V20A151003-01

4) Start engine and warm it up to normal operating

temperature.
5) Measure oil pressure at 4,000 rpm.
Oil pressure specification
280 – 500 kPa (2.9 – 5.0 kgf/cm2, 40.6 – 72.5 psi,
2.8 – 5 bar) at 4,000 rpm
6) Stop engine.
IYSQ01020012-01
7) Remove special tools.
2. LOW level mark (hole)
8) Install oil pressure switch. (Page 1E-5)
9) Start engine and check oil pressure switch for oil
• Oil quality leakage. If oil leakage is found, repair incorrect
If oil is discolored or deteriorated, change installation of oil pressure switch.
it. (Page 1E-4) 10) Check DTC. (Page 1A-23)
• Oil leakage If any DTC is displayed, clear DTC. (Page 1A-24)
If leakage is found, repair leaky point.

1) For M/T model, place gear shift lever in “Neutral” and

apply parking brake.
For A/T model, place select lever in “P” and apply
parking brake.
2) Remove oil pressure switch. (Page 1E-5)
 Engine Lubrication System: K15B 1E-4

Repair Instructions
Engine Oil and Filter Change 7) Loosen oil filter using special tool and remove oil
AENJHB0B1516001 filter.
! CAUTION
Special tool
There is an increased risk of severe personal (A): 09915M47341
injury or health problems if the procedure
described below is performed without taking
proper precautions.
• Engine oil has an adverse health effect.
Read and understand the instructions in (A)
“General Precautions” in Section 00 (Page
00-1) and follow all the instructions.
• Check that the engine is not running when
performing Step 1) – 12) of the procedure.
• Adequately ventilate the working area
when starting the engine in Step 13).
I7V20A151009-02
Before draining engine oil, check engine for oil leakage.
8) Wipe oil filter mounting surface of oil pan clean.
If any evidence of leakage is found, correct defective
part before proceeding to the following procedure. 9) Apply engine oil to new oil filter gasket.
1) Remove oil filler cap and oil level gauge from engine.
2) Hoist vehicle.
3) Drain engine oil by removing drain plug (1).
4) Wipe drain plug clean.
5) Replace gasket with new one.
6) Reinstall drain plug and tighten it to specified torque.
Tightening torque
Engine oil drain plug (a): 35 N·m (3.6 kgf-m, 26.0
lbf-ft)
IYSQ01020009-01

10) Install the oil filter according to the following

procedure.
a) Tighten the oil filter (1) by hand until its gasket
touches the oil pan.
b) Using the special tool, rotate the oil filter a three-
quarter turn (2) to tighten it.

NOTE
1, (a) When tightening oil filter using torque
wrench, apply 14 Nm (1.4 kgf-m, 10.5 lbf-ft).
I8C50B150002-01

Special tool
(A): 09915M47341

(A)
1

IFRA0A151001-01
1E-5 Engine Lubrication System: K15B

11) Add oil until oil level is brought to FULL level mark Oil Pressure Switch On-Vehicle Inspection
(hole) on oil level gauge (oil pan and oil filter AENJHB0B1516002

capacity). It is recommended to use engine oil of SG, ! CAUTION

SH, SJ, SL, SM or SN grade. Select appropriate oil Touching a hot exhaust system component
viscosity according to engine oil viscosity chart [A] will cause a burn.
below. Do not perform any service work on and
SAE 0W-16 oil is the best choice for good fuel around the exhaust system until the exhaust
economy and good starting in cold weather. system is cool.
NOTE
1) Disconnect oil pressure switch lead wire (1).
• Engine oil capacity is as specified below. 2) Check for continuity between oil pressure switch
However, note that actual amount of oil terminal (2) and cylinder block (3) as shown.
required during oil change may somewhat If check result is not as specified, replace oil
differ from that indicated below depending pressure switch (4). (Page 1E-5)
on such factors as temperature, viscosity,
etc. Oil pressure sensor specification
With engine running: No continuity
• Engine oil specification and viscosity chart
At engine stop: Continuity exists
[A] indicated in this manual are typical
ones.
For the specific information on the engine
oil and proper engine oil viscosity, refer to
2
“Engine Oil and Filter” section of the
Owner's Manual. 4 1

3
Engine oil specification
Oil change only: About 2.9 liters (6.13 / 5.10 US /
Imp pt.)
Oil and oil filter change: About 3.1 liters (6.55 /
5.46 US / Imp pt.)
After overhaul: About 3.4 liters (7.19 / 5.98 US / I7V20A151006-01
Imp pt.)
Oil Pressure Switch Removal and Installation
[A] 20W-40 AENJHB0B1516003

15W-40
Removal
10W-30, 10W-40
! CAUTION
0W-16, 0W-20, 5W-30
o
C -30 -20 -10 0 10 20 30 40 To avoid the danger of being burned, do not
F -22
o
-4 14 32 50 68 86 104 touch the exhaust system when the system is
IJHB0A151001-01
hot.
12) Install oil filler cap and oil level gauge to engine. Any service on the exhaust system should be
13) Start engine and run it for 5 minutes. Stop it and wait performed when the system is cool.
for 5 minutes before checking oil level. Add oil, if
necessary, to bring oil level to FULL level mark (hole) 1) Disconnect oil pressure switch lead wire (1).
(1) on oil level gauge. 2) Remove oil pressure switch (2) from cylinder block.

IYSQ01020012-01
1
2. LOW level mark (hole)
I7V20A151002-01

14) Check oil filter and drain plug for oil leakage.
 Engine Lubrication System: K15B 1E-6

Installation
1) Apply sealant to thread portion of oil pressure switch
(1), and then tighten oil pressure switch to specified
torque.

NOTICE
If sealant is applied to the hole when
applying sealant to thread portion of the oil
pressure switch, the engine oil pressure light
will not operate properly due to clogging.
Avoid applying sealant to the oil pressure
switch hole.

“A”: Thread lock cement 99000–32150 (Thread

Lock Cement Super 1322)
Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
lbf-ft)

“A” 1

1, (a)

I9R90A150004-01

2) Connect oil pressure switch lead wire (1).

I7V20A151005-01
1E-7 Engine Lubrication System: K15B

Oil Pan and Oil Pump Strainer Components

AENJHB0B1516004

6
6
OIL

1
7 1217G
OIL

1 (c)

2
8 (c)
(c)
3 (c) 11
4 (c) 12 (b)

10 (a)

9 (c)

OIL
13
IJHA0A150002-02

1. O-ring 7. Oil pan 13. Oil filter

: Apply engine oil.
2. Oil pump strainer
3. Oil pump strainer bolt
: For tightening order, refer to “Oil Pan
and Oil Pump Strainer Removal and
Installation”: K15B (Page 1E-7).
4. Oil pan baffle plate nut
: For tightening order, refer to “Oil Pan
and Oil Pump Strainer Removal and
Installation”: K15B (Page 1E-7).
5. Oil pan baffle plate
6. Dowel pin
: Apply sealant 99000-31260 to : For tightening procedure, refer to
cylinder block mating surface. “Engine Oil and Filter Change”: K15B
(Page 1E-4).
: Apply engine oil to oil filter gasket.
8. Oil pan bolt No.1 : 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
: For tightening order, refer to “Oil Pan
and Oil Pump Strainer Removal and
Installation”: K15B (Page 1E-7).
9. Oil pan bolt No.2 : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
: For tightening order, refer to “Oil Pan
and Oil Pump Strainer Removal and
Installation”: K15B (Page 1E-7).
10. Drain plug : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: Apply engine oil to mating surface.
11. Gasket : Do not reuse.
12. Oil filter stand

Oil Pan and Oil Pump Strainer Removal and

Installation
AENJHB0B1516005

Removal
2
1) Remove oil level gauge.
2) Remove right side engine under side cover. (Page
9H-15)
3) Drain engine oil by removing drain plug.
4) Remove oil filter. (Page 1E-4)
1
5) Remove exhaust pipe. (Page 1K-4) I7V20A151012-01

6) Remove transaxle bolts (1). 8) Using a large flat-bladed screwdriver (heavy duty
7) Remove oil pan bolts (2). type) or the like, open oil pan gradually and carefully
from the lug portions and remove it from cylinder
block.
 Engine Lubrication System: K15B 1E-8

9) Remove oil pump stainer (1) with O-ring (2). Installation

1) Clean sealing surface between oil pan and cylinder
block.
Remove oil, old sealant and dust from sealing
surface.
2) Install oil filter stand (1) to oil pan, if removed, and
tighten it with special tool to specified torque.
Special tool
(A): 09915M47350
2
Tightening torque
Oil filter stand (a): 18 N·m (1.8 kgf-m, 13.5 lbf-ft)

IFAE0A150038-01

10) Remove oil pan baffle plate (1).

(A)
11) Remove oil pan baffle plate stud bolt (2) from main
bearing cap, if necessary.

1, (a)

IFRA0A151016-01
2
3) Install oil pan baffle plate stud bolt (1) if removed,
and tighten it to specified torque.
1
Tightening torque
Oil pan baffle plate stud bolt (a): 11 N·m (1.1 kgf-
IFAE0A150016-01 m, 8.5 lbf-ft)
12) Remove oil filter stand (1) from oil pan using special
tool and wrenches, if necessary. 4) Install oil pan baffle plate (2), and then tighten oil pan
baffle plate bolts (3) to specified torque.
Special tool
(A): 09915M47350 Tightening torque
Oil pan baffle plate bolt (b): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)

(A)

1 1,(a)

IFRA0A151015-01 3,(b)
I9P60A151002-01
1E-9 Engine Lubrication System: K15B

5) Apply engine oil to new O-ring (1), and install it to oil 9) Apply engine oil to new O-ring (1), and install it to
pump strainer (2). position as shown in figure.
6) Install oil pump stainer with O-ring to oil pump, and 10) Apply sealant to oil pan mating surface as shown in
then tighten oil pump stainer bolt (3) first and oil pan figure.
baffle plate nut (4) to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
Tightening torque No.1217G)
Oil pump stainer bolt (a): 11 N·m (1.1 kgf-m, 8.5
Sealant amount for oil pan
lbf-ft)
Width “a”: 3 mm (0.12 in.)
Oil pan baffle plate nut (b): 11 N·m (1.1 kgf-m,
Height “b”: 2 mm (0.08 in.)
8.5 lbf-ft)

1 “a”
“A”
“A”
“b”

2 4, (b)
IFRA0A151017-01

3, (a) 11) Within 2 minutes after applying sealant, install oil pan
IFAE0A150039-01
to cylinder block and then tighten oil pan bolts No.1
7) Check that dowel pins (1) are installed in oil pan and (1) and oil pan bolt No.2 (2) in numerical order (“1” –
cylinder block. “17”) evenly and gradually to specified torque.
Tightening torque
Oil pan bolt No.1 (a): 11 N·m (1.1 kgf-m, 8.5 lbf-
1
ft)
Oil pan bolt No.2 (b): 11 N·m (1.1 kgf-m, 8.5 lbf-
ft)

1, “9”, (a) 1, “5”, (a) 1, “7”, (a)

1, “11”, (a) 2, “1”, (b) 1, “3”, (a) 1, “13”, (a)

1, “15”, (a)
1, “16”, (a)

1
1, “14”, (a)
I9P60A151004-01

8) Clean mating surfaces of oil pan and cylinder block. 1, “17”, (a)

1, “12”, (a) 1, “4”, (a) 1, “6”, (a)

1, “8”, (a) 1, “2”, (a) 1, “10”, (a)
IFRA0A151006-01
 Engine Lubrication System: K15B 1E-10

12) Tighten transaxle to engine bolts (1) to specified 13) Install exhaust pipe. (Page 1K-4)
torque. 14) Install oil filter. (Page 1E-4)
Tightening torque 15) Install drain plug with new gasket and refill engine
Transaxle to engine bolt (M/T model) (a): 55 N·m with engine oil. (Page 1E-4)
(5.6 kgf-m, 40.5 lbf-ft) 16) Install oil level gauge.
Transaxle to engine bolt (A/T model) (a): 54 N·m
17) Check that there is no engine oil leakage and
(5.5 kgf-m, 40.0 lbf-ft)
exhaust gas leakage at each connection.
18) Install right side engine under side cover. (Page
9H-15)

1, (a)

I9P60A151006-01

Oil Pump Assembly Components

AENJHB0B1516006

8 (b)

4
OIL

5
OIL

3
OIL

6
OIL

7 (a)
IHL10A151002-03

1. Timing chain cover 4. Rotor plate 7. Retainer : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
2. Inner rotor 5. Relief valve 8. Rotor plate bolt
: Apply engine oil. : Apply engine oil.
3. Outer rotor 6. Spring : 28 Nm (2.9 kgf-m, 21.0 lbf-ft)
: Apply engine oil. : Apply engine oil.

Oil Pump Assembly Removal and Installation

AENJHB0B1516007
Oil pump is incorporated in timing chain cover.
For removal and installation, refer to “Timing Chain
Cover Removal and Installation”: K15B in Section 1D
(Page 1D-33).
1E-11 Engine Lubrication System: K15B

Oil Pump Assembly Disassembly and Reassembly

Reassembly 1) Clean and then dry all disassembled parts.
AENJHB0B1516008
2) Apply thin coat of engine oil to the following parts.
Disassembly • Inner rotor
1) Remove rotor plate (1) by removing rotor plate bolts. • Outer rotor
• Inside surfaces of timing chain cover
3) Install outer rotor (1) and inner rotor (2) to timing
chain cover.

NOTE
When installing the outer rotor and inner
1
rotor, face the front marks (3) toward cylinder
block.

3
IHL10A151003-02
1
2) Remove outer rotor (1) and inner rotor (2).

1
IHL10A151006-02

4) Apply engine oil to relief valve (1) and relief valve

spring (2), and install them to rotor plate (4).
5) Tighten retainer (3) to specified torque.
2 Tightening torque
Retainer (a): 28 N·m (2.9 kgf-m, 21.0 lbf-ft)

IHL10A151004-02

3) Remove retainer (1), relief valve spring (2) and relief

valve (3). 1

4 2

3,(a)

I7V20A151023-01
4

IHL10A151005-01

4. Rotor plate
 Engine Lubrication System: K15B 1E-12

6) Install rotor plate and tighten rotor plate bolts to • Check that relief valve (1) is not excessively worn or
specified torque. After installing plate, check that damaged and operates smoothly.
rotors turned smoothly by hand.
Tightening torque
Rotor plate bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)

1
(a)

IHL10A151007-01

Oil Pump Inspection

AENJHB0B1516009 I8C50A150029-01

Oil Seal Radial clearance

Check oil seal lip for defects and damage. Replace it if
necessary.
Check radial clearance between outer rotor (1) and
timing chain cover (2) using feeler gauge (3).
If clearance is out of specification, replace oil pump
assembly.
Radial clearance between outer rotor and case of oil
pump
Standard: 0.135 – 0.205 mm (0.0054 – 0.0080 in.)
Limit: 0.21 mm (0.0083 in.)

I2RH0B150023-01

Oil Pump
• Check outer rotor (1), inner rotor (2), rotor plate and
1
timing chain cover for excessive wear or damage.
2
IFRA0A151013-01

IHL10A151006-02

3. Front mark
1E-13 Engine Lubrication System: K15B

Side clearance Relief valve spring free length and load

Using straightedge (1) and feeler gauge (2), measure Check free length and load of relief valve spring as
side clearance. shown in figure. If any of measurement is smaller than
If side clearance is out of specification, replace oil pump specification, replace relief valve spring.
assembly.
Relief valve spring free length and load
Side clearance of oil pump inner rotor Standard Limit
Standard: 0.024 – 0.069 mm (0.00095 – 0.00271 in.) 32.7 mm
Limit: 0.103 mm (0.00406 in.) Free length —
(1.29 in.)
Side clearance of oil pump outer rotor Load at spring 54.5 N 48.3 N
Standard: 0.038 – 0.083 mm (0.0015 – 0.0032 in.) length (5.6 kgf, 12.3 (4.9 kgf, 10.9
Limit: 0.103 mm (0.00406 in.) 26.0 mm (1.02 in.) lbf) lbf)

IFRA0A151014-01

I2RH01150023-01

Specifications
Tightening Torque Specifications
AENJHB0B1517001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Engine oil drain plug 35 3.6 26.0 (Page 1E-4)
Oil pressure switch 13 1.3 9.5 (Page 1E-6)
Oil filter stand 18 1.8 13.5 (Page 1E-8)
Oil pan baffle plate stud bolt 11 1.1 8.5 (Page 1E-8)
Oil pan baffle plate bolt 11 1.1 8.5 (Page 1E-8)
Oil pump stainer bolt 11 1.1 8.5 (Page 1E-9)
Oil pan baffle plate nut 11 1.1 8.5 (Page 1E-9)
Oil pan bolt No.1 11 1.1 8.5 (Page 1E-9)
Oil pan bolt No.2 11 1.1 8.5 (Page 1E-9)
Transaxle to engine bolt (M/T model) 55 5.6 40.5 (Page 1E-10)
Transaxle to engine bolt (A/T model) 54 5.5 40.0 (Page 1E-10)
Retainer 28 2.9 21.0 (Page 1E-11)
Rotor plate bolt 11 1.1 8.5 (Page 1E-12)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Oil Pan and Oil Pump Strainer Components”: K15B (Page 1E-7)
“Oil Pump Assembly Components”: K15B (Page 1E-10)
“Fasteners Information” in Section 0A (Page 0A-5)
 Engine Lubrication System: K15B 1E-14

Special Tools and Equipment

Recommended Service Material
AENJHB0B1518001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 (Page 1E-9)
Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32150 (Page 1E-6)

NOTE
Required service material(s) is also described in:
“Oil Pan and Oil Pump Strainer Components”: K15B (Page 1E-7)
“Oil Pump Assembly Components”: K15B (Page 1E-10)

Special Tool
AENJHB0B1518002
09915M47341 09915M47350
Oil filter wrench socket Oil filter stand remover
(Page 1E-4) / (Page 1E-8) /
(Page 1E-4) (Page 1E-8)

09915M77311 09915M78211
Oil pressure gauge Oil pressure gauge
attachment
(Page 1E-3) (Page 1E-3)
1E-15 Engine Lubrication System: D13A

D13A
General Description
Engine Lubrication Description
AENJHB0B1521001
The oil pump is of a trochoid type pump installed inside the bottom part of the timing chain cover. The pump draws up
oil from the oil pan through the oil pump strainer. The oil then flows through the oil cooler and engine oil filter before
being distributed to each engine part.

Diagnostic Information and Procedures

Oil Pressure Check 4) Start engine and warm it up to normal operating
AENJHB0B1524001 temperature.
1) Before checking oil pressure, check the following
items. NOTE
• Oil level in oil pan Place gear shift lever in “Neutral”, apply
If engine oil level is low, add oil up to FULL level parking brake and block drive wheels.
mark (1) on oil level gauge (3).
• Oil quality 5) Measure oil pressure at specified engine speed.
Change engine oil if discolored or deteriorated. NOTE
For engine oil to be used, refer to “Engine Oil and
Filter Change”: D13A (Page 1E-16). For specified idle speed, refer to “Idle Speed
Inspection”: D13A in Section 1A (Page 1A-
• Oil leakage 340).
If leakage is found, repair leaky point(s).
Oil pressure specification:
Minimum: 180 kPa (1.8 kgf/cm2, 26.1 psi, 1.80 bar)
at 2,000 rpm.
Minimum: 280 kPa (2.9 kgf/cm2, 40.6 psi, 2.80 bar)
at 4,000 rpm.
6) Stop engine, and remove special tools.
7) Install oil pressure switch. (Page 1E-17)
8) Start engine, and check oil pressure switch for oil
leakage.
If oil leakage is found, repair it.
I3RB0A153001-01

2. LOW level mark

2) Remove oil pressure switch. (Page 1E-17)

3) Install special tools to threaded hole where oil
pressure switch was removed.
Special tool
(A): 09915M77311
(B): 09919M46010

(B)

(A)

I5RS0B150001-01
 Engine Lubrication System: D13A 1E-16

Repair Instructions
Engine Oil Level Check c) Pull out oil filter (1) from oil filter housing cover.
AENJHB0B1526001
1) Check engine oil level as follows:
a) Place vehicle on a level surface.
1
b) Warm up engine to normal operating
temperature.
c) Stop engine and wait for 10 min.
d) Remove oil level gauge and wipe it with a clean
lint-free cloth.
e) Reinsert oil level gauge fully.
f) Remove oil level gauge again and check oil
level. IBP80A152001-01

2) If engine oil level is above FULL level mark on the oil 2) Drain engine oil by removing drain plug (1).
level gauge, adjust engine oil level to upper limit. 3) Wipe drain plug clean and replace seal ring with a
3) If engine oil level is near LOW level mark on oil level new one. Reinstall drain plug, and tighten it to
gauge, add engine oil to FULL level mark. (Page specified torque.
1E-16)
Tightening torque
Engine oil drain plug (a): 20 N·m (2.0 kgf-m, 15.0
Engine Oil and Filter Change lbf-ft)
AENJHB0B1526002
! WARNING
There is an increased risk of severe personal
injury or health problems if the procedure
described below is performed without taking
proper precautions.
• Engine oil has an adverse health effect. 1, (a)
Read and understand the instructions in
“General Precautions” in Section 00 (Page I5RS0B020001-01
00-1) and follow all the instructions.
4) Install oil filter.
• Check that the engine is not running when
a) Replace O-ring (1) of oil filter housing cover (2)
performing Step 1) – 6) of the procedure.
with new one and apply engine oil to O-ring.
• Adequately ventilate the working area
when starting the engine in Step 7).

Before draining engine oil, check engine for oil leakage.

If any evidence of leakage is found, correct defective 1
part before proceeding to the following procedure.
1) Remove oil filter element.
a) Place oil collecting basin under oil filter. 2
b) Loosen and remove oil filter housing cover (1). IBP80A152003-01

b) Install new oil filter to housing.

IJHB0A153001-01
1E-17 Engine Lubrication System: D13A

c) Install oil filter housing cover (1) and tighten it to

specified torque.
Tightening torque
Oil filter housing cover (a): 25 N·m (2.5 kgf-
m, 18.5 lbf-ft) 1 2

I3RM0B020008-01
1, (a)
2. LOW level mark

Oil Pressure Switch On-Vehicle Inspection

AENJHB0B1526003
1) Disconnect oil pressure switch connector.
2) Check for continuity between oil pressure switch
terminal (2) and cylinder head (3) as shown.
IJHB0A153002-01 If check result is not as specified, replace oil
5) Add engine oil until oil level is brought to FULL level pressure switch (1).
mark on oil level gauge (oil pan and oil filter Oil pressure switch specification
capacity). It is recommended to use engine oil of With engine running: No continuity
ACEA A5/B5 grade. Select appropriate oil viscosity At engine stop: Continuity
according to engine oil viscosity chart [A] below.
SAE 5W-30 oil is the best choice for good fuel
economy and good starting in cold weather.

NOTE
• Engine oil capacity is as specified below.
However, note that actual amount of
engine oil required during engine oil 1

change may somewhat differ from that

indicated below depending on such
factors as temperature, viscosity, etc.
• Engine oil specification and viscosity chart
3
[A] indicated in this manual are typical
ones.
For the specific information on the engine
1
oil and proper engine oil viscosity, refer to
“Engine Oil and Filter” section of the
Owner's Manual.
2

Engine oil specification

Engine oil and oil filter change: About 3.2 liters
(6.76 / 5.63 US / Imp pt.)
IJHB0A153004-01
After overhaul: About 3.5 liters (7.39 / 6.15 US /
Imp pt.)
Oil Pressure Switch Removal and Installation
AENJHB0B1526004
[A]
Removal
5W-40
1) Remove air cleaner outlet hose No.1. (Page 1D-
5W-30 81)
o
C -30 -20 -10 0 10 20 30 40 2) Disconnect oil pressure switch connector.
o -22
F -4 14 32 50 68 86 104
IJHB0A153003-01

6) Check oil filter and drain plug for oil leakage.

7) Start engine and run it for 5 minutes. Stop it and wait
for 5 minutes before checking engine oil level. Add
oil, if necessary, to bring engine oil level to FULL
level mark (1) on oil level gauge.
 Engine Lubrication System: D13A 1E-18

3) Remove oil pressure switch (1) from cylinder head. • Tighten oil pressure switch (1) to specified torque.
Tightening torque
Oil pressure switch (a): 32 N·m (3.3 kgf-m, 24.0
lbf-ft)

1, (a)

IJHB0A153005-01

Installation
Reverse removal procedure noting the following points.
IJHB0A153006-01
• Check oil pressure switch gasket for deterioration and
• Check that there is no engine oil leakage.
damage. If defect is found, replace oil pressure
switch.

Oil Cooler Components

AENJHB0B1526005

4 (a)
1

(b)
5

7
3

(b)

IJHB0A153007-01

1. Filler cap 5. Oil filter : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
2. O-ring 6. Oil cooler inlet pipe : Do not reuse.
3. Gasket 7. Oil cooler assembly
: Never disassemble oil cooler assembly.
4. Oil filter housing cover : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
1E-19 Engine Lubrication System: D13A

Oil Cooler Removal and Installation Installation

AENJHB0B1526006 Reverse removal procedure noting the following points.
Removal • Install oil cooler assembly (1) with new gasket and
tighten oil cooler bolts (2) to specified torque.
1) Drain coolant. (Page 1F-25)
2) Remove turbocharger oil intake pipe (1) and Tightening torque
gaskets. Oil cooler bolt (a): 9.0 N·m (0.92 kgf-m, 7.0 lbf-ft)
3) Remove oil cooler inlet pipe bolts No.1 (2) and oil
cooler inlet pipe bolt No.2 (3).

2, (a)
1

2
3

2, (a)
IJHB0A153010-01

IJHB0A153008-01
• Install new gasket to coolant feed pipe.
4) Remove radiator outlet hose (1). • Temporarily tighten oil cooler inlet pipe bolt No.2 (1)
by hand, and then tighten oil cooler inlet pipe bolts
5) Disconnect wire harness clamps from oil cooler
No.1 (2) to specified torque.
assembly.
6) Remove oil cooler assembly (2). Tightening torque
Oil cooler inlet pipe bolt No.1 (a): 9.0 N·m (0.92
kgf-m, 7.0 lbf-ft)
• Tighten oil cooler inlet pipe bolt No.2 to specified
torque.
2
Tightening torque
Oil cooler inlet pipe bolt No.2 (b): 9.0 N·m (0.92
kgf-m, 7.0 lbf-ft)
1 • Install turbocharger oil intake pipe with new gaskets,
and then tighten turbocharger oil intake pipe bolts (3)
to specified torque.
Tightening torque
IJHB0A153009-01 Turbocharger oil intake pipe bolt (c): 22 N·m (2.2
kgf-m, 16.5 lbf-ft)

2, (a) 3, (c)
3, (c) 1, (b)

IJHB0A153011-01

• Refill cooling system with coolant. (Page 1F-25)

• Check coolant system for leakage. (Page 1F-24)
• Check that there is no oil leakage at each connection.
 Engine Lubrication System: D13A 1E-20

Oil Pan Components

AENJHB0B1526007

(b) (b)
3

2 (a)
I9P60A152011-01

1. Oil pan 3. O-ring : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)

: Apply sealant 99000-85E11 to mating surface.
2. Drain plug : 20 Nm (2.0 kgf-m, 15.0 lbf-ft) : Do not reuse.

Oil Pan Removal and Installation 8) Remove oil pan bolts (1) and nuts (2).
AENJHB0B1526008

Removal
1) Remove oil level gauge.
2) Hoist vehicle and remove right side engine under 1
side cover. 2

3) Drain engine oil. (Page 1E-16)

4) Remove exhaust No.1 pipe. (Page 1K-8)
5) Remove catalytic converter brace bolt (1).
6) Remove clutch housing plate (2).
I9P60A152020-01

9) Cut sealant at hatched part shown in the figure using

special tool and hammer (1).
Special tool
(A): 09921M96510

NOTE
Be careful not to damage stud bolt (4)
between oil pan and crankcase when cutting
1
sealant.
2

IJHB0A153012-01

7) Remove transaxle stiffener (1).

IJHB0A153013-01
1E-21 Engine Lubrication System: D13A

10) Remove oil pan (2) from lower crankcase (3). 2) Apply continuous bead of sealant to oil pan mating
surface as shown in figure.
3
“A”: Sealant 99000–85E11 (Three Bond TB
1227®)

(A) “A”

I5RS0B150012-01

3) Fit oil pan to lower crankcase and lightly tighten oil

pan bolts and nuts.
Then, starting from the central bolt at either side of
oil pan, tighten oil pan bolts and nuts diagonally to
specified torque.
Tightening torque
Oil pan bolt and nut (a): 9.0 N·m (0.92 kgf-m, 7.0
4 lbf-ft)
4) Install new O-ring and drain plug (1) to oil pan.
I5RS0B150010-01
Tighten drain plug to specified torque.
Installation Tightening torque
1) Clean mating surfaces of oil pan and lower Drain plug (b): 20 N·m (2.0 kgf-m, 15.0 lbf-ft)
crankcase.

(a)

1, (b)
I5RS0B150013-01

5) Install transaxle stiffener (1) and tighten transaxle

stiffener bolts (2) to specified torque.
Tightening torque
Transaxle stiffener bolt (a): 34 N·m (3.5 kgf-m,
25.0 lbf-ft)

I5RS0B150011-01
 Engine Lubrication System: D13A 1E-22

6) Tighten transaxle-engine bolt (3) to specified torque. Oil Pump / Oil Pump Strainer Components
(Page 5B-57) AENJHB0B1526009

2, (a)

1 (a)

2, (a)
IJHB0A153014-01

7) Install clutch housing plate (1).

8) Tighten transaxle-engine bolt (2) to specified torque. I9P60A152013-01
(Page 5B-57) 1. Timing chain cover : 9.0 Nm (0.92 kg-m, 7.0
9) Tighten catalytic converter brace bolt (3) to specified : Oil pump is incorporated in lbf-ft)
timing chain cover.
torque. (Page 1K-8) 2. Oil pump strainer gasket : Do not reuse.
3. Oil pump strainer

Oil Pump / Oil Pump Strainer Removal and

Installation
AENJHB0B1526010
3
Removal
1) Remove timing chain cover. (Page 1D-105)
2
2) Remove oil pump strainer (1) and gasket (2) from
rotor plate (3).
1

IJHB0A153015-01
3

10) Install exhaust No.1 pipe. (Page 1K-8)

11) Install oil level gauge.
12) Refill engine with engine oil. (Page 1E-16)
13) Check that there is no engine oil leakage and
exhaust gas leakage at each connection.
2
1
I9P60A152014-01
1E-23 Engine Lubrication System: D13A

Installation Oil Pump Strainer Cleaning

Reverse removal procedure noting the following points. AENJHB0B1526011
Clean oil pump strainer screen.
• Clean mating surfaces of rotor plate (3) and oil pump
strainer (1).
• Install oil pump strainer with new gasket (2) to timing
chain cover.
• Tighten oil strainer bolts to specified torque.
Tightening torque
Oil strainer bolt (a): 9.0 N·m (0.92 kgf-m, 7.0 lbf-ft)
I9P60A152016-01

3
Oil Pump Inspection
AENJHB0B1526012

(a) Oil Seal

Refer to “Timing Chain Cover and Timing Chain
Inspection”: D13A in Section 1D (Page 1D-112).

2 Oil Pump
1 Check that rotors rotate smoothly by hand.
I9P60A152015-01
If not, replace timing chain cover.

I3RB0A153007-01

Specifications
Tightening Torque Specifications
AENJHB0B1527001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Engine oil drain plug 20 2.0 15.0 (Page 1E-16)
Oil filter housing cover 25 2.5 18.5 (Page 1E-17)
Oil pressure switch 32 3.3 24.0 (Page 1E-18)
Oil cooler bolt 9.0 0.92 7.0 (Page 1E-19)
Oil cooler inlet pipe bolt No.1 9.0 0.92 7.0 (Page 1E-19)
Oil cooler inlet pipe bolt No.2 9.0 0.92 7.0 (Page 1E-19)
Turbocharger oil intake pipe bolt 22 2.2 16.5 (Page 1E-19)
Oil pan bolt and nut 9.0 0.92 7.0 (Page 1E-21)
Drain plug 20 2.0 15.0 (Page 1E-21)
Transaxle stiffener bolt 34 3.5 25.0 (Page 1E-21)
Oil strainer bolt 9.0 0.92 7.0 (Page 1E-23)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Oil Cooler Components”: D13A (Page 1E-18)
“Oil Pan Components”: D13A (Page 1E-20)
“Oil Pump / Oil Pump Strainer Components”: D13A (Page 1E-22)
 Engine Lubrication System: D13A 1E-24

“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Recommended Service Material
AENJHB0B1528001
Material SUZUKI recommended product or Specification Note
Sealant Three Bond TB 1227® P/No.: 99000–85E11 (Page 1E-21)

NOTE
Required service material(s) is also described in:
“Oil Pan Components”: D13A (Page 1E-20)

Special Tool
AENJHB0B1528002
09915M77311 09919M46010
Oil pressure gauge Fuel pressure hose
attachment
(Page 1E-15) (Page 1E-15)

09921M96510
Oil pan seal cutter
(Page 1E-20)
1F-1 Engine Cooling System: K15B

Engine Cooling System

Engine

K15B
Precautions
Precautions for Cooling System
AENJHB0B1610001
! WARNING
If the radiator cap is removed while the engine is hot and pressure is high, the inside coolant will
instantaneously boil up and spew out. This could cause severe burns or could cause a fire if coolant is
splashed over the hot engine and exhaust system components, as the coolant contains a flammable
anti-freeze material.
Never check the coolant level or add coolant by removing the radiator cap. Instead, check the coolant
level only on the coolant reservoir and, if necessary, add coolant to the reservoir.
Also, check that the engine coolant temperature is cold before removing any part of cooling system.

! CAUTION

• If service operations are performed on the engine cooling system with the battery connected, there
is a risk of injury by accidental movement of the radiator cooling fan or other electric components.
Disconnect the negative (–) cable at the battery terminal before performing any service operations
on the engine cooling system.
• The radiator cooling fan can come on whenever the ignition is “ON”. This electric fan starts
automatically anytime the ECT sensor senses a coolant temperature higher than a predetermined
level even when the engine is not running.
When the ignition is “ON”, keep hands, tools, clothing, and other items away from the radiator
cooling fan.
 Engine Cooling System: K15B 1F-2

General Description
Cooling System Description Cooling Fan Operation Description
AENJHB0B1611001 AENJHB0B1611003
The cooling system consists of the radiator, coolant Radiator cooling fan motor is controlled by ECM as
reservoir, water pump, cooling fan and thermostat. The follows.
radiator is of a tube-and-fin type.
[A]
Coolant Description
AENJHB0B1611002
[B]
The coolant recovery system is a standard system,
which allows part of coolant to flow from the radiator into
[C]
the coolant reservoir when it expands by heat. When the
cooling system cools down, the coolant in the coolant 95 97 100 102 (°C)
reservoir is drawn back into the radiator. 203.0 206.6 212.0 215.6 (°F)
IFRA0A161001-01
The cooling system has been filled with a SUZUKI long
life coolant (coolant color: Yellow) that is a 30/70 mixture [A]: High [C]: OFF
of ethylene glycol antifreeze and deionized water. This [B]: Low

coolant solution provides freezing protection to –14.5 °C

(5.9 °F).
• This 30/70 mixture coolant also provides protection
against corrosion and loss of coolant from boiling.
Keep cooling system filled with this coolant even
where freezing temperatures are not expected.
• When replenishing the system due to loss of coolant,
the same ethylene glycol base coolant should be used
in order to ensure the same level of protection against
freezing and corrosion.
NOTICE
Using alcohol or methanol base coolant or
plain water alone may cause damage to the
cooling system.
Use the specified coolant.
The following controls are also performed when A/C
switch is ON.
Low speed:
Cooling fan operates at low speed when A/C refrigerant
pressure is more than specified value of 1.1 MPa (11.2
kgf/cm2, 160 psi) or vehicle speed is lower than 30 km/h
(19 mile/h).
High speed:
Cooling fan speed changes from low to high speed when
A/C refrigerant pressure exceeds specified value of 1.5
MPa (15.3 kgf/cm2, 218 psi).
Fail-Safe
Cooling fan operates at high speed if malfunction related
to ECT sensor is detected.

Coolant table
°C –14.5
Freezing temperature
°F 5.9
Antifreeze / Anti-corrosion
% 30
coolant concentration

Coolant capacity
M/T model:
• Engine, radiator and heater: 4.2 liters (8.88/7.39
US/Imp pt.)
• Reservoir: 0.5 liters (1.06/0.88 US/Imp pt.)
• Total: 4.7 liters (9.93/8.27 US/Imp pt.)
A/T model:
• Engine, radiator and heater: 4.1 liters (8.66/7.21
US/Imp pt.)
• Reservoir: 0.5 liters (1.06/0.88 US/Imp pt.)
• Total: 4.6 liters (9.72/8.09 US/Imp pt.)
1F-3 Engine Cooling System: K15B

Schematic and Routing Diagram

Coolant Circulation
AENJHB0B1612001

[A] 7

5
4

3
2
1

[B] 7

5
4

3
2
1

IJHB0A161001-01

[A]: Engine is cool (thermostat closed) 2. Radiator outlet hose 5. Engine

[B]: Engine is normal at operating temperature (thermostat open) 3. Thermostat 6. Radiator
1. Radiator inlet hose 4. Water pump 7. Heater core
 Engine Cooling System: K15B 1F-4

Radiator Cooling Fan Control System Circuit Diagram

AENJHB0B1612002

7
1 BLU
2
+BB
6 LT GRN E01-2
GRY
A1 BLU
GRN
3 B1 4 GRN E01-27
L+
H+ L-
PNK 5 BLK

A2 H- C1 C2
B2
LT GRN
8 5V
A3
BLU C01-20

GRY C01-4

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A160002-01

[A]: ECM connector (View: [a]) C1: Radiator cooling fan motor ground circuit 5. Radiator cooling fan motor
A1: Radiator cooling fan relay No.1 power supply circuit (switch side) C2: Radiator cooling fan relay No.3 ground circuit 6. “RDTR” fuse
A2: Radiator cooling fan relay No.2 power supply circuit (switch side) 1. To main relay 7. ECM
A3: Radiator cooling fan relay No.3 power supply circuit (switch side) 2. Radiator cooling fan relay No.1 8. ECT sensor
B1: Radiator cooling fan motor drive circuit (low speed) 3. Radiator cooling fan relay No.2
B2: Radiator cooling fan motor drive circuit (high speed) 4. Radiator cooling fan relay No.3
1F-5 Engine Cooling System: K15B
Diagnostic Information and Procedures
Engine Cooling Symptom Diagnosis
Condition Possible cause
Engine overheats Broken water pump belt
(Radiator fan operates) Not enough coolant
Faulty thermostat
Faulty water pump
Dirty or bent radiator fins
Coolant leakage on cooling system
Clogged radiator
Faulty radiator cap
Dragging brakes
Slipping clutch (M/T model)
Poorly charged battery
Poor electricity generated by generator Check generator. (Page 1J-3)
Faulty ECT sensor
Faulty radiator cooling fan motor
Faulty ECM
Faulty radiator cooling fan relay
Faulty wiring or grounding
Too many optional electric devices
Engine overheats Blown fuse
(Radiator fan does not Faulty radiator cooling fan relay
operate)
Faulty ECT sensor
Faulty radiator cooling fan motor
Faulty wiring or grounding
Faulty ECM
AENJHB0B1614001
Correction / Reference Item
Replace water pump belt. (Page 1J-7)
Check coolant level and add if necessary.
(Page 1F-10)
Replace thermostat assembly. (Page 1F-12)
Replace water pump. (Page 1F-17)
Clean or repair. (Page 1F-16)
Check cooling system for leakage. (Page
1F-10)
Replace radiator. (Page 1F-16)
Check radiator cap. (Page 1F-10)
Check brake. (Page 4A-2)
Check clutch. (Page 5C-2)
Check battery. (Page 1J-5)
Check ECT sensor. (Page 1C-9)
Check radiator cooling fan motor. (Page 1F-
14)
Check ECM and its circuit. (Page 1A-150)
Check radiator cooling fan relay. (Page 1F-
14)
Repair wiring.
Remove electrical devices.
Check fuse.
Check radiator cooling fan relay. (Page 1F-
14)
Check ECT sensor. (Page 1C-9)
Check radiator cooling fan motor. (Page 1F-
14)
Repair wiring.
Check ECM and its circuit. (Page 1A-150)
 Engine Cooling System: K15B 1F-6

Radiator Cooling Fan System Check

AENJHB0B1614002
Circuit Diagram

7
1 BLU
2
+BB
6 LT GRN E01-2
GRY
A1 BLU
GRN
3 B1 4 GRN E01-27
L+
H+ L-
PNK 5 BLK

A2 H- C1 C2
B2
LT GRN
8 5V
A3
BLU C01-20

GRY C01-4

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A160002-01

[A]: ECM connector (View: [a]) C1: Radiator cooling fan motor ground circuit 5. Radiator cooling fan motor
A1: Radiator cooling fan relay No.1 power supply circuit (switch side) C2: Radiator cooling fan relay No.3 ground circuit 6. “RDTR” fuse
A2: Radiator cooling fan relay No.2 power supply circuit (switch side) 1. To main relay 7. ECM
A3: Radiator cooling fan relay No.3 power supply circuit (switch side) 2. Radiator cooling fan relay No.1 8. ECT sensor
B1: Radiator cooling fan motor drive circuit (low speed) 3. Radiator cooling fan relay No.2
B2: Radiator cooling fan motor drive circuit (high speed) 4. Radiator cooling fan relay No.3

Troubleshooting

NOTE
• For details of engine cooling fan operation, refer to “Cooling Fan Operation Description”: K15B
(Page 1F-2).
• Before beginning troubleshooting, read “Precautions for Engine (K15B)” in Section 1 (Page 1-1).
• When measuring circuit voltage, resistance and/or pulse signal of ECM, refer to “Inspection of ECM
and Its Circuits”: K15B in Section 1A (Page 1A-150).

Step Action Yes No

1 DTC check Go to applicable DTC Go to Step 2.
1) Set ignition “OFF” and connect SUZUKI scan tool to troubleshooting and
DLC. recheck DTC.
2) Set ignition “ON” and check DTC. (Page 1A-23)

Is there DTC(s)?
2 Radiator cooling fan low-speed operation control check Go to Step 3. Go to Step 4.
1) Check radiator cooling fan control for low-speed
operation. (Page 1F-14)

Is check result OK?

1F-7 Engine Cooling System: K15B

Step Action Yes No

3 Radiator cooling fan high-speed operation control Radiator cooling fan Go to Step 8.
check control system is in
1) Check radiator cooling fan control for high-speed good condition.
operation. (Page 1F-14)

Is check result OK?

4 Radiator cooling fan relay No.1 power supply circuit Go to Step 5. Repair “A1” circuit.
(switch side) check
1) Set ignition “OFF” and remove radiator cooling fan relay
No.1 from individual circuit fuse box No.1.
2) Check for proper connection to radiator cooling fan relay
No.1 at each terminal.
3) If OK, measure voltage between “A1” circuit and ground.

Is it 10 – 14 V?
5 Radiator cooling fan relay No.1 check Go to Step 6. Replace radiator cooling
1) Check radiator cooling fan relay No.1. (Page 1F-14) fan relay No.1.

Is check result OK?

6 Radiator cooling fan motor drive circuit (low speed) Go to Step 7. Repair “B1” circuit.
check
1) Set ignition “OFF” and disconnect radiator cooling fan
motor connector.
2) Check for proper connection to radiator cooling fan
motor at each terminal.
3) If OK, check the following points.
• Resistance of “B1” circuit: 1 Ω or less
• Resistance between “B1” circuit and ground: infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

7 Radiator cooling fan motor ground circuit check Go to Step 14. Repair “C1” circuit.
1) Measure resistance between “C1” circuit and ground.

Is resistance 1 Ω or less?
8 Radiator cooling fan relay No.2 power supply circuit Go to Step 9. Repair “A2” circuit.
(switch side) check
1) Set ignition “OFF” and remove radiator cooling fan relay
No.2 from individual circuit fuse box No.1.
2) Check for proper connection to radiator cooling fan relay
No.2 at each terminal.
3) If OK, measure voltage between “A2” circuit and ground.

Is it 10 – 14 V?
9 Radiator cooling fan relay No.2 check Go to Step 10. Replace radiator cooling
1) Check radiator cooling fan relay No.2. (Page 1F-14) fan relay No.2.

Is check result OK?

 Engine Cooling System: K15B 1F-8

Step Action Yes No

10 Radiator cooling fan motor drive circuit (high speed) Go to Step 11. Repair “B2” circuit.
check
1) Set ignition “OFF” and disconnect radiator cooling fan
motor connector.
2) Check for proper connection to radiator cooling motor at
each terminal.
3) If OK, check the following points.
• Resistance of “B2” circuit: 1 Ω or less
• Resistance between “B2” circuit and ground: infinity
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

11 Radiator cooling fan relay No.3 power supply circuit Go to Step 12. Repair “A3” circuit.
(switch side) check
1) Set ignition “OFF” and remove radiator cooling fan relay
No.3 from individual circuit fuse box No.1.
2) Check for proper connection to radiator cooling fan relay
No.3 at each terminal.
3) If OK, check the following points.
• Resistance of “A3” circuit: 1 Ω or less
• Resistance between “A3” circuit and ground: infinity
• Voltage of “A3” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

12 Radiator cooling fan relay No.3 check Go to Step 13. Replace radiator cooling
1) Check radiator cooling fan relay No.3. (Page 1F-14) fan relay No.3.

Is check result OK?

13 Radiator cooling fan relay No.3 ground circuit check Go to Step 14. Repair “C2” circuit.
1) Measure resistance between “C2” circuit and ground.

Is resistance 1 Ω or less?
14 Radiator cooling fan motor check Replace ECM and Replace radiator cooling
1) Check radiator cooling fan motor. (Page 1F-14) recheck radiator cooling fan motor. (Page 1F-
fan system. (Page 15)
Is check result OK? 1C-2)
1F-9 Engine Cooling System: K15B

Repair Instructions
Cooling System Components
AENJHB0B1616001

19
32

31
(e)
(a)

8 13
(e)
20 (b)
7
9 (a)
2
9

19
1 18
(a)
17
29 16
(d)

3 30
10

(g)

10 4
28

(f) 26 (c)
5
27 12
(a)

(a)
23

25

24 1207F
11

15

(a) 21

33

14

22

33
IJHB0B161001-01
 Engine Cooling System: K15B 1F-10

1. Radiator 15. Water inlet pipe 29. Retainer clip

2. Radiator cap 16. Thermostat cap 30. Torque washer
3. Drain plug 17. Thermostat 31. Engine harness bracket
: For installation, refer to “Thermostat Removal
and Installation”: K15B (Page 1F-12).
4. Radiator cooling fan 18. Thermostat case 32. Cylinder head
5. Radiator cooling fan shroud 19. Gasket 33. To heater core
: Match gasket with a shape of the mating face
of cylinder head.
6. Radiator cooling fan motor 20. ECT sensor : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
7. Radiator support upper left bracket 21. Heater outlet hose : 12 Nm (1.2 kgf-m, 9.0 lbf-ft)
8. Radiator support upper right bracket 22. Heater inlet hose : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
9. Radiator support upper mount 23. O-ring : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
10. Radiator support lower mount 24. Water pump : 8.5 Nm (0.87 kgf-m, 6.5 lbf-ft)
: Apply sealant 99000-31250 referring to “Water
Pump Removal and Installation”: K15B (Page
1F-17).
11. Reservoir 25. Generator arm : 5.0 Nm (0.51 kgf-m, 4.0 lbf-ft)
12. Reservoir hose 26. Water pump pulley : 2.2 Nm (0.22 kgf-m, 2.0 lbf-ft)
13. Radiator inlet hose 27. Reservoir cap : Do not reuse.
14. Radiator outlet hose 28. Heat shield

Coolant Level Check 4) Check cooling system for coolant leakage according
AENJHB0B1616002 to the following procedure.
Before performing the following procedure, observe
“Precautions for Cooling System”: K15B (Page 1F-1). a) Attach pressure tester (1) to radiator, and then
It is not necessary to remove radiator cap to check apply specified pressure to cooling system.
coolant level. Cooling system holding pressure
When engine is cool, check coolant level in reservoir (1). 123 kPa (1.3 kgf/cm2, 17.8 psi, 1.23 bar)
Normal coolant level should be between “FULL” mark (2)
and “LOW” mark (3) on reservoir.
If coolant level is below “LOW” mark, remove reservoir
cap (4) and add proper coolant to reservoir to bring
coolant level up to “FULL” mark.

NOTE
If proper quality antifreeze is used, there is
no need to add extra rust inhibitors or other
additives that claim to improve system. They
may be harmful to proper operation of
system, and are unnecessary expense. I8T401162005-01

b) Check that cooling system holds the pressure.

If cooling system does not hold applied pressure,
check cooling system for leakage.
2
5) Check radiator cap according to the following
procedure.
4
a) Attach pressure tester (1) to radiator cap (2), and
1 then apply specified pressure.
Radiator cap valve opening pressure
93 – 123 kPa (0.9 – 1.3 kgf/cm2, 13.5 – 17.8 psi,
0.93 – 1.23 bar)
3

IJHA0A160005-01
1 2

Engine Cooling System Inspection

AENJHB0B1616003
Before performing the following procedure, observe
“Precautions for Cooling System”: K15B (Page 1F-1).
1) Check cooling system for leakage or damage. IFRA0A161006-01

2) Remove radiator cap. b) If radiator cap valve opening pressure is out of

3) Check coolant for proper level and freeze protection. specification, replace radiator cap.
1F-11 Engine Cooling System: K15B

6) Detach pressure tester and rinse off spilled coolant. 7) Repeat Step 4) – 6).
7) Install radiator cap on radiator. 8) Check that coolant level in reservoir is at “FULL”
mark. If coolant is insufficient, add coolant.
Cooling System Draining 9) Check cooling system for leakage. (Page 1F-10)
AENJHB0B1616004
Before performing the following procedure, observe
“Precautions for Cooling System”: K15B (Page 1F-1). Water Inlet Pipe Removal and Installation
AENJHB0B1616006
1) Remove radiator cap.
2) Drain coolant from drain plug (1). Removal
3) Tighten drain plug securely. 1) Drain coolant. (Page 1F-11)
2) Remove intake manifold. (Page 1D-13)
NOTICE
3) Disconnect the following hoses and clamp from
If drain plug is tightened excessively, the water inlet pipe.
plug could be damaged.
• Heater outlet hose (1)
Do not tighten the drain plug too much.
• Radiator outlet hose (2)
Tightening torque • Clamp (3)
Drain plug (reference torque) (a): 1.0 N·m (0.10
kgf-m, 1.0 lbf-ft)
1

1, (a) 2

IJHB0A161002-01

4) Remove thermostat case nut (1) and water inlet pipe

IJHA0A160006-01 bolt (2) from water inlet pipe (3).

Cooling System Refilling

AENJHB0B1616005
Before performing the following procedure, observe
“Precautions for Cooling System”: K15B (Page 1F-1). 2
1
1) Fill reservoir (1) with coolant up to “FULL” mark (2). 3
2) Install reservoir cap (3) on reservoir.

3
IJHB0A161003-01
1
5) Remove water inlet pipe (1) with O-ring (2).

IJHA0A160008-01

3) Fill radiator with coolant up to bottom of radiator filler

neck and install radiator cap. (Page 1F-2)
1 2
4) Run engine at idle speed until radiator fan motor is
operated.
5) Stop engine and wait until engine cools down fully. IJHB0A161004-01
6) Add coolant to radiator up to bottom of radiator filler
neck, and install radiator cap.
 Engine Cooling System: K15B 1F-12

Installation Thermostat Removal and Installation

Reverse removal procedure noting the following points. AENJHB0B1616007
Removal
• Use new O-ring (2).
1) Drain coolant. (Page 1F-11)
• Apply coolant to O-ring and insert water inlet pipe (1)
all the way into cylinder block. 2) Remove thermostat cap (1) from thermostat case
(2).

1 2

1
IJHB0A161005-01

• Tighten thermostat case nut (1) to specified torque.

IFRA0A161009-01
Tightening torque
3) Remove thermostat (1) from thermostat case (2).
Thermostat case nut (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)

1, (a)

IFRA0A161010-01

IJHB0A161006-01

• If there is matchmark on each of hose and pipe, install Installation

the hose aligning matchmark on hose with matchmark
on pipe and then install each clamp in proper position.
• Refill cooling system with coolant. (Page 1F-11)
• Check cooling system for leakage. (Page 1F-10)
Reverse removal procedure noting the following points.
• Install thermostat (1) to thermostat case (2) by
aligning air bleed valve (3) of thermostat with mark (4)
of thermostat case.

4
3

2
1

IFRA0A161011-01
1F-13 Engine Cooling System: K15B

• Tighten thermostat cap bolts (1) to specified torque. • Check thermostat operation as follows.
Tightening torque a. Immerse thermostat (1) in water, and heat water
Thermostat cap bolt (a): 25 N·m (2.5 kgf-m, 18.5 gradually.
lbf-ft) b. Check that wax pellet starts to open at specific
temperature.
Temperature at which valve starts to open (lift
0.05 mm (0.002 in))
86.5 – 89.5 °C (187.7 – 193.1 °F)
Temperature at which valve becomes fully
open
100 °C (212 °F)
1, (a)
Valve lift
More than 8 mm (0.31 in) at 100 °C (212 °F)

IFRA0A161012-01

• Refill cooling system with coolant. (Page 1F-11)

• Check cooling system for leakage. (Page 1F-10)

Thermostat Inspection
AENJHB0B1616008
• Check that air bleed valve (1) is clean.
• Check that valve seat (2) is free from foreign material
that would prevent valve from seating tight.
• Check thermostat seal (3) for breakage, deterioration
or any other damage. I2RH01160012-01

2. Thermometer 3. Heater

• If check result is not as specified, replace thermostat.

(Page 1F-12)

I3RM0A160008-01
 Engine Cooling System: K15B 1F-14

Radiator Cooling Fan Assembly On-Vehicle Radiator Cooling Fan Motor

Inspection 1) Disconnect radiator cooling fan motor connector (1).
AENJHB0B1616009
Radiator Cooling Fan Operation
1) Connect SUZUKI scan tool to DLC (1) with ignition
“OFF”.
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)

IJHA0A160021-01

2) Using service wire, connect radiator cooling fan

motor connector and battery as shown in figure.
1
[A] [B]

IAP70A160002-01

[A]: Low speed [B]: High speed

(A)

IJHA0A110021-01 3) Check that radiator cooling fan motors rotate

2) Set ignition “ON” and clear DTC. (Page 1A-24) smoothly and properly.
3) Select “Radiator Fan” function in “Active Test”. If any abnormality is found, replace radiator cooling
fan motor.
4) Check radiator cooling fan operation at low and high
modes. Reference: Fan motor specified current at 12 V
If any abnormality is found, check cooling fan control Low speed: 11.4 – 12.5 A
system. (Page 1F-6) High speed: 16.7 – 18.3 A
Radiator cooling fan operation
Radiator Cooling Fan Relay Inspection
Radiator cooling fan motor AENJHB0B1616010
OFF OFF Refer to “Control Relay Inspection” in Section 10B (Page
Low mode Low speed 10B-61).
High mode High speed
1F-15 Engine Cooling System: K15B

Radiator Cooling Fan Assembly Removal and Radiator Cooling Fan Disassembly and
Installation Reassembly
AENJHB0B1616011 AENJHB0B1616012

Removal Disassembly
1) Disconnect negative (–) cable at battery. 1) Remove retainer clip (1) and torque washer (2).
2) Disconnect radiator cooling fan motor connector (1) 2) Remove radiator cooling fan (3) from radiator cooling
and clamp (2). fan motor (4).
3) Remove reservoir (3). 3) Remove radiator cooling fan motor from radiator
cooling fan shroud (5).
4) Remove heat shield (6), if necessary.
3
2 3

1
2
6
1 4

1
IJHA0A160022-01

4) Remove radiator cooling fan assembly from radiator.

Installation 2
Reverse removal procedure noting the following points.
IJHB0B161002-01
• If there is matchmark on each of hose and pipe, install
the hose aligning matchmark on hose with matchmark
Reassembly
on pipe and then set each clamp to the original
Reverse disassembly procedure noting the following
position.
point.
• Refill cooling system with coolant. (Page 1F-11)
• Tighten radiator cooling fan motor screws (1) to
• Check cooling system for leakage. (Page 1F-10) specified torque, if removed.
• Tighten heat shield screws (2) to specified torque, if
removed.
Tightening torque
Radiator cooling fan motor screw (a): 5.0 N·m (
0.51 kgf-m, 4.0 lbf-ft)
Heat shield screw (b): 2.2 N·m (0.22 kgf-m, 2.0 lbf-
ft)

2, (b)

1, (a)

IJHB0B161003-01
 Engine Cooling System: K15B 1F-16

• Insert new retainer clip (1) to fit the opening to
protrusion (2) on radiator cooling fan (3).
3
6) Remove condenser upper and lower bolts.
• Manual A/C single model: (Page 7B-34)
• Manual A/C dual model: (Page 7B-87)
• Automatic A/C model: (Page 7B-126)

NOTICE
1
The A/C condenser assembly may be
damaged if it hits against or interferes with
other parts.
Suspend the removed A/C condenser
1
assembly in a place where no damage will be
caused during removal and installation of the
radiator.

2 7) For A/T model, disconnect ATF cooler hoses.

(Page 5A-146)
IJHB0B161004-01
8) Disconnect radiator inlet hose (1) and radiator outlet
Radiator On-Vehicle Inspection and Cleaning hose (2) from radiator.
AENJHB0B1616013
Inspection
Check radiator for leakage or damage. Straighten bent
fins, if any.

Cleaning
Clean frontal area of radiator cores. 1

IJHB0A161007-01

9) Remove radiator cooling fan assembly. (Page 1F-

15)
10) Remove radiator support upper brackets (1).
I2RH01160014-01
11) Remove radiator (2) from vehicle.

Radiator Removal and Installation

AENJHB0B1616014
1

Removal
1
1) Disconnect negative (–) cable at battery.
2) Drain coolant. (Page 1F-11)
3) For A/T model, drain ATF. (Page 5A-119) 2
4) Remove front bumper. (Page 9H-2)
5) Remove front end upper and lower cover. (Page
9H-5)
IJHA0A160017-01
1F-17 Engine Cooling System: K15B

Installation Installation
Reverse removal procedure noting the following points. 1) Clean mating surfaces of water pump and cylinder
• Tighten radiator support upper bracket bolts to block.
specified torque. 2) Apply sealant to mating surface of water pump as
Tightening torque shown in figure.
Radiator support upper bracket bolt (a): 8.5 N·m ( “A”: Sealant 99000–31250 (SUZUKI Bond
0.87 kgf-m, 6.5 lbf-ft) No.1207F)

“A”

(a)

(a)
“a”

“b”

“A”
I7V20A161015-01

“a”: 3 mm (0.12 in.) “b”: 2 mm (0.08 in.)

IJHA0A160018-01

• If there is matchmark on each of hose and pipe, install 3) Install water pump (1) with ISG arm (3) to cylinder
the hose aligning matchmark on hose with matchmark block and tighten bolts and nuts to specified torque.
on pipe and then install each clamp in proper position.
Tightening torque
• Refill cooling system with coolant. (Page 1F-11)
Water pump bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-
• For A/T model, refill transaxle with ATF. (Page 5A- ft)
119) Water pump nut (b): 25 N·m (2.5 kgf-m, 18.5 lbf-
• Check cooling system for leakage. (Page 1F-10) ft)
4) Install water pump pulley (2) and tighten bolts to
Water Pump Removal and Installation specified torque.
AENJHB0B1616015
Removal Tightening torque
1) Drain coolant. (Page 1F-11) Water pump pulley bolt (c): 11 N·m (1.1 kgf-m,
2) Remove air cleaner assembly and air cleaner 8.5 lbf-ft)
suction hose. (Page 1D-9)
3) Remove ISG drive belt. (Page 1J-7) (a)
4) Remove ISG upper bolt.
1
5) Remove water pump pulley (2) and ISG arm (3).
6) Remove water pump assembly (1). 3 2

1 (c)
(b)
3 2
IJHB0A161009-01

5) Tighten ISG upper bolt. (Page 1J-7)

6) Install ISG drive belt. (Page 1J-7)
7) Install air cleaner assembly and air cleaner suction
hose. (Page 1D-9)
IJHB0A161008-01
8) Refill cooling system with coolant. (Page 1F-11)
9) Check cooling system for leakage. (Page 1F-10)
 Engine Cooling System: K15B 1F-18

Water Pump Inspection

AENJHB0B1616016
Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
abnormal noise, replace it.

I2RH0B160019-01

Specifications
Tightening Torque Specifications
AENJHB0B1617001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Drain plug (reference torque) 1.0 0.10 1.0 (Page 1F-11)
Thermostat case nut 25 2.5 18.5 (Page 1F-12)
Thermostat cap bolt 25 2.5 18.5 (Page 1F-13)
Radiator cooling fan motor screw 5.0 0.51 4.0 (Page 1F-15)
Heat shield screw 2.2 0.22 2.0 (Page 1F-15)
Radiator support upper bracket bolt 8.5 0.87 6.5 (Page 1F-17)
Water pump bolt 25 2.5 18.5 (Page 1F-17)
Water pump nut 25 2.5 18.5 (Page 1F-17)
Water pump pulley bolt 11 1.1 8.5 (Page 1F-17)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Cooling System Components”: K15B (Page 1F-9)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Recommended Service Material
AENJHB0B1618001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1207F P/No.: 99000–31250 (Page 1F-17)

NOTE
Required service material(s) is also described in:
“Cooling System Components”: K15B (Page 1F-9)

Special Tool
AENJHB0B1618002
SUZUKI scan tool (Suzuki
SDT-II)
—
(Page 1F-14)
1F-19 Engine Cooling System: D13A

D13A
Precautions
Precautions for Cooling System
AENJHB0B1620001
! WARNING
If the degassing tank cap is removed while the engine is hot and pressure is high, the inside coolant
will instantaneously boil up and spew out. This could cause severe burns or could cause fire if coolant
is splashed over the hot engine and fenders, as the coolant contains a flammable anti-freeze material.
Do not remove the degassing tank cap while the engine is hot.
Also, check that the engine coolant temperature is cold before removing any part of cooling system.

! CAUTION

• If service operations are performed on the engine cooling system with the battery connected, there
is a risk of injury by accidental movement of the radiator cooling fan or other electric components.
Disconnect the negative (–) cable at the battery terminal before performing any service operations
on the engine cooling system.
• The radiator cooling fan can come on whenever the ignition is “ON”. This electric fan starts
automatically anytime the ECT sensor senses a coolant temperature higher than a predetermined
level even when the engine is not running.
When the ignition is “ON”, keep hands, tools, clothing, and other items away from the radiator
cooling fan.

General Description
Cooling System Description NOTICE
AENJHB0B1621001
The cooling system consists of the radiator, degassing Using alcohol or methanol base coolant or
tank, hoses, water pump, cooling fan and thermostat. plain water alone may cause damage to the
The radiator is of a tube-and-fin type. cooling system.
Use the specified coolant.
Coolant Description
AENJHB0B1621002 NOTE
When the system cools down, the coolant is drawn back Coolant must be mixed with demineralized
from degassing tank into the radiator. water or distilled water.
The cooling system has been filled at the factory with a
quality coolant that is a 50/50 mixture of water and Anti-freeze proportioning table
ethylene glycol antifreeze.
°C –36
This 50/50 mixture coolant solution provides freezing Freezing temperature
°F –33
protection to –36 °C (–33 °F).
Antifreeze / Anti-corrosion
• This 50/50 mixture coolant also provides protection % 50
coolant concentration
against corrosion and loss of coolant from boiling.
Keep cooling system filled with this coolant even Coolant capacity
where freezing temperatures are not expected. Total: Engine, radiator, heater and degassing tank
• When replenishing the system due to loss of coolant, etc.: 5.9 liters (12.47/10.38 US/Imp pt.)
the same ethylene glycol base coolant should be used
in order to ensure the same level of protection against
freezing and corrosion.
 Engine Cooling System: D13A 1F-20

Cooling Fan Operation Description Cooling fan operates at high mode when A/C refrigerant
AENJHB0B1621003 pressure is higher than specified value of 1.6 MPa (16.3
Radiator cooling fan motors are controlled by ECM as kgf/cm2, 232 psi) and turns to low mode when A/C
follows. refrigerant pressure is lower than specified value of 1.3
MPa (13.2 kgf/cm2, 189 psi).
[A]
Fail-Safe
[B] Cooling fan operates at high mode if malfunction related
to ECT sensor is detected.
[C]

95 98 103 (°C)
Coolant Degassing Tank Description
AENJHB0B1621004
203.0 208.4 217.4 (°F)
IJHB0A163001-01
The degassing tank (1) consists of a “see-through”
plastic tank, a hose and a degassing tank cap (2).
[A]: High [B]: Low [C]: OFF
During operation, inside of the degassing tank is under
pressure.
Radiator cooling fan operation As the coolant warms up and expands, the coolant level
“Radiator Fan” function in “Active Radiator cooling in the degassing tank rises. The coolant level lowers as
Test” mode on SUZUKI scan tool fan motor the coolant cools down and contracts. When the
OFF OFF pressure applied to the inside of the degassing tank
Low mode Low speed constantly exceeds the specified value, the pressure is
High mode High speed relieved through the degassing tank cap. Therefore,
cooling level should be between “FULL” (3) and “LOW”
The following controls are also performed when A/C (4) marks on the degassing tank.
switch is ON.
Low mode:
Cooling fan operates at low mode when A/C refrigerant 2
pressure is higher than specified value of 1.3 MPa (13.2
kgf/cm2, 189 psi) and switches off when A/C refrigerant 3
pressure is lower than specified value of 1.0 MPa (10.2
kgf/cm2, 145 psi). 1
High mode:

IJHB0A163002-01

Water Pump Drive Belt Description

AENJHB0B1621005
The water pump drive belt is a low modulus belt. It stretches itself to maintain the belt tension. Therefore, a tension
pulley, which is used to adjust the belt tension, or components for adjusting the clearance between the crankshaft
pulley and the water pump pulley are not necessary. When removing or installing the low modulus belt, use the special
tool to prevent the belt from being damaged.
1F-21 Engine Cooling System: D13A

Schematic and Routing Diagram

Coolant Circulation
AENJHB0B1622001

[A] [B]
8 8

9 9
4 4
6 6
5 5

2
2

7 7

3 1 3 1

IDL10A160002-01

[A]: Thermostat: close 3. Oil cooler 7. Water pump

[B]: Thermostat: open 4. Engine 8. Heater core
1. Radiator 5. Degassing tank 9. EGR cooler
2. Thermostat 6. Degassing tank cap

Diagnostic Information and Procedures
Engine Cooling Symptom Diagnosis
Condition Possible cause
Engine overheats (When Loose or broken water pump drive belt
radiator cooling fan Not enough coolant
operates)
Faulty thermostat
Faulty water pump
Dirty or bent radiator fins
Coolant leakage
Clogged radiator
Faulty degassing tank cap
Dragging brakes
Slipping clutch
Poorly charged battery
Poor electricity generated by ISG
Faulty ECT sensor
Faulty radiator cooling fan motor
Faulty radiator cooling fan relay
Faulty ECM
Faulty wiring or grounding
Equipped with too much electric load
part(s)
Engine overheats (When Blown fuse
radiator cooling fan does
not operate) Faulty radiator cooling fan relay
Faulty ECT sensor
Faulty radiator cooling fan motor
Faulty wiring or grounding
Faulty ECM
Radiator Fan Control System Inspection
Check system for operation. (Page 1A-326)
Engine Cooling System: D13A 1F-22
AENJHB0B1624001
Correction / Reference Item
Check water pump drive belt. (Page 1F-31)
Check coolant level and add coolant if
necessary. (Page 1F-24)
Replace thermostat assembly. (Page 1F-26)
Replace water pump. (Page 1F-34)
Clean or repair radiator. (Page 1F-30)
Repair cooling system. (Page 1F-24)
Check and replace radiator if necessary.
• Check: (Page 1F-30)
• Replace: (Page 1F-30)
Replace degassing tank cap.
Check brake. (Page 4A-2)
Replace clutch cover and clutch disc. (Page
5C-11)
Check and replace battery if necessary.
• Check: (Page 1J-13)
• Replace: (Page 1J-16)
Check and replace ISG if necessary.
• Replace: (Page 1J-20)
• Check: (Page 1J-15)
Check and replace ECT sensor if necessary.
• Check: (Page 1C-26)
• Replace: (Page 1C-25)
Check and replace radiator cooling fan motor if
necessary.
• Check: (Page 1F-28)
• Replace: (Page 1F-29)
Check and replace radiator cooling fan relay if
necessary. (Page 10B-61)
Check and replace ECM if necessary.
Repair wiring.
Dismount.
Check fuse of relay/fuse box and check for
short circuit to ground.
Check and replace radiator cooling fan relay if
necessary. (Page 10B-61)
Check and replace ECT sensor if necessary.
• Check: (Page 1C-26)
• Replace: (Page 1C-25)
Check and replace radiator cooling fan motor if
necessary.
• Check: (Page 1F-28)
• Replace: (Page 1F-29)
Repair wiring.
Check and replace ECM if necessary.
AENJHB0B1624002
1F-23 Engine Cooling System: D13A

Repair Instructions
Cooling System Components
AENJHB0B1626001

(c)
(c) 29
26

(c) 33 28
23
25

(c)
32
30 27
31

24 [b] 32
(a)

20
[c] 34
(d)
12
(d) 25
4 (a) [b]

3 21
5
30
5 [a]
22
15
14 29
[a]
13

33
(c)

31
[c]
18
16
17

2 6

(d)
(d) 19

(b)

10
11

1
7 9

(e)

8
IJHB0A163003-01
 Engine Cooling System: D13A 1F-24

1. Radiator 15. Radiator to degassing tank hose 29. O-ring

2. Drain plug
3. Radiator support upper left bracket
4. Radiator support upper right bracket
5. Radiator support upper mount
6. Radiator support lower mount
7. Radiator cooling fan
8. Radiator cooling fan shroud
9. Radiator cooling fan motor
10. Torque washer
11. Retainer clip
12. Radiator inlet hose
13. Radiator outlet hose
14. Degassing tank
16. Engine to degassing tank hose 30. To EGR cooler
17. Degassing tank outlet hose 31. To oil cooler assembly
18. Degassing tank bracket 32. To heater core
19. Battery tray 33. To cylinder block
20. Thermostat assembly 34. To cylinder head
21. EGR cooler inlet hose : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
22. Water pump assembly : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
23. Oil cooler inlet pipe : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
24. Oil cooler inlet hose : 8.5 Nm (0.87 kgf-m, 6.5 lbf-ft)
25. Gasket : 5.0 Nm (0.51 kgf-m, 4.0 lbf-ft)
26. Heater outlet pipe : Do not reuse.
27. Heater inlet hose
28. Heater outlet hose

Coolant Level Check
AENJHB0B1626002
Before performing the following procedure, observe
“Precautions for Cooling System”: D13A (Page 1F-19).
To check level, lift hood and look at “see-through”
degassing tank (1).
It is not necessary to remove degassing tank cap (2) to
check coolant level.
When engine is cool, check coolant level in degassing
tank.
Coolant level should be between “FULL” mark (3) and
“LOW” mark (4) on degassing tank.
If coolant level is below “LOW” mark, remove degassing
tank cap and add recommended coolant to tank to bring
coolant level up to “FULL” mark. After refilling, install
degassing tank cap by turning it clockwise to stop.
2) Wash degassing tank cap and filler neck with clean
water by removing degassing tank cap when engine
is cold.
3) Check coolant for proper level and freeze protection.
4) Using a pressure tester (1), check system and
degassing tank cap (2) for proper pressure
performance.
If check result is not as specified, repair cooling
system and/or replace degassing tank cap.
Cooling system holding pressure
155 kPa (1.6 kgf/cm², 22.5 psi)
Degassing tank cap valve opening pressure
140 – 155 kPa (1.4 – 1.6 kgf/cm², 20.3 – 22.5 psi)

NOTE
If proper quality antifreeze is used, there is
no need to add extra additives that claim to
improve system. They may be harmful to
1
proper operation of system, and are
unnecessary expense.

3
1
1 2

4
IJHB0A163004-01

5) Install degassing tank cap to degassing tank turning

IJHB0A163002-01 it clockwise to stop.
6) Tighten hose clamps and check all hoses. Replace
Engine Cooling System Inspection and hoses if they are cracked, swollen or deteriorated.
Cleaning 7) Clean frontal area of radiator core.
AENJHB0B1626003
Before performing the following procedure, observe
“Precautions for Cooling System”: D13A (Page 1F-19).
Check cooling system as follows.
1) Check cooling system for leakage or damage.
1F-25 Engine Cooling System: D13A
Cooling System Draining
AENJHB0B1626004
Before performing the following procedure, observe
“Precautions for Cooling System”: D13A (Page 1F-19).
1) Remove degassing tank cap by turning it
counterclockwise slowly to release pressure.
2) Loosen drain plug (1) on radiator to drain out
coolant.
3) Tighten drain plug securely.
NOTICE
If drain plug is tightened excessively, the
plug could be damaged.
Do not tighten the drain plug too much.
Tightening torque
Drain plug (reference torque) (a): 1.0 N·m (0.10
kgf-m, 1.0 lbf-ft)
1,(a)
IJHB0A163005-01
Cooling System Refilling
AENJHB0B1626005
Before performing the following procedure, observe
“Precautions for Cooling System”: D13A (Page 1F-19).
1) Fill degassing tank (1) with coolant up to “FULL”
mark (3).
Recommended coolant
SUZUKI long life coolant (coolant color: Green)
Coolant specification
Freezing temperature: –36 °C (–33 °F)
Anti-freeze / anti-corrosion coolant
concentration: 50%
Coolant capacity
Total: 5.9 liters (12.47/10.38 US/Imp pt.)
2) Install degassing tank cap (2) on degassing tank.
3) Run engine at idle speed.
4) Run engine until radiator fan motor starts operating.
NOTE
If coolant level comes lower than “LOW”
mark (4) during this step, perform the
following procedure.
1. Stop engine and wait until engine is
cooled.
2. Fill degassing tank with coolant up to
“FULL” mark.
3. Return to Step 2).
5) Stop engine and wait until engine is cooled.
6) Fill degassing tank with coolant up to “FULL” mark.
7) Check cooling system for leakage. (Page 1F-24)
4
IJHB0A163002-01
Cooling Water Pipe or Hose Removal and
Installation
AENJHB0B1626006
Before performing the following procedure, observe
“Precautions for Cooling System”: D13A (Page 1F-19).
Removal
1) Drain out coolant. (Page 1F-25)
2) Loosen clip on hose and pull hose end off before
removing each pipe or hose.
Installation
Reverse removal procedure noting the following points.
• If there is matchmark on each of hose and pipe, install
the hose aligning matchmark on hose with matchmark
on pipe and then install each clamp in proper position.
• Refill cooling system with coolant. (Page 1F-25)
 Engine Cooling System: D13A 1F-26

Thermostat Assembly Removal and Installation 5) Remove breather pipe bolt (1), air intake joint bolt (2)
AENJHB0B1626007 and vacuum pipe bolts (3).
Before performing the following procedure, observe
“Precautions for Cooling System”: D13A (Page 1F-19).

Removal 2
1) Drain coolant. (Page 1F-25)
2) Remove battery and battery tray. (Page 1J-16)
3) Disconnect engine to degassing tank hose (1) from 1
thermostat assembly.

IJHB0A163008-01
IJHB0A163006-01 6) Disconnect radiator inlet hose (1), EGR cooler inlet
4) Disconnect breather pipe (1) from air cleaner outlet hose (2) and oil cooler inlet hose (3) from thermostat
hose No.2 (2). assembly (4).

1
2

IJHB0A163007-01 IJHB0A163009-01

7) Disconnect ECT sensor connector (1) from

thermostat assembly (2).
8) Remove thermostat assembly.

IJHB0A163010-01

9) Remove ECT sensor, if necessary. (Page 1C-25)

1F-27 Engine Cooling System: D13A

Installation • Check that wax pallet moves as follows.

Reverse removal procedure noting the following points. a. Immerse thermostat assembly (1) in water, and
• Use new gasket and new clamp. (Page 1F-23) heat water gradually.
• Tighten thermostat assembly bolts (1) to specified b. Check that valve starts to open at specified
torque. temperature.
Tightening torque Temperature at which valve starts to open
Thermostat assembly bolt (a): 25 N·m (2.5 kgf-m, 86 – 90 °C (187 – 194 °F)
18.5 lbf-ft)
Valve lift
7.5 mm (0.29 in.) at 101 – 105 °C (214 – 221 °F)
1, (a) If valve starts to open at a temperature
substantially below or above specified
temperature, thermostat assembly should be
replaced with a new one. Such a unit, if reused,
will cause overcooling or overheating tendency.

3
1, (a)
1

IJHB0A163011-01

• Tighten heater outlet pipe to specified torque. (Page

1F-23) 2
• If there is matchmark on each of hose and pipe, install
the hose aligning matchmark on hose with matchmark
IDL10A160008-01
on pipe and then install each clamp in proper position.
2. Heater 3. Thermometer
• Tighten breather pipe bolt and its clamp to specified
torque. (Page 1D-81)
• Refill cooling system with coolant. (Page 1F-25)
• Check coolant system for leakage.

Thermostat Inspection
AENJHB0B1626008
• Check that valve seat (1) is free from foreign material
which would prevent valve from seating tight. Replace
thermostat assembly if necessary.

2
1
IJHB0A163012-01

2. Wax pellet
 Engine Cooling System: D13A 1F-28

Radiator Cooling Fan Assembly On-Vehicle 2) Using service wire, connect radiator cooling fan
Inspection motor connector and battery as shown in figure.
AENJHB0B1626009
Radiator Cooling Fan Operation [A] [B]
1) Connect SUZUKI scan tool to DLC (1) with ignition
“OFF”.
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)

IAP70A160002-01

[A]: Low speed [B]: High speed

3) Check that radiator cooling fan motor rotate

1 smoothly and properly.
If any abnormality is found, replace radiator cooling
fan motor.
Reference: Fan motor specified current at 12 V
Low speed: 8.1 – 8.9 A
High speed: 13.1 – 14.4 A

Radiator Cooling Fan Relay Inspection

AENJHB0B1626010
Check radiator cooling fan relay referring to (Page
10B-61).

(A) Radiator Cooling Fan Assembly Removal and

IJHA0A110021-01
Installation
AENJHB0B1626011
2) Set ignition “ON” and clear DTC. (Page 1A-181)
3) Select “Radiator Fan” function in “Active Test”. Removal
4) Check radiator cooling fan operation at low and high 1) Disconnect negative (–) cable at battery.
modes. (Page 1F-20) 2) Drain coolant. (Page 1F-25)
If any abnormality is found, check cooling fan control 3) Remove left side engine under side cover.
system. (Page 1A-326)
4) Disconnect degassing tank outlet hose (1) from
radiator.
Radiator Cooling Fan Motor
5) Detach degassing tank outlet hose from clamp (2).
1) Disconnect radiator cooling fan motor connector (1).

1
IJHB0A163014-01

IJHB0A163013-01
1F-29 Engine Cooling System: D13A

6) Remove air cleaner suction pipe. (Page 1D-81) Installation

7) Disconnect A/F sensor connector (1). Reverse removal procedure noting the following points.
8) Remove A/F sensor bracket (2). • Tighten radiator cooling fan bolts (1) to specified
torque.
Tightening torque
1 Radiator cooling fan bolt (a): 10 N·m (1.0 kgf-m,
2
7.5 lbf-ft)

1, (a)

1, (a)

IJHB0A163015-01

9) Disconnect cooling fan motor connector (1).

IJHB0A163017-01

• Tighten A/F sensor bracket bolt to specified torque.

(Page 1K-7)
• If there is matchmark on each of hose and pipe, install
the hose aligning matchmark on hose with matchmark
on pipe and then install each clamp in proper position.
• Refill cooling system with coolant. (Page 1F-25)
• After installation, check coolant system for leakage.

1
Radiator Cooling Fan Disassembly and
Reassembly
IJHB0A163013-01 AENJHB0B1626012
10) Disconnect harness clamps from radiator.
11) Remove radiator cooling fan bolts (1) and then Disassembly
remove radiator cooling fan assembly (2) downward. 1) Remove retainer clip (1) and torque washer (2).
2) Remove radiator cooling fan (3) from radiator cooling
1 fan shroud assembly (4).

2 3
4
1

2
IJHB0A163016-01

IJHB0A163018-01
 Engine Cooling System: D13A 1F-30

3) Remove radiator cooling fan motor (1) from radiator Radiator On-Vehicle Inspection and Cleaning
cooling fan shroud (2). AENJHB0B1626013
Inspection
Check radiator for leakage or damage. Straighten bent
fins, if any.

Cleaning
1
Clean frontal area of radiator cores.

2
IJHB0A163019-01

Reassembly
Reverse removal procedure noting the following points.
• Tighten radiator cooling fan motor screws (1) to
specified torque. I2RH01160014-01

Tightening torque
Radiator cooling fan motor screw (a): 5.0 N·m ( Radiator Removal and Installation
AENJHB0B1626014
0.51 kgf-m, 4.0 lbf-ft)
Removal
1) Disconnect negative (–) cable at battery.
2) Drain coolant. (Page 1F-25)
3) Remove radiator cooling fan. (Page 1F-28)
4) Remove front bumper. (Page 9H-2)
5) Remove front end upper cover and front end lower
cover. (Page 9H-5)
1, (a)
6) Disconnect intercooler outlet hose No.1 (1) from
IJHB0A163020-01
intercooler.
• Insert new retainer clip (1) to fit the opening to
protrusion (2) on radiator cooling fan (3).

IJHB0A163022-01

IJHB0A163021-04
1F-31 Engine Cooling System: D13A

7) Disconnect radiator outlet hose (1) from radiator. 10) Remove radiator support upper left bracket (1) and
right bracket (2).
11) Remove radiator (3).

3
2 1

IJHB0A163023-01

8) Disconnect radiator inlet hose (1) and radiator to

degassing tank hose (2). IJHB0A163025-01

Installation
Reverse removal procedure noting the following points.
• Tighten radiator support upper left bracket bolts (1)
and right bracket bolts (2) to specified torque.
1 2
Tightening torque
Radiator support upper left bracket bolt (a): 8.5
N·m (0.87 kgf-m, 6.5 lbf-ft)
Radiator support upper right bracket bolt (b): 8.5
N·m (0.87 kgf-m, 6.5 lbf-ft)

IJHB0A163024-01

9) Remove condenser upper and lower bolts.

• Manual A/C single model: (Page 7B-34) 2, (b)

• Manual A/C dual model: (Page 7B-87)

1, (a)
• Automatic A/C dual model: (Page 7B-126)

NOTICE
The condenser assembly may be damaged if
it hits against or interferes with other parts.
Suspend the removed condenser assembly
in a place where no damage will be caused IJHB0A163026-01

during removal and installation of the • If there is matchmark on each of hose and pipe, install
radiator. the hose aligning matchmark on hose with matchmark
on pipe and then install each clamp in proper position.
• Tighten intercooler outlet hose No.1 clamp to
specified torque. (Page 1D-83)
• Refill cooling system with coolant. (Page 1F-25)
• After installation, check each joint for leakage.

Water Pump Drive Belt Inspection

AENJHB0B1626015
1) Check water pump drive belt (1) for wear, crack,
deformation and contamination. If any defect is
found, replace water pump drive belt with new one.
(Page 1F-32)
2) Hoist vehicle and remove right side front wheel.
(Page 2D-3)
3) Remove right side engine under side cover.
 Engine Cooling System: D13A 1F-32

4) When engine is cool, with the belt tension meter, Water Pump Drive Belt Removal and Installation
measure water pump drive belt tension at the AENJHB0B1626016

midpoint between crankshaft pulley (2) and magnet Removal

clutch pulley (3). If water pump drive belt tension is 1) Hoist vehicle and remove right side front wheel.
less than limit, replace water pump drive belt with (Page 2D-3)
new one. (Page 1F-32) 2) Remove right side engine under side cover.
Water pump drive belt tension 3) Place special tool between crankshaft pulley (1) and
Standard: 286 – 834 N (29.2 – 85.0 kgf or 64.3 – water pump drive belt (2) as shown in figure.
187.5 lbf)
NOTE
Limit: 240 N (24.5 kgf or 54.0 lbf)
Place special tool while positioning it along
Recommended belt tension meter specification wall “a” of crankshaft pulley.
Gates Corporation “507C” or equivalent
Setting value for belt tension meter “507C” Special tool
MASS 58 (A): 09991M07410
WIDTH 1.0
SPAN 170 (A)

NOTE “a”

• For using general belt tension meter (other

than Gates Corporation “507C”), refer to (A)

the following belt specification values.

– Length: 884 mm (34.8 in.)
– Weight: 49.6 g (1.8 oz)
– Distance between the contact points of
belt and pulley: 170.1 mm (6.696 in.)
• For the setting of the belt tension meter, 1
follow the operation manual of the belt 2
tension meter. IJHB0A163028-01

4) Remove water pump drive belt (1) by turning

crankshaft pulley (2) clockwise.
1

2 3

IJHB0A163027-01
2
5) Install right side engine under side cover.
1
6) Install right side front wheel. (Page 2D-3) IJHB0A163029-01
1F-33 Engine Cooling System: D13A

Installation
1) Fit ribs of water pump drive belt (1) into grooves of 4 2

water pump pulley (2) and magnet clutch pulley (3).

2) Install water pump drive belt and special tool to
crankshaft pulley (4) as shown in figure.
Special tool
(A): 09991M07460

NOTICE
Installing water pump drive belt using special
tool without its protective cover attached 3
may cause damage to crankshaft pulley or
peeling of its surface coating. (A) 1
Always use special tool with its protective
cover (5) attached. If designated protective (A)
1
cover is not available, cut PVC (soft polyvinyl
chloride) hose to specified dimension as
shown below and attach it to special tool. 4
Protective cover dimensions
Outside diameter “a”: 18 mm (0.70 in.)
Inside diameter “b”: 15 mm (0.59 in.)
5
Length “c”: 15 mm (0.59 in.)
Thickness “d”: 1.5 mm (0.059 in.) IJHB0A163030-01

3) Turn crankshaft pulley (1) clockwise until ribs of

water pump drive belt (2) fit into grooves of
crankshaft pulley, magnet clutch pulley (3) and water
pump pulley (4) completely.
(A)

NOTICE
Turning crankshaft pulley with water pump
“d”
drive belt improperly attached to magnet
clutch pulley and water pump pulley may
5
“b” cause scratch on water pump drive belt.
“c” If water pump drive belt is not installed
“a”
properly, remove and then reinstall it
properly.
IFL10A160004-01
 Engine Cooling System: D13A 1F-34

NOTE Water Pump Removal and Installation

When installing water pump drive belt, push
water pump drive belt at a location closer to
crankshaft pulley than water pump pulley
toward timing chain cover to prevent
misalignment between water pump drive belt
and water pump pulley.
AENJHB0B1626017
Removal
1) Drain coolant. (Page 1F-25)
2) Remove engine assembly. (Page 1D-99)
3) Remove water pump (1) and O-ring (2).

IJHB0A163033-01

IJHB0A163031-01
Installation
Reverse removal procedure noting the following points.
4 • Use new O-ring (1).
1
• Tighten water pump nuts (2) to specified torque.
Tightening torque
Water pump nut (a): 9.0 N·m (0.92 kgf-m, 7.0 lbf-ft)

3
2, (a)
1
2
IJHB0A163032-01

4) Turn crankshaft clockwise 720° and check that all 2, (a)

ribs of belt fit into grooves of pulleys.
5) Start engine and stabilize water pump drive belt
tension. IJHB0A163034-01

6) Stop engine, and then inspect water pump drive belt

tension. (Page 1F-31)
7) Install right side engine under side cover.
8) Install right side front wheel. (Page 2D-3)
1F-35 Engine Cooling System: D13A

Water Pump Inspection

AENJHB0B1626018
Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
abnormal noise, replace it.

IFL10A160010-01

Specifications
Tightening Torque Specifications
AENJHB0B1627001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Drain plug (reference torque) 1.0 0.10 1.0 (Page 1F-25)
Thermostat assembly bolt 25 2.5 18.5 (Page 1F-27)
Radiator cooling fan bolt 10 1.0 7.5 (Page 1F-29)
Radiator cooling fan motor screw 5.0 0.51 4.0 (Page 1F-30)
Radiator support upper left bracket bolt 8.5 0.87 6.5 (Page 1F-31)
Radiator support upper right bracket bolt 8.5 0.87 6.5 (Page 1F-31)
Water pump nut 9.0 0.92 7.0 (Page 1F-34)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Cooling System Components”: D13A (Page 1F-23)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Special Tool
AENJHB0B1628001
09991M07410 09991M07460
Drive belt remover Low modulus belt installer
(Page 1F-32) (Page 1F-33)

SUZUKI scan tool (Suzuki

SDT-II)
—
(Page 1F-28)
 Fuel System: K15B 1G-1

Fuel System
Engine

K15B
Precautions
Precautions for Fuel System Service
AENJHB0B1710001
! WARNING
Service operation of any type performed on the fuel system involves a risk of fire and personal injury if
proper precautions are not taken.
Take the following precautions whenever working on the fuel system.
• Disconnect the negative (–) cable at the battery.
• Do not smoke. Put up no smoking signs around the work area.
• Have CO2 fire extinguishers handy.
• Perform service operations only in a well-ventilated outdoor area away from any open flames such
as gas water heaters.
• Wear safety glasses.
• Remove the fuel filler cap from the fuel filler neck to relieve the fuel tank of fuel vapor pressure, and
then reinstall the cap.
• Before loosening or disconnecting the fuel feed line, relieve the fuel system of fuel pressure by the
following “Fuel Pressure Relief Procedure”: K15B (Page 1G-14).
• When disconnecting a fitting on the fuel line, cover the fitting with a shop cloth to soak up the small
amount of fuel that may flow out from the disconnected fuel line. Put the used cloth in an approved
container.
• Never run the engine with the fuel pump relay disconnected when the engine and exhaust system
are hot.
• Since fuel hose connections vary with the pipe type, connect and clamp each hose using the correct
method for each specific connection. (Page 1G-13)
After connecting a hose, check that there is no twist or kink in the hose.
• When installing a fuel injector or a fuel feed pipe, lubricate its O-rings with gasoline.
• Handle the fuel tank carefully. Do not allow it to touch sharp edges or hot surfaces. Do not drop it. If
the tank is dropped, the tank and all components on and in it should be replaced because they may
have been damaged.
• When any pit and/or crack is found in fuel tank, never repair the tank but always replace it with a new
fuel tank.

NOTICE
If a leaded or low-lead fuel is used for this engine, the engine itself and the emission control system
will be damaged.
Use only unleaded fuel for this engine.
1G-2 Fuel System: K15B

General Description
Fuel System Description Also, fuel vapor generated in fuel tank is led through the
AENJHB0B1711001 fuel vapor line into the EVAP canister.
The main components of the fuel system are fuel tank,
For system diagram, refer to “Fuel Delivery System
fuel pump assembly (with fuel level sensor and fuel
Diagram”: K15B (Page 1G-2).
pressure regulator), fuel filter, fuel feed line and fuel
vapor line.
For the details of fuel flow, refer to “Fuel Delivery System Fuel Pump Description
AENJHB0B1711003
Diagram”: K15B (Page 1G-2). The fuel pump (1) is an in-tank type electric pump.
Incorporated in the pump assembly are;
Fuel Delivery System Description fuel pressure regulator (2) and fuel level sensor (3).
AENJHB0B1711002
The fuel delivery system consists of the fuel tank, fuel
pump assembly (with fuel level sensor and fuel pressure
regulator), fuel filter, delivery pipe, injectors and fuel feed
line.
2
The fuel in the fuel tank is pumped up by the fuel pump,
sent into fuel filter beside the tank and delivery pipe and 1
injected by the fuel injectors. 3
As the fuel pump assembly is equipped with built-in fuel
pressure regulator, the fuel is filtered and its pressure is
regulated before being sent to the feed pipe.
The excess fuel at fuel pressure regulation process is
returned back into the fuel tank. IBP80A171001-01

Schematic and Routing Diagram

Fuel Delivery System Diagram
AENJHB0B1712001

13

12 10
11

6 7
2

8 3

14
4

9
1

5
IJHB0A171001-01

1. Fuel tank 6. Fuel feed line 11. Intake manifold

2. Fuel pump assembly 7. Fuel filter 12. EVAP canister
3. Fuel pressure regulator 8. Fuel level sensor 13. EVAP canister purge valve
4. Fuel delivery pipe 9. Fuel pump 14. Fuel cut valve
5. Fuel injector 10. Fuel vapor line
 Fuel System: K15B 1G-3

Fuel Injector Control System Circuit Diagram

AENJHB0B1712002

A1 4 A2
C01-31 PNK 1
B1 5 B2
C01-11 WHT
C1 6 C2
C01-10 RED
D1 7 D2
C01-12 GRN

3
E01-1 WHT 2

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A170002-01

[A]: ECM connector (View: [a]) C2: Fuel injector No.3 power supply circuit 4. Fuel injector No.1
A1: Fuel injector No.1 drive circuit D1: Fuel injector No.4 drive circuit 5. Fuel injector No.2
A2: Fuel injector No.1 power supply circuit D2: Fuel injector No.4 power supply circuit 6. Fuel injector No.3
B1: Fuel injector No.2 drive circuit 1. To main relay 7. Fuel injector No.4
B2: Fuel injector No.2 power supply circuit 2. To IG12 relay 8. ECM
C1: Fuel injector No.3 drive circuit 3. “IG” fuse

Fuel Pump Control System Circuit Diagram

AENJHB0B1712003

6
B1 A1
4
E01-24 RED 1
BLK 5 PNK

B3 B2 A2

3
E01-1 WHT 2

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A170003-01

[A]: ECM connector (View: [a]) B2: Fuel pump power supply circuit 3. “IG” fuse
A1: Fuel pump relay power supply circuit (coil side) B3: Fuel pump ground circuit 4. Fuel pump relay
A2: Fuel pump relay power supply circuit (switch side) 1. To main relay 5. Fuel pump
B1: Fuel pump relay drive circuit 2. To IG12 relay 6. ECM
1G-4 Fuel System: K15B

Diagnostic Information and Procedures

Fuel System Inspection
AENJHB0B1714001

Step Action Yes No

1 Fuel pump inspection Go to Step 2. Check fuel pump circuit.
1) Remove fuel filler cap and set ignition “ON”. (Page 1G-7)
2) Check that fuel pump operating sound can be heard
from fuel filler port for about 2 seconds.

Is check result OK?

2 Fuel pressure check Go to Step 3. Repair defective part.
1) Check fuel pressure. (Page 1G-9)

Is check result OK?

3 Power balance test Fuel system is in good Go to Step 4.
1) Check power balance. (Page 1G-4) condition.

Is check result OK?

4 Fuel injector circuit check Go to Step 5. Repair defective part.
1) Check fuel injector circuit. (Page 1G-5)

Is check result OK?

5 Fuel injector check Replace ECM and Replace fuel injector.
1) Check fuel injector. (Page 1G-18) recheck fuel system. (Page 1G-16)
(Page 1C-2)
Is check result OK?

Power Balance Test

AENJHB0B1714002
NOTICE
The engine could be damaged if it is
accelerated to a high rpm with a fuel injector
connector disconnected.
Always perform power balance test with
engine running at an idle speed.
1
1) For M/T model, place gear shift lever in “Neutral” and
apply parking brake.
For A/T model, place select lever in P range and
apply parking brake.
2) Connect SUZUKI scan tool to DLC (1) with ignition
“OFF”.
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)

(A)

IJHA0A110021-01

3) Clear DTC. (Page 1A-24)

4) Warm up engine to normal operating temperature.
5) Using SUZUKI scan tool, select “Fuel Injector” in
“Active Test” and turn off each fuel injector.
6) With each fuel injector turned off, check that engine
speed decreases from specified idle speed.
 Fuel System: K15B 1G-5

7) If decreasing rates of engine speed are not in scale, • Spark plug: (Page 1H-7)
check the following items. • Ignition coil circuit: (Page 1H-4)
• Fuel injector circuit: (Page 1G-5) • Ignition coil: (Page 1H-8)
• Fuel injector: (Page 1G-18) • Engine compression: (Page 1D-4)

Fuel Injector Circuit Check

AENJHB0B1714003
Circuit Diagram

A1 4 A2
C01-31 PNK 1
B1 5 B2
C01-11 WHT
C1 6 C2
C01-10 RED
D1 7 D2
C01-12 GRN

3
E01-1 WHT 2

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A170002-01

[A]: ECM connector (View: [a]) C2: Fuel injector No.3 power supply circuit 4. Fuel injector No.1
A1: Fuel injector No.1 drive circuit D1: Fuel injector No.4 drive circuit 5. Fuel injector No.2
A2: Fuel injector No.1 power supply circuit D2: Fuel injector No.4 power supply circuit 6. Fuel injector No.3
B1: Fuel injector No.2 drive circuit 1. To main relay 7. Fuel injector No.4
B2: Fuel injector No.2 power supply circuit 2. To IG12 relay 8. ECM
C1: Fuel injector No.3 drive circuit 3. “IG” fuse

Troubleshooting
Step Action Yes No
1 Fuel injector check for operating sound Fuel injectors circuit is Go to Step 2.
1) Remove air cleaner assembly, if necessary. (Page 1D- in good condition.
9)
2) Using sound scope, check each fuel injector for
operating sound at engine running or cranking.

Do all fuel injectors make operating sound?

2 Fuel injector resistance check Go to Step 3. Replace fuel injector.
1) Set ignition “OFF”, disconnect connectors from fuel (Page 1G-16)
injectors.
2) Check for proper terminal connection to fuel injector
connectors.
3) If connections are OK, check all fuel injectors for
resistance. (Page 1G-16)

Is check result OK?

1G-6 Fuel System: K15B

Step Action Yes No

3 Fuel injector insulation resistance check Go to Step 4. Replace fuel injector.
1) Check that resistance between each fuel injector (Page 1G-16)
terminal and ground is infinity.

Is check result OK?

4 Fuel injector power supply circuit check Go to Step 5. Repair fuel injector
1) Set ignition “ON”. power supply circuit.
2) Check that voltage between each of “A2”, “B2”, “C2” and
“D2” and ground is battery voltage.

Is check result OK?

5 Fuel injector drive circuit check Go to Step 6. Repair fuel injector drive
1) Set ignition “OFF”, disconnect “C01” and “E01” circuit.
connectors from ECM.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A1”, “B1”, “C1” and “D1” circuits: less
than 1 Ω
• Resistance between each of “A1”, “B1”, “C1” and “D1”
circuits and ground: infinity
• Resistance between “A1” circuit terminal and “A2”
circuit terminal at fuel injector connector: infinity
• Resistance between “B1” circuit terminal and “B2”
circuit terminal at fuel injector connector: infinity
• Resistance between “C1” circuit terminal and “C2”
circuit terminal at fuel injector connector: infinity
• Resistance between “D1” circuit terminal and “D2”
circuit terminal at fuel injector connector: infinity
• Voltage of “A1”, “B1”, “C1” and “D1” circuits: approx. 0
V (When ignition is “ON”)

Is check result OK?

6 Fuel injector check Replace ECM and Replace fuel injector.
1) Check fuel injector. (Page 1G-18) recheck fuel injector (Page 1G-16)
operation. (Page 1C-
Is check result OK? 2)
 Fuel System: K15B 1G-7

Fuel Pump and Its Circuit Check

AENJHB0B1714004
Circuit Diagram

6
B1 A1
4
E01-24 RED 1
BLK 5 PNK

B3 B2 A2

3
E01-1 WHT 2

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A170003-01

[A]: ECM connector (View: [a]) B2: Fuel pump power supply circuit 3. “IG” fuse
A1: Fuel pump relay power supply circuit (coil side) B3: Fuel pump ground circuit 4. Fuel pump relay
A2: Fuel pump relay power supply circuit (switch side) 1. To main relay 5. Fuel pump
B1: Fuel pump relay drive circuit 2. To IG12 relay 6. ECM

Troubleshooting
Step Action Yes No
1 Fuel pump control system check Fuel pump circuit is in Go to Step 2.
1) Remove fuel filler cap. good condition.
Reinstall fuel filler cap.
2) Set ignition “ON”.
3) Check that fuel pump operating sound is heard from fuel
filler for about 2 seconds.

Is check result OK?

2 Fuel pump relay power supply circuit check Go to Step 3. Repair fuel pump relay
1) Reinstall fuel filler cap. power supply circuit.
2) Set ignition “OFF”.
3) Remove fuel pump relay from individual circuit fuse box
No.1.
4) Check for proper terminal connection to fuel pump relay
connector.
5) If connections are OK, set ignition “ON”.
6) Check that voltage between each of “A1” and “A2” and
ground is battery voltage.

Is check result OK?

3 Fuel pump relay check Go to Step 4. Replace fuel pump
1) Check fuel pump relay. (Page 10B-61) relay.

Is check result OK?

1G-8 Fuel System: K15B

Step Action Yes No

4 Fuel pump relay drive circuit check Go to Step 5. Repair fuel pump relay
1) Set ignition “OFF”. drive circuit.
2) Disconnect “C01” and “E01” connectors from ECM.
3) Check for proper terminal connection to “C01” and “E01”
connectors.
4) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at fuel pump relay connector: infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 Fuel pump relay drive circuit signal check Go to Step 6. Replace ECM and
1) Set ignition “OFF”. recheck fuel pump
operation. (Page 1C-
2) Connect “C01” and “E01” connectors to ECM.
2)
3) Using service wire, connect fuel pump relay.
4) Check that voltage between “B1” and ground is approx.
0 V for 2 sec. after the ignition is “ON”.

Is check result OK?

6 Fuel pump power supply circuit check 1 Go to Step 7. Repair fuel pump power
1) Check that ignition is “OFF”. supply circuit.
2) Remove fuel tank. (Page 1G-21)
3) Disconnect fuel pump connector.
4) Check that resistance between “B2” and ground is
infinity.

Is check result OK?

7 Fuel pump power supply circuit check 2 Go to Step 8. Repair fuel pump power
1) Connect service wire between “B1” and ground. supply circuit.
2) Set ignition “ON”.
3) Check that voltage between “B2” and ground is battery
voltage.

Is check result OK?

8 Fuel pump ground circuit check Replace fuel pump. Repair fuel pump
1) Set ignition “OFF”. (Page 1G-24) ground circuit.
2) Check that resistance between “B3” and ground is less
than 1 Ω

Is check result OK?

 Fuel System: K15B 1G-9

Fuel Pressure Check

AENJHB0B1714005
System Diagram
Special tool
(A): 09912M58442
(B): 09912M58432
(C): 09912M58490

I3RM0A110081-01

1. Fuel injector 2. Fuel delivery pipe 3. Fuel pump assembly

Troubleshooting

NOTE
Before using the following flow, check that battery voltage is 11 V or more. If it is lower, fuel pressure
becomes lower than specification even if fuel pump and line are in good condition.

Step Action Yes No

1 Was “Fuel Pump and Its Circuit Check” performed? Go to Step 2. Go to “Fuel Pump and
Its Circuit Check”: K15B
(Page 1G-7).
2 Fuel pressure check 1 Go to Step 3. Go to Step 5.
1) Check fuel pressure. (Page 1G-10)

Is check result OK?

3 Fuel pressure check 2 Go to Step 4. Fuel pressure regulator
1) Start engine and warm it up to normal operating is in faulty condition.
temperature. Replace fuel pump
assembly. (Page 1G-
2) Keep engine speed at 4,000 rpm.
24)
Does fuel pressure show about the same value as Step 2?
4 Fuel line check Fuel system is in good Repair defective part.
1) Check fuel pipe and joint for fuel leakage, damage or condition.
deformation.

Is check result OK?

1G-10 Fuel System: K15B

Step Action Yes No

5 Fuel line check Clogged fuel filter, faulty Repair defective part.
1) Check fuel pipe and joint for damage or deformation. fuel pump, faulty fuel
pressure regulator or
Is check result OK? fuel leakage from pipe
connection in fuel tank.

Fuel Pressure Basic Check 9) Connect fuel feed hose to fuel delivery pipe and
AENJHB0B1714006 clamp it securely.
Before performing the following procedure, observe
“Precautions for Fuel System Service”: K15B (Page 1G- 10) With engine stopped and ignition “ON”, check for fuel
1). leakage. (Page 1G-14)
1) Relieve fuel pressure from fuel feed line. (Page 11) Install air cleaner assembly. (Page 1D-9)
1G-14)
2) Remove air cleaner assembly. (Page 1D-9)
3) Disconnect fuel feed hose from fuel delivery pipe.
4) Connect special tools and hose between fuel feed
hose (1) and fuel delivery pipe as shown in figure,
and clamp hoses securely to check that no leakage
occurs during check.
Special tool
(A): 09912M58442
(B): 09912M58432
(C): 09912M58490

(B)
(A)

1
(C)

IJHA0A170004-01

5) Check that battery voltage is 11 V or more.

6) Measure fuel pressure as follows.
If measured pressure is out of specification, refer to
“Fuel Pressure Check”: K15B (Page 1G-9) and
check each possible defective part. Replace if found
defective.
a) Set ignition “ON” to operate fuel pump and turn it
“OFF” after 2 seconds. Repeat this 3 or 4 times
and then check fuel pressure.
Fuel pressure specification
375 – 385 kPa (3.8 – 3.9 kgf/cm2, 54.3 – 55.8
psi, 3.75 – 3.85 bar)
7) Relieve fuel pressure. (Page 1G-14)
8) Remove special tools from fuel delivery pipe and fuel
feed hose.
 Fuel System: K15B 1G-11

Repair Instructions
Fuel System Components
AENJHB0B1716001

(b)
4
3 5

[a]

(c) 11
(e)
23

(f)
12
7
26
22

13 19
14 (d)
8 10
[c] 25 (g)
[b]
20
6
(d) 24 (g)

21
[a]
15

9
[c]
16 8

17 26
[b]
(a)
18

8
(a)

17
(a)

IJHB0A171002-01
1G-12 Fuel System: K15B

1. Fuel injector 13. Gasket 25. Fuel filler side clamp

: For installation, refer to “Fuel Injector
Removal and Installation”: K15B (Page 1G-
16).
2. Injector O-ring 14. Fuel tank pad 26. To EVAP canister
: Apply a bit of fuel to install.
3. Fuel injector clip 15. Fuel tank protector : 45 Nm (4.6 kgf-m, 33.5 lbf-ft)
: For installation, refer to “Fuel Injector
Removal and Installation”: K15B (Page 1G-
16).
4. Fuel delivery pipe 16. Fuel tank cover : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
5. Fuel feed hose 17. Fuel tank belt : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
6. Fuel feed pipe 18. Fuel filter assembly : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
7. Fuel pipe 19. Breather hose : 4.0 Nm (0.41 kgf-m, 3.0 lbf-ft)
8. Fuel hose 20. Fuel tank filler hose : 3.0 Nm (0.31 kgf-m, 2.5 lbf-ft)
9. Fuel EVAP hose 21. Fuel inlet valve : 2.0 Nm (0.20 kgf-m, 1.5 lbf-ft)
10. Fuel tank 22. Fuel filler neck : Do not reuse.
11. Fuel pump plate 23. Fuel filler cap
12. Fuel pump assembly 24. Fuel tank side clamp
 Fuel System: K15B 1G-13

Fuel Hose Disconnection and Reconnection

AENJHB0B1716002
Before performing the following procedure, observe “Precautions for Fuel System Service”: K15B (Page 1G-1).

Non-Quick Joint Connections

Clamp around fuel tank

NOTE
Install hose in the raised part of pipe securely.

“a”
“g” “a”
7
3
3

“g”

2 3 1 7
2 1
6 1

“f”
2
“a”

“c” 7
2
3 1 8
“b” 4
7
1 (a)

1
2
“a” “e” 5 “d” “f” (a)
“e” 2
IJHB0A171003-01

“a”: 3 – 7 mm (0.11 – 0.27 in.) “g”: 0° 6. Vehicle leftward

“b”: 5 – 10 mm (0.19 – 0.39 in.) 1. Pipe 7. Vehicle rightward
“c”: 0 – 8 mm (0 – 0.31 in.) 2. Hose 8. Vehicle forward
“d”: 5 – 12 mm (0.19 – 0.47 in.) 3. Clamp : 2.0 Nm (0.20 kgf-m, 1.5 lbf-ft)
“e”: 45° 4. Fuel tank side clamp
“f”: 22.5° 5. Fuel filler side clamp
1G-14 Fuel System: K15B

Clamp other than around fuel tank 2) For M/T model, place gear shift lever in “Neutral”,
apply parking brake and block drive wheels.
For A/T model, place select lever in P range, apply
parking brake and block drive wheels.
3) Remove fuel pump relay (1) from individual circuit
fuse box No.1.
4) Remove fuel filler cap to release fuel vapor pressure
from fuel tank, and then reinstall fuel filler cap.
5) Start engine and run it until engine stops for lack of
fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time to dissipate fuel pressure in lines.
Fuel connections are now safe for servicing.
6) After servicing, install fuel pump relay to individual
circuit fuse box No.1 and install individual circuit fuse
box No.1 cover.

I7V20A171005-01

[A]: With short pipe, fit hose as far as it 1. Pipe 1

reaches the end of pipe joint as shown.
[B]: With the above type pipe, fit hose as far 2. Hose
as it reaches bulge on fuel pipe.
“a”: 3 – 7 mm (0.11 – 0.27 in.) 3. Clamp

Quick Joint Connections

Disconnection
1) Remove mud, dust and/or foreign material between
pipe (1) and quick joint (2) by blowing compressed
air. IGSB0A173014-01

2) Unlock joint lock by inserting special tool between

pipe and quick joint. Fuel Leakage Check Procedure
AENJHB0B1716004
Special tool After performing any service on fuel system, check that
(A): 09919M47020 there is no fuel leakage as follows.
1) Set ignition “ON” for 3 seconds (to operate fuel
3) Disconnect quick joint from pipe.
pump) and then to “OFF”. Repeat this cycle of
operation 3 or 4 times.
1
Fuel pressure should now be established in fuel
2 (A)
system and felt by hand on fuel feed hose.
2) Check that there is no fuel leakage from any part of
fuel system.
2
1 Fuel Line On-Vehicle Inspection
I4RS0A170019-01 AENJHB0B1716005
Visually check fuel lines for evidence of fuel leakage,
Reconnection hose crack and deterioration or damage.
Insert quick joint to fuel pipe until they lock securely (a Check that all clamps are secure.
click is heard), and check that quick joint is not Replace parts if necessary.
disconnected by hand.

Fuel Pressure Relief Procedure

AENJHB0B1716003
NOTICE
Performing this procedure when the engine
is still hot can damage the catalyst.
Wait until the engine has cooled down before
performing this procedure.

1) Check that engine is cold.

IJHB0A171004-01
 Fuel System: K15B 1G-15

Fuel Pipe Removal and Installation
AENJHB0B1716006
Before performing the following procedure, observe
“Precautions for Fuel System Service”: K15B (Page 1G-
1).
Removal
1) Relieve fuel pressure from fuel feed line. (Page
1G-14)
2) Disconnect negative (–) cable at battery.
3) Hoist vehicle.
4) Remove left side engine under side cover, if
necessary.
5) Remove fuel tank. (Page 1G-21)
6) Remove Left pipe between brake 4-way joint and
rear brake flexible hose. (Page 4A-13)
7) Remove fuel pipe protector with clamp (1) from fuel
pipes (2).
8) Disconnect fuel hoses (1) from fuel pipes (2) at both
front and rear ends of each fuel pipe. (Page 1G-
13)
9) Mark the location of clamps (3) on fuel pipes, so that
the clamps can be reinstalled to the original position.
10) Remove clamps from vehicle body and fuel pipes.
NOTICE
Fuel pipes may be bent or damaged if you are
not careful when unclamping them.
Properly support fuel pipes when removing
clamps.
[A]
3
1
2

2
IJHA0A170009-01
1

[B]

IJHA0A170008-01

3 1
IJHB0A171005-01

2
[C]

IJHA0A170011-01

[A]: Engine side [C]: Fuel tank rear side

[B]: Fuel tank front side

11) Remove fuel pipes.

1G-16 Fuel System: K15B
Installation
1) Install pipes to vehicle.
2) Install clamps to marked position on pipes. If clamp
is deformed or has bent or broken claws, replace it
with new one.
3) Connect fuel hoses to pipes. (Page 1G-13)
4) Install Left pipe between brake 4-way joint and rear
brake flexible hose. (Page 4A-13)
5) Install fuel pipe protector with clamp (1) to marked
position on fuel pipes (2). If clamp is deformed or has
bent or broken claws, replace it with new one.
1
IJHA0A170008-01
6) Install fuel tank. (Page 1G-21)
7) Connect negative (–) cable at battery.
8) With engine stopped, set ignition “ON” and check for
fuel leakage. (Page 1G-14)
9) Bleed brake system. (Page 4A-5)
10) Install left side engine under side cover, if removed.
Fuel Injector On-Vehicle Inspection
AENJHB0B1716007
1) Remove air cleaner assembly, if necessary. (Page
1D-9)
2) Using sound scope (1) or the like, check operating
sound of fuel injector (2) when engine is running or
cranking.
Cycle of operating sound should vary according to
engine speed.
If no sound or unusual sound is heard, check fuel
injector circuit (wire or connector) or fuel injector.
I2RH0B170007-01
3) Disconnect connector (1) from fuel injector, connect
ohmmeter between terminals of fuel injector and
check resistance.
If resistance is out of reference value greatly, replace
injector.
Reference resistance of fuel injector
11.6 – 12.4 Ω at 20 °C (68 °F)
I2RH0B170008-01
4) Connect connector to fuel injector securely.
5) Install air cleaner assembly. (Page 1D-9)
Fuel Injector Removal and Installation
AENJHB0B1716008
Before performing the following procedure, observe
“Precautions for Fuel System Service”: K15B (Page 1G-
1).
Removal
NOTICE
If injectors are removed without observing
the following precautions, nozzle sleeve (1)
may fall off and enter the combustion
chamber, possibly causing the engine
damage.
• Remove the injectors straight, evenly and
gently.
• After removal, check that the tip is fitted.
1
IJHB0B171004-01
1) Relieve fuel pressure. (Page 1G-14)
2) Disconnect negative (–) cable at battery.
3) Remove air cleaner assembly. (Page 1D-9)
4) Disconnect fuel injector connectors and engine
harness clamps.
5) Disconnect PCV hose (1).
 Fuel System: K15B 1G-17

6) Disconnect fuel feed hose (2) from fuel delivery pipe 1) Install fuel injectors to fuel delivery pipe as follows.
(3). a) Install new injector O-rings (1) to injector (2).
7) Remove fuel delivery pipe with fuel injectors.

2 1
2

IFRA0A171051-01
IGSB0A173017-01
b) Install fuel injector clip (1) to injector (3) inserting
8) Remove fuel injector from fuel delivery pipe as its cutout (2) to slot (4) and fitting tabs (5) aligned
follows. with protrusion (6).
a) Expand fuel injector clip (1) in arrow “1”
directions to unhook it and remove it in arrow “2”
direction. 4 1
b) Remove fuel injector (2).

“1” 6 5
2
“1”

3
“2”
1 IDLA0A170021-01

2
c) Apply thin coat of fuel to fuel delivery pipe side
IDLA0A170019-01 injector O-ring.
d) Insert fuel injector to fuel delivery pipe (3) with
Installation fuel injector clip (1) aligning slot (2) with
NOTICE protrusion (4) and then fit slots (5) to protrusions
(6).
Failure to take the following precautions may
affect injector O-rings and cause leakage of
3
high pressure fuel.
• Replace O-rings in clean condition. 4
6
• To avoid damaging injector, do not use
metal tool for removal of O-rings.
4
• Check injector groove for cleanliness 6
before fitting O-rings.
2
• Fit new O-rings with a minimum stretch.
• Do not reuse O-rings once removed. 2

• After fitting O-rings, check for proper 5

seating and cleanliness.
5
1

IDLA0A170022-01
1G-18 Fuel System: K15B

2) Install fuel delivery pipe with injectors to cylinder Fuel Injector Inspection
head as follows. AENJHB0B1716009
Before performing the following procedure, observe
a) Apply thin coat of fuel to fuel injector nozzle side “Precautions for Fuel System Service”: K15B (Page 1G-
injector O-rings. 1).
b) Fit injectors (1) to cylinder head. 1) Remove fuel injector. (Page 1G-16)
c) Tighten fuel delivery pipe nuts (2) to specified 2) Set special tools as follows.
torque.
Special tool
Tightening torque (A): 09912M58421
Fuel delivery pipe nut (a): 25 N·m (2.5 kgf-m, (B): 09912M57610
18.5 lbf-ft) (C): 09912M97110
(D): 09930M86310
2, (a)
a) Install special tool (A) and special tool (C) to fuel
injector (1).
b) Connect special tool (D) to fuel injector.
c) Install special tool (B) to special tool (A).
d) Connect fuel feed hose to special tool (A).

(B)
1
1
1

IFRA0A171025-01
(A) (C)
d) Check that injectors (1) can be rotated smoothly
(2).
If not, probable cause is incorrect installation of
injector O-ring. In such a case, replace the O-
ring with new one again. (D)

1 1
(C)

1 IFRA0A171027-01

IFRA0A171026-01

3) Connect fuel feed hose to fuel delivery pipe.

4) Connect fuel injector connectors and engine harness
clamps.
5) Connect PCV hose.
6) Connect negative (–) cable at battery.
7) After completing installation, check fuel line
connections for leakage with engine not running and
ignition “ON”. (Page 1G-14)
8) Install air cleaner assembly. (Page 1D-9)
 Fuel System: K15B 1G-19

3) Install suitable vinyl tube (1) onto injector nozzle to 6) Operate fuel pump and apply fuel pressure to fuel
prevent fuel from splashing out during injection. injector as follows:
4) Put graduated cylinder (2) under fuel injector. Using SUZUKI scan tool:
5) Connect one of terminal of special tool (D) to battery a) Connect SUZUKI scan tool to DLC (1) with
positive (+) terminal. ignition “OFF”.
b) Set ignition “ON”, clear DTC and select “Active
! WARNING Test” mode on scan tool.
There is an increased risk of personal injury c) Operate fuel pump on using scan tool.
and fire if the following procedure is Special tool
performed without taking proper precautions. (A): SUZUKI scan tool (Suzuki SDT-II)
Put fuel injectors as far away from the battery
as possible when connecting / disconnecting
the test lead to / from the battery.

Special tool
(D): 09930M86310

(D)

IFRA0A171028-01

(A)

IJHA0A110021-01
1G-20 Fuel System: K15B

Without using SUZUKI scan tool:
a) Remove fuel pump relay from individual circuit
fuse box No.1.
b) Connect two terminals of relay connector using
service wire (1) as shown in figure.
NOTICE
If the service wire is connected between the
wrong terminals, the ECM, wire harness, etc.
may be damaged.
Connect the service wire to the correct
terminals.
c) Set ignition “ON”.
1 No.1, if removed.
9) Release fuel pressure in fuel feed line according to
steps below and remove fuel injector from special
tools.
a) Stop operation of fuel pump.
b) Put graduated cylinder under fuel injector.
c) Apply battery voltage to fuel injector until no fuel
is injected from fuel injector.
10) Carry out Step 2) – 9) on each fuel injector to obtain
4 readings.
11) After checking, remove special tools from fuel
injector and fuel feed hose.
12) Install fuel injectors to cylinder head. (Page 1G-16)
13) Connect fuel feed hose to delivery pipe.
14) Install fuel pump relay to individual circuit fuse box
15) Check for fuel leakage. (Page 1G-14)

Fuel Filler Cap Inspection

AENJHB0B1716010
NOTICE
Failure to use correct cap can result in EVAP
leakage.
If cap requires replacement, use a cap with
genuine SUZUKI parts.

Remove cap (1), and check gasket for even filler neck
imprint, deterioration or any damage. If gasket (2) is
defective, replace cap.
IGSB0A173019-01

7) Apply battery voltage to fuel injector for 15 sec. and

measure injected fuel volume with graduated
cylinder. Test each fuel injector two or three times. If
2
injected volume is out of reference value greatly,
replace fuel injector.
Reference injected fuel volume 1
Approx. 27 – 29 cm3/15 sec. (27 – 29 ml, 0.92 –
0.98 US.oz, 0.96 – 1.02 Imp.oz/15 sec.) I9W10P170020-01

8) Check fuel leakage from injector nozzle. Do not

operate fuel injector for this check (but fuel pump
should be at work). If fuel leaks (1) more than the
following specification, replace fuel injector.
Fuel leakage
Less than 1 drop/min.

IFRA0A171031-01
 Fuel System: K15B 1G-21

Fuel Tank Removal and Installation 6) Disconnect breather hose (1) and fuel tank filler hose
AENJHB0B1716011 (2) form fuel filler neck (3) and turn plastic clamp (4).
Before performing the following procedure, observe
“Precautions for Fuel System Service”: K15B (Page 1G- NOTICE
1).
The plastic clamp could be damaged if
excessive force is applied when turning it.
Removal
Turn plastic clamp carefully.
1) Relieve fuel pressure from fuel feed line. (Page
1G-14)
2) Disconnect negative (–) cable at battery.
3) Remove fuel filler cap. 3
4) Insert hose of a hand operated pump into fuel filler 1
hose (1) and pump out fuel in space “a” shown in 2
figure.
4
! WARNING
There is a risk of fire or explosion due to
static electricity if the drained fuel is stored in
an open container or plastic container.
Store the fuel in a sealed metal container.

NOTICE IJHA0A170012-01

The hose of the hand operated pump could
damage the fuel tank inlet valve if excessive
force is applied when inserting or removing it
from the fuel tank.
Do not apply excessive force when inserting
or removing the hose of the hand operated
pump.
7) Remove exhaust center pipe. (Page 1K-4)
8) Disconnect fuel hose (1) from tank side pipe (2).
9) Disconnect fuel EVAP hose (3) from fuel EVAP pipe
(4).
1

1
2

“a”
4 3

IBP70A170006-01

5) Hoist vehicle.
IJHB0A171006-01

10) Disconnect fuel pump connector (1).

IJHB0B171001-01
1G-22 Fuel System: K15B

11) Support fuel tank (1) with jack (2) and remove its 5) Install fuel tank (1) to vehicle and tighten new fuel
mounting bolts. tank bolts (2) to specified torque.

NOTICE

1
The fuel tank bolts are pre-coated with
friction stabilizer. If the bolts are reused, they
may work loose.
Use the new fuel tank bolts.

Tightening torque
Fuel tank bolt (a): 45 N·m (4.6 kgf-m, 33.5 lbf-ft)
2
IJHB0A171007-01
1
12) Remove fuel tank.
13) Remove fuel filter assembly, if necessary. (Page
2, (a)
1G-26)
14) Remove fuel tank filler hose, if necessary.
15) Remove fuel tank inlet valve, if necessary. (Page
2, (a)
1G-11)

Installation

! WARNING IJHB0A171008-01

6) Connect fuel breather hose (1) and fuel tank filler

Failure to take proper precautions when
hose (2).
reinstalling the fuel tank connections can
For proper installation, refer to “Fuel Hose
result in fuel leakage or damage.
Disconnection and Reconnection”: K15B (Page 1G-
Clean the outside surface of the pipe where
13).
each quick joint is to be installed, push the
pipe into the joint until the joint lock clicks, 7) Turn plastic clamp (3).
and then check that the pipe is connected NOTICE
securely.
The plastic clamp could be damaged if
1) Install fuel tank inlet valve, if removed. (Page 1G- excessive force is applied when turning it.
11) Turn plastic clamp carefully.
2) Install fuel tank filler hose to fuel tank, if removed.
(Page 1G-13)
3) Install fuel filter assembly, if removed. (Page 1G-
26)
4) Raise fuel tank with jack and connect fuel pump 1
connector. 2

IJHA0A170016-01

8) Visually check bulge on fuel tank filler hose. Repeat
Step 6) – 7) if check result is not as specified.
Fuel tank filler hose bulge is in good shape
Bulge “A” = “B”: In uniform contact with pipe
“A”
“B”
IFRA0A171016-01
Fuel tank filler hose bulge is not in good shape
Bulge “C”: In excess contact with pipe
Bulge “D”: In poor contact with pipe
“C”
“D”
IFRA0A171017-01
9) Connect fuel hose (1) to tank side pipe (2).
10) Connect fuel EVAP hose (3) to fuel EVAP pipe (4).
(Page 1G-13)
1
4 3
IJHB0A171006-01
11) Install exhaust center pipe. (Page 1K-4)
12) Install fuel filler cap.
13) Connect negative (–) cable at battery.
14) With engine stopped, set ignition “ON” and check for
fuel leakage. (Page 1G-14)
Fuel System: K15B 1G-23
Fuel Tank Inspection
AENJHB0B1716012
• Check fuel tank for crack, deformation or damage.
• Check fuel tank inlet valve for damage, smooth
opening and closing.
If faulty condition is found, replace fuel tank.
• Check fuel pump O-ring for fuel leakage.
If faulty condition is found, replace O-ring and fuel
pump lock nut.
• Check hoses and pipes connected to fuel tank for
leakage, loose connections, deterioration or damage.
If faulty condition is found, replace hoses and/or
pipes.
Fuel Tank Flushing Procedure
AENJHB0B1716013
! WARNING
This flushing procedure cannot remove all
fuel vapors in the fuel tank completely, so
using a flame or electric heater to dry the fuel
tank will increase the risk of an explosion
which may cause human injury.
Do not use a flame and/or electric heater to
dry the fuel tank.
Before performing the following procedure, observe
“Precautions for Fuel System Service”: K15B (Page 1G-
1).
1) After removing fuel tank, remove all hoses, pipes
and fuel pump assembly from fuel tank.
2) Drain all remaining fuel from tank.
3) Place fuel tank to flushing area.
4) Fill tank with warm water or tap water, agitate water
vigorously, and drain water out of tank. Repeat this
process until inside of tank is clean.
5) Completely flush out remaining water.
6) Dry fuel tank assembly thoroughly in a place free of
direct sunlight.
1G-24 Fuel System: K15B

Fuel Pump On-Vehicle Inspection
AENJHB0B1716014
NOTE
Fuel pressure regulator is an integral part of
fuel pump assembly.
Fuel pressure regulator cannot be
individually checked.
1) Remove fuel filler cap and set ignition “ON”. Fuel
pump operation sound should be heard from fuel
filler (1) for about 2 seconds. Reinstall fuel filler cap.
If check result is not as specified, go to “Fuel Pump
and Its Circuit Check”: K15B (Page 1G-7).
Fuel Pump Assembly Removal and Installation
AENJHB0B1716015
NOTICE
The fuel pump assembly components except
the fuel level sensor will lose their original
performance if each part is removed from the
fuel pump assembly.
Do not remove each of the fuel pump
assembly components except the fuel level
sensor. If any faulty condition is found,
replace the fuel pump assembly with a new
one.

Removal
1) Remove fuel tank from vehicle. (Page 1G-21)
2) Disconnect fuel pump connector (1) from fuel pump
assembly (2).
1
3) Disconnect quick joint (3) from fuel pump assembly.
(Page 1G-13)

IAW101170034-01
1
2) Set ignition “OFF” and leave it over 10 seconds as it
is.
3) Fuel pressure should be felt at fuel feed hose (1) for 2
about 2 seconds after setting ignition “ON”.
IJHB0B171002-01
If fuel pressure is not felt, go to “Fuel Pressure
Check”: K15B (Page 1G-9). 4) Remove fuel pump plate (1).
5) Remove fuel pump assembly (2) and gasket (3).

IFRA0A171040-01 3
IJHB0A171009-01
 Fuel System: K15B 1G-25

Installation 4) Tighten fuel pump assembly bolts (1) to specified

torque.
! WARNING
Tightening torque
Failure to take proper precautions when Fuel pump assembly bolt (a): 10 N·m (1.0 kgf-m,
reinstalling the fuel tank connections can 7.5 lbf-ft)
result in fuel leakage or damage.
5) Positioning ground cable (2) to specified angle as
Clean the outside surface of the pipe where
shown, tighten fuel pump assembly bolt (3) to
each quick joint is to be installed, push the
specified torque.
pipe into the joint until the joint lock clicks,
and then check that the pipe is connected Position range for ground cable
securely. “a”: 45°
Tightening torque
NOTE Fuel pump assembly bolt (a): 10 N·m (1.0 kgf-m,
Before fitting fuel pump assembly, check that 7.5 lbf-ft)
wiring harness (1) is not in contact with
6) Connect quick joint (4) to fuel pump assembly (5).
surrounding parts.
(Page 1G-13)
7) Connect fuel pump connector (6) to fuel pump
assembly.
1

“a” “a”

4
1, (a) 2

IJHB0B171005-01

3, (a)
1) Clean mating surfaces of fuel pump assembly and 6
fuel tank.
2) Install new gasket (1) and fuel pump assembly (2). 1, (a) 1, (a)

3) Put fuel pump plate (3) on fuel pump assembly by 5

matching the protrusion (4) of fuel pump assembly to IJHB0B171003-01

plate hole (5). 8) Install fuel tank to vehicle. (Page 1G-21)

Fuel Pump Inspection

AENJHB0B1716016
• Check fuel pump assembly for damage.
3
• Check fuel suction filter for contamination.
If contaminated, replace or clean the filter and check
5
2
fuel tank inside for presence of dirt.

1
IJHB0A171010-01
1G-26 Fuel System: K15B

Fuel Level Sensor Removal and Installation Fuel Level Sensor Inspection
AENJHB0B1716017 AENJHB0B1716018
NOTICE • Check that resistance between terminals “1” and “2”
Failure to take proper precautions when of fuel level sensor changes depending on float
removing or installing the fuel level sensor position.
can result in damage. • Check resistance between terminals “1” and “2” at
To prevent failure of the fuel level sensor, be each float position in the following table.
careful not to touch the resistor plate (1) or If check result is not as specified, replace fuel level
deform the arm (2) when performing the sensor.
service operations described below.
Fuel level sensor specifications
Float position Resistance (Ω)
“a” 10.8 mm (0.425 in.) 280 ± 3.3
1
“b” 63.9 mm (2.515 in.) 160 ± 10.0
“c” 106.1 mm (4.177 in.) 40 ± 2.0

2 1

IAW101170039-01
“c”
“b”
Removal
1) Remove fuel pump assembly from fuel tank. (Page
1G-24) “a”
IJHA0A170023-01
2) Disconnect fuel level sensor connector (1).
3) Release lock (2), and remove fuel level sensor (3) Fuel Filter Removal and Installation
from fuel pump (4) by sliding it in arrow direction as AENJHB0B1716019
shown in figure. Removal
1) Relieve fuel pressure from fuel feed line. (Page
1 1G-14)
2) Disconnect negative (–) cable at battery.
3) Disconnect fuel hoses (1) from fuel filter (2).
2

3 1

4
IJHA0A170022-01
2

Installation
Reverse removal procedure. IJHB0A171011-01

4) Remove fuel filter from fuel tank.

Installation
1) Install fuel filter to fuel tank.
2) Connect fuel hoses to fuel filter.
3) Connect negative (–) cable at battery.
4) With engine stopped, set ignition “ON” and check for
fuel leakage. (Page 1G-14)
 Fuel System: K15B 1G-27

Specifications
Tightening Torque Specifications
AENJHB0B1717001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Fuel delivery pipe nut 25 2.5 18.5 (Page 1G-18)
Fuel tank bolt 45 4.6 33.5 (Page 1G-22)
Fuel pump assembly bolt (Page 1G-25) /
10 1.0 7.5
(Page 1G-25)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fuel System Components”: K15B (Page 1G-11)
“Fuel Hose Disconnection and Reconnection”: K15B (Page 1G-13)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Special Tool
AENJHB0B1718001
09912M57610 09912M58421
Injector checking tool plate Checking tool set
(Page 1G-18) This kit includes the
following items. 1. Tool body
and washer 2. Body plug 3.
Body attachment-1 4. Holder
5. Return hose and clamp 6.
Body attachment-2 and
washer 7. Hose attachment-
1, 8. Hose attachment-2
(Page 1G-18)
09912M58432 09912M58442
Fuel pressure gauge hose Fuel pressure gauge
This tool is included in fuel This tool is included in fuel
pressure gauge set (09912- pressure gauge set (09912-
58413). 58413).
(Page 1G-9) / (Page 1G-9) /
(Page 1G-10) (Page 1G-10)
09912M58490 09912M97110
3-way joint & hose Checking tool attachment
(Page 1G-9) / (Page 1G-18)
(Page 1G-10)

09919M47020 09930M86310
Quick joint remover Injector test harness
(Page 1G-14) (Page 1G-18) /
(Page 1G-19)
1G-28 Fuel System: K15B

SUZUKI scan tool (Suzuki

SDT-II)
—
(Page 1G-4) /
(Page 1G-19)
 Fuel System: D13A 1G-29

D13A
Precautions
Precautions for Fuel System Service
AENJHB0B1720001
! WARNING
Service operation of any type performed on the fuel system involves a risk of fire and personal injury if
proper precautions are not taken.
Take the following precautions whenever working on the fuel system.
• Disconnect the negative (–) cable at the battery.
• Do not smoke. Put up no smoking signs around the work area.
• Have CO2 fire extinguishers handy.
• Perform service operations only in a well-ventilated area away from any open flames such as gas
water heaters.
• Wear safety glasses.
• Remove the fuel filler cap from the fuel filler neck to relieve the fuel tank of fuel vapor pressure, and
then reinstall the cap.
• Before loosening or disconnecting the fuel feed line, relieve the fuel system of fuel pressure by
following the “Fuel Pressure Relief Procedure”: D13A (Page 1G-41).
• When disconnecting a fitting on the fuel line, cover the fitting with a shop cloth to soak up the small
amount of fuel that may flow out from the disconnected fuel line. Put the used cloth in an approved
container.
• Never run the engine with the fuel pump relay disconnected when the engine and exhaust system
are hot.
• Since fuel hose connections vary with the pipe type, connect and clamp each hose using the correct
method for each specific connection. (Page 1G-39)
After connecting a hose, check that there is no twist or kink in the hose.
• When installing an injector or a fuel feed pipe, lubricate its O-rings with fuel.
• Do not set ignition “ON” when disconnecting fuel pipe and/or removing fuel system components.
• Handle the fuel tank carefully. Do not allow it to touch sharp edges or hot surfaces. Do not drop it. If
the tank is dropped, the tank and all components on and in it should be replaced because they may
have been damaged.

• Fuel system must be checked for fuel leakage after service work. (Page 1G-41)
• Fuel system is very sensitive to contamination. Problems caused by introduction of contamination into the system
include:
– Damage to or destruction of high pressure injection system and engine.
– Seized or leaky component.
• When servicing high pressure direct injection system, perform operation in very clean condition. Never allow any
contamination to get into fuel system during removal of components and disconnection of unions. Maintaining
cleanliness is especially important when servicing any part between fuel filter and injectors.
• Avoid especially the following contaminants.
– Metal or plastic chips
– Paint
– Fibres from boxes, brushes, paper, clothing or cloths
– Hair
– Dust brought by air
• Do not clean engine using high pressure washing machine because of the risk of damage and moisture collection in
connections. This may also create electrical connection problems.
• Wear clean overalls.
• Prepare plugs or covers for closing disconnected unions to prevent any entry of impurities into fuel system.
1G-30 Fuel System: D13A

• Plug or cover unions as soon as possible when removing / disconnecting fuel system component to prevent dust
from entering.
Similarly, remove plugs or covers only immediately before installing / connecting fuel system component.
• Keep removed fuel system parts in plastic bags with hermetically closing fasteners to protect them from impurities.
Plastic bags must be used only once.

I3RB0A173003-01

• Use only lint-free cloth for wiping fuel system parts. Never use any other wiping materials. Lint-free cloth must be
used only once.
• Keep plug cap installed unless its removal is absolutely necessary to prevent impurities from entering the system.
• Follow the instructions below before opening the fuel circuit.
– Use new thinner from clean receptacle every time connection is cleaned (used thinner contains impurities).
– Use only clean brush in good condition (without loose bristles) for applying thinner.
– Use brush and thinner to clean connections to be opened.
– Blow compressed air over cleaned parts (connections and injection system area including tools). Check that no
bristles remain on cleaned surfaces.
– Wash your hands before and during the operation if necessary.
– When wearing leather gloves, cover them with latex gloves.
• Follow the instructions below during operation.
– As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system using
plug caps. Do not reuse removed plugs.
– Close plastic bag every time it is opened, even if it has to be reopened shortly afterwards.
Ambient air carries contamination.
– All removed components of injection system must be kept in a plastic bag with hermetically closing fastener once
openings are closed with plugs.
– The use of brush, thinner, bellows, sponge or normal cloth is strictly forbidden once fuel system circuit has been
opened. These items are likely to allow impurities to enter the system.
– Open package of replacement part only immediately before installation.
 Fuel System: D13A 1G-31

General Description
Fuel System Description
AENJHB0B1721001
Low-Pressure Fuel Supply Circuit [A]
The fuel pump in the fuel tank (1) pumps fuel into the high pressure fuel supply circuit [B] through the fuel filter (2).
The fuel pump assembly (3) is composed of a fuel pump (4), a fuel suction filter (5) and a fuel level gauge (6). The fuel
pump is an electric pump.

High-Pressure Fuel Supply Circuit [B]

The high pressure pump (7) driven by the engine boosts pressure of low pressure fuel to create high pressure fuel.
The high pressure fuel is supplied to the common rail (8) through the high pressure fuel pipe. The injectors (9) atomize
the fuel to charge the cylinders.
The fuel flow actuator (12) located on the high pressure pump regulates the quantity of fuel to the high pressure pump
according to ECM signal to control the fuel pressure in the common rail.

9
7
10

12
11

3
1

8 [A]

[B]

[C]

6 4 5
IJHB0A173002-01

[C]: Return for circuit 10. Fuel damper 11. Fuel pressure sensor
1G-32 Fuel System: D13A

Diagnostic Information and Procedures

Low-Pressure Fuel Supply Circuit Check
AENJHB0B1724001
System Diagram

: [A]

[F] [E] 4 : [B]

3
: [C]
5
[D]

2 6

[F]
[D]

5
[E]

6
3

IJHB0B172001-01

[A]: Fuel feed line [E]: Measurement point [E] 3. Fuel flow actuator
[B]: Fuel return line [F]: Pinching point [F] 4. High pressure pump
[C]: Fuel high pressure line 1. Fuel tank 5. Common rail
[D]: Measurement point [D] 2. Fuel filter 6. Fuel injector
 Fuel System: D13A 1G-33

Troubleshooting

NOTE
Before performing the following check, check that battery voltage is 12 V or more.

Before performing the following procedure, observe “Precautions for Fuel System Service”: D13A (Page 1G-29).
Step Action Yes No
1 Preliminary check Go to Step 2. Fuel tank contains
1) Check that fuel tank contains correct type of fuel. improper substances
(petrol or other fluids).
Is check result OK? Clean fuel tank and refill
it correctly.
2 Preliminary check Go to Step 3. Add fuel up to more
1) Check that fuel remaining in tank is more than 5 liters than 5 liters (10.57/8.80
(10.57/8.80 US/Imp pt.). US/Imp pt.).

Is check result OK?

3 Preliminary check Go to Step 4. Repair or, if necessary,
1) Check the following points. replace faulty
components.
• Check for fuel leakage in fuel circuit.
• Check hoses and pipes for obstructions, damage,
leakage, breaks, scratches, etc.
• Check fittings and seals for correct installation.
• Check for blockages, presence of air or water in fuel
system.

Is check result OK?

4 Fuel pump operation check Go to Step 5. Go to “Table A-1: Fuel
1) Check fuel pump operation. (Page 1G-56) Pump Relay Operation
Check”: D13A in
Is check result OK? Section 1A (Page 1A-
291).
1G-34 Fuel System: D13A

Step Action Yes No

5 Fuel pressure check End. • If fuel pressure is
1) Set ignition “OFF”. higher than 450 kPa
(4.6 kgf/cm2, 65.3 psi,
2) Connect special tools and hose (1) to measurement
4.5 bar), go to Step 6.
point [D] as shown in figure.
• If fuel pressure is
NOTE lower than 390 kPa
Install clean hose (inside diameter: 8 mm (0.31 (4.0 kgf/cm2, 56.6 psi,
in.)) between connector (2) and special tool (3) as 3.9 bar), go to Step 7.
shown in figure.

Special tool
: 09912M58432
: 09914M08410
: 09919M48410

IHL10A172051-01

3) Within 20 sec. after setting ignition “ON”, check that fuel

pressure is within 390 to 450 kPa (4.0 to 4.6 kgf/cm2,
56.6 to 65.3 psi, 3.9 to 4.5 bar).

Is check result OK?

 Fuel System: D13A 1G-35

Step Action Yes No

6 Fuel pressure check Replace fuel filter. Replace high pressure
1) Set ignition “OFF”. (Page 1G-58) pump. (Page 1G-49)
2) Remove special tools connected in Step 5.
3) Connect special tools and hose (1) to measurement
point [E] as shown in figure.

NOTE
Install clean hose (inside diameter: 8 mm (0.31
in.)) between connector (2) and special tool (3) as
shown in figure.

Special tool
: 09912M58432
: 09914M08410
: 09919M48410

1
2

IDL10A170003-01

4) Within 20 sec. after setting ignition “ON”, check that fuel

pressure.

Is measured fuel pressure by less than 30 kPa (0.3 kgf/cm2,

4.35 psi, 0.3 bar) from value of measured fuel pressure in
Step 5?
7 Fuel pressure check Replace high pressure Replace fuel pump.
1) Set ignition “OFF”. pump. (Page 1G-49) (Page 1G-56)
2) Pinch fuel hose at pinching point [F] by hand to block up
fuel flow.
3) Within 20 sec. after setting ignition “ON”, check that fuel
pressure is within 720 to 780 kPa (7.3 to 8.0 kgf/cm2,
104 to 113 psi, 7.2 to 7.8 bar).

Is check result OK?

1G-36 Fuel System: D13A

High-Pressure Fuel Supply Circuit Check

AENJHB0B1724002
Before performing the following procedure, observe “Precautions for Fuel System Service”: D13A (Page 1G-29).

Troubleshooting

NOTE
• Before troubleshooting, check low-pressure fuel circuit. (Page 1G-32)
• Before troubleshooting, check that battery voltage is 12 V or more.

Step Action Yes No

1 Fuel injector calibration code check Go to Step 2. Register correct fuel
1) Using SUZUKI scan tool, check that fuel injector injector calibration
calibration codes registered in ECM correspond to codes in ECM. (Page
calibration codes stamped on fuel injectors. 1C-22)

Is check result OK?

2 Fuel injector check Go to Step 3. Replace faulty fuel
1) Check fuel injector for resistance. (Page 1G-46) injector. (Page 1G-47)

Is check result OK?

 Fuel System: D13A 1G-37

Step Action Yes No

3 Fuel injector leakage check Go to Step 4. Replace faulty fuel
1) Relieve fuel pressure. (Page 1G-41) injector. (Page 1G-47)
2) Set ignition “OFF”.
3) Remove air cleaner assembly. (Page 1D-82)
4) Disconnect connectors from all injectors.
5) After removing clips, disconnect fuel return hose (1) from
all fuel injectors.
6) Plug fuel return hose with plug cap (2) so that no fuel
comes out during this check. For details, refer to
“Precautions for Fuel System Service”: D13A (Page 1G-
29).
7) Connect special tool to fuel injectors.

NOTE
For adapters (3) between special tool and
injectors, use return fuel hose supplied as spare
part.

Special tool
(A): 09912M96540

(A)
IJHB0A173004-01

8) Install air cleaner assembly. (Page 1D-82)

9) Crank engine for 5 sec.
10) Check that quantities of return fuel from all injectors are
almost the same.

Is check result OK?

4 Fuel injector leakage check Go to Step 5. Replace faulty fuel
1) Set ignition “OFF”. injector. (Page 1G-47)
2) Connect connectors to all injectors.
3) Check that quantities of return fuel from all injectors are
almost the same under each of the following conditions
respectively in the same manner as in Step 3.
• Engine running at idle speed for 3 min.
• Engine running at 1,500 rpm for 3 min.
• Engine running at 3,000 rpm for 3 min.

Is check result OK?

1G-38 Fuel System: D13A

Step Action Yes No

5 High pressure fuel circuit check End. Go to Step 6.
1) Set ignition “OFF”.
2) Remove air cleaner assembly. (Page 1D-82)
3) Disconnect connector from all fuel injectors.
4) Install air cleaner assembly. (Page 1D-82)
5) Connect SUZUKI scan tool to DLC.
6) Crank engine for 5 sec.
7) Check that “Fuel Rail Pressure” displayed on SUZUKI
scan tool is higher than 28 MPa (285.5 kgf/cm2,
4061.psi, 280 bar) at engine speed higher than 200 rpm.

Is check result OK?

6 Fuel pressure sensor circuit check Go to Step 7. Repair or replace
1) Check fuel pressure sensor circuit. (Page 1A-296) defective wire harness.

Is check result OK?

7 Fuel flow actuator operation check End. Repair or replace
1) Check fuel flow actuator operation. (Page 1A-298) defective part.

Is check result OK?

 Fuel System: D13A 1G-39

Repair Instructions
Fuel Hose Disconnection and Reconnection
AENJHB0B1726001
Before performing the following procedure, observe “Precautions for Fuel System Service”: D13A (Page 1G-29).

Non-Quick Joint Connections

Clamp around fuel tank

NOTE
Contact fuel hose end with bulge on fuel pipe or pipe joint end when connecting fuel hose to pipe.

“a”
“g” “a”
7
3
3

“g”

2 3 1 7
2 1
6 1

“f”
2
“a”

“c” 7
2
3 1 7
“b” 4
7
1 (a)
“g”
1
2
“a” “e” 5 “d” “f” (a)
2
IJHB0A173005-01

“a”: 3 – 7 mm (0.12 – 0.27 in.) “f”: 22.5° 4. Fuel tank side clamp
“b”: 5 – 10 mm (0.20 – 0.39 in.) “g”: 0° 5. Fuel filler side clamp
“c”: 0 – 8 mm (0 – 0.31 in.) 1. Pipe 6. Vehicle leftward
“d”: 5 – 12 mm (0.20 – 0.47 in.) 2. Hose 7. Vehicle rightward
“e”: 45° 3. Clamp : 2.0 Nm (0.20 kgf-m, 1.5 lbf-ft)
1G-40 Fuel System: D13A

Clamp other than around fuel tank Type B (lock pin type)
Disconnection
1) Remove mud, dust and/or foreign material between
pipe (1) and quick joint (2) by blowing compressed
air.
2) Release fuel pipe quick joint lock pin (3) in arrow
direction as shown in figure, and disconnect fuel
pipe.

2 3
1

1
I7V20A171005-01 IFRA0A171018-01
[A]: With short pipe, fit hose as far as it 1. Pipe Reconnection
reaches the end of pipe joint as shown.
Insert quick joint (fuel pipe) to high pressure pump until
[B]: With the following type pipe, fit hose as 2. Hose
far as it reaches bulge on fuel pipe. they lock securely (a click is heard), and check that quick
“a”: 3 – 7 mm (0.12 – 0.27 in.) 3. Clamp joint (fuel pipe) is not disconnected by hand.

Quick Joint Connections Type C (special tool inserting type)

Type A (lock button type) Disconnection
Disconnection 1) Remove mud, dust and/or foreign material between
1) Remove mud, dust and/or foreign material between pipe (1) and quick joint (2) by blowing compressed
pipe (1) and quick joint (2) using compressed air. air.
2) Disconnect quick joint from fuel pipe while pushing 2) Unlock joint lock by inserting special tool between
lock button (3) on joint. pipe and quick joint.
Special tool
1 (A): 09919M47020
3) Disconnect quick joint from pipe.

1
2 (A)
2
3
I8T401171011-01

Reconnection
Insert quick joint to fuel pipe until it locks securely (a click 2
is heard), and check that quick joint is not disconnected 1
I4RS0A170019-01
by hand.
Reconnection
Insert quick joint to fuel pipe until it locks securely (a click
is heard), and check that quick joint is not disconnected
by hand.
 Fuel System: D13A 1G-41

Fuel Pressure Relief Procedure 5) Check for fuel leakage in each part which was
AENJHB0B1726002 serviced.
1) Check that engine is cold.
2) Connect SUZUKI scan tool to DLC (1) with ignition Water Draining of Fuel Filter
“OFF”. AENJHB0B1726004
1) Disconnect negative (–) cable at battery.
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II) 2) Hoist vehicle.
3) Place container under bleed screw (1), and drain out
water by loosening bleed screw from lower side of
engine until fuel flows out.
4) Tighten bleed screw to specified torque.
Tightening torque
Bleed screw (a): 1.0 N·m (0.10 kgf-m, 1.0 lbf-ft)

1, (a)
IHL10A172013-02

5) Lower vehicle.
(A)
6) Connect negative (–) cable at battery.
IJHA0A110021-01

3) Set ignition “ON”. Air Bleeding of Fuel System

AENJHB0B1726005
4) Check that fuel pressure line is not under pressure
Air bleeding must be carried out when fuel system has
using “Fuel Rail Pressure” parameter of SUZUKI
been disassembled or when vehicle ran out of fuel.
scan tool.
Set ignition “ON” to operate fuel pump and after about 5
sec. set ignition “OFF”. Repeat this operation 6 times
Fuel Leakage Check Procedure and then check that engine starts.
AENJHB0B1726003
! CAUTION
High-pressure fuel supply circuit of fuel
system gets to be high temperature and high
pressurized condition at 160,000 kPa (1,631.5
kgf/cm2, 23,206 psi, 1,600 bar). Touching the
fuel being spurted from the leaky point on
high-pressure fuel supply circuit can cause a
burn or personal injury.
If the fuel leakage is found, perform “Fuel
Pressure Relief Procedure”: D13A (Page 1G-
41) before repairing fuel leakage.

1) Set ignition “ON”.

2) Check for fuel leakage in each part which was
serviced.
3) Start the engine, and then check for fuel leakage in
each part which was serviced.
4) Run engine at 4,000 rpm for about 30 sec. and then
stop engine.
1G-42 Fuel System: D13A

Fuel System Components

AENJHB0B1726006
Low-Pressure Fuel Supply Circuit

NOTE
Install clip within 3.0 – 7.0 mm (0.12 – 0.27 in.) from end of hose.

27

26
26

25
(c)

27
24
28 29
23

[a]
(c)

21

22
20

(b)
3
(e)
15
4
(f)
19

19 14

5 12
2 (d)
21
1
13 (g)
20 11

[a] (d) 10 (g)

16
8

7
(a) 17

5
(a)

7 18 (h)

(a)

IJHB0A173006-01
 Fuel System: D13A 1G-43

1. Fuel tank 14. Fuel filler neck 27. Fuel return hose
2. Fuel tank pad 15. Fuel filler cap 28. To high pressure pump
3. Fuel pump plate 16. Upper housing 29. To fuel damper
4. Fuel pump assembly 17. Fuel filter element : 45 Nm (4.6 kgf-m, 33.5 lbf-ft)
5. Gasket 18. Lower housing : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
6. Fuel tank protector 19. Fuel pipe : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
7. Fuel tank belt 20. Fuel feed pipe : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
8. Fuel tank cover 21. Fuel return pipe : 4.0 Nm (0.41 kgf-m, 3.0 lbf-ft)
9. Fuel inlet valve 22. Fuel filter : 3.0 Nm (0.31 kgf-m, 2.5 lbf-ft)
10. Fuel tank side clamp 23. Fuel filter bracket : 2.0 Nm (0.20 kgf-m, 1.5 lbf-ft)
11. Fuel tank filler hose 24. Fuel pipe No.1 : 28 Nm (2.9 kgf-m, 21.0 lbf-ft)
12. Breather hose 25. Fuel pipe No.2 : Do not reuse.
13. Fuel filler side clamp 26. Fuel feed hose
1G-44 Fuel System: D13A

High-Pressure Fuel Supply Circuit

(b)

9 (d)

(c)

(c)

(b) 8

13
11
1 (a)

(e) 13

(b)
4
1

(a)

4
10
(e) 7

(g)
2 1

10 6

(f)
12
IJHB0A173007-01

1. Fuel injector 8. Common rail bracket : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
2. Sealing ring 9. Fuel pressure sensor : 22 Nm (2.2 kgf-m, 16.5 lbf-ft)
3. Sealing washer 10. Fuel injector bracket : 70 Nm (7.1 kgf-m, 52.0 lbf-ft)
4. Washer 11. Engine side hook : 24 Nm (2.4 kgf-m, 18.0 lbf-ft)
5. Common rail 12. Fuel flow actuator : 15 Nm (1.5 kgf-m, 11.0 lbf-ft)
6. High pressure pump 13. High pressure pipe : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
: For tightening order, refer to “High Pressure Pipe
Removal and Installation”: D13A (Page 1G-45)
7. Fuel damper : 20 Nm (2.0 kgf-m, 15.0 lbf-ft) : Do not reuse.
 Fuel System: D13A 1G-45

High Pressure Pipe Removal and Installation Installation

AENJHB0B1726007
NOTICE
If the union nut of the high pressure pipe
connecting to the high pressure pump / fuel
injectors is loosened and tightened without
holding the union nuts (1), the high pressure
pump / fuel injectors may be damaged.
Hold the union nuts whenever loosening and
tightening the union nut of the high pressure
pipe.
1
IJHB0B172002-01
Removal
1) Release fuel pressure. (Page 1G-41)
2) Disconnect negative (–) cable at battery.
3) Remove air cleaner assembly. (Page 1D-82).
4) Remove intercooler outlet pipe No.3. (Page 1D-
83)
5) Remove high pressure pipes as follows.
a) Loosen high pressure pipe union nuts (1) from
fuel injectors and high pressure pump.
b) Loosen high pressure pipe union nuts (2) from
common rail (3), and remove high pressure
pipes (4).
3 2
NOTICE
Failure to take proper precautions when
installing the high pressure pipe can cause
damage to the high pressure pipe and may
lead to fuel leakage.
Take the following precautions when
removing and installing the high pressure
pipe.
• Never reuse high pressure pipe.
• Before tightening the union nut to
specified torque, tighten the union nuts of
the both sides evenly and gradually by
hand.
• When the union nut of high pressure pipe
is tightened using the special tool until the
torque wrench reads the specified torque,
the pulley will actually be tightened to a
torque much more than the specified
torque. This could damage the related
components.
Use the formula shown below to determine
the correct reading of the torque wrench
for its length. Then tighten the union nut of
high pressure pipe until the torque wrench
indicates the value thus determined.
Tightening torque formula.
M = T x L / (L + “a”)
M: Value indicated on torque wrench
T: Specified tightening torque
L: Length of torque wrench
“a”: Length of special tool
Special tool
(A): 09911M75420
(B): 09950M76510
“a”

L
4 4

(A)

1 (A) “a” (B)

“b”
IJHB0B172003-01

IDL10A170038-01

“a”: 19.5 mm (0.768 in.) “b”: 20.3 mm (0.799 in.)

1G-46 Fuel System: D13A

Reverse removal procedure noting the following points. Fuel Injector On-Vehicle Inspection
AENJHB0B1726008
• Use new high pressure pipe.
1) Using sound scope or the like, check operating
• Tighten injector side union nuts and high pressure sound of fuel injectors when engine is running or
pump side union nut (1) to specified torque. cranking.
Special tool Cycle of operating sound should vary according to
: 09950M76510 engine speed.
If no sound or an unusual sound is heard, check that
Tightening torque result of each step is in good condition. (Page 1A-
High pressure pipe union nut (fuel injector side 293)
and high pressure pump side)* (a): 24 N·m (2.4
kgf-m, 18.0 lbf-ft)
• Tighten common rail side union nuts (2) to specified
torque.
Special tool
: 09911M75420
Tightening torque
High pressure pipe union nut (common rail side)*
(b): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)

2, (b) I3RM0B172008-01

2) Remove air cleaner assembly. (Page 1D-82)

3) Disconnect connector from fuel injector.
4) Connect ohmmeter between terminals of fuel injector
and check resistance.
If resistance is out of specification, replace fuel
injector.
Resistance of fuel injector
0.215 – 0.295 Ω
1, (a)
IJHB0B172004-01

• Check for fuel leakage. (Page 1G-41)

IJHB0B172005-01

5) Connect connector to fuel injector securely.

6) Install air cleaner assembly. (Page 1D-82)
 Fuel System: D13A 1G-47

Fuel Injector Removal and Installation Removal

AENJHB0B1726009
1) Disconnect negative (–) cable at battery.
NOTE 2) Remove high pressure pipes between fuel injectors
The calibration code (1) is given to each fuel and common rail. (Page 1G-45)
injector, and it represents the performance 3) Disconnect connectors (1) from fuel injectors.
characteristics of the fuel injector. It is 4) Remove clips (2), and then disconnect return hose
registered in ECM, and ECM controls fuel (3) from fuel injectors.
injection according to the performance
characteristics of the fuel injector.
Therefore, after removing fuel injectors,
2
install them as they were. In case that the fuel
injector is replaced with new one, register
3
each calibration code in ECM. For details,
refer to “Description of ECM Registration”:
D13A in Section 1C (Page 1C-18). If it is not
registered correctly, DTC is stored in ECM
and MIL lights up.
Also calibration codes registration in ECM
can be checked by SUZUKI scan tool.

1 1
IJHB0B172006-01

5) Remove fuel injector bracket nut (1).

6) Remove fuel injectors with its bracket (3) from
camshaft housing.
7) Remove sealing rings (4) from camshaft housing.

2
I3RM0B172010-01

Before performing the following procedure, observe

“Precautions for Fuel System Service”: D13A (Page 1G-
29).
4
IJHB0A173013-01

2. Common rail
1G-48 Fuel System: D13A
Installation
1) Install new sealing rings (1) to camshaft housing.
2) Install new sealing washer (3) to fuel injectors (2).
3) Set fuel injector brackets (4) to fuel injectors.
4) Install fuel injectors to camshaft housing, and tighten
fuel injector bracket nut (5) temporarily by hand.
5) Install new high pressure pipes (6) and tighten each
union nut temporarily by hand.
6) Tighten fuel injector bracket nut to specified torque.
Tightening torque
Fuel injector bracket nut (a): 20 N·m (2.0 kgf-m,
15.0 lbf-ft)
5, (a)
6 1
4
2 2) Install new high pressure pipes. Tighten each union
1
3
IJHB0A173014-01
7) Tighten high pressure pipe union nuts to specified
torque. (Page 1G-45)
8) Connect return hose (3) to fuel injectors, and then
install clips (2) to fuel injectors.
9) Connect fuel injector connectors (1).
2
1 torque. (Page 1G-45)
IJHB0B172006-01
10) Connect negative (–) cable at battery.
11) Check for fuel leakage. (Page 1G-41)
12) When replacing any one of injectors, register injector
calibration code in ECM. (Page 1C-22)
Common Rail Removal and Installation
AENJHB0B1726010
Before performing the following procedure, observe
“Precautions for Fuel System Service”: D13A (Page 1G-
29).
Removal
1) Release fuel pressure. (Page 1G-41)
2) Disconnect negative (–) cable at battery.
3) Remove high pressure pipes. (Page 1G-45)
4) Disconnect connector (1) from fuel pressure sensor.
5) Remove common rail (2) from its bracket (3).
3
IJHB0B172007-01
Installation
1) Install common rail (1) to its bracket (2) and tighten
common rail bolts (3) temporarily by hand.
nut temporarily by hand.
3) Tighten common rail bolts to specified torque.
Tightening torque
Common rail bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-
ft)
4) Connect connector (4) to fuel pressure sensor.
3, (a)
2
1
IJHB0B172008-01
5) Tighten high pressure pipe union nuts to specified
6) Connect negative (–) cable at battery.
7) Check for fuel leakage. (Page 1G-41)
 Fuel System: D13A 1G-49

High Pressure Pump Removal and Installation
AENJHB0B1726011
Before performing the following procedure, observe
“Precautions for Fuel System Service”: D13A (Page 1G-
29).
7) Disconnect fuel flow actuator connector (1).
8) Remove vacuum pump.(Page 1D-85)
9) Remove high pressure pump (2) from camshaft
housing.

Removal
1) Release fuel pressure. (Page 1G-41)
2) Remove battery from vehicle. (Page 1J-16) 2
3) With hose connected, move degassing tank (1) in
arrow direction to release it from stay.

1
IJHB0A173019-01

Installation
IJHB0A173017-01
4) Disconnect fuel feed hose (2).
5) Remove high pressure pipe (1) between common
rail and high pressure pump. (Page 1G-45)
6) Disconnect fuel return hose (3) from high pressure
pump.
1) Clean mating surfaces of high pressure pump and
camshaft housing.
2) Install new gasket (1) to high pressure pump.
3) Install high pressure pump (2) to camshaft housing.
Fit dogs (3) of high pressure pump coupling into the
grooves (4) in camshaft.
4) Tighten high pressure pump bolts (5) to specified
torque.
Tightening torque
High pressure pump bolt (a): 15 N·m (1.5 kgf-m,
11.0 lbf-ft)

2
3 2

5, (a)
1
4
1

IJHB0A173018-01
3

IJHB0A173020-01

5) Install vacuum pump.(Page 1D-85)

6) Connect fuel flow actuator connector.
1G-50 Fuel System: D13A

7) Install new high pressure pipe (1) between high Installation

pressure pump and common rail. (Page 1G-45) 1) Install fuel pressure sensor (1) to common rail.
8) Connect fuel feed hose (2) and return hose (3) to Tighten fuel pressure sensor to specified torque.
high pressure pump.
Tightening torque
Fuel pressure sensor (a): 70 N·m (7.1 kgf-m,
52.0 lbf-ft)
2) Connect fuel pressure sensor connector (2).
2
3

IJHB0A173018-01

9) Connect negative (–) cable at battery.

10) Check for fuel leakage. (Page 1G-41)
Fuel Pressure Sensor Removal and Installation
AENJHB0B1726012
NOTE
If fuel pressure sensor is replaced, initialize
fuel pressure sensor data in ECM.
For details, refer to “Rail Pressure Sensor
Initialization”: D13A in Section 1C (Page 1C-
22).
Before performing the following procedure, observe
“Precautions for Fuel System Service”: D13A (Page 1G-
29).
1, (a)
IJHB0A173024-01
3) Install intercooler outlet pipe No.3. (Page 1D-83)
4) Install air cleaner assembly. (Page 1D-82)
5) Connect negative (–) cable at battery.
6) Check for fuel leakage. (Page 1G-41)
Fuel Flow Actuator On-Vehicle Inspection
AENJHB0B1726013
Check resistance between terminals of fuel flow
actuator.
If check result is not as specified, replace high pressure
pump. (Page 1G-49)

Removal Fuel flow actuator resistance

2.5 – 3.1 Ω at 20 °C (68 °F)
1) Release fuel pressure. (Page 1G-41)
2) Disconnect negative (–) cable at battery.
3) Remove air cleaner assembly. (Page 1D-82)
4) Remove intercooler outlet pipe No.3. (Page 1D-
83)
5) Disconnect connector (1) from fuel pressure sensor.
6) Remove fuel pressure sensor (2) from common rail.

2 IJHB0A173025-01

IJHB0A173022-01
 Fuel System: D13A 1G-51

Fuel Line and Connection Inspection Removal

AENJHB0B1726014
1) Disconnect negative (–) cable at battery.
! WARNING
2) Disconnect fuel pipe joints (1), fuel filter (2) and fuel
Fuel in the fuel feed line (1) is under high hose (3) from fuel pipes (4) at both front and rear
pressure and can spray out causing a fire ends of each fuel pipe. (Page 1G-39)
and/or personal injury. 3) Mark the locations of clamps (5) on fuel pipes, so
Use special care when checking the fuel feed that the clamps can be reinstalled to original
line. locations.

Before performing the following procedure, observe [A]

“Precautions for Fuel System Service”: D13A (Page 1G-
29).
Visually check fuel lines and connections for evidence of
fuel leakage, crack and deterioration of hose or other 3
damage.
Check that all clamps are secure.
4
Replace hoses that show sign of crack.
5
2

IJHB0A173027-01

[B]
1

IJHB0A173026-01 5
4
Fuel Pipe Removal and Installation
AENJHB0B1726015
IJHB0A173028-01
Before performing the following procedure, observe
“Precautions for Fuel System Service”: D13A (Page 1G- [A]: Engine side [B]: Fuel tank side

29).
4) Remove fuel pipes (1) together with clamps (2) from
vehicle.
5) Remove clamps from pipes.

2
2
2
1
2
2
IJHB0A173029-01
1G-52 Fuel System: D13A

Installation Fuel Tank Inlet Valve Removal and Installation

AENJHB0B1726017
1) Install clamps to marked locations on pipes. Replace Removal
any clamp that is deformed or its claw is bent or
1) Remove fuel tank filler hose from fuel tank. (Page
broken with new one.
1G-53)
2) Install pipes with pipe clamps to vehicle.
2) Remove fuel tank inlet valve (1) using flat-bladed
3) Connect fuel pipe joints, fuel filter and fuel hose to screwdriver (2) or the like.
pipes. (Page 1G-39)
NOTICE
! WARNING
Failure to take adequate precautions when
Failure to take proper precautions when removing the fuel tank inlet valve, the valve
reinstalling the fuel tank connections can may be damaged.
result in fuel leakage or damage. Be careful not to damage the fuel tank inlet
Clean the outside surface of the pipe where valve when using the flat-bladed screwdriver
each quick joint is to be installed, push the or the like.
pipe into the joint until the joint lock clicks,
and then check that the pipe is connected
securely.

4) Check for fuel leakage. (Page 1G-41)

Fuel Filler Cap Inspection

AENJHB0B1726016
Remove cap (1), and check gasket for even filler neck
imprint, deterioration or any damage. If gasket (2) is
defective, replace cap.

NOTICE IDL10A170016-01

Failure to use correct cap can result in EVAP

leakage. Installation
If cap requires replacement, use a cap with 1) Install fuel tank inlet valve (1) to fuel tank.
genuine SUZUKI parts.

I2RH0B170018-01

2) Install fuel tank filler hose to fuel tank. (Page 1G-

1 53)

I9W10P170020-01
 Fuel System: D13A 1G-53

Fuel Tank Inlet Valve Inspection 3) Insert hose of a hand operated pump into fuel filler
AENJHB0B1726018 hose (1) and drain fuel in space “a” as shown in
Check fuel tank inlet valve for the following points.
figure.
If any damage or malfunction is found, replace fuel tank
inlet valve. ! WARNING
• No damage or deformation
There is a risk of fire or explosion due to
• Smooth opening and closing static electricity if the drained fuel is stored in
an open container or plastic container.
Store the fuel in a sealed metal container.

NOTICE
The hose of the hand operated pump could
damage the fuel tank inlet valve if excessive
force is applied when inserting or removing it
from the fuel tank.
Do not apply excessive force when inserting
or removing the hose of the hand operated
IJHB0A173030-01 pump.

Fuel Tank On-Vehicle Inspection

AENJHB0B1726019 1
Check fuel tank for damage, crack, deformation, fuel
leakage, corrosion and tank bolts looseness. “a”
Repair or replace fuel tank if defective.

IBP70A170006-01

4) Hoist vehicle.
5) Disconnect breather hose (1) and fuel tank filler hose
(2) form fuel filler neck (3) and turn plastic clamp (4).

NOTICE
The plastic clamp could be damaged if
excessive force is applied when turning it.
Turn plastic clamp carefully.

IJHB0A173031-01

Fuel Tank Removal and Installation

AENJHB0B1726020
Before performing the following procedure, observe 1
3
“Precautions for Fuel System Service”: D13A (Page 1G-
2
29).

Removal 4
1) Disconnect negative (–) cable at battery.
2) Remove fuel filler cap.

IJHB0A173032-01

6) Remove exhaust center pipe. (Page 1K-8)

1G-54 Fuel System: D13A

7) Disconnect quick joints (1) from fuel pipes (2). Installation

(Page 1G-39)
! WARNING
Failure to take proper precautions when
reinstalling the fuel tank connections can
result in fuel leakage or damage.
Clean the outside surface of the pipe where
each quick joint is to be installed, push the
pipe into the joint until the joint lock clicks,
and then check that the pipe is connected
2
securely.

1
1) Install fuel tank inlet valve, if removed. (Page 1G-
52)
IJHB0A173033-01
2) Install fuel tank filler hose to fuel tank, if removed.
8) Disconnect fuel pump connector (1). (Page 1G-39)
3) Raise fuel tank with jack and connect fuel pump
connector.
1
4) Install fuel tank (1) to vehicle and tighten new fuel
tank bolts (2) to specified torque.

NOTICE
The fuel tank bolts are pre-coated with
friction stabilizer. If the bolts are reused, they
may work loose.
Use the new fuel tank bolts.

Tightening torque
Fuel tank bolt (a): 45 N·m (4.6 kgf-m, 33.5 lbf-ft)

IJHB0B172009-01

9) Support fuel tank (1) with jack (2) and remove its
mounting bolts. 2, (a)

2, (a)
1

IJHB0A173035-01

IJHB0A173034-01

10) Remove fuel tank.

11) Remove fuel tank filler hose, if necessary.
12) Remove fuel tank inlet valve, if necessary. (Page
1G-52)
 Fuel System: D13A 1G-55

5) Connect fuel breather hose (1) and fuel tank filler
hose (2).
For proper installation, refer to “Fuel Hose
Disconnection and Reconnection”: D13A (Page 1G-
39).
6) Turn plastic clamp (3).
Fuel tank filler hose bulge is not in good shape
Bulge “C”: In excess contact with pipe
Bulge “D”: In poor contact with pipe
“C”

NOTICE
The plastic clamp could be damaged if
excessive force is applied when turning it.
Turn plastic clamp carefully.

1 “D”
IFRA0A171017-01

8) Connect quick joints (1) to fuel pipes (2). (Fuel Hose

2
Disconnection and Reconnection)

2
IJHB0A173036-01

7) Visually check bulge on fuel tank filler hose. Repeat 1

Step 5) – 6) if check result is not as specified.
Fuel tank filler hose bulge is in good shape
Bulge “A” = “B”: In uniform contact with pipe
“A”
IJHB0A173033-01
9) Install exhaust center pipe. (Page 1K-8)
10) Install fuel filler cap.
11) Connect negative (–) cable at battery.
12) With engine stopped, set ignition “ON” and check for
fuel leakage. (Page 1G-41)

Fuel Tank Inspection

AENJHB0B1726021
• Check fuel tank for cracks, deformation or damage.
• Check fuel tank inlet valve for damage, smooth
opening and closing.
If faulty condition is found, replace fuel tank inlet
“B” valve.
IFRA0A171016-01
• Check fuel pump O-ring for fuel leakage. If faulty
condition is found, replace O-ring.
• Check hoses and pipes connected to fuel tank for
leaks, loose connections, deterioration or damage. If
faulty condition is found, replace hoses and/or pipes.
1G-56 Fuel System: D13A

Fuel Tank Flushing Procedure 2) Check that fuel pressure is felt at fuel feed hose (1)
AENJHB0B1726022 for about 20 sec. after setting ignition “ON”.
If fuel pressure is not felt, check fuel line for fuel
! WARNING
leakage and clogging.
This flushing procedure cannot remove all
fuel vapors in the fuel tank completely, so
using a flame or electric heater to dry the fuel 1
tank will increase the risk of an explosion
which may cause human injury.
Do not use a flame and/or electric heater to
dry the fuel tank.

Before performing the following procedure, observe

“Precautions for Fuel System Service”: D13A (Page 1G-
29)
1) After removing fuel tank, remove all hoses, pipes
and fuel pump assembly from fuel tank.
2) Drain all remaining fuel from tank.
3) Place fuel tank in flushing area.
4) Fill tank with warm water or tap water, and agitate
vigorously and drain out water. Repeat this operation
until inside of tank is clean.
5) Completely empty tank of remaining water.
6) Dry fuel tank assembly thoroughly in a place not
exposed to direct sunlight.
Fuel Pump On-Vehicle Inspection
AENJHB0B1726023
1) Remove fuel filler cap and set ignition “ON”. Fuel
pump operation sound should be heard from fuel
filler (1) for about 20 sec. Reinstall fuel filler cap. If
check result is not as specified, go to “Low-Pressure
Fuel Supply Circuit Check”: D13A (Page 1G-32).
IJHB0A173037-01
Fuel Pump Assembly Removal and Installation
AENJHB0B1726024
NOTICE
The fuel pump assembly will lose its original
performance if it is disassembled.
Do not disassemble and repair the fuel pump
assembly. If any faulty condition is found,
replace the fuel pump assembly with a new
one.
Removal
1) Remove fuel tank from vehicle. (Page 1G-53)
2) Disconnect quick joints (1) from fuel pump. (Page
1G-39)
3) Disconnect fuel pump connector (2) and remove
ground wire (3).

3 1

IJHB0A173038-01
IAW101170034-01
 Fuel System: D13A 1G-57

4) Remove fuel pump plate (1), fuel pump assembly (2) 4) Tighten fuel pump assembly bolts (1) to specified
and fuel pump gasket (3) from fuel tank. torque.
Tightening torque
1
Fuel pump assembly bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
5) Positioning ground cable (2) to specified angle as
shown, tighten fuel pump assembly bolt (3) to
specified torque.
Position range for ground cable
“a”: 45°
Tightening torque
2 Fuel pump assembly bolt (a): 10 N·m (1.0 kgf-m,
3
7.5 lbf-ft)
6) Connect quick joint (4) to fuel pump assembly.
(Page 1G-39)
7) Connect fuel pump connector (5) to fuel pump
IJHB0A173039-01 assembly.

Installation
1, (a) 1, (a)
! WARNING
Failure to take proper precautions when 5
2 4
reinstalling the fuel tank connections can
result in fuel leakage or damage.
Clean the outside surface of the pipe where
each quick joint is to be installed, push the
pipe into the joint until the joint lock clicks,
and then check that the pipe is connected 3, (a)
1, (a)
securely.

1) Clean mating surfaces of fuel pump assembly and

fuel tank.
2) Install new gasket (1) and fuel pump assembly (2).
3) Put fuel pump plate (3) on fuel pump assembly by [f] “a” “a”
matching the protrusion (4) of fuel pump assembly to IJHB0B172010-01
plate hole (5). [f]: Forward

3
8) Install fuel tank to vehicle. (Page 1G-53)

Fuel Pump Inspection

5 AENJHB0B1726025
• Check fuel pump assembly for damage.
2 • Check fuel suction filter for evidence of dirt and
contamination. If check result is not OK, replace or
4
1
clean and check for presence of dirt in fuel tank.

IJHB0A173040-01
1G-58 Fuel System: D13A

Fuel Level Sensor Inspection 5) Remove fuel filter assembly.

AENJHB0B1726026
Check resistance between terminals “3” and “4” at each 6) By turning lower housing (1) counterclockwise,
float position indicated below. remove lower housing from upper housing (2) using
If check result is not as specified, replace fuel level vise (3).
sensor. 7) Remove fuel filter element.
Fuel level sensor specifications 1
Float position Resistance (Ω)
“a” 113.0 mm (4.448 in.) 38 – 42
“b” 68.5 mm (2.696 in.) 157 – 163 3
“c” 18.0 mm (0.709 in.) 276 – 284
2

3 4

IHL10A172040-01

Installation
Reverse removal procedure noting the following points.
• Replace fuel filter element and gasket with new ones.
1
• Clean fuel filter case as follows.
a. Place container under bleed screw, and drain out
fuel by loosening bleed screw.
b. Tighten bleed screw.
c. Remove upper housing.
d. Clean upper housing with brush.
e. Dry and wipe out upper housing.
“a” • Tighten lower housing (1) to specified torque using
2
vise (2).
Tightening torque
“b”
Lower housing (a): 28 N·m (2.9 kgf-m, 21.0 lbf-ft)
“c”
IJHB0A173042-01
1, (a)
1. Fuel pump 2. Float

Fuel Filter Element Removal and Installation 2

AENJHB0B1726027
Removal
1) Remove battery and battery tray. (Page 1J-16)
2) Place container under bleed screw (1), and drain out
fuel by loosening bleed screw.
IHL10A172041-01

• Install battery and battery tray. (Page 1J-16)

• Bleed fuel system. (Page 1G-41)
• Check for fuel leakage. (Page 1G-41)

1
IJHB0A173043-01

3) Disconnect fuel filter joint from fuel filter assembly.

(Page 1G-39)
4) Disconnect connector from fuel filter assembly.
 Fuel System: D13A 1G-59

Fuel Filter Assembly Removal and Installation 2) Check resistance between fuel temperature sensor
AENJHB0B1726028 terminals.
Removal
If check result is not as specified, replace fuel filter
1) Disconnect fuel joints and connector in the same assembly.
manner as in Step 1) – 4) of “Removal” under “Fuel
Filter Element Removal and Installation”: D13A Fuel temperature sensor resistance
(Page 1G-58). Fuel temperature °C (°F) Resistance (kΩ)
2) Remove fuel filter assembly (1) from fuel filter –30 (–22) 23.6 – 28.6
bracket (2). 0 (32) 5.47 – 6.33
25 (77) 1.94 – 2.17
60 (140) 0.57 – 0.61
1 100 (212) 0.18 – 0.19
115 (239) 0.12 – 0.13

2
IJHB0A173044-01

Installation
Reverse removal procedure noting the following points.
• Bleed fuel system. (Page 1G-41) IHL10A172043-01
• Check for fuel leakage. (Page 1G-41)
Water Detection Sensor
Water Detection Sensor with Fuel Temperature 1) Connect battery (1), voltmeter (2) and resistance (3
Sensor Removal and Installation kΩ) (3) to connector (4) of water detection sensor on
AENJHB0B1726029 fuel filter assembly as shown in figure.
Removal
Remove water detection sensor with fuel temperature 2) Check voltage between terminal (5) and battery
sensor (included in upper housing). (Page 1G-58) negative (–) terminal.

5
Installation
Reverse removal procedure.
2

Water Detection Sensor with Fuel Temperature 4

Sensor Inspection
AENJHB0B1726030

Fuel Temperature Sensor 3

1) Remove water detection sensor with fuel

1
temperature sensor. (Page 1G-59)

IHL10A172044-01

If the voltage is alarm condition, drain water. (Page

1G-41)
Fuel filter water detection sensor voltage
Normal condition: 11.5 V or more
Alarm condition (trapped water exceeds limit):
Approx. less than 1.5 V
1G-60 Fuel System: D13A

Specifications
Tightening Torque Specifications
AENJHB0B1727001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Bleed screw 1.0 0.10 1.0 (Page 1G-41)
High pressure pipe union nut (fuel injector side (Page 1G-46)
24 2.4 18.0
and high pressure pump side)*
High pressure pipe union nut (common rail (Page 1G-46)
25 2.5 18.5
side)*
Fuel injector bracket nut 20 2.0 15.0 (Page 1G-48)
Common rail bolt 25 2.5 18.5 (Page 1G-48)
High pressure pump bolt 15 1.5 11.0 (Page 1G-49)
Fuel pressure sensor 70 7.1 52.0 (Page 1G-50)
Fuel tank bolt 45 4.6 33.5 (Page 1G-54)
Fuel pump assembly bolt (Page 1G-57) /
10 1.0 7.5
(Page 1G-57)
Lower housing 28 2.9 21.0 (Page 1G-58)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fuel Hose Disconnection and Reconnection”: D13A (Page 1G-39)
“Fuel System Components”: D13A (Page 1G-42)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Special Tool
AENJHB0B1728001
09911M75420 09912M58432
Crowfoot flare-nut wrench Fuel pressure gauge hose
18.17 This tool is included in fuel
(Page 1G-45) / pressure gauge set (09912-
(Page 1G-46) 58413).
(Page 1G-34) /
(Page 1G-35)
09912M96540 09914M08410
Injector flow measuring kit Gauge, diesel fuel pressure
Mot. 1711 (Page 1G-34) /
(Page 1G-37) (Page 1G-35)

09919M47020 09919M48410
Quick joint remover Fuel pressure gauge
adapter set
(Page 1G-40) (Page 1G-34) /
(Page 1G-35)
 Fuel System: D13A 1G-61

09950M76510 SUZUKI scan tool (Suzuki

SDT-II)
Pipe spanner —
OUT0000148 (Page 1G-41)
(Page 1G-45) /
(Page 1G-46)
1H-1 Ignition System:

Ignition System
Engine

General Description
Ignition System Construction
AENJHB0B1801001
The ignition system is of an electronic ignition type which consists of the following components.
• ECM
It monitors the engine and vehicle conditions through the signals from the sensors, determines the most suitable
ignition timing and duration and sends a signal to the ignition coil assembly.
• Ignition coil assembly
One ignition coil assembly is provided for each cylinder.
The ignition coil assembly turns on and off the current to the primary coil according to the signal from ECM. When
the current flow to the primary coil is turned off, a high voltage is induced in the secondary coil.
• Spark plugs
• CMP sensor and CKP sensor
Using signals from these sensors, ECM identifies the specific cylinder whose piston is in the compression stroke,
detects the crank angle and adjusts initial ignition timing automatically.
• TP sensor, ECT sensor, MAP sensor, IAT sensor, knock sensor and other sensors / switches
Using signals from these sensors / switches, the ECM corrects the initial ignition timing and sets the optimum timing
according to the engine conditions.
 Ignition System: 1H-2

Schematic and Routing Diagram

Ignition System Circuit Diagram
AENJHB0B1802001

A1
A2 3 13
WHT 4 B1
B2 7 5V
8 C1 5V
BRN C01-44
C2
GRN C01-33
A3
A4 5
WHT 6 B3
B4 9 5V
10 C3 5V
PNK C01-34
C4
LT BLU C01-35
2
1 WHT E01-1

+B
5V
11
PPL C01-30

5V
12

PNK C01-39

BLK

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHB0A180001-01

[A]: ECM connector (View: [a]) 3. Ignition coil assembly No.1 9. Spark plug No.3
A1 – A4: Ignition coil assembly power supply circuits 4. Ignition coil assembly No.2 10. Spark plug No.4
B1 – B4: Ignition coil assembly drive circuits 5. Ignition coil assembly No.3 11. CMP sensor
C1 – C4: Ignition coil assembly ground circuits 6. Ignition coil assembly No.4 12. CKP sensor
1. To ignition power supply 7. Spark plug No.1 13. ECM
2. “IG” fuse 8. Spark plug No.2
1H-3 Ignition System:

Component Location
Ignition System Component Location
AENJHB0B1803001

3
4
5
6

IJHB0A180002-01

1. ECM 4. Ignition coil assembly No.2 7. CMP sensor

2. CKP sensor 5. Ignition coil assembly No.3
3. Ignition coil assembly No.1 6. Ignition coil assembly No.4
 Ignition System: 1H-4

Diagnostic Information and Procedures

Ignition System Check
AENJHB0B1804001
Circuit Diagram

A1
A2 3 13
WHT 4 B1
B2 7 5V
8 C1 5V
BRN C01-44
C2
GRN C01-33
A3
A4 5
WHT 6 B3
B4 9 5V
10 C3 5V
PNK C01-34
C4
LT BLU C01-35
2
1 WHT E01-1

+B
5V
11
PPL C01-30

5V
12

PNK C01-39

BLK

[A] C01 E01

[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHB0A180001-01

[A]: ECM connector (View: [a]) 3. Ignition coil assembly No.1 9. Spark plug No.3
A1 – A4: Ignition coil assembly power supply circuits 4. Ignition coil assembly No.2 10. Spark plug No.4
B1 – B4: Ignition coil assembly drive circuits 5. Ignition coil assembly No.3 11. CMP sensor
C1 – C4: Ignition coil assembly ground circuits 6. Ignition coil assembly No.4 12. CKP sensor
1. To ignition power supply 7. Spark plug No.1 13. ECM
2. “IG” fuse 8. Spark plug No.2
1H-5 Ignition System:

Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K15B in
Section 1A (Page 1A-
21).
2 Ignition spark test 1 Go to Step 3. Go to Step 4.
1) Perform ignition spark test. (Page 1H-6)

Is test result OK?

3 Ignition timing check Ignition system is in Repair or replace
1) Check ignition timing. (Page 1H-8) good condition. defective part.

Is check result OK?

4 Confirmation of malfunctioning cylinder Go to Step 7. Go to Step 5.
1) Check cylinder(s) that failed in ignition spark test.

Did all cylinders fail in ignition spark test?

5 Ignition spark test 2 Replace spark plug. Go to Step 6.
1) Replace spark plug of each malfunctioning cylinder with (Page 1H-7)
normal cylinder’s one.
2) Perform ignition spark test. (Page 1H-6)

Is test result OK?

6 Ignition spark test 3 Replace ignition coil. Go to Step 7.
1) Replace ignition coil of each malfunctioning cylinder with (Page 1H-8)
normal cylinder’s one.
2) Perform ignition spark test. (Page 1H-6)

Is test result OK?

7 Ignition coil assembly power supply and ground circuit Go to Step 8. Repair or replace
check defective wiring
1) Check power supply (“A1”, “A2”, “A3” and “A4”) and harness.
ground (“C1”, “C2”, “C3” and “C4”) circuits of each
ignition coil assembly for open, short and poor
connection.

Is check result OK?

 Ignition System: 1H-6

Step Action Yes No

8 Ignition coil assembly drive circuit check Go to Step 9. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wiring
connectors from ECM. harness.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1”, “B2”, “B3” and “B4” circuits: less
than 1 Ω
• Resistance between each of “B1”, “B2”, “B3” and “B4”
circuits and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “B2” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “B3” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “B4” circuit terminal and other
terminal at ignition coil connector: infinity
• Voltage of “B1”, “B2”, “B3” and “B4” circuits: approx. 0
V (When ignition is “ON”)

Is check result OK?

9 CKP sensor and CMP sensor check Replace ECM and Replace CKP sensor or
1) Check CKP sensor and CMP sensor. recheck ignition spark. CMP sensor.
(Page 1C-2)
• CKP sensor: (Page 1C-11)
• CMP sensor: (Page 1C-10)

Is check result OK?

Ignition Spark Test

AENJHB0B1804002
! WARNING
If this test is performed without
disconnecting the injector connectors, a
spark from a plug may ignite fuel vapor 2
coming out of the spark plug holes during the
test, causing a fire or explosion.
1
Disconnect the injector connectors from the
injectors before performing this test.

1) Remove spark plugs. (Page 1H-7) 3

2) Check spark plugs. (Page 1H-7) IJHA0A180003-01

3) Remove air cleaner assembly. (Page 1D-9)
4) Disconnect all fuel injector connectors.
5) Connect ignition coil connector (1) to ignition coil
assembly (3).
6) Connect spark plug (2) to ignition coil assembly, and
ground spark plug.
7) Crank engine and check if each spark plug sparks.
8) If no spark is emitted, check the related parts.
(Page 1H-4)
9) Connect all fuel injector connectors.
10) Install air cleaner assembly. (Page 1D-9)
11) Install spark plugs. (Page 1H-7)
1H-7 Ignition System:

Repair Instructions
Spark Plug Removal and Installation Check spark plug air gap “a” using special tool.
AENJHB0B1806001 If out of specification of the air gap or any other
Removal
abnormality is found with iridium spark plug, replace it
1) Remove ignition coil assemblies. (Page 1H-8) with new plug.
2) Remove spark plugs.
Spark plug air gap “a”
: 0.95 – 1.05 mm (0.037 to 0.041 in.)
Installation
1) Install spark plugs and tighten them to specified Spark plug type
torque. NGK: KR6A-10

Tightening torque Special tool

Spark plug: 18 N·m (1.8 kgf-m, 13.5 lbf-ft) (A): 09930M77410

2) Install ignition coil assemblies. (Page 1H-8)

Spark Plug Inspection

AENJHB0B1806002
Check spark plug for:
• Electrode wear
• Carbon deposits
• Insulator damage
• Spark plug air gap
IHSB0A181001-01

IYSQ01181012-01
 Ignition System: 1H-8

Ignition Coil Assembly Removal and Installation Ignition Coil Assembly Inspection
AENJHB0B1806003 AENJHB0B1806004
Removal Check ignition coil assembly for the following points:
1) Disconnect ignition coil connectors. • Damage
2) Remove ignition coil bolts (1) and then pull out • Deterioration
ignition coil assemblies (2). • Corrosion on terminals
If check result is not OK, replace ignition coil assembly.
1
Ignition Timing Inspection
AENJHB0B1806005
NOTE
For identification of each ignition coil
assembly, refer to “Ignition System
Component Location” (Page 1H-3).
2
1) Connect SUZUKI scan tool to DLC (1) with ignition
IJHA0A180004-01 “OFF”.
Special tool
Installation
(A): SUZUKI scan tool (Suzuki SDT-II)
Reverse removal procedure noting the following point.
• Tighten ignition coil bolts (1) to specified torque.
Tightening torque
Ignition coil bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)

1, (a)

IGRA0A183002-01

(A)

IJHA0A110021-01

2) Start engine and warm it up to normal operating

temperature.
3) Check that all electrical loads except ignition system
are switched off.
4) Check that idle speed is within specification referring
to “Idle Speed Inspection”: K15B in Section 1A (Page
1A-165).
1H-9 Ignition System:

5) Grip ignition coil No.1 harness (1) by probe of timing 7) If check result is not as specified, check the following
light (2) directing arrow (3) at ignition coil side, and points.
check that ignition is within specification. • CKP sensor and sensor plate: (Page 1C-11)
Special tool • ECM and its circuit: (Page 1A-150)
(A): 09930M76311 • CMP sensor: (Page 1C-10)
6) Fix ignition timing using “Fixed Spark” function in • Signal rotor: (Page 1D-14)
“Active Test” mode on scan tool. • Crankshaft: (Page 1D-68)
Initial ignition timing • Crankshaft pulley
Fixed with SUZUKI scan tool: –10 to 10° BTDC • Crankshaft sprocket key
(at specified idle speed) 8) After checking initial ignition timing, release ignition
Ignition order timing fixation using scan tool.
1–3–4–2 9) With engine idling (throttle opening at default
position and vehicle stopped), check that ignition
2, (A) timing is about –10 to 10° BTDC (Constant variation
within a few degrees from –10 to 10° BTDC indicates
no abnormality but proves operation of ignition
timing control system.) Also, check that increasing
engine speed advances ignition timing.
If check result is not as specified, check the following
points.
• ECM and its circuit: (Page 1A-150)
3 1 • TP sensor: (Page 1C-4)
• APP sensor: (Page 1C-6)
IFRA0A180006-03

2, (A)

4
5

IJHB0A180003-01

4. TDC 6. 10° BTDC

5. 5° BTDC

Specifications
Tightening Torque Specifications
AENJHB0B1807001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Spark plug 18 1.8 13.5 (Page 1H-7)
Ignition coil bolt 11 1.1 8.5 (Page 1H-8)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0A (Page 0A-5)
 Ignition System: 1H-10

Special Tools and Equipment

Special Tool
AENJHB0B1808001
09930M76311 09930M77410
Timing light Plug gap gauge
(Page 1H-9) (Page 1H-7)

SUZUKI scan tool (Suzuki

SDT-II)
—
(Page 1H-8)
1I-1 Starting System: K15B

Starting System
Engine

K15B
General Description
Cranking System Description
AENJHB0B1911001
Cranking Circuit
The cranking circuit consists of the battery, starting motor, starting motor control relay, BCM (keyless push start
model), ignition switch (ignition switch model) or engine switch (keyless push start model), transmission range sensor
(A/T model) or CPP No.1 switch (M/T model), and related electrical wiring.

Starting Motor Circuit

In the circuit shown in “Cranking System Circuit Diagram”: K15B (Page 1I-1), the coil of the magnetic switch in starting
motor is energized when the engine starts. The resulting movement of the plunger and pinion drive lever causes the
pinion to engage with the drive plate (A/T model) or engine flywheel (M/T model), while closing the contacts of the
magnetic switch. This causes the starting motor to rotate to crank the engine.
When the engine starts, the pinion overrunning clutch protects the armature from excessive speed until the switch is
opened, at which time the return spring causes the pinion to disengage.

Schematic and Routing Diagram

Cranking System Circuit Diagram
AENJHB0B1912001

Ignition switch model

10

6 7

GRY GRN E01-17

5 8
RED LT GRN E01-43

4
WHT
3 YEL

IJHB0B191001-01

1. Battery 5. “ST” fuse 9. ECM

2. Main fuse box 6. Ignition switch 10. CPP No.1 switch (M/T model) or transmission range sensor (A/T model)
3. Starting motor 7. Starting motor control relay
4. “KEY2” fuse 8. “ST SIG2” fuse
 Starting System: K15B 1I-2

Keyless push start model

10

9
6
7

5 GRY GRN E01-17

4
RED YEL LT GRN E01-43
8

WHT 3

YEL
2

IJHB0B191002-01

1. Battery 5. BCM 9. ECM

2. Main fuse box 6. Engine switch 10. CPP No.1 switch (M/T model) or transmission range sensor (A/T model)
3. Starting motor 7. Starting motor control relay
4. “ST” fuse 8. “ST SIG2” fuse

Diagnostic Information and Procedures

Cranking System Symptom Diagnosis
AENJHB0B1914001
Possible symptoms of starting system trouble are as follows:
• Starting motor does not run (or runs slowly).
• Starting motor runs but fails to crank engine.
• Abnormal noise is heard.
Proper diagnosis must be made to determine in which of the battery, wiring harness, starting motor (including
magnetic switch) and engine the cause of each trouble lies.
Before removing the starting motor, check the following items to identify most possible cause of trouble.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine) and starting motor terminals
3) Discharge of battery
4) Mounting of starting motor
1I-3 Starting System: K15B

Condition Possible cause Correction / Reference Item

Starting motor not Malfunction of transmission range Check transmission range sensor. (Page 5A-
running (No operating sensor (A/T model) 131)
sound of magnetic Malfunction of CPP No.1 switch (M/T Check CPP No.1 switch. (Page 5C-3)
switch) model)
Battery voltage is too low Check battery. (Page 1J-2)
Impossible charging due to deteriorated Replace battery. (Page 1J-5)
battery
Poor battery terminal connection Check terminal connection or replace battery.
(Page 1J-5)
Poor ground cable connection Tighten ground cable.
Blown fuse Replace fuse and check its circuit.
Faulty magnetic switch Check magnetic switch. (Page 1I-11)
Poor magnetic switch lead wire Check connector connection. (Page 1I-4)
connector connection
Open circuit in pull-in coil Check pull-in coil circuit. (Page 1I-11)
Defective brushes and/or brush springs Check brushes and brush springs. (Page 1I-
11)
Poor sliding of plunger and/or pinion Check plunger and pinion. (Page 1I-11)
Faulty starting motor control relay Check starting motor control relay. (Page 1I-
4)
Faulty keyless push start system Check keyless push start system. (Page
(Keyless push start model) 10E-14)
Faulty ignition switch (Ignition switch Check ignition switch. (Page 6B-14)
model)
Starting motor not Battery voltage is too low Check battery. (Page 1J-2)
running (Operating sound Impossible charging due to deteriorated Replace battery. (Page 1J-5)
of magnetic switch heard) battery
Poor battery terminal connection Check terminal connection or replace battery.
(Page 1J-5)
Poor ground terminal connection Tighten ground cable.
Faulty magnetic switch Check magnetic switch. (Page 1I-11)
Defective brushes and/or brush springs Check brushes and brush springs. (Page 1I-
11)
Defective brush holder Check brush holder. (Page 1I-11)
Burnt commutator Check commutator. (Page 1I-11)
Short circuit between commutator and Check commutator. (Page 1I-11)
armature
Poor starting motor cable connection Check starting motor cable connection.
(Page 1I-4)
Open circuit between battery and Repair circuit.
magnetic switch
Obstructed crankshaft rotation Repair engine assembly.
Starting motor running Faulty magnetic switch Check magnetic switch. (Page 1I-11)
but too slow (small Low battery voltage Check battery. (Page 1J-2)
torque) Impossible charging due to deteriorated Replace battery. (Page 1J-5)
battery
Poor battery terminal connection Check terminal connection or replace battery.
(Page 1J-5)
Short circuit between commutator and Check commutator. (Page 1I-11)
armature
Burnt commutator Check commutator. (Page 1I-11)
Defective brushes and/or brush springs Check brushes and brush springs. (Page 1I-
11)
Defective brush holder Check brush holder. (Page 1I-11)
Defective end housing bushing Check end housing bushing. (Page 1I-11)
 Starting System: K15B 1I-4

Condition Possible cause Correction / Reference Item

Starting motor running, Worn pinion tip
but not cranking engine Poor sliding of overrunning clutch
Slipping overrunning clutch
Worn teeth of ring gear
Noise Abnormally worn bushing
Worn teeth of pinion
Worn teeth of ring gear
Replace overrunning clutch. (Page 1I-7)
Check overrunning clutch. (Page 1I-11)
Replace overrunning clutch. (Page 1I-7)
Replace flywheel (M/T model) or drive plate (A/
T model). (Page 1D-37)
Replace bushing. (Page 1I-7)
Replace overrunning clutch. (Page 1I-7)
Replace flywheel (M/T model) or drive plate (A/
T model). (Page 1D-37)

Repair Instructions
Starting Motor Control Relay Inspection
AENJHB0B1916001
Refer to “Control Relay Inspection” in Section 10B (Page 10B-61).

Starting Motor Removal and Installation

AENJHB0B1916002
Removal
1) Disconnect negative (–) cable at battery.
2) For M/T model, remove cable bracket as follows.
a) Remove gear shift and gear select control cables from transaxle. (Page 5B-11)
b) Remove cable bracket from transaxle. (Page 5B-10)
3) Remove starting motor mounting bolt (upper side) (1).
4) Disconnect magnetic switch lead wire (2) and starting motor cable (3) from starting motor.
5) Remove starting motor mounting bolts (lower side) (4).
6) Remove starting motor (5).

I9P60A191003-02
1I-5 Starting System: K15B

Installation
Reverse removal procedures noting the following point.
• Tighten starting motor cable nut (1) to specified torque.
Tightening torque
Starting motor cable nut (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)

IFRA0A191003-01
 Starting System: K15B 1I-6

Starting Motor Components

AENJHB0B1916003

(a) 7
A

9 A
8 A

10 A 5
4 (d)

2 A

3 1
(b)

14

13

(c) 15 A
12

11

IHL10A191003-02

1. Armature housing 8. Internal gear 15. Bushing

2. Bushing 9. Planetary carrier shaft : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
3. Snap ring 10. Planetary gear : 6.1 Nm (0.62 kgf-m, 4.5 lbf-ft)
4. Pinion stop ring 11. Yoke : 3.4 Nm (0.35 kgf-m, 2.5 lbf-ft)
5. Overrunning clutch 12. Armature : 5.9 Nm (0.60 kgf-m, 4.5 lbf-ft)
6. Drive lever assembly 13. Brush assembly : Apply grease 99000-25011 to sliding
surface of each part.
7. Magnetic switch 14. End housing : Do not reuse.
1I-7 Starting System: K15B

Starting Motor Disassembly and Reassembly 5) Remove bolts (1) and separate yoke from armature
AENJHB0B1916004 housing (2).
Disassembly
1) Before disassembly, draw matchmarks (1) and (2) as
shown in figure to assure proper alignment when
2
reassembled.

1
2 I8C50B190008-01

6) Remove grommet (2) and planetary gears (1).

I8C50B190005-01

2) Remove nut (1) and disconnect lead wire (2) from

magnetic switch (3).

I8C50B190009-01

7) Remove seal rubber (1) and plate (2).

1

I8C50B190006-01

3) Remove screws (4) and pull out magnetic switch (1)

from starting motor assembly.
4) Remove spring (2) and plunger (3) from magnetic
switch body.

4
I8C50B190010-01

8) Remove shaft assembly (1) together with drive lever

1 (2).

1 2 3

I8C50B190011-01
I8C50B190007-01
 Starting System: K15B 1I-8

9) With pinion stop ring (3) moved toward overrunning 13) Remove brushes (1) and brush springs (2).
clutch (4) side (in arrow direction), remove snap ring
(2) using snap ring pliers (5).
10) Remove pinion stop ring, overrunning clutch and
internal gear (1) from gear shaft.

1 1

2 2

I8C50B190012-01

11) Remove end housing (1) and remove brush

1 1
assembly (2) from yoke (3). I6JB01190014-01

Reassembly
2 1 1) Install brush springs (2) and brushes (1) to brush
holder (3).

1 1
3

I8C50B190013-01

12) Remove armature (1) from yoke (2).

2 2
2

1 1
I6JB01190015-01

I8C50B190014-02
1I-9 Starting System: K15B

2) Install armature (2) to yoke. 6) Install internal gear and overrunning clutch (1) to
3) Install brush assembly (1) to armature while pushing gear shaft (4) using new snap ring (3) and pinion
4 brushes (3) outward. stop ring (2).

NOTE
Install pinion stop ring in the direction and
position as shown in figure.
2
1

3
IYSQ01190024-01

7) Apply grease to drive lever (2) and insert shaft

assembly (1) into armature housing with drive lever
positioned as shown in figure.
“A”: Grease 99000–25011 (SUZUKI Super
3 Grease A)
I8C50B190015-01

4) Install end housing (1) to brush holder and tighten

brush holder screws (2) to specified torque.
Tightening torque
Brush holder screw (a): 3.4 N·m (0.35 kgf-m, 2.5
lbf-ft)

2, (a)

IAY301190005-02

8) With armature housing bolt holes (3) and cutouts in

grommet aligned, install grommet (1) in armature
housing.
9) Install plate (5) and seal rubber (4) to armature
housing.
1 10) Apply grease to planetary gears (2) and install
I8C50B190016-01
planetary gears to gear shaft.
5) Apply grease to spline of planetary carrier shaft (1)
and teeth of internal gear (2). “A”: Grease 99000–25011 (SUZUKI Super
Grease A)
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)

I9P60A191019-01

I8C50B190019-01
 Starting System: K15B 1I-10

11) Install yoke, armature, brush assembly and end
housing (4) to armature housing (2) while aligning
matchmarks (3) drawn before disassembly.
12) Tighten end housing bolts (1) to specified torque.
Tightening torque
End housing bolt (a): 6.1 N·m (0.62 kgf-m, 4.5
lbf-ft)
14) Install magnetic switch (1), spring (2) and plunger (3)
to armature housing (5) while aligning matchmarks
drawn before removal.
15) Tighten magnetic switch screws (4) to specified
torque.
Tightening torque
Magnetic switch screw (a): 5.9 N·m (0.60 kgf-m,
4.5 lbf-ft)

2 4, (a)

1, (a)

3 5

1 2 3
1, (a)
I8C50B190020-01

13) Apply grease to plunger.

“A”: Grease 99000–25011 (SUZUKI Super
I8C50B190022-01
Grease A)
16) Connect lead wire (1) to “M” terminal and tighten
lead wire nut (2) to specified torque.
Tightening torque
Lead wire nut (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)

I8C50B190021-01

I8C50B190023-01

17) Check magnetic switch for operation. (Page 1I-11)

1I-11 Starting System: K15B

Starting Motor Inspection 2) Perform hold-in test as follows.

AENJHB0B1916005
a) From the state of Step 1) with plunger and pinion
Starting Motor Operation Check in “out” position, disconnect negative (–) lead
from “M” terminal.
! CAUTION b) Check that plunger and pinion remain in “out”
Sparks resulting from a short circuit between position.
the positive (+) and negative (–) terminals If plunger and pinion return inward, replace
during connections to the battery may cause magnetic switch.
burns.
Be careful not to short circuit the positive (+)
and negative (–) cables, and connect them
only to the correct terminals.

NOTICE
If battery power is applied too long in any of
the following tests, coil of the magnetic
switch may burn.
Each test must be completed within 3 – 5
seconds to avoid burning of the coil. I2RH01190003-01

3) Perform plunger and pinion return test as follows.

1) Perform pull-in test as follows.
a) Disconnect lead wire (3) from “M” terminal (2).
b) Connect battery to magnetic switch as shown in
figure.
c) Check that plunger and pinion move outward.
If plunger and pinion do not move, replace
magnetic switch.
a) From the state of Step 2) with plunger and pinion
in “out” position, disconnect negative (–) lead
from starting motor body.
b) Check that plunger and pinion return inward.
If plunger and pinion do not return, replace
magnetic switch.

I2RH01190004-01

I2RH01190002-01

1. Terminal “S”
 Starting System: K15B 1I-12

4) Perform no-load performance test as follows. Pull-in coil open circuit test
a) Fix starting motor with vice or the like. Check for continuity between magnetic switch “S”
terminal (1) and “M” terminal (2). If there is no continuity,
b) Connect battery and ammeter to starting motor
replace magnetic switch.
as shown in figure.
c) Check that starting motor rotates smoothly and
steadily with pinion moving out.
d) Check that ammeter indicates specified current.
If check result is not as specified, repair or
replace starting motor.
Specified current (No-load performance test)
95 A MAX. at 11 V

I2RH01190010-01

Hold-in coil open circuit test

Check for continuity between magnetic switch “S”
terminal (1) and coil case. If there is no continuity,
replace magnetic switch.

I7V20A191004-01

Plunger
Check plunger for wear. Replace magnetic switch, if
defective.

I2RH01190011-01

End Housing Bushing

Check end housing bushing for wear or damage.
Replace bushing if defective.

I2RH01190008-01

Magnetic Switch
Check that plunger quickly returns to its original position
when plunger is pushed in with a finger and released. If
check result is not OK, replace magnetic switch.
I2RH01190012-01

I2RH01190009-01
1I-13 Starting System: K15B

Brush Armature
• Check brushes for wear. • Check commutator for dirt or burn. Correct
Measure length of each brush. If length is less than commutator with sandpaper or lathe, if defective.
the limit, replace brush assembly.
Brush length
Standard: 12.3 mm (0.48 in.)
Limit: 4.6 mm (0.18 in.)

I7RW01190005-02

1. Sandpaper of #300 – 400

• Check commutator for uneven wear with armature (1)

supported on V-blocks (2) using dial gauge (4). If dial
I2RH01190013-01
gauge deflection exceeds the limit, repair commutator
• After installing brushes into their holders, check that or replace armature.
movement of brushes is smooth.
Commutator out of round
Spring Standard: 0.05 mm (0.002 in.) or less
Check brush springs for wear, damage or other Limit: 0.1 mm (0.0039 in.)
abnormal conditions. Replace brush assembly if
defective.
Brush spring tension
Standard: 16 – 19 N (1.6 – 1.9 kgf, 3.6 – 4.3 lbf)
Limit: 2.7 N (0.28 kgf, 0.61 lbf)

Brush Holder
• Check brush holder for brush movement problems,
distortion, and dirt on sliding surface.
Clean or correct brush holder if defective.
• Check for continuity between insulated brush (positive I2RH01190016-01
(+) side) and grounded brush (negative (–) side). 3. Magnetic stand
If there is continuity, replace brush holder.
• Check commutator for wear and measure diameter of
commutator. If diameter of commutator is lower than
the limit, replace armature.
Commutator outside diameter
Standard: 29.4 mm (1.16 in.)
Limit: 28.4 mm (1.12 in.)

I4RS0A190004-01

I2RH01190017-01
 Starting System: K15B 1I-14

• Check commutator (1) for insulator (2) depth. Correct

insulator depth if it is smaller than limit.
Commutator insulator depth “a”
Standard: 0.75 mm (0.029 in.)
Limit: 0.5 mm (0.020 in.)

I2RH01190021-01

Pinion and Overrunning Clutch

• Check pinion for wear, damage or other abnormal
conditions.
• Check that clutch locks when turned in normal rotation
direction and rotates freely when turned in reverse
direction. Replace pinion and overrunning clutch if
defective.

I3RH0A190005-01

[A]: Correct [B]: Incorrect

• Check insulation between commutator and armature

core. If there is continuity, replace armature.

I2RH01190022-01

• Check spline teeth for wear or damage. If check result

is not OK, replace pinion and overrunning clutch.
• Check pinion for smooth movement.

I2RH01190019-01

• Check for continuity between segments. If there is no

continuity at any test point, replace armature.

I2RH01190023-01

Armature Housing Bushing

Check bushing for wear and damage. Replace bushing if
defective.

I2RH01190020-01

Gear
Check internal gear and planetary gears for wear,
damage or other abnormal conditions. Replace gear set
if defective.
I2RH01190024-01
1I-15 Starting System: K15B

Specifications
Cranking System Specifications
AENJHB0B1917001
Voltage 12 V
Output 1.0 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Number of pinion teeth 8
Performance Voltage Current Torque Revolution speed
No-load characteristic 11 V 95 A MAX — 2,500 rpm MIN
8.8 Nm (0.90 kgf-m,
Loaded characteristic 7.5 V 300 A 870 rpm MIN
6.5 lbf-ft) MIN
At around 20 °C
17 Nm (1.7 kgf-m, 12.5
(68 °F) Locked characteristic 4V 680 A MAX —
lbf-ft) MIN
Magnetic switch
8 volts MAX
operating voltage

Tightening Torque Specifications

AENJHB0B1917002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Starting motor cable nut 11 1.1 8.5 (Page 1I-5)
Brush holder screw 3.4 0.35 2.5 (Page 1I-9)
End housing bolt 6.1 0.62 4.5 (Page 1I-10)
Magnetic switch screw 5.9 0.60 4.5 (Page 1I-10)
Lead wire nut 11 1.1 8.5 (Page 1I-10)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Starting Motor Components”: K15B (Page 1I-6)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Recommended Service Material
AENJHB0B1918001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 (Page 1I-9) / (Page 1I-9)
/ (Page 1I-9) / (Page 1I-
10)

NOTE
Required service material(s) is also described in:
“Starting Motor Components”: K15B (Page 1I-6)
 Starting System: D13A 1I-16

D13A
General Description
Cranking System Description
AENJHB0B1921001
Cranking Circuit
The cranking circuit consists of the battery, starting motor, starting motor control relay, keyless start control module
(keyless push start model), ignition switch (ignition switch model) or engine switch (keyless push start model), CPP
No.1 switch, and related electrical wiring.

Starting Motor Circuit

In the circuit shown in (Page 1I-16), the coil of the magnetic switch in starting motor is energized when ignition is set
to “START”. The resulting movement of the plunger and pinion drive lever causes the pinion to engage with the engine
flywheel gear while closing the contacts of the magnetic switch. This causes the starting motor to rotate to crank the
engine.
When the engine starts, the pinion overrunning clutch protects the armature from excessive speed until the switch is
opened, at which time the return spring causes the pinion to disengage.

Schematic and Routing Diagram

Cranking System Circuit Diagram
AENJHB0B1922001

Ignition switch model

6 8 9
GRY GRN BLK

4
RED
5 10

BLK
YEL
GRN E01-91
3

2 7
LT GRN E01-83

1 M

IJHB0B192001-01

1. Battery 5. “KEY2” fuse 9. CPP No.1 switch

2. Main fuse box 6. Ignition switch 10. ECM
3. Starting motor 7. “ST SIG” fuse
4. “ST” fuse 8. Starting motor control relay
1I-17 Starting System: D13A

Keyless push start model

10
GRN BLK

6 9

7
5 GRY GRN GRN E01-91

4
RED YEL LT GRN E01-83
8
BLK

2
YEL

1 M

IJHB0B192002-01

1. Battery 5. Keyless start control module 9. ECM

2. Main fuse box 6. Engine switch 10. CPP No.1 switch
3. Starting motor 7. Starting motor control relay
4. “ST” fuse 8. “ST SIG” fuse

Diagnostic Information and Procedures

Cranking System Symptom Diagnosis
AENJHB0B1924001
Possible symptoms of starting system trouble are as follows:
• Starting motor does not run (or runs slowly).
• Starting motor runs but fails to crank engine.
• Abnormal noise is heard.
• Starting motor does not stop running.
Proper diagnosis must be made to determine in which of the battery, wiring harness, starting motor (including
magnetic switch) and engine the cause of each trouble lies.
Before removing the starting motor, check the following items to identify most possible causes of trouble.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine) and starting motor terminals
3) Discharge of battery
4) Mounting of starting motor
 Starting System: D13A 1I-18

Condition Possible cause Correction / Reference Item

Starting motor not Malfunction of CPP No.1 switch Check CPP No.1 switch. (Page 5C-3)
running (No operating Battery voltage is too low Check battery. (Page 1J-13)
sound of magnetic Impossible charging due to deteriorated Replace battery. (Page 1J-16)
switch) battery
Poor battery terminal connection Check terminal connection or replace battery.
(Page 1J-16)
Poor ground cable connection Tighten ground cable.
Blown fuse Replace fuse and check its circuit.
Faulty magnetic switch Check magnetic switch. (Page 1I-25)
Poor magnetic switch lead wire Check connector connection. (Page 1I-19)
connector connection
Open circuit in pull-in coil Check pull-in coil circuit. (Page 1I-25)
Poor sliding of plunger and/or pinion Check plunger and pinion. (Page 1I-25)
Faulty starting motor control relay Check starting motor control relay. (Page 1I-
19)
Faulty keyless push start system Check keyless push start system. (Page
(Keyless push start model) 10E-60)
Faulty ignition switch (Ignition switch Check ignition switch. (Page 6B-14)
model)
Starting motor not Battery voltage is too low Check battery. (Page 1J-13)
running (Operating sound Impossible charging due to deteriorated Replace battery. (Page 1J-16)
of magnetic switch heard) battery
Poor battery terminal connection Check terminal connection or replace battery.
(Page 1J-16)
Poor ground terminal connection Tighten ground cable.
Defective magnetic switch Check magnetic switch. (Page 1I-25)
Defective brushes and/or brush springs Check brushes and brush springs. (Page 1I-
25)
Faulty starter end frame Check starter end frame. (Page 1I-25)
Burnt commutator Check commutator. (Page 1I-25)
Short circuit between commutator and Check commutator. (Page 1I-25)
armature
Poor starting motor cable connection Check starting motor cable connection.
(Page 1I-19)
Open circuit between battery and Repair circuit.
magnetic switch
Obstructed crankshaft rotation Repair engine assembly.
Starting motor running Faulty magnetic switch Check magnetic switch. (Page 1I-25)
but too slow (small Low battery voltage Check battery. (Page 1J-13)
torque) Impossible charging due to deteriorated Replace battery. (Page 1J-16)
battery
Poor battery terminal connection Check terminal connection or replace battery.
(Page 1J-16)
Short circuit between commutator and Check commutator. (Page 1I-25)
armature
Burnt commutator Check commutator. (Page 1I-25)
Defective brushes and/or brush springs Check brushes and brush springs. (Page 1I-
25)
Defective starter end frame Check starter end frame. (Page 1I-25)
Defective starter housing bushing Check starter housing bushing. (Page 1I-25)
Starting motor running, Worn pinion tip Replace gear shaft assembly. (Page 1I-22)
but not cranking engine Poor sliding of overrunning clutch Replace gear shaft assembly. (Page 1I-22)
Slipping overrunning clutch Replace gear shaft assembly. (Page 1I-22)
Worn teeth of ring gear Replace flywheel. (Page 1D-105)
Noise Abnormally worn bushing Replace starter housing or starter end frame.
(Page 1I-22)
Worn teeth of pinion Replace gear shaft assembly. (Page 1I-22)
Worn teeth of ring gear Replace flywheel. (Page 1D-105)
1I-19 Starting System: D13A

Condition Possible cause Correction / Reference Item

Starting motor does not
stop running
Faulty magnetic switch
Faulty keyless push start system
(Keyless push start model)
Faulty ignition switch (Ignition switch
model)
Faulty starting motor control relay
Check magnetic switch. (Page 1I-25)
Check keyless push start system. (Page
10E-60)
Check ignition switch. (Page 6B-14)
Check starting motor control relay. (Page 1I-
19)

Repair Instructions
Starting Motor Control Relay Inspection
AENJHB0B1926001
Refer to “Control Relay Inspection” in Section 10B (Page 10B-61).

Starting Motor Removal and Installation

AENJHB0B1926002
Removal
1) Remove battery and battery tray. (Page 1J-16)
2) Remove gear shift control cable (1) from shift cable lever (2) and bracket (3).

IJHB0A193003-01

3) Remove vacuum tank (1).

IJHB0A193004-01
 Starting System: D13A 1I-20

4) Remove vacuum tank bracket (1).

IFL10A190029-01

5) Remove cap (1) and starting motor mounting bolt (2) (upper side).
6) Disconnect magnetic switch lead wire (3) and starting motor cable (4) from starting motor terminals.
7) Remove starting motor mounting bolt (5) (lower side).
8) Remove starting motor (6).

1 2

3
5

4
IFL10A190002-01
1I-21 Starting System: D13A

Installation
Reverse removal procedure noting the following points.
• Tighten starting motor cable nut (1) and magnetic switch lead wire nut (2) to specified torque.
Tightening torque
Starting motor cable nut (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
Magnetic switch lead wire nut (b): 6.0 N·m (0.61 kgf-m, 4.5 lbf-ft)

2, (b)

1, (a)

IFL10A190003-01

• Tighten vacuum tank bracket bolts (1) to specified torque.

Tightening torque
Vacuum tank bracket bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)

1, (a)

IFL10A190030-01
 Starting System: D13A 1I-22

• Tighten vacuum tank bolts (1) to specified torque.

Tightening torque
Vacuum tank bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)

1, (a)

IJHB0A193005-01

Starting Motor Components

AENJHB0B1926003

(c)

4 6

1 5

(a)
A
8 (b)

A
7

IFL10A190005-02

1. Starter housing 5. Gear shaft assembly : 3.6 Nm (0.37 kgf-m, 3.0 lbf-ft)
2. Magnetic switch assembly 6. Armature : 6.4 Nm (0.65 kgf-m, 5.0 lbf-ft)
3. Drive lever 7. Yoke : 9.5 Nm (0.97 kgf-m, 7.0 lbf-ft)
4. Lever stop 8. Starter end frame : Apply grease 99000-25011 to sliding surface of each part.
1I-23 Starting System: D13A

Starting Motor Disassembly and Reassembly 4) Remove lever stop (1) from starter housing (2).
AENJHB0B1926004

Disassembly
1) Remove nut (1) and disconnect lead wire (2) from
magnetic switch (3). 1

3 2

1
2

IFL10A190009-01

5) Remove gear shaft assembly (1) together with drive

lever (2) and plunger assembly (3).

IFL10A190006-01 2
2) Remove magnetic switch (1) from starter housing
1
(2).

IFL10A190010-01

2 6) Using flat-bladed screwdriver (1) or the like, remove

starter end frame (2) from yoke (3).
7) Remove armature (4) from yoke.

IFL10A190007-01

3) Remove bolts (1), and then separate yoke (2) from 1

starter housing (3).

3
4
IFL10A190011-01

1
IFL10A190008-01
 Starting System: D13A 1I-24

8) Pull drive lever (1) in arrow direction “1”. 4) Install drive lever (1) to plunger assembly (2).
9) Remove drive lever from plunger assembly (2) by
2
moving it in arrow direction “2”.
1
2

“2”

“1”

IFL10A190015-01

5) Apply grease to sliding parts of armature (1) and

IFL10A190012-02 starter end frame (2).
“A”: Grease 99000–25011 (SUZUKI Super
Reassembly
Grease A)
1) Apply grease to sliding parts of plunger (1).
6) Install armature to yoke (3).
“A”: Grease 99000–25011 (SUZUKI Super
7) Install starter end frame to yoke.
Grease A)
2) Install boot (2), spring (3), and shim (4) to plunger. 2

“A”
3
3
2

1 1

4
2 3
1 “A”
“A”
IFL10A190016-02

8) Insert gear shaft assembly (1) into starter housing

(2) with drive lever (3) and plunger assembly (4)
positioned as shown in figure.
IFL10A190013-01

3) Apply grease to sliding parts of drive lever (1).

4
“A”: Grease 99000–25011 (SUZUKI Super
3
Grease A)

2
1
IFL10A190017-01

“A”
IFL10A190014-01
1I-25 Starting System: D13A

9) Install lever stop (1) to starter housing (2). Tightening torque

Lead wire nut (a): 9.5 N·m (0.97 kgf-m, 7.0 lbf-ft)

3, (a)
2 1

IFL10A190009-01

10) Install yoke (2) to starter housing (3), and then

tighten starter end frame bolts (1) to specified IFL10A190019-01
torque.
Tightening torque Starting Motor Inspection
AENJHB0B1926005
Starter end frame bolt (a): 6.4 N·m (0.65 kgf-m,
5.0 lbf-ft) Starting Motor Operation Check

! CAUTION
Sparks resulting from a short circuit between
the positive (+) and negative (–) terminals
during connections to the battery may cause
burns.
Be careful not to short-circuit the positive (+)
and negative (–) cables, and connect them
only to the correct terminals.
3
NOTICE
2
If battery power is applied too long in any of
1, (a)
the following tests, coil of the magnetic
IFL10A190018-01 switch may burn.
11) Install magnetic switch (1) to starter housing (2), and Each test must be completed within 3 to 5
then tighten magnetic switch bolts (3) to specified seconds to avoid burning of the coil.
torque.
1) Perform pull-in test as follows.
Tightening torque
Magnetic switch bolt (a): 3.6 N·m (0.37 kgf-m, a) Disconnect lead wire (3) from “M” terminal (2).
3.0 lbf-ft) b) Connect battery to magnetic switch as shown in
figure.
1 c) Check that plunger and pinion move outward.
3, (a) If plunger and pinion do not move, replace
magnetic switch.

IFL10A190031-01

12) Connect lead wire (1) to magnetic switch (2), and

then tighten lead wire nut (3) to specified torque. I5RS0B190002-01

1. “S” terminal

2) Perform hold-in test as follows.
a) From the state of Step 1) with plunger and pinion
in “out” position, disconnect negative (–) lead
from “M” terminal.
b) Check that plunger and pinion remain in “out”
position.
If plunger and pinion return inward, replace
magnetic switch.
I5RS0B190003-01
3) Perform plunger and pinion return test as follows.
a) From the state of Step 2) with plunger and pinion
in “out” position, disconnect negative (–) lead
from starting motor body.
b) Check that plunger and pinion return inward. If
plunger and pinion do not return, replace
magnetic switch.
I5RS0B190004-01
4) Perform non-load performance test as follows.
! CAUTION
If the cable used for the test is not adequately
thick, the cable may become extremely hot
due to large current flowing through it and
you could get burned.
Use a cable with thickness equal to or larger
than the cable used between the vehicle’s
battery and the starter.
Starting System: D13A 1I-26
a) Fix starting motor with vice or the like.
b) Connect battery and ammeter to starting motor
as shown in figure.
c) Check that starting motor rotates smoothly and
steadily with pinion moving out.
d) Check that ammeter indicates specified current.
If check result is not as specified, repair or
replace starting motor.
Specified current (No-load performance test)
: 77 A MAX. at 11.5 V
I9P60A192023-01
Plunger
Check plunger for wear or damage. Replace magnetic
switch if defective.
IFL10A190020-01
Magnetic Switch
Check that plunger quickly returns to its original position
when plunger is pushed in with a finger and released. If
check result is not OK, replace magnetic switch.
IFL10A190021-01
1I-27 Starting System: D13A

Pull-in coil open circuit test Brush length “a”

Check for continuity between magnetic switch “S” Standard: 15.0 – 15.4 mm (0.59 – 0.60 in.)
terminal (1) and “M” terminal (2). If there is no continuity, Limit: 9.0 mm (0.35 in.)
replace magnetic switch.
“a”

IFL10A190023-01
2
• Check that movement of brushes is smooth.
I9P60A192025-01
Spring
Hold-in coil open circuit test Check brush springs for wear, damage or other
Check for continuity between magnetic switch “S” abnormal conditions. Replace starter end frame if
terminal (1) and coil case. If there is no continuity, defective.
replace magnetic switch.
Starter End Frame
• Check starter end frame for brush movement
problems, distortion, and dirt on sliding surface.
Clean or correct starter end frame if defective.
• Check for continuity between insulated brush (positive
(+) side) and grounded brush (negative (–) side).
If there is continuity, replace starter end frame.

I9P60A192026-01

Starter End Frame Bushing

Check starter end frame bushing for wear or damage. If
check result is not OK, replace starter end frame.

IFL10A190024-01

Armature
• Check commutator for dirt or burn. Correct
commutator with sandpaper or lathe, if defective.

IFL10A190022-01 1

Brush
• Check brushes for wear.
Measure length of each brush. If length is less than
the limit, replace starter end frame. IFL10A190025-01

1. Sandpaper of #300 – 400

 Starting System: D13A 1I-28

• Check commutator (1) for insulator (2) depth. If depth Pinion and Overrunning Clutch
is less than the limit, replace armature. • Check pinion for wear, damage and other abnormal
Commutator insulator depth “a” conditions.
Limit: 0.2 mm (0.007 in.) • Check that clutch locks when turned in normal rotation
direction and rotates freely when turned in opposite
“a” direction. Replace gear shaft assembly if defective.
2 1

IFL10A190026-01

• Check insulation between commutator and armature

core. If there is continuity, replace armature.

I2RH01190022-01

• Check spline teeth for wear or damage. Replace gear

shaft assembly if defective.
• Check pinion for smooth movement.

IFL10A190027-01

• Check for continuity between segments. If there is no

continuity at any test point, replace armature. I2RH01190023-01

Starter Housing Bushing

Check bushing for wear or damage. Replace starter
housing if defective.

IFL10A190028-01

I2RH01190024-01
1I-29 Starting System: D13A

Specifications
Cranking System Specifications
AENJHB0B1927001
Voltage 12 V
Output 1.2 kW
Rating 30 seconds
Direction of rotation Clockwise viewed from pinion end
Number of pinion teeth 9
Performance Voltage Current Torque Revolution speed
No-load characteristic 11.5 V 77 A MAX — 3,350 rpm MIN
5.5 Nm (0.56 kgf-m,
Loaded characteristic — 290 A MAX 1,650 rpm
At around 4.0 lbf-ft) MIN
21 °C 10.5 Nm (1.1 kgf-m,
Locked characteristic — 520 A MAX 200 rpm
(69.8 °F) 8.0 lbf-ft) MIN
Magnetic switch
8 V MAX
operating voltage

Tightening Torque Specifications

AENJHB0B1927002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Starting motor cable nut 11 1.1 8.5 (Page 1I-21)
Magnetic switch lead wire nut 6.0 0.61 4.5 (Page 1I-21)
Vacuum tank bracket bolt 25 2.5 18.5 (Page 1I-21)
Vacuum tank bolt 11 1.1 8.5 (Page 1I-22)
Starter end frame bolt 6.4 0.65 5.0 (Page 1I-25)
Magnetic switch bolt 3.6 0.37 3.0 (Page 1I-25)
Lead wire nut 9.5 0.97 7.0 (Page 1I-25)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Starting Motor Components”: D13A (Page 1I-22)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Recommended Service Material
AENJHB0B1928001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 (Page 1I-24) / (Page 1I-
24) / (Page 1I-24)

NOTE
Required service material(s) is also described in:
“Starting Motor Components”: D13A (Page 1I-22)
 Charging System: K15B 1J-1

Charging System
Engine

K15B
Precautions
Precautions for Handling Battery 2) Keep the battery cable connections clean.
AENJHB0B1A10001 The cable connections, particularly at the positive (+)
! WARNING terminal post, tend to corrode. The corrosion or rust
on the mating faces of conductors resists the flow of
Failure to take proper precautions when
current.
handling the battery may cause severe
Clean the terminals and fittings periodically to
personal injury.
ensure good metal-to-metal contact, and grease the
• Never expose the battery to an open flame connections after each cleaning to protect them
or electric spark. A battery generates against rusting.
highly flammable and explosive hydrogen
3) Periodically check the state of charge of the battery.
gas.
The simplest way to tell the state of charge is to carry
• Battery fluid is a corrosive acid. Do not out a hydrometer test. The hydrometer is an
allow it to contact eyes, skin, fabrics or instrument for measuring the specific gravity of the
painted surfaces of the vehicle. If the fluid battery electrolyte. The specific gravity of the
contacts any of them, immediately and electrolyte is indicative of the state of charge.
thoroughly flush the affected area with a (Page 1J-2)
large quantity of water.
• Keep the battery out of reach of children. Precautions for Replacing Battery
AENJHB0B1A10002
1) The battery is a very reliable component, but needs Use SUZUKI genuine battery specified for SHVS
periodical attentions. system. (Page 1J-10)
• Keep the battery tray clean.
Precautions for Handling Auxiliary Power
• Prevent rust formation on the terminal posts.
Module (Lithium-Ion Battery)
• Keep electrolyte up to the upper level uniformly in AENJHB0B1A10003
all cells. (If cell caps are equipped) Refer to “Precautions for Handling Auxiliary Power
• When keeping battery on vehicle over a long Module (Lithium-Ion Battery)” in Section 10K (Page 10K-
period, follow instructions given below. 1).
– Weekly, start the engine and run it until it
reaches normal operating temperature with
engine speed of 2,000 to 3,000 rpm. Check that
all electric switches are turned off before storing
the vehicle.
– Recharge the battery twice a month to prevent
it from discharging excessively. This is
especially important when ambient temperature
is low.
The battery discharges even when it is not
used, while vehicles are stored. Battery
electrolyte can freeze and battery case can
crack in cold ambient condition if the battery is
not properly charged.
1J-2 Charging System: K15B

General Description
Battery Description
AENJHB0B1A11001
The battery has three major functions in the electrical
system.
Electric load current sensor incorporating battery
temperature sensor is fitted on the battery negative (–)
terminal.
• It is a source of electrical energy for cranking the
engine.
• It acts as a voltage stabilizer for the electrical system.
• It can, for a limited time, provide energy when the
electrical load exceeds the output of generator.
Carrier and Hold-Down Clamp
The battery carrier should be in good condition so that it
supports the battery securely and keeps it level. Before
installing the battery, check that the battery carrier and
hold-down clamp are clean and free from corrosion and
that there is no foreign material in the carrier.
To prevent the battery from shaking in its carrier, the
hold-down clamp nuts should be tightened enough but
not over-tightened.
Electrolyte Freezing
The freezing point of electrolyte depends on its specific
gravity. Since freezing may ruin a battery, it should be
protected against freezing by keeping it in a fully
charged condition. If a battery freezes accidentally, it
should not be charged until it will unfreeze.
Sulfation
If the battery is left for a long period in discharged
condition, the lead sulfate becomes converted into a
hard, crystalline substance, which will not easily turn
back to the active material again during the subsequent
recharging. “Sulfation” means the result as well as the
process of that reaction. Such a battery can be revived
by very slow charging and may be restored to usable
condition but its capacity will be lower than before.
Generator Description
AENJHB0B1A11002
For the details on electricity generating mechanism,
refer to “Description of SHVS System”: K15B Model in
Section 11A (Page 11A-2).

Auxiliary Power Module (Lithium-Ion Battery)

Control System Description
AENJHB0B1A11003
For the details, refer to “Auxiliary Power Module
(Lithium-Ion Battery) Control System Description” in
Section 10K (Page 10K-1).

Diagnostic Information and Procedures

Battery Inspection
AENJHB0B1A14001
Common Causes of Failure
The following are the most common causes of battery failures.
• Accessories left on overnight or for an extended period without the generator operation.
• Frequent driving at slow speeds for short periods.
• Electrical load exceeds generator output, particularly due to additional fitting of aftermarket equipment.
• Defects in charging system. (Page 1J-3)
• Including failure to keep terminals clean or making hold-down clamps too loose or too tight.
• Mechanical problems in electrical system such as short-circuit or pinched wires.
• Deterioration of battery due to long-term use.
• Deterioration of battery due to long-term storage.

Visual Inspection
Check for visible damage, such as a cracked or broken case or cover, make corrections loss of electrolyte. If visible
damage is noted, replace battery. Determine cause of damage and make corrections if necessary.
 Charging System: K15B 1J-3

Generator Symptom Diagnosis

AENJHB0B1A14002
Trouble in charging system will show up as one or more of the following conditions.

Charging Warning Light Operation Failure

Condition Possible cause Correction / Reference Item
Charge warning light Blown fuse Replace fuse and check its circuit.
does not light with Faulty combination meter Replace combination meter. (Page 9C-34)
ignition “ON” and engine Faulty ECM Check ECM. (Page 1A-150)
off Faulty CAN communication line Repair or replace CAN communication line.
(Page 10H-7)
Faulty wiring Repair wiring.
Faulty ISG Replace ISG. (Page 1J-7)
Charge warning light Malfunctioning charging system Perform generator test. (Page 1J-3)
does not go out with Loose or worn ISG drive belt Replace ISG drive belt. (Page 1J-7)
engine running (battery Faulty ISG drive belt tensioner and idler Replace ISG drive belt tensioner and idler
requires frequent pulley pulley. (Page 1J-9)
recharging) Faulty combination meter Replace combination meter. (Page 9C-34)
Faulty ECM Check ECM. (Page 1A-150)
Faulty ISG Replace ISG. (Page 1J-7)
Faulty wiring Repair wiring.

Battery Charging Failure

Condition Possible cause Correction / Reference Item
Undercharged battery Loose or worn ISG drive belt Replace ISG drive belt. (Page 1J-7)
Faulty ISG drive belt tensioner and idler Replace ISG drive belt tensioner and idler
pulley pulley. (Page 1J-9)
Loosen or corroded battery terminals Tighten battery terminals or replace battery.
(Page 1J-5)
Faulty ISG Replace ISG. (Page 1J-7)
Overcharged battery Faulty ISG Replace ISG. (Page 1J-7)

Noise
Condition Possible cause Correction / Reference Item
Noisy ISG Loose mounting bolts Tighten mounting bolts. (Page 1J-7)
Faulty rotor, stator or inverter Replace ISG. (Page 1J-7)
Dirty, worn or faulty bearings Replace ISG. (Page 1J-7)

SHVS System Check

AENJHB0B1A14003
For the details, refer to “SHVS System Check”: K15B Model in Section 11A (Page 11A-15).

Generator Test Parameter Check

AENJHB0B1A14004
This condition, as evidenced by slow cranking or low
specific gravity, can be caused by one or more of the
following conditions even though warning light operates
normally. The following procedure also applies to cars
with voltmeter and ammeter.
• Check that undercharged condition has not been
caused by accessories being left on for an extended
period.
• Check ISG drive belt for wear and tension. (Page
1J-6)
• If battery defect is suspected, refer to “Battery
Description”: K15B (Page 1J-2).
• Check wiring for defects. Check all connections for
tightness and cleanliness, battery cable connections
at battery, starting motor and ignition ground cable.
NOTE
• Use fully charged battery.
• The following check is for generating
mode. If the generating mode operates
normally, driving mode of ISG is judged to
be normal.
• Operating time of generating mode right
after the engine start varies according to
state-of-charge of the battery (lead-acid
battery) and auxiliary power module
(lithium-ion battery). Therefore, check the
parameter when 30 seconds have elapsed
since the engine was started.
1J-4 Charging System: K15B

1) Turn off all electrical loads. NOTE

2) Set ignition “OFF”. • “ISG control Mode” is parameter of ECM.
3) Connect SUZUKI scan tool to DLC (1). “Relay 2P Current”, “Relay 3P Current”
Special tool and “ISG + Terminal Voltage” are
(A): SUZUKI scan tool (Suzuki SDT-II) parameters of auxiliary power module
(lithium-ion battery).
• *1: In the generating mode, “Relay 2P
Current” is displayed in a negative value.
Standard current value is sum of “Relay 2P
Current” converted into a positive value
and “Relay 3P Current”.
• Connect voltmeter (1) and ammeter (2) as
shown in figure for measurement.
1

1
5
+
V

+ A 2

3
(A) IEV00PB10007-01

IJHA0A110021-01 3. ISG 5. “ISG +” terminal

4) Run engine at idle speed. 4. Auxiliary power module (lithium-ion battery)

5) Turn lighting switch to “HEAD” position.

6) Measure parameter data of “ISG Control Mode”,
“Relay 2P Current”, “Relay 3P Current” and “ISG +
Terminal Voltage” selecting them in “Data List”, and
check that the result is as specified.
Generating mode specifications
Parameter Standard value
Power
ISG control
Mode generating
mode
mode
Relay 2P
current
Standard current 10 A or more (*1)
Relay 3P
current
Regulated
ISG + terminal
voltage at 25 °C 10.7 – 16.0 V
voltage
(77 °F)
 Charging System: K15B 1J-5

Repair Instructions
Jump-Starting in Case of Emergency
AENJHB0B1A16001
With Booster Battery
NOTICE
Trying to start a vehicle equipped with a
catalytic converter by pushing or towing it
may cause damage to the emission control
system and/or other components.
Do not start a vehicle by pushing or towing it.
NOTE
Engine is started with the hood open in case
of jump-starting with a discharged or
deteriorated lead-acid battery etc., or the
hood is opened while the engine is running,
ECM inhibits engine auto stop and auto
restart control until the ignition is set “OFF”.
Both booster and discharged battery should be treated
carefully when using jumper cables. Follow the
procedure outlined as follows, being careful not to cause
sparks.
! WARNING
Failure to take proper precautions when jump
starting a vehicle may result in serious
personal injury and/or damage to electronic
components of either the vehicle with a dead
battery or the vehicle used for jump starting.
• Never expose the battery to open flame or
electric spark. A battery generates highly
flammable and explosive hydrogen gas.
• Remove rings, watches and other jewelry.
Wear approved eye protector.
6) Attach end of one jumper cable to positive (+)
terminal of booster battery and the other end of the
same cable to positive (+) terminal of discharged
battery (Use 12-volt battery only to jump-start
engine).
7) Attach one end of the remaining negative (–) cable to
negative (–) terminal of booster battery, and the
other end to a solid engine ground (such as exhaust
manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
8) Start engine of vehicle with booster battery and turn
off its electrical loads. Then try to start engine of
vehicle with discharged battery.
9) Disconnect jumper cables in the exact reverse order.
With Charging Equipment
NOTICE
Using 24-volt charging equipment to jump-
start the engine will cause serious damage to
electric and electronic system components.
Use only 12-volt charging equipment to
jump-start the engine.
Battery Removal and Installation
AENJHB0B1A16002
Removal
1) Disconnect negative (–) cable (1) at battery.
2) Disconnect positive (+) cable (2) at battery.
3) Remove battery band (3).
4) Remove battery (4).
1
3

• Battery fluid is a corrosive acid. Do not

allow it to contact eyes, skin, fabrics or 4
painted surfaces of the vehicle. If the fluid
contacts any of them, immediately and
thoroughly flush the affected area with
water.
• To avoid a danger of short circuit, do not
allow a metal tool or jumper cable to touch
the positive terminal of the battery (or a
metal piece in contact with it) and any 2
metal part of the vehicle at the same time. IJHB0A1A1001-01
• Keep the battery out of the reach of
children.

1) Place gear shift lever in “Neutral”.

2) Apply parking brake.
3) Set ignition “OFF”.
4) Turn off lights and all other electrical loads.
5) For battery with cell caps, check electrolyte level. If it
is below low level line, add distilled water.
1J-6 Charging System: K15B

5) Remove battery tray (1) if necessary. • Tighten battery band nuts (1) to specified torque.
Tightening torque
Battery band nut (a): 3.3 N·m (0.34 kgf-m, 2.5 lbf-
ft)
• Tighten positive (+) cable nut (2) and negative (–)
1 cable nut (3) to specified torque.
Tightening torque
Positive (+) cable nut (b): 5.0 N·m (0.51 kgf-m, 4.0
lbf-ft)
Negative (–) cable nut (c): 5.0 N·m (0.51 kgf-m,
4.0 lbf-ft)

3, (c)
1, (a)
IJHB0A1A1002-01

Installation 1, (a)
Reverse removal procedure noting the following points.
• Tighten new battery tray bolts (1) and nut (2) to
specified torque.

NOTICE
The battery tray bolts and nut are pre-coated.
If these bolts and nut are reused, they may
work loose.
Replace the battery tray bolts and nut with
new ones whenever they are removed. 2, (b)

Tightening torque
Battery tray bolt (a): 13 N·m (1.3 kgf-m, 9.5 lbf-ft)
Battery tray nut (b): 13 N·m (1.3 kgf-m, 9.5 lbf-ft)

IJHB0A1A1004-01
2, (b)

ISG Drive Belt Inspection

AENJHB0B1A16003
1, (a)
NOTE
Check ISG drive belt when engine is cool and
the belt is dry.

Check the following points. If check result is not OK,

1, (a) replace ISG drive belt. (Page 1J-7)
• Check ISG drive belt for crack, tear, deformation,
IJHB0A1A1003-01
wear or dirt.
• When engine is idling or racing, check that there is
noise from ISG drive belt.

ISG Drive Belt Removal and Installation
AENJHB0B1A16004
! CAUTION
When removing and installing ISG drive belt,
repulsive power of auto tensioner may cause
a finger injury.
Handle auto tensioner carefully during
service for ISG drive belt.
NOTICE
Failure to take proper precautions when
compressing the ISG drive belt tensioner can
cause damage to the tensioner.
• Compress the tensioner very slowly using
a suitable wrench.
• Do not apply a force of more than 150 Nm
(15.3 kgf-m, 111.0 lbf-ft) when compressing
the tensioner.
• Do not apply more force when the
tensioner stops at full stroke.
Removal
1) Hoist vehicle and right side engine under side cover.
(Page 9H-15)
2) Remove compressor drive belt.
• Manual A/C single model (Page 7B-49)
• Manual A/C dual model (Page 7B-92)
• Auto A/C model (Page 7B-135)
3) Remove right side apron lower member bracket.
(Page 9H-5)
4) Fitting a suitable wrench (1) to hexagonal section
(2), turn ISG drive belt auto tensioner (3) clockwise
as shown to compress the tensioner.
5) Remove ISG drive belt (4).
ISG Removal and Installation
3 AENJHB0B1A16005
4
2
1 Removal
IJHB0B1A1001-01
Installation
1) Fitting a suitable wrench (1) to hexagonal section
(2), turn ISG drive belt auto tensioner (3) clockwise
as shown to compress the tensioner.
Charging System: K15B 1J-7
2) Put ISG drive belt (4) on crankshaft pulley, water
pump pulley and ISG pulley fitting belt ribs to pulley
grooves correctly.
3
4
2
1
IJHB0B1A1001-01
3) Remove wrench slowly to give tension to the belt.
4) Turn crankshaft clockwise 720° and check that all of
belt ribs are fitted into all of pulley grooves.
5) Start engine for 2 to 3 seconds to stabilize the belt
tension.
6) Stop engine and check the state of the belt. (Page
1J-6)
7) Install right side apron lower member bracket.
(Page 9H-5)
8) Install compressor drive belt.
• Manual A/C single model (Page 7B-49)
• Manual A/C dual model (Page 7B-92)
• Auto A/C model (Page 7B-135)
9) Install right side engine under side cover. (Page
9H-15)
NOTICE
The ISG consists of precision parts. Without
taking the following precautions, it may lose
its original performance.
• Do not disassemble the ISG.
• Do not drop or expose the ISG to large
shock.
1) Relieve fuel pressure from fuel feed line. (Page
1G-14)
2) Disconnect negative (–) cable at battery.
3) Remove air cleaner assembly. (Page 1D-9)
4) Remove Fuel feed hose. (Page 1G-11)
5) Remove intake manifold. (Page 1D-13)
6) Remove ISG drive belt. (Page 1J-7)
7) Remove idler pulley. (Page 1J-9)
1J-8 Charging System: K15B

8) Remove nut (1) and disconnect “B” terminal wire (3), • Tighten ISG upper bolt (5) and lower bolt (6) as
and then disconnect ISG connector (4) from ISG (2). follows.
9) Remove ISG upper bolt (5) and lower bolt (6), and a. Put ISG (2) on cylinder block and tighten ISG
then remove ISG. lower bolt temporarily.
b. Tighten ISG upper bolt to specified torque.
5
1 Tightening torque
3 ISG upper bolt (a): 30 N·m (3.1 kgf-m, 22.5 lbf-
ft)
c. Tighten ISG lower bolt to 30 Nm (3.1 kgf-m, 22.5
lbf-ft) and check that bushing (7) in ISG bracket is
in contact with cylinder block, and then loosen the
4
bolt.
d. Tighten ISG lower bolt to specified torque.
6 Tightening torque
2
IHL10A1A1001-02 ISG lower bolt (b): 48 N·m (4.9 kgf-m, 35.5 lbf-
10) Remove ISG arm, if necessary. (Page 1F-17) ft)
11) Remove ISG bracket (1), if necessary. • Insert lugs (8) of “B” terminal wire (3) into groove (9)
and then tighten “B” terminal nut (1) to specified
torque.
Tightening torque
1 “B” terminal nut (c): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)

1, (c)
8

9
1
3 5, (a)
IHL10A1A1007-01

Installation
Reverse removal procedure noting the following points.
• Tighten ISG bracket bolts in numerical order (“1” – “4”)
evenly and gradually to specified torque, if removed.
Tightening torque 4
ISG bracket bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)

“3”, (a) 7
6, (b)
IHL10A1A1002-06
“1”, (a)
4. ISG connector

• Check for fuel leakage. (Page 1G-14)

“4”, (a) “2”, (a)

IHL10A1A1008-01
 Charging System: K15B 1J-9

ISG Inspection Installation

AENJHB0B1A16006
Check the following points. If check result is not OK, 1) Install ISG drive belt auto tensioner bracket (7) and
replace ISG (1). then tighten ISG drive belt auto tensioner bracket
bolt (6) to specified torque.
• Turn pulley (2) and check that it rotates smoothly
without any abnormal noise. 2) Install idler pulley (2) and then tighten idler pulley
bolt (1) to specified torque.
• Check damage on ISG.
3) Install ISG drive belt auto tensioner (5) and then
2 tighten ISG drive belt tensioner upper bolt (3) and
lower bolt (4) to specified torque.
1
Tightening torque
Idler pulley bolt (a): 45 N·m (4.6 kgf-m, 33.5 lbf-
ft)
ISG drive belt auto tensioner upper bolt (b): 25
N·m (2.5 kgf-m, 18.5 lbf-ft)
ISG drive belt auto tensioner lower bolt (c): 55
N·m (5.6 kgf-m, 40.5 lbf-ft)
IHL10A1A1003-02 ISG drive belt auto tensioner bracket bolt (d): 25
N·m (2.5 kgf-m, 18.5 lbf-ft)
ISG Drive Belt Auto Tensioner / Idler Pulley
Removal and Installation
AENJHB0B1A16007 3, (b)
Removal
1) Remove ISG drive belt. (Page 1J-7)
2) Remove idler pulley bolt (1) and then remove idler
pulley (2). 7
2
3) Remove ISG drive belt auto tensioner upper bolt (3)
and lower bolt (4) and then remove the tensioner (5).
4) Remove ISG drive belt auto tensioner bracket bolt
(6) and then remove ISG drive belt auto tensioner
bracket (7).
6, (d)
1, (a)
5 4, (c)
IJHB0A1A1005-01

4) Using a suitable wrench, compress ISG drive belt

3 auto tensioner fully.

NOTICE
6
2
Failure to take proper precautions when
7
compressing the ISG drive belt tensioner can
cause damage to the tensioner.
• Compress the tensioner very slowly using
a suitable wrench.
6 • Do not apply a force of more than 150 Nm
1 (15.3 kgf-m, 111.0 lbf-ft) when compressing
5 4
IJHB0B1A1002-01 the tensioner.
• Do not apply more force when the
tensioner stops at full stroke.

5) Release the compression.

6) Repeat Step 4) – 5) 2 times.
7) Install ISG drive belt. (Page 1J-7)
1J-10 Charging System: K15B

ISG Drive Belt Auto Tensioner / Idler Pulley

Inspection 1
AENJHB0B1A16008
Check the following points. If check result is not OK,
replace ISG drive belt auto tensioner (1) and/or drive belt
idler pulley (3).
• Turn ISG drive belt auto tensioner pulley (2) and drive
belt idler pulley and check that each pulley rotates 2
smoothly without any abnormal noise.
• Check damage on ISG drive belt auto tensioner and
drive belt idler pulley.
• Check that there is no leakage of ISG drive belt auto
3
tensioner oil.

IFKA0P1A2002-01

Specifications
Charging System Specifications
AENJHB0B1A17001
Battery
Battery type
: N-55
Battery specification
: CCA 480A (EN) (36AH/5H) 12 V

ISG
Rated voltage 12 V
Permissible max. speed 18,000 rpm
Starting speed 1,400 rpm MAX.
Permissible ambient temperature –30 to 110 °C (–22 to 230 °F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side
Nominal output 210 A
Electricity generating mode
Regulated voltage 10.6 to 16.0 V
Max. output 1.8 kW
Driving mode
Max. torque 50 Nm (4.1 kgf-m, 29.5 lbf-ft)

Tightening Torque Specifications

AENJHB0B1A17002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Battery tray bolt 13 1.3 9.5 (Page 1J-6)
Battery tray nut 13 1.3 9.5 (Page 1J-6)
Battery band nut 3.3 0.34 2.5 (Page 1J-6)
Positive (+) cable nut 5.0 0.51 4.0 (Page 1J-6)
Negative (–) cable nut 5.0 0.51 4.0 (Page 1J-6)
ISG bracket bolt 25 2.5 18.5 (Page 1J-8)
ISG upper bolt 30 3.1 22.5 (Page 1J-8)
ISG lower bolt 48 4.9 35.5 (Page 1J-8)
“B” terminal nut 11 1.1 8.5 (Page 1J-8)
Idler pulley bolt 45 4.6 33.5 (Page 1J-9)
ISG drive belt auto tensioner upper bolt 25 2.5 18.5 (Page 1J-9)
ISG drive belt auto tensioner lower bolt 55 5.6 40.5 (Page 1J-9)
ISG drive belt auto tensioner bracket bolt 25 2.5 18.5 (Page 1J-9)

Reference:
 Charging System: K15B 1J-11

For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Special Tool
AENJHB0B1A18001
SUZUKI scan tool (Suzuki
SDT-II)
—
(Page 1J-4)
1J-12 Charging System: D13A

D13A
Precautions
Precautions for Handling Battery
AENJHB0B1A20001
! WARNING
Failure to take proper precautions when handling the battery may cause severe personal injury.
• Never expose the battery to an open flame or electric spark. A battery generates highly flammable
and explosive hydrogen gas.
• Battery fluid is a corrosive acid. Do not allow it to contact eyes, skin, fabrics or painted surfaces of
the vehicle. If the fluid contacts any of them, immediately and thoroughly flush the affected area with
a large quantity of water.
• Keep the battery out of reach of children.

1) The battery is a very reliable component, but needs periodical attentions.

• Keep the battery tray clean.
• Prevent rust formation on the terminal posts.
• Keep electrolyte up to the upper level uniformly in all cells. (If cell caps are equipped)
• When keeping battery on vehicle over a long period, follow instructions given below.
– Weekly, start the engine and run it until it reaches normal operating temperature with engine speed of 2,000
to 3,000 rpm. Check that all electric switches are turned off before storing the vehicle.
– Recharge the battery twice a month to prevent it from discharging excessively. This is especially important
when ambient temperature is low.
The battery discharges even when it is not used, while vehicles are stored. Battery electrolyte can freeze and
battery case can crack in cold ambient condition if the battery is not properly charged.
2) Keep the battery cable connections clean.
The cable connections, particularly at the positive (+) terminal post, tend to corrode. The corrosion or rust on the
mating faces of conductors resists the flow of current.
Clean the terminals and fittings periodically to ensure good metal-to-metal contact, and grease the connections
after each cleaning to protect them against rusting.
3) Periodically check the state of charge of the battery. The simplest way to tell the state of charge is to carry out a
hydrometer test. The hydrometer is an instrument for measuring the specific gravity of the battery electrolyte. The
specific gravity of the electrolyte is indicative of the state of charge. (Page 1J-13)

Precautions for Replacing Battery

AENJHB0B1A20002
Use SUZUKI genuine battery specified for SHVS system. (Page 1J-22)

General Description
Battery Description
AENJHB0B1A21001
The battery has three major functions in the electrical system.
• It is a source of electrical energy for cranking the engine.
• It acts as a voltage stabilizer for the electrical system.
• It can, for a limited time, provide energy when the electrical load exceeds the output of generator.

Carrier and Hold-Down Clamp

The battery carrier should be in good condition so that it supports the battery securely and keeps it level. Before
installing the battery, check that the battery carrier and hold-down clamp are clean and free from corrosion and that
there is no foreign material in the carrier.
To prevent the battery from shaking in its carrier, the hold-down clamp nuts should be tightened enough but not over-
tightened.
 Charging System: D13A 1J-13

Electrolyte Freezing
The freezing point of electrolyte depends on its specific gravity. Since freezing may ruin a battery, it should be
protected against freezing by keeping it in a fully charged condition. If a battery freezes accidentally, it should not be
charged until it will unfreeze.

Sulfation
If the battery is left for a long period in discharged condition, the lead sulfate becomes converted into a hard,
crystalline substance, which will not easily turn back to the active material again during the subsequent recharging.
“Sulfation” means the result as well as the process of that reaction. Such a battery can be revived by very slow
charging and may be restored to usable condition but its capacity will be lower than before.

Generator Description
AENJHB0B1A21002
For the details on electricity generating mechanism, refer to “SHVS System Description”: D13A Model in Section 11A
(Page 11A-40).

Diagnostic Information and Procedures

Battery Inspection
AENJHB0B1A24001
Common Causes of Failure
The following are the most common causes of battery failures.
• Accessories left on overnight or for an extended period without the generator operation.
• Frequent driving at slow speeds for short periods.
• Electrical load exceeds generator output, particularly due to additional fitting of aftermarket equipment.
• Defects in charging system. (Page 1J-14)
• Including failure to keep terminals clean or making hold-down clamps too loose or too tight.
• Mechanical problems in electrical system such as short-circuit or pinched wires.
• Deterioration of battery due to long-term use.
• Deterioration of battery due to long-term storage.

Visual Inspection
Check for visible damage, such as a cracked or broken case or cover, make corrections loss of electrolyte. If visible
damage is noted, replace battery. Determine cause of damage and make corrections if necessary.
1J-14 Charging System: D13A

Generator Symptom Diagnosis

AENJHB0B1A24002
Trouble in charging system will show up as one or more of the following conditions.

Charging Warning Light Operation Failure

Condition Possible cause Correction / Reference Item
Charge warning light Blown fuse Replace fuse and check its circuit.
does not light with Faulty combination meter Replace combination meter. (Page 9C-34)
ignition “ON” and engine Faulty ECM Check ECM. (Page 1A-329)
off Faulty gateway control module Check gateway control module. (Page 11A-
74)
Faulty CAN communication line Repair or replace CAN communication line.
(Page 10H-30)
Faulty LIN communication line Repair or replace LIN communication line.
Faulty wiring Repair wiring.
Faulty ISG Replace ISG. (Page 1J-20)
Charge warning light Malfunctioning charging system Perform generator test. (Page 1J-15)
does not go out with Loose or worn ISG drive belt Replace ISG drive belt. (Page 1J-18)
engine running (battery Faulty ISG drive belt tensioner and idler Replace ISG drive belt tensioner and idler
requires frequent pulley pulley. (Page 1J-19)
recharging) Faulty combination meter Replace combination meter. (Page 9C-34)
Faulty ECM Check ECM. (Page 1A-329)
Faulty gateway control module Check gateway control module. (Page 11A-
74)
Faulty ISG Replace ISG. (Page 1J-20)
Faulty wiring Repair wiring.

Battery Charging Failure

Condition Possible cause Correction / Reference Item
Undercharged battery Loose or worn ISG drive belt Replace ISG drive belt. (Page 1J-18)
Faulty ISG drive belt tensioner and idler Replace ISG drive belt tensioner and idler
pulley pulley. (Page 1J-19)
Loosen or corroded battery terminals Tighten battery terminals or replace battery.
(Page 1J-16)
Faulty ISG Replace ISG. (Page 1J-20)
Overcharged battery Faulty ISG Replace ISG. (Page 1J-20)

Noise
Condition Possible cause Correction / Reference Item
Noisy ISG Loose mounting bolts Tighten mounting bolts. (Page 1J-20)
Faulty rotor, stator or inverter Replace ISG. (Page 1J-20)
Dirty, worn or faulty bearings Replace ISG. (Page 1J-20)
 Charging System: D13A 1J-15

Generator Test 5) Run engine around 2,000 rpm and read meters.
AENJHB0B1A24003 If voltage is out of specified range, replace ISG.
This condition, as evidenced by slow cranking or low
(Page 1J-20)
specific gravity, can be caused by one or more of the
following conditions even though warning light operates Specification for undercharged battery (No-load
normally. The following procedure also applies to cars check)
with voltmeter and ammeter. Current: 10.2 A
• Check that undercharged condition has not been Regulated voltage: 14.2 – 14.8 V (at 25 °C, 77 °F)
caused by accessories being left on for an extended
period. Load Check
• Check ISG drive belt for wear and tension. (Page NOTE
1J-18)
Use fully charged battery.
• If battery defect is suspected, refer to “Battery
Description”: D13A (Page 1J-12). 1) Connect ammeter in the same way as “No-Load
• Check wiring for defects. Check all connections for Check”: D13A (Page 1J-15).
tightness and cleanliness, battery cable connections 2) Run engine around 2,000 rpm and turn on the
at battery, starting motor and ignition ground cable. following electrical loads.
• Headlight (High beam)
No-Load Check
• Rear window defogger
NOTE • Blower motor (Maximum speed)
Use fully charged battery. 3) Read ammeter.
If meter reading is less than 20 A, replace ISG.
1) Check for DTC. (Page 11A-50) (Page 1J-20)
If there is any DTC, perform troubleshooting for
applicable DTC and then clear DTC.
• Troubleshooting: (Page 11A-51)
• DTC clearance: (Page 11A-51)
2) Turn off all electrical loads (5).
3) Connect voltmeter (3) and ammeter (2) as shown in
figure.
4) Start engine and warm it up to normal operating
temperature.

I9P60A1A1018-01

1. ISG 6. Switch
4. Battery 7. “B” terminal
1J-16 Charging System: D13A

Repair Instructions
Jump-Starting in Case of Emergency
AENJHB0B1A26001
With Booster Battery
NOTICE
Trying to start a vehicle equipped with a
catalytic converter by pushing or towing it
may cause damage to the emission control
system and/or other components.
Do not start a vehicle by pushing or towing it.
7) Attach one end of the remaining negative (–) cable to
negative (–) terminal of booster battery, and the
other end to a solid engine ground (such as exhaust
manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
8) Start engine of vehicle with booster battery and turn
off its electrical loads. Then try to start engine of
vehicle with discharged battery.
9) Disconnect jumper cables in the exact reverse order.

Both booster and discharged battery should be treated With Charging Equipment
carefully when using jumper cables. Follow the
procedure outlined as follows, being careful not to cause NOTICE
sparks. Using 24-volt charging equipment to jump-
start the engine will cause serious damage to
! WARNING electric and electronic system components.
Failure to take proper precautions when jump Use only 12-volt charging equipment to
starting a vehicle may result in serious jump-start the engine.
personal injury and/or damage to electronic
components of either the vehicle with a dead Battery Removal and Installation
battery or the vehicle used for jump starting. AENJHB0B1A26002
Removal
• Never expose the battery to open flame or
electric spark. A battery generates highly 1) Disconnect negative (–) cable (1) at battery.
flammable and explosive hydrogen gas. 2) Disconnect positive (+) cable (2) at battery.
• Remove rings, watches and other jewelry. 3) Remove battery band (3).
Wear approved eye protector. 4) Remove battery (4).
• Battery fluid is a corrosive acid. Do not
allow it to contact eyes, skin, fabrics or 4
1
painted surfaces of the vehicle. If the fluid
contacts any of them, immediately and
thoroughly flush the affected area with
water.
• To avoid a danger of short circuit, do not
allow a metal tool or jumper cable to touch 3
the positive terminal of the battery (or a 2
metal piece in contact with it) and any
metal part of the vehicle at the same time.
• Keep the battery out of the reach of
children.
IJHB0A1A3001-01

1) Place gear shift lever in “Neutral”.

2) Apply parking brake.
3) Set ignition “OFF”.
4) Turn off lights and all other electrical loads.
5) For battery with cell caps, check electrolyte level. If it
is below low level line, add distilled water.
6) Attach end of one jumper cable to positive (+)
terminal of booster battery and the other end of the
same cable to positive (+) terminal of discharged
battery (Use 12-volt battery only to jump-start
engine).
 Charging System: D13A 1J-17

5) With hose connected, move degassing tank (1) in Installation

arrow direction to release it from bracket, if Reverse removal procedure noting the following points.
necessary. • Tighten new battery tray bolts (1) and new battery tray
nut (2) to specified torque, if removed.

NOTICE
1 The battery tray bolts and nut are pre-coated.
If these bolts and nut are reused, they may
work loose.
Replace the battery tray bolts and nut with
new ones whenever they are removed.

Tightening torque
Battery tray bolt (a): 13 N·m (1.3 kgf-m, 9.5 lbf-ft)
Battery tray nut (b): 13 N·m (1.3 kgf-m, 9.5 lbf-ft)
IJHB0A1A3002-01

6) Remove battery bracket (1) together with degassing

2, (b)
tank bracket (2), if necessary. 1, (a)

IJHB0A1A3004-01

• Tighten battery band bolt (1) to specified torque.

Tightening torque
IJHB0A1A3003-01 Battery band bolt (a): 5.5 N·m (0.56 kgf-m, 4.0 lbf-
ft)

1, (a)

IJHB0A1A3005-01

• Tighten battery cables securely.

• Initialize electrical devices if necessary.
1J-18 Charging System: D13A

ISG Drive Belt Inspection ISG Drive Belt Removal and Installation
AENJHB0B1A26003 AENJHB0B1A26004
1) Check ISG drive belt (1) for crack, tear, deformation, Removal
wear and cleanliness. If any defect exists, replace 1) Hoist vehicle and remove right side front wheel.
belt. (Page 1J-18) (Page 2D-3)
2) Check that engine is cold. 2) Remove right side engine under side cover.
3) Place special tool onto pulleys (2) of ISG drive belt 3) Remove water pump drive belt. (Page 1F-32)
tensioner as shown in figure and check that width (3) 4) Turn pulley (1) of ISG drive belt tensioner
is smaller than width (4). counterclockwise until lever arm (2) passes holes
If check result is not OK, replace ISG drive belt. (3).
Special tool 5) Insert a retaining pin (4) through the holes to hold the
(A): 09932M97650 lever arm in the position.

2 1
(A)

[A] [B]
3
(A) 3
(A)

2 4 2 2 4 2

IJHB0B1A2001-01
3
[A]: OK [B]: NG 2
IJHB0A1A3006-01

6) Remove ISG drive belt.

 Charging System: D13A 1J-19

Installation ISG Drive Belt Tensioner and Idler Pulley

1) Fit ribs of ISG drive belt (1) into grooves of Removal and Installation
AENJHB0B1A26005
crankshaft pulley (2), ISG pulley (3), and idler pulleys
ISG Drive Belt Idler Pulley
(4).
Removal
2) Turn pulley (5) of ISG drive belt tensioner
1) Remove ISG drive belt. (Page 1J-18)
counterclockwise and remove the pin (6).
2) Remove ISG drive belt idler pulleys (1).
3) Turn pulley of ISG drive belt tensioner clockwise to
remove any slack in belt while checking that ribs on
ISG drive belt and grooves in crankshaft pulley, ISG
pulley, and idler pulleys are not misaligned.

3 5 4

IJHB0A1A3008-01

Installation
4
Reverse removal procedure noting the following points.
• Tighten ISG drive belt idler pulley bolts (1) to specified
torque.
Tightening torque
ISG drive belt idler pulley bolt (a): 55 N·m (5.6
kgf-m, 40.5 lbf-ft)

IJHB0A1A3007-01

4) Turn crankshaft clockwise 720° and check that all

ribs on belt fit into grooves in pulleys.
5) Start engine and stabilize ISG drive belt tension.
6) Stop engine, and then inspect ISG drive belt. 1, (a)
(Page 1J-18)
7) Install water pump drive belt. (Page 1F-32)
IJHB0A1A3009-01
8) Install right side engine under side cover.
• Check ISG drive belt. (Page 1J-18)
9) Install right side front wheel. (Page 2D-3)
1J-20 Charging System: D13A

ISG Drive Belt Tensioner
Removal
1) Remove engine assembly from vehicle. (Page 1D-
99)
2) Remove ISG drive belt. (Page 1J-18)
3) Remove ISG drive belt tensioner (1).
1 and that pulleys turn smoothly.
ISG Drive Belt Tensioner and Idler Pulley
Inspection
AENJHB0B1A26006
Check the following points. If check result is not OK,
replace ISG drive belt tensioner and/or idler pulley.
• With bracket (1) of ISG drive belt tensioner secured in
place, turn spring (2) and check that there is no
abnormal noise and that spring turns smoothly.
• Turn pulleys (3) of ISG drive belt tensioner or idler
pulleys (4) and check that there is no abnormal noise
• Check that there is no damage or scratch on surfaces
of ISG drive belt tensioner and idler pulleys.

IJHB0A1A3010-01

Installation
Reverse removal procedure noting the following points. 2 4
• Tighten ISG drive belt tensioner bolts (1) to specified 1
torque.
Tightening torque
IFL10A1A0006-01
ISG drive belt tensioner bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)
ISG Removal and Installation
AENJHB0B1A26007
1, (a) 1, (a) Removal
1) Remove engine assembly from vehicle. (Page 1D-
99)
2) Remove ISG drive belt. (Page 1J-18)
3) Disconnect “B” terminal wire (1) and connector (2)
from ISG (3).
4) Remove ISG.

1, (a) 1, (a)

IJHB0A1A3011-01

• Check ISG drive belt. (Page 1J-18)

3

1
IJHB0A1A3012-01

5) Remove ISG drive belt tensioner from ISG, if

necessary. (Page 1J-19)
 Charging System: D13A 1J-21

Installation
Reverse removal procedure noting the following points.
• Tighten ISG bolts (1) and “B” terminal nut (2) to
specified torque.
Tightening torque
ISG bolt (a): 50 N·m (5.1 kgf-m, 37.0 lbf-ft)
“B” terminal nut (b): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)

1, (a)

2, (b)

IJHB0A1A3013-01

• Check ISG drive belt. (Page 1J-18)

ISG Inspection
AENJHB0B1A26008
Check the following points. If check result is not OK,
replace ISG.
• Turn pulley (1) and check that there is no abnormal
noise and that pulley turns smoothly.
• Check that there is no damage or scratch on surface
of ISG.

IFL10A1A0012-01
1J-22 Charging System: D13A

Specifications
Charging System Specifications
AENJHB0B1A27001
Battery
Battery specification
: CCA 630A (EN) (70AH/20H, 60AH/5H) 12 V

ISG
Rated voltage 12 V
Permissible max. speed 18,000 rpm
Starting speed 1,500 rpm MAX.
Permissible ambient temperature –30 to 120 °C (–22 to 248 °F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side
Nominal output 200 A
Electricity generating mode
Regulated voltage 10.6 to 16.0 V
Max. output 1.7 kW
Driving mode
Max. torque 60 Nm (6.1 kgf-m, 44.5 lbf-ft)

Tightening Torque Specifications

AENJHB0B1A27002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Battery tray bolt 13 1.3 9.5 (Page 1J-17)
Battery tray nut 13 1.3 9.5 (Page 1J-17)
Battery band bolt 5.5 0.56 4.0 (Page 1J-17)
ISG drive belt idler pulley bolt 55 5.6 40.5 (Page 1J-19)
ISG drive belt tensioner bolt 10 1.0 7.5 (Page 1J-20)
ISG bolt 50 5.1 37.0 (Page 1J-21)
“B” terminal nut 11 1.1 8.5 (Page 1J-21)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Special Tool
AENJHB0B1A28001
09932M97650
Belt tensioner gauge
(Page 1J-18)
 Exhaust System: K15B 1K-1

Exhaust System
Engine

K15B
General Description
Exhaust System Description
AENJHB0B1B11001
The exhaust system consists of an exhaust manifold, a three-way catalytic converter (TWC) in the exhaust manifold,
exhaust pipes, a muffler and seals, gasket, and so on.
The three-way catalytic converter is 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 exhaust gases.

Diagnostic Information and Procedures

Exhaust System Check
AENJHB0B1B14001
! CAUTION
Touching a hot exhaust system component will cause a burn.
Do not perform any service work on the exhaust system until the exhaust system is cool.

Exhaust system should be checked as follows at specified periodic maintenance intervals and on every occasion of
service operations performed with vehicle hoisted.
• Check rubber mountings for damage, deterioration and dislocation.

IYSY011B0003-01

• Check mating surface of cylinder head with exhaust manifold for distortion.
• Check exhaust system for leakage, loose connection, dent and damage.
• If bolts or nuts are loosened, and then tighten them to specified torque. (Page 1K-2)
• Check for any damages, holes or crack, which may permit exhaust gas to enter the vehicle.
• Check that exhaust system components have enough clearance from underbody components to avoid overheating
and possible damage to these components.
• Check for any defects and fix them whenever found.
1K-2 Exhaust System: K15B

Repair Instructions
Exhaust System Components
AENJHB0B1B16001

5
13
3 (c)
(a)

1
(d) 19
8
12

6 16

7 (b)
4 (c)
19
10 11
18

15

(b)

14
17 18 19

12

17 (d)
IJHA0A1B0001-01

1. Exhaust manifold 9. Exhaust manifold stiffener No.1 bolt 17. Mounting No.1
: For tightening order, refer to “Exhaust
Manifold Removal and Installation”: K15B
(Page 1K-3).
2. Exhaust manifold gasket 10. Exhaust manifold stiffener No.2 nut 18. Mounting No.2
: For tightening order, refer to “Exhaust : For installation, refer to “Exhaust Pipe
Manifold Removal and Installation”: K15B and Muffler Removal and Installation”:
(Page 1K-3). K15B (Page 1K-4).
3. HO2S-1 11. Exhaust manifold stiffener No.2 bolt 19. Mounting No.3
: For tightening order, refer to “Exhaust
Manifold Removal and Installation”: K15B
(Page 1K-3).
4. HO2S-2 12. Seal ring : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
5. Caution plate 13. Exhaust pipe : 50 Nm (5.1 kgf-m, 37.0 lbf-ft)
6. Exhaust manifold stiffener No.1 14. Exhaust center pipe : 45 Nm (4.6 kgf-m, 33.5 lbf-ft)
7. Exhaust manifold stiffener No.2 15. Gasket : 43 Nm (4.4 kgf-m, 32.0 lbf-ft)
8. Exhaust manifold stiffener No.1 nut 16. Muffler : Do not reuse.
: For tightening order, refer to “Exhaust
Manifold Removal and Installation”: K15B
(Page 1K-3).
 Exhaust System: K15B 1K-3

Exhaust Manifold Removal and Installation 6) Remove exhaust manifold stiffener No.1 (1).
AENJHB0B1B16002
7) Remove exhaust manifold stiffener No.2 (2).
! CAUTION 8) Remove exhaust manifold (3) and its gasket from
Touching a hot exhaust system component cylinder head.
will cause a burn.
Do not perform any service work on the
exhaust system until the exhaust system is
cool.

Removal
3
NOTICE
Applying a shock to the exhaust manifold
1
may cause damage to the three-way catalytic
converter inside the exhaust manifold.
Handle the exhaust manifold carefully. Be
careful not to drop it or hit it against 2
something. IFRA0A1B1003-01

1) Remove HO2S-1 and HO2S-2 clamps (1). Installation

2) Disconnect HO2S-1 (2) and HO2S-2 (3) connectors
and then detach from HO2S bracket (4).
3) Remove HO2S-1 and HO2S-2, if necessary.
(Page 1C-9)
4) Remove caution plate (5) from exhaust manifold.
4
3 2
Reverse removal procedure noting the following points.
• Use new gasket and seal ring.
• Tighten exhaust manifold bolts (1) and nuts (2) to
specified torque.
Tightening torque
Exhaust manifold bolt (a): 60 N·m (6.1 kgf-m, 44.5
lbf-ft)
Exhaust manifold nut (b): 60 N·m (6.1 kgf-m, 44.5
lbf-ft)

1 2, (b)
1, (a) 2, (b)
1, (a)

IJHA0A1B0002-01
1, (a)
5) Remove exhaust pipe (1) from exhaust manifold. 2, (b)

IFRA0A1B1004-01

I7V20A1B1003-01
1K-4 Exhaust System: K15B

• Install HO2S-1 and HO2S-2, if removed. (Page 1C-
9)
• Install exhaust manifold stiffeners as follows.
a. Install exhaust manifold stiffener No.1 (1) and
No.2 (2), then tighten exhaust manifold stiffener
No.1 nut (3) and No.2 nut (4) by hand.
b. Fully tighten all bolts and nuts in numerical order
(“1” – “4”).
Exhaust Manifold Inspection
AENJHB0B1B16003
Using straightedge and feeler gauge, check gasket
surface for distortion. If distortion exceeds its limit, repair
it.
If repair is not possible, replace exhaust manifold.
Distortion of exhaust manifold [a] – [e]
Limit: 0.3 mm (0.012 in.)
Distortion of exhaust manifold [f] – [i]
Limit: 0.7 mm (0.028 in.)

[b] [c] [d] [e]

[h]
[f]

[g]
[i]
[a]
4, “4” “2”
1
3, “3” IFKA0P1B0005-01

Exhaust Pipe and Muffler Removal and

2 Installation
“1”
AENJHB0B1B16004
IGSB0A1B3003-01

• Tighten exhaust pipe bolts to specified torque. ! CAUTION

Tightening torque Touching a hot exhaust system component
Exhaust pipe bolt (a): 43 N·m (4.4 kgf-m, 32.0 lbf- will cause a burn.
ft) Do not perform any service work on the
exhaust system until the exhaust system is
cool.

Removal
1) Remove exhaust pipe (1).
2) Remove seal rings (2) from exhaust pipe and
exhaust manifold (3).

(a)
I9P60A1B1004-01

• Run engine and check for exhaust gas leakage. 3

2
2

1
IJHB0A1B1001-01
 Exhaust System: K15B 1K-5

3) Remove exhaust center pipe (1) from muffle (2). 5) Remove gasket from exhaust center pipe.
4) Remove exhaust center pipe from mounting No.1 (3) 6) Remove muffler (1) from mounting No.3 (2).
and No.2 (4).
2

1
1
4

IJHA0A1B0007-01

IJHA0A1B0004-01
Installation
Reverse removal procedure noting the following points.
• Use new gasket and seal rings.
• Install mounting No.2 (1) positioning its cavity (2)
longitudinally.

1
3
1

IJHA0A1B0005-01

[f]
IJHA0A1B0008-01

[f]: Forward

• Tighten bolts and nuts to specified torque when

reassembling. (Page 1K-2)
• Run engine and check for exhaust gas leakage.

Specifications
Tightening Torque Specifications
AENJHB0B1B17001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Exhaust manifold bolt 60 6.1 44.5 (Page 1K-3)
Exhaust manifold nut 60 6.1 44.5 (Page 1K-3)
Exhaust pipe bolt 43 4.4 32.0 (Page 1K-4)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Exhaust System Components”: K15B (Page 1K-2)
“Fasteners Information” in Section 0A (Page 0A-5)
1K-6 Exhaust System: D13A

D13A
General Description
Exhaust System Description
AENJHB0B1B21001
The exhaust system consists of an exhaust manifold, catalytic converter, a turbocharger, an exhaust pipe, a muffler,
and seals, gaskets, etc.
The catalytic converter is an emission control device added to the exhaust system to lower the levels of Hydrocarbon
(HC) and Carbon Monoxide (CO) pollutants in the exhaust gas.

Diagnostic Information and Procedures

Exhaust System Check
AENJHB0B1B24001
! CAUTION
Touching a hot exhaust system component will cause a burn.
Do not perform any service work on the exhaust system until the exhaust system is cool.

Check the exhaust system at every periodic vehicle inspection and when the vehicle is hoisted for other service noting
the following points:
• Check rubber mountings for damage, deterioration and dislocation.

IYSY011B0003-01

• Check exhaust system for exhaust gas leakage, loose connection, dent and damage.
• If bolts, nuts, clamp and sensors are loosened, tighten them to specified torque. (Page 1K-7)
• Check nearby body areas for damaged, missing or improper installing part, open seam, hole or any other defect
which could permit exhaust fumes to penetrate into vehicle.
• Check that exhaust system components have enough clearance from other underbody components to avoid
overheating and possible damage to these components.
• Check for any defects and fix them whenever found.
 Exhaust System: D13A 1K-7

Repair Instructions
Exhaust System Components
AENJHB0B1B26001

13
10
13

(b)
(e) 12

4 (c)

5
(d)
(b)
9 (b)
3
6

3
7
8
1
(b)
11
(a) 11 12 13

(a)

IJHB0B1B2001-01

1. Catalytic converter 8. Exhaust No.1 pipe : 50 Nm (5.1 kgf-m, 37.0 lbf-ft)
2. Lock plate 9. Exhaust No.2 pipe : 45 Nm (4.6 kgf-m, 33.5 lbf-ft)
3. Gasket 10. Muffler : 30 Nm (3.1 kgf-m, 22.5 lbf-ft)
4. A/F sensor 11. Mounting No.1 : 7.0 Nm (0.71 kgf-m, 5.5 lbf-ft)
5. A/F sensor bracket 12. Mounting No.2 : Do not reuse.
: For installation, refer to “Exhaust Pipe and
Muffler Removal and Installation”: D13A
(Page 1K-8).
6. Turbocharger 13. Mounting No.3
7. Catalytic converter brace : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
1K-8 Exhaust System: D13A

Exhaust Manifold Removal and Installation • Tighten new catalytic converter bolts (2) to specified
AENJHB0B1B26002 torque.
Refer to “Exhaust Manifold Removal and Installation”:
D13A in Section 1D (Page 1D-91). Tightening torque
Catalytic converter bolt (a): 30 N·m (3.1 kgf-m,
Catalytic Converter Assembly Removal and 22.5 lbf-ft)
Installation • Bend tabs (3) of lock plate to prevent catalytic
AENJHB0B1B26003
Removal converter bolts from loosening.
1) Remove oil cooler. (Page 1E-19) • Tighten catalytic converter brace bolt to specified
torque. (Page 1K-7)
2) Remove A/F sensor. (Page 1B-14)
• Tighten A/F sensor to specified torque. (Page 1B-
3) Remove catalytic converter (3) as follows. 14)
a) Remove catalytic converter brace and catalytic
converter brace bolt. (Page 1K-7) 2, (a)

b) Unbend caulking tabs of lock plate (1). 3

c) Remove catalytic converter bolts (2).

d) Remove catalytic converter (3) and its gasket
together.
1
2 3

2, (a)

3
1
IBP80A1B2003-01

3 Exhaust Pipe and Muffler Removal and

2 Installation
AENJHB0B1B26004

Removal
IBP80A1B2002-01
1) Remove exhaust No.1 pipe (1) and gasket from
Installation vehicle.
Reverse removal procedure noting the following points.

NOTICE
If the turbocharger is to be reused, check the
threaded holes in the flange and the mating
surfaces for rust which may cause loosening
of the bolts and nuts.
If rusted, remove the rust by grinding the
surfaces and tapping the threaded holes.

• Install new gasket and new lock plate (1). 1

NOTE IJHB0A1B3002-01
When installing catalytic converter with
gasket and lock plate, insertion of M6 bolts or
about 6 mm diameter pins to two bolt holes
as a guide will prevent the gasket and lock
plate from falling down.
 Exhaust System: D13A 1K-9

2) Remove exhaust No.2 pipe (1) and gasket from Installation

vehicle. Reverse removal procedure noting the following points.
• Use new gaskets.
• Install mounting No.2 (1) positioning its cavity (2)
longitudinally.

1
1

IJHB0A1B3003-01

3) Remove muffler (1) from vehicle.

[f]
IJHB0B1B2002-01

[f]: Forward

1 • Tighten exhaust pipe nuts to specified torque. (Page

1K-7)
• Run engine and check for exhaust gas leakage.

IJHB0A1B3004-01

Specifications
Tightening Torque Specifications
AENJHB0B1B27001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Catalytic converter bolt 30 3.1 22.5 (Page 1K-8)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Exhaust System Components”: D13A (Page 1K-7)
“Fasteners Information” in Section 0A (Page 0A-5)
1K-10 Exhaust System: D13A

Section 2
Suspension
CONTENTS
Precautions .................................................2-1
Precautions............................................................. 2-1
Precautions for Suspension .................................. 2-1
Suspension General Diagnosis.............. 2A-1
Diagnostic Information and Procedures............2A-1
Suspension, Wheel and Tire Symptom
Diagnosis .......................................................... 2A-1
Repair Instructions ..............................................2A-4
Suspension System Check ................................. 2A-4
Front Suspension .................................... 2B-1
Precautions...........................................................2B-1
Precautions for Handling of Front Strut............... 2B-1
General Description .............................................2B-1
Front Suspension Description ............................. 2B-1
Front Wheel Alignment Description..................... 2B-2
Repair Instructions ..............................................2B-2
Front Wheel Alignment Inspection and
Adjustment ........................................................ 2B-2
Front Strut Assembly Components ..................... 2B-4
Front Strut Assembly Removal and
Installation ......................................................... 2B-4
Front Strut Assembly Disassembly and
Reassembly ...................................................... 2B-6
Front Strut Inspection.......................................... 2B-7
Coil Spring, Strut Bearing and Strut Support
Check................................................................ 2B-7
Suspension Arm Components ............................ 2B-8
Suspension Arm Removal and Installation ......... 2B-8
Suspension Arm Check ...................................... 2B-9
Front Suspension Frame and Stabilizer Bar
Components.................................................... 2B-12
Front Suspension Frame, Stabilizer Bar and
Bushing Removal and Installation................... 2B-13
Front Suspension Frame Check ....................... 2B-15
Front Stabilizer Bar, Bushing and Joint Check .. 2B-15
Front Suspension Fastener Check ................... 2B-15
Specifications.....................................................2B-16
Tightening Torque Specifications...................... 2B-16
Special Tools and Equipment ...........................2B-16
Special Tool ...................................................... 2B-16
Table of Contents 2- i
Rear Suspension ..................................... 2C-1 2
Precautions...........................................................2C-1
Precautions for Handling of Rear Shock
Absorber............................................................2C-1
General Description .............................................2C-1
Rear Suspension Description..............................2C-1
Repair Instructions ..............................................2C-1
Rear Wheel Alignment Inspection.......................2C-1
Rear Suspension Components ...........................2C-2
Rear Shock Absorber Removal and
Installation .........................................................2C-3
Rear Shock Absorber Inspection ........................2C-4
Rear Coil Spring and Spring Seat Removal
and Installation ..................................................2C-4
Rear Coil Spring and Spring Seat Check............2C-5
Rear Axle Removal and Installation ....................2C-6
Rear Axle Check .................................................2C-7
Rear Suspension Fastener Check ......................2C-7
Specifications .......................................................2C-7
Tightening Torque Specifications........................2C-7
Wheels and Tires ..................................... 2D-1
Precautions...........................................................2D-1
Precautions for Servicing Wheel and Tire...........2D-1
General Description .............................................2D-1
Tire Description ...................................................2D-1
Replacement Tire Description.............................2D-1
Wheel Description ...............................................2D-2
Replacement Wheel Description.........................2D-2
Wheel-Tire Assembly Description (for Vehicle
Equipped with Steel Wheel) ..............................2D-2
Wheel-Tire Assembly Description (for Vehicle
Equipped with Aluminum Wheel) ......................2D-2
Tire Placard Description......................................2D-2
Repair Instructions ..............................................2D-3
Wheel (with Tire) Removal and Installation.........2D-3
Tire Inspection.....................................................2D-4
Wheel Inspection.................................................2D-5
Tire Rotation........................................................2D-5
Specifications .......................................................2D-6
Tightening Torque Specifications........................2D-6
2-1 Precautions:

Precautions
Suspension

Precautions
Precautions for Suspension
AENJHB0B2000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Caution for Fastener

Refer to “Caution for Fastener” in Section 00 (Page 00-5).

Caution for Suspension

Refer to “Caution for Suspension” in Section 00 (Page 00-6).

Warning for Wheel and Tire

Refer to “Warning for Wheel and Tire” in Section 00 (Page 00-6).

Warning for Air Bag

Refer to “Warning for Air Bag” in Section 00 (Page 00-7).

Suspension General Diagnosis
Suspension
Diagnostic Information and Procedures
Suspension, Wheel and Tire Symptom Diagnosis
Condition Possible cause
Vehicle pulls to one side Mismatched or unevenly worn tires
(leads) Tires not adequately inflated
Broken or sagging coil springs
Abnormal lateral force created by radial Replace tire. (Page 2D-3)
tire
Disturbed wheel alignment
Brake dragging in one wheel
Loose, bent or broken front or rear
suspension parts
Excessive tire wear Broken or sagging coil springs
Wheel out of balance
Disturbed wheel alignment
Faulty front strut assembly (shock
absorber)
Hard driving
Overloaded vehicle
Not rotated tires
Worn or loose wheel bearing
Wheel or tire wobbles
Tires not adequately inflated
Wheel tramp Blister or bump on tire
Improper front strut assembly (shock
absorber) action
Suspension General Diagnosis: 2A-1
AENJHB0B2104001
Correction / Reference Item
Replace tires. (Page 2D-3)
Adjust tire pressure.
Replace coil springs.
• Front: (Page 2B-6)
• Rear: (Page 2C-4)
Check and adjust wheel alignment. (Page
2B-2)
Adjust or repair brake.
Tighten or replace related suspension parts.
(Page 2A-4)
Replace coil springs.
• Front: (Page 2B-6)
• Rear: (Page 2C-4)
Adjust balance or replace tire.
Check and adjust wheel alignment. (Page
2B-2)
Replace front strut assembly (shock absorber).
(Page 2B-6)
Replace tires. (Page 2D-3)
Replace tires. (Page 2D-3)
Replace or rotate tires.
Replace wheel bearing.
• Front: (Page 3A-17)
• Rear: (Page 3A-21)
Replace wheel or tire. (Page 2D-3)
Adjust tire pressure.
Replace tire. (Page 2D-3)
Replace front strut assembly (shock absorber).
(Page 2B-6)
2A-2 Suspension General Diagnosis:
Condition Possible cause
Shimmy, shake or Wheel out of balance
vibration
Loose wheel bearings
Worn tie-rod ends
Worn suspension arm joints
Excessive tire or wheel run-out
Blister or bump on tire
Excessive radial runout of tire / wheel
assembly
Disturbed wheel alignment
Loose or worn steering linkage
Loose steering gear case bolts
Abnormal noise Damaged front strut assembly (shock
absorber) or mountings
Damaged rear shock absorber or
mountings
Worn, sticky or loose tie-rod ends
Worn or damaged suspension arm joints Replace suspension arm. (Page 2B-8)
Worn, sticky or loose tie-rod ball joints Replace tie-rod. (Page 6B-19)
Worn, sticky or loose drive shaft joints Replace drive shaft joints. (Page 3A-3)
Worn suspension arm front bushings
Worn suspension arm rear bushings
Loose stabilizer bar
Loose wheel nuts
Loose suspension bolts or nuts
Broken or damaged wheel bearings
Broken coil springs
Poorly lubricated or worn strut bearings Replace strut bearings. (Page 2B-6)
Steering system malfunction
Deteriorated rear axle bushings
Too low or uneven trim Broken or sagging coil springs
heights
NOTE
Overloaded vehicle
See NOTE *1.
Incorrect coil springs
Poorly inflated tires
Too soft ride Faulty front strut assembly (shock
absorber)
Faulty rear shock absorber
Correction / Reference Item
Balance wheel(s) or replace tire(s) and/or
wheel(s).
Replace wheel bearings.
• Front: (Page 3A-17)
• Rear: (Page 3A-21)
Replace tie-rod ends. (Page 6B-17)
Replace suspension arm. (Page 2B-8)
Repair or replace wheel and/or tire. (Page
2D-3)
Replace tire. (Page 2D-3)
Replace tire or wheel. (Page 2D-3)
Check and adjust wheel alignment. (Page
2B-2)
Check steering system.
• Steering wheel: (Page 6C-32)
• Steering shaft joint: (Page 6B-10)
• Pinion shaft: (Page 6B-21)
• Tie-rod end: (Page 6B-18)
Tighten steering gear case bolts. (Page 6B-
18)
Repair or replace front strut assembly (shock
absorber) or mountings. (Page 2B-6)
Replace rear shock absorber. (Page 2C-3)
Replace tie-rod ends. (Page 6B-17)
Replace suspension arm. (Page 2B-8)
Replace suspension arm. (Page 2B-8)
Tighten bolts or nuts and/or replace bushings.
(Page 2B-12)
Tighten wheel nuts. (Page 2D-3)
Tighten suspension bolts or nuts. (Page 2B-
8)
Replace wheel bearings. (Page 3A-17)
Replace coil springs.
• Front: (Page 2B-4)
• Rear: (Page 2C-4)
Check and correct malfunction. (Page 6A-1)
Replace rear axle. (Page 2C-6)
Replace coil springs.
• Front: (Page 2B-6)
• Rear: (Page 2C-4)
Check loading.
Replace coil springs.
• Front: (Page 2B-6)
• Rear: (Page 2C-4)
Adjust tire pressure.
Replace front strut assembly (shock absorber).
(Page 2B-6)
Replace rear shock absorber. (Page 2C-3)
 Suspension General Diagnosis: 2A-3

Condition Possible cause Correction / Reference Item

Suspension bottoms Overloaded vehicle Check loading.
Faulty front strut assembly (shock Replace front strut assembly (shock absorber).
absorber) (Page 2B-6)
Incorrect, broken or sagging coil springs Replace coil springs.
• Front: (Page 2B-6)
• Rear: (Page 2C-4)
Body leans or sways in Loose stabilizer bar Tighten stabilizer bar bolts or nuts, or replace
corners bushings. (Page 2B-12)
Faulty front strut assembly (shock Replace front strut assembly (shock absorber)
absorber) or mounting or tighten mounting. (Page 2B-6)
Faulty rear shock absorber Replace rear shock absorber. (Page 2C-3)
Broken or sagging coil springs Replace coil springs.
• Front: (Page 2B-6)
• Rear: (Page 2C-4)
Overloaded vehicle Check loading.
Cupped tires Disturbed wheel alignment Check and adjust wheel alignment. (Page
2B-2)
Faulty front strut assembly Replace front strut assembly. (Page 2B-6)
Worn wheel bearings Replace wheel bearings. (Page 3A-17)
Excessive tire or wheel run-out Repair or replace tire and/or wheel. (Page
2D-3)
Worn suspension arm joints Replace suspension arm. (Page 2B-8)
Wheel out of balance Adjust balance or replace tire.

NOTE
*1: Right-to-left trim height (“h”) difference should be within 15 mm (0.6 in.) with curb weight. (The
same applies to both front and rear suspensions.)

I8C50A210002-01
2A-4 Suspension General Diagnosis:

Repair Instructions
Suspension System Check
AENJHB0B2106001
Hoist vehicle and check the following parts. Retighten,
repair or replace defective part with new one if
necessary.
Front suspension
• Front suspension frame: (Page 2B-15)
• Suspension arm: (Page 2B-9)
• Front strut assembly: (Page 2B-7)
• Coil spring, strut bearing and strut support: (Page
2B-7)
• Front stabilizer bar and joint: (Page 2B-15)

IJHA0A210001-02

Rear suspension
• Rear axle: (Page 2C-7)
• Rear shock absorber: (Page 2C-4)
• Rear coil spring: (Page 2C-5)

IJHA0A210002-01
 Front Suspension: 2B-1

Front Suspension
Suspension

Precautions
Precautions for Handling of Front Strut
AENJHB0B2200001
! WARNING
Since a high-pressure gas is sealed inside each front strut (1), there is a risk of personal injury if you
do not take proper precautions when handling them.
• Do not disassemble any front strut.
• Do not put it into fire.
• Do not store a front strut where it gets hot.
• Before disposing of a front strut, drill an approximately 3 mm (0.12 in.) diameter hole (2) in it at the
point indicated in the figure and let the gas and oil out of the cylinder.
• Wear eye protection when drilling a gas release hole. Although the gas itself is harmless, metal
chips produced by the drilling can injure your eyes.

1 2

IDL10A220001-01

General Description
Front Suspension Description
AENJHB0B2201001
• Front suspension employs a McPherson strut type combined with suspension frame (1).
• The suspension frame supports steering gear case assembly (2), engine rear torque rod (3) and suspension arms
(4), to reduce vehicle vibration.
• Front strut assembly consists of a sealed cylindrical strut (5) filled with high-pressure gas and a coil spring (6).
• The front suspension also includes stabilizer bar (7), to improve anti-rolling performance of vehicle.

2
7

4
1
3
IJHA0A220001-02
2B-2 Front Suspension:

Front Wheel Alignment Description

AENJHB0B2201002
Among factors for front wheel alignment, only toe setting can be adjusted. Camber and caster cannot be adjusted.
Therefore, should camber or caster be out of specification due to the damage caused by hazardous road conditions or
collision, whether the damage is in body or in suspension should be determined. If body is damaged, it should be
repaired. If suspension is damaged, it should be replaced.

Repair Instructions
Front Wheel Alignment Inspection and Front toe (Total) “b” – “a”
Adjustment : IN 1 ± 1 mm (IN 0.04 ± 0.04 in.)
AENJHB0B2206001
Preparation
Perform the following items before checking and [f]

adjusting front wheel alignment.

• Check each tire as follows. “a”
– Check that tire is of specified size. Replace tire with
correct one if necessary.
– Check that tire is inflated correctly. Adjust pressure
if necessary.
– Check that tire does not have abnormal wear and is
not worn more than the other tires. Replace tire
with proper one if necessary.
– Check that tire is of the same brand as the other
tires. Replace tire with one of correct brands if “b”
necessary. I7V10A220002-02

• Check that wheel bearing is not damaged. Replace [f]: Forward

wheel hub assembly if defective.
• Check wheel (with tire) for deflection. If necessary,
repair or replace.
• Check if each suspension part is installed properly. If
faulty condition is found, repair or replace.
• Check that each suspension part is free from bend,
dent, wear or damage.
• Place vehicle in non-loaded state on level surface.
• Set steering wheel in straight ahead position.
• Bounce vehicle up and down several times to stabilize
suspension.
• Check that ground clearance at the right and left is
almost the same.
Toe Inspection
Measure toe using toe-in gauge (1).
If toe is out of specification, adjust it at tie-rod.
Toe Adjustment
NOTICE
The rack boot may break if it is twisted.
Check that the rack boot does not get twisted
during adjustment of front wheel alignment.
NOTE
Never adjust only right or left tie-rod, adjust
both tie-rods by the same amount.
1) Loosen tie-rod end lock nuts.
2) Tighten or loosen right and left tie-rods by the same
amount to adjust toe to specification.
3) Check that length “a” on right tie-rod is equal to that
on left tie-rod. If they are not equal, readjust toe.

“a”

I6RS0C220007-01
IFRA0A220002-01

4) Tighten tie-rod end lock nuts to specified torque.

(Page 6B-16)
 Front Suspension: 2B-3

Reference Information
Front camber “a”
Side slip
: +0° 23’ ± 1° 00’
When checked using side slip tester, side slip should be
within the following specification. Front caster “b”
: 4° 30’ ± 2° 00’
Side slip (On one person)
: 0 to IN 3 mm/m (0 to IN 0.12 in./3.3 ft.) Kingpin inclination angle “c”
Front: 12° 10’ ± 2° 00
If side slip deviates from specification greatly, front wheel
alignment may be out of specification. NOTE
Camber, caster and kingpin inclination angle
Toe angle
are not adjustable. If they are out of
Reference front toe angle when measured using total
specification, repair vehicle body or replace
wheel alignment tester or the like, is as follows.
related part.
Front toe angle (Each wheel)
: IN 0° 03’ ± 0° 05’
[A] [k]
2
If front toe angle is out of specification, adjust it at the tie-
rod.
“c”
[t]
Camber, Caster and Kingpin Inclination Angle
Inspection
Check camber, caster and kingpin inclination angle
using camber caster kingpin gauge (1) and turning [s]
radius gauge (2). If measured value is not as specified,
check the following items for damage, deformation and
crack. Repair or replace any defective part.
• Strut assembly components “d” 1
• Suspension arms and bushings
• Front suspension frame “a”
• Front wheel hubs, steering knuckles and wheel
[B]
bearings “b”
• Vehicle body

[f]

“d”
2

IGRA0A220001-01

[A]: Camber and kingpin [t]: Center line of wheel

I7RS0A220003-01 inclination angle (Front view)
[B]: Caster (Side view) “d”: 90°
[f]: Forward 1. Suspension arm joint
[k]: Center line of kingpin 2. Strut support
[s]: Vehicle body center

Steering Angle Inspection and Adjustment

When tie-rod or tie-rod end is replaced, check toe and
then also steering angle using turning radius gauge. If
measured value is not as specified, check and adjust
toe.
Inside steering angle
: 41° 15’ ± 2° 00’
Outside steering angle
: 33° 53’ ± 2° 00’
2B-4 Front Suspension:

Front Strut Assembly Components

AENJHB0B2206002

11

(a)
10

(a)

9 1
8
15
7

(a)

5
13 (b)

12

3
14

[f]
2

IJHA0A220002-03

[f]: Forward 7. Strut bearing 14. Steering knuckle

1. Front strut 8. Strut bearing plate 15. Damper cap
2. Coil spring lower seat 9. Strut support : 50 Nm (5.1 kgf-m, 37.0 lbf-ft)
3. Coil spring 10. Rebound stopper : 90 Nm (9.2 kgf-m, 66.5 lbf-ft)
4. Bump stopper 11. Strut rod cap : Do not reuse.
5. Strut dust cover 12. Strut bracket bolt
: Insert from vehicle front side.
6. Coil spring upper seat 13. Stabilizer joint

Front Strut Assembly Removal and Installation Removal

AENJHB0B2206003
1) Remove strut rod cap.
NOTICE
NOTE
The strut bracket nut is pre-coated with
friction stabilizer. If the nut is reused, it may When servicing strut assembly components,
work loose. loosen strut support upper nut a little before
Never reuse the strut bracket nut. removing strut assembly. This will facilitate
service work. Note that the nut must not be
NOTE removed at this point.

Pulling steering knuckle outward with drive 2) Hoist vehicle, allowing front suspension to be free of
shaft fixed to steering knuckle could cause vehicle weight.
drive shaft to be removed from transaxle. 3) Remove front wheel. (Page 2D-3)
Do not pull steering knuckle outward.
If drive shaft is removed, replace drive shaft
circlip with new one.
 Front Suspension: 2B-5

4) Remove stabilizer joint nut while holding stud using Installation

hexagon wrench (2) and then disconnect stabilizer Reverse removal procedure noting the following points.
upper joint (1) from strut (3). • Insert strut bracket bolts (1) in the direction shown in
figure.
• Use new strut bracket nuts (2).
• Tighten strut bracket nuts, front brake hose strut bolt
(3) and stabilizer joint nut (4) to specified torque.
3 2 Tightening torque
Strut bracket nut (a): 90 N·m (9.2 kgf-m, 66.5 lbf-
1 ft)
Front brake hose strut bolt (b): 26 N·m (2.7 kgf-
m, 19.5 lbf-ft)
Stabilizer joint nut (c): 50 N·m (5.1 kgf-m, 37.0 lbf-
ft)
IFRA0A220004-01 • Install front wheel speed sensor harness by fitting its
5) Remove front brake hose strut bolt (1), to detach grommet (5) on hook of bracket (6).
brake hose (2) from front strut (4).
NOTE
6) Detach front wheel speed sensor harness (3) from
Do not twist brake hose and front wheel
front strut.
speed sensor harness when installing them.
7) Remove strut bracket nuts (5) and bolts (6).
• Tighten wheel nuts to specified torque. (Page 2D-3)
• Lower hoist with vehicle in unloaded condition, and
then tighten new strut support upper nut (7) to
specified torque.
4 Tightening torque
6
Strut support upper nut (d): 50 N·m (5.1 kgf-m,
37.0 lbf-ft)
3

7, (d)
2
5

IJHA0A220003-01
5
8) Remove strut support upper nut (1) and rebound 3, (b)
stopper (2), and then remove front strut assembly
from vehicle. [f]
6
NOTE
Hold strut assembly by hand so that it will 4, (c)
not fall off.

2
1

2, (a)

IJHA0A220004-01
1
[f]: Forward

IFRA0A220006-01
• After completing installation, check front wheel
alignment. (Page 2B-2)
2B-6 Front Suspension:

Front Strut Assembly Disassembly and Reassembly

Reassembly 1) Compress coil spring using special tool (spring
AENJHB0B2206004
compressor) evenly until total length “a” becomes
! WARNING the same length as recorded in disassembly.

Failure to take proper precautions when Special tool

compressing the coil spring can result in (A): 09943M25010
severe personal injury.
“a”
• Attach the spring compressors to the
positions that allow compressing the
spring evenly.
• Do not use an impact wrench when
[u] [l] (A)
compressing the coil spring.
• When using commercially available spring
compressors, follow the manufacturer’s
instructions described in the manual
I9P60A220009-02
attached to the spring compressors.
[u]: Upper side (large diameter) [l]: Lower side (small diameter)

Disassembly
2) Install coil spring lower seat (2) to front strut by fitting
1) Attach special tool (A) to coil spring as shown. Screw
its protrusions (1) into holes (3) in front strut.
in special tool bolts (1) alternately until coil spring
tension is released from strut. Rotate strut to check 1
that it is free of coil spring tension. Record total
length of compressed coil spring when it is
compressed.
Special tool
(A): 09943M25010 3
2

(A)
1

IDL10A220004-01

3) Install compressed coil spring to front strut by fitting

coil spring end (1) with protrusion of coil spring lower
seat (2) as shown in figure.

NOTE
I9P60A220008-02
Coil spring end should not ride on step in coil
2) While keeping coil spring compressed using special spring lower seat.
tool, remove strut support lower nut (1) using
hexagon wrench (2) as shown in figure.

IFRA0A220031-01

3) Disassemble front strut assembly. (Page 2B-4) 1

IDL10A220005-01

4) Set bump stopper. (Page 2B-4)

 Front Suspension: 2B-7

5) Set strut dust cover (1) over three claws (2) of Front Strut Inspection
damper cap (3). AENJHB0B2206005
• Check each front strut for oil leakage, damage or
deformation. If check result is not OK, replace front
strut as an assembly, as it is not repairable.
3

IDAA0A220010-01

6) Pull strut rod as far up as possible and use care not

to allow it to retract into strut.
7) Install coil spring upper seat.
8) Install strut bearing, strut bearing plate, strut support
and strut support lower nut in this sequence. IJHA0A220005-01

(Page 2B-4) • Check front strut function as follows. If check result is

Then tighten strut support lower nut (1) to specified not OK, replace front strut as an assembly, because it
torque while holding stud using hexagon wrench. is not repairable.
Tightening torque a. Check and adjust tire pressures as specified.
Strut support lower nut (a): 50 N·m (5.1 kgf-m, b. Bounce vehicle body up and down 3 or 4 times
37.0 lbf-ft) continuously by pushing front end of vehicle side
body to check front strut.
Also, note how many times vehicle body rebounds
to stop after force application.
c. Repeat the same procedure to the other front strut
to check that both struts equally function.
1, (a) If conditions of front struts are in doubt, compare
them with known-good vehicle or front strut.

Coil Spring, Strut Bearing and Strut Support

Check
AENJHB0B2206006
IFRA0A220032-02 • Check coil spring for weakening, crack, deformation
9) Remove special tool (spring compressor) from coil and damage.
spring. Then check that coil spring end does not ride • Check bump stopper, strut dust cover, coil spring
on protrusion of spring lower seat. upper seat, coil spring lower seat and strut support for
crack, deformation and damage.
• Check strut bearing for wear, abnormal noise and
damage.
If check result is not OK, replace defective parts with
new ones.
2B-8 Front Suspension:

Suspension Arm Components Removal

AENJHB0B2206007
1) Hoist vehicle and remove front wheel. (Page 2D-3)
2) Remove engine under side cover.
1 3) Remove clip (2).
4) Loosen suspension arm joint nut (1) until nut end
becomes flush with stud end of suspension arm joint.
2

(a)
1
2
(b)
(a)

[f]

IGRA0B220001-02

[f]: Forward : 95 Nm (9.7 kgf-m, 70.0 lbf-ft)

1. Suspension arm : 55 Nm (5.6 kgf-m, 40.5 lbf-ft) IFRA0A220010-01
2. Clip : Do not reuse. 5) Disconnect suspension arm joint (1) from steering
knuckle (2) using puller (3).
Suspension Arm Removal and Installation
AENJHB0B2206008 ! CAUTION
NOTICE Ball joint puller may fall off when suspension
arm joint is disconnected and cause an
• Unless you pay adequate attention when
injury.
removing the suspension arm joint from
Suspend the ball joint puller from the vehicle
the steering knuckle, the dust cover of the
body using a rope to prevent the puller from
suspension arm joint may be damaged by
falling off.
the puller.
When you remove the suspension arm
joint from the steering knuckle, be careful
not to damage the dust cover of the
suspension arm joint.
• The following bolts are pre-coated with 2
friction stabilizer. If these bolts are reused,
they may work loose.
Never reuse the following bolts.
– Suspension arm front bushing bolt
– Front suspension frame bolt 3

1
NOTE
Suspension arm front bushing and rear IFRA0A220033-01

bushing are not individually replaceable. 6) Remove suspension arm joint nut.
Replace suspension arm if the bushings are
defective.
 Front Suspension: 2B-9

7) Remove suspension arm front bushing bolt (2) and
front suspension frame bolt (3), and then remove
suspension arm (1).
2 Suspension arm front bushing bolt (a): 95 N·m (
1
4) Install front wheel and tighten wheel nuts to specified
torque. (Page 2D-3)
5) Lower hoist and bounce vehicle up and down
several times to stabilize suspension. Then, tighten
suspension arm front bushing bolt (2) and front
suspension frame bolt (3) to specified torque.
Tightening torque
9.7 kgf-m, 70.0 lbf-ft)
Front suspension frame bolt (b): 95 N·m (9.7
kgf-m, 70.0 lbf-ft)

IJHA0A220006-01

Installation 2, (a)

1) Install suspension arm (1) and tighten new

suspension arm front bushing bolt (2) and new front 1
suspension frame bolt (3) temporarily by hand.
3, (b)

IJHA0A220007-01

1. Suspension arm
2
6) Hoist vehicle again, and then install engine under
1
side cover.
7) Lower hoist, and then check front wheel alignment.
(Page 2B-2)
3

Suspension Arm Check

IJHA0A220006-01 AENJHB0B2206009
2) Connect suspension arm joint to steering knuckle
and then tighten new suspension arm joint nut (1) to Arm
specified torque. Check body of suspension arm (1) for damage and
deterioration. Replace suspension arm if check result is
NOTE not OK.
If grease is stuck on taper surface of
suspension arm joint and knuckle, remove it
before connecting these parts.

Tightening torque
Suspension arm joint nut (a): 55 N·m (5.6 kgf-m,
40.5 lbf-ft)
3) Insert new clip (2) to suspension arm joint.

1, (a)

IFRA0A220013-01
2B-10 Front Suspension:

Bushing 5) Push suspension arm up at near ball joint by hand

Check suspension arm front bushing (2) for damage,
wear and deterioration. Replace suspension arm if
check result is not OK.
Check suspension arm rear bushing (3) for damage,
wear and deterioration. Replace suspension arm if
check result is not OK.
3
with force of about 20 to 30 N (2.0 to 3.1 kgf, 4.5 to
6.7 lbf) and hold this state for 2 to 3 seconds, and
then read dial gauge.
6) Reversing direction of force, pull suspension arm
down at near ball joint by hand with force of about 20
to 30 N (2.0 to 3.1 kgf, 4.5 to 6.7 lbf) and hold this
state for 2 to 3 seconds, and then read dial gauge.
7) Check total “a” of readings in Steps 5) – 6), amount
of looseness.
If measured looseness exceeds specified range,
replace suspension arm.

1 Amount of looseness in suspension arm ball

joint
“a”: less than 0.2 mm (0.008 in.)

IJHA0A220008-01

Joint
1) Remove front wheel. (Page 2D-3)
2) Using washers (2) and nuts (3) other than the wheel
3 “a”
nuts, fix front brake disc (1) diagonally.

! CAUTION 0
90 10
If the wheel nut is used to fix the front brake 20
80
disc, the tapered end of the wheel nut may be
damaged. 30
70 1
Do not use wheel nut for the brake disc 2
60 40
fixation in this step. 50

IA1J0P020019-01

1 8) Lightly push ball joint dust cover (1) with fingers to

check whether there is water inside.
2 If water is found to come out, replace suspension
arm.

IJHA0A220009-01 1

3) Using magnetic stand (1), set dial gauge (2) on front

brake disc.

NOTE
Apply measuring tip of dial gauge ICP50A220001-01
perpendicular to bottom center surface of
ball joint as much as possible.

4) Set pointer to 0 (zero) by turning dial (3).

 Front Suspension: 2B-11

9) Push top end (1) of ball joint dust cover down to

check for rust on ball stud’s surface (2) in contact
with dust cover.
If surface is found rusted, replace suspension arm.

ICP50A220002-01

10) Move top end of ball joint dust cover back to original
position.
11) Check ball joint dust cover (1) for crack and damage.
If it is cracked or damaged, replace suspension arm.

ICP50A220003-01

12) Detach ball joint stud from steering knuckle. (Page

2B-8)
13) Check that ball joint stud (1) moves without sticking.
If not, replace suspension arm.

ICP70A220001-01

14) Connect suspension arm ball joint to steering

knuckle. (Page 2B-8)
15) Install front wheel and tighten wheel nuts to specified
torque. (Page 2D-3)
2B-12 Front Suspension:

Front Suspension Frame and Stabilizer Bar Components

AENJHB0B2206010

10 (a)

2 1

(b)

8 4
(b)
6

8
8

12 (d)
11 (c)

A
9

11 (c)
(c)
A “1”
[f]

“2”

IJHB0B220001-01

[f]: Forward 6. Front suspension frame 12. Front suspension frame rear bolt
: For tightening procedure, refer to
“Front Suspension Frame, Stabilizer Bar
and Bushing Removal and Installation”
(Page 2B-13).
1. Stabilizer bar 7. Engine rear torque rod : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
2. Stabilizer bar bushing 8. To body : 50 Nm (5.1 kgf-m, 37.0 lbf-ft)
: For installing direction of stabilizer bar bushing,
refer to “Front Suspension Frame, Stabilizer Bar
and Bushing Removal and Installation” (Page
2B-13).
3. Stabilizer mounting bracket 9. Torque rod cover : 95 Nm (9.7 kgf-m, 70.0 lbf-ft)
4. Stabilizer joint 10. Stabilizer bar mounting bracket bolt : 75 Nm (7.6 kgf-m, 55.5 lbf-ft)
: For tightening procedure, refer to
“Front Suspension Frame, Stabilizer Bar
and Bushing Removal and Installation”
(Page 2B-13).
5. Suspension arm 11. Front suspension frame bolt : Do not reuse.
: For tightening procedure, refer to
“Front Suspension Frame, Stabilizer Bar
and Bushing Removal and Installation”
(Page 2B-13).
 Front Suspension: 2B-13

Front Suspension Frame, Stabilizer Bar and 10) Support front suspension frame (2) using
Bushing Removal and Installation transmission jack (1).
AENJHB0B2206011

! CAUTION 2

• If the front suspension frame is not stably

supported on a transmission jack or other
supporting equipment during its removal
and installation, the frame could drop and
cause personal injury.
Check that the weight of the front
suspension frame is supported at the
frame’s center and that the frame is well
balanced on the support.
1
• Touching a hot exhaust system component IJHA0A220011-01
will cause a burn.
11) Remove front suspension frame bolts (1) and front
Do not perform any service work on the
suspension frame rear bolts (2), and then lower
exhaust system until the exhaust system is
transmission jack to remove suspension frame (3)
cool.
together with stabilizer bar, torque rod and steering
gear case from vehicle body.
NOTICE
• The front suspension frame bolt, front
3
suspension frame rear bolt and steering
gear case bolt are pre-coated with friction
1 1
stabilizer. If these bolts are reused, they
may work loose.
Never reuse the front suspension frame
bolt, front suspension frame rear bolt and
steering gear case bolt.
• Once steering gear packing use, the 2 2
packing part transforms. If this packing is
reused, water may enter into gearbox.
Never reuse the steering gear packing. IJHA0A220012-01

12) Remove steering gear case assembly from front

Removal
suspension frame. (Page 6B-18)
1) Disconnect steering lower shaft from pinion shaft.
13) Remove torque rod cover from front suspension
(Page 6B-14)
frame. (Page 2B-12)
2) Hoist vehicle and remove front wheels. (Page 2D-
14) Remove torque rod from front suspension frame.
3)
• K15B model: (Page 1D-26)
3) Remove engine under side covers.
• D13A model: (Page 1D-98)
4) Disconnect muffler mounting from front suspension
frame. 15) Remove stabilizer mounting bracket (1), stabilizer
bar bushing (2) and stabilizer bar (3) from front
• K15B model: (Page 1K-2)
suspension frame (4).
• D13A model: (Page 1K-7)
5) Disconnect stabilizer joint from stabilizer bar.
6) Disconnect tie-rod end from steering knuckle. 1 3
(Page 6B-17)
2
7) Remove suspension arm. (Page 2B-8)
8) Remove apron lower member bracket. (Page 9H-
5)
4
9) Remove engine rear torque rod bolt.
• K15B model: (Page 1D-26)
• D13A model: (Page 1D-98) IFRA0A220022-01
2B-14 Front Suspension:

Installation 3) Install torque rod cover (1) to front suspension frame

1) Install front stabilizer bar (1), bushings (2) and (2) as shown in figure.
mounting brackets (3) to front suspension frame as
follows.
a) Position stabilizer bar with identification painting
(5) facing up at right side.
b) Position stabilizer bar bushing with its slit (6)
facing frontward and its end closely fit against
ring (4) of stabilizer bar.
c) Tighten stabilizer bar mounting bracket bolts (7)
temporarily, and then tighten them to specified 1

torque.
2
Tightening torque 1
Stabilizer bar mounting bracket bolt* (a): 23 [f]
N·m (2.3 kgf-m, 17.0 lbf-ft)
2

[f] 7, (a)
2
6 IGRA0B220003-01

[f]: Vehicle forward

4 3
[f] 4) Install steering gear case assembly to front
[i] 7, (a) suspension frame. (Page 6B-18)
5) Install suspension arm to front suspension frame,
and then tighten new suspension arm front bushing
bolts temporarily by hand. (Page 2B-8)
6) Put front suspension frame (2) on transmission jack
1 (1) and raise jack.

IJHA0A220013-01

[f]: Forward [i]: Vehicle inside

2) Install torque rod to front suspension frame.

• K15B model: (Page 1D-26)
• D13A model: (Page 1D-98)
1
IJHA0A220014-01
 Front Suspension: 2B-15

7) Fix front suspension frame with new bolts as follows. Front Suspension Frame Check
AENJHB0B2206012
a) Tighten front suspension frame bolt (1) Check front suspension frame for crack, deformation
temporarily. and damage. Replace front suspension frame if check
b) Tighten front suspension frame bolt (2) to result is not OK. (Page 9K-38)
specified torque.
c) Tighten front suspension frame bolts (1), (3) and
front suspension frame rear bolts (4) to specified
torque.
Tightening torque
Front suspension frame bolt (a): 95 N·m (9.7
kgf-m, 70.0 lbf-ft)
Front suspension frame rear bolt (b): 75 N·m
(7.6 kgf-m, 55.5 lbf-ft)

3, (a) 3, (a)

IFRA0A220026-01

1, (a) 2, (a) Front Stabilizer Bar, Bushing and Joint Check

AENJHB0B2206013
Stabilizer Bar
Check stabilizer bar for damage and deformation.
Replace stabilizer bar if check result is not OK.
4, (b) 4, (b)
Stabilizer Bar Bushing
Check stabilizer bar bushing for damage and
IJHA0A220015-01 deterioration. Replace stabilizer bar bushing if check
8) Lower transmission jack. result is not OK.
9) Install apron lower member bracket. (Page 9H-5)
10) Install new engine rear torque rod bolt to specified Stabilizer Joint
torque. • Check ball stud for smooth movement.
• K15B model: (Page 1D-26) • Check ball stud for looseness.
• D13A model: (Page 1D-98) • Check dust cover for damage and crack.
11) Connect suspension arm joint to steering knuckle. • Check rod for damage and deformation.
(Page 2B-8)
NOTE
12) Connect tie-rod end to steering knuckle. (Page 6B-
17) Stabilizer joint cannot be disassembled.
13) Connect stabilizer joint to stabilizer bar. (Page 2B- If check result is not OK, replace stabilizer joint
4) assembly.
14) Install muffler mounting to front suspension frame.
• K15B model: (Page 1K-2) Front Suspension Fastener Check
AENJHB0B2206014
• D13A model: (Page 1K-7) Check bolts and nuts fastening suspension parts for
15) Install front wheels and tighten wheel nuts to tightness. Tighten loose fastener, if any, to specified
specified torque. (Page 2D-3) torque.
16) Connect steering lower shaft to pinion shaft. (Page For specified torque, refer to:
6B-14) • “Front Strut Assembly Components” (Page 2B-4)
17) Lower hoist and bounce vehicle up and down • “Suspension Arm Components” (Page 2B-8)
several times to stabilize suspension. And then, • “Front Suspension Frame and Stabilizer Bar
tighten suspension arm front bushing bolts to Components” (Page 2B-12)
specified torque. (Page 2B-8)
18) Install engine under side covers.
19) Check front wheel alignment. (Page 2B-2)
2B-16 Front Suspension:

Specifications
Tightening Torque Specifications
AENJHB0B2207001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Strut bracket nut 90 9.2 66.5 (Page 2B-5)
Front brake hose strut bolt 26 2.7 19.5 (Page 2B-5)
Stabilizer joint nut 50 5.1 37.0 (Page 2B-5)
Strut support upper nut 50 5.1 37.0 (Page 2B-5)
Strut support lower nut 50 5.1 37.0 (Page 2B-7)
Suspension arm joint nut 55 5.6 40.5 (Page 2B-9)
Suspension arm front bushing bolt 95 9.7 70.0 (Page 2B-9)
Front suspension frame bolt (Page 2B-9) /
95 9.7 70.0
(Page 2B-15)
Stabilizer bar mounting bracket bolt* 23 2.3 17.0 (Page 2B-14)
Front suspension frame rear bolt 75 7.6 55.5 (Page 2B-15)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Strut Assembly Components” (Page 2B-4)
“Suspension Arm Components” (Page 2B-8)
“Front Suspension Frame and Stabilizer Bar Components” (Page 2B-12)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Special Tool
AENJHB0B2208001
09943M25010
Spring compressor
(Page 2B-6) /
(Page 2B-6)
 Rear Suspension: 2C-1

Rear Suspension
Suspension

Precautions
Precautions for Handling of Rear Shock Absorber
AENJHB0B2300001
! WARNING
Since a high-pressure gas is sealed inside each rear shock absorber (1), there is a risk of personal
injury if you do not take proper precautions when handling it.
• Do not disassemble any shock absorber.
• Do not put it into fire.
• Do not store a shock absorber where it gets hot.
• Before disposing of a shock absorber, drill an approximately 3 mm (0.12 in.) diameter hole (2) in it at
the point indicated in the figure and let the gas and oil out of the cylinder.
• Wear eye protection when drilling a gas release hole. Although the gas itself is harmless, metal
chips produced by the drilling can injure your eyes.

2
1

IFRA0A230001-01

General Description
Rear Suspension Description
AENJHB0B2301001
Rear suspension is of a torsion beam type having rear axle connected with torsion beam.

Repair Instructions
Rear Wheel Alignment Inspection • Check that each suspension part is free from bend,
AENJHB0B2306001 dent, wear or damage.
Preparation
Before checking rear wheel alignment, perform the • Place vehicle in non-loaded state on level surface.
following items. • Bounce vehicle up and down several times to stabilize
• Empty luggage compartment. suspension.
• Check tires for specified size. • Check that ground clearance at the right and left is
If not, replace tires with those of the specified size. almost the same.
• Check that inflation pressure of each tire is adjusted
properly. If necessary, adjust tire pressure, repair or
replace tire.
• Check all tires for even wear and that they are of the
same brand. Replace tire(s) if necessary.
• Check that wheel bearing is not damaged. Replace
wheel hub assembly if defective.
• Check each wheel (with tire) for deflection. If
necessary, repair or replace wheel.
• Check that each suspension part is installed properly.
If faulty condition is found, repair or replace part.
2C-2 Rear Suspension:

Inspection If measured value is not as specified, check the following

Measure toe and camber. (Page 2B-2) parts for damage, deformation and crack.
• Rear axle (torsion beam)
NOTE
• Wheel hub assembly
Rear toe and camber are not adjustable. If
they are out of specification, replace • Vehicle body
reference part.
Reference Information
Rear toe (Total) Toe angle
: IN 4.4 ± 4.3 mm (IN 0.17 ± 0.17 in.) Reference rear toe angle when measured with total
wheel alignment tester or the like, is as follows.
Rear camber (reference)
: –1° ± 1° 00’ Rear toe angle (Total)
: IN 0° 30’

Rear Suspension Components

AENJHB0B2306002

10

(d)

7 9
(c)

5
(b)
3
6

[f]

(a)
IJHA0A230001-02

[f]: Forward
1. Rear coil spring
2. Rear spring lower seat
3. Rear spring upper seat
4. Rear axle
5. Rear wheel hub assembly
6. Brake backing plate : 90 Nm (9.2 kgf-m, 66.5 lbf-ft)
7. Rear shock absorber : 77 Nm (7.9 kgf-m, 57.0 lbf-ft)
8. Shock absorber upper bushing : 28 Nm (2.9 kgf-m, 21.0 lbf-ft)
: For installing direction of shock absorber upper bushings,
refer to “Rear Shock Absorber Removal and Installation”
(Page 2C-3).
9. Shock absorber upper washer : Do not reuse.
10. Rear shock absorber cap
: 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
 Rear Suspension: 2C-3

Rear Shock Absorber Removal and Installation 7) Remove shock absorber upper bushings (1).
AENJHB0B2306003

NOTICE
• The shock absorber upper nut is self-
locking nut. If the nut is reused, it may 1
work loose.
Never reuse the shock absorber upper nut.
• The shock absorber lower bolt is
precoated with friction stabilizer. If the bolt
is reused, it may work loose.
Never reuse the shock absorber lower bolt.

Removal
1) Hoist vehicle and remove rear wheel. (Page 2D-3) 1

2) Remove quarter lower trim cap. (Page 9H-24)

3) Remove rear shock absorber cap. (Page 2C-2)
4) Support rear axle using floor jack to prevent it from
lowering.
5) Remove rear shock absorber lower bolt (1). IJHA0A230003-01
6) Remove upper nut (2), shock absorber (3) and shock
absorber upper washer (4). Installation
1) Install shock absorber upper bushings (1), shock
absorber (2) and shock absorber upper washer (3)
as shown in figure.
Tighten new shock absorber upper nut (4), and new
2 lower bolt (5) temporarily.

4
4
2 3

1 6

5
1 IJHA0A230004-01

6. Body panel

2) Remove floor jack from rear axle.

3) Install rear wheel. (Page 2D-3)

IJHA0A230002-01
2C-4 Rear Suspension:

4) Lower hoist. With vehicle in unloaded condition, Rear Coil Spring and Spring Seat Removal and
tighten new rear shock absorber upper nut (1) and Installation
lower bolt (2) to specified torque. AENJHB0B2306005

Tightening torque NOTICE

Rear shock absorber upper nut (a): 28 N·m (2.9 The shock absorber lower bolt is precoated
kgf-m, 21.0 lbf-ft) with friction stabilizer. If the bolt is reused, it
Rear shock absorber lower bolt (b): 90 N·m (9.2 may work loose.
kgf-m, 66.5 lbf-ft) Never reuse the shock absorber lower bolt.

Removal
1) Hoist vehicle and remove rear wheels. (Page 2D-
3)
1, (a) 2) Support both ends of rear axle (1) using two floor
jacks (2) to prevent it from lowering.

2 1
2
2, (b) IJHA0A230006-01

3) Remove rear shock absorber lower bolts. (Page

IJHA0A230005-01
2C-3)
5) Install rear shock absorber cap. (Page 2C-2) 4) Lower rear axle gradually if necessary for removing
6) Install quarter lower trim cap. (Page 9H-24) coil spring(s) (1).

Rear Shock Absorber Inspection
AENJHB0B2306004
• Check shock absorber for deformation or damage.
• Check shock absorber upper bushings for wear or
damage.
• Check shock absorber for evidence of oil leakage.
• Check shock absorber for deterioration.
If check result is not OK, replace shock absorber with
new one.
NOTICE
Lowering the rear axle too much may cause
damage to the flexible brake hose, wheel
speed sensor lead wire and parking brake
cable.
Limit the distance that you lower the rear axle
to the minimum distance necessary.
5) Remove coil spring(s).

IJHA0A230007-01
 Rear Suspension: 2C-5

6) Remove spring upper seat(s) (1) from vehicle body
and spring lower seat(s) (2) from rear axle.
1
4) Jack up rear axle and then connect shock absorber
(1) lower end to rear axle at each of right and left
sides.
5) Tighten new shock absorber lower bolt(s) (2)
temporarily by hand.

2 2

IJHA0A230008-01

Installation
1) Install spring upper seat(s) (1) to vehicle body.
IJHA0A230009-01
2) Install spring lower seat(s) (2) to rear axle. At this
6) Remove floor jack from rear axle.
time, fit protrusions (5) of spring lower seat into holes
(6) in rear axle. 7) Install rear wheels. (Page 2D-3)
3) Install coil spring(s) (3). At this time, contact coil 8) Lower hoist and bounce vehicle up and down
spring end (4) with protrusion (7) of spring lower seat several times to stabilize suspension.
as shown in figure. 9) Tighten shock absorber lower bolt(s) to specified
torque.
NOTICE
Tightening torque
To avoid abnormal noise from rear Rear shock absorber lower bolt: 90 N·m (9.2
suspension, position spring seats and kgf-m, 66.5 lbf-ft)
springs correctly.
Rear Coil Spring and Spring Seat Check
AENJHB0B2306006
1
• Check rear coil spring for crack, damage and
deformation.
• Check spring seat for crack, damage and
[u]
[f] deformation.
If check result is not OK, replace rear coil spring and / or
2 5 spring seat with new one.

5 7

6
4 4

3 3

7 7
2 2
[A] [B]
IJHA0A230014-01

[A]: Left side [f]: Vehicle forward

[B]: Right side [u]: Vehicle upward
2C-6 Rear Suspension:

Rear Axle Removal and Installation 8) Remove right and left rear axle bolts (1), and then
AENJHB0B2306007 remove rear axle from vehicle by lowering the jacks
NOTICE gradually.

• Brake fluid is extremely damaging to

painted surfaces. If brake fluid contacts a
painted surface, immediately wipe it off
and flush the surface with water
thoroughly.
1
• The rear axle bolts are pre-coated with
friction stabilizer. If these bolts are reused,
they may work loose.
Never reuse the rear axle bolts.

NOTE
Rear axle bushing is not individually IJHA0A230011-01

replaceable. Replace rear axle if the bushing

is defective. Installation
1) Place rear axle on floor jacks and align its front ends
Removal with mounting positions in vehicle body.
1) Hoist vehicle and remove rear wheels. (Page 2D- 2) Insert new right and left rear axle bolts (1) and
3) tighten them temporarily.
2) Remove rear fender linings. (Page 9H-9)
3) Remove rear brake backing plate for each of right
and left rear wheels. (Page 4C-6)
4) Disconnect rear wheel speed sensor harness (1)
from rear axle at each of right and left sides.
5) Remove parking brake cable clamp (2) from rear 1

axle at each of right and left sides.

6) Remove E-ring(s) (3) and disconnect brake pipe
clamp (4) at each of right and left sides.

3 1 IJHA0A230011-01

3) Install coil springs and rear shock absorbers to rear

axle. (Page 2C-4)
2 4) Connect brake pipes to rear axle, and then install E-
rings. (Page 4A-12)
5) Install parking brake cable clamps to rear axle.
(Page 4D-1)
6) Install rear wheel speed sensor harness (1) to rear
IJHA0A230010-01
axle at each of right and left sides.
7) While supporting rear axle at both ends using floor
jacks, remove right and left rear shock absorber
lower bolts, and then remove rear coil springs from
rear axle. (Page 2C-4) 1

IJHA0A230012-01

7) Install rear brake backing plate for each of right and

left sides. (Page 4C-6)
8) Install rear wheels. (Page 2D-3)
 Rear Suspension: 2C-7

9) Lower hoist and bounce vehicle up and down Rear Axle Check
several times to stabilize suspension. AENJHB0B2306008

10) Tighten shock absorber lower bolts to specified • Check rear axle (1) for deformation and damage.
torque. (Page 2C-3) • Check rear axle bushings (2) for crack, deformation
11) Tighten rear axle bolts to specified torque. and damage. If check result is not OK, replace rear
axle with new one. (Page 2C-6)
Tightening torque
Rear axle bolt: 100 N·m (10.2 kgf-m, 74.0 lbf-ft)
12) Install rear fender linings. (Page 9H-2)
13) Check that rear brakes are free from dragging and
proper braking is obtained.
14) Check all installed parts for brake fluid leakage.
2
1

2
IJHA0A230013-01

Rear Suspension Fastener Check

AENJHB0B2306009
Check bolts and nuts fastening suspension parts for
tightness. Tighten loose fastener, if any, to specified
torque. (Page 2C-2)

Specifications
Tightening Torque Specifications
AENJHB0B2307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear shock absorber upper nut 28 2.9 21.0 (Page 2C-4)
Rear shock absorber lower bolt (Page 2C-4) /
90 9.2 66.5
(Page 2C-5)
Rear axle bolt 100 10.2 74.0 (Page 2C-7)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Rear Suspension Components” (Page 2C-2)
“Fasteners Information” in Section 0A (Page 0A-5)
2D-1 Wheels and Tires:

Wheels and Tires

Suspension

Precautions
Precautions for Servicing Wheel and Tire
AENJHB0B2400001
! WARNING
Using tires of different types such as radial, bias and bias-belted tires on the same vehicle may
increase stress on drivetrain components. In addition, as this affects vehicle handling, there is an
increased risk of loss of control and an accident.
Do not mix different type tires on the same vehicle except in an emergency.

Repairs by any means including welding, heating or peening are not permitted. All damaged wheels should be
replaced.

General Description
Tire Description Correct tire pressures and driving habits have an
AENJHB0B2401001 important influence on tire life. Hard cornering,
This vehicle is equipped with tubeless tires of the
excessively rapid acceleration, and unnecessary hard
following specifications.
braking increase tire wear.
Tire specification
: 185/65 R15 88H Replacement Tire Description
AENJHB0B2401002
NOTE Replacement tires should be of the same size, load
range and construction as those originally installed on
• Tire inflation pressure should be checked the vehicle refer to the “Tire Placard”. Using tires of any
when tires are cool. other size or type may affect ride, handling,
• The tire inflation pressure will change due speedometer / odometer calibration, vehicle ground
to changes in atmospheric pressure and clearance and tire or snow chain clearance to the body
temperature as well as in temperature of and chassis.
tire itself when driving. It is important to It is recommended that new tires be installed in pairs on
check and adjust the tire pressures when the same axle. If replacing only one tire is unavoidable, it
the tires are cold. Tires that appear to be at should be paired with the tire of the best tread condition
the specified pressure when checked after to equalize tire-road friction during braking.
driving (when the tires are warm) will have The tire inflation pressure is indicated in kilo-pascal
pressure below the specification when the (kPa) while it is also indicated in kgf/cm2 and psi on the
tires cool down. Also, tires that are inflated “Tire Placard”. Metric tire gauges are available from tool
to the specified pressure in a warm garage suppliers. The table below shows unit conversion for
may have pressure below the specification commonly used inflation pressures.
when the vehicle is driven outside in very kPa kgf/cm2 psi
cold temperature. If the tire pressure is Conversion: 160 1.6 23
adjusted in a place warmer than the 1 psi = 6.895 kPa 180 1.8 26
outside, add 1.2 kPa (0.01 kgf/cm2, 0.17 psi, 1 kgf/cm2 = 98.066 kPa 200 2.0 29
0.01 bar) to the recommended cold tire 220 2.2 32
inflation pressure for every 1 °C (1.8 °F) 240 2.4 35
increase in the temperature of the 260 2.6 38
adjustment place compared to the outside 280 2.8 41
air temperature. 300 3.0 44
• Specified tire inflation pressure is 320 3.2 47
indicated on the “Tire Placard” or in the 340 3.4 50
vehicle’s Owner’s Manual.

The tires are designed to operate satisfactorily with

loads up to the full rated load capacity when inflated to
the recommended inflation pressure.
 Wheels and Tires: 2D-2

Wheel Description Wheel-Tire Assembly Description (for Vehicle

AENJHB0B2401003
Wheel Maintenance
Wheels must be replaced if they have any of the
following conditions: bends, dents, excessive lateral or
radial runout, air leakage through welds, elongated bolt
holes, failure of lug nuts to stay tight, heavy rust. Wheels
with great runout will cause objectionable vibrations.
Wheel specification
: 15 X 5 1/2J inset 45
Replacement Wheel Description
AENJHB0B2401004
Replacement wheels must be equivalent to the originally
installed wheels in load capacity, diameter, rim width,
offset and mounting configuration.
Using wheel in improper size or type may affect its and
bearing life, brake cooling performance, speedometer /
odometer calibration, ground clearance and clearance to
the body and chassis.
Equipped with Aluminum Wheel)
AENJHB0B2401006
Tires and wheels are match mounted at the assembly
plant.
This means that the light point of the tire is aligned with
air valve position of wheel for compensation of each
weight imbalance.
When mounting a tire on the wheel, air valve (1) should
be aligned with the tires’ paint dot (yellow) (2) as shown
in figure.
Whenever a tire is dismounted from its wheel, it should
be remounted so that the tire and wheel are balanced in
weight. If the tire’s paint dot cannot be located, a line
should be scribed on the tire and wheel before
dismounting to assure that it is remounted in the same
position.

Wheel-Tire Assembly Description (for Vehicle

Equipped with Steel Wheel)
AENJHB0B2401005
Tires and wheels are match mounted at the assembly
plant.
This means that the radially stiffest part of the tire, or
“high spot”, is matched to the smallest radius or “low
spot” of the wheel.
This is done to provide the smoothest possible ride.
The “high spot” of the tire is originally marked by paint
dot on the outboard sidewall.
2
The “low spot” of the wheel is originally marked by paint
dot on the wheel rim-flange. When assembling, the 1
IJHA0A240003-01
wheel rims’ paint dot (1) (blue) should be aligned with
the tires’ paint dot (2) (red) as shown in figure.
Whenever a tire is dismounted from its wheel, it should Tire Placard Description
AENJHB0B2401007
be remounted so that the tire and wheel are matched. If The “Tire Placard” is located on the driver’s side door
the tire’s paint dot cannot be located, a line should be lock pillar and should be referred to for tire information.
scribed on the tire and wheel before dismounting to The placard lists the tire size, rim size and cold tire
assure that it is remounted in the same position. pressure.

IJHA0A240002-01
2D-3 Wheels and Tires:

Repair Instructions
Wheel (with Tire) Removal and Installation • Check for roughness, scoring or stepped wear on
AENJHB0B2406001 surfaces of nut taper (1) and wheel holes (2), and
Removal
if any abnormality is found, repair or replace wheel
NOTICE nut and/or wheel.
Using heat to loosen a tight wheel bolt for
removal may shorten the life of the wheel and
damage the wheel bearings. 1

Never use heat to loosen a wheel bolt for

removal. 2

1) Loosen wheel nuts by approximately 180°.

IGAD0A240003-01

• Check that any foreign material, rust, oil and

grease are removed from thread part of wheel nut
(1) and hub bolts (2).

IDAA0A240002-02

2) Hoist vehicle.
3) Remove wheel with tire. 1

Installation
1) Before installing wheels, check the following points.
• Check for buildup of corrosion / foreign material
on mating surfaces of wheel (1) and brake disc /
drum (2), and remove any buildup if any.

2
2
IGAD0A240004-01

2) Install each wheel nut by hand and if it is not

1 screwed until nut comes in contact with seat of wheel
hole or any abnormality is found, replace wheel nut
and/or hub bolt.

2
IGAD0A240002-01

IGAD0A240005-01
 Wheels and Tires: 2D-4

3) Lower vehicle and tighten wheel nuts in numerical Wheel alignment should be checked if one of the
order (“1” – “5”) to specified torque. following conditions is noted.
Tightening order • Front tires wear unevenly.
“1” – “2” – “3” – “4” – “5” • Uneven wear between both sides of tread on the
same front tire.
Tightening torque
Wheel nut* (a): 100 N·m (10.2 kgf-m, 74.0 lbf-ft) • Front tire treads show scuffs with “feather” edges on
one side of tread ribs or blocks.
“4”, (a)

“1”, (a) “2”, (a)

“3”, (a) “5”, (a)

IJHA0A240001-01

Tire Inspection
AENJHB0B2406002
Irregular and/or Premature Wear
Irregular and/or premature wear occurs due to incorrect
inflation pressures, lack of tire rotation, rough driving, I3RH0A240002-01
improper alignment. If one of the following conditions is
[A]: Hard cornering, under inflation or non-rotated tires
noted, tire rotation is necessary.
[B]: Incorrect wheel alignment, use of tires of different types or wheel
• Front tires wear differently from rear tires. heavy acceleration

• Uneven wear between both sides of tread on the

same tire. Wear Indicator
Originally installed tires have built-in tread wear
• Both front tires wear unevenly.
indicators (1).
• Both rear tires wear unevenly. These indicators appear when the tire tread depth
• Abnormal wear such as cupping or flat spotting is becomes 1.6 mm (0.063 in). If a tire has the indicators
noted. appearing across 3 or more tread grooves at 6 locations,
replacement of the tire is recommended.
Tire wear
Limit: 1.6 mm (0.063 in)

I2RH01240005-01
2D-5 Wheels and Tires:

Wheel Inspection Tire Rotation

AENJHB0B2406003 AENJHB0B2406004
Wheels must be replaced if they are bent, dented, have To equalize tire wear, rotate tires periodically as shown
excessive lateral or radial runout, air leakage through in figure.
welds, have elongated nut holes, if wheel nuts do not
stay tight, or if they are heavily rusted. Wheels with
greater runout than shown in the figure may cause
objectionable vibrations.
To measure the wheel runout, it is necessary to use
accurate dial indicator.
The tire may be on or off the wheel. The wheel should be
installed to the wheel balancer or the like for proper
measurement.
Take measurements of both lateral runout and radial
runout at both inside and outside of the rim flange. With
dial indicator set in place securely, turn the wheel one full
revolution slowly and record every reading the indicator.
When the measured runout exceeds the specification
and correction by the balancer adjustment is impossible,
replace the wheel. If the reading is affected by welding,
paint or scratch, it should be ignored.
Wheel runout
Lateral runout Radial runout
limit “a” limit “b”
IBP80A240001-04
0.90 mm 0.70 mm
Steel wheel [A]: 5-tire rotation [f]: Vehicle forward
(0.035 in.) (0.027 in.)
[B]: 4-tire rotation
0.30 mm 0.30 mm
Aluminum wheel
(0.011 in.) (0.011 in.)

“a”

“b”

IAW101240001-02
 Wheels and Tires: 2D-6

Specifications
Tightening Torque Specifications
AENJHB0B2407001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Wheel nut* 100 10.2 74.0 (Page 2D-4)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0A (Page 0A-5)
2D-7 Wheels and Tires:

Section 3
Driveline / Axle
CONTENTS
Precautions .................................................3-1
Precautions............................................................. 3-1
Precautions for Driveline / Axle ............................. 3-1
Drive Shaft / Axle ..................................... 3A-1
Front .........................................................................3A-1
General Description .............................................3A-1
Front Drive Shaft Construction............................ 3A-1
Diagnostic Information and Procedures............3A-1
Front Drive Shaft Symptom Diagnosis ................ 3A-1
Repair Instructions ..............................................3A-2
Front Drive Shaft Components ........................... 3A-2
Front Drive Shaft Assembly On-Vehicle
Inspection.......................................................... 3A-3
Front Drive Shaft Assembly Removal and
Installation ......................................................... 3A-3
Front Drive Shaft Disassembly and
Reassembly ...................................................... 3A-5
Drive Intermediate Shaft Assembly Removal
and Installation ................................................ 3A-11
Table of Contents 3- i
Drive Intermediate Shaft Assembly
Disassembly and Reassembly ........................3A-12
Front Wheel Hub Assembly and Steering
Knuckle Components ......................................3A-16
Wheel Bearing Check .......................................3A-16
Front Wheel Hub Assembly and Steering 3
Knuckle Removal and Installation ...................3A-17
Specifications .....................................................3A-19
Tightening Torque Specifications......................3A-19
Special Tools and Equipment ...........................3A-19
Recommended Service Material .......................3A-19
Special Tool ......................................................3A-19
Rear ........................................................................3A-21
Repair Instructions ............................................3A-21
Rear Axle Components .....................................3A-21
Wheel Bearing Check .......................................3A-21
Rear Wheel Hub Assembly Removal and
Installation .......................................................3A-21
Specifications .....................................................3A-22
Tightening Torque Specifications......................3A-22
3-1 Precautions:

Precautions
Driveline / Axle

Precautions
Precautions for Driveline / Axle
AENJHB0B3000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Caution for Fastener

Refer to “Caution for Fastener” in Section 00 (Page 00-5).

Warning for Air Bag

Refer to “Warning for Air Bag” in Section 00 (Page 00-7).
 Drive Shaft / Axle: Front 3A-1

Drive Shaft / Axle

Driveline / Axle

Front
General Description
Front Drive Shaft Construction
AENJHB0B3111001
A constant velocity ball joint is used on the wheel side of both right and left drive shaft assemblies. A tripod type
constant velocity joint is used on the differential and drive intermediate shaft sides. The tripod joint allows each drive
shaft to slide in the extension / contraction directions.

Diagnostic Information and Procedures

Front Drive Shaft Symptom Diagnosis
AENJHB0B3114001

Condition Possible cause Correction / Reference Item

Abnormal noise Wear or breakage of drive shaft joint Replace. (Page 3A-3)
Wear or breakage of intermediate shaft Replace. (Page 3A-11)
bearing
Wear or breakage of the wheel bearing Replace. (Page 3A-17)
3A-2 Drive Shaft / Axle: Front

Repair Instructions
Front Drive Shaft Components
AENJHB0B3116001

3
1
[F] [B]
5
[A]
2
9
[D],[E]

4 5

10 (a) 6 7 [F]
5
7

8
[D],[E]
8
5
[D],[E]
7
5
7
6

[F]
5 [D],[E]
9
19 3
[D],[E] [A]
20
[F] 5
19 10 (a)

[C]
[F] 4
5
2

[D]
15 A

13
[E]

1 15 A
12 (b)

17
11

16 1
14 A
18
12 (b)
17
13 11
16
15 A
[F] 14 A
15 A

12 (c)

17
13
11
16
14 A 15 A

IJHB0B311001-02
 Drive Shaft / Axle: Front 3A-3

[A]: Wheel side 10. Drive shaft nut

: After tightening nut to specified torque, caulk nut securely.
[B]: Left side 11. Drive intermediate shaft
[C]: Right side 12. Intermediate support bolt
: For tightening order, refer to “Drive Intermediate Shaft Assembly
Removal and Installation”: Front (Page 3A-11).
[D]: K15B-A/T model 13. Intermediate shaft bearing support
[E]: K15B-M/T model 14. Intermediate shaft bearing
: Apply grease 99000-25011 to side space.
[F]: D13A model 15. Dust seal
: Apply grease 99000-25011 to dust seal lip.
1. Circlip 16. Deflector
2. Differential side joint housing 17. Bearing support snap ring
: Apply grease from the service kit to differential side joint housing.
3. Snap ring 18. Bearing shield
4. Tripod joint 19. Damper
: Do not disassemble.
: Apply grease from the service kit to tripod joint.
5. Boot band (Big) 20. Damper band
6. Differential side (or drive intermediate shaft side) boot : 200 Nm (20.4 kgf-m, 147.5 lbf-ft)
7. Boot band (Small) : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
8. Wheel side boot : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
9. Wheel side joint assembly : Do not reuse.
: Do not disassemble.
: Apply grease from the service kit to wheel side joint assembly.

Front Drive Shaft Assembly On-Vehicle Removal

Inspection 1) Hoist vehicle and remove front wheel. (Page 2D-3)
AENJHB0B3116002
2) Release caulking (1) from drive shaft nut and
• Check boots for breakage, leakage, tear or
remove drive shaft nut (2) with brake pedal
deterioration.
depressed.
• Check boot bands for looseness, crack or damage.
• Check drive shafts for crack or damage.
• Check wheel side joint for smooth rotation and no 1
rattle.
• Check differential side joint for smooth rotation.
Replace if any abnormalities are found.

Front Drive Shaft Assembly Removal and

Installation
AENJHB0B3116003 2
IHSB0A311003-01
! CAUTION 3) Remove engine under side covers.
Touching a hot exhaust system component 4) Drain transaxle oil (M/T model) or ATF (A/T model).
will cause a burn.
• M/T model
Do not perform any service work on the
exhaust system until the exhaust system is – K15B model: (Page 5B-8)
cool. – D13A model: (Page 5B-53)
• A/T model: (Page 5A-119)
5) Disconnect suspension arm joint from steering
knuckle. (Page 2B-8)
6) Disconnect tie-rod end from steering knuckle.
(Page 6B-17)
3A-4 Drive Shaft / Axle: Front

7) Pull out drive shaft joint (1) from transaxle or drive Reverse removal procedure noting the following points.
intermediate shaft using tire lever (2), or appropriate • Use new differential side joint circlip.
bar (4) with hammer (3).
• Apply grease to mating surface of front wheel hub
NOTE assembly for front drive shaft. (Page 3A-17)
Turning drive shaft while pulling out drive • Tighten tie-rod end nut to specified torque. (Page
shaft joint may facilitate release of the circlip 6B-17)
fitting of joint spline. • Tighten suspension arm joint nut to specified torque.
(Page 2B-8)
• Tighten new drive shaft nut (1) to specified torque.
[A] [B]
1 1
NOTICE
Once the drive shaft nut is removed, it will no
longer have the necessary fastening
performance.
2
3 Never reuse the drive shaft nut.

Tightening torque
4
Drive shaft nut (a): 200 N·m (20.4 kgf-m, 147.5 lbf-
ft)
IJHA0A311001-01

[A]: Left side drive shaft [B]: Right side drive shaft • Caulk drive shaft nut as shown.

Installation 1, (a)

NOTICE
Failure to take proper precautions when
installing the drive shaft may result in
damage to or breakage of the drive shaft
assembly.
• Before inserting drive shaft (1), check that
2
there is no foreign material around
encoder (2) on wheel bearing.

IHSB0A311008-01

2. Caulking part

• Install front wheel. (Page 2D-3)

• Fill transaxle with transaxle oil (M/T model) or ATF (A/
T model) as specified.
– M/T model
– K15B model: (Page 5B-8)
2 – D13A model: (Page 5B-53)
1 – A/T model: (Page 5A-119)
• Check front wheel alignment. (Page 2B-2)

IFRA0A311006-01

• Be careful not to damage the oil seals and

boots when installing the drive shaft.
• Insert joints only by hand. Never hit joint
boots with a hammer.
• Check that the differential side joint is fully
inserted and the circlip is seated in
position.
 Drive Shaft / Axle: Front 3A-5

Front Drive Shaft Disassembly and Reassembly • For D13A model, using flat-bladed screwdriver (1)
AENJHB0B3116004 or the like, release caulking (2) of boot small band
(3).
Disassembly

NOTICE
Disassembly of the wheel side joint or the
tripod joint can cause performance 2
1
problems.
If anything abnormal (damage, noise, etc.) is
found with either of these joints, replace the
3
joint as an assembly.
I8V101311031-01

Differential side joint 2) Remove differential side joint housing from tripod
1) Remove boot big band and small band according to joint.
the following procedure. 3) Wipe off grease from shaft and use snap ring pliers
(2) to remove snap ring (1).
NOTE
Use nippers to cut boot band if it is of a
welded type.
Take care not to damage boot while cutting
band.

• For K15B model, using flat-bladed screwdriver (1)

or the like, release caulking (2) of boot small band
(3) and big band (4).

4
2
I7RW01311003-01

3 4) Remove tripod joint (1) using 3-arm puller (2).

NOTICE
Except for the housing, washing the tripod
2 joint parts with a washing solution may cause
1 problems with the joint.
Do not use a washing solution to clean any
tripod joint parts other than the housing. Use
IFFA0A311002-01
a cloth to remove grease from tripod joints.
• For D13A model, using nose pliers (1), disengage
hooks of boot big band (2) and remove band.

I9P60A311005-01

5) Pull out differential side boot from shaft.

IEL10A311006-01
3A-6 Drive Shaft / Axle: Front

6) For D13A model, use flat-bladed screwdriver (1) or • For D13A model, using flat-bladed screwdriver (1)
the like, release caulking (2) of damper band (3) or the like, release caulking (2) of boot small band
(right side). (3) and big band (4).

4
2
2
1 3

IFFA0A311003-01
2
1
7) Remove damper from shaft.

Wheel side joint IFFA0A311002-01

1) Remove boot big band and small band according to
the following procedure.
NOTE
Use nippers to cut boot band if it is of a
welded type.
Take care not to damage boot while cutting
band.
• For K15B model, using nose pliers (1), disengage
hooks of boot big band (2) and remove band.
IEL10A311006-01
2) Pull out wheel side boot from shaft.
Reassembly
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly.
Check that wheel side joint assembly (1) and housing of
tripod joint (2) are washed thoroughly and air-dried.
NOTICE
Joints may not perform as designed if proper
cleaning and lubrication precautions are not
taken.
• Do not wash boots with solvents such as
gasoline or kerosene. Washing boots with
these solvents causes deterioration of the
boots.
• Lubricate joints with the specified amount
of the specified grease. Follow the
instructions below to identify the specified
grease and specified amount for each
joint.

• For K15B model, using flat-bladed screwdriver (1)

or the like, release caulking (2) of boot small band
(3).

2
1

I8V101311031-01 2

I9P60A311027-01

[A]: Wheel side [B]: Differential side

 Drive Shaft / Axle: Front 3A-7

Wheel side joint 7) Fasten new boot bands using special tool as shown
1) Wash disassembled parts (except boots). After in figure.
washing parts, air-dry them completely.
NOTICE
2) Clean boots with shop cloth.
Squeezing or distorting the boot will reduce
3) Apply grease in the service kit to wheel side joint. its durability.
Grease specification for front drive shaft wheel Do not force air out of the boot by squeezing
side joint or distorting it when fastening it with boot
Engine type Grease color Grease amount bands.
70 – 90 g (2.46 – 3.17
K15B model Tan Install each boot band using the appropriate
oz)
method referring to the following table
95 – 105 g (3.35 – 3.70
D13A model Black Engine type Band Method
oz)
Big band a
K15B model
4) Install wheel side boot on shaft. Small band b
Big band b
5) Insert flat-bladed screwdriver or the like into boot (1) D13A model
Small band b
and allow air to enter boot so that air pressure in
boot becomes the same as atmospheric pressure at
• Method a:
boot fixing position.
Fasten boot band (1) by pinching hooks (2) with
1
special tool and engage hooks (3) as shown in
figure.
Special tool
(A): 09943M57021

IFRA0A311007-01

6) Place new boot big band (3) and small band (4) onto (A)
boot putting each band outer end (1) against forward
rotation (2) as shown in figure.

3 2

I8C50A311034-01

IJHB0A311007-01

[A]: K15B model [B]: D13A model

3A-8 Drive Shaft / Axle: Front

• Method b: 9) For D13A model, fasten new damper band (1) as

Fasten boot band (1) using special tool as shown shown in figure (right side).
in figure.
Damper band fastening distance
Boot band fastening distance “a” “a”: Less than 1.5 mm (0.05 in.)
K15B model: 1.2 – 4.0 mm (0.04 – 0.15 in.)
Special tool
D13A model: Less than 1.5 mm (0.05 in.)
(A): 09943M57011
Special tool
(B): 09943M57011

“a”

“a”

1 (A)
IAV10A311009-01

(B)
IDL10A311008-01 Differential side joint
8) For right side drive shaft, install damper to specified 1) Wash disassembled parts (except boots). After
position on shaft as shown in figure. washing parts, air-dry them completely.
Drive shaft damper installing position 2) Clean boots with shop cloth.
“a”: 207 – 213 mm (8.14 – 8.38 in.) 3) Install new boot small band and differential side boot
on shaft.
[A] 4) Install tripod joint (1) on shaft using special tool with
hammer, directing its chamfered spline (3) toward
[B] “a” wheel side, and then fasten tripod joint with new
snap ring (2) using snap ring pliers (4).
Special tool
(A): 09925M98221

3
[C] “a”

I8G001311014-01

1
IJHB0A311008-01

[A]: Wheel side [C]: D13A model

[B]: K15B model 1. Damper band

I8C50A311007-01
 Drive Shaft / Axle: Front 3A-9

5) Apply grease “A” in the service kit to tripod joint and 7) Insert flat-bladed screwdriver or the like into boot
joint housing (1). and allow air to enter boot so that air pressure in
boot becomes the same as atmospheric pressure at
Grease specification for front drive shaft
boot fixing position.
differential side joint
Engine Transaxle Drive Grease Grease Drive shaft boot fixing position (distance
type type shaft color amount between differential side joint end and boot small
Right and 130 – 150 g end)
M/T Tan
left side (4.58 – 5.29 oz) Engine Transaxle Drive
Fixing position “a”
K15B Right 115 – 135 g type type shaft
Tan
model side (4.05 – 4.76 oz) Right side 191.0 mm (7.519 in.)
A/T M/T
110 – 130 g K15B Left side 174.9 mm (6.885 in.)
Left side Tan
(3.88 – 4.58 oz) model Right side 190.5 mm (7.500 in.)
A/T
D13A Right and 139 – 149 g Left side 175.4 mm (6.905 in.)
M/T Brown
model left side (4.90 – 5.25 oz) 184.2 – 190.2 mm
Right side
D13A (7.251 – 7.488 in.)
M/T
model 164.3 – 170.3 mm
Left side
(6.468 – 6.704 in.)

[A]
“a”

I4RS0B310003-01

6) Fit boot (1) to grooves on shaft and joint housing (2).

1
2
[B]
“a”

1
2
IJHA0A311003-01

2
I8C50A311008-01

[A]: Differential side [B]: Drive intermediate shaft side

3A-10 Drive Shaft / Axle: Front

8) Place new boot big band (3) and small band (4) onto • Method a:
boot putting each band outer end (1) against forward Fasten boot band (1) by pinching hooks (2) with
rotation (2) as shown in figure. special tool and engage hooks (3) as shown in
figure.
Special tool
(A): 09943M57021

(A)

3 2

I8C50A311034-01
IJHB0A311009-01
• Method b:
[A]: K15B model [B]: D13A model
Fasten boot band (1) using special tool as shown
in figure.
9) Fasten new boot bands using special tool as shown
in figure. Boot band fastening distance “a”
K15B model: 1.2 – 4.0 mm (0.04 – 0.15 in.)
NOTICE D13A model: Less than 1.5 mm (0.05 in.)
Squeezing or distorting the boot will reduce
Special tool
its durability.
(B): 09943M57011
Do not force air out of the boot by squeezing
or distorting it when fastening it with boot
bands.

Install each boot band using the appropriate “a”

method referring to the following table
Engine type Band Method
Big band b
K15B model
Small band b
1
Big band a
D13A model
Small band b
(B)
IDL10A311008-01
 Drive Shaft / Axle: Front 3A-11

Drive Intermediate Shaft Assembly Removal Installation

and Installation Reverse removal procedure noting the following points.
AENJHB0B3116005
• Use new circlip.
NOTICE
• Tighten intermediate support bolts (1) in numerical
Oil leakage will occur if the oil seal lip is
order as shown in figure.
damaged.
Do not pull out or push in the drive a. Temporarily tighten intermediate support bolts in
intermediate shaft at an angle. Slide the shaft numerical order (“1” – “3”).
in axial direction. b. Tighten intermediate support bolts to specified
torque in numerical order (“1” – “3”).
Removal
Tightening torque
1) Drain transaxle oil (M/T model) or ATF (A/T model). Intermediate support bolt* (K15B model) (a):
• M/T model 55 N·m (5.6 kgf-m, 40.5 lbf-ft)
– K15B model: (Page 5B-8) Intermediate support bolt* (D13A model) (a):
– D13A model: (Page 5B-53) 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
• A/T model: (Page 5A-119) [A]
2) Remove right side front drive shaft assembly.
1, “1”, (a)
(Page 3A-3)
3) Remove intermediate support bolts (1) and drive 1, “3”, (a)
intermediate shaft assembly (2) from transaxle.
1, “2”, (a)

[A]

[B]

2 1, “1”, (a)
1, “3”, (a)

1, “2”, (a)
[B]

IJHB0A311012-01

[A]: K15B model [B]: D13A model

IJHB0A311011-01

[A]: K15B model [B]: D13A model

3A-12 Drive Shaft / Axle: Front

Drive Intermediate Shaft Assembly 3) Remove dust seal(s) (1) from intermediate shaft
Disassembly and Reassembly bearing support using special tool.
AENJHB0B3116006
NOTE
Disassembly For MT model, intermediate shaft bearing
1) Remove circlip (1) from drive intermediate shaft (2). support is equipped with two dust seals at
both sides.
[A] [B]
Special tool
(A): 09913M50121

[A] [B]
2 2

(A) (A)
1 1

IJHB0A311013-01
1 1
[A]: K15B model [B]: D13A model

2) Using hydraulic press (1), remove drive intermediate IJHB0A311014-01

shaft (2) from intermediate shaft bearing. [A]: K15B model [B]: D13A model

NOTICE
4) Remove bearing support snap ring (1) using snap
For A/T model, if bearing shield (1) interferes ring pliers (2).
with support (2) on press, the shield could be
damaged.
When removing the shaft, do not touch the
shield to the support.

I6RS0B310006-03
1
5) Using hydraulic press and special tool, remove
intermediate shaft bearing from intermediate shaft
2 bearing support (1) by pushing the bearing from
IJHA0A311015-01
transaxle side.
Special tool
(A): 09913M75810

(A)

IBP80A311008-01
IBP80A311012-01
 Drive Shaft / Axle: Front 3A-13

6) Remove deflector (1) from drive intermediate shaft 2) For A/T model, install new bearing shield (1) to
using flat-bladed screwdriver or the like, if necessary. intermediate shaft using special tool, if removed.
Special tool
(A): 09940M51710

1 (A)

IBP80A311025-01

Reassembly IBP60A311008-01
1) Install new deflector (1) onto drive intermediate 3) Using hydraulic press and special tool, install new
shaft, if removed, by tapping flat-surface of deflector intermediate shaft bearing to intermediate shaft
indicated by arrow in figure, along the circle little by bearing support (1) by pushing the bearing from
little using flat-end rod covered with cloth (2) so as drive shaft side.
not to warp it.
Special tool
NOTICE (A): 09913M75520
(B): 09924M74510
• Denting or scratching the oil seal contact (C): 09944M68510
surface of drive intermediate shaft will
cause oil leakage.
M/T model
Do not damage the contact surface when
installing the deflector.
• Incomplete installation of the deflector will
damage the oil seal and result in oil
leakage.
Check that the deflector end (3) is in (A)
contact with the shoulder (4) of the shaft
evenly.

1
IBP80A311010-01

A/T model

(B)
(C)

4
1

3
1 IBP60A311010-04

IBP80A311026-02
3A-14 Drive Shaft / Axle: Front

4) Install new bearing support snap ring (1) in groove 6) For M/T model, install new dust seal (1) at specified
(2) of intermediate shaft bearing support. position and in specified direction as shown in figure
using special tool.
[A] [B]
Special tool
(A): 09925M15410
1 Distance
“a”: 4 – 5 mm (0.16 – 0.19 in.)

1 1
2
2 (A)

IJHB0A311015-01

[A]: K15B model [B]: D13A model

5) For M/T model, apply grease to seal lip of new dust

seal and space on bearing indicated in the figure.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A) “a”
ICL80C311007-01

“A” 7) Apply grease to hatched area on new dust seal and

bearing for M/T and bearing for A/T as shown.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)

[A] [B]

“A” “A” “A”

IBP60A311012-02

“A”
IJHB0A311016-01

[A]: M/T model [B]: A/T model

 Drive Shaft / Axle: Front 3A-15

8) Install new dust seal (1) in specified direction as 9) Press-fit drive intermediate shaft (2) into inner race
shown in figure using special tools. (1) of intermediate shaft bearing from transaxle side
using hydraulic press and special tool.
Special tool
(A): 09926M27610 Special tool
(B): 09924M74510 (A): 09913M84510
(C): 09924M07720
(D): 09913M70123
Distance
“a”: 0.5 – 1.5 mm (0.02 – 0.05 in.)
“b”: 0.5 – 2.5 mm (0.02 – 0.1 in.) 2 1

M/T model
(A)

2
(B)

(A)

(A)

ICL80C311009-01

10) Install new circlip (1) to drive intermediate shaft (2).

[A] [B]
“a”
ICL80C311008-01

A/T model
2 2
1 (C)
(D)
1 1

IJHB0A311013-01

[A]: K15B model [B]: D13A model

“b”

ICL80C311006-02
3A-16 Drive Shaft / Axle: Front

Front Wheel Hub Assembly and Steering Knuckle Components

AENJHB0B3116007

[f]

4
2

1 (a)

6 (b)

5
IJHB0B311002-01

[f]: Vehicle forward 4. Brake disc dust cover : 70 Nm (7.1 kgf-m, 52.0 lbf-ft)
1. Drive shaft nut 5. Steering knuckle : Do not reuse.
: After tightening nut to specified torque,
caulk nut securely.
2. Front wheel hub assembly 6. Wheel hub mounting bolt
: Apply grease 99000-25011 to mating
surface of front wheel hub assembly for
front drive shaft. (Page 3A-17)
3. Hub bolt : 200 Nm (20.4 kgf-m, 147.5 lbf-ft)

Wheel Bearing Check 4) Check wheel bearing noise and smooth wheel
AENJHB0B3116008 rotation by rotating wheel.
1) Check tightness of wheel nuts and retighten them to If check result is not OK, replace wheel hub
specified torque if necessary. (Page 2D-3) assembly.
2) Hoist vehicle.
3) Check wear of wheel bearing. When measuring
thrust play, apply a dial gauge to front wheel as
shown in figure.
If check result is not as specified, replace wheel hub
assembly.
Front wheel bearing thrust play
Limit: 0.05 mm (0.002 in.)

I3RM0A230050-01

I3RM0A230049-01
 Drive Shaft / Axle: Front 3A-17

Front Wheel Hub Assembly and Steering 9) Remove wheel hub housing bolts (1), and remove
Knuckle Removal and Installation front wheel hub assembly (3) and brake disc dust
AENJHB0B3116009 cover (4) from steering knuckle (2).
NOTICE
• If the steering knuckle is removed and 2
installed without care, the front brake disc
dust cover may damage the dust cover of
the suspension arm joint. 1
3
When removing and installing the steering
knuckle assembly, do not damage the
suspension arm joint dust cover.
• If front wheel speed sensor receives large
shock, the sensor could be damaged.
4
Do not drop or expose the sensor to large
shock. IFRA0A311014-01
Any front wheel speed sensor that has 10) Remove hub bolts (1) with copper hammer or
received large shock should be replaced. hydraulic press, if necessary.
• If front wheel speed sensor is brought
closer to magnetic force, the sensor could NOTICE
become inoperative. Removing the hub bolts will break the
Do not bring the sensor closer to magnetic serrations on the hub bolts.
force. Avoid removing the hub bolts unless their
replacement is absolutely necessary. If the
Removal hub bolts are removed, never reuse the bolts.
1) Hoist vehicle and remove front wheel. (Page 2D-3) Replace them with new ones.
2) Remove drive shaft nut. (Page 3A-3)
NOTE
3) Remove front wheel speed sensor. (Page 4E-41)
There are recesses on periphery of the
4) Remove brake disc. (Page 4B-4)
bearing holder. To avoid interference
5) Disconnect tie-rod end from steering knuckle. between bolt flange and bearing holder, align
(Page 6B-17) hub bolt with a recess on the holder when
6) Disconnect suspension arm joint from steering removing it.
knuckle. (Page 2B-8)
7) Remove strut bracket nuts and bolts. (Page 2B-4)
8) Remove steering knuckle(1), front wheel hub
assembly(2), brake disc dust cover(3) all together
from strut bracket (4).

4
1
1
3

IJHA0A311006-01
2

IJHA0A311005-01
3A-18 Drive Shaft / Axle: Front

Installation
1) Insert new hub bolts (1) in hub holes, if removed.
Rotate each hub bolt slowly to assure that serrations
are aligned with those made by original bolt and then
press-fit one by one.
3) Install brake disc dust cover (3) and front wheel hub
assembly (2) to steering knuckle (1) and tighten new
wheel hub housing bolts (4) to specified torque.
NOTICE
The wheel hub housing bolts are pre-coated
with friction stabilizer. If the bolts are reused,
they may work loose.
Use new wheel hub housing bolts.

Tightening torque
Wheel hub housing bolt (a): 70 N·m (7.1 kgf-m,
52.0 lbf-ft)
1 3

IJHA0A311007-01

2) Apply grease to inner ring surface of front wheel hub

assembly (1). 2
4, (a)
“A”: Grease 99000–25011 (SUZUKI Super
Grease A) IJHA0A311009-01

4) Install steering knuckle (1) with brake disc dust cover

and front wheel hub assembly to strut bracket (2).

2
“A”
1
4

3
1
[f]

IJHA0A311010-01

[f]: Forward 4. Brake disc dust cover

IJHB0B311003-01 3. Front wheel hub assembly

5) Install strut bracket bolts and nuts. (Page 2B-4)

6) Connect steering knuckle to suspension arm.
(Page 2B-8)
7) Connect tie-rod end to steering knuckle. (Page 6B-
17)
8) Install brake disc. (Page 4B-4)
9) Install front wheel speed sensor. (Page 4E-41)
10) Tighten new drive shaft nut to specified torque.
(Page 3A-3)
11) Install front wheel. (Page 2D-3)
12) Check front wheel alignment. (Page 2B-2)
 Drive Shaft / Axle: Front 3A-19

Specifications
Tightening Torque Specifications
AENJHB0B3117001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Drive shaft nut 200 20.4 147.5 (Page 3A-4)
Intermediate support bolt* (K15B model) 55 5.6 40.5 (Page 3A-11)
Intermediate support bolt* (D13A model) 23 2.3 17.0 (Page 3A-11)
Wheel hub housing bolt 70 7.1 52.0 (Page 3A-18)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Drive Shaft Components”: Front (Page 3A-2)
“Front Wheel Hub Assembly and Steering Knuckle Components”: Front (Page 3A-16)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Recommended Service Material
AENJHB0B3118001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 (Page 3A-14) / (Page
3A-14) / (Page 3A-18)

NOTE
Required service material(s) is also described in:
“Front Drive Shaft Components”: Front (Page 3A-2)
“Front Wheel Hub Assembly and Steering Knuckle Components”: Front (Page 3A-16)

Special Tool
AENJHB0B3118002
09913M50121 09913M70123
Oil seal remover Bearing installer
(Page 3A-12) (Page 3A-15)

09913M75520 09913M75810
Bearing installer Bearing installer
(Page 3A-13) (Page 3A-12)

09913M84510 09924M07720
Bearing installer Synchronizer hub installer
(Page 3A-15) (Page 3A-15)
3A-20 Drive Shaft / Axle: Front

09924M74510 09925M15410
Bearing and oil seal handle Oil seal installer
(Page 3A-13) / (Page 3A-14)
(Page 3A-15)

09925M98221 09926M27610
Bearing installer Oil seal installer
(Page 3A-8) (Page 3A-15)

09940M51710 09943M57011
Bearing installer Band compressor
(Page 3A-13) (Page 3A-8) /
(Page 3A-8) /
(Page 3A-10)

09943M57021 09944M68510
Low-profile clamp pliers Bearing installer attachment
(Page 3A-7) / (Page 3A-13)
(Page 3A-10)
 Drive Shaft / Axle: Rear 3A-21

Rear
Repair Instructions
Rear Axle Components
AENJHB0B3126001

[f]
1

2
4

6 (a)
IJHA0A312001-02

[f]: Forward 3. Rear drum brake assembly 6. Rear hub mounting bolt
1. Rear axle 4. Rear wheel hub assembly : 77 Nm (7.9 kgf-m, 57.0 lbf-ft)
2. Rear brake drum 5. Hub bolt : Do not reuse.

Wheel Bearing Check 4) Remove rear hub mounting bolts (1), and then
AENJHB0B3126002 remove rear wheel hub assembly (2).
Check rear wheel bearing in the same manner as front
wheel bearing. (Page 3A-16) 5) Using a rope, hold rear brake assembly (3) with
brake pipe connected.
Rear wheel bearing thrust play
Limit: 0.05 mm (0.002 in.)
3
Rear Wheel Hub Assembly Removal and 2

Installation
AENJHB0B3126003
Removal
1
1) Hoist vehicle and remove rear wheel. (Page 2D-3)
2) Remove rear brake drum. (Page 4C-3) 1

3) Disconnect rear wheel speed sensor connector (1)

and detach rear wheel speed sensor clip (2) from
rear axle. IJHA0A312003-01

6) Remove rear wheel speed sensor from rear wheel

hub assembly. (Page 4E-42)
1

IJHA0A312002-01
3A-22 Drive Shaft / Axle: Rear

7) Remove hub bolts (1) with copper hammer or 3) Install rear wheel hub assembly (1) and tighten new
hydraulic press, if necessary. rear hub mounting bolts (3) to specified torque.
Locate socket (2) installed with the speed sensor in
NOTICE Step 2) to the lower side.
Removing the hub bolts will break the
Tightening torque
serrations on the hub bolts.
Hub mounting bolt (a): 77 N·m (7.9 kgf-m, 57.0
Avoid removing the hub bolts unless their
lbf-ft)
replacement is absolutely necessary. If the
hub bolts are removed, never reuse the bolts.
Replace them with new bolts.

[f]
1

3, (a) 2

IJHA0A312006-01

[f]: Forward
IJHA0A312004-01

4) Connect rear wheel speed sensor connector (1) and

Installation clip (2).
1) Insert new hub bolts (1) in hub holes, if removed.
Rotate each hub bolt slowly to assure that serrations
are aligned with those made by original bolt and then 1

press-fit one by one.

2
1

IJHA0A312002-01

5) Install rear brake drum. (Page 4C-3)

6) Install rear wheel. (Page 2D-3)
IJHA0A312005-01
7) Check rear wheel alignment. (Page 2C-1)
2) With rear wheel speed sensor connector
disconnected, install the sensor to rear wheel hub
assembly. (Page 4E-42)

Specifications
Tightening Torque Specifications
AENJHB0B3127001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Hub mounting bolt 77 7.9 57.0 (Page 3A-22)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Rear Axle Components”: Rear (Page 3A-21)
“Fasteners Information” in Section 0A (Page 0A-5)

Section 4
Brakes
CONTENTS
Precautions .................................................4-1
Precautions............................................................. 4-1
Precautions for Brakes.......................................... 4-1
Brake Control System and Diagnosis ... 4A-1
Precautions...........................................................4A-1
Precautions for Brake Service ............................ 4A-1
General Description .............................................4A-1
Brake System Description................................... 4A-1
Diagnostic Information and Procedures............4A-2
Brake Symptom Diagnosis.................................. 4A-2
Repair Instructions ..............................................4A-4
Brake Fluid Level Inspection ............................... 4A-4
Brake Fluid Level Switch Inspection ................... 4A-4
Brake Fluid Replacement.................................... 4A-4
Air Bleeding of Brake System ............................. 4A-5
Brake Pedal Components ................................... 4A-7
Brake Pedal Assembly Removal and
Installation ......................................................... 4A-8
Brake Pedal Free Height Inspection ................... 4A-9
Brake Pedal Play Inspection ............................. 4A-10
Excessive Pedal Travel Inspection ................... 4A-10
Brake Light Switch On-Vehicle Inspection ........ 4A-10
Brake Light Switch Removal and Installation .... 4A-11
Brake Light Switch Inspection ........................... 4A-11
Brake Flexible Hose and Pipe Components ..... 4A-12
Brake Flexible Hose and Pipe Removal and
Installation ....................................................... 4A-13
Brake Flexible Hose and Pipe Inspection ......... 4A-15
Brake Master Cylinder Components ................. 4A-15
Brake Master Cylinder Assembly On-Vehicle
Inspection........................................................ 4A-16
Brake Master Cylinder Assembly Removal
and Installation ................................................ 4A-16
Brake Master Cylinder Reservoir Removal
and Installation ................................................ 4A-17
Brake Master Cylinder Assembly Inspection..... 4A-18
Brake Booster Components .............................. 4A-20
Brake Booster Function Check ......................... 4A-21
Brake Booster Removal and Installation ........... 4A-22
Brake Booster Inspection .................................. 4A-23
Brake Booster Switch Inspection (M/T Model) .. 4A-24
Brake Booster Pressure Sensor Inspection
(A/T Model) ..................................................... 4A-25
Table of Contents 4- i
Specifications .....................................................4A-27
Tightening Torque Specifications......................4A-27
Special Tools and Equipment ...........................4A-27
Recommended Service Material .......................4A-27
Special Tool ......................................................4A-27
Front Brakes ............................................ 4B-1
General Description .............................................4B-1
Front Brake Description ......................................4B-1
Repair Instructions ..............................................4B-1 4
Front Brake Components ....................................4B-1
Front Brake Pad On-Vehicle Inspection..............4B-2
Front Brake Pad Removal and Installation..........4B-2
Front Brake Pad Inspection.................................4B-4
Front Brake Disc Removal and Installation .........4B-4
Front Brake Disc Inspection ................................4B-5
Front Brake Caliper Removal and Installation.....4B-5
Front Brake Caliper Disassembly and
Reassembly ......................................................4B-7
Front Brake Caliper Inspection............................4B-9
Specifications .....................................................4B-10
Tightening Torque Specifications......................4B-10
Special Tools and Equipment ...........................4B-10
Recommended Service Material .......................4B-10
Rear Brakes.............................................. 4C-1
General Description .............................................4C-1
Rear Drum Brake Description .............................4C-1
Repair Instructions ..............................................4C-2
Rear Drum Brake Components...........................4C-2
Rear Brake Shoe On-Vehicle Inspection ............4C-3
Rear Brake Drum Removal and Installation........4C-3
Rear Brake Drum and Shoe Inspection ..............4C-3
Rear Brake Shoe Removal and Installation ........4C-4
Rear Brake Adjuster and Brake Shoe Lever
Check ................................................................4C-5
Wheel Cylinder Removal and Installation ...........4C-5
Wheel Cylinder Inspection ..................................4C-6
Brake Backing Plate Removal and Installation ....4C-6
Specifications .......................................................4C-7
Tightening Torque Specifications........................4C-7
Special Tools and Equipment .............................4C-7
Recommended Service Material .........................4C-7
Special Tool ........................................................4C-7
4-ii Table of Contents
Parking Brake .......................................... 4D-1
General Description .............................................4D-1
Parking Brake Description...................................4D-1
Repair Instructions ..............................................4D-1
Parking Brake Components ................................4D-1
Parking Brake Inspection ....................................4D-2
Parking Brake Adjustment...................................4D-2
Parking Brake Cable Removal and
Installation .........................................................4D-2
Parking Brake Cable Inspection..........................4D-3
Parking Brake Lever Removal and Installation ....4D-3
Parking Brake Switch Inspection.........................4D-4
Specifications.......................................................4D-4
Tightening Torque Specifications........................4D-4
ABS............................................................4E-1
Precautions........................................................... 4E-1
Precautions for ABS............................................ 4E-1
Precautions for Diagnosing Trouble.................... 4E-1
General Description ............................................. 4E-1
ABS Description .................................................. 4E-1
OBD System Description .................................... 4E-3
Warning Light Description ................................... 4E-3
DLC Description .................................................. 4E-4
CAN Communication System Description........... 4E-4
Schematic and Routing Diagram........................ 4E-4
ABS Diagram ...................................................... 4E-4
ABS Input / Output Diagram................................ 4E-5
ABS Circuit Diagram ........................................... 4E-6
Component Location ........................................... 4E-8
ABS Component Location................................... 4E-8
Diagnostic Information and Procedures.......... 4E-10
ABS Check........................................................ 4E-10
Visual Inspection ...............................................4E-12
ABS Symptom Diagnosis ..................................4E-13
Warning Light Check.........................................4E-14
DTC Check........................................................ 4E-14
DTC Clearance ................................................. 4E-15
DTC Table.........................................................4E-16
Fail-Safe Table..................................................4E-17
Scan Tool Data ................................................. 4E-19
ABS Warning Light Does Not Come ON after
Setting Ignition “ON” ....................................... 4E-20
ABS Warning Light Comes ON Steady............. 4E-21
EBD Warning Light (Brake Warning Light)
Does Not Come ON after Setting Ignition
“ON” ................................................................4E-22
EBD Warning Light (Brake Warning Light)
Comes ON Steady .......................................... 4E-22
DTC C1016 ....................................................... 4E-23
DTC C1021 / C1022 / C1025 / C1026 / C1031
/ C1032 / C1035 / C1036 ................................ 4E-25
DTC C1041 / C1042 / C1045 / C1046 / C1051
/ C1052 / C1055 / C1056 / C1063...................4E-28
DTC C104F ....................................................... 4E-29
DTC C1057 ....................................................... 4E-30
DTC C1061 ....................................................... 4E-31
DTC C1071 ....................................................... 4E-32
DTC C1080 ....................................................... 4E-32
DTC C1091 .......................................................4E-33
DTC U0073 .......................................................4E-34
DTC U0100 .......................................................4E-34
DTC U0155 .......................................................4E-34
ABS Control Module Power Supply and
Ground Circuit Check......................................4E-34
Repair Instructions ............................................4E-36
ABS Hydraulic Unit Operation Check................4E-36
ABS Hydraulic Unit / Control Module
Assembly Components ...................................4E-37
ABS Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection ....................4E-38
ABS Hydraulic Unit / Control Module
Assembly Removal and Installation ................4E-38
Front and Rear Wheel Speed Sensor On-
Vehicle Inspection ...........................................4E-40
Front Wheel Speed Sensor Removal and
Installation .......................................................4E-41
Rear Wheel Speed Sensor Removal and
Installation .......................................................4E-42
Front and Rear Wheel Speed Sensor
Inspection........................................................4E-43
Front Wheel Speed Sensor Encoder Removal
and Installation ................................................4E-43
Rear Wheel Speed Sensor Encoder Removal
and Installation ................................................4E-43
Front and Rear Wheel Speed Sensor
Encoder Inspection .........................................4E-43
Specifications .....................................................4E-43
Tightening Torque Specifications......................4E-43
Special Tools and Equipment ...........................4E-43
Special Tool ......................................................4E-43
Electronic Stability Program ...................4F-1
Precautions........................................................... 4F-1
Precautions for ESP® ......................................... 4F-1
Precautions for Diagnosing Trouble .................... 4F-1
Test with Speedometer Tester or Other
Equipment ......................................................... 4F-1
General Description ............................................. 4F-1
ABS Description .................................................. 4F-1
ESP® Description ............................................... 4F-1
ESP® Component Description............................ 4F-2
OBD System Description .................................... 4F-3
Warning / Indicator Light Description .................. 4F-4
Description of Sensor Calibrating Condition ....... 4F-5
DLC Description .................................................. 4F-5
CAN Communication System Description........... 4F-5
Schematic and Routing Diagram ........................ 4F-5
ESP® System Diagram....................................... 4F-5
ESP® Input / Output Diagram ............................. 4F-6
ESP® Circuit Diagram......................................... 4F-7
Component Location ........................................... 4F-9
ESP® Component Location ................................ 4F-9
Diagnostic Information and Procedures .......... 4F-10
ESP® System Check ........................................ 4F-10
Visual Inspection ............................................... 4F-12
ESP® Symptom Diagnosis ............................... 4F-12
Warning Light Check......................................... 4F-13

DTC Check ....................................................... 4F-14
DTC Clearance ................................................. 4F-15
DTC Table......................................................... 4F-16
Fail-Safe Table.................................................. 4F-19
Scan Tool Data ................................................. 4F-23
ESP® Warning Light Does Not Come ON
after Setting Ignition “ON” ............................... 4F-27
ESP® Warning Light Comes ON Steady .......... 4F-28
ABS Warning Light Does Not Come ON after
Setting Ignition “ON” ....................................... 4F-28
ABS Warning Light Comes ON Steady............. 4F-29
EBD Warning Light (Brake Warning Light)
Does Not Come ON after Setting Ignition
“ON” ................................................................ 4F-30
EBD Warning Light (Brake Warning Light)
Comes ON Steady .......................................... 4F-30
DTC C1015 / C1017 / C1023 ............................ 4F-31
DTC C1016 ....................................................... 4F-32
DTC C101C ...................................................... 4F-34
DTC C1020 ....................................................... 4F-35
DTC C1021 / C1022 / C1025 / C1026 / C1031
/ C1032 / C1035 / C1036 ................................ 4F-35
DTC C1024 ....................................................... 4F-38
DTC C1027 ....................................................... 4F-38
DTC C1028 ....................................................... 4F-39
DTC C102B....................................................... 4F-40
DTC C1037 ....................................................... 4F-41
DTC C1038 ....................................................... 4F-42
DTC C1040 ....................................................... 4F-43
DTC C1041 / C1042 / C1043 / C1044 / C1045
/ C1046 / C1051 / C1052 / C1053 / C1054 /
C1055 / C1056 ................................................ 4F-43
DTC C1057 ....................................................... 4F-44
DTC C1061 ....................................................... 4F-45
DTC C1063 ....................................................... 4F-46
DTC C1069 ....................................................... 4F-47
DTC C1071 ....................................................... 4F-48
DTC C1074 / C1075 / C1076 / C1078 .............. 4F-48
DTC C1090 ....................................................... 4F-49
DTC C1091 / C1094 ......................................... 4F-50
DTC C1092 ....................................................... 4F-50
DTC C1099 ....................................................... 4F-51
DTC U0073 ....................................................... 4F-51
DTC U0100 ....................................................... 4F-51
Table of Contents 4-iii
DTC U0101 ....................................................... 4F-51
DTC U0126 ....................................................... 4F-51
DTC U0140 ....................................................... 4F-52
DTC U0155 ....................................................... 4F-52
DTC U1082 ....................................................... 4F-52
ESP® Control Module Power Supply and
Ground Circuit Check...................................... 4F-52
Repair Instructions ............................................ 4F-53
ESP® Hydraulic Unit Operation Check ............. 4F-53
Sensor Calibration............................................. 4F-54
ESP® Hydraulic Unit / Control Module
Assembly Components ................................... 4F-56
ESP® Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection .................... 4F-57
ESP® Hydraulic Unit / Control Module
Assembly Removal and Installation ................ 4F-57
Front and Rear Wheel Speed Sensor On-
Vehicle Inspection ........................................... 4F-58
Front Wheel Speed Sensor Removal and
Installation ....................................................... 4F-58
Rear Wheel Speed Sensor Removal and
Installation ....................................................... 4F-58
Front and Rear Wheel Speed Sensor
Inspection........................................................ 4F-58
Front Wheel Speed Sensor Encoder Removal
and Installation ................................................ 4F-59
Rear Wheel Speed Sensor Encoder Removal
and Installation ................................................ 4F-59
Front and Rear Wheel Speed Sensor
Encoder Inspection ......................................... 4F-59
Brake Master Cylinder Pressure Sensor On-
Vehicle Inspection ........................................... 4F-59
Steering Angle Sensor On-Vehicle Inspection .. 4F-59
Steering Angle Sensor Removal and
Installation ....................................................... 4F-60
Steering Angle Sensor Inspection..................... 4F-60
ESP® OFF Switch Removal and Installation .... 4F-60
ESP® OFF Switch Inspection ........................... 4F-60
Specifications ..................................................... 4F-60
Tightening Torque Specifications...................... 4F-60
Special Tools and Equipment ........................... 4F-61
Special Tool ...................................................... 4F-61
4-1 Precautions:

Precautions
Brakes

Precautions
Precautions for Brakes
AENJHB0B4000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Caution for Fastener

Refer to “Caution for Fastener” in Section 00 (Page 00-5).

Warning for Wheel and Tire

Refer to “Warning for Wheel and Tire” in Section 00 (Page 00-6).

Warning for Brake

Refer to “Warning for Brake” in Section 00 (Page 00-6).

Precautions for Vehicle Equipped with ESP® System

Refer to “Precautions for Vehicle Equipped with ESP® System” in Section 00 (Page 00-6).

Warning for Air Bag

Refer to “Warning for Air Bag” in Section 00 (Page 00-7).

Reassembling Note for Wiring Harness

Observe “Reassembling Note for Wiring Harness” in Section 9A (Page 9A-142) whenever installing wiring harness.
Otherwise, electrical trouble may occur.
 Brake Control System and Diagnosis: 4A-1

Brake Control System and Diagnosis

Brakes

Precautions
Precautions for Brake Service
AENJHB0B4100001
Road Test
NOTE
Brakes should be tested on dry, clean,
reasonably level, and smooth road. Road test
brakes by applying brake with both light and
heavy pedal forces at various speeds to
determine if the vehicle stops evenly and
effectively. Also drive vehicle to see if it pulls
to one side without brake application. If it
does, check the tire pressure, front wheel
alignment and installing condition of front
suspensions. See diagnosis table for other
causes.
Brake Fluid Leakage
NOTE
Check the brake fluid level. Although a slight
drop results from normal lining wear, an
abnormally low level indicates leakage of
brake fluid. In such a case, check the entire
brake system for leakage. If even a slight
evidence of leakage is noted, the cause
should be corrected or defective parts should
be replaced.
Substandard or Contaminated Brake Fluid
Substandard or contaminated brake fluid with mineral oil
or moisture will lower fade resistance or deteriorate
rubber parts resulting in the leakage of brake fluid.
In case improper brake fluid as mentioned above
entered into the brake system, or in case such doubt
exists, disassemble the system and clean the parts with
alcohol. For the parts which cannot be disassembled,
replace them as an assembly. Rubber parts and brake
hoses should be replaced with new ones.

General Description
Brake System Description
AENJHB0B4101001
When the foot brake pedal is depressed, hydraulic pressure is developed in the brake master cylinder to actuate
pistons, two in front disc brakes or four (two in each cylinder) in rear drum brakes.
The brake master cylinder is a tandem master cylinder. Brake pipes are connected to the brake master cylinder and
they make two independent circuits. One connects front right and rear left brakes and the other connects front left and
rear right brakes.

[A]

5
3
4 7
1

6
2

7
8

IFRA0A410001-01

[A]: Forward 3. Secondary side 6. Parking brake lever

1. Brake booster 4. Primary side 7. Parking brake cable
2. Brake master cylinder 5. ABS / ESP® hydraulic unit / control module assembly 8. Brake 4-way joint
4A-2 Brake Control System and Diagnosis:

Diagnostic Information and Procedures

Brake Symptom Diagnosis
AENJHB0B4104001

Condition Possible cause Correction / Reference Item

Not enough braking force Brake fluid leakage from brake lines Locate leaking point and repair. (Page 4A-
15)
Brake disc or pads stained with fluid, Clean or replace.
grease or other oil • Front brake disc: (Page 4B-4)
• Front brake pad: (Page 4B-2)
Overheated brakes Determine cause and repair.
Poor contact of shoes on brake drum Repair for proper contact. (Page 4C-3)
Brake drum and/or shoe stained with oil Replace.
or wet with water • Rear brake drum: (Page 4C-3)
• Rear brake shoe: (Page 4C-4)
Badly worn brake pad and/or shoe Replace.
• Front brake pad: (Page 4B-2)
• Rear brake shoe: (Page 4C-4)
Defective wheel cylinders Repair or replace. (Page 4C-5)
Malfunctioning brake caliper assembly Repair or replace. (Page 4B-5)
Air in system Bleed brake system. (Page 4A-5)
Brake booster internal failure Replace brake booster. (Page 4A-22)
Inadequate negative pressure for brake Check engine condition and vacuum hose.
booster
Malfunctioning ABS / ESP® Check system and replace if necessary.
• ABS model: (Page 4E-10)
• ESP® model: (Page 4F-10)
Vehicle pulls to one side Pad, disc, shoe and/or drum are wet Clean or replace.
(Brakes not working with water or stained with oil in some • Front brake disc: (Page 4B-4)
uniformly) brakes
• Front brake pad: (Page 4B-2)
• Rear brake drum: (Page 4C-3)
• Rear brake shoe: (Page 4C-4)
Drum-to-shoe clearance out of Check for inoperative auto adjusting
adjustment in some brake mechanism. (Page 4C-5)
(Malfunctioning auto adjusting
mechanism)
Disc and/or drum are out of round in Replace.
some brakes • Front brake disc: (Page 4B-4)
• Rear brake drum: (Page 4C-3)
Tires are inflated unequally Inflate equally.
Malfunction in wheel cylinders Repair or replace. (Page 4C-5)
Disturbed front wheel alignment Adjust as specified. (Page 2B-2)
Unmatched tires on the same axle Tires with approximately the same amount of
tread should be used on the same axle.
Restricted brake pipes or hoses Check for damage and replace pipes and/or
hoses if necessary. (Page 4A-15)
Malfunctioning brake caliper assembly Check for stuck or sluggish pistons and proper
lubrication of caliper slide pin. (Page 4B-9)
Loose suspension parts Check all suspension mountings. (Page 2A-
4)
Loose brake calipers Check and tighten bolts to specified torque.
(Page 4B-5)
Noise (High pitched Contact of wear indicator to brake disc Replace brake pad. (Page 4B-2)
squeak without brake Worn rear brake shoe Replace brake shoe. (Page 4C-4)
applied)
 Brake Control System and Diagnosis: 4A-3

Condition Possible cause Correction / Reference Item

Excessive pedal travel Brake fluid leakage Locate leaking point and repair. (Page 4A-
(Pedal stroke too large) 15)
Air in system (soft / spongy pedal) Bleed brake system. (Page 4A-5)
Badly worn brake pad and/or shoe Replace.
• Front brake pad: (Page 4B-2)
• Rear brake shoe: (Page 4C-4)
Rear brake system not adjusted Repair auto adjusting mechanism.
(malfunctioning auto adjusting Adjust rear brakes. (Page 4D-2)
mechanism)
Bent brake shoes Replace brake shoes. (Page 4C-4)
Brake locked Malfunctioning ABS / ESP® Check system and replace if necessary.
• ABS model: (Page 4E-10)
• ESP® model: (Page 4F-10)
Dragging brakes (A very Master cylinder pistons not returning Replace brake master cylinder. (Page 4A-
light drag is present in all correctly 16)
brakes immediately after Restricted brake pipes or hoses Check for damage and replace pipes and/or
pedal is released) hoses if necessary. (Page 4A-15)
Incorrect parking brake adjustment on Check and adjust to correct specifications.
rear brakes (Page 4D-2)
Weakened or broken return springs in Replace. (Page 4C-4)
brake
Sluggish parking brake cables or linkage Repair or replace. (Page 4D-2)
Wheel cylinder or brake caliper piston Repair if necessary.
sticking • Front brake caliper piston: (Page 4B-7)
• Rear brake wheel cylinder: (Page 4C-5)
Badly worn piston seal in brake caliper Replace piston seal. (Page 4B-7)
Improper brake pedal free height Check brake pedal free height. (Page 4A-9)
Pedal pulsation (Pedal Damaged or loose front and/or rear Replace front wheel hub assembly and/or rear
pulsates when depressed wheel bearings wheel hub assembly.
for braking) • Front: (Page 3A-17)
• Rear: (Page 3A-21)
Distorted steering knuckle or rear wheel Replace.
hub assembly • Knuckle: (Page 3A-17)
• Rear wheel hub: (Page 3A-21)
Excessive disc lateral runout Check per instructions. If not as specified,
replace or machine disc. (Page 4B-5)
Rear drums out of round Check runout.
Repair or replace drum if necessary. (Page
4C-3)
Braking noise Glazed brake pad and/or brake shoe Repair or replace brake pad and/or brake
shoe.
• Front brake pad: (Page 4B-2)
• Rear brake shoe: (Page 4C-4)
Worn or distorted brake shoe Replace brake shoe. (Page 4C-4)
Loose front and/or rear wheel bearings Replace front wheel hub assembly and/or rear
wheel hub assembly.
• Front: (Page 3A-17)
• Rear: (Page 3A-21)
Distorted backing plates or loose Replace or retighten securing bolts. (Page
mounting bolts 4C-6)
Contact of wear indicator to brake disc Replace brake pads. (Page 4B-2)
4A-4 Brake Control System and Diagnosis:
Repair Instructions
Brake Fluid Level Inspection
AENJHB0B4106001
• Use brake fluid indicated on brake master cylinder
reservoir cap or in Owner’s Manual.
• Check that brake fluid level is between MAX and MIN
marks on reservoir of brake master cylinder.
NOTE
If brake warning light comes on during
driving or brake fluid level on brake master
cylinder reservoir is “MIN” mark or lower,
check the following points:
• Thickness of front brake pads, rear brake
shoes
• Fluid leakage from piston seal of front
brake caliper
• Fluid leakage from rear brake wheel
cylinder
• Crack or damage to brake hoses and brake
pipes
• Damage to clutch hose and clutch pipe (M/
T model)
• Fluid leakage from brake master cylinder
and reservoir
In case any abnormality is found, repair or
replace affected parts.
After the check and repair are completed,
replenish the system with brake fluid so that
fluid level falls between “MAX” and “MIN”
marks on brake master cylinder reservoir.
Brake Fluid Level Switch Inspection
AENJHB0B4106002
Check continuity between terminals of brake fluid level
switch connector (1). If check result is not as specified,
replace reservoir.
Brake fluid level switch specification
MAX position (float up): No continuity
MIN position (float down): Continuity exists
IJHB0A410001-01
Brake Fluid Replacement
AENJHB0B4106003
NOTICE
• Using improper or contaminated brake
fluid can cause brake system failure. Using
shock absorber fluid or any other fluid that
contains mineral oil for the brake fluid will
cause the rubber parts in the brake
hydraulic system to swell or distort. If
water is mixed in the brake fluid, the
boiling point will be lowered.
– Use only the specified brake fluid from a
sealed container.
– Do not use a container that has been
used for a mineral oil or is wet with
water for refilling the brake system.
– Keep all fluid containers capped to
prevent contamination and entry of
moisture.
• Brake fluid is extremely damaging to
painted surfaces.
If brake fluid contacts painted surfaces,
immediately wipe it off and flush the
surfaces with water thoroughly.
NOTE
• When replacing brake fluid, start with the
brake closest to the brake master cylinder.
• To prevent air from getting into reservoir,
be careful not to let the reservoir be short
of fluid while operating brake pedal.
1) Using a dropper or the like, extract some brake fluid
from reservoir of brake master cylinder.
IJHB0A410002-01
 Brake Control System and Diagnosis: 4A-5

2) Add new brake fluid to reservoir of brake master Air Bleeding of Brake System
cylinder. AENJHB0B4106004
NOTICE
Brake fluid specification
: Refer to reservoir cap • Using improper or contaminated brake
fluid can cause brake system failure. Using
3) Remove bleeder plug cap on brake caliper. Attach a shock absorber fluid or any other fluid that
vinyl tube (1) to bleeder plug, and insert the other contains mineral oil for the brake fluid will
end into container (2). cause the rubber parts in the brake
hydraulic system to swell or distort. If
water is mixed in the brake fluid, the
boiling point will be lowered.
– Use only the specified brake fluid from a
sealed container.
– Do not use a container that has been
used for a mineral oil or is wet with
water for refilling the brake system.
– Keep all fluid containers capped to
prevent contamination and entry of
I2RH01410015-01
moisture.
4) Depress brake pedal several times with bleeder plug • Brake fluid is extremely damaging to
loosened. painted surfaces.
If brake fluid contacts painted surfaces,
5) If new brake fluid starts coming out, tighten bleeder
immediately wipe it off and flush the
plug to specified torque.
surfaces with water thoroughly.
• Front: (Page 4B-1)
• If ABS / ESP® depressurization check is
• Rear: (Page 4C-2) performed when air is trapped in brake
6) Perform Step 3) – 5) for remaining wheels as well. line, air may be taken in hydraulic unit. To
7) If necessary, bleed brake system. (Page 4A-5) prevent this, bleed brake system before
performing hydraulic unit operation check.

Hydraulic brake system must be bled whenever air

enters the system.
As the system is of a diagonal split configuration, if pipe
or hose is disconnected from one brake, the line
concerned must be bled not only at the end of that brake
but also at the end of the diagonally opposite brake.
If any joint on master cylinder or any intermediate joint
between master cylinder and a brake is disconnected,
then the system must be bled at all four brakes.

NOTE
Perform bleeding operation starting from the
brake farthest from brake master cylinder
and then at the brake on the same brake line.
Do the same on the other brake line.
4A-6 Brake Control System and Diagnosis:

3) Depress brake pedal several times, and then while

[A] holding it depressed, loosen bleeder plug about one-
third to one-half a turn.
1 3
4) When fluid pressure in cylinder is almost completely
released, retighten bleeder plug.
5) Repeat this operation until air is completely removed
from hydraulic line.

2 4
IFRA0A410004-01

[A]: Forward 3. Rear right wheel cylinder

1. Front right brake caliper 4. Rear left wheel cylinder
2. Front left brake caliper I2RH01410016-01

6) When air bubbles disappear from fluid flowing into

1) Fill brake master cylinder reservoir with new brake container, depress and hold brake pedal and tighten
fluid and keep the reservoir at least one-half full of bleeder plug.
fluid during bleeding operation.
• Front: (Page 4B-1)
Brake fluid specification • Rear: (Page 4C-2)
Refer to reservoir cap (1) of brake master
cylinder or Owner’s Manual.

I2RH01410017-01

7) Attach bleeder plug cap.

8) After completing bleeding operation, apply fluid
pressure to brake lines and check for leakage.
9) Replenish reservoir with new fluid up to specified
level. (Page 4A-4)
10) Check brake pedal stroke. If the stroke is so large,
repeat entire procedure of bleeding.
IJHB0A410003-01

2) Remove bleeder plug cap. Attach a vinyl tube (1) to

bleeder plug, and insert the other end into container
(2).

I2RH01410015-01
 Brake Control System and Diagnosis: 4A-7

Brake Pedal Components

AENJHB0B4106005

10 (a)

[C]

(c)

6
12

(b)

4 3 5

9 (a)

11 (a)

8
1

2 11 (a)
[A]

2
[B]
IJHB0B410001-01
4A-8 Brake Control System and Diagnosis:

[A]: M/T model 4. Spacer 10. Brake pedal bracket nut

[B]: A/T model 5. Pedal spring
: Apply grease 99000-25011 to
inside of spring.
[C]: ENG A-STOP model 6. Brake pedal bracket
1. Brake pedal 7. Brake light switch
: Apply grease 99000-25011 to
inside of hole.
2. Pedal pad 8. Accelerator pedal assembly
3. Pedal bushing 9. Brake booster nut
: Apply grease 99000-25011 to all : Tighten brake booster nut, brake
around surface. pedal bracket nut and accelerator
pedal assembly nut in this order.
: Tighten brake booster nut, brake pedal bracket nut
and accelerator pedal assembly nut in this order.
11. Accelerator pedal assembly nut
: Tighten brake booster nut, brake pedal bracket nut
and accelerator pedal assembly nut in this order.
12. Brake stroke sensor
: 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
: 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)

Brake Pedal Assembly Removal and Installation 7) Remove brake pedal bracket nut (1).
AENJHB0B4106006
Removal
1) Remove steering column hole cover. (Page 9C-35)
2) Disconnect brake light switch connector. (Page
4A-11)
1
3) For ENG A-STOP model, disconnect brake stroke
sensor connector.
• K15B model: (Page 11A-37)
• D13A model: (Page 11A-78)
4) Remove accelerator pedal assembly.
• K15B model: (Page 1C-7)
• D13A model: (Page 1C-25) IJHA0A410022-01
5) Disconnect harness clamp (1) from brake pedal 8) Remove brake pedal assembly.
bracket.
9) Remove brake light switch and/or brake stroke
sensor, if necessary.
• Brake light switch: (Page 4A-11)
• Brake stroke sensor
– K15B model: (Page 11A-37)
– D13A model: (Page 11A-78)
1
Installation
1) Install brake light switch and/or brake stroke sensor,
if removed.
• Brake light switch: (Page 4A-11)
• Brake stroke sensor
– K15B model: (Page 11A-37)
IJHA0A410005-01
– D13A model: (Page 11A-78)
6) Remove clip, clevis pin and brake booster nuts from
brake pedal bracket. (Page 4A-22) 2) Install brake pedal assembly to brake booster.
 Brake Control System and Diagnosis: 4A-9

3) Tighten brake booster nuts (1) to specified torque. 8) Connect brake light switch connector. (Page 4A-
11)
Tightening torque
Brake booster nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf- 9) For ENG A-STOP model, connect brake stroke
ft) sensor connector.
• K15B model: (Page 11A-37)
• D13A model: (Page 11A-78)
10) Check brake pedal free height and play.
• Brake pedal free height: (Page 4A-9)
• Brake pedal play: (Page 4A-10)
11) Check all connections for fluid leakage and check
that brake system operates properly.
12) Install steering column hole cover. (Page 9C-35)

Brake Pedal Free Height Inspection

AENJHB0B4106007
NOTE
1, (a)
IFRA0A410009-01 The brake pedal to carpet clearance must be
4) Tighten brake pedal bracket nut (1) to specified measured between the specified points that
torque. vary with steering wheel position and
transaxle type. Select the appropriate
Tightening torque measuring point (1) according to the figure
Brake pedal bracket nut (a): 13 N·m (1.3 kgf-m, below.
9.5 lbf-ft)
[A] [B]

1, (a)
1 1
IFRA0A410011-01

[A]: M/T model [B]: A/T model

Check brake pedal free height. If it is not within

specification, check and adjust the following items.
IJHA0A410023-01 • Brake booster for installation.
5) Install accelerator pedal assembly. • Length of brake booster push rod.
• K15B model: (Page 1C-7)
Brake pedal free height from carpet (1)
• D13A model: (Page 1C-25) “a”: 102 – 132 mm (4.02 – 5.19 in.)
6) Install clevis pin and clip. (Page 4A-22)
7) Connect harness clamp (1).

1
“a”

I8G001410006-01

IJHA0A410005-01
4A-10 Brake Control System and Diagnosis:

Brake Pedal Play Inspection 3) With brake pedal depressed with force of about 300
AENJHB0B4106008 N (30.6 kgf, 67.4 lbf), measure clearance “a”
With engine stopped, depress brake pedal several
between brake pedal and carpet. If clearance “a” is
times.
less than specification, check the following points.
Depress brake pedal with a finger until resistance is felt
and measure distance to that point. • Air in brake system. (Page 4A-5)
If brake pedal play is not as specified, check push rod • Brake fluid leakage
length. (Page 4A-23) • Length of brake booster push rod. (Page 4A-23)
If push rod length is as specified, check cylinder push
rod clevis and clevis pin for installation condition and Brake pedal to carpet clearance “a”
looseness. Replace brake booster or clevis pin if they When pedal is depressed at 300 N (30.6 kgf,
are loose. 67.4 lbf):
• K15B model: Over 51 mm (2.00 in.)
Brake pedal play “a” • D13A model: Over 44 mm (1.73 in.)
: 1 – 8 mm (0.04 – 0.31 in.)

“a” “a”
I3RH0A410010-01 IBP80A410011-01

Excessive Pedal Travel Inspection Brake Light Switch On-Vehicle Inspection

AENJHB0B4106009
NOTE
The brake pedal to carpet clearance must be
measured between the specified points that
vary with steering wheel position and
transaxle type. Select the appropriate
measuring point (1) according to the figure
below.
AENJHB0B4106010
Depress the brake pedal until brake light turns on and
measure the brake pedal stroke to that point.
If the pedal stroke is not as specified, remove and
reinstall brake light switch.
Brake pedal stroke until brake light turns on
“a”: 5 – 15 mm (0.19 – 0.59 in.)

[A] [B]

1 1
IFRA0A410011-01

[A]: M/T model [B]: A/T model

“a”
IAP70B410015-01

1) Start engine.
2) Depress brake pedal a few times.
 Brake Control System and Diagnosis: 4A-11

Brake Light Switch Removal and Installation 2) Connect brake light switch connector (3).
AENJHB0B4106011
Removal 3
1) Remove steering column hole cover. (Page 9C-35)
2) Disconnect brake light switch connector (1).
3) Remove brake light switch (2) from brake pedal
assembly.

1
1

IFRA0A410013-01
2
3) Install steering column hole cover. (Page 9C-35)

Brake Light Switch Inspection

AENJHB0B4106012

NOTE
IFRA0A410012-01
Reference voltage of each measurement is as
Installation follows.
1) While pulling up brake pedal (2) fully, install brake • Hi: Higher than battery voltage –0.5 V
light switch (1) pressing it to pedal bracket so that • Lo: Lower than 0.5 V
the switch stroke becomes 0 (zero) and turning it
clockwise viewed from above by approx. 90°. 1) Connect battery positive (+) terminal to terminal “1”
and negative (–) terminal to terminal “3” as shown.
NOTE 2) Measure the terminal voltage at each shaft condition.
While installing brake light switch turning it
Brake light switch voltage
clockwise, the switch body rises from the
pedal bracket. Terminal Shaft condition Voltage
This movement automatically creates Free [A] Hi
2
specified clearance “a” between switch Pushed [B] Lo
screw end and the pedal bracket.
Clearance “a”: 1.2 to 2.2 mm (0.047 to 0.086
in.)

5 4 3 2 1

“a”
IFRA0B410010-01

IBP80A410014-01 [A] [B]

IFRA0B410011-01
4A-12 Brake Control System and Diagnosis:

Brake Flexible Hose and Pipe Components

AENJHB0B4106013

[A] 9 4 3 8 [A]
(d) (d)

(d)

1
5 1

7
2 2

[B] 9 4 3 8
[B]
(d)
(c)
(d)

17
1
(d)
(d)
(c) 1 12
(d)

7
2 15
2 6 16
12

3
12
(a) (d)

10 [f]

(b)

13

4
(d)
(d) (d)
12
9 18
10 12
15

12
(b) (d)
(a) 8
11 14 16
(d)

13 (e) 14 (d)
IJHA0A410006-01
 Brake Control System and Diagnosis: 4A-13

[A]: ABS model
[B]: ESP® model
[f]: Forward
1. Pipe between master cylinder primary and ABS /
ESP® hydraulic unit / control module assembly
2. Pipe between master cylinder secondary and
ABS / ESP® hydraulic unit / control module
assembly
3. Right pipe between ABS / ESP® hydraulic unit /
control module assembly and front brake flexible
hose
4. Left pipe between ABS / ESP® hydraulic unit /
control module assembly and front brake flexible
hose
5. ABS hydraulic unit / control module assembly
6. ESP® hydraulic unit / control module assembly
7. Brake master cylinder
8. Left pipe between ABS / ESP® hydraulic unit /
control module assembly and brake 4-way joint
9. Right pipe between ABS / ESP® hydraulic unit /
control module assembly and brake 4-way joint
10. Front brake flexible hose
11. Brake 4-way joint
12. E-ring
13. Flexible hose gasket
14. Left pipe between brake 4-way joint and rear
brake flexible hose
15. Right pipe between brake 4-way joint and rear
brake flexible hose
16. Rear brake flexible hose
17. Right pipe between rear brake
flexible hose and wheel cylinder
18. Left pipe between rear brake
flexible hose and wheel cylinder
: 26 Nm (2.7 kgf-m, 19.5 lbf-ft)
: 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: 21 Nm (2.1 kgf-m, 15.5 lbf-ft)
: 16 Nm (1.6 kgf-m, 12.0 lbf-ft)
: 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: Do not reuse.

Brake Flexible Hose and Pipe Removal and Installation

AENJHB0B4106014

NOTICE
Brake fluid is extremely damaging to painted surfaces. If brake fluid contacts painted surfaces,
immediately wipe it off and flush the surfaces with water thoroughly.

Removal
1) Hoist vehicle and remove wheel. (Page 2D-3)

NOTE
This operation is not necessary when removing pipes connecting to brake master cylinder.

2) Remove dirt and foreign material from fittings at both flexible hose end and pipe end.
3) Drain brake fluid in reservoir. (Page 4A-4)
4) Remove the following parts according to the pipe:
Pipes Model Parts to be removed
• Pipe between master cylinder primary • Liquid pipe, liquid hose, suction hose and/or suction pipe
and ABS / ESP® hydraulic unit / control – Manual A/C single type: (Page 7B-32)
module assembly
– Manual A/C dual type: (Page 7B-84)
• Pipe between master cylinder
– Automatic A/C dual type: (Page 7B-126)
secondary and ABS / ESP® hydraulic
unit / control module assembly • Air cleaner assembly
• Right pipe between ABS / ESP® – K15B model: (Page 1D-9)
hydraulic unit / control module assembly All models – D13A model: (Page 1D-82)
and front brake flexible hose • Fuel feed pipe and purge pipe
– K15B model: (Page 1G-15)
– D13A model: (Page 1G-51)
• Heater inlet hose and outlet hose
– K15B model: (Page 1F-9)
– D13A model: (Page 1F-23)
D13A model Fuel filter (Page 1G-59)
M/T model Clutch fluid pipe (Page 5C-7)
Left pipe between ABS / ESP® hydraulic
unit / control module assembly and front K15B model ECM and ECM bracket: (Page 1C-2)
brake flexible hose
Pipes between ABS / ESP® hydraulic unit / K15B model ECM and ECM bracket: (Page 1C-2)
control module assembly and brake 4-way • Right pipe between ABS / ESP® hydraulic unit / control
joint module assembly and front brake flexible hose
All models
• Left pipe between ABS / ESP® hydraulic unit / control
module assembly and front brake flexible hose
4A-14 Brake Control System and Diagnosis:

Pipes Model Parts to be removed

Left pipe between brake 4-way joint and
All models —
rear brake flexible hose
Right pipe between brake 4-way joint and Fuel tank
rear brake flexible hose All models • K15B model: (Page 1G-21)
• D13A model: (Page 1G-53)
Pipes between rear brake flexible hose and
All models —
wheel cylinder

5) Remove brake flexible hose or pipe.

Special tool
: 09950M78220

Installation
Reverse removal procedure noting the following points.
• Tighten flare nuts to specified torque referring to “Brake Flexible Hose and Pipe Components” (Page 4A-12).
• Install all removed clamps properly.
– Brake pipe clamp: (Page 4A-12)
– Fuel pipe clamp
– K15B model: (Page 1G-11)
– D13A model: (Page 1G-42)
• If liquid pipe, liquid hose, suction hose and/or suction pipe is removed, evacuate and charge A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure for Refrigerant Charge”.
– Manual A/C single type: (Page 7B-26)
– Manual A/C dual type: (Page 7B-78)
– Automatic A/C dual type: (Page 7B-126)
• If heater inlet hose and outlet hose are removed, check cooling system for leakage.
– K15B model: (Page 1F-10)
– D13A model: (Page 1F-24)
• If fuel feed pipe, purge pipe, fuel tank and/or fuel filter is removed, check fuel line connections for leakage with
engine not running and ignition “ON”.
– K15B model: (Page 1G-14)
– D13A model: (Page 1G-41)
• Check that steering wheel is in straight-forward position and flexible hoses are not twisted or kinked.
• Check that flexible hose is not in contact with any part of suspension when steering wheel is turned fully right and
left.
• Bleed brake system. (Page 4A-5)
• If clutch fluid pipe is removed, bleed clutch system. (Page 5C-5)
• Check that brake system operates properly and there is no fluid leakage.
 Brake Control System and Diagnosis: 4A-15

Brake Flexible Hose and Pipe Inspection

AENJHB0B4106015

Flexible Hose
Check the following points. If check result is not OK,
replace brake flexible hose.
• Connection for leakage and other damage
• Blister, crack and other damage

IJHA0A410007-01

Pipe
Check brake pipe for damage, crack, dents and
corrosion. If check result is not OK, replace pipe.

Brake Master Cylinder Components

AENJHB0B4106016

[A]
7

3
5 FLD

(a)
IJHB0A410005-01

[A]: M/T model 4. O-ring 8. Reservoir cap

: Apply grease to O-ring included in spare part
for brake master cylinder or brake booster.
1. Brake master cylinder 5. Grommet 9. Reservoir filter
: Do not disassemble. : Apply brake fluid.
2. Reservoir 6. Clutch reservoir hose : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
3. Spring pin 7. Hose clamp : Do not reuse.
4A-16 Brake Control System and Diagnosis:

Brake Master Cylinder Assembly On-Vehicle Removal

Inspection 1) Clean external surface of brake master cylinder.
AENJHB0B4106017
Check brake master cylinder for crack, damage and 2) Disconnect brake fluid level switch connector (1) on
brake fluid leakage. If check result is not OK, replace reservoir.
brake master cylinder.

IJHB0A410001-01

IJHB0A410006-01 3) Drain brake fluid in reservoir.

4) For M/T model, disconnect clutch reservoir hose (3)
Brake Master Cylinder Assembly Removal and from reservoir.
Installation 5) Loosen flare nuts with special tool and disconnect
AENJHB0B4106018
brake pipes (1) from brake master cylinder.
NOTICE
Special tool
• The brake master cylinder and brake : 09950M78220
booster will lose their original performance
6) Remove brake master cylinder fixing nuts (2).
if they are disassembled and reassembled.
If any faulty condition is found in the brake
master cylinder or brake booster, replace
the part rather than trying to disassemble
and repair it.
• Brake fluid is extremely damaging to 3
painted surfaces. If brake fluid contacts
painted surfaces, immediately wipe it off
and flush the surfaces with water
thoroughly.

1 2
IJHB0A410007-01
 Brake Control System and Diagnosis: 4A-17

7) Remove brake master cylinder (1) and O-ring (2). 4) Connect brake pipes (1) to brake master cylinder
and tighten flare nuts (3) to specified torque.
Tightening torque
1
Brake pipe flare nut (ABS) (b): 16 N·m (1.6 kgf-
m, 12.0 lbf-ft)
Brake pipe flare nut (ESP®) (b): 21 N·m (2.1 kgf-
m, 15.5 lbf-ft)

IJHB0A410008-01

Installation
1) Apply grease included in spare part for brake master
1
cylinder or brake booster to new O-ring (2), and
install it to brake master cylinder assembly (1).

3, (b)
1 1
3, (b) 2, (a)
IJHB0A410009-01

5) For M/T model, connect clutch reservoir hose to

reservoir.
6) Connect brake fluid level switch connector.
7) Bleed brake system. (Page 4A-5)
2
8) For M/T model, bleed clutch system. (Page 5C-5)
9) Check installed parts for brake fluid leakage.
IJHB0A410008-01 10) Check brake pedal for play. (Page 4A-10)
2) Install brake master cylinder to brake booster. 11) Check that brake system operates properly without
3) Tighten brake master cylinder fixing nuts (2) to fluid leakage.
specified torque.
Brake Master Cylinder Reservoir Removal and
Tightening torque
Installation
Brake master cylinder fixing nut (a): 18 N·m (1.8 AENJHB0B4106019
kgf-m, 13.5 lbf-ft)
NOTICE
Brake fluid is extremely damaging to painted
surfaces. If brake fluid contacts painted
surfaces, immediately wipe it off and flush
the surfaces with water thoroughly.
4A-18 Brake Control System and Diagnosis:

Removal 3) Install new spring pin (2) from chamfered side (1)
1) Clean outside surface of reservoir. using special tool until protrusion “a” at both ends
become equal.
2) Remove brake master cylinder together with
reservoir from brake booster. (Page 4A-16) Special tool
3) Remove spring pin (1) using special tool. (A): 09916M43211

Special tool
(A): 09916M43211

(A) 1

“a” “a”
IFRA0P410030-01

4) Install brake master cylinder with reservoir to brake

booster. (Page 4A-16)

Brake Master Cylinder Assembly Inspection

AENJHB0B4106020
1 (A)
IJHB0A410010-01
No-Load Inspection
4) Remove reservoir (1) and grommets (2). 1) Fit special tool to primary port (1) as shown below.

NOTE
1
If the vehicle is not equipped with ESP®,
special tool (B) is unused for this inspection.

Special tool
(A): 09918M78230
(B): 09952M48010

2
3

(A)
2
1

IJHB0A410011-01

Installation
1) Lubricate new grommets with the same brake fluid
(B)
as the one to fill reservoir before fitting grommets IJHB0A410012-01
into master cylinder. 2. Secondary port 3. Brake master cylinder assembly
2) Install reservoir to brake master cylinder.
2) Apply pressure to brake master cylinder assembly
with special tool (A) and check that pressure does
not build up in cylinder.
If pressure builds up, brake master cylinder
assembly is defective and must be replaced.
3) Repeat Step 1) – 2) for secondary port as well.
 Brake Control System and Diagnosis: 4A-19

Air Tightness Inspection

1) With brake master cylinder assembly (1) fixed in vise
(2) as shown below, fit special tool to primary port.

NOTE
• When using vise, put clean cloth between
brake master cylinder and vise so as not to
cause damage to brake master cylinder.
• If the vehicle is not equipped with ESP®,
special tool (B) is unused for this
inspection.

Special tool
(A): 09918M78230
(B): 09952M48010

1
“a”

(B)
(A)

IJHB0A410013-01

“a”: 50 mm (2.0 in.)

2) Using special tool, apply pressure of 50 kPa (0.5 kgf/

cm2, 7.25 psi, 0.5 bar) to brake master cylinder
assembly.
If above pressure does not build up, brake master
cylinder assembly is defective and must be replaced.
3) Repeat Step 1) – 2) for secondary port.
4A-20 Brake Control System and Diagnosis:

Brake Booster Components

AENJHB0B4106021

[C]
5
3 2
4 6
5
1 (a) 7

(b)

(c)
8

[A]
5
5
9
[B]

10
13

[D]
5

5 6
7

(c)

14 5
8
5

12
11

IJHB0B410002-01

[A]: M/T model 5. Hose clamp 13. To intake manifold

[B]: A/T model 6. Brake vacuum hose No.1 14. To vacuum pump
[C]: K15B model 7. Brake vacuum pipe : 26 Nm (2.7 kgf-m, 19.5 lbf-ft)
[D]: D13A model 8. Brake vacuum hose No.2 : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
1. Brake booster 9. Brake booster switch : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: Do not disassemble.
2. Gasket 10. Brake booster pressure sensor : Do not reuse.
3. Clevis pin 11. Clamp
4. Clip 12. Brake vacuum connector
 Brake Control System and Diagnosis: 4A-21

Brake Booster Function Check Operation Check

AENJHB0B4106022
NOTE 1) With engine stopped, depress brake pedal several
times with the same force and check that pedal
Check that no air is in hydraulic line before travel does not change.
this check.

Air Tightness Check

1) Start engine.
2) Stop engine after running for 1 to 2 minutes.
3) Depress brake pedal several times with the same
force as in ordinary braking to see how pedal travel
changes. Brake booster is air tight if pedal travel
decreases every time the pedal is depressed.

I2RH01410007-01

2) Start engine while depressing brake pedal. If pedal

travel increases a little, brake booster operation is
satisfactory. No change in pedal travel indicates
malfunction of brake booster.

I2RH01410005-01

1. 1st 3. 3rd
2. 2nd

4) If pedal travel does not change, brake booster is

defective in air tightness.

NOTE
If faulty condition is found, check vacuum
lines and sealing parts, and replace the faulty
part. After this, repeat the entire test.
I2RH01410008-01
Air Tightness Check under Loaded Condition
1) With engine running, depress brake pedal. Then
stop engine while holding brake pedal depressed.

I2RH01410006-01
I2RH01410009-01
1. 1st, 2nd, 3rd
H: Hold
4A-22 Brake Control System and Diagnosis:

2) Hold brake pedal depressed for 30 seconds. If pedal
height does not change, brake booster is in good
condition. If pedal height changes, brake booster is
not in good condition.
7) Disconnect vacuum hose from brake booster.
8) Remove clip (2) and clevis pin (1).
2

IFRA0A410031-02

I2RH01410010-01
9) Remove brake booster nuts (1) and remove brake
booster from dash panel.
H: Hold T: 30 seconds

Brake Booster Removal and Installation

AENJHB0B4106023

Removal
1) Remove intake manifold.
• K15B model: (Page 1D-13)
• D13A model: (Page 1D-93)
2) Remove brake master cylinder assembly from brake
booster. (Page 4A-16)
3) Remove the following brake pipes. (Page 4A-13)
• Pipe between master cylinder primary and ABS / 1 1
ESP® hydraulic unit / control module assembly
• Pipe between master cylinder secondary and ABS
/ ESP® hydraulic unit / control module assembly IHSB0A410006-01
4) For M/T model, disconnect brake booster switch 10) Remove brake vacuum hose and pipe, if necessary.
connector.
5) For A/T model, disconnect brake booster pressure Installation
sensor connector. 1) Install brake vacuum hose and pipe, if removed.
6) For D13A model, remove the following parts. 2) Loosen brake pedal bracket nut (1).
• ISG: (Page 1J-20)
• Engine hook (1) and engine hook bolt (2)

2 IJHA0A410022-01

3) Loosen accelerator pedal assembly nut.

• K15B model: (Page 1C-7)
IFRA0A410030-02
• D13A model: (Page 1C-25)
 Brake Control System and Diagnosis: 4A-23

4) Install brake booster to dash panel. Then connect 9) For M/T model, connect brake booster switch
clevis (3) to brake pedal arm with clevis pin (2) and connector.
new clip (1). 10) For A/T model, connect brake booster pressure
sensor connector.
3 1
11) Install the following brake pipes, and tighten flare
nuts to specified torque. (Page 4A-13)
• Pipe between master cylinder primary and ABS /
ESP® hydraulic unit / control module assembly
2 • Pipe between master cylinder secondary and ABS
/ ESP® hydraulic unit / control module assembly
12) Install brake master cylinder assembly to brake
booster. (Page 4A-16)
13) Bleed brake system. (Page 4A-5)
IFRA0A410032-01
14) For M/T model, bleed clutch system. (Page 5C-5)
5) Tighten brake booster nuts (1) to specified torque. 15) Check installed parts for brake fluid leakage.
16) Check brake pedal for play. (Page 4A-10)
Tightening torque
Brake booster nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf- 17) Check that brake system operates properly without
ft) brake fluid leakage.
18) For D13A model, install the following parts.
• ISG: (Page 1J-20)
• Engine hook (1) and engine hook bolt (2)
Tightening torque
Engine hook bolt (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)

1, (a)
IFRA0A410009-01

6) Tighten brake pedal bracket nut (1) to specified

torque. 1

Tightening torque
2, (a)
Brake pedal bracket nut (a): 13 N·m (1.3 kgf-m,
9.5 lbf-ft)
IFRA0A410034-02

19) Install intake manifold.

• K15B model: (Page 1D-13)
• D13A model: (Page 1D-93)
1, (a)
Brake Booster Inspection
AENJHB0B4106024
• Check brake booster for damage.
• Check brake booster for operation referring to
“Operation Check” under “Brake Booster Function
Check” (Page 4A-21).
• Check boot for damage and deterioration.
IJHA0A410023-01
• Check push rod length.
7) Tighten accelerator pedal assembly nut.
If check result is not as specified, adjust distance
• K15B model: (Page 1C-7) between booster installation surface (without including
• D13A model: (Page 1C-25) packing) and the center of clevis pin hole to standard
8) Connect vacuum hose to brake booster. value “a” and tighten push rod nut (1) to specified
torque.
4A-24 Brake Control System and Diagnosis:

Push rod length 3) Connect SUZUKI scan tool to DLC (1).

“a”: 114.5 – 115.5 mm (4.508 – 4.547 in.)
Special tool
Tightening torque (A): SUZUKI scan tool (Suzuki SDT-II)
Push rod nut (a): 26 N·m (2.7 kgf-m, 19.5 lbf-ft)

IGRA0A410007-01

Brake Booster Switch Inspection (M/T Model)

AENJHB0B4106025
! CAUTION
2
Do not remove brake booster switch.
Removal and reinstallation will spoil its
original performance.
If faulty condition is observed, replace brake
booster assembly with new one. (A)

IJHA0A110011-01
Using SUZUKI Scan Tool 2. VCI
1) Disconnect vacuum hose from brake booster (2).
2) Connect special tool (A) to brake booster. 4) Set ignition “ON”, and select “Brake Booster Vacuum
Condition” in “Data list” mode under “ECM” on
Special tool
SUZUKI scan tool.
(A): 09917M47011
5) Check data displayed on SUZUKI scan tool at each
2 negative pressure specified. If the data displayed is
not as shown in the table, replace brake booster
assembly with new one.
Brake booster switch reference value
Negative pressure Scan tool display
1 30.7 kPa (0.3 kgf/cm2, 4.45 psi) Value Lo
38.7 kPa (0.4 kgf/cm2, 5.61 psi) Value Hi

(A)

IJHB0A410015-01

1. Brake booster switch

 Brake Control System and Diagnosis: 4A-25

Using Circuit Tester Brake Booster Pressure Sensor Inspection (A/T

1) Disconnect connector from brake booster switch (1). Model)
AENJHB0B4106026
2) Disconnect vacuum hose from brake booster (2). ! CAUTION
3) Connect special tool (A) to brake booster.
• If excessive negative pressure is applied,
Special tool the brake booster pressure sensor may be
(A): 09917M47011 damaged.
Do not exceed a negative pressure of –100
2
kPa (–1.0 kgf/cm2, –14.5 psi, –1.0 bar).
• Do not remove brake booster sensor.
Removal and reinstallation will spoil its
original performance.
If faulty condition is observed, replace
1 brake booster assembly with new one.

Using SUZUKI Scan Tool

1) Connect SUZUKI scan tool to DLC (1).
Special tool
(A) : SUZUKI scan tool (Suzuki SDT-II)
(A)

IJHB0A410015-01

4) Apply vacuum to brake booster (1) by special tool

and check for continuity between switch terminal and 1
ground at each specified negative pressure in the
following table.
5) If the tester reading is not as shown in the table,
replace brake booster assembly with new one.
Brake booster switch reference value
Negative pressure Scan tool display
30.7 kPa (0.3 kgf/cm2, 4.45 psi) Continuity exists
2
38.7 kPa (0.4 kgf/cm2, 5.61 psi) No continuity

3
1
(A)

IJHA0A110011-01

2. VCI

2) Set ignition “ON”, and select “Brake Booster

2. Brake booster switch
Pressure Sensor” in “Data list” mode on SUZUKI
scan tool.
3) Check parameter displayed on SUZUKI scan tool at
each negative pressure specified. Refer to “Scan
Tool Data” in Section 4F (Page 4F-23).
If the parameter is not as shown in the table, check
the following points.
2 • Brake booster pressure sensor (1) and grommet
IJHB0A410016-01
(2) for installation
3. Circuit tester
• Grommet damage
• Wiring and connection
4A-26 Brake Control System and Diagnosis:

• Brake vacuum hose (3) c) Check that voltage varies gradually when
• Brake booster pressure sensor: (Page 4A-26) negative pressure is gradually applied with
special tool.
• Brake booster (4): (Page 4A-23)
Vacuum sensor reference voltage
Negative pressure 0 kPa (0.0 kgf/cm2, 0.0 psi,
0.0 bar): Approx. 0.5 V
3
Negative pressure –70 kPa (–0.7 kgf/cm2, –
10.1 psi, –0.7 bar): Approx. 2.1 V

(A)

2 2 1

IHSE0A410024-01 1 2 3

Using Circuit Tester

1) Remove brake booster with brake master cylinder 4
assembly (1). (Page 4A-22)
2) Check brake booster pressure sensor output voltage 3
as follows.
If check result is not as specified, replace brake
booster. IHSE0A410025-01

NOTICE 5. Adapter included in special tool

Specified input voltage of this brake booster

pressure sensor is between 4.8 and 5.2 V.
Therefore, arrangement of three 1.5 V dry
batteries (4.5 V) is not enough, and four 1.5 V
dry batteries (6 V) exceeds the limit which
may affect the sensor.
Use four 1.2 V chargeable batteries for this
check.

a) Arrange four 1.2 V chargeable batteries (3) in

series and check that total voltage is 4.8 – 5.2 V.
b) Connect special tool, voltmeter (4) and batteries
to brake booster and brake booster pressure
sensor (2) as shown in figure.
Special tool
(A): 09917M47011
 Brake Control System and Diagnosis: 4A-27

Specifications
Tightening Torque Specifications
AENJHB0B4107001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Brake booster nut (Page 4A-9) /
13 1.3 9.5
(Page 4A-23)
Brake pedal bracket nut (Page 4A-9) /
13 1.3 9.5
(Page 4A-23)
Brake master cylinder fixing nut 18 1.8 13.5 (Page 4A-17)
Brake pipe flare nut (ABS) 16 1.6 12.0 (Page 4A-17)
Brake pipe flare nut (ESP®) 21 2.1 15.5 (Page 4A-17)
Engine hook bolt 25 2.5 18.5 (Page 4A-23)
Push rod nut 26 2.7 19.5 (Page 4A-24)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Brake Pedal Components” (Page 4A-7)
“Brake Flexible Hose and Pipe Components” (Page 4A-12)
“Brake Master Cylinder Components” (Page 4A-15)
“Brake Booster Components” (Page 4A-20)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Recommended Service Material
AENJHB0B4108001
NOTE
Required service material(s) is also described in:
“Brake Pedal Components” (Page 4A-7)
“Brake Master Cylinder Components” (Page 4A-15)

Special Tool
AENJHB0B4108002
09916M43211 09917M47011
Valve guide remover (4.4 Vacuum pump gauge
mm)
(Page 4A-18) / (Page 4A-24) /
(Page 4A-18) (Page 4A-25) /
(Page 4A-26)

09918M78230 09950M78220
Master cylinder leakage Flare nut wrench (10 x 12
tester mm)
(Page 4A-18) / (Page 4A-14) /
(Page 4A-19) (Page 4A-16)

09952M48010 SUZUKI scan tool (Suzuki

SDT-II)
Master cylinder attachment —
adapter
(Page 4A-18) / (Page 4A-24) /
(Page 4A-19) (Page 4A-25)
4B-1 Front Brakes:

Front Brakes
Brakes

General Description
Front Brake Description
AENJHB0B4201001
Front brake system is of a ventilated disc brake type.

Repair Instructions
Front Brake Components
AENJHB0B4206001

19 17

18
16

(c)
15
13 (d) (b)

14

4
(a)
1

5
12
3

11

10 6

9
9

9
IJHB0A420001-01
 Front Brakes: 4B-2

1. Front brake caliper
2. Front brake caliper carrier
3. Pin boot
4. Slide pin without bushing
: Apply rubber grease included in pin
boot set of supply parts.
5. Slide pin with bushing
: Apply rubber grease included in pin
boot set of supply parts.
6. Pad spring
7. Inner brake pad
8. Outer brake pad
9. Shim 17. Front brake disc dust cover
: If brake pads are replaced, use new
shim included in supply parts.
10. Piston boot 18. Front wheel hub
: Apply small amount of rubber grease : Apply grease 99000-25011 to mating
included in piston seal set of supply surface of front wheel hub assembly for front
parts or specified brake fluid. drive shaft. (Page 3A-17)
11. Piston seal 19. Steering knuckle
: Apply small amount of rubber grease
included in piston seal set of supply
parts or specified brake fluid.
12. Brake piston : 85 Nm (8.7 kgf-m, 63.0 lbf-ft)
: Apply small amount of rubber grease
included in piston seal set of supply
parts or specified brake fluid.
13. Bleeder plug : 27 Nm (2.8 kgf-m, 20.0 lbf-ft)
14. Flexible hose gasket : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
15. Front brake flexible hose : 8.5 Nm (0.87 kgf-m, 6.5 lbf-ft)
16. Front brake disc : Do not reuse.

Front Brake Pad On-Vehicle Inspection
AENJHB0B4206002
Check pad linings periodically according to maintenance
schedule and whenever wheels are removed (for tire
rotation or other reason). Check lining thickness of
outside and inside pads.
If lining is worn and its thickness (“a” in figure) is less
than the limit, all pads must be replaced at the same
time.
Front brake pad thickness (lining thickness) “a”
Standard: 10 mm (0.39 in.)
Limit: 1.5 mm (0.05 in.)
Front Brake Pad Removal and Installation
AENJHB0B4206003
NOTICE
Failure to take proper precautions during
front brake caliper removal may cause
damage to the front brake flexible hose and/
or the brake piston.
• Be careful not to damage the front brake
flexible hose during front brake pad
removal.
• Avoid depressing the brake pedal during
the front brake pad removal procedure to
prevent the brake piston from being forced
out of the cylinder.

NOTE
• Check for leakage of brake fluid when
removing front brake pads and repair front
brake caliper if leakage is found.
• Replace all brake pads at the same time
even if only one pad is defective.

Removal
I7RW01420009-01
1) Hoist vehicle and remove front wheel. (Page 2D-3)
2) Remove front brake caliper pin bolts (1).

IA1J0P420002-01
4B-3 Front Brakes:

3) Remove front brake caliper (1) from front brake 2) Fit shims (1) to front brake pads (2).
caliper carrier (2).
[A] [B]
NOTICE 2

If the removed front brake caliper is left hung 2

by the front brake flexible hose (6), the front
brake flexible hose may be damaged due to
the tension caused by the caliper’s weight.
Hang a removed front brake caliper with a
wire hook (4) or the like to relieve the front 1
1
brake flexible hose of the tension. 1
IJHB0A420003-01

4) Remove front brake pads (3) and pad springs (5) [A]: Inside [B]: Outside
from front brake caliper carrier.
3) Install the brake pad with wear indicator (1) to the
vehicle center side of front right and left brake pad.
4

6
5

3 1

IJHA0A420003-01
5 4) Install front brake pads (1) with shims to front brake
caliper carrier (2) as shown in figure.
2

1
IJHB0A420002-01

Installation
1) Install pad springs (1) to front brake caliper carrier
(2).
1

2
IJHB0A420004-01

NOTE
Install inner pad at vehicle center side of
1 caliper carrier with its wear indicator (1)
positioned upside.

IGSB0A420004-01

IJHA0A420003-01

5) Install front brake caliper (2) to front brake caliper
carrier (3) and tighten caliper pin bolts (1) to
specified torque.
Tightening torque
Front brake caliper pin bolt (a): 27 N·m (2.8 kgf-
m, 20.0 lbf-ft)
1, (a)
3
IGSB0A420007-01
6) Install front wheel. (Page 2D-3)
7) Check that brake system operates properly.
Front Brake Pad Inspection
AENJHB0B4206004
NOTICE
If the front brake pad lining is polished with
sandpaper, abrading particles will be
embedded in the lining and will damage the
front brake disc.
Do not polish pad lining with sandpaper.
Replace the front brake pad with a new one.
NOTE
• Check for leakage of brake fluid when
removing front brake pads and repair front
brake caliper if leakage is found.
• Replace all brake pads at the same time
even if only one pad is defective.
Front Brakes: 4B-4
Check thickness of each front brake pad lining. If any
lining is thinner than limit or is excessively worn on one
side, replace all front brake pads.
Front brake pad thickness (lining thickness) “a”
Standard: 10 mm (0.39 in.)
Limit: 1.5 mm (0.05 in.)
“a”
IFRA0B420003-01
Front Brake Disc Removal and Installation
AENJHB0B4206005
NOTICE
Failure to take proper precautions during
front brake caliper removal may cause
damage to the front brake flexible hose and/
or the brake piston.
• Hang removed front brake caliper with a
wire hook or the like not to twist the front
brake flexible hose during front brake
caliper removal.
• Avoid depressing the brake pedal during
the brake disc removal procedure to
prevent the brake piston from being forced
out of the cylinder.
Removal
1) Hoist vehicle and remove front wheel. (Page 2D-3)
2) Remove front brake caliper carrier bolts (1) and
remove front brake caliper (2) from steering knuckle.
1
I9P60A420030-01
4B-5 Front Brakes:

3) Pull off front brake disc (2) by M8 bolts (1). Front Brake Disc Inspection
AENJHB0B4206006
• Using magnetic stand (1), set dial gauge (2) with prod
positioned about 10 mm (0.39 in.) inward from
periphery of disc, measure deflection of disc. If it
exceeds the limit, correct or replace the front brake
disc.
Front brake disc deflection
2 Limit: 0.10 mm (0.004 in.)

1
1
IJHA0A420004-01

Installation

NOTICE 2

If the front brake flexible hose is twisted, the

hose will be damaged.
If the front brake flexible hose is twisted,
reinstall front brake caliper being careful not IJHA0A420005-01
to let front brake flexible hose get twisted.
• Using micrometer, measure thickness of front brake
1) Install front brake disc to front wheel hub assembly. disc. If it is less than limit, replace front brake disc.
2) Install front brake caliper to steering knuckle and Front brake disc thickness “a”
tighten front brake caliper carrier bolts (1) to Standard: 22.0 mm (0.86 in.)
specified torque. Limit: 20.0 mm (0.79 in.)
Tightening torque “a”
Front brake caliper carrier bolt (a): 85 N·m (8.7
kgf-m, 63.0 lbf-ft)

1, (a)

I9W10P420012-02

Front Brake Caliper Removal and Installation

AENJHB0B4206007

IFRA0A420003-01
3) Install front wheel. (Page 2D-3)
4) Check that brake system operates properly.
! WARNING
If front brake flexible hose gaskets are
reused, brake fluid may leak, which could
result in an accident.
Always use new flexible hose gaskets when
reinstalling the flexible hose.
 Front Brakes: 4B-6

NOTICE
Failure to take proper precautions during
front brake caliper removal may cause
damage to the front brake flexible hose and/
or the brake piston.
• Be careful not to damage the front brake
flexible hose during front brake caliper
removal.
• Avoid depressing the brake pedal during
the front brake caliper removal procedure
to prevent the brake piston from being
forced out of the cylinder.
Installation
NOTICE
If the front brake flexible hose is twisted, the
hose will be damaged.
If the front brake flexible hose is twisted,
reinstall front brake caliper being careful not
to let front brake flexible hose get twisted.
1) Install front brake caliper to front brake caliper
carrier.
Tighten front brake caliper pin bolts (1) to specified
torque.

Removal Tightening torque

Front brake caliper pin bolt (a): 27 N·m (2.8 kgf-
1) Hoist vehicle and remove front wheel. (Page 2D-3)
m, 20.0 lbf-ft)
2) Place a container below caliper to catch brake fluid.
3) Remove flexible hose joint bolt (1) from front brake
caliper (2).
1, (a)

IDL10A420003-02

2) Connect brake flexible hose (1) with new flexible

hose gaskets (2) to caliper as shown in figure.
IDL10A420002-01 Tighten flexible hose joint bolt (3) to specified torque.
4) Remove front brake caliper pin bolts (1).
Tightening torque
5) Remove front brake caliper (2) from front brake Front brake flexible hose joint bolt (a): 23 N·m (
caliper carrier (3). 2.3 kgf-m, 17.0 lbf-ft)

2
1

3, (a) 1

IA1J0P420011-01
IFRA0A420005-01

3) Fill reservoir with brake fluid and bleed brake

system. (Page 4A-5)
4) Check that there is no leakage of the brake fluid.
5) Install front wheel. (Page 2D-3)
6) Check that brake system operates properly.
4B-7 Front Brakes:

Front Brake Caliper Disassembly and 3) Remove piston boot (1) and bleeder plug (2) from
Reassembly brake caliper (3).
AENJHB0B4206008
2
Disassembly
Caliper
1) Clean surfaces around caliper with brake cleaner 3
before disassembly.
2) Remove brake piston by blowing air into the hole for
front brake flexible hose joint bolt.

! CAUTION
If you place your fingers in front of the piston
when you push it out with compressed air, 1
you may hurt your fingers. IDL10A420005-01

Do not place your fingers in front of the 4) Remove piston seal (1) from cylinder of front brake
piston when removing it using compressed caliper (3) using flat-bladed screwdriver (2) or the
air. like.

NOTICE NOTICE

Failure to take proper precautions while
servicing front brake caliper and brake piston
may damage piston and/or brake caliper.
• Place a cloth (1) in front of the piston to
prevent it from jumping out.
• Do not scratch sealing surface (2) with air
blow gun.
• Use a moderate air pressure to push the
piston out of the cylinder slowly.
If the inside surface of the cylinder (bore
wall) and outside surface of piston are
damaged, brake fluid leakage may result.
Be extremely careful not to damage the
inside surface of the cylinder and outside
surface of piston when removing the piston
seal.
3
1

2
I9P60A420026-01
I2RH01420011-01

Slide pin
Remove slide pins (1) and pin boots (2) from front brake
caliper carrier (3).

3 2
2

IGRA0A420001-01
IGSB0A420013-01
 Front Brakes: 4B-8

Reassembly c) Apply rubber grease included in piston seal set

of supply parts or specified brake fluid to new
! WARNING piston boot (1). And then install it onto brake
piston as shown.
Failure to take proper precautions when
assembling the brake caliper can result in
brake system failure, which could lead to an
accident. 1

• Clean each part before installation using

[B] [A]
the same brake fluid as that in the master
cylinder reservoir.
Never use any other brake fluid or volatile
solvent.
• Before installing the piston seal and piston
boot to the cylinder, apply rubber grease I9P60A420019-01

included in the piston seal set or brake [A]: Caliper cylinder side [B]: Brake pad side
fluid to them.
• Fit a new piston seal securely into the 2) Fit piston boot (1) with piston into boot groove in
groove of the cylinder checking that it is cylinder by hand as shown below.
not twisted.

Caliper
1) Perform the following steps before installing brake
piston to front brake caliper.
a) Check entire periphery of brake piston and inside
surface of cylinder for rust, corrosion and any
other damage. If check result is not OK, replace
brake piston and/or front brake caliper. IAP70A420017-01

b) After applying rubber grease included in piston 3) Insert brake piston (1) into cylinder by hand and fit
seal set of supply parts or specified brake fluid to piston boot (2) in boot groove on brake piston.
new piston seal (1), fit the seal into groove in
NOTE
cylinder taking care not to twist the seal.
Check that boot is securely fitted in boot
Brake fluid specification grooves in piston and cylinder.
Refer to reservoir cap of brake master
cylinder or Owner’s Manual.

IAP70A420018-01

I2RH01420017-01
4B-9 Front Brakes:

4) To check that piston boot (2) is fitted in its groove in 2) Install slide pin without bushing (1) into upper side
cylinder properly, pull piston (1) a little outward and slide pin with bushing (2) into lower side of front
without moving it fully out. brake caliper carrier (3) as shown.

[A]
1

IAP70A420019-01 IDAA0A420032-01

5) Insert piston into cylinder by hand. [A]: Upward

6) Install bleeder plug to front brake caliper and tighten
it to specified torque. Front Brake Caliper Inspection
AENJHB0B4206009
Tightening torque NOTE
Bleeder plug: 8.5 N·m (0.87 kgf-m, 6.5 lbf-ft)
Perform this inspection in the following
cases.
Slide pin
• When replacing front brake pads with new
1) Check the following points before installing slide pins
ones.
to front brake caliper carrier.
• When removing front brake caliper.
a) Check slide pins for rust, corrosion and other
damage. Replace slide pin if defective. Caliper Body and Carrier
b) Install new pin boots (1) to front brake caliper Check brake caliper body and carrier for deformation,
carrier (2) with their ends directed as shown crack, damage and rust. Replace front brake caliper and
below. carrier if defective.

2 Piston Boot
Check piston boot (1) for break and crack. Replace
piston boot if defective.

IDAA0A420031-01

c) Apply rubber grease included in pin boot set of

supply parts to slide pin (1).

I8RW01420003-01

IAW101420005-01
 Front Brakes: 4B-10

Slide Pin
Before installing caliper to carrier (2), check slide pins (1)
for smooth thrust movement.

2
IGSB0A420017-01

Specifications
Tightening Torque Specifications
AENJHB0B4207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Front brake caliper pin bolt (Page 4B-4) /
27 2.8 20.0
(Page 4B-6)
Front brake caliper carrier bolt 85 8.7 63.0 (Page 4B-5)
Front brake flexible hose joint bolt 23 2.3 17.0 (Page 4B-6)
Bleeder plug 8.5 0.87 6.5 (Page 4B-9)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Brake Components” (Page 4B-1)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Recommended Service Material
AENJHB0B4208001
NOTE
Required service material(s) is also described in:
“Front Brake Components” (Page 4B-1)
4C-1 Rear Brakes:

Rear Brakes
Brakes

General Description
Rear Drum Brake Description
AENJHB0B4301001
The rear brake is of a leading-trailing drum type.
 Rear Brakes: 4C-2

Repair Instructions
Rear Drum Brake Components
AENJHB0B4306001

18
(c)
(b)

12

13

20 17

(d)

19 15 (a)

14

16
9 8
5
2

10
6
11

7
8 3 1

2
7 4

IJHB0B430001-01

1. Rear brake drum 10. Anti-rattle spring 19. Parking brake cable
2. Brake shoe 11. Quadrant spring 20. Rear axle
3. Shoe return upper spring 12. Brake backing plate : 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)
: After cleaning backing plate, apply heat-resistant
brake grease or grease included in supply part.
4. Shoe return lower spring 13. Wheel cylinder : 12 Nm (1.2 kgf-m, 9.0 lbf-ft)
5. Brake shoe lever 14. Bleeder plug cap : 16 Nm (1.6 kgf-m, 12.0 lbf-ft)
6. E-ring 15. Bleeder plug : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
4C-3 Rear Brakes:

7. Shoe hold down spring
8. Shoe hold down pin
9. Brake adjuster (strut)
16. Rear wheel cylinder cup set : Do not reuse.
: Apply small amount of rubber grease or specified
brake fluid.
17. Backing plate plug
18. Rear brake pipe

Rear Brake Shoe On-Vehicle Inspection Installation

AENJHB0B4306002
Amount of brake shoe wear can be checked as follows.
1) Hoist vehicle.
2) Remove backing plate plug (1) from brake backing
plate.
3) Through hole in backing plate, visually check for
thickness “a” of brake shoe lining (2). If brake shoe
lining is found significantly worn, check rear brake
shoe lining thickness as follows.
a) Remove rear brake drum. (Page 4C-3)
b) Check rear brake shoe lining thickness referring
to “Rear Brake Shoe” under “Rear Brake Drum
and Shoe Inspection” (Page 4C-3).
Rear brake shoe lining thickness “a”
Standard: 3.9 mm (0.15 in.)
Limit: 1.0 mm (0.04 in.)
2
Reverse removal procedure noting the following points.
• Adjust parking brake cable referring to “Parking Brake
Adjustment” in Section 4D (Page 4D-2).
• Check that brake drum does not drag and brake
provides proper braking. Perform brake test (foot
brake and parking brake).
Rear Brake Drum and Shoe Inspection
AENJHB0B4306004
Rear Brake Drum
• Check rear brake drum for damage, deformation and
cracks. If check result is not OK, replace brake drum
with new one.
• Check brake drum for wear.
If drum inner diameter exceeds the limit or uneven or
stepped wear is excessive, replace brake drum with
new one.
Rear brake drum inner diameter “a”
Standard: 220 mm (8.66 in.)
Limit: 222 mm (8.74 in.)

1
I4RS0B430004-01

Rear Brake Drum Removal and Installation

AENJHB0B4306003
Removal
1) Hoist vehicle and remove rear wheel. (Page 2D-3)
2) Release parking brake.
“a”
3) Remove rear brake drum (2) by screwing M8 bolts
(1) evenly.

IJHA0A430002-01
2

IJHA0A430007-01
 Rear Brakes: 4C-4

Rear Brake Shoe 4) Disconnect brake shoe lever (1) from parking brake
• Check surface of lining (1) for hardening, excessive cable (2).
wear, peel-off and oil.
• Measure brake shoe thickness “a” (not including
backing plate) at least three points (2). If any
measured value is not as specified or if remarkable
uneven wear is found, replace all the shoes of the
vehicle.
Rear brake shoe lining thickness “a”
Standard: 3.9 mm (0.15 in.)
Limit: 1.0 mm (0.04 in.)
2

1
IJHA0A430004-02

2
5) Remove E-ring (1).
6) Remove brake shoe lever (2) from rear brake shoe
(3).
“a”
1
2
I9P60A431014-01
3

Rear Brake Shoe Removal and Installation

AENJHB0B4306005

NOTE 1

Replace both right and left brake shoes as a

set.

Removal
1) Remove rear brake drum. (Page 4C-3)
2) Remove shoe hold down springs (1) by turning shoe
hold down pins (2).

IJHB0A430002-01

Installation
Reverse removal procedure noting the following points.
• Before installing brake shoes to brake backing plate,
clean brake backing plate and apply grease “A”.
1
“A”: Heat-resistant brake grease

IJHA0A430003-01

3) Remove shoe return springs, anti-rattle spring, brake

shoes and brake adjuster.

“A” “A”

“A”
IJHA0A430005-01

• Use a new E-ring.

4C-5 Rear Brakes:

• Insert flat-bladed screwdriver (2) or the like as shown Wheel Cylinder Removal and Installation
avoiding contact with ratchet teeth (1), and move it in AENJHB0B4306007

arrow direction to push quadrant (3) inward. NOTICE

• Compress brake shoe until its outer diameter is small Brake fluid is extremely damaging to painted
enough to install rear brake drum. surfaces. If brake fluid contacts any painted
surface, immediately wipe it off and flush the
3 surface with water thoroughly.
1

Removal
1) Remove rear brake shoes. (Page 4C-4)
2) Loosen brake pipe flare nut (1) but limit loosening to
extent in which fluid does not leak.
Special tool
2
: 09950M78220

3 1

2
IJHB0A430003-01

• Connect brake shoe lever to parking brake cable

I9P60A431010-01
securely.
3) Remove wheel cylinder mounting bolts. Disconnect
• Install rear brake drum. (Page 4C-3)
brake pipe from wheel cylinder and put bleeder plug
• Adjust parking brake cable. (Page 4D-2) cap (1) onto pipe to prevent fluid from spilling.
• Check that brake drum is free from dragging and
check that brake system operates properly.

Rear Brake Adjuster and Brake Shoe Lever 1

Check
AENJHB0B4306006
• Check ratchet of brake adjuster (1) for wear or
damage.
• Check shoe return springs, anti-rattle spring, quadrant
spring and shoe hold down springs for damage,
corrosion and weakening.
• Check for smooth movement of brake shoe lever (2)
along shoe rim.
If check result is not OK, repair or replace brake adjuster IJHA0A430006-01
and/or brake shoe lever.
Installation
1) Install wheel cylinder to brake backing plate (1), and
then connect brake pipe (2) to wheel cylinder.
2

IJHB0A430004-01

2) Tighten wheel cylinder mounting bolts (3) and rear
brake pipe flare nut (4) to specified torque.
Tightening torque
Wheel cylinder mounting bolt (a): 12 N·m (1.2
kgf-m, 9.0 lbf-ft)
Rear brake pipe flare nut (b): 16 N·m (1.6 kgf-m,
12.0 lbf-ft)
3, (a) 1
3, (a)
2 2
4, (b)
IFRA0A430003-01
3) Install rear brake shoes. (Page 4C-4)
4) Install rear brake drum. (Page 4C-3)
5) Bleed brake system. (Page 4A-5)
6) Adjust parking brake cable. (Page 4D-2)
7) Check that brake drum is free from dragging and
check that brake system operates properly.
Wheel Cylinder Inspection
AENJHB0B4306008
• Check wheel cylinder for fluid leakage and boots for
breakage, crack and damage. If check result is not
OK, replace boots and cups.
• Check wheel cylinder for wear, crack, corrosion or
damage. If check result is not OK, replace wheel
cylinder assembly with a new one.
NOTE
Oil for assembling wheel cylinder may
remain in wheel cylinder boot inside and it
could cause misjudgment of the fluid
leakage.
If wheel cylinder boot inside is wet, wipe off
the oil and check the leakage.
I7V20A430004-02
Rear Brakes: 4C-6
Brake Backing Plate Removal and Installation
AENJHB0B4306009
Removal
1) Remove wheel cylinder. (Page 4C-5)
2) Remove parking brake cable cap nut (1) and parking
brake cable (2) from brake backing plate.
1
IFRA0B431002-01
3) Remove rear wheel hub assembly. (Page 3A-21)
4) Remove brake backing plate.
Installation
Reverse removal procedure noting the following points.
• Install brake backing plate and rear wheel hub
assembly. (Page 3A-21)
• Install parking brake cable (1) to brake backing plate
and tighten parking brake cable cap nut (2) to
specified torque.
Tightening torque
Parking brake cable cap nut (a): 11 N·m (1.1 kgf-
m, 8.5 lbf-ft)
1
2, (a)
IFRA0A430005-02
• Install rear brake drum. (Page 4C-3)
• Bleed brake system. (Page 4A-5)
• Adjust parking brake cable. (Page 4D-2)
• Check that brake drum is free from dragging and
check that brake system operates properly.
4C-7 Rear Brakes:

Specifications
Tightening Torque Specifications
AENJHB0B4307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Wheel cylinder mounting bolt 12 1.2 9.0 (Page 4C-6)
Rear brake pipe flare nut 16 1.6 12.0 (Page 4C-6)
Parking brake cable cap nut 11 1.1 8.5 (Page 4C-6)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Rear Drum Brake Components” (Page 4C-2)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Recommended Service Material
AENJHB0B4308001
Material SUZUKI recommended product or Specification Note
Heat-resistant brake — — (Page 4C-4)
grease

NOTE
Required service material(s) is also described in:
“Rear Drum Brake Components” (Page 4C-2)

Special Tool
AENJHB0B4308002
09950M78220
Flare nut wrench (10 x 12
mm)
(Page 4C-5)
 Parking Brake: 4D-1

Parking Brake
Brakes

General Description
Parking Brake Description
AENJHB0B4401001
The parking brake system is mechanically controlled. The system applies braking force to only the rear wheels by
means of the cable and mechanical linkage system. The same brake shoes are used for parking and foot brakes.

Repair Instructions
Parking Brake Components
AENJHB0B4406001

(a)

(b)

(b)

(b)

(b)
(b) (b)

(b)

4
(b)

(b)

2 4

(b)
IJHA0A440001-01

1. Parking brake lever 4. Parking brake cable : 26 Nm (2.7 kgf-m, 19.5 lbf-ft)
2. Equalizer 5. Brake shoe lever : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
3. Parking brake cable end (equalizer side) 6. Parking brake cable end (shoe lever side)
4D-2 Parking Brake:
Parking Brake Inspection
AENJHB0B4406002
NOTE
Check the following conditions before
parking brake inspection and adjustment.
• No air is trapped in brake system.
• Brake pedal travel is proper.
• Rear brake shoes are not worn beyond
limit.
• With parking brake lever pulled up, check the
following items. If check result is not OK, adjust or
replace parking brake cable.
a. Operation of parking brake lever is smooth.
b. Rear wheels are locked firmly.
c. Operate parking brake lever with force of 200 N
(20.4 kgf, 45.0 lbf) as shown, counting number of
clicks ratchet notches generate.
NOTE
One click sound corresponds to one notch.
Parking brake stroke “a”
When lever pulled up at 200 N (20.4 kgf, 45.0
lbf): 4 to 9 notches
I7V20A440002-01
• Release parking brake lever and check that brake
warning light turns off. Then check that brake warning
light turns on within 1 notch when parking brake lever
is pulled up. If check result is not OK, check and, if
necessary, repair the following items.
NOTE
• Warning light should be checked when
ignition is “ON”.
• Check that ABS warning light is turned off.
a. Remaining amount of brake fluid: (Page 4A-4)
b. Brake fluid level switch (attached to brake master
cylinder reservoir): (Page 4A-4)
c. Parking brake switch: (Page 4D-4)
Parking Brake Adjustment
AENJHB0B4406003
1) Place gear shift lever in “1st” (M/T model) or selector
lever in “P” range (A/T model), and block drive
wheels.
2) Remove floor console rear box. (Page 9H-34)
3) Release parking brake.
4) Loosen parking brake adjusting nut (1) until parking
brake cable becomes free of tension.
5) Start engine and depress brake pedal more than 15
times with about 150 N (15.3 kgf, 33.7 lbf) to obtain
proper drum-to-shoe clearance.
6) Stop engine and adjust parking brake lever stroke to
specified value with adjusting nut.
7) Check equalizer (2) inclination angle. If angle is not
as specified, check the following parts.
• Parking brake cable: (Page 4D-2)
• Rear brake shoe: (Page 4C-3)
Equalizer inclination angle
“a”: within 15 degrees
1
“a”
2
IFRA0A440002-01
8) After completion of adjustment, check that brake
drum is not dragging.
Parking Brake Cable Removal and Installation
AENJHB0B4406004
Removal
1) Place gear shift lever in “1st” (M/T model) or selector
lever in “P” range (A/T model), and block drive
wheels.
2) Remove floor console box. (Page 9H-34)
3) Disconnect parking brake cable from brake shoe
lever. (Page 4C-3)
4) Disconnect parking brake cable from vehicle.
(Page 4D-1)
NOTE
If necessary to remove both right and left
parking brake cables, repeat above steps.
Installation
Reverse removal procedure noting the following points.
• Install clamps properly. (Page 4D-1)
• Tighten each bolt to specified torque. (Page 4D-1)
 Parking Brake: 4D-3

• Check that parking brake cable end is installed to 5) Remove parking brake lever bolts (1) and then
equalizer and lever securely. remove parking brake lever (2) together with
• Adjust parking brake cable. (Page 4D-2) equalizer (3).
• After completion of the installation and adjustment of
parking brake lever stroke, check that brake system
operates properly.
2

Parking Brake Cable Inspection

AENJHB0B4406005
Check the following points.
If check result is not OK, repair or replace defective 3
parts.
• Check that parking brake cable clamps are properly
positioned and free from any abnormal conditions.
• Check that parking brake cable is not damaged or 1 1
IFRA0A440004-01
bent.
• Push and pull parking brake inner cable from input Installation
side (1) and check that the other side (2) follows
smoothly. 1) Tighten parking brake lever bolts (1) to specified
torque.
1
Tightening torque
Parking brake lever bolt (a): 26 N·m (2.7 kgf-m,
19.5 lbf-ft)

IJHA0A440002-02

Parking Brake Lever Removal and Installation

AENJHB0B4406006
Removal
1) Place gear shift lever in “1st” (M/T model) or selector
lever in “P” range (A/T model), and block drive
wheels.
2) Remove floor console box. (Page 9H-34)
3) Disconnect parking brake switch connector from
parking brake lever.
4) Loosen parking brake cable adjusting nut (1).
1, (a) 1, (a)
IFRA0A440005-01
2) Connect parking brake cable to equalizer, and then
adjust parking brake cable. (Page 4D-2)
3) Connect parking brake switch connector to parking
brake lever.
4) Check that brake system operates properly.
5) Install floor console rear box. (Page 9H-34)

IFRA0A440003-01
4D-4 Parking Brake:

Parking Brake Switch Inspection

AENJHB0B4406007 2
Check for continuity between parking brake switch
terminal and vehicle body ground as shown in figure. If
check result is not as specified, replace parking brake
lever assembly.
Parking brake switch specification
Parking brake released: No continuity
Parking brake lever pulled up: Continuity exists

I9P60A440007-02

1. Parking brake switch 2. Parking brake lever

Specifications
Tightening Torque Specifications
AENJHB0B4407001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Parking brake lever bolt 26 2.7 19.5 (Page 4D-3)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Parking Brake Components” (Page 4D-1)
“Fasteners Information” in Section 0A (Page 0A-5)
 ABS: 4E-1

ABS
Brakes

Precautions
Precautions for ABS • Follow trouble diagnosis procedure described in “ABS
AENJHB0B4500001 Check” (Page 4E-10). If trouble diagnosis procedure
When disconnecting ABS control module connector,
is not followed properly, incorrect diagnosis may
disconnect the negative (–) cable at battery since the
result. (If incorrect procedure is performed, other DTC
battery voltage is constantly applied to ABS hydraulic
may be stored in the ABS hydraulic unit / control
unit / control module assembly.
module assembly.)
• When disconnecting ABS control module connector
Precautions for Diagnosing Trouble (1), pull down the lock lever (2) of connector.
AENJHB0B4500002
To check that the trouble diagnosis is done accurately When connecting the connector, set the connector in
and smoothly, observe the following and follow “ABS position on ABS hydraulic unit / control module
Check” (Page 4E-10). assembly and pull up the lock lever (2) until it locks.
• Before using scan tool, read its Operator’s Manual to
know how to use it.
• If the vehicle was operated in any of the following
conditions, ABS warning light may light momentarily
but this does not indicate any fault in ABS.
– The vehicle is driven with parking brake applied.
[A] [D]
– The vehicle is driven with brake dragging.
– The vehicle is stuck in mud, sand, etc.
2
– Wheel spins while driving. [C]
[B]
– Wheels are rotated while the vehicle is jacked up. 1
IFRA0A450022-02

[A]: Pull down to unlock [C]: Connect

[B]: Disconnect [D]: Pull up to lock

General Description
ABS Description ABS Hydraulic Unit / Control Module Assembly
AENJHB0B4501001
The ABS (Anti-lock Brake System) controls the fluid • ABS hydraulic unit / control module assembly detects
pressure applied to the caliper or wheel cylinder of each wheel slip by the signal from wheel speed sensor of
brake from the master cylinder so that each wheel is not each wheel and sends control signals to the hydraulic
locked even when hard braking is applied. unit.
This ABS is equipped with EBD (Electronic Brake force ABS hydraulic unit / control module assembly also
Distributions) function. monitors system conditions and stops the function of
While brake pedal is depressed not so hard as to ABS and lights the ABS warning light in case it judges
activate ABS control, brake force is proportionally that the system is faulty.
distributed between front and rear brakes to prevent rear
wheels from being locked too early for better stability of
the vehicle.
If the EBD control is deactivated, the EBD warning light
(brake warning light) lights to inform the driver of
abnormality.
4E-2 ABS:

• ABS hydraulic unit is composed of inlet solenoid Wheel Speed Sensor

valves (4) (normally-opened valves), outlet solenoid
valves (5) (normally-closed valves), pumps (3), pump
motor (2), reservoirs (6) and check valves (7). It
activates inlet and outlet solenoid valves by the
signals from ABS hydraulic unit / control module
assembly and controls the brake fluid pressure
applied on each wheel brake. (The following figure
shows the circuit for one wheel, with inlet and outlet
solenoid valves in OFF positions.)
1 which then calculates the wheel speed based on such
All wheel speeds are detected by the Magnetic
Resistive Effect element type wheel speed sensor (1)
and encoder (2). The wheel speed sensor is fixed to
each front steering knuckle and rear wheel hub
assembly.
The encoder consists of a permanent magnet which has
south poles and north poles. As it is located on the wheel
hub it turns along with the wheel.
The wheel speed sensor feeds pulse signals in
proportion to the wheel speed to ABS control module,
signal information.

[A] 1 [B]
7

7
3 2

4
7 5

8
6 1
2
2
IJHA0A450001-01

IFRA0B460028-01 [A]: Front side [B]: Rear side

1. Master cylinder 8. Caliper or wheel cylinder

The hydraulic pressure control is performed in 3 modes:

pressure increase, pressure keeping and pressure
reduction.
• In the pressure increase mode, inlet and outlet
solenoid valves are turned OFF, and the brake fluid
pressure applied from the master cylinder to the
caliper or wheel cylinder is increased.
• In the pressure keeping mode, the inlet solenoid valve
is turned ON, and the brake fluid pressure in the
caliper or wheel cylinder is kept constant.
• In the pressure reduction mode, inlet and outlet
solenoid valves are turned ON, and the brake fluid
pressure applied to the caliper or wheel cylinder is
released to the reservoir. Thus the brake pressure
applied to the wheel likely to be locked is reduced.
The brake fluid temporarily stored in the reservoir is
pumped back to the master cylinder.
 ABS: 4E-3

OBD System Description

AENJHB0B4501002 [A]
ABS control module is built in ABS hydraulic unit /
control module assembly and has the following
functions.

Self-Diagnosis Function
ABS hydraulic unit / control module assembly monitors
each input and output signal. When ABS hydraulic unit /
control module assembly detects any malfunction, ABS
warning light (1) and/or EBD warning light (brake
warning light) (2) are turned ON to inform the driver of 2 1

the abnormality.
• When ignition is set “ON”, ABS warning light and EBD
warning light (brake warning light) turn on for 2
[B]
seconds to check its circuit.
• When no abnormality is detected (the system is in
good condition), these lights turn OFF after 2
seconds. However, when parking brake is applied,
EBD warning light (brake warning light) remains ON.
• When an abnormality in the system is detected, ABS
warning light and/or EBD warning light (brake warning
light) are turned ON and DTC is stored in ABS IJHB0A450001-01
hydraulic unit / control module assembly. [A]: Segment display type [B]: Dot display type

Fail-Safe Mode
If ABS hydraulic unit / control module assembly stores a
DTC, ABS hydraulic unit / control module assembly
stops ABS and/or EBD function corresponding to the
faulty area. It is possible to check the stopped function(s)
by the warning lights in combination meter. (Page 4E-
3)

Warning Light Description

AENJHB0B4501003
There are two warning lights controlled by ABS hydraulic unit / control module assembly in combination meter. They
give warning to driver by changing their modes: light ON / blinking / light OFF.

[A] [B]

2 1

IJHB0A450002-01

[A]: Segment display type 1. ABS warning light

[B]: Dot display type 2. EBD warning light (brake warning light)
4E-4 ABS:

Condition and Operation of Warning Light

Warning light Condition and operation
ABS warning light If ABS control is deactivated by ABS failure, the light turns “ON”.
• If EBD control is deactivated by ABS failure, the light turns “ON”.
EBD warning light (brake warning
• If brake fluid level in reservoir is lower than minimum level, the light turns “ON”.
light)
• If parking brake lever is pulled up, the light turns “ON”.

DLC Description
AENJHB0B4501004
Refer to “DLC Description”.
• K15B model: (Page 1A-4)
• D13A model: (Page 1A-168)

CAN Communication System Description

AENJHB0B4501005
Refer to “Communication System Description”.
• K15B model: (Page 10H-1)
• D13A model: (Page 10H-24)

Schematic and Routing Diagram

ABS Diagram
AENJHB0B4502001

8
8
6
5

1 2
4
3

8
8

10 11 12
IGSB0A450022-01

1. ABS hydraulic unit / control module assembly 5. Other control modules (if equipped) 9. Brake booster switch (M/T model)
2. ABS control module 6. Combination meter 10. Electronic signal
3. Hydraulic unit 7. Brake light switch 11. CAN signal
4. ECM 8. Wheel speed sensor 12. Hydraulic circuit
 ABS: 4E-5

ABS Input / Output Diagram

AENJHB0B4502002

INPUT OUTPUT
ABS hydraulic unit / control module assembly

Battery power supply Solenoid valve power

supply driver

Right-front inlet solenoid valve

Right-front outlet solenoid valve

Left-front inlet solenoid valve

Wheel speed sensor (Right-Front)
Wheel speed sensor (Left-Front)
Wheel speed sensor (Right-Rear)
Wheel speed sensor (Left-Rear)
Brake booster switch (M/T model)
Left-front outlet solenoid valve
Solenoid valve
driver Right-rear inlet solenoid valve
CPU
Right-rear outlet solenoid valve
Left-rear inlet solenoid valve
Left-rear outlet solenoid valve

Pump motor Pump motor

driver

ECM CAN driver ECM

BCM

P/S control module

Combination meter
: CAN communication
IJHB0B450001-01
4E-6 ABS:

ABS Circuit Diagram

AENJHB0B4502003

2
GRN
33
RED
34

21
3

36
GRY YEL E09-29
35 [B]
4
37
E09-28 PPL 31

38
WHT
[C]
YEL 14
E09-27 PNK
6 PNK

8 7
10
1 32 YEL E09-25 BLK
9

BLK
5

E09-13
RED E09-24
WHT

WHT 11 30
25
RED
M
22 24
15
12
GRY BLK
13 23
LT GRN
26
RED
WHT
27

30
28
RED E09-32
5
WHT E09-31

[A] E09 16 RED E09-33

5 5
WHT E09-30
24 13

1
26
2
15
3
27 16
4
28 17
5
29 18
6 GRN E09-11
19 17
7 BLK E09-12
30 20
8
21 GRN E09-2
9 18
31 22 GRY E09-1
10 29
32 BRN E09-4
11 [a] 19
33 23 YEL E09-5
12
LT BLU E09-9
25 14 20
PNK E09-8
: 39 : 40

: 5V : 12V
IJHB0A450004-01
 ABS: 4E-7

[A]: ABS hydraulic unit / control module 13. Parking brake switch 28. Solenoid valve relay
assembly connector (View: [a])
[B]: Keyless push start model 14. Brake booster switch 29. Wheel speed sensor driver
[C]: M/T model 15. BCM 30. To other control modules by CAN
1. Battery 16. ECM 31. To BCM
2. Relay box 17. Left-front wheel speed sensor 32. To ECM
3. J/B 18. Right-front wheel speed sensor 33. “ABS MOT” fuse
4. IG11 relay 19. Left-rear wheel speed sensor 34. “ABS SOL” fuse
5. CAN driver 20. Right-rear wheel speed sensor 35. “IGN” fuse
6. Combination meter 21. ABS hydraulic unit / control module assembly 36. “ABS” fuse
7. ABS warning light 22. CPU 37. “MTR” fuse
8. EBD warning light (brake warning light) 23. Internal memory 38. “STOP” fuse
9. CPU (combination meter) 24. Pump motor relay 39. Engine ground
10. Brake light switch 25. Pump motor 40. Ground
11. DLC 26. Solenoid valve power supply relay
12. Brake fluid level switch 27. Solenoid valve

Terminal Wire color Circuit

1 GRY Right-front wheel speed sensor signal circuit
2 GRN Right-front wheel speed sensor power supply circuit
4 BRN Left-rear wheel speed sensor power supply circuit
5 YEL Left-rear wheel speed sensor signal circuit
8 PNK Right-rear wheel speed sensor signal circuit
9 LT BLU Right-rear wheel speed sensor power supply circuit
11 GRN Left-front wheel speed sensor power supply circuit
12 BLK Left-front wheel speed sensor signal circuit
13 RED Solenoid valve power supply circuit
24 GRN Pump motor power supply circuit
25 BLK ABS control module ground circuit
27 PNK Brake booster switch signal circuit
28 PPL Vehicle speed output circuit
29 YEL Ignition power supply circuit
30 WHT CAN communication line (low) for ECM
31 WHT CAN communication line (low) for BCM
32 RED CAN communication line (high) for BCM
33 RED CAN communication line (high) for ECM
4E-8 ABS:

Component Location
ABS Component Location
AENJHB0B4503001
 ABS: 4E-9

1
6
1

2 [A] [B]

8 8
9 10

12

11

IJHB0A450005-01
4E-10 ABS:

[A]: Segment display type
[B]: Dot display type
1. Rear wheel speed sensor
2. Front wheel speed sensor
3. Brake booster switch (M/T model)
4. ABS hydraulic unit / control module assembly 9. EBD warning light (brake warning light)
5. ECM (K15B model) 10. ABS warning light
6. ECM (D13A model) 11. Brake light switch
7. Individual circuit fuse box No.1 12. BCM
8. Combination meter

Diagnostic Information and Procedures

ABS Check
AENJHB0B4504001
Refer to the description after the following general flow for details of each step.
Step Action Yes No
1 Malfunction analysis (Page 4E-11) Check and repair Go to Step 2.
1) Perform “Customer complaint analysis” (Page 4E-11). referring to applicable
DTC troubleshooting,
2) Perform “Problem symptom confirmation” (Page 4E-11).
and then go to Step 6.
3) Perform “DTC check, record and clearance” (Page 4E-
11) and recheck DTC.

Is the same DTC detected again after performing DTC

clearance?
2 Visual inspection Repair or replace Go to Step 3.
1) Perform “Step 2: Visual Inspection” (Page 4E-11). defective part, and then
go to Step 6.
Is there any faulty condition?
3 Road test Repair or replace Go to Step 4.
1) Perform “Step 3: Road Test” (Page 4E-12). defective part, and then
go to Step 6.
Is malfunction detected?
4 Brake diagnosis Repair or replace Go to Step 5.
1) Check and repair brake system. (Page 4E-12) defective part, and then
go to Step 6.
Is malfunction detected?
5 Intermittent problem check Repair or replace Go to Step 6.
1) Check for intermittent problems. (Page 4E-12) defective part, then go
to Step 6.
Is malfunction detected?
6 Final confirmation test Go to Step 4. End.
1) Perform “Step 6: Final Confirmation Test” (Page 4E-12).

Is malfunction detected?
 ABS: 4E-11

Step 1: Malfunction Analysis

Customer complaint analysis
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form shown below table will facilitate collecting information required for
proper analysis and diagnosis.
Customer questionnaire form (Example)

IAP70B450007-01

Problem symptom confirmation
If symptom in “Customer Questionnaire” is found or
reproduced in the vehicle, check that the symptom is
problem or not. (This step should be done with the
customer if possible.) Check warning light related to
brake system referring to “EBD Warning Light (Brake
Warning Light) Check” and “ABS Warning Light Check”
under “Warning Light Check” (Page 4E-14).
DTC check, record and clearance
Perform “DTC Check” (Page 4E-14) procedure, record it
and then clear it. (Page 4E-15)
Recheck DTC. (Page 4E-14)
When DTC which is recorded at DTC check procedure is
detected again after performing DTC clearance, go to
“DTC Check” (Page 4E-14) to perform the diagnosis.
When DTC which is recorded at DTC check procedure is
not detected anymore after performing DTC clearance,
ABS control module does not perform the system
diagnosis, or temporary abnormality may occur,
therefore go to “Step 3: Road Test” (Page 4E-12) to
proceed to the diagnosis.
Step 2: Visual Inspection
As a preliminary step, perform visual check of the items
that support proper function of the ABS. (Page 4E-12)
4E-12 ABS:

Step 3: Road Test
! WARNING
If you do not select a suitable route and take
proper precautions when performing a road
test, an accident can occur.
• Select a level road with no traffic to
minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a
driver and a tester.
NOTE
Limit the driving speed permissible in road
conditions and regulations.
Perform Road Test as follows to check if each warning
light lights up.
1) Drive at 40 km/h (25 mph) for over two minutes.
2) Turn right and left at over 10 km/h (6 mph) for over a
second by turning steering wheel over 45 degrees.
3) Drive at 60 km/h (37 mph) for over three seconds.
4) Stop the vehicle using foot brake from driving at 60
km/h (37 mph).
Step 4: Brakes Diagnosis
Check the parts or system suspected as a possible
cause referring to “Brake System Description” in Section
4A (Page 4A-1) and based on symptoms appearing on
the vehicle (symptoms observed through Step 1 – 3).
Repair faulty parts or replace them, if necessary.
Step 5: Intermittent Problem
Check parts that are prone to cause intermittent trouble
(e.g. wire harness, connector), referring to “Intermittent
Connection and Poor Contact Inspection” in Section 00
(Page 00-12) and the related circuit of which DTC is
recorded in Step 1 – 5.
Step 6: Final Confirmation Test
Check that the problem symptom is not observed any
more and ABS is free from any abnormal condition. If
what has been repaired is related to malfunction DTC,
clear the DTC referring to “DTC Clearance” (Page 4E-
15), perform road test and confirm that the DTC is not
indicated.

Visual Inspection
AENJHB0B4504002
Visually check the following parts and systems.
Inspection item Referring section
• K15B model: “Battery Description”: K15B in Section 1J
(Page 1J-2)
Battery Fluid level, leakage
• D13A model: “Battery Description”: D13A in Section 1J
(Page 1J-12)
Connectors of electric wire “Intermittent Connection and Poor Contact Inspection” in
Disconnection, friction
harness Section 00 (Page 00-12)
Fuses Burning —
Brake fluid Level, leakage “Brake Fluid Level Inspection” in Section 4A (Page 4A-4)
ABS warning light Operation
“Warning Light Check” (Page 4E-14)
EBD warning light Operation
Other parts that can be checked visually —

ABS Symptom Diagnosis
Condition
ABS warning light
remains lit for more than 2
seconds after setting
ignition “ON”
ABS warning light does
not turn ON after setting
ignition “ON”
ABS warning light blinks
EBD warning light (Brake
warning light) remains lit
for more than 2 seconds
after setting ignition “ON”
EBD warning light (Brake
warning light) does not
turn ON after setting
ignition “ON”
ABS: 4E-13
AENJHB0B4504003
Possible cause Correction / Reference Item
Malfunctioning ABS function Perform ABS check. (Page 4E-10)
Malfunctioning ABS warning light circuit Check ABS warning light circuit. (Page 4E-
21)
Malfunctioning ABS function Perform ABS check. (Page 4E-10)
Malfunctioning CAN communication Check CAN communication system.
system function • K15B model: (Page 10H-7)
• D13A model: (Page 10H-30)
Malfunctioning ABS warning light circuit Check ABS warning light circuit. (Page 4E-
20)
Improper air bleed from ABS hydraulic Perform ABS hydraulic unit operation check.
unit / control module assembly (Page 4E-36)
Parking brake applied Release parking brake and check that EBD
warning light (brake warning light) turns OFF.
Insufficient amount of brake fluid Check brake fluid level. (Page 4A-4)
Faulty parking brake switch circuit and/ Check BCM and its circuit. (Page 10B-37)
or brake fluid level switch circuit
Faulty parking brake switch and/or Check parking brake switch and/or brake fluid
brake fluid level switch level switch.
• Parking brake switch: (Page 4D-4)
• Brake fluid level switch: (Page 4A-4)
Malfunctioning EBD system Perform ABS check. (Page 4E-10)
Faulty ABS control module power Check ABS control module power supply and
supply and ground circuit ground circuits. (Page 4E-34)
Malfunctioning CAN communication Check CAN communication system.
system • K15B model: (Page 10H-7)
• D13A model: (Page 10H-30)
Faulty BCM Check BCM and its circuit. (Page 10B-37)
Faulty ABS control module Replace ABS control module. (Page 4E-38)
Malfunctioning EBD warning light circuit Check EBD warning light circuit. (Page 4E-
22)
Malfunctioning EBD system Perform ABS check. (Page 4E-10)
Malfunctioning CAN communication Check CAN communication system.
system • K15B model: (Page 10H-7)
• D13A model: (Page 10H-30)
Malfunctioning EBD warning light circuit Check EBD warning light circuit. (Page 4E-
22)
4E-14 ABS:

Warning Light Check 4) Check that EBD warning light (brake warning light)
AENJHB0B4504004 (1) comes ON. If EBD warning light (brake warning
ABS Warning Light
light) never lights up, go to “EBD Warning Light
1) Set ignition “ON”. (Brake Warning Light) Does Not Come ON after
2) Check that ABS warning light (1) comes ON for Setting Ignition “ON”” (Page 4E-22).
about 2 seconds and then goes OFF. If ABS warning
light never lights up, go to “ABS Warning Light Does [A]

Not Come ON after Setting Ignition “ON”” (Page 4E-

20). If ABS warning light remains ON and no DTC is
stored in ABS control module, go to “ABS Warning
Light Comes ON Steady” (Page 4E-21).

[A]

[B]

[B]

IJHB0A450007-01

[A]: Segment display type [B]: Dot display type

5) Release parking brake lever and check that EBD

warning light goes OFF. If EBD warning light (brake
warning light) remains ON and no DTC is stored in
IJHB0A450006-01 ABS control module, go to “EBD Warning Light
[A]: Segment display type [B]: Dot display type (Brake Warning Light) Comes ON Steady” (Page 4E-
22).
EBD Warning Light (Brake Warning Light)
DTC Check
NOTE AENJHB0B4504005

Perform this check on a level place. 1) Set ignition “OFF”.

2) Connect SUZUKI scan tool to DLC (1).
1) Check brake fluid level. (Page 4A-4)
Special tool
2) Pull parking brake lever.
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
3) Set ignition “ON”.

4) Read DTC according to instructions displayed on
SUZUKI scan tool and print it or write it down. Refer
to Operator’s Manual of SUZUKI scan tool for further
details.
NOTE
If communication between SUZUKI scan tool
and ABS control module is not possible,
perform the following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.)
– K15B model: (Page 10H-17)
– D13A model: (Page 10H-38)
• Check ABS control module power supply
circuit and ground circuit. (Page 4E-34)
2
(A)
IJHA0A110011-01
5) After completing the check, set ignition “OFF” and
disconnect SUZUKI scan tool from DLC.
DTC Clearance
AENJHB0B4504006
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
ABS: 4E-15
3) Set ignition “ON”.
4) Clear DTC according to instructions displayed on
SUZUKI scan tool. Refer to Operator’s Manual of
SUZUKI scan tool for further details.
NOTE
• If communication between SUZUKI scan
tool and ABS control module is not
possible, perform the following checks:
– Check communication condition
between PC and VCI (2) using SUZUKI
scan tool function.
– Check DLC power circuit and ground
circuit.
– Check DLC cable. If necessary, check
DLC cable by substituting a known-good
DLC cable.
– Check CAN communication system.
(“Control Module Communication Bus
Off” is detected in any control module.)
– K15B model: (Page 10H-17)
– D13A model: (Page 10H-38)
– Check ABS control module power circuit
and ground circuit. (Page 4E-34)
• Current DTCs cannot be cleared as long as
current trouble is present. Solve the
trouble and check that the system is
normal condition referring to “Fail-safe
cancel condition” under “Fail-Safe Table”
(Page 4E-17). Clear DTCs after changing
current DTCs to history DTCs.
1
2
(A)
IJHA0A110011-01
5) After completing the clearance, set ignition “OFF”
and disconnect SUZUKI scan tool from DLC.
4E-16 ABS:

DTC Table
AENJHB0B4504007
NOTE
• Perform “ABS Check” (Page 4E-10) before diagnosing DTC.
• Skipping “ABS Check” (Page 4E-10) may show a false result.
• *1: Whether ABS warning light or EBD warning light (brake warning light) lights up or not depends
on DTC detecting condition.
• *2: EBD warning light (brake warning light) lights up when 2 or more wheel speed sensors
malfunction.

ABS EBD
DTC DTC name DTC detecting condition warning warning
light light
Brake light switch ON signal is detected
for more than specified time while vehicle
speed is more than specified value.
C1016 (Page Brake Light Switch Circuit
Brake light switch ON signal is not OFF OFF
4E-23) Performance
detected although master cylinder
pressure sensor signal is more than
specified value.
C1021 (Page Right-Front Wheel Speed Sensor Wheel speed sensor signal is out of
Lights up *2
4E-25) Circuit Voltage specified range.
C1022 (Page Right-Front Wheel Speed Sensor or Abnormal wheel speed sensor signal is
Lights up *2
4E-25) Encoder Signal Performance detected continuously.
C1025 (Page Left-Front Wheel Speed Sensor Wheel speed sensor signal is out of
Lights up *2
4E-25) Circuit Voltage specified range.
C1026 (Page Left-Front Wheel Speed Sensor or Abnormal wheel speed sensor signal is
Lights up *2
4E-25) Encoder Signal Performance detected continuously.
C1031 (Page Right-Rear Wheel Speed Sensor Wheel speed sensor signal is out of
Lights up *2
4E-25) Circuit Voltage specified range.
C1032 (Page Right-Rear Wheel Speed Sensor or Abnormal wheel speed sensor signal is
Lights up *2
4E-25) Encoder Signal Performance detected continuously.
C1035 (Page Left-Rear Wheel Speed Sensor Wheel speed sensor signal is out of
Lights up *2
4E-25) Circuit Voltage specified range.
C1036 (Page Left-Rear Wheel Speed Sensor or Abnormal wheel speed sensor signal is
Lights up *2
4E-25) Encoder Signal Performance detected continuously.
C1041 (Page Right-Front Inlet Solenoid Valve Solenoid output and solenoid monitor
Lights up Lights up
4E-28) Circuit Correlation data disagree.
C1042 (Page Right-Front Outlet Solenoid Valve Solenoid output and solenoid monitor
Lights up Lights up
4E-28) Circuit Correlation data disagree.
C1045 (Page Left-Front Inlet Solenoid Valve Circuit Solenoid output and solenoid monitor
Lights up Lights up
4E-28) Correlation data disagree.
C1046 (Page Left-Front Outlet Solenoid Valve Solenoid output and solenoid monitor
Lights up Lights up
4E-28) Circuit Correlation data disagree.
Brake booster switch is ON (insufficient
negative pressure) even though there is
negative pressure in brake booster.
C104F (Page
Brake Booster Switch Failure Brake booster switch is OFF (enough OFF OFF
4E-29)
negative pressure) even though there is
insufficient negative pressure in brake
booster.
C1051 (Page Right-Rear Inlet Solenoid Valve Solenoid output and solenoid monitor
Lights up Lights up
4E-28) Circuit Correlation data disagree.
C1052 (Page Right-Rear Outlet Solenoid Valve Solenoid output and solenoid monitor
Lights up Lights up
4E-28) Circuit Correlation data disagree.
C1055 (Page Left-Rear Inlet Solenoid Valve Circuit Solenoid output and solenoid monitor
Lights up Lights up
4E-28) Correlation data disagree.
C1056 (Page Left-Rear Outlet Solenoid Valve Solenoid output and solenoid monitor
Lights up Lights up
4E-28) Circuit Correlation data disagree.
 ABS: 4E-17

ABS EBD
DTC DTC name DTC detecting condition warning warning
light light
ABS control module power supply
C1057 (Page voltage is higher than specified value.
Power Supply Voltage Lights up *1
4E-30) ABS control module power supply
voltage is lower than specified value.
Pump motor power supply voltage is out
of specified range.
C1061 (Page Pump motor is activated although pump
Pump Motor Circuit Performance Lights up OFF
4E-31) motor control relay is OFF.
Pump motor is not activated although
pump motor control relay is ON.
Solenoid valve power supply relay output
is “ON”, although monitored output is
C1063 (Page Solenoid Valve Power Supply Driver “OFF”.
Lights up Lights up
4E-28) Circuit Performance Solenoid valve power supply relay output
is “OFF”, although monitored output is
“ON”.
C1071 (Page ABS control module internal failure is
ABS Control Module Internal Failure Lights up Lights up
4E-32) detected.
Invalid Data Received From
C1080 (Page Abnormal information of vehicle
Instrument Panel Cluster (IPC) OFF OFF
4E-32) equipment.
Control Module
C1091 (Page
CAN Invalid Data from ECM DTC concerned with ECM is detected. OFF OFF
4E-33)
U0073 (Page Control Module Communication Bus Impossible to receive and transmit CAN
OFF OFF
4E-34) Off data.
U0100 (Page ECM message data is missing from CAN
Lost Communication With ECM OFF OFF
4E-34) communication.
Instrument panel cluster (IPC) control
U0155 (Page Lost Communication With Instrument
module message data is missing from OFF OFF
4E-34) Panel Cluster (IPC) Control Module
CAN communication.

Fail-Safe Table
AENJHB0B4504008
When any of the following DTCs is detected, ABS control module enters fail-safe mode and ABS and EBD functions
are deactivated until ABS control module judges the system is normal.

NOTE
• O: Activated
• —: Deactivated
• *: Whether ABS is engaged in fail-safe mode or not depends on malfunction part. Fail-safe mode can
be checked by lighting status of ABS warning light or EBD warning light (brake warning light).
– When ABS warning light lights up, ABS control is deactivated.
– When EBD warning light (brake warning light) lights up, EBD control is deactivated.

Fail-safe
DTC operation Fail-safe cancel condition
ABS EBD
C1016 (Page When ABS control module judges the system to be normal, after switching ignition from
4E-23) “OFF” to “ON”.
C1021 (Page When ABS control module judges the system to be normal after switching ignition from
— *
4E-25) “OFF” to “ON”.
C1022 (Page When ABS control module judges the system to be normal and “Road Test” under
— *
4E-25) “ABS Check” (Page 4E-10) is performed after switching ignition from “OFF” to “ON”.
C1025 (Page When ABS control module judges the system to be normal after switching ignition from
— *
4E-25) “OFF” to “ON”.
4E-18 ABS:

Fail-safe
DTC operation Fail-safe cancel condition
ABS EBD
C1026 (Page When ABS control module judges the system to be normal and “Road Test” under
— *
4E-25) “ABS Check” (Page 4E-10) is performed after switching ignition from “OFF” to “ON”.
C1031 (Page When ABS control module judges the system to be normal after switching ignition from
— *
4E-25) “OFF” to “ON”.
C1032 (Page When ABS control module judges the system to be normal and “Road Test” under
— *
4E-25) “ABS Check” (Page 4E-10) is performed after switching ignition from “OFF” to “ON”.
C1035 (Page When ABS control module judges the system to be normal after switching ignition from
— *
4E-25) “OFF” to “ON”.
C1036 (Page When ABS control module judges the system to be normal and “Road Test” under
— *
4E-25) “ABS Check” (Page 4E-10) is performed after switching ignition from “OFF” to “ON”.
C1041 (Page
— —
4E-28)
C1042 (Page
— —
4E-28)
C1045 (Page When ABS control module judges the system to be normal after switching ignition from
— —
4E-28) “OFF” to “ON”.
C1046 (Page
— —
4E-28)
C104F (Page
4E-29)
C1051 (Page
— —
4E-28)
C1052 (Page
— —
4E-28) When ABS control module judges the system to be normal after switching ignition from
C1055 (Page “OFF” to “ON”.
— —
4E-28)
C1056 (Page
— —
4E-28)
C1057 (Page
— * When ABS control module judges the system to be normal.
4E-30)
C1061 (Page When ABS control module judges the system to be normal and “Road Test” under
—
4E-31) “ABS Check” (Page 4E-10) is performed after switching ignition from “OFF” to “ON”.
C1063 (Page When ABS control module judges the system to be normal and “Road Test” under
— —
4E-28) “ABS Check” (Page 4E-10) is performed after switching ignition from “OFF” to “ON”.
C1071 (Page When ABS control module judges the system to be normal after switching ignition from
— —
4E-32) “OFF” to “ON”.
C1080 (Page When ABS control module judges the cause of the inconsistency is eliminated after
4E-32) switching ignition from “OFF” to “ON”.
C1091 (Page When ABS control module judges the system to be normal after switching ignition from
4E-33) “OFF” to “ON”.
U0073 (Page
4E-34)
U0100 (Page When ABS control module judges the system to be normal after switching ignition from
4E-34) “OFF” to “ON”.
U0155 (Page
4E-34)
 ABS: 4E-19

Scan Tool Data

AENJHB0B4504009
As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles
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. Therefore, judgment as abnormal should not
be made depending on these data alone.

NOTE
If communication between SUZUKI scan tool and ABS control module is not possible, perform the
following checks:
• Check communication condition between PC and VCI using SUZUKI scan tool function.
• Check DLC power circuit and ground circuit.
• Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
• Check CAN communication system. (“Control Module Communication Bus Off” is detected in any
control module.)
– K15B model: (Page 10H-17)
– D13A model: (Page 10H-38)
• Check ABS control module power circuit and ground circuit. (Page 4E-34)

Scan tool data Vehicle condition Condition / Reference value

RF Wheel Speed (Page 4E-
At stop (Stationary vehicle) 0 km/h (0 mph)
20)
LF Wheel Speed (Page 4E-
At stop (Stationary vehicle) 0 km/h (0 mph)
20)
RR Wheel Speed (Page 4E-
At stop (Stationary vehicle) 0 km/h (0 mph)
20)
LR Wheel Speed (Page 4E-
At stop (Stationary vehicle) 0 km/h (0 mph)
20)
Battery Voltage (Page 4E-20) Ignition “ON” (Engine stopped) 10.0 – 14.0 V
Pump Motor Driver (Page Inactive (Pump motor not working) 0.0 V
4E-20) Active (Pump motor working) 13.0 – 15.0 V
Master Cyl Press (Page 4E- Brake pedal: Depressed Over 0 ± 0.9 Mpa
20) Brake pedal: Released 0 ± 0.9 Mpa
Set ignition “ON” 0 rpm
Engine Speed (Page 4E-20)
Engine running at idle speed after warming up Specified idle speed
Depressed brake pedal ON
Brake Switch (Page 4E-20)
Released brake pedal OFF
Depressed brake pedal several times in condition of
Brake Booster SW (Page 4E- ON
engine stopped.
20)
Released brake pedal in condition of engine running. OFF
Inlet Solenoid RF (Page 4E- Right-front inlet solenoid: Operating ON
20) Other than above condition OFF
Outlet Solenoid RF (Page Right-front outlet solenoid: Operating ON
4E-20) Other than above condition OFF
Inlet Solenoid LF (Page 4E- Left-front inlet solenoid: Operating ON
20) Other than above condition OFF
Outlet Solenoid LF (Page Left-front outlet solenoid: Operating ON
4E-20) Other than above condition OFF
Inlet Solenoid RR (Page 4E- Right-rear inlet solenoid: Operating ON
20) Other than above condition OFF
Outlet Solenoid RR (Page Right-rear outlet solenoid: Operating ON
4E-20) Other than above condition OFF
Inlet Solenoid LR (Page 4E- Left-rear inlet solenoid: Operating ON
20) Other than above condition OFF
Outlet Solenoid LR (Page Left-rear outlet solenoid: Operating ON
4E-20) Other than above condition OFF
Pump Motor Relay (Page Pump motor: Working ON
4E-20) Other than above condition OFF
4E-20 ABS:

Scan tool data Vehicle condition Condition / Reference value

Solenoid Valve Relay (Page Ignition “ON” ON
4E-20) Other than above condition OFF
Hill Hold Control (Page 4E-
— Without
20)

Scan Tool Data Definition

RF Wheel Speed, LF Wheel Speed, RR Wheel Speed and LR Wheel Speed (km/h, MPH): Wheel speed is ABS
control module internal parameter. It is computed by reference pulses from the wheel speed sensor.
Battery Voltage (V): Battery voltage is an analog input signal read by ABS control module. ABS control module
functions may be stopped if battery voltage falls below or rises above programmed thresholds.
Pump Motor Driver (V): This parameter indicates operational condition of pump motor driver (transistor).
Master Cyl Press (MPa): This indicates brake fluid pressure from brake master cylinder.
If this sensor detects an incomplete calibration, the live value shown may not be the accurate.
Engine Speed (rpm): This parameter indicates engine speed sent from ECM through CAN.
Brake Switch (ON, OFF): These switch signals are provided to ABS control module whether the brake pedal is
depressed or not.
Brake Booster SW (ON, OFF): These switch signals are provided to ABS control module whether negative pressure
in brake booster is insufficient or enough.
Inlet Solenoid RF, Inlet Solenoid LF, Inlet Solenoid RR and Inlet Solenoid LR (ON / OFF): This parameter
indicates the operational condition of the inlet solenoid valve.
Outlet Solenoid RF, Outlet Solenoid LF, Outlet Solenoid RR and Outlet Solenoid LR (ON / OFF): This
parameter indicates the operational condition of the outlet solenoid valve.
Pump Motor Relay (ON / OFF): This parameter indicates the state of the pump motor relay.
Solenoid Valve Relay (ON / OFF): ABS control module monitor the voltage to fail safe relay.
If the voltage is supplied, ON is displayed. Beside, OFF is displayed.
Hill Hold Control (Without): This parameter is indicated all the time without change.

ABS Warning Light Does Not Come ON after Setting Ignition “ON”
AENJHB0B4504010
System Description
Operation (ON/OFF) of ABS warning light is controlled by ABS control module through light driver module in
combination meter.
If ABS is in good condition, ABS control module turns ON ABS warning light with ignition “ON”, keeps the light ON for
2 seconds and then turns it OFF. If ABS control is deactivated by ABS failure, ABS warning light is turned ON
continuously by ABS control module. Also, the light is turned ON continuously by light driver module when the
connector of ABS control module is disconnected.

Troubleshooting
Step Action Yes No
1 Warning light check Go to Step 2. Go to Step 3.
1) Set ignition “ON”.

Do other indicator lights light up within 2 seconds after

setting ignition “ON”?
 ABS: 4E-21

Step Action Yes No

2 DTC check Go to troubleshooting Replace combination
1) Check that ignition is “OFF”. for applicable DTC. meter and recheck
warning light operation.
2) Connect scan tool to DLC.
If ABS warning light
3) Set ignition “ON”. does not come ON,
4) Check DTC related to CAN communication. replace ABS hydraulic
unit / control module
Is there any CAN-DTC(s) detected? assembly and recheck
warning light operation.
• Combination meter:
(Page 9C-34)
• ABS hydraulic unit /
control module
assembly: (Page
4E-38)
3 Fuse check Go to Step 4. Replace “MTR” fuse
and check for short
Is “MTR” fuse in good condition? circuit to ground.
4 CAN communication circuit check Go to Step 5. Repair or replace
1) Check CAN communication circuit between ABS control defective wire harness.
module and combination meter referring to
“Troubleshooting for Communication Bus Off”.
• K15B model: (Page 10H-17)
• D13A model: (Page 10H-38)

Is check result OK?

5 Combination meter power supply and ground circuit Replace combination Repair or replace
check meter and recheck defective wire harness.
1) Check combination meter power supply and ground warning light operation.
circuits. (Page 9C-29) If ABS warning light
does not come ON,
Is check result OK? replace ABS hydraulic
unit / control module
assembly and recheck
warning light operation.
• Combination meter:
(Page 9C-34)
• ABS hydraulic unit /
control module
assembly: (Page
4E-38)

ABS Warning Light Comes ON Steady

AENJHB0B4504011
System Description
Refer to “System Description” under “ABS Warning Light Does Not Come ON after Setting Ignition “ON”” (Page 4E-
20).

Troubleshooting
Step Action Yes No
1 ABS control module connector check Go to Step 2. Connect connector
1) Check for proper connection to ABS control module securely.
connector.

Is connection in good condition?

4E-22 ABS:

Step Action Yes No

2 DTC check for ABS Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4E-14). for applicable DTC.

Is there any DTC(s)?

3 ABS control module power supply and ground circuit Go to Step 4. Repair or replace
check defective wire harness.
1) Check ABS control module power supply and ground
circuits. (Page 4E-34)

Is check result OK?

4 Combination meter check Replace ABS hydraulic End.
1) Replace combination meter. (Page 9C-34) unit / control module
assembly and recheck
2) Set ignition “ON”.
warning light operation.
Does ABS warning light stay on? (Page 4E-38)

EBD Warning Light (Brake Warning Light) Does Not Come ON after Setting Ignition “ON”
AENJHB0B4504012
System Description
Refer to “System Description” under “EBD Warning Light (Brake Warning Light) Comes ON Steady” (Page 4E-22).

Troubleshooting
Refer to “Troubleshooting” under “ABS Warning Light Does Not Come ON after Setting Ignition “ON”” (Page 4E-20).

EBD Warning Light (Brake Warning Light) Comes ON Steady

AENJHB0B4504013
System Description
EBD warning light (brake warning light) is controlled by ABS control module and BCM through light driver module in
combination meter.
If EBD system is in good condition, ABS control module turns ON EBD warning light (brake warning light) when
ignition is set “ON”, keeps it ON for 2 seconds and then turns it OFF.
EBD warning light (brake warning light) is turned ON continuously in the following conditions.
• EBD control is deactivated by ABS failure.
• Parking brake lever is pulled up.
• Brake fluid level is lower than minimum level.
The information of parking brake switch and brake fluid level is transmitted from BCM to light driver module in
combination meter through CAN communication line.
Also, the warning light is turned ON continuously by light driver module when the connector of ABS control module is
disconnected.

Troubleshooting
Step Action Yes No
1 ABS control module connector check Go to Step 2. Connect connector
1) Check for proper connection to ABS control module securely.
connector.

Is connection in good condition?

2 Parking brake and brake fluid level check Go to Step 3. Release parking brake
1) Check the following points. and check brake fluid
level. (Page 4A-4)
• Parking brake is completely released.
• Brake fluid level is above minimum level. (Page 4A-
4)

Is check result OK?

3 ABS warning light operation check Perform “ABS Warning Go to Step 4.
1) Set ignition “ON”. Light Comes ON
Steady” (Page 4E-21).
Does ABS warning light stay on?
 ABS: 4E-23

Step Action Yes No

4 Parking brake switch signal circuit and brake fluid level Go to Step 5. Repair or replace
switch signal circuit check defective part.
1) Check parking brake switch signal circuit and brake fluid
level switch signal circuit. (Page 10B-37)

Is check result OK?

5 CAN communication circuit check Go to troubleshooting Go to Step 6.
1) Check that ignition is “OFF”. for applicable DTC.
2) Connect scan tool to DLC.
3) Set ignition “ON”.
4) Perform “DTC Check” (Page 4E-14).

Is DTC U0073 detected?

6 DTC check for BCM Go to troubleshooting Go to Step 7.
1) Check BCM for DTC. (Page 10B-16) for applicable DTC.

Is DTC U0073 detected?

7 Combination meter check Replace ABS hydraulic End.
1) Replace combination meter. (Page 9C-34) unit / control module
assembly and recheck
2) Set ignition “ON”.
warning light operation.
Does EBD warning light stay on? (Page 4E-38)

DTC C1016
AENJHB0B4504014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1016: Brake Light Switch Circuit Performance • Brake light switch circuit
• Brake light switch ON signal is detected for more than specified • Brake light switch
time while vehicle speed is more than specified value. • ECM
• Brake light switch ON signal is not detected although master • ABS control module
cylinder pressure sensor signal is more than specified value.
4E-24 ABS:

Circuit Diagram

12V A1 3
1
PNK A2
4 YEL E323-24

A3
[C] E01-18
LT BLU E323-29
[D] E01-26
5

[C] E01-28 7 LT BLU E323-25

RED E09-33
E01-
[D] E01-62
6 6
[C] E01-29
WHT E09-30
E01-29
[D] E01-36

[A] E09 [B] E323

24 13 [a] [b]
6 5 4 3 2 1
1 22 21 20 19 18 17 16 15 14 1312 11 10 9 8 7
26
2 37 36 35 34 33 32 3130 29 28 27 26 25 24 23
15
3
27 16
4
28 17
5
29 18 [C] [D] E01
6 E01
19
7
30 20
8
21 12 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23
9
31 22
10 24 23 22 21 20 19 18 17 16 15 14 13 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 46
32
11 36 35 34 33 32 31 30 29 28 27 26 25 48 47
33 23
12 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
48 47 46 45 44 43 42 41 40 39 38 37
25 14 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 94 72 71
56 55 54 53 52 51 50 49

IJHB0B450002-01

[A]: ABS control module connector (View: [a]) A2: Brake light switch signal circuit 1 4. ECM
[B]: J/B connector (View: [b]) A3: Brake light switch signal circuit 2 5. ABS control module
[C]: ECM connector (K15B model) (View: [b]) 1. “STOP” fuse 6. CAN driver
[D]: ECM connector (D13A model) (View: [b]) 2. Brake light switch 7. To brake light
A1: Brake light switch power supply circuit 3. J/B

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-10).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4E-14). for applicable DTC.

Is DTC U0073 and/or U0100 detected?

3 Brake light switch power supply circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect brake light switch defective wire harness.
connector.
2) Check for proper terminal connection to brake light
switch connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

 ABS: 4E-25

Step Action Yes No

4 Brake light switch signal circuit check Go to Step 5. Repair or replace
1) Disconnect negative (–) cable at battery. defective wire harness.
2) Disconnect ECM and “E323” connectors.
3) Check for proper terminal connection to ECM and
“E323” connectors.
4) If connections are OK, check the following points.
• Resistance of “A2” and “A3” circuits: less than 1 Ω
• Resistance between each of “A2” and “A3” circuits
and ground: infinity
• Resistance between each of “A2” and “A3” circuit
terminals and each terminal at “E323” connector:
infinity
• Resistance between each of “A2” and “A3” circuits
and battery positive (+) cable: infinity
• Resistance between each of “A2” and “A3” circuits
and each fuse in J/B: infinity

Is check result OK?

5 Brake light switch check Replace ECM and Replace brake light
1) Check brake light switch. (Page 4A-11) recheck DTC. If DTC switch. (Page 4A-11)
C1016 is still detected,
Is check result OK? replace ABS hydraulic
unit / control module
assembly and recheck
DTC.
• ECM
– K15B model:
(Page 1C-2)
– D13A model:
(Page 1C-20)
• ABS hydraulic unit /
control module
assembly: (Page
4E-38)

DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036

AENJHB0B4504015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1021 / C1025 / C1031 / C1035: Right-Front / Left-Front / Right-Rear • Wheel speed sensor
/ Left-Rear Wheel Speed Sensor Circuit Voltage • Wheel speed sensor circuit
Wheel speed sensor signal is out of specified range.
• Wheel speed sensor encoder
C1022 / C1026 / C1032 / C1036: Right-Front / Left-Front / Right-Rear
/ Left-Rear Wheel Speed Sensor or Encoder Signal Performance • ABS control module
Abnormal wheel speed sensor signal is detected continuously.

NOTE
When vehicle was placed in any of the following conditions, one of these DTCs may be set although
sensor is in good condition. If such possibility is suspected, clear DTC once (Page 4E-15) and check
whether any abnormality exists or not by performing road test as described in Step 3 of “ABS Check”
(Page 4E-10).
• Vehicle is driven with parking brake lever pulled.
• Wheel spins while driving.
• Wheel(s) is rotated while vehicle is jacked up.
4E-26 ABS:

Circuit Diagram

5
[A] E09
A1
GRN E09-11 [a] 24 13
1
BLK E09-12 1
26
A2 2
15
B1 3
GRN E09-2 27 16
4
2 28 17
GRY E09-1 5
29 18
B2 6
19
C1 7
6 30 20
BRN E09-4 8
3 21
YEL E09-5 9
31 22
C2 10
32
D1 11
33 23
LT BLU E09-9 12
4
PNK E09-8 25 14
D2

IGSB0A450008-01

[A]: ABS control module connector (View: [a])
A1: Left-front wheel speed sensor power supply circuit
A2: Left-front wheel speed sensor signal circuit
B1: Right-front wheel speed sensor power supply circuit
B2: Right-front wheel speed sensor signal circuit
C1: Left-rear wheel speed sensor power supply circuit 2. Right-front wheel speed sensor
C2: Left-rear wheel speed sensor signal circuit 3. Left-rear wheel speed sensor
D1: Right-rear wheel speed sensor power supply circuit 4. Right-rear wheel speed sensor
D2: Right-rear wheel speed sensor signal circuit 5. ABS control module
1. Left-front wheel speed sensor 6. Wheel speed sensor driver

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– DTC C1057 is not detected.

1) Set ignition “ON”.

2) Drive vehicle at 20 km/h (12 mile/h) or more for 1 minute or more.
3) Stop vehicle and set ignition “OFF”.
4) Repeat Step 1) – 3) 7 times.

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-10).
2 Tire pressure check Go to Step 3. Adjust tire pressure or
1) Check that tire pressure is at specified value. replace tire and recheck
DTC.
Is check result OK?
 ABS: 4E-27

Step Action Yes No

3 Wheel speed sensor power supply circuit and signal Go to Step 4. Repair or replace
circuit check defective wire harness.
1) Set ignition “OFF”.
2) Disconnect “E09” and each of wheel speed sensor
connectors.
3) Check for proper terminal connection to “E09” and each
of wheel speed sensor connectors.
4) If connections are OK, check the following points.
• Resistance of “A1”, “A2”, “B1”, “B2”, “C1”, “C2”, “D1”
and “D2” circuits: less than 1 Ω
• Resistance between each of “A1”, “A2”, “B1”, “B2”,
“C1”, “C2”, “D1” and “D2” circuits and ground: infinity
• Resistance between each terminal of “A1” – “A2”, “B1”
– “B2”, “C1” – “C2” and “D1” – “D2” circuits and each
terminal of “E09” connector: infinity
• Voltage of “A1”, “A2”, “B1”, “B2”, “C1”, “C2”, “D1” and
“D2” circuits: approx. 0 V (When ignition is “ON”)

Is check result OK?

4 Wheel speed sensor signal check Replace ABS hydraulic Go to Step 5.
1) Check applicable wheel speed sensor for output voltage unit / control module
and waveform. (Page 4E-40) assembly and recheck
DTC. (Page 4E-38)
Is check result OK?
5 Wheel speed sensor check Go to Step 6. Clean, repair or replace
1) Check applicable wheel speed sensor. (Page 4E-43) wheel speed sensor.
• Front wheel speed
Is check result OK? sensor: (Page 4E-
41)
• Rear wheel speed
sensor: (Page 4E-
42)
6 Wheel speed sensor encoder check Replace ABS hydraulic Clean, repair or replace
1) Check applicable wheel speed sensor encoder. (Page unit / control module wheel speed sensor
4E-43) assembly and recheck encoder.
DTC. (Page 4E-38) • Front wheel speed
Is check result OK?
sensor encoder:
(Page 4E-43)
• Rear wheel speed
sensor encoder:
(Page 4E-43)
4E-28 ABS:

DTC C1041 / C1042 / C1045 / C1046 / C1051 / C1052 / C1055 / C1056 / C1063
AENJHB0B4504016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1041 / C1045 / C1051 / C1055: Right-Front / Left-Front / Right-Rear • ABS control module power supply circuit
/ Left-Rear Inlet Solenoid Valve Circuit Correlation • ABS control module ground circuit
C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear
• ABS control module
/ Left-Rear Outlet Solenoid Valve Circuit Correlation
Solenoid output and solenoid monitor data disagree.
C1063: Solenoid Valve Power Supply Driver Circuit Performance
• Solenoid valve power supply relay output is “ON”, although monitored
output is “OFF”.
• Solenoid valve power supply relay output is “OFF”, although
monitored output is “ON”.

Circuit Diagram

4
2 A1

3
1 RED E09-13
[a]
5V

[A] E09
6
24 13

6 1
26
2
15
6 3
27 16
7 4
6 28 17
5
29 18
6
6 19
7
30 20
8
6 21
9
31 22
10
6 32
11
B1 33 23
6 12
BLK E09-25 25 14

IGSB0A450009-01

[A]: ABS control module connector (View: [a]) 2. Relay box 6. Solenoid valve
A1: Solenoid valve power supply circuit 3. “ABS SOL” fuse 7. CPU
B1: ABS control module ground circuit 4. ABS control module
1. Lead to battery 5. Solenoid valve power supply relay

DTC Troubleshooting
Step Action No Yes
1 Was “ABS Check” performed? Go to Step 2.
Go to “ABS Check”
(Page 4E-10).
2 Solenoid valve power supply and ABS control module Replace ABS hydraulic Repair or replace
ground circuit check unit / control module defective wire harness.
1) Check solenoid valve power supply and ground circuits. assembly and recheck
(Page 4E-34) DTC. (Page 4E-38)

Is check result OK?

 ABS: 4E-29

DTC C104F
AENJHB0B4504017
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C104F: Brake Booster Switch Failure • Brake booster switch
• Brake booster switch is ON (insufficient negative pressure) • Brake booster switch circuit
even though there is negative pressure in brake booster. • ABS control module
• Brake booster switch is OFF (enough negative pressure) even
though there is insufficient negative pressure in brake booster.

Circuit Diagram

[A] E09

[a] 24 13

1
26
2
15
3
27 16
2 4
28 17
5
29 18
A1 6
19
1 7
30 20
8
PNK E09-27 21
9
31 22
10
32
11
33 23
12

25 14

IGSB0A450010-01

[A]: ABS control module connector (View: [a]) 1. Brake booster switch
A1: Brake booster switch signal circuit 2. ABS control module

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
Limit the driving speed permissible in road conditions and regulations.

1) Run engine at idle speed for 1 min.

2) Drive vehicle at 10 km/h (6 mile/h) or more once.
3) Stop vehicle.
4) Repeat Step 2) – 3) 2 times.

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-10).
4E-30 ABS:

Step Action Yes No

2 Brake booster switch signal circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect “E09” connector and defective wire harness.
brake booster switch connector.
2) Check for proper terminal connection to “E09” connector
and brake booster switch connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Voltage of “A1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

3 Brake booster switch check Replace ABS hydraulic Replace brake booster.
1) Check brake booster switch. (Page 4A-24) unit / control module (Page 4A-22)
assembly and recheck
Is check result OK? DTC. (Page 4E-38)

DTC C1057
AENJHB0B4504018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1057: Power Supply Voltage • ABS control module power supply circuit
• ABS control module power supply voltage is higher • ABS control module ground circuit
than specified value. • Charging system
• ABS control module power supply voltage is lower than • ABS control module
specified value.

Circuit Diagram

[A] E09
[a]
24 13
5 1
2 26
A1 2
3 15
RED E09-13 6 3
A2 27 16
4 4
1 GRN E09-24 7 28 17
5
29 18
6
19
7
30 20
8
21
B1 9
31 22
BLK E09-25 10
32
11
33 23
12

25 14

IGSB0A450011-01

[A]: ABS control module connector (View: [a]) 1. Lead to battery 5. ABS control module
A1: Solenoid valve power supply circuit 2. Relay box 6. Lead to solenoid valve power supply relay
A2: Pump motor power supply circuit 3. “ABS SOL” fuse 7. Lead to pump motor relay
B1: ABS control module ground circuit 4. “ABS MOT” fuse

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-10).
 ABS: 4E-31

Step Action Yes No

2 ABS control module power supply and ground circuit Go to Step 3. Repair or replace
check defective wire harness.
1) Check ABS control module power supply and ground
circuits. (Page 4E-34)

Is check result OK?

3 ABS control module power supply voltage check Replace ABS hydraulic Check charging system.
1) Measure battery voltage with engine running at 3,000 unit / control module • K15B model: (Page
rpm. assembly and recheck 1J-3)
DTC. (Page 4E-38)
Is voltage between 9.8 V and 16.9 V? • D13A model: (Page
1J-15)

DTC C1061
AENJHB0B4504019
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1061: Pump Motor Circuit Performance • ABS control module (pump motor)
• Pump motor power supply voltage is out of specified range. power supply circuit
• Pump motor is activated although pump motor control relay is OFF. • ABS control module ground circuit
• Pump motor is not activated although pump motor control relay is ON. • ABS control module

Circuit Diagram

1
[A] E09
[a]
A1 24 13
7
6 1
5 GRN E09-24 26
2
15
3
5V 27 16
4
28 17
5
29 18
6
2 19
3 7
30 20
8
21
9
B1 31 22
M 10
32
BLK E09-25 4 11
33 23
12

25 14

IGSB0A450012-01

[A]: ABS control module connector (View: [a]) 2. CPU 6. “ABS MOT” fuse
A1: Pump motor power supply circuit 3. Pump motor relay 7. Relay box
B1: ABS control module ground circuit 4. Pump motor
1. ABS control module 5. Lead to battery

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.
4E-32 ABS:

NOTE
Limit the driving speed permissible in road conditions and regulations.

1) Set ignition “ON”.

2) Drive vehicle at 40 km/h (25 mile/h) or higher for more than 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-10).
2 ABS control module power supply and ground circuit Replace ABS hydraulic Repair or replace
check unit / control module defective wire harness.
1) Check ABS control module power supply and ground assembly and recheck
circuits. (Page 4E-34) DTC. (Page 4E-38)

Is check result OK?

DTC C1071
AENJHB0B4504020
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1071: ABS Control Module Internal Failure • ABS control module power supply circuit
ABS control module internal failure is detected. • ABS control module ground circuit
• ABS control module

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-10).
2 ABS control module power supply and ground circuit Replace ABS hydraulic Repair or replace
check unit / control module defective wire harness.
1) Check ABS control module power supply and ground assembly and recheck
circuits. (Page 4E-34) DTC. (Page 4E-38)

Is check result OK?

DTC C1080
AENJHB0B4504021
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1080: Invalid Data Received From Instrument Panel • CAN communication circuit
Cluster (IPC) Control Module • ECM
Abnormal information of vehicle equipment.
• Combination meter
• ABS control module

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-10).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4E-14). for applicable DTC.

Is there DTC(s) other than C1080?

 ABS: 4E-33

Step Action Yes No

3 CAN communication circuit check Replace ECM and/or Repair or replace
1) Check CAN communication circuit between ECM and combination meter and defective wire harness.
combination meter referring to “Troubleshooting for recheck DTC. If DTC
Communication Bus Off”. C1080 is still detected,
replace ABS hydraulic
• K15B model: (Page 10H-17)
unit / control module
• D13A model: (Page 10H-38) assembly and recheck
Is check result OK? DTC.
• ECM
– K15B model:
(Page 1C-2)
– D13A model:
(Page 1C-20)
• Combination meter:
(Page 9C-34)
• ABS hydraulic unit /
control module
assembly: (Page
4E-38)

DTC C1091
AENJHB0B4504022
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1091: CAN Invalid Data from ECM • CAN communication circuit
DTC concerned with ECM is detected. • Engine control system
• ECM
• ABS control module

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-10).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4E-14). for applicable DTC.

Is there DTC(s) other than C1091?

3 DTC check for ECM Go to troubleshooting Go to Step 4.
1) Check ECM for DTC. for applicable DTC.
• K15B model: (Page 1A-23)
• D13A model: (Page 1A-180)

Is DTC U0073 or U0121 detected?

4E-34 ABS:

Step Action Yes No

4 CAN communication circuit check Replace ECM and Repair or replace
1) Check CAN communication circuit between ECM and recheck DTC. If DTC defective wire harness.
ABS control module referring to “Troubleshooting for C1091 is still detected,
Communication Bus Off”. replace ABS hydraulic
unit / control module
• K15B model: (Page 10H-17)
assembly and recheck
• D13A model: (Page 10H-38) DTC.
Is check result OK? • ECM
– K15B model:
(Page 1C-2)
– D13A model:
(Page 1C-20)
• ABS hydraulic unit /
control module
assembly: (Page
4E-38)

DTC U0073
AENJHB0B4504023
Refer to “Troubleshooting for Communication Bus Off”.
• K15B model: (Page 10H-17)
• D13A model: (Page 10H-38)

DTC U0100
AENJHB0B4504024
Refer to “Troubleshooting for Lost Communication”.
• K15B model: (Page 10H-10)
• D13A model: (Page 10H-32)

DTC U0155
AENJHB0B4504025
Refer to “Troubleshooting for Lost Communication”.
• K15B model: (Page 10H-10)
• D13A model: (Page 10H-32)

ABS Control Module Power Supply and Ground Circuit Check

AENJHB0B4504026
Circuit Diagram

[A] E09
[a]
24 13
8 1
3 26
A1 2
4 15
RED E09-13 9 3
A2 27 16
5 4
1 GRN E09-24 10 28 17
5
29 18
6
19
7
6 30 20
8
B1 21
7
2 YEL E09-29 9
31 22
10
32
C1 11
33 23
BLK E09-25 12

25 14

IGSB0A450013-01
 ABS: 4E-35

[A]: ABS control module connector (View: [a]) 1. Lead to battery 6. J/B
A1: Solenoid valve power supply circuit 2. Ignition power supply 7. “ABS” fuse
A2: Pump motor power supply circuit 3. Relay box 8. ABS control module
B1: Ignition power supply circuit 4. “ABS SOL” fuse 9. Lead to solenoid valve power supply relay
C1: ABS control module ground circuit 5. “ABS MOT” fuse 10. Lead to pump motor relay

Circuit Description
When the ignition is set “ON”, power is supplied to ABS control module. Then power is supplied to pump motor and
solenoid valve in other line by the switching function in ABS control module.

Troubleshooting
Step Action Yes No
1 Fuse check Go to Step 2. Replace fuse and check
for short circuit to
Are “ABS MOT” fuse, “ABS SOL” fuse and “ABS” fuse in ground.
good condition?
2 ABS control module power supply circuit check Go to Step 3. Repair or replace
1) Check that ignition is “OFF”. defective wire harness.
2) Disconnect “E09” connector.
3) Check for proper terminal connection to “E09” connector.
4) If connection is OK, set ignition “ON”.
5) Check that voltage between “B1” circuit and ground is
battery voltage.

Is check result OK?

3 Pump motor and solenoid valve power supply circuit Go to Step 4. Repair or replace
check defective wire harness.
1) Set ignition “OFF”.
2) Check the following points.
• Voltage between “A1” circuit and ground is battery
voltage.
• Voltage between “A2” circuit and ground is battery
voltage.

Is check result OK?

4 ABS control module ground circuit check ABS control module Repair or replace
1) Check that ignition is “OFF”. power supply and defective wire harness.
ground circuit are in
2) Check that resistance between “C1” circuit and ground is
good condition.
less than 1 Ω.

Is check result OK?

4E-36 ABS:

Repair Instructions
ABS Hydraulic Unit Operation Check
AENJHB0B4506001
NOTE
• A false diagnosis may result if operation
check of the ABS hydraulic unit is
performed without satisfying all of the
specified conditions below.
Check that all the following conditions are
met before performing operation check of
the ABS hydraulic unit.
– Battery voltage is 12 V or more.
– No air is trapped in the brake system.
– Brakes do not drag.
– No DTC is stored in ABS hydraulic unit /
control module.
• Operation check must be performed by 2
persons.
• Lighting or blinking of warning light stops
when ignition is set “ON” after completing
ABS hydraulic unit operation check.
5) Set ignition “ON”, and select “Depressurization
check” in “Hydraulic control test” under “Utility” mode
of SUZUKI scan tool.
Refer to Operator’s Manual of SUZUKI scan tool for
further details.
6) Perform the following check with help of another
person.
• Depressurization check
Step on brake pedal and then select testing wheel
by SUZUKI scan tool and the wheel should be
turned by another person’s hand. At this time,
check whether the wheel rotates freely due to
brake depressurization.
NOTE
Depressurization by SUZUKI scan tool is
available for 0.5 seconds.

1) Check that ignition is “OFF”.

2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
I8G001460007-01

7) Check all 4-wheels respectively.

8) Check that ABS warning light is turned off after
switching ignition from “OFF” to “ON”. Check for
DTC and repair problem if lights are still lit.
9) If any faulty condition is found in Step 6) – 7), replace
ABS hydraulic unit /control module assembly.
10) After completing the check, confirm that ignition is
1 “OFF” and then disconnect SUZUKI scan tool from
DLC.

(A)

IJHA0A110021-01

3) Hoist vehicle until tire can be rotated.

4) Set transmission to neutral and release parking
brake.
 ABS: 4E-37

ABS Hydraulic Unit / Control Module Assembly Components

AENJHB0B4506002

8 7 6 9

(a)

(a)

(a) (c)

3 (b)
5

(a)

3 (b)

(c)

IJHA0A450009-01

1. ABS hydraulic unit / control module assembly 5. To master cylinder secondary 9. To Left-rear brake
2. Actuator bracket 6. To Right-front brake : 16 Nm (1.6 kgf-m, 12.0 lbf-ft)
3. Actuator mount bolt 7. To Left-front brake : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
4. To master cylinder primary 8. To Right-rear brake : 26 Nm (2.7 kgf-m, 19.5 lbf-ft)
4E-38 ABS:
ABS Hydraulic Unit / Control Module Assembly
On-Vehicle Inspection
AENJHB0B4506003
Check the following points. Repair or replace defective
parts.
• Check ABS hydraulic unit / control module assembly
(1) for dents, crack, deformation and leakage.
• Check actuator bracket (2) and its mounting surface
for dents, crack and deformation.
• Check actuator mount bolts and actuator bracket nuts
for looseness.
• Check ABS control module connector (ABS control
module side and harness side) and its connector lock
mechanism for damage or crack.
• Check connector terminals for bend, corrosion or rust.
1 – Use care not to allow dust to enter ABS
2 burrs at the edge and may damage or
IJHA0A450010-01
ABS Hydraulic Unit / Control Module Assembly
Removal and Installation
AENJHB0B4506004
NOTICE
• Performing the following prohibited
operations will affect the original
performance of ABS hydraulic unit /
control module assembly.
– Do not disassemble the ABS hydraulic
unit / control module assembly.
– Do not loosen the blind plug.
– Do not remove the motor.
– Regarding ABS hydraulic unit / control
module assembly removal and
installation, check specified torque and
do not use impact tool.
hydraulic unit / control module.
– Do not place ABS hydraulic unit / control
module on its side or upside down.
– Do not give an impact to hydraulic unit.
• Brake fluid is extremely damaging to
painted surfaces. If brake fluid contacts
painted surfaces, immediately wipe it off
and flush the surfaces with water
thoroughly.
• The bracket of the ABS hydraulic unit /
control module assembly may have some
deform the bushing, resulting in abnormal
operation of the ABS.
Be careful not to scratch bushings with the
burr of the bracket when removing /
installing the ABS hydraulic unit / control
module assembly from / to the bracket.
 ABS: 4E-39

Removal 5) Remove actuator mount bolts (3).

1) Remove battery and battery tray.
• K15B model: (Page 1J-5) 1
• D13A model: (Page 1J-16) (A)

2) Disconnect clutch fluid pipe (1) from clamp (2).

2

1
2
IJHA0A450012-01

6) Remove ABS hydraulic unit / control module

assembly from actuator bracket.
7) Remove actuator bracket, if necessary. (Page 4E-
37)
IJHA0A450011-01

3) Disconnect ABS control module connector (1) by Installation

pulling down the lock lever (2). Reverse removal procedure noting the following points.
• Tighten brake pipe flare nuts (1), actuator mount bolts
(2) and actuator bracket nuts (3) (if removed) to
specified torque.
1
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 12.0
lbf-ft)
2 [a]
Actuator mount bolt (b): 9.0 N·m (0.92 kgf-m, 7.0
lbf-ft)
Actuator bracket nut (c): 26 N·m (2.7 kgf-m, 19.5
lbf-ft)
IFRA0A450024-02

[a]: Pull down to unlock 1, (a)

4) Loosen flare nuts (1) using special tool and

disconnect brake pipes from ABS hydraulic unit / 3, (c)
control module assembly (2).

NOTE
Put bleeder plug cap or the like onto pipe to
prevent fluid from spilling.
2, (b)
1, (a)
Special tool
(A): 09950M78220

3, (c)
IJHA0A450013-01

• Bleed brake system. (Page 4A-4)

• Check for leakage of brake fluid and perform ABS
hydraulic unit operation check. (Page 4E-36)
4E-40 ABS:

Front and Rear Wheel Speed Sensor On-Vehicle 5) Measure voltage at both ends of resistance with
Inspection rotating wheel. Check that high (1) and low (2)
AENJHB0B4506005 voltages are as specified. Check that waveform is
NOTICE not discord.
Incorrect voltage or mis-connection will
Voltage at resistance (100 Ω) with wheel rotating
damage the wheel speed sensor.
Low voltage: 600 to 800 mV
Check that the power supply voltage and test
High voltage: 1200 to 1600 mV
connections are both correct before
connecting battery.

Output Voltage Inspection

1) Hoist vehicle until tire can be rotated.
2) Disconnect wheel speed sensor connector (1).
3) Set up measuring devices as shown in figure.

[a]
1

[A] IAP70A460015-01

IAP70A460014-02

[A]: Wheel speed sensor connector (View: [a])

2. Resistance (100 Ω)
3. Power supply (12 V)

4) Measure voltage at both ends of resistance without

wheel rotation. If check result is not as specified,
check sensor, mating encoder and their installation
conditions.
Voltage at resistance (100 Ω) without wheel
rotation
600 to 800 mV or 1200 to 1600 mV
 ABS: 4E-41

Front Wheel Speed Sensor Removal and • Check that there is no space between front wheel
Installation speed sensor and steering knuckle (3).
AENJHB0B4506006

[A] [B]
Removal 1 2,(a) 1 2,(a)
3 3
1) Hoist vehicle a little and remove front wheel.
2) Remove front fender lining. (Page 9J-3)
3) Remove clips (1) and grommets (2), and disconnect
front wheel speed sensor connector (3). I9W10P460009-02
4) Remove front wheel speed sensor bolt (4). [A]: OK [B]: NG
5) Remove front wheel speed sensor (5) from steering
knuckle. • Positioning mark (1) on grommet (2) upward.
• Positioning line (3) on the sensor wire (4) outward.
3

1
1

2 1 2

5
3

IJHA0A450014-01 4

Installation IJHA0A450015-01

Reverse removal procedures noting the following points. • Install front wheel. (Page 2D-3)
• Check that no iron powder is stuck to sensing area of
wheel speed sensor (1).
• Tighten front wheel speed sensor bolt (2) to specified
torque.
Tightening torque
Front wheel speed sensor bolt (a): 11 N·m (1.1
kgf-m, 8.5 lbf-ft)
4E-42 ABS:

Rear Wheel Speed Sensor Removal and c) Disconnect rear wheel speed sensor connector
Installation (1).
AENJHB0B4506007
d) Remove grommets (2).
Removal
1) Hoist vehicle a little and remove rear wheel.
2) Disconnect rear wheel speed sensor connector (1).
3) Remove clips (2).

1
1
2

IJHA0A450016-01

4) Remove rear wheel hub assembly. (Page 3A-21)

5) Remove rear wheel speed sensor (1) from rear IJHA0A450018-01

wheel hub assembly.

Installation
Reverse removal procedures noting the following points.
• Check that no iron powder is stuck to sensing area of
wheel speed sensor (2).
• Tighten rear wheel speed sensor bolt (1) to specified
torque.

NOTICE
When installing rear wheel speed sensor,
damaged O-ring may cause water to enter
into bearing.
Be careful not to damage O-ring when
installing rear wheel speed sensor.

Tightening torque
Rear wheel speed sensor bolt (a): 11 N·m (1.1
1 kgf-m, 8.5 lbf-ft)
IJHA0A450017-01
• Check that there is no space between rear wheel
6) Remove rear wheel speed sensor wire as follows, if
speed sensor and rear wheel hub assembly (3).
necessary.
a) Remove quarter lower trim. (Page 9H-24) [A] [B]
b) Remove rear fender lining. (Page 9H-9) 2 1,(a) 2 1,(a)
3 3

I9P60A460033-01

[A]: OK [B]: NG

• Install rear wheel. (Page 2D-3)

 ABS: 4E-43

Front and Rear Wheel Speed Sensor Inspection
AENJHB0B4506008
Replace or clean wheel speed sensor if sensing area of
front and rear wheel speed sensor(s) is damaged or
covered with iron powder.
Front Wheel Speed Sensor Encoder Removal
and Installation
AENJHB0B4506009
NOTE
Front wheel speed sensor encoder is
included in front wheel hub assembly. If front
wheel speed sensor encoder needs to be
replaced, replace front wheel hub assembly.
For removal and installation of front wheel speed sensor
encoder (included in front wheel hub assembly), refer to
“Front Wheel Hub Assembly and Steering Knuckle
Removal and Installation”: Front in Section 3A (Page 3A-
17).
Rear Wheel Speed Sensor Encoder Removal
and Installation
AENJHB0B4506010
NOTE
Rear wheel speed sensor encoder is included
in rear wheel hub assembly. If rear wheel
speed sensor encoder needs to be replaced,
replace rear wheel hub assembly.
For removal and installation of rear wheel speed sensor
encoder (included in rear wheel hub assembly), refer to
“Rear Wheel Hub Assembly Removal and Installation”:
Rear in Section 3A (Page 3A-21).
Front and Rear Wheel Speed Sensor Encoder
Inspection
AENJHB0B4506011
NOTE
Wheel speed sensor encoder is included in
wheel hub assembly. Replace wheel hub
assembly if wheel speed sensor encoder
needs to be replaced.

Check front and rear wheel speed sensor encoders for

crack, damage, or deformation.
Replace wheel hub assembly if defective.

Specifications
Tightening Torque Specifications
AENJHB0B4507001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Brake pipe flare nut 16 1.6 12.0 (Page 4E-39)
Actuator mount bolt 9.0 0.92 7.0 (Page 4E-39)
Actuator bracket nut 26 2.7 19.5 (Page 4E-39)
Front wheel speed sensor bolt 11 1.1 8.5 (Page 4E-41)
Rear wheel speed sensor bolt 11 1.1 8.5 (Page 4E-42)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“ABS Hydraulic Unit / Control Module Assembly Components” (Page 4E-37)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Special Tool
AENJHB0B4508001
09950M78220 SUZUKI scan tool (Suzuki
SDT-II)
Flare nut wrench (10 x 12 —
mm)
(Page 4E-39) (Page 4E-14) /
(Page 4E-15) /
(Page 4E-36)
4F-1 Electronic Stability Program:

Electronic Stability Program

Brakes

Precautions
Precautions for ESP®
AENJHB0B4600001
When disconnecting ESP® control module connector,
disconnect the negative (–) cable at battery since the
battery voltage is constantly applied to ESP® hydraulic
unit / control module assembly.

Precautions for Diagnosing Trouble [A] [D]

AENJHB0B4600002
To check that the trouble diagnosis is done accurately
2
and smoothly, observe the following and follow “ESP®
[C]
System Check” (Page 4F-10). [B]
1
• Before using SUZUKI scan tool, read its Operator’s IFRA0A450022-02

Manual to know how to use it.
• If the vehicle was operated in any of the following
conditions, ABS warning light and ESP® warning light
may light momentarily but this does not indicate any
fault in ESP® system.
– The vehicle is driven with parking brake applied.
– The vehicle is driven with brake dragging.
– The vehicle is stuck in mud, sand, etc.
– Wheel spins while driving.
– Wheels are rotated while the vehicle is jacked up.
• Follow trouble diagnosis procedure described in
“ESP® System Check” (Page 4F-10). If trouble
diagnosis procedure is not followed properly, incorrect
diagnosis may result. (If incorrect procedure is
performed, other DTC may be stored in the ESP®
hydraulic unit / control module assembly.)
• When disconnecting ESP® control module connector
(1), pull down the lock lever (2) of connector.
When connecting the connector, set the connector in
position on ESP® hydraulic unit / control module
assembly and pull up the lock lever (2) until it locks.
[A]: Pull down to unlock [C]: Connect
[B]: Disconnect [D]: Pull up to lock
• Communication of ESP® control module and other
control module is established by CAN.
Therefore, read “Precautions for Installing Mobile
Communication Equipment” in Section 00 (Page 00-
10) before inspection and handling CAN
communication line.
Test with Speedometer Tester or Other
Equipment
AENJHB0B4600003
NOTE
Before performing speedometer test or other
tests using speedometer tester or chassis
dynamometer, traction control system of
ESP® must be deactivated by ESP® OFF
switch or using SUZUKI scan tool.

General Description
ABS Description EBD
AENJHB0B4601001 Refer to “ABS Description” (Page 4F-1).
Refer to “ABS Description” in Section 4E (Page 4E-1).
Engine Torque-Up Control
ESP® Description This function controls the engine torque to release lock-
AENJHB0B4601002
NOTE up of the driving wheel(s) to maintain vehicle stability
and steering when the lock-up occurs while engine brake
ESP® is registered trademark of Daimler AG. is functioning with accelerator pedal released.
When ESP® hydraulic unit / control module detects the
ESP® (Electronic Stability Program) is an auxiliary
lock-up, the control module computes target minimum
function to enable the vehicle to stabilize while the
slip and target engine torque according to the vehicle
vehicle is running, stopping or turning.
speed based on the engine speed signal and engine
ESP® consists of the following functions.
torque signal from ECM, and demands engine torque up
to ECM.
ABS
Refer to “ABS Description” (Page 4F-1).
 Electronic Stability Program: 4F-2

Traction Control Hydraulic Brake Assist Control

This function controls the engine and brakes to prevent
the driving wheels from spinning at the time of starting
and accelerating. Particularly, this function is helpful for
safe driving on muddy or icy roads. When ESP®
hydraulic unit / control module assembly detects wheel
spinning using information from the yaw rate / G sensor
assembly and wheel speed sensors, it lowers the engine
torque by reducing throttle opening and retarding the
ignition timing. At the same time, brake is applied to the
spinning wheel so that the engine torque can be
transmitted to the other wheel.
Stability Control
This function maintains the vehicle stability by controlling
the engine and brakes to prevent the vehicle from
oversteering or understeering while turning.
When understeering occurs, this function lowers the
engine torque and applies brake to the inner rear wheel
to prevent the vehicle from moving outward. When
oversteering occurs, this function applies brake to the
outer front wheel to prevent the vehicle from moving
inward.
This function controls brake fluid pressure to satisfy the
pressure range for activation of ABS. When ESP®
hydraulic unit / control module detects hard braking
sensing variation of signal from brake master cylinder
pressure sensor, pump motor in ESP® hydraulic unit /
control module functions to add brake pressure to the
pressure generated by driver’s brake operation for
activation of ABS.
Hill Hold Control
This function prevents occurrence of creeping down
which may occur when the driver shifts from the brake
pedal depression to the accelerator pedal operation to
restart moving forward the vehicle stopped on the up-
slope. The ESP® control module activates each solenoid
in the hydraulic unit to keep the brake pressure to each
brake caliper or wheel cylinder, which is applied by brake
pedal depression.
The vehicle remains stationary at the position for 2
seconds without operation of the accelerator pedal.
Operating the accelerator pedal within 2 seconds
releases the brake pressure.

ESP® Component Description

AENJHB0B4601003
ESP® hydraulic unit / control module assembly is composed of the following components. Regarding location, refer to
“ESP® Component Location” (Page 4F-9).

ESP® Hydraulic Unit / Control Module

The ESP® control module receives signals from each wheel speed sensor, ESP® OFF switch, brake master cylinder
pressure sensor (7) and steering angle sensor. Based on these signals, the ESP® control module judges the vehicle
conditions and controls the brake hydraulic pressure by combining the ON/OFF operation of the solenoid valves in the
hydraulic unit and the pump motor operation.
The hydraulic unit contains an inlet solenoid valve (8) and an outlet solenoid valve (9) for each wheel as well as a cut
solenoid valve (10) and a low pressure solenoid valve (11) for each hydraulic circuit. Also, a brake master cylinder
pressure sensor, pump motor (6), etc. are included. The hydraulic pressure control is performed in 3 modes: pressure
increase, pressure keeping and pressure reduction.
• Pump motor:
The pump motor turns on and applies pressure to each brake when braking is activated in the traction control and
stability control state. In the pressure reduction mode, the pump motor returns the brake fluid in the reservoir (12) to
the brake master cylinder (1).
• Brake master cylinder pressure sensor:
This sensor detects the brake hydraulic pressure in the primary piping when brakes are applied in the normal
condition. Also, it detects the pump motor driving state when a brake is applied in the traction control and stability
control state.
• Inlet solenoid valve:
When the ABS, traction control and stability control functions are working, this valve is activated in the pressure
keeping and pressure reduction modes to close the fluid passage, thereby restricting increase of the hydraulic
pressure applied to the brake caliper or wheel cylinder.
• Outlet solenoid valve:
When the ABS, traction control and stability control functions are working, this valve is activated in the pressure
reduction mode to open the fluid passage, thereby lowering the hydraulic pressure in the brake caliper or wheel
cylinder.
• Cut solenoid valve:
When brake application is commanded while the traction control and stability control functions are working, this
valve is activated to close the fluid passage to apply the hydraulic pressure generated by the pump motor to the
brake caliper or wheel cylinder.
4F-3 Electronic Stability Program:

• Low pressure solenoid valve:

When brake application is commanded while the traction control and stability control functions are working, this
valve is activated to open the fluid passage from the master cylinder to the pump motor.
• Yaw rate / G sensor:
The yaw rate / G sensor incorporated in ESP® control module detects yaw rate and acceleration of gravity on the
vehicle.

10 10

11 11
6

7
12 12

8 8 8 8

9 9 9 9

5 2 3 4

IGSB0A460001-01

2. Brake caliper (left-front) 4. Brake caliper or wheel cylinder (left-rear)

3. Brake caliper (right-front) 5. Brake caliper or wheel cylinder (right-rear)

Steering Angle Sensor OBD System Description

The steering angle sensor is a unit including a contact AENJHB0B4601004

coil and mounted to the steering column. Detecting the
angle as the steering wheel is turned, it sends that
information to the ESP® hydraulic unit / control module
assembly.
ESP® OFF Switch
This switch is of a momentary contact type, and is
located at the switch bezel of the instrument panel.
When the ESP® OFF switch is pressed for about 3
seconds, the ESP® hydraulic unit / control module
assembly stops the traction control and stability control
functions. The ESP® OFF light in the combination meter
lights and informs driver that these functions are
inactive. When the ESP® OFF switch is pressed again
momentarily, the ESP® hydraulic unit / control module
assembly resumes these functions.
Wheel Speed Sensor
Refer to “Wheel speed sensor” under “ABS Description”
(Page 4F-1).
ESP® control module is built in ESP® hydraulic unit /
control module assembly and has the following
functions.
Self-Diagnosis Function
ESP® hydraulic unit / control module assembly monitors
each input and output signal. When ESP® hydraulic unit /
control module assembly detects any malfunction, ABS
warning light (2), EBD warning light (brake warning light)
(1), ESP® warning light (3), and/or ESP® OFF light (4)
are turned ON to inform the driver of the abnormality.
• When ignition is set “ON”, ABS warning light, EBD
warning light (brake warning light), ESP® warning light
and ESP® OFF light turn ON for 2 seconds to check
its circuit.
• When no abnormality is detected (the system is in
good condition), these lights turn OFF after 2
seconds. However, when parking brake is applied,
EBD warning light (brake warning light) remains ON.
 Electronic Stability Program: 4F-4

• When an abnormality in the system is detected, ABS Fail-Safe Mode

warning light, EBD warning light (brake warning light), If ESP® hydraulic unit / control module assembly stores a
ESP® warning light and/or ESP® OFF light are turned DTC, ESP® hydraulic unit / control module assembly
ON and DTC is stored in ESP® hydraulic unit / control stops ABS, EBD, traction control function, stability
module assembly. control function, etc. corresponding to the faulty area. It
is possible to check the stopped function(s) by the
1 2 3 4 warning / indicator lights in combination meter. (Page
4F-4)

IJHB0A460001-01

Warning / Indicator Light Description

AENJHB0B4601005
There are three warning and one indicator lights controlled by ESP® hydraulic unit / control module assembly in
combination meter. They give warning and indication to driver by changing their modes: light ON / blinking / light OFF.

1 2 3 4

IJHB0A460001-01

1. EBD warning light (brake warning light) 3. ESP® warning light

2. ABS warning light 4. ESP® OFF light

Condition and Operation of Warning Light and Indicator Light

Warning light / Indicator light
ABS warning light
EBD warning light (brake warning
light)
ESP® warning light
ESP® OFF light
Condition and operation
If ABS control is deactivated by ESP® system failure, the light turns “ON”.
• If EBD control is deactivated by ESP® system failure, the light turns “ON” with
ABS warning light.
• If brake fluid level in reservoir is lower than minimum level, the light turns “ON”.
• If parking brake lever is pulled up, the light turns “ON”.
• If traction control and stability control are deactivated by ESP® system failure,
the light turns “ON”.
• If traction control and/or stability control is activated, the light blinks.
ESP® OFF light turns “ON” to indicate that ESP® hydraulic unit / control module
assembly stops traction control and stability control functions.
4F-5 Electronic Stability Program:

Description of Sensor Calibrating Condition

AENJHB0B4601006
When the following conditions are met, sensor calibration should be performed since the original calibration data are
deleted.
Sensor to be calibrated Condition requiring calibration
• Steering angle sensor is replaced.
Steering angle sensor
• ESP® hydraulic unit / control module assembly is replaced.
Brake master cylinder pressure sensor • ESP® hydraulic unit / control module assembly is replaced.
Yaw rate / G sensor assembly • ESP® hydraulic unit / control module assembly is replaced or removed.

Perform sensor calibration according to “Sensor Calibration” (Page 4F-53).

DLC Description
AENJHB0B4601007
Refer to “DLC Description”: K15B in Section 1A (Page 1A-4).

CAN Communication System Description

AENJHB0B4601008
Refer to “Communication System Description”: K15B Model in Section 10H (Page 10H-1).

Schematic and Routing Diagram

ESP® System Diagram
AENJHB0B4602001

10 10
6
5
11

12

1
2
9
8 4
3

10 10

13 14 15
IJHA0A460002-01

1. ESP® hydraulic unit / control module assembly 6. Combination meter 11. ESP® OFF switch
2. ESP® control module 7. Brake light switch 12. Brake booster pressure sensor
3. Hydraulic unit 8. Brake master cylinder pressure sensor 13. Electronic signal
4. ECM 9. Yaw rate / G sensor 14. CAN signal
5. Other control modules (if equipped) and steering 10. Wheel speed sensor 15. Hydraulic circuit
angle sensor
 Electronic Stability Program: 4F-6

ESP® Input / Output Diagram

AENJHB0B4602002

INPUT ESP® hydraulic unit / control module assembly OUTPUT

Battery power supply

Solenoid valve power supply driver

Brake master cylinder pressure

sensor Right-front inlet solenoid valve

Right-front outlet solenoid valve

Yaw rate / G sensor
Left-front inlet solenoid valve

Left-front outlet solenoid valve

Right-rear inlet solenoid valve

Wheel speed sensor (Right-front)
Solenoid valve Right-rear outlet solenoid valve
Wheel speed sensor (Left-front) driver
Left-rear inlet solenoid valve

Wheel speed sensor (Right-rear) Left-rear outlet solenoid valve

Low pressure solenoid valve No.1

CPU
Wheel speed sensor (Left-rear)
Low pressure solenoid valve No.2

Brake booster pressure sensor Cut solenoid valve No.1

Cut solenoid valve No.2

ESP® OFF switch
Pump motor Pump motor
driver

BCM BCM

TCM CAN driver TCM

ECM ECM

Steering angle sensor Combination meter

P/S control module

: CAN communication
IJHB0A460002-01
4F-7 Electronic Stability Program:

ESP® Circuit Diagram

AENJHB0B4602003

2
GRN
38
RED
39 3
24
41
GRY YEL E09-29
40
4
42
E09-16 BLU
43 E09-15 GRN 22
WHT
E09-23 GRY

YEL PNK

12
37 YEL 25
E09-7 WHT
1 6 BLK
10 9 8 7

11

BLK
5

23 BLU
E09-25 BLK
RED
5
WHT
BLK
RED
E09-13
WHT
E09-24
WHT 13 35
RED

16 33
14
GRY BLK M
30 32
15
LT GRN

RED
31
WHT
27
35 26
5
28

RED E09-32

[A] E09 WHT E09-31

29

24 13 17 RED E09-33
1 5 5
26 WHT E09-30
2
15
3
27 16
4
28 17
5 GRN
29 18 E09-11
6 18
19 BLK E09-12
7
30 20 GRN E09-2
8 19
21 GRY E09-1
9 34
31 22
10 BRN E09-4
32 20
11 YEL E09-5
33 23 [a]
12 LT BLU E09-9
21
25 14 PNK E09-8
: 44 : 45

: 5V : 12V
IJHB0B460001-01
 Electronic Stability Program: 4F-8

[A]: ESP® hydraulic unit / control module 16. BCM 32. Pump motor relay
assembly connector (View: [a])
1. Battery 17. ECM 33. Pump motor
2. Relay box 18. Left-front wheel speed sensor 34. Wheel speed sensor driver
3. J/B 19. Right-front wheel speed sensor 35. To other control modules by CAN
4. IG11 relay 20. Left-rear wheel speed sensor 36. To BCM
5. CAN driver 21. Right-rear wheel speed sensor 37. To ECM
6. Combination meter 22. Brake booster pressure sensor 38. “ABS MOT” fuse
7. ESP® OFF light 23. Steering angle sensor 39. “ABS SOL” fuse
8. ESP® warning light 24. ESP® hydraulic unit / control module assembly 40. “IGN” fuse
9. ABS warning light 25. ESP® OFF switch 41. “ABS” fuse
10. EBD warning light (brake warning light) 26. Yaw rate / G sensor 42. “MTR” fuse
11. CPU (combination meter) 27. Solenoid valve power supply relay 43. “STOP” fuse
12. Brake light switch 28. Solenoid valve 44. Engine ground
13. DLC 29. Solenoid valve relay 45. Ground
14. Brake fluid level switch 30. CPU
15. Parking brake switch 31. Internal memory

Terminal Wire color Circuit

1 GRY Right-front wheel speed sensor signal circuit
2 GRN Right-front wheel speed sensor power supply circuit
4 BRN Left-rear wheel speed sensor power supply circuit
5 YEL Left-rear wheel speed sensor signal circuit
7 WHT ESP® OFF switch signal circuit
8 PNK Right-rear wheel speed sensor signal circuit
9 LT BLU Right-rear wheel speed sensor power supply circuit
11 GRN Left-front wheel speed sensor power supply circuit
12 BLK Left-front wheel speed sensor signal circuit
13 RED Solenoid valve power supply circuit
15 GRN Brake booster pressure sensor signal circuit
16 BLU Brake booster pressure sensor power supply circuit
23 GRY Brake booster pressure sensor ground circuit
24 GRN Pump motor power supply circuit
25 BLK ESP® control module ground circuit
27 PPL Not connected
29 YEL Ignition power supply circuit
30 WHT CAN communication line (low) for ECM
31 WHT CAN communication line (low) for BCM
32 RED CAN communication line (high) for BCM
33 RED CAN communication line (high) for ECM
4F-9 Electronic Stability Program:

Component Location
ESP® Component Location
AENJHB0B4603001

1 3

5
6

8 9 10 11

12

15

17 13

14

16

IJHB0A460004-01
 Electronic Stability Program: 4F-10

1. Rear wheel speed sensor 7. Combination meter 13. ESP® OFF switch
2. Front wheel speed sensor 8. EBD warning light (brake warning light) 14. Brake light switch
3. Brake booster pressure sensor 9. ABS warning light 15. P/S control module
4. ESP® hydraulic unit / control module assembly 10. ESP® warning light 16. TCM
5. ECM 11. ESP® OFF light 17. BCM
6. Individual circuit fuse box No.1 12. Steering angle sensor

Diagnostic Information and Procedures

ESP® System Check
AENJHB0B4604001
Refer to the description after the following general flow for details of each step.
Step Action Yes No
1 Malfunction analysis Check and repair Go to Step 2.
1) Perform “Customer complaint analysis” (Page 4F-11). referring to applicable
DTC troubleshooting,
2) Perform “Problem symptom confirmation” (Page 4F-11).
and then go to Step 6.
3) Perform “DTC check, record and clearance” (Page 4F-
11) and recheck DTC.

Is the same DTC detected again after performing DTC

clearance?
2 Visual inspection Repair or replace Go to Step 3.
1) Perform “Step 2: Visual Inspection” (Page 4F-12). defective part, and then
go to Step 6.
Is there any faulty condition?
3 Road test Repair or replace Go to Step 4.
1) Perform “Step 3: Road Test” (Page 4F-12). defective part, and then
go to Step 6.
Is malfunction detected?
4 Brake diagnosis Repair or replace Go to Step 5.
1) Check and repair brake system. (Page 4F-12) defective part, and then
go to Step 6.
Is malfunction detected?
5 Intermittent problem check Repair or replace Go to Step 6.
1) Check for intermittent problems. (Page 4F-12) defective part, and then
go to Step 6.
Is malfunction detected?
6 Final confirmation test Go to Step 4. End.
1) Perform “Step 6: Final Confirmation Test” (Page 4F-12).

Is malfunction detected?
4F-11 Electronic Stability Program:

Step 1: Malfunction Analysis

Customer complaint analysis
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form shown below will facilitate collecting information for proper analysis
and diagnosis.
Customer questionnaire form (Example)

IAP70A460005-01

Problem symptom confirmation DTC check, record and clearance

If symptom in “Customer Questionnaire” is found or
reproduced in the vehicle, check that the symptom is
problem or not. (This step should be done with the
customer if possible.) Check warning light related to
brake system referring to “EBD Warning Light (Brake
Warning Light) Check”, “ABS Warning Light Check” and
“ESP® Warning Light Check” under “Warning Light
Check” (Page 4F-13).
Perform “DTC Check” (Page 4F-14) procedure, record it
and then clear it. (Page 4F-15)
Recheck DTC. (Page 4F-14)
When DTC which is recorded at DTC check procedure is
detected again after performing DTC clearance, go to
“DTC Check” (Page 4F-14) to perform the diagnosis.
When DTC which is recorded at DTC check procedure is
not detected anymore after performing DTC clearance,
ESP® control module does not perform the system
 Electronic Stability Program: 4F-12

diagnosis, or temporary abnormality may occur,
therefore go to “Step 3: Road Test” (Page 4F-12) to
perform the diagnosis.
Step 2: Visual Inspection
As a preliminary step, perform visual check of the items
that support proper function of the ESP® system.
(Page 4F-12)
Step 3: Road Test
! WARNING
If you do not select a suitable route and take
proper precautions when performing a road
test, an accident can occur.
• Select a level road with no traffic to
minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a
driver and a tester.
NOTE
Limit the driving speed permissible in road
conditions and regulations.
Perform Road Test as follows to check if each warning
lamp lights up.
1) Drive at 40 km/h (25 mph) for over two minutes.
2) Turn right and left at over 10 km/h (6 mph) for over a
second by turning steering wheel over 45 degrees.
3) Drive at 60 km/h (37 mph) for over three seconds.
4) Stop the vehicle using foot brake from driving at 60
km/h (37 mph).
Step 4: Brake Diagnosis
Check the parts or system suspected as a possible
cause referring to “Brake System Description” in Section
4A (Page 4A-1) and based on symptoms appearing on
the vehicle (symptoms observed through Step 1 – 3).
Repair faulty parts or replace them, if necessary.
Step 5: Intermittent Problem Check
Check parts that are prone to cause intermittent trouble
(e.g. wire harness, connector), referring to “Intermittent
Connection and Poor Contact Inspection” in Section 00
(Page 00-12) and the related circuit of which DTC is
recorded in Step 1 – 5.
Step 6: Final Confirmation Test
Check that the problem symptom is not observed any
more and ESP® is free from any abnormal conditions. If
what has been repaired is related to malfunction DTC,
clear the DTC referring to “DTC Clearance” (Page 4F-
15), perform road test and check that the DTC is not
indicated.

Visual Inspection
AENJHB0B4604002
Visually check the following parts and systems.
Inspection item Referring section
• Battery – Fluid level, leakage “Battery Description”: K15B in Section 1J (Page 1J-2)
• Connectors of electric wire harness – “Intermittent Connection and Poor Contact Inspection” in
Disconnection, friction Section 00 (Page 00-12)
• Fuses – Burning —
• Brake fluid – Fluid level, leakage “Brake Fluid Level Inspection” in Section 4A (Page 4A-4)
• ABS warning light – Operation
• EBD warning light (Brake warning light) – Operation “Warning Light Check” (Page 4F-13)
• ESP® warning light – Operation
• Other parts that can be checked visually —

ESP® Symptom Diagnosis

AENJHB0B4604003

Condition Possible cause Correction / Reference Item

ESP® warning light
remains lit for more than 2
seconds after setting
ignition “ON”
ABS warning light
remains lit for more than 2
seconds after setting
ignition “ON”
Malfunctioning ESP® function Perform ESP® system check. (Page 4F-10)
Malfunctioning ESP® warning light Check ESP® warning light circuit. (Page 4F-
circuit 27)
Malfunctioning ESP® function Perform ESP® system check. (Page 4F-10)
Malfunctioning ABS warning light circuit Check ABS warning light circuit. (Page 4F-
28)
4F-13 Electronic Stability Program:

Condition Possible cause Correction / Reference Item

ABS and/or ESP® warning Malfunctioning ESP® function Perform ESP® system check. (Page 4F-10)
light does not turn ON Malfunctioning CAN communication Check CAN communication system. (Page
after setting ignition “ON” system function 10H-7)
Malfunctioning ESP® warning light Check ESP® warning light circuit. (Page 4F-
circuit 26)
Malfunctioning ABS warning light circuit Check ABS warning light circuit. (Page 4F-
27)
ABS warning light blinks Brake system is not filled with brake fluid Fill brake system with brake fluid.
EBD warning light (Brake Parking brake applied Release parking brake and check that EBD
warning light) remains lit warning light (brake warning light) turns OFF.
for more than 2 seconds Insufficient amount of brake fluid Check brake fluid level. (Page 4A-4)
after setting ignition “ON” Faulty parking brake switch circuit and/ Check BCM and its circuit. (Page 10B-37)
or brake fluid level switch circuit
Faulty parking brake switch and/or Check parking brake switch and/or brake fluid
brake fluid level switch level switch.
• Parking brake switch: (Page 4D-4)
• Brake fluid level switch: (Page 4A-4)
Malfunctioning ESP® function Perform ESP® system check. (Page 4F-10)
®
Faulty ESP control module power Check ESP® control module power supply and
supply and ground circuits ground circuits. (Page 4F-51)
Malfunctioning CAN communication Check CAN communication system. (Page
system 10H-7)
Faulty BCM Check BCM and its circuit. (Page 10B-37)
Faulty ESP® control module Replace ESP® control module. (Page 4F-56)
Malfunctioning EBD warning light circuit Check EBD warning light circuit. (Page 4F-
29)
EBD warning light (Brake Malfunctioning ESP® function Perform ESP® system check. (Page 4F-10)
warning light) does not Malfunctioning CAN communication Check CAN communication system. (Page
turn ON after setting system 10H-7)
ignition “ON” Malfunctioning EBD warning light circuit Check EBD warning light circuit. (Page 4F-
29)

Warning Light Check

AENJHB0B4604004
1
ESP® Warning Light Check
1) Set ignition “ON”.
2) Check that ESP® warning light (1) comes ON for
about 2 seconds and then goes OFF.
If ESP® warning light never lights up, go to “ESP®
Warning Light Does Not Come ON after Setting
Ignition “ON”” (Page 4F-26). If ESP® warning light
remains ON and no DTC is stored in ESP® control
module, go to “ESP® Warning Light Comes ON
Steady” (Page 4F-27).

IJHB0A460005-01

ABS Warning Light
1) Set ignition “ON”.
2) Check that ABS warning light (1) comes ON for
about 2 seconds and then goes OFF. If ABS warning
light never lights up, go to “ABS Warning Light Does
Not Come ON after Setting Ignition “ON”” (Page 4F-
27). If ABS warning light remains ON and no DTC is
stored in ESP® control module, go to “ABS Warning
Light Comes ON Steady” (Page 4F-28).
1
IJHB0A460006-01
EBD Warning Light (Brake Warning Light)
NOTE
Perform this check on a level place.
1) Check brake fluid level. (Page 4A-4)
2) Pull parking brake lever.
3) Set ignition “ON”.
4) Check that EBD warning light (brake warning light)
(1) comes ON. If EBD warning light (brake warning
light) never lights up, go to “EBD Warning Light
(Brake Warning Light) Does Not Come ON after
Setting Ignition “ON”” (Page 4F-29).
IJHB0A460007-01
5) Release parking brake lever and check that EBD
warning light goes OFF. If EBD warning light (brake
warning light) remains ON and no DTC is stored in
ESP® control module, go to “EBD Warning Light
(Brake Warning Light) Comes ON Steady” (Page 4F-
29).
Electronic Stability Program: 4F-14
DTC Check
AENJHB0B4604005
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Read DTC according to instructions displayed on
SUZUKI scan tool and print it or write it down. Refer
to Operator’s Manual of SUZUKI scan tool for further
details.
NOTE
If communication between SUZUKI scan tool
and ESP® control module is not possible,
perform the following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-17)
• Check ESP® control module power supply
circuit and ground circuit. (Page 4F-51)
(A)
IJHA0A110011-01
5) After completing the check, set ignition “OFF” and
disconnect SUZUKI scan tool from DLC.
4F-15 Electronic Stability Program:

DTC Clearance
AENJHB0B4604006
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Clear DTC according to instructions displayed on 1
SUZUKI scan tool. Refer to Operator’s Manual of
SUZUKI scan tool for further details.

NOTE
• If communication between SUZUKI scan
tool and ESP® control module is not
possible, perform the following checks:
– Check communication condition 2
between PC and VCI (2) using SUZUKI
scan tool function.
– Check DLC power circuit and ground
circuit. (A)
– Check DLC cable. If necessary, check
IJHA0A110011-01
DLC cable by substituting a known-good
5) After completing DTC clearance, set ignition “OFF”
DLC cable.
and disconnect SUZUKI scan tool from DLC.
– Check CAN communication system.
(“Control Module Communication Bus
Off” is detected in any control module.)
(Page 10H-17)
– Check ESP® control module power
circuit and ground circuit. (Page 4F-
51)
• Current DTCs cannot be cleared as long as
current trouble is present. Solve the
trouble and check that the system is in
normal condition referring to “Fail-safe
condition” under “Fail-Safe Table” (Page
4F-19). Clear DTCs after changing current
DTCs to history DTCs.
 Electronic Stability Program: 4F-16

DTC Table
AENJHB0B4604007
NOTE
• If you do not perform “ESP® System Check” (Page 4F-10) before starting the diagnosis, the
diagnosis will show a false result.
Perform “ESP® System Check” (Page 4F-10) before starting the diagnosis.
• *1: Whether ABS warning light, EBD warning light (brake warning light) or ESP® warning light lights
up or not depends on DTC detecting condition.
• *2: DTC is cleared automatically when sensor is calibrated.
• *3: In case that both DTC C1024 and C1075 are detected, go to DTC C1024 troubleshooting.
• *4: EBD warning light lights up when 2 or more wheel speed sensors malfunction.

ABS EBD ESP®

DTC DTC name DTC detecting condition warning warning warning
light light light
Longitudinal G sensor signal is out of
Longitudinal G Sensor in specified range.
C1015 (Page
Yaw Rate / G Sensor Longitudinal G sensor signal does not OFF OFF Lights up
4F-30)
Assembly Failure change although vehicle is accelerating or
decelerating.
Brake light switch ON signal is detected
for more than specified time while vehicle
speed is more than specified value.
C1016 (Page Brake Light Switch Circuit
Brake light switch ON signal is not OFF OFF Lights up
4F-31) Performance
detected although brake master cylinder
pressure sensor signal is more than
specified value.
Lateral G sensor signal is out of specified
C1017 (Page Lateral G Sensor Circuit range.
OFF OFF Lights up
4F-30) Performance Lateral G sensor signal does not change
although vehicle is turning right or left.
C101C (Page Vehicle Variant Data Mismatch ESP® control module variant
OFF OFF Lights up
4F-33) Mismatched and vehicle specification.
Master Cylinder Pressure Power supply voltage to brake master
C1020 (Page
Sensor Power Supply cylinder pressure sensor in ESP® control OFF OFF Lights up
4F-34)
Voltage module is out of specified range.
C1021 (Page Right-Front Wheel Speed Wheel speed sensor signal is out of
Lights up *4 Lights up
4F-34) Sensor Circuit Voltage specified range.
Right-Front Wheel Speed
C1022 (Page Abnormal wheel speed sensor signal is
Sensor or Encoder Signal Lights up *4 Lights up
4F-34) detected continuously.
Performance
Yaw rate sensor signal is out of specified
range.
C1023 (Page Yaw Rate Sensor Circuit
Although vehicle is in a stop, yaw rate OFF OFF Lights up
4F-30) Performance
sensor signal is more than specified
value.
CPU in steering angle sensor detects
internal defect.
Steering angle sensor signal is out of
C1024 *3 Steering Angle Sensor
specified range. OFF OFF Lights up
(Page 4F-37) Circuit Performance
Steering angle sensor signal does not
change although vehicle is turning right or
left.
C1025 (Page Left-Front Wheel Speed Wheel speed sensor signal is out of
Lights up *4 Lights up
4F-34) Sensor Circuit Voltage specified range.
Left-Front Wheel Speed
C1026 (Page Abnormal wheel speed sensor signal is
Sensor or Encoder Signal Lights up *4 Lights up
4F-34) detected continuously.
Performance
4F-17 Electronic Stability Program:

ABS EBD ESP®

DTC DTC name DTC detecting condition warning warning warning
light light light
C1027 (Page ESP® OFF Switch Circuit ESP® OFF switch remains “ON” for more
OFF OFF OFF
4F-37) Failure than specified time.
C1028 (Page Master Cylinder Pressure Brake master cylinder pressure sensor
OFF OFF Lights up
4F-38) Sensor Circuit Voltage signal is out of specified range.
Brake booster pressure sensor signal is
C102B (Page Brake Booster Pressure kept stuck.
OFF OFF Lights up
4F-39) Sensor System Malfunction Brake booster pressure sensor signal is
out of specified range.
C1031 (Page Right-Rear Wheel Speed Wheel speed sensor signal is out of
Lights up *4 Lights up
4F-34) Sensor Circuit Voltage specified range.
Right-Rear Wheel Speed
C1032 (Page Abnormal wheel speed sensor signal is
Sensor or Encoder Signal Lights up *4 Lights up
4F-34) detected continuously.
Performance
C1035 (Page Left-Rear Wheel Speed Wheel speed sensor signal is out of
Lights up *4 Lights up
4F-34) Sensor Circuit Voltage specified range.
Left-Rear Wheel Speed
C1036 (Page Abnormal wheel speed sensor signal is
Sensor or Encoder Signal Lights up *4 Lights up
4F-34) detected continuously.
Performance
C1037 (Page Steering Angle Sensor Steering angle sensor power supply
OFF OFF Lights up
4F-40) Power Supply Voltage voltage is out of specified range.
Steering Angle Sensor
C1038 (Page Steering angle sensor detects invalid CAN
Detect Rolling Counter OFF OFF Lights up
4F-41) data from ESP® control module.
Failure
C1040 (Page ESP® Continuous Stability control is activated for more than
OFF OFF Lights up
4F-42) Operation specified time.
C1041 (Page Right-Front Inlet Solenoid
Electrical failure of solenoid valve. Lights up Lights up Lights up
4F-42) Valve Circuit Correlation
C1042 (Page Right-Front Outlet Solenoid
Electrical failure of solenoid valve. Lights up Lights up Lights up
4F-42) Valve Circuit Correlation
C1043 (Page Cut Solenoid No.1 Valve
Electrical failure of solenoid valve. Lights up Lights up Lights up
4F-42) Circuit Correlation
C1044 (Page Cut Solenoid No.2 Valve
Electrical failure of solenoid valve. Lights up Lights up Lights up
4F-42) Circuit Correlation
C1045 (Page Left-Front Inlet Solenoid
Electrical failure of solenoid valve. Lights up Lights up Lights up
4F-42) Valve Circuit Correlation
C1046 (Page Left-Front Outlet Solenoid
Electrical failure of solenoid valve. Lights up Lights up Lights up
4F-42) Valve Circuit Correlation
C1051 (Page Right-Rear Inlet Solenoid
Electrical failure of solenoid valve. Lights up Lights up Lights up
4F-42) Valve Circuit Correlation
C1052 (Page Right-Rear Outlet Solenoid
Electrical failure of solenoid valve. Lights up Lights up Lights up
4F-42) Valve Circuit Correlation
Low Pressure Solenoid
C1053 (Page
No.1 Valve Circuit Electrical failure of solenoid valve. Lights up Lights up Lights up
4F-42)
Correlation
Low Pressure Solenoid
C1054 (Page
No.2 Valve Circuit Electrical failure of solenoid valve. Lights up Lights up Lights up
4F-42)
Correlation
C1055 (Page Left-Rear Inlet Solenoid
Electrical failure of solenoid valve. Lights up Lights up Lights up
4F-42) Valve Circuit Correlation
C1056 (Page Left-Rear Outlet Solenoid
Electrical failure of solenoid valve. Lights up Lights up Lights up
4F-42) Valve Circuit Correlation
®
ESP control module power supply
Lights up
C1057 (Page voltage is higher than specified value.
Power Supply Voltage ® Lights up Lights up
4F-43) ESP control module power supply
*1
voltage is lower than specified value.
 Electronic Stability Program: 4F-18

ABS EBD ESP®

DTC DTC name DTC detecting condition warning warning warning
light light light
Pump motor power supply voltage is out
of specified range.
When pump motor is activated, a
C1061 (Page Pump Motor Circuit
malfunction in pump motor is detected. Lights up OFF Lights up
4F-44) Performance
Power supply from CPU to pump motor
and pump motor relay monitor data
disagree.
Solenoid valve power supply relay output
is “ON”, although monitored output is
Solenoid Valve Power
C1063 (Page “OFF”.
Supply Driver Circuit Lights up Lights up Lights up
4F-45) Solenoid valve power supply relay output
Performance
is “OFF”, although monitored output is
“ON”.
C1069 (Page Steering Angle Sensor Steering angle sensor detects
OFF OFF Lights up
4F-46) Specification Unregistered unconfirmed failure.
C1071 (Page ®
ESP Control Module ®
ESP control module internal failure is
Lights up Lights up Lights up
4F-47) Internal Failure detected.
C1074 *2 Yaw rate / G sensor calibration is not
G Sensor Calibration OFF OFF Lights up
(Page 4F-47) completed.
C1075 *2, *3 Steering Angle Sensor Steering angle sensor calibration is not
OFF OFF Lights up
(Page 4F-47) Calibration completed.
Master Cylinder Pressure
C1076 *2 Brake master cylinder pressure sensor
Sensor Calibration OFF OFF Lights up
(Page 4F-47) calibration is not completed.
Incomplete
Lateral G Sensor in Yaw
C1078 *2 Lateral G sensor in yaw rate / G sensor
Rate / G Sensor Assembly OFF OFF Lights up
(Page 4F-47) assembly calibration is not completed.
Calibration Incomplete
ECM Detect Rolling
C1090 (Page ESP® control module sends invalid CAN
Counter Failure From ESP® OFF OFF Lights up
4F-48) data to ECM.
Control Module
C1091 (Page CAN Invalid Data from
DTC concerned with ECM is detected. OFF OFF Lights up
4F-49) ECM
C1092 (Page CAN Invalid Data from
DTC concerned with TCM is detected. OFF OFF Lights up
4F-49) TCM
®
ESP control module receives invalid
C1094 (Page Torque Request Reject
CAN data from ECM (about engine torque OFF OFF Lights up
4F-49) Status
control).
Invalid Data Received
C1099 (Page
From ENG A-STOP Control DTC concerned with ECM is detected. OFF OFF Lights up
4F-50)
Module
U0073 (Page Control Module Impossible to receive and transmit CAN
OFF OFF Lights up
4F-50) Communication Bus Off data.
U0100 (Page Lost Communication With ECM message data is missing from CAN
OFF OFF Lights up
4F-50) ECM communication.
U0101 (Page Lost Communication With TCM message data is missing from CAN
OFF OFF Lights up
4F-50) TCM communication.
Lost Communication With
U0126 (Page Steering angle sensor message data is
Steering Angle Sensor OFF OFF Lights up
4F-50) missing from CAN communication.
Module
U0140 (Page Lost Communication With BCM message data is missing from CAN
OFF OFF Lights up
4F-51) Body Control Module communication.
Lost Communication With Instrument panel cluster (IPC) control
U0155 (Page
Instrument Panel Cluster module message data is missing from OFF OFF OFF
4F-51)
(IPC) Control Module CAN communication.
Lost Communication With
U1082 (Page ECM message data is missing from CAN
ENG A-STOP Control OFF OFF Lights up
4F-51) communication.
Module
4F-19 Electronic Stability Program:

Fail-Safe Table
AENJHB0B4604008
When any of the following DTCs is detected, ESP® control module changes the control to the fail-safe mode and ABS,
EBD, traction control and stability control functions are deactivated until ESP® control module judges the system is
normal.

NOTE
• O: Activated
• —: Deactivated
• *1: Whether ESP® system is engaged in fail-safe mode or not depends on malfunction part. Fail-safe
mode can be checked by lighting status of ABS warning light, EBD warning light (brake warning
light) or ESP® warning light.
– When ABS warning light lights up, ABS control is deactivated.
– When EBD warning light (brake warning light) lights up, EBD control is deactivated.
– When ESP® warning light lights up, traction control and stability control are deactivated.

Fail-safe operation
DTC Traction control / Hill hold Fail-safe cancel condition
ABS EBD
Stability control control
When ESP® control module judges the system to be
C1015 (Page
— — normal, after switching ignition from “OFF” to “ON”
4F-30)
and the vehicle runs at 10 km/h (6 mile/h) or more.
When ESP® control module judges the system to be
C1016 (Page normal, after switching ignition from “OFF” to “ON”
— —
4F-31) and normal operation of brake light switch is
counted 1 time.
When ESP® control module judges the system to be
C1017 (Page normal and “Road Test” under “ESP® System
—
4F-30) Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
C101C (Page When ESP® control module judges the system to be
— —
4F-33) normal, after switching ignition from “OFF” to “ON”.
C1020 (Page When ESP® control module judges the system to be
— —
4F-34) normal, after switching ignition from “OFF” to “ON”.
C1021 (Page When ESP® control module judges the system to be
— *1 — —
4F-34) normal, after switching ignition from “OFF” to “ON”.
When ESP® control module judges the system to be
C1022 (Page normal and “Road Test” under “ESP® System
— *1 — —
4F-34) Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
When ESP® control module judges the system to be
C1023 (Page normal and “Road Test” under “ESP® System
—
4F-30) Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
• When ESP® control module judges the system to
be normal, after switching ignition from “OFF” to
“ON”.
C1024 (Page
— • When ESP® control module judges the system to
4F-37)
be normal and “Road Test” under “ESP® System
Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
C1025 (Page When ESP® control module judges the system to be
— *1 — —
4F-34) normal, after switching ignition from “OFF” to “ON”.
When ESP® control module judges the system to be
C1026 (Page normal and “Road Test” under “ESP® System
— *1 — —
4F-34) Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
C1027 (Page When ESP® control module judges the system to be
4F-37) normal, after switching ignition from “OFF” to “ON”.
 Electronic Stability Program: 4F-20

Fail-safe operation
DTC Traction control / Hill hold Fail-safe cancel condition
ABS EBD
Stability control control
C1028 (Page When ESP® control module judges the system to be
— —
4F-38) normal, after switching ignition from “OFF” to “ON”.
When any of the following conditions is met, fail-
safe operation is canceled.
• Ignition is “OFF”.
C102B (Page • Brake booster pressure sensor signal is returned
—
4F-39) to normal.
• After switching ignition from “OFF” to “ON”, brake
booster vacuum is judged to be normal by
depressing brake pedal 1 time or more.
C1031 (Page When ESP® control module judges the system to be
— *1 — —
4F-34) normal, after switching ignition from “OFF” to “ON”.
When ESP® control module judges the system to be
C1032 (Page normal and “Road Test” under “ESP® System
— *1 — —
4F-34) Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
C1035 (Page When ESP® control module judges the system to be
— *1 — —
4F-34) normal, after switching ignition from “OFF” to “ON”.
When ESP® control module judges the system to be
C1036 (Page normal and “Road Test” under “ESP® System
— *1 — —
4F-34) Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
When ESP® control module judges the system to be
C1037 (Page normal and “Road Test” under “ESP® System
—
4F-40) Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
C1038 (Page When ESP® control module judges the system to be
—
4F-41) normal, after switching ignition from “OFF” to “ON”.
• When ESP® control module judges the system to
be normal, after switching ignition from “OFF” to
“ON”.
C1040 (Page
— • When ESP® control module judges the system to
4F-42)
be normal and “Road Test” under “ESP® System
Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
• When ESP® control module judges the system to
be normal, after switching ignition from “OFF” to
“ON”.
C1041 (Page
— — — — • When ESP® control module judges the system to
4F-42)
be normal and “Road Test” under “ESP® System
Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
• When ESP® control module judges the system to
be normal, after switching ignition from “OFF” to
“ON”.
C1042 (Page
— — — — • When ESP® control module judges the system to
4F-42)
be normal and “Road Test” under “ESP® System
Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
4F-21 Electronic Stability Program:

Fail-safe operation
DTC Traction control / Hill hold Fail-safe cancel condition
ABS EBD
Stability control control
• When ESP® control module judges the system to
be normal, after switching ignition from “OFF” to
“ON”.
C1043 (Page
— — — — • When ESP® control module judges the system to
4F-42)
be normal and “Road Test” under “ESP® System
Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
• When ESP® control module judges the system to
be normal, after switching ignition from “OFF” to
“ON”.
C1044 (Page
— — — — • When ESP® control module judges the system to
4F-42)
be normal and “Road Test” under “ESP® System
Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
• When ESP® control module judges the system to
be normal, after switching ignition from “OFF” to
“ON”.
C1045 (Page
— — — — • When ESP® control module judges the system to
4F-42)
be normal and “Road Test” under “ESP® System
Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
• When ESP® control module judges the system to
be normal, after switching ignition from “OFF” to
“ON”.
C1046 (Page
— — — — • When ESP® control module judges the system to
4F-42)
be normal and “Road Test” under “ESP® System
Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
• When ESP® control module judges the system to
be normal, after switching ignition from “OFF” to
“ON”.
C1051 (Page
— — — — • When ESP® control module judges the system to
4F-42)
be normal and “Road Test” under “ESP® System
Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
• When ESP® control module judges the system to
be normal, after switching ignition from “OFF” to
“ON”.
C1052 (Page
— — — — • When ESP® control module judges the system to
4F-42)
be normal and “Road Test” under “ESP® System
Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
• When ESP® control module judges the system to
be normal, after switching ignition from “OFF” to
“ON”.
C1053 (Page
— — — — • When ESP® control module judges the system to
4F-42)
be normal and “Road Test” under “ESP® System
Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
 Electronic Stability Program: 4F-22

Fail-safe operation
DTC Traction control / Hill hold Fail-safe cancel condition
ABS EBD
Stability control control
• When ESP® control module judges the system to
be normal, after switching ignition from “OFF” to
“ON”.
C1054 (Page
— — — — • When ESP® control module judges the system to
4F-42)
be normal and “Road Test” under “ESP® System
Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
• When ESP® control module judges the system to
be normal, after switching ignition from “OFF” to
“ON”.
C1055 (Page
— — — — • When ESP® control module judges the system to
4F-42)
be normal and “Road Test” under “ESP® System
Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
• When ESP® control module judges the system to
be normal, after switching ignition from “OFF” to
“ON”.
C1056 (Page
— — — — • When ESP® control module judges the system to
4F-42)
be normal and “Road Test” under “ESP® System
Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
C1057 (Page When ESP® control module judges the system to be
— *1 — *1
4F-43) normal.
When ESP® control module judges the system to be
C1061 (Page normal and “Road Test” under “ESP® System
— — —
4F-44) Check” (Page 4F-10) is performed after switching
ignition from “OFF” to “ON”.
C1063 (Page When ESP® control module judges the system to be
— — — —
4F-45) normal, after switching ignition from “OFF” to “ON”.
C1069 (Page When ESP® control module judges the system to be
—
4F-46) normal, after switching ignition from “OFF” to “ON”.
C1071 (Page When ESP® control module judges the system to be
— — — —
4F-47) normal, after switching ignition from “OFF” to “ON”.
C1074 (Page
— — When yaw rate / G sensor calibration is completed.
4F-47)
C1075 (Page When steering angle sensor calibration is
—
4F-47) completed.
C1076 (Page When brake master cylinder pressure sensor
— —
4F-47) calibration is completed.
C1078 (Page
— When yaw rate / G sensor calibration is completed.
4F-47)
C1090 (Page When ESP® control module judges the system to be
— —
4F-48) normal, after switching ignition from “OFF” to “ON”.
C1091 (Page When ESP® control module judges the system to be
— —
4F-49) normal, after switching ignition from “OFF” to “ON”.
C1092 (Page When ESP® control module judges the system to be
— —
4F-49) normal, after switching ignition from “OFF” to “ON”.
C1094 (Page When ESP® control module judges the system to be
—
4F-49) normal, after stopping engine and restarting.
C1099 (Page When ESP® control module judges the system to be
—
4F-50) normal, after switching ignition from “OFF” to “ON”.
4F-23 Electronic Stability Program:

Fail-safe operation
DTC Traction control / Hill hold Fail-safe cancel condition
ABS EBD
Stability control control
U0073 (Page
— —
4F-50)
U0100 (Page
— —
4F-50)
U0101 (Page
— —
4F-50)
U0126 (Page When ESP® control module judges the system to be
—
4F-50) normal, after switching ignition from “OFF” to “ON”.
U0140 (Page
— —
4F-51)
U0155 (Page
4F-51)
U1082 (Page
—
4F-51)

Scan Tool Data

AENJHB0B4604009

NOTE
If communication between SUZUKI scan tool and ESP® control module is not possible, perform the
following checks:
• Check communication condition between PC and VCI using SUZUKI scan tool function.
• Check DLC power circuit and ground circuit.
• Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
• Check CAN communication system. (“Control Module Communication Bus Off” is detected in any
control module.) (Page 10H-17)
• Check ESP® control module power circuit and ground circuit. (Page 4F-51)

Scan tool data Vehicle condition Condition / Reference value

RF Wheel Speed (Page 4F-
25)
LF Wheel Speed (Page 4F-
25)
RR Wheel Speed (Page 4F-
25)
LR Wheel Speed (Page 4F-
25)
G sensor (Page 4F-25)
Battery Voltage (Page 4F-25) Ignition: “ON” (Engine stopped)
Pump Motor Driver (Page
4F-25)
Brake Booster Pressure
Sensor (Page 4F-25)
Master Cyl Press (Page 4F- Brake pedal: Depressed
25)
G Sensor (Lateral) (Page 4F-
25)
At stop (Stationary vehicle) 0 km/h (0 MPH)
At stop (Stationary vehicle) 0 km/h (0 MPH)
At stop (Stationary vehicle) 0 km/h (0 MPH)
At stop (Stationary vehicle) 0 km/h (0 MPH)
Parking (Ignition: “ON”, on level surface) 0 ± 0.1 G
Accelerating 0 ± 0.1 G or more
Decelerating 0 ± 0.1 G or less
10.0 – 14.0 V
Inactive (Pump motor not working) 0.0 V
Active (Pump motor working) 13.0 – 15.0 V
When brake pedal is depressed 3 or more times with
0 kPa
engine stopped.
Engine: Idle speed
60 to 70 kPa
Brake pedal: Released
Engine: Idle speed
50 to 60 kPa
Brake pedal: Fully depressed
Over 0 ± 0.9 MPa
Brake pedal: Released 0 ± 0.9 MPa
Parking (Ignition: “ON”, on level surface) 0 ± 0.1 G
Right turning 0 ± 0.1 G or more
Left turning 0 ± 0.1 G or less
 Electronic Stability Program: 4F-24

Scan tool data Vehicle condition Condition / Reference value

Parking (Ignition: “ON”, on level surface) 0 ± 4 deg/s
Yaw Rate Sensor (Page 4F-
Right turning 0 ± 5 deg/s or more
25)
Left turning 0 ± 5 deg/s or less
Engine Speed (Page 4F-25) Engine: Idle speed with no load after warning up 750 – 850 rpm
Front wheels in straight ahead position 0 ± 3°
Steering Angle Sensor (Page
Rotate steering wheel once clockwise 360° ± 3°
4F-25)
Rotate steering wheel once counterclockwise –360° ± 3°
Hill Hold Control State (Page Hill hold control: Operating ON
4F-25) Other than above condition OFF
Brake pedal: Depressed ON
Brake Switch (Page 4F-25)
Brake pedal: Released OFF
Stability Control (Page 4F- Operating ON
25) Not operating OFF
TCS Control (Brake) (Page Active brake applied to wheel ON
4F-25) Other than above condition OFF
TCS Control (Engine) (Page Engine torque control: Operating ON
4F-25) Other than above condition OFF
ESP® OFF SW State (Page ESP® OFF switch: Released OFF
4F-25) ESP® OFF switch: Pushed ON
Steering Angle Signal (Page Front wheels in straight ahead position (–5° to 5°) Neutral
4F-25) Other than above condition, or not calibrated Not N
Inlet Solenoid RF (Page 4F- Right-front inlet solenoid: Operating ON
25) Other than above condition OFF
Outlet Solenoid RF (Page Right-front outlet solenoid: Operating ON
4F-25) Other than above condition OFF
Inlet Solenoid LF (Page 4F- Left-front inlet solenoid: Operating ON
25) Other than above condition OFF
Outlet Solenoid LF (Page 4F- Left-front outlet solenoid: Operating ON
25) Other than above condition OFF
Inlet Solenoid RR (Page 4F- Right-rear inlet solenoid: Operating ON
25) Other than above condition OFF
Outlet Solenoid RR (Page Right-rear outlet solenoid: Operating ON
4F-25) Other than above condition OFF
Inlet Solenoid LR (Page 4F- Left-rear inlet solenoid: Operating ON
25) Other than above condition OFF
Outlet Solenoid LR (Page Left-rear outlet solenoid: Operating ON
4F-25) Other than above condition OFF
Cut Solenoid No.1 (Page 4F- Active brake applied to left-front or right-rear wheel ON
25) Other than above condition OFF
Cut Solenoid No.2 (Page 4F- Active brake applied to right-front or left-rear wheel ON
25) Other than above condition OFF
Suction Solenoid No.1 (Page Active brake applied to left-front or right-rear wheel ON
4F-25) Other than above condition OFF
Suction Solenoid No.2 (Page Active brake applied to right-front or left-rear wheel ON
4F-25) Other than above condition OFF
Pump Motor Relay (Page 4F- Pump motor: Working ON
25) Other than above condition OFF
Solenoid Valve Relay (Page Ignition “ON” ON
4F-25) Other than above condition OFF
Hill Hold Control (Page 4F- Equipped with hill hold control function With
25) Not equipped with hill hold control function Without
IPC Communication State Equipped with correct steering angle sensor normal
(Page 4F-25) Other than above condition abnormal
4F-25 Electronic Stability Program:
Scan Tool Data Definition
RF Wheel Speed, LF Wheel Speed, RR Wheel Speed
and LR Wheel Speed (km/h / MPH)
Wheel speed is ESP® control module internal parameter.
It is computed by reference pulses from the wheel speed
sensor.
G Sensor (G)
Acceleration and deceleration are measured by yaw rate
/ G sensor in ESP® control module.
Battery Voltage (V)
Battery voltage is an analog input signal read by ESP®
control module. ESP® control module functions may be
stopped if battery voltage falls below or rises above
programmed thresholds.
Pump Motor Driver (V)
This parameter indicates operational condition of pump
motor driver (transistor).
Brake Booster Pressure Sensor (kPa)
This parameter indicates negative pressure value in
brake booster.
Master Cyl Press (MPa)
This indicates brake fluid pressure from brake master
cylinder.
G Sensor (Lateral) (G)
Lateral acceleration is measured by yaw rate / G sensor
in ESP® control module.
Yaw Rate Sensor (Deg/s)
Yaw rate is measured by yaw rate / G sensor in ESP®
control module.
Engine Speed (rpm)
This parameter indicates engine speed sent from ECM
through CAN.
Steering Angle Sensor (°)
Steering wheel rotation angle is measured by steering
angle sensor and output to ESP® control module by CAN
communication signal.
Hill Hold Control State (ON / OFF)
This informs whether hill hold control is operating or not.
Brake Switch (ON / OFF)
These switch signals inform ESP® control module
whether brake pedal is depressed or not.
Stability Control (ON / OFF)
This parameter informs whether active brake is
operating or not when vehicle is oversteering or
understeering.
TCS Control (Brake) (ON / OFF)
This informs whether active brake is operating or not
when vehicle is accelerating.
TCS Control (Engine) (ON / OFF)
This informs whether engine torque control is operating
or not when vehicle is accelerating.
ESP® OFF SW State (ON / OFF)
This indicates state of ESP® OFF switch.
Steering Angle Signal (Neutral / Not N)
This indicates whether steering wheel is in straight
ahead position or not as detected by steering angle
sensor.
Inlet Solenoid RF, Inlet Solenoid LF, Inlet Solenoid
RR and Inlet Solenoid LR (ON / OFF)
This parameter indicates the operational condition of the
inlet solenoid valve.
Outlet Solenoid RF, Outlet Solenoid LF, Outlet
Solenoid RR and Outlet Solenoid LR (ON / OFF)
This parameter indicates the operational condition of the
outlet solenoid valve.
Cut Solenoid No.1 and Cut Solenoid No.2 (ON / OFF)
This parameter indicates the state of the cut solenoid
no.1 and no.2.
Suction Solenoid No.1 and Suction Solenoid No.2
(ON / OFF)
This parameter indicates the state of the suction
solenoid no.1 and no.2.
Pump Motor Relay (ON / OFF)
This parameter indicates the state of the pump motor
relay.
Solenoid Valve Relay (ON / OFF)
ABS control module monitor the voltage to fail safe relay.
If the voltage is supplied, ON is displayed. Beside, OFF
is displayed.
Hill Hold Control (With / Without)
This informs whether vehicle is equipped with hill hold
control function or not.
IPC Communication State (normal / abnormal)
This informs whether steering angle sensor is for ESP®
or not.
 Electronic Stability Program: 4F-26

ESP® Warning Light Does Not Come ON after Setting Ignition “ON”
AENJHB0B4604010
System Description
Operation (ON/OFF) of ESP® warning light is controlled by ESP® control module through light driver module in
combination meter.
If ESP® system is in good condition, ESP® control module turns ON ESP® warning light with ignition “ON”, keeps the
light ON for 2 seconds and then turns it OFF. If traction control and stability control are deactivated by ESP® system
failure, ESP® warning light is turned ON continuously by ESP® control module. Also, the light is turned ON
continuously by light driver module when the connector of ESP® control module connector is disconnected.

Troubleshooting
Step Action Yes No
1 Warning light check Go to Step 2. Go to Step 3.
1) Set ignition “ON”.

Do other indicator lights light up within 2 seconds after

setting ignition “ON”?
2 DTC check Go to troubleshooting Replace combination
1) Check that ignition is “OFF”. for applicable DTC. meter and recheck
warning light operation.
2) Connect scan tool to DLC.
If ESP® warning light
3) Set ignition “ON”. does not come ON,
4) Check DTC related to CAN communication. replace ESP® hydraulic
unit / control module
Is there any CAN-DTC(s) detected? assembly and recheck
warning light operation.
• Combination meter:
(Page 9C-34)
• ESP® hydraulic unit /
control module
assembly: (Page
4F-56)
3 Fuse check Go to Step 4. Replace “MTR” fuse
and check for short
Is “MTR” fuse in good condition? circuit to ground.
4 CAN communication circuit check Go to Step 5. Repair or replace
1) Check CAN communication circuit between ESP ® defective wire harness.
control module and combination meter referring to
“Troubleshooting for Communication Bus Off”: K15B
Model in Section 10H (Page 10H-17).

Is check result OK?

5 Combination meter power supply and ground circuit Replace combination Repair or replace
check meter and recheck defective wire harness.
1) Check combination meter power supply and ground warning light operation.
circuits. (Page 9C-29) If ESP® warning light
does not come ON,
Is check result OK? replace ESP® hydraulic
unit / control module
assembly and recheck
warning light operation.
• Combination meter:
(Page 9C-34)
• ESP® hydraulic unit /
control module
assembly: (Page
4F-56)
4F-27 Electronic Stability Program:

ESP® Warning Light Comes ON Steady

AENJHB0B4604011
System Description
Refer to “System Description” under “ESP® Warning Light Does Not Come ON after Setting Ignition “ON”” (Page 4F-
26).

Troubleshooting
Step Action Yes No
1 ESP® control module connector check Go to Step 2. Connect connector
1) Check for proper connection to ESP® control module securely.
connector.

Is connection in good condition?

2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4F-14). for applicable DTC.

Is there any DTC(s) detected?

3 ESP® control module power supply and ground circuit Go to Step 4. Repair or replace
check defective wire harness.
1) Check ESP® control module power supply and ground
circuits. (Page 4F-51)

Is check result OK?

4 Combination meter check Replace ESP® hydraulic End.
1) Replace combination meter. (Page 9C-34) unit / control module
assembly and recheck
2) Set ignition “ON”.
warning light operation.
Does ESP® warning light stay on? (Page 4F-56)

ABS Warning Light Does Not Come ON after Setting Ignition “ON”
AENJHB0B4604012
System Description
Operation (ON/OFF) of ABS warning light is controlled by ESP® control module through light driver module in
combination meter.
If ESP® system is in good condition, ESP® control module turns ON ABS warning light with ignition “ON”, keeps the
light ON for 2 seconds and then turns it OFF. If ABS control is deactivated by ESP® system failure, ABS warning light
is turned ON continuously by ESP® control module. Also, the light is turned ON continuously by light driver module
when the connector of ESP® control module is disconnected.

Troubleshooting
Step Action Yes No
1 Warning light check Go to Step 2. Go to Step 3.
1) Set ignition “ON”.

Do other indicator lights light up within 2 seconds after

setting ignition “ON”?
 Electronic Stability Program: 4F-28

Step Action Yes No

2 DTC check Go to troubleshooting Replace combination
1) Check that ignition is “OFF”. for applicable DTC. meter and recheck
warning light operation.
2) Connect scan tool to DLC.
If ABS warning light
3) Set ignition “ON”. does not come ON,
4) Check DTC related to CAN communication. replace ESP® hydraulic
unit / control module
Is there any CAN-DTC(s) detected? assembly and recheck
warning light operation.
• Combination meter:
(Page 9C-34)
• ESP® hydraulic unit /
control module
assembly: (Page
4F-56)
3 Fuse check Go to Step 4. Replace “MTR” fuse
and check for short
Is “MTR” fuse in good condition? circuit to ground.
4 CAN communication circuit check Go to Step 5. Repair or replace
1) Check CAN communication circuit between ESP ® defective wire harness.
control module and combination meter referring to
“Troubleshooting for Communication Bus Off”: K15B
Model in Section 10H (Page 10H-17).

Is check result OK?

5 Combination meter power supply and ground circuit Replace combination Repair or replace
check meter and recheck defective wire harness.
1) Check combination meter power supply and ground warning light operation.
circuits. (Page 9C-29) If ABS warning light
does not come ON,
Is check result OK? replace ESP® hydraulic
unit / control module
assembly and recheck
warning light operation.
• Combination meter:
(Page 9C-34)
• ESP® hydraulic unit /
control module
assembly: (Page
4F-56)

ABS Warning Light Comes ON Steady

AENJHB0B4604013
System Description
Refer to “System Description” under “ABS Warning Light Does Not Come ON after Setting Ignition “ON”” (Page 4F-
27).

Troubleshooting
Step Action Yes No
1 ESP® control module connector check Go to Step 2. Connect connector
1) Check for proper connection to ESP® control module securely.
connector.

Is connection in good condition?

4F-29 Electronic Stability Program:

Step Action Yes No

2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4F-14). for applicable DTC.

Is there any DTC(s) detected?

3 ESP® control module power supply and ground circuit Go to Step 4. Repair or replace
check defective wire harness.
1) Check ESP® control module power supply and ground
circuits. (Page 4F-51)

Is check result OK?

4 Combination meter check Replace ESP® hydraulic End.
1) Replace combination meter. (Page 9C-34) unit / control module
assembly and recheck
2) Set ignition “ON”.
warning light operation.
Does ABS warning light stay on? (Page 4F-56)

EBD Warning Light (Brake Warning Light) Does Not Come ON after Setting Ignition “ON”
AENJHB0B4604014
System Description
Refer to “System Description” under “EBD Warning Light (Brake Warning Light) Comes ON Steady” (Page 4F-29).

Troubleshooting
Step
1 Warning light check
1) Set ignition “ON”.
Does ABS warning light stay on?
Action Yes No
Go to “ESP® Warning Replace combination
Light Comes ON meter and recheck
Steady” (Page 4F-27). warning light operation.
If EBD warning light
(brake warning light)
does not come ON,
replace ESP® hydraulic
unit / control module
assembly and recheck
warning light operation.
• Combination meter:
(Page 9C-34)
• ESP® hydraulic unit /
control module
assembly: (Page
4F-56)

EBD Warning Light (Brake Warning Light) Comes ON Steady

AENJHB0B4604015
System Description
EBD warning light (brake warning light) is controlled by ESP® control module and BCM through light driver module in
combination meter.
If ESP® system is in good condition, ESP® control module turns ON EBD warning light (brake warning light) when
ignition is set “ON”, keeps it ON for 2 seconds and then turns it OFF.
EBD warning light (brake warning light) is turned ON continuously in the following conditions.
• EBD control is deactivated by ESP® system failure.
• Parking brake lever is pulled up.
• Brake fluid level is lower than minimum level.
The information of parking brake switch and brake fluid level is transmitted from BCM to light driver module in
combination meter through CAN communication line.
Also, the warning light is turned ON continuously by light driver module when the connector of ESP® control module is
disconnected.
 Electronic Stability Program: 4F-30

Troubleshooting
Step Action Yes No
1 ESP® control module connector check Go to Step 2. Connect connector
1) Check for proper connection to ESP® control module securely.
connector.

Is connection in good condition?

2 Parking brake and brake fluid level check Go to Step 3. Release parking brake
1) Check the following points. and check brake fluid
level. (Page 4A-4)
• Parking brake is completely released.
• Brake fluid level is above minimum level. (Page 4A-
4)

Is check result OK?

3 ABS warning light operation check Perform “ABS Warning Go to Step 4.
1) Set ignition “ON”. Light Comes ON
Steady” (Page 4F-28).
Does ABS warning light stay on?
4 Parking brake switch signal circuit and brake fluid level Go to Step 5. Repair or replace
switch signal circuit check defective part.
1) Check parking brake switch signal circuit and brake fluid
level switch signal circuit. (Page 10B-37)

Is check result OK?

5 CAN communication circuit check Go to “Troubleshooting Go to Step 6.
1) Check that ignition is “OFF”. for Communication Bus
Off”: K15B Model in
2) Connect scan tool to DLC.
Section 10H (Page 10H-
3) Set ignition “ON”. 17).
4) Perform “DTC Check” (Page 4F-14).

Is DTC U0073 detected?

6 DTC check for BCM Go to “Troubleshooting Go to Step 7.
1) Check BCM for DTC. (Page 10B-16) for Communication Bus
Off”: K15B Model in
Is DTC U0073 detected? Section 10H (Page 10H-
17).
7 Combination meter check Replace ESP® hydraulic End.
1) Replace combination meter. (Page 9C-34) unit / control module
assembly and recheck
2) Set ignition “ON”.
warning light operation.
Does EBD warning light stay on? (Page 4F-56)

DTC C1015 / C1017 / C1023

AENJHB0B4604016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1015: Longitudinal G Sensor in Yaw Rate / G Sensor Assembly Failure • ESP® control module
• Longitudinal G sensor signal is out of specified range. • Actuator bracket
• Longitudinal G sensor signal does not change although vehicle is accelerating or
decelerating.
C1017: Lateral G Sensor Circuit Performance
• Lateral G sensor signal is out of specified range.
• Lateral G sensor signal does not change although vehicle is turning right or left.
C1023: Yaw Rate Sensor Circuit Performance
• Yaw rate sensor signal is out of specified range.
• Although vehicle is in a stop, yaw rate sensor signal is more than specified value.
4F-31 Electronic Stability Program:

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 ESP® control module and actuator bracket check Go to Step 3. Repair or replace
®
1) Check ESP hydraulic unit / control module assembly defective parts.
and actuator bracket. (Page 4F-56)

Is check result OK?

3 DTC check Go to troubleshooting Replace ESP® hydraulic
1) Perform “DTC Check” (Page 4F-14). for applicable DTC. unit / control module
assembly and recheck
Is other DTC(s) than C1015, C1017 and C1023 detected? DTC. (Page 4F-56)

DTC C1016
AENJHB0B4604017
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1016: Brake Light Switch Circuit Performance • Brake light switch circuit
• Brake light switch ON signal is detected for more than specified time • Brake light switch
while vehicle speed is more than specified value. • ECM
• Brake light switch ON signal is not detected although brake master • ESP® control module
cylinder pressure sensor signal is more than specified value.
 Electronic Stability Program: 4F-32

Circuit Diagram

12V A1 3
1
PNK A2
YEL E323-24
4
A3
E01-18 LT BLU E323-29
5

E01-28 RED E09-33 7 LT BLU E323-25

6 6
E01-29 WHT E09-30

[A] E09 [a]

[B] E323
24 13

1
26 6 5 4 3 2 1
2 [b]
15 22 21 20 19 18 17 16 15 14 1312 11 10 9 8 7
3
27 16 37 36 35 34 33 32 3130 29 28 27 26 25 24 23
4
28 17
5
29 18
6 [C]
19 C01 E01
7
30 20
8
21
9
31 22 12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
10
32
11 24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
33 23
12 36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25

25 14 48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49

IJHA0A450008-01

[A]: ESP control module connector (View: [a])

® A3: Brake light switch signal circuit 2 5. ESP control module
®

[B]: J/B connector (View: [b]) 1. “STOP” fuse 6. CAN driver

[C]: ECM connector (View: [b]) 2. Brake light switch 7. To brake light
A1: Brake light switch power supply circuit 3. J/B
A2: Brake light switch signal circuit 1 4. ECM

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4F-14). for applicable DTC.

Is DTC U0073 and/or U0100 detected?

4F-33 Electronic Stability Program:

Step Action Yes No

3 Brake light switch power supply circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect brake light switch defective wire harness.
connector.
2) Check for proper terminal connection to brake light
switch connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

4 Brake light switch signal circuit check Go to Step 5. Repair or replace
1) Disconnect negative (–) cable at battery. defective wire harness.
2) Disconnect ECM and “E323” connectors.
3) Check for proper terminal connection to ECM and
“E323” connectors.
4) If connections are OK, check the following points.
• Resistance of “A2” and “A3” circuits: less than 1 Ω
• Resistance between each of “A2” and “A3” circuits
and ground: infinity
• Resistance between each of “A2” and “A3” circuit
terminals and each terminal at “E323” connector:
infinity
• Resistance between each of “A2” and “A3” circuits
and battery positive (+) cable: infinity
• Resistance between each of “A2” and “A3” circuits
and each fuse in J/B: infinity

Is check result OK?

5 Brake light switch check Replace ECM and Replace brake light
1) Check brake light switch. (Page 4A-11) recheck DTC. If DTC switch. (Page 4A-11)
C1016 is still detected,
Is check result OK? replace ESP® hydraulic
unit / control module
assembly and recheck
DTC.
• ECM: (Page 1C-2)
• ESP® hydraulic unit /
control module
assembly: (Page
4F-56)

DTC C101C
AENJHB0B4604018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C101C: Vehicle Variant Data Mismatched • ECM
Mismatch ESP® control module variant and vehicle specification. • Combination meter
• ESP® control module

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
 Electronic Stability Program: 4F-34

Step Action Yes No

2 ECM specification check Go to Step 3. Replace ECM with a
1) Check ECM part number of the vehicle in service. correct one and recheck
DTC. (Page 1C-2)
Is a correct ECM used for the vehicle in service?
3 Combination meter specification check Go to Step 4. Replace combination
1) Check combination meter part number of the vehicle in meter with the correct
service. one and recheck DTC.
(Page 9C-34)
Is a correct combination meter used for the vehicle in
service?
4 ESP® control module specification check Replace ESP® hydraulic Replace ESP® hydraulic
1) Check ESP® control module part number of the vehicle unit / control module unit / control module
in service. assembly and recheck assembly with the
DTC. (Page 4F-56) correct one and recheck
Is a correct ESP® control module used for the vehicle in DTC. (Page 4F-56)
service?

DTC C1020
AENJHB0B4604019
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1020: Master Cylinder Pressure Sensor Power Supply Voltage ESP® control module
Power supply voltage to brake master cylinder pressure sensor in
ESP® control module is out of specified range.

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 DTC check Replace ESP® hydraulic End.
1) Clear DTC. (Page 4F-15) unit / control module
assembly and recheck
2) Set ignition “OFF”.
DTC. (Page 4F-56)
3) Set ignition “ON”.
4) Recheck DTC. (Page 4F-14)

Is DTC C1020 still detected?

DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036

AENJHB0B4604020
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1021 / C1025 / C1031 / C1035: Right-Front / Left-Front / Right-Rear • Wheel speed sensor
/ Left-Rear Wheel Speed Sensor Circuit Voltage • Wheel speed sensor circuit
Wheel speed sensor signal is out of specified range.
• Wheel speed sensor encoder
C1022 / C1026 / C1032 / C1036: Right-Front / Left-Front / Right-Rear
/ Left-Rear Wheel Speed Sensor or Encoder Signal Performance • ESP® control module
Abnormal wheel speed sensor signal is detected continuously.
4F-35 Electronic Stability Program:

NOTE
When vehicle was placed in any of the following conditions, one of these DTCs may be set although
sensor is in good condition. If such possibility is suspected, clear DTC once (Page 4F-15) and check
whether any abnormality exists or not by performing road test as described in Step 3 of “ESP® System
Check” (Page 4F-10).
• Vehicle is driven with parking brake lever pulled.
• Wheel spins while driving.
• Wheel(s) is rotated while vehicle is jacked up.

Circuit Diagram

5
[A] E09
A1
GRN E09-11 [a] 24 13
1
BLK E09-12 1
26
A2 2
15
B1 3
GRN E09-2 27 16
4
2 28 17
GRY E09-1 5
29 18
B2 6
19
C1 7
6 30 20
BRN E09-4 8
3 21
YEL E09-5 9
31 22
C2 10
32
D1 11
33 23
LT BLU E09-9 12
4
PNK E09-8 25 14
D2

IGSB0A460013-01

[A]: ESP® control module connector (View: [a])
A1: Left-front wheel speed sensor power supply circuit
A2: Left-front wheel speed sensor signal circuit
B1: Right-front wheel speed sensor power supply circuit
B2: Right-front wheel speed sensor signal circuit
C1: Left-rear wheel speed sensor power supply circuit 2. Right-front wheel speed sensor
C2: Left-rear wheel speed sensor signal circuit 3. Left-rear wheel speed sensor
D1: Right-rear wheel speed sensor power supply circuit 4. Right-rear wheel speed sensor
D2: Right-rear wheel speed sensor signal circuit 5. ESP® control module
1. Left-front wheel speed sensor 6. Wheel speed sensor driver

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– DTC C1057 is not detected.

1) Set ignition “ON”.

2) Drive vehicle at 20 km/h (12 mile/h) or more for 1 minute or more.
3) Stop vehicle and set ignition “OFF”.
4) Repeat Step 1) – 3) 7 times.
 Electronic Stability Program: 4F-36

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 Tire pressure check Go to Step 3. Adjust tire pressure or
1) Check that tire pressure is at specified value. replace tire and recheck
DTC.
Is check result OK?
3 Wheel speed sensor power supply circuit and signal Go to Step 4. Repair or replace
circuit check defective wire harness.
1) Set ignition “OFF”.
2) Disconnect “E09” and each of wheel speed sensor
connectors.
3) Check for proper terminal connection to “E09” and each
of wheel speed sensor connectors.
4) If connections are OK, check the following points.
• Resistance of “A1”, “A2”, “B1”, “B2”, “C1”, “C2”, “D1”
and “D2” circuits: less than 1 Ω
• Resistance between each of “A1”, “A2”, “B1”, “B2”,
“C1”, “C2”, “D1” and “D2” circuits and ground: infinity
• Resistance between each terminal of “A1” – “A2”, “B1”
– “B2”, “C1” – “C2” and “D1” – “D2” circuits and each
terminal of “E09” connector: infinity
• Voltage of “A1”, “A2”, “B1”, “B2”, “C1”, “C2”, “D1” and
“D2” circuits: approx. 0 V (When ignition is “ON”)

Is check result OK?

4 Wheel speed sensor signal check Replace ESP® hydraulic Go to Step 5.
1) Check applicable wheel speed sensor for output voltage unit / control module
and waveform. (Page 4F-57) assembly and recheck
DTC. (Page 4F-56)
Is check result OK?
5 Wheel speed sensor check Go to Step 6. Clean, repair or replace
1) Check applicable wheel speed sensor. (Page 4F-57) wheel speed sensor.
• Front wheel speed
Is check result OK?
sensor: (Page 4F-
57)
• Rear wheel speed
sensor: (Page 4F-
57)
6 Wheel speed sensor encoder check Replace ESP® hydraulic Clean, repair or replace
1) Check applicable wheel speed sensor encoder. (Page unit / control module wheel speed sensor
4F-58) assembly and recheck encoder.
DTC. (Page 4F-56) • Front wheel speed
Is check result OK? sensor encoder:
(Page 4F-58)
• Rear wheel speed
sensor encoder:
(Page 4F-58)
4F-37 Electronic Stability Program:

DTC C1024
AENJHB0B4604021
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1024: Steering Angle Sensor Circuit Performance • Steering angle sensor
• CPU in steering angle sensor detects internal defect. • ESP® control module
• Steering angle sensor signal is out of specified range.
• Steering angle sensor signal does not change although vehicle is turning right or left.

DTC Troubleshooting

NOTE
Detection of both DTC C1024 and C1075 means internal malfunction of steering angle sensor.
Replace steering angle sensor. (Page 6B-7)

Step Action Yes No

1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4F-14). for applicable DTC.

Is DTC U0073 and/or U0126 detected?

3 Are both DTC C1024 and C1075 detected? Replace steering angle Go to Step 4.
sensor. (Page 6B-7)
4 Steering angle sensor on-vehicle inspection Replace ESP® hydraulic Replace steering angle
1) Check steering angle sensor. (Page 4F-58) unit / control module sensor. (Page 6B-7)
assembly and recheck
Is check result OK? DTC. (Page 4F-56)

DTC C1027
AENJHB0B4604022
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1027: ESP® OFF Switch Circuit Failure • ESP® OFF switch
ESP® OFF switch remains “ON” for more than specified time. • ESP® OFF switch circuit
• ESP® control module

Circuit Diagram

[A] E09
[a]
24 13

1
26
2
15
2 3
27 16
4
12V 28 17
A1 5
1 29 18
6
19
7
BLK WHT E09-7 30 20
8
21
9
31 22
10
32
11
33 23
12

25 14

IGSB0A460014-01

[A]: ESP control module connector (View: [a])

® 1. ESP OFF switch
®

A1: ESP® OFF switch signal circuit 2. ESP® control module

 Electronic Stability Program: 4F-38

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 ESP® OFF switch circuit check Go to Step 3. Repair or replace
1) Check that ignition is “OFF”. defective wire harness.
2) Disconnect “E09” and ESP® OFF switch connectors.
3) Check for proper terminal connection to “E09” and ESP®
OFF switch connectors.
4) If connections are OK, check that resistance between
“A1” circuit and ground is infinity.

Is check result OK?

3 ESP® OFF switch check Replace ESP® hydraulic Replace ESP® OFF
1) Check ESP® OFF switch. (Page 4F-59) unit / control module switch. (Page 4F-59)
assembly and recheck
Is check result OK? DTC. (Page 4F-56)

DTC C1028
AENJHB0B4604023
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1028: Master Cylinder Pressure Sensor Circuit Voltage • Brake system
Brake master cylinder pressure sensor signal is out of specified range. • ESP® control module

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4F-14). for applicable DTC.

Is DTC C1057 detected?

3 Brake master cylinder pressure sensor check Go to Step 4. Replace ESP® hydraulic
1) Check brake master cylinder pressure sensor. (Page unit / control module
4F-58) assembly and recheck
DTC. (Page 4F-56)
Is check result OK?
4 Brake system check Replace ESP® hydraulic Repair, replace or adjust
1) Check the following points. unit / control module brake system.
assembly and recheck
• Leakage of brake fluid or air in the hydraulic brake
DTC. (Page 4F-56)
system.
• Too large front brake pad-to-disc clearance.
• Too large rear brake drum-to-shoe clearance.

Is check result OK?

4F-39 Electronic Stability Program:

DTC C102B
AENJHB0B4604024
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C102B: Brake Booster Pressure Sensor System Malfunction • Brake booster pressure sensor
• Brake booster pressure sensor signal is kept stuck. • Brake booster pressure sensor circuit
• Brake booster pressure sensor signal is out of specified range. • ESP® control module
• Barometric pressure sensor in ECM

Circuit Diagram

[A] E09

[a] 24 13

1
26
2
15
3
27 16
2 4
28 17
5
5V 29 18
1 6
A1 19
7
BLU E09-16 30 20
A2 8
21
GRN E09-15 9
A3 31 22
10
GRY E09-23 32
11
33 23
12

25 14

IGSB0A460015-01

[A]: ESP® control module connector (View: [a]) A2: Brake booster pressure sensor signal circuit 1. Brake booster pressure sensor
A1: Brake booster pressure sensor power supply circuit A3: Brake booster pressure sensor ground circuit 2. ESP® control module

DTC Troubleshooting
Step Action Yes No
1 DTC check for ECM Go to troubleshooting Go to Step 2.
1) Check ECM for DTC. (Page 1A-23) for applicable DTC.

Is DTC P2226 and/or P2227 detected?

2 Was “ESP® System Check” performed? Go to Step 3. Go to “ESP® System
Check” (Page 4F-10).
3 Brake booster pressure sensor power supply circuit Go to Step 5. Go to Step 4.
check
1) With ignition “OFF”, disconnect brake booster pressure
sensor connector.
2) Check for proper terminal connection to brake booster
pressure sensor connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” circuit is
approx. 5 V.

Is check result OK?

4 Brake booster pressure sensor ground circuit check Repair or replace “A3”
1) Check that voltage between “A1” circuit and ground is circuit. If DTC C102B is
approx. 5 V. still detected, replace
ESP® hydraulic unit /
Is check result OK? control module
assembly and recheck
DTC. (Page 4F-56)
Repair or replace “A1”
circuit. If DTC C102B is
still detected, replace
ESP® hydraulic unit /
control module
assembly and recheck
DTC. (Page 4F-56)
 Electronic Stability Program: 4F-40

Step Action Yes No

5 Brake booster pressure sensor signal circuit check Go to Step 6. Repair or replace
1) With ignition “OFF”, disconnect “E09” connector. defective wire harness.
2) Check for proper terminal connection to “E09” connector.
3) If connection is OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at “E09” connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

6 Brake booster pressure sensor check Replace ESP® hydraulic Replace brake booster.
1) Check brake booster pressure sensor. (Page 4A-25) unit / control module (Page 4A-22)
assembly and recheck
Is check result OK? DTC. (Page 4F-56)

DTC C1037
AENJHB0B4604025
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1037: Steering Angle Sensor Power Supply Voltage • Steering angle sensor power supply circuit
Steering angle sensor power supply voltage is out of • Steering angle sensor ground circuit
specified range.
• Steering angle sensor
• CAN communication circuit
• ESP® control module

Circuit Diagram

2
[A] E09
1 A1 7
3 24 13

G37-4 BLU YEL E09-29 1

26
2
5 6 15
3
27 16
RED 4
G37-3 RED RED E09-32 28 17
4 4 4 4 5
G37-2 WHT WHT WHT E09-31 29 18
6
19
7
30 20
8
21
A2 9
[a] 31 22
10
32
G37-1 BLK 11
33 23
12
[B] G37
25 14
1 2 3 4 5

IJHA0A460007-01

[A]: ESP® control module connector (View: [a]) 1. Steering angle sensor 5. Other control module (if equipped)
[B]: Steering angle sensor connector (View: [a]) 2. Ignition power supply 6. BCM
A1: Steering angle sensor power supply circuit 3. “ABS” fuse 7. ESP® control module
A2: Steering angle sensor ground circuit 4. CAN driver
4F-41 Electronic Stability Program:

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2 Go to “ESP® System
Check” (Page 4F-10).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4F-14). for applicable DTC.

Is other DTC(s) than C1037 and C1038 detected?

3 DTC check for BCM Go to troubleshooting Go to Step 4.
1) Check BCM for DTC. (Page 10B-16) for applicable DTC.

Is any of DTC U0073 and/or U0121 detected?

4 Fuse check Go to Step 5. Replace “ABS” fuse and
1) Check “ABS” fuse. check for short circuit to
ground.
Is check result OK?
5 Steering angle sensor power supply circuit check Go to Step 6. Repair or replace “A1”
1) Check that ignition is “OFF”. circuit.
2) Disconnect steering angle sensor connector.
3) Disconnect “E09” connector.
4) Check for proper connection to “A1” circuit.
5) If connection is OK, set ignition “ON”.
6) Measure voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

6 Steering angle sensor ground circuit check Go to Step 7. Repair or replace “A2”
1) Set ignition “ON”. circuit.
2) Check that resistance between “A2” circuit and ground is
less than 1 Ω.

Is check result OK?

7 Steering angle sensor check
1) Connect steering angle sensor connector.
2) Check steering angle sensor. (Page 4F-58)
Is check result OK?
Replace ESP® hydraulic Replace steering angle
unit / control module sensor and recheck
assembly and recheck DTC. (Page 6B-7)
DTC. (Page 4F-56)

DTC C1038
AENJHB0B4604026
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1038: Steering Angle Sensor Detect Rolling Counter Failure • CAN communication circuit
Steering angle sensor detects invalid CAN data from ESP® control module. • Steering angle sensor
• ESP® control module

DTC Confirmation Procedure

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4F-14). for applicable DTC.

Is other DTC(s) than C1038 detected?

 Electronic Stability Program: 4F-42

Step Action Yes No

3 CAN communication circuit check Replace steering angle Repair or replace
1) Check CAN communication circuit between ESP® sensor and recheck defective wire harness.
control module and steering angle sensor referring to DTC. If DTC C1038 is
“Troubleshooting for Communication Bus Off”: K15B still detected, replace
Model in Section 10H (Page 10H-17). ESP® hydraulic unit /
control module
Is check result OK? assembly and recheck
DTC.
• Steering angle
sensor: (Page 6B-
7)
• ESP® hydraulic unit /
control module
assembly: (Page
4F-56)

DTC C1040
AENJHB0B4604027
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1040: ESP® Continuous Operation ESP® control module
Stability control is activated for more than specified time.

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 DTC check Go to troubleshooting Replace ESP® hydraulic
1) Perform “DTC Check” (Page 4F-14). for applicable DTC. unit / control module
assembly and recheck
Is other DTC(s) than C1040 detected? DTC. (Page 4F-56)

DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056
AENJHB0B4604028
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1041 / C1045 / C1051 / C1055: Right-Front / Left-Front / Right-Rear / Left- • ESP® control module power
Rear Inlet Solenoid Valve Circuit Correlation supply circuit
C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left- • ESP® control module ground
Rear Outlet Solenoid Valve Circuit Correlation circuit
C1043 / C1044: Cut Solenoid No.1 / No.2 Valve Circuit Correlation
• ESP® control module
C1053 / C1054: Low Pressure Solenoid No.1 / No.2 Valve Circuit Correlation
Electrical failure of solenoid valve.
4F-43 Electronic Stability Program:

Circuit Diagram

4
2 A1

3
1 RED E09-13
[a]
5V

[A] E09
6
24 13

6 1
26
2
15
6 3
27 16
7 4
6 28 17
5
29 18
6
6 19
7
30 20
8
6 21
9
31 22
10
6 32
11
B1 33 23
6 12
BLK E09-25 25 14

IGSB0A460017-01

[A]: ESP® control module connector (View: [a]) 2. Relay box 6. Solenoid valve
A1: Solenoid valve power supply circuit 3. “ABS SOL” fuse 7. CPU
B1: ESP® control module ground circuit 4. ESP® control module
1. Lead to battery 5. Solenoid valve power supply relay

DTC Troubleshooting
Step Action No Yes
1 Was “ESP® System Check” performed? Go to Step 2.
Go to “ESP® System
Check” (Page 4F-10).
2 Solenoid valve power supply and ESP® control module Replace ESP® hydraulic Repair or replace
ground circuit check unit / control module defective wire harness.
1) Check solenoid valve power supply and ground circuits. assembly and recheck
(Page 4F-51) DTC. (Page 4F-56)

Is check result OK?

DTC C1057
AENJHB0B4604029
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1057: Power Supply Voltage • ESP® control module power supply circuit
• ESP® control module power supply voltage is higher • ESP® control module ground circuit
than specified value. • Charging system
• ESP® control module power supply voltage is lower • ESP® control module
than specified value.
 Electronic Stability Program: 4F-44

Circuit Diagram

[A] E09
[a]
24 13
5 1
2 26
A1 2
3 15
RED E09-13 6 3
A2 27 16
4 4
1 GRN E09-24 7 28 17
5
29 18
6
19
7
30 20
8
21
B1 9
31 22
BLK E09-25 10
32
11
33 23
12

25 14

IGSB0A460019-01

[A]: ESP® control module connector (View: [a]) 1. Lead to battery 5. ESP® control module
A1: Solenoid valve power supply circuit 2. Relay box 6. Lead to solenoid valve power supply relay
A2: Pump motor power supply circuit 3. “ABS SOL” fuse 7. Lead to pump motor relay
B1: ESP® control module ground circuit 4. “ABS MOT” fuse

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 ESP® control module power supply and ground circuit Go to Step 3. Repair or replace
check defective wire harness.
1) Check ESP® control module power supply and ground
circuits. (Page 4F-51)

Is check result OK?

3 ESP® control module power supply voltage check Replace ESP® hydraulic Check charging system.
1) Measure battery voltage with engine running at 3,000 unit / control module (Page 1J-3)
rpm. assembly and recheck
DTC. (Page 4F-56)
Is voltage between 9.8 V and 17.4 V?

DTC C1061
AENJHB0B4604030
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1061: Pump Motor Circuit Performance • ESP® control module (pump motor)
• Pump motor power supply voltage is out of specified range. power supply circuit
®
• When pump motor is activated, a malfunction in pump motor is detected. • ESP control module ground circuit
®
• Power supply from CPU to pump motor and pump motor relay monitor • ESP control module
data disagree.
4F-45 Electronic Stability Program:

Circuit Diagram

1
[A] E09
[a]
A1 24 13
7
6 1
5 GRN E09-24 26
2
15
3
5V 27 16
4
28 17
5
29 18
6
2 19
3 7
30 20
8
21
9
B1 31 22
M 10
32
BLK E09-25 4 11
33 23
12

25 14

IGSB0A460020-01

[A]: ESP® control module connector (View: [a]) 2. CPU 6. “ABS MOT” fuse
A1: Pump motor power supply circuit 3. Pump motor relay 7. Relay box
B1: ESP® control module ground circuit 4. Pump motor
1. ESP® control module 5. Lead to battery

DTC Troubleshooting
Step Action No Yes
1 Was “ESP® System Check” performed? Go to Step 2.
Go to “ESP® System
Check” (Page 4F-10).
2 ESP® control module power supply and ground circuit Replace ESP® hydraulic Repair or replace
check unit / control module defective wire harness.
®
1) Check ESP control module power supply and ground assembly and recheck
circuits. (Page 4F-51) DTC. (Page 4F-56)

Is check result OK?

DTC C1063
AENJHB0B4604031
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1063: Solenoid Valve Power Supply Driver Circuit Performance • ESP® control module power supply circuit
• Solenoid valve power supply relay output is “ON”, although • ESP® control module ground circuit
monitored output is “OFF”. • ESP® control module
• Solenoid valve power supply relay output is “OFF”, although
monitored output is “ON”.
 Electronic Stability Program: 4F-46

Circuit Diagram

4
2 A1

3
1 RED E09-13
[a]
5V

[A] E09
6
24 13

6 1
26
2
15
6 3
27 16
7 4
6 28 17
5
29 18
6
6 19
7
30 20
8
6 21
9
31 22
10
6 32
11
B1 33 23
6 12
BLK E09-25 25 14

IGSB0A460017-01

[A]: ESP® control module connector (View: [a]) 2. Relay box 6. Solenoid valve
A1: Solenoid valve power supply circuit 3. “ABS SOL” fuse 7. CPU
B1: ESP® control module ground circuit 4. ESP® control module
1. Lead to battery 5. Solenoid valve power supply relay

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4F-14). for applicable DTC.

Is DTC C1057 detected?

3 ESP® control module power supply and ground circuit Replace ESP® hydraulic Repair or replace
check unit / control module defective wire harness.
1) Check ESP ® control module power supply and ground assembly and recheck
circuits. (Page 4F-51) DTC. (Page 4F-56)

Is check result OK?

DTC C1069
AENJHB0B4604032
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1069: Steering Angle Sensor Specification Unregistered • ESP® control module
Steering angle sensor detects unconfirmed failure. • Steering angle sensor
4F-47 Electronic Stability Program:

DTC Troubleshooting
Step Action Yes No
1 DTC check Replace ESP® hydraulic End.
1) Replace steering angle sensor. (Page 6B-7) unit / control module
assembly and recheck
2) Perform “DTC Check” (Page 4F-14).
DTC. (Page 4F-56)
Is DTC C1069 detected?

DTC C1071
AENJHB0B4604033
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1071: ESP® Control Module Internal Failure • ESP® control module power supply circuit
ESP® control module internal failure is detected. • ESP® control module ground circuit
• ESP® control module

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 ESP® control module power supply and ground circuit Replace ESP® hydraulic Repair or replace
check unit / control module defective wire harness.
1) Check ESP® control module power supply and ground assembly and recheck
circuits. (Page 4F-51) DTC. (Page 4F-56)

Is check result OK?

DTC C1074 / C1075 / C1076 / C1078

AENJHB0B4604034
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1074: G Sensor Calibration • Yaw rate / G sensor calibration is incomplete
Yaw rate / G sensor calibration is not completed. • ESP® control module
C1075: Steering Angle Sensor Calibration • Steering angle sensor
Steering angle sensor calibration is not completed. • Steering angle sensor calibration is incomplete
• ESP® control module
C1076: Master Cylinder Pressure Sensor Calibration • Brake master cylinder pressure sensor calibration is not
Incomplete completed
Brake master cylinder pressure sensor calibration is not • ESP® control module
completed.
C1078: Lateral G Sensor in Yaw Rate / G Sensor • Yaw rate / G sensor calibration is not completed
Assembly Calibration Incomplete • ESP® control module
Lateral G sensor in yaw rate / G sensor assembly
calibration is not completed.

DTC Confirmation Procedure

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4F-14). for applicable DTC.

Is other DTC(s) than C1074, C1075, C1076 and C1078

detected?
 Electronic Stability Program: 4F-48

Step Action Yes No

3 Sensor calibration • DTC C1074, C1076 End.
1) Calibrate all sensors. (Page 4F-53) and C1078: Replace
ESP® hydraulic unit /
2) Perform “DTC Check” (Page 4F-14).
control module
Is DTC C1074, C1075, C1076 and/or C1078 still detected? assembly and
recheck DTC.
(Page 4F-56)
• DTC C1075: Replace
steering angle sensor
and recheck DTC. If
DTC C1075 is still
detected, replace
ESP® hydraulic unit /
control module
assembly and
recheck DTC.
– Steering angle
sensor: (Page
6B-7)
– ESP® hydraulic
unit / control
module assembly:
(Page 4F-56)

DTC C1090
AENJHB0B4604035
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1090: ECM Detect Rolling Counter Failure From ESP® Control Module • CAN communication circuit
ESP® control module sends invalid CAN data to ECM. • ECM
• ESP® control module

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4F-14). for applicable DTC.

Is other DTC(s) than C1090 detected?

3 DTC check for ECM Go to troubleshooting Go to Step 4.
1) Check ECM for DTC. (Page 1A-23) for applicable DTC.

Is DTC U0073 or U0121 detected?

4 CAN communication circuit check Replace ECM and Repair or replace
1) Check CAN communication circuit between ECM and recheck DTC. If DTC defective wire harness.
ESP® control module referring to “Troubleshooting for C1090 is still detected,
Communication Bus Off”: K15B Model in Section 10H replace ESP® hydraulic
(Page 10H-17). unit / control module
assembly and recheck
Is check result OK? DTC.
• ECM: (Page 1C-2)
• ESP® hydraulic unit /
control module
assembly: (Page
4F-56)
4F-49 Electronic Stability Program:

DTC C1091 / C1094

AENJHB0B4604036
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1091: CAN Invalid Data from ECM • CAN communication circuit
DTC concerned with ECM is detected. • Engine control system
C1094: Torque Request Reject Status
• ECM
ESP® control module receives invalid CAN data from ECM
(about engine torque control). • ESP® control module

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4F-14). for applicable DTC.

Is other DTC(s) than C1091 or C1094 detected?

3 DTC check for ECM Go to troubleshooting Go to Step 4.
1) Check ECM for DTC. (Page 1A-23) for applicable DTC.

Is DTC U0073 or U0121 detected?

4 CAN communication circuit check Replace ECM and Repair or replace
1) Check CAN communication circuit between ECM and recheck DTC. If DTC defective wire harness.
ESP® control module referring to “Troubleshooting for C1091 or C1094 is still
Communication Bus Off”: K15B Model in Section 10H detected, replace ESP®
(Page 10H-17). hydraulic unit / control
module assembly and
Is check result OK? recheck DTC.
• ECM: (Page 1C-2)
• ESP® hydraulic unit /
control module
assembly: (Page
4F-56)

DTC C1092
AENJHB0B4604037
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1092: CAN Invalid Data from TCM • CAN communication circuit
DTC concerned with TCM is detected. • A/T system
• TCM
• ESP® control module

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4F-14). for applicable DTC.

Is other DTC(s) than C1092 detected?

3 DTC check for TCM Go to troubleshooting Go to Step 4.
1) Check TCM for DTC. (Page 5A-17) for applicable DTC.

Is there any DTC(s) detected?

 Electronic Stability Program: 4F-50

Step Action Yes No

4 CAN communication circuit check Replace TCM and Repair or replace
1) Check CAN communication circuit between TCM and recheck DTC. If DTC defective wire harness.
ESP® control module referring to “Troubleshooting for C1092 is still detected,
Communication Bus Off”: K15B Model in Section 10H replace ESP® hydraulic
(Page 10H-17). unit / control module
assembly and recheck
Is check result OK? DTC.
• TCM: (Page 5A-
143)
• ESP® hydraulic unit /
control module
assembly: (Page
4F-56)

DTC C1099
AENJHB0B4604038
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1099: Invalid Data from ENG A-STOP Control Module • CAN communication circuit
DTC concerned with ECM is detected. • ECM
• ESP® control module

DTC Troubleshooting
Step Action Yes No
1 Was “ESP® System Check” performed? Go to Step 2. Go to “ESP® System
Check” (Page 4F-10).
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 4F-14). for applicable DTC.

Is other DTC(s) than C1099 detected?

3 DTC check for ECM Go to troubleshooting Go to Step 4.
1) Check ECM for DTC. (Page 1A-23) for applicable DTC.

Is any DTC(s) detected?

4 CAN communication circuit check Replace ECM and Repair or replace
1) Check CAN communication circuit between ECM and recheck DTC. If DTC defective wire harness.
ESP® control module referring to “Troubleshooting for C1099 is still detected,
Communication Bus Off”: K15B Model in Section 10H replace ESP® hydraulic
(Page 10H-17). unit / control module
assembly and recheck
Is check result OK? DTC.
• ECM: (Page 1C-2)
• ESP® hydraulic unit /
control module
assembly: (Page
4F-56)

DTC U0073 DTC U0101

AENJHB0B4604039 AENJHB0B4604041
Refer to “Troubleshooting for Communication Bus Off”: Refer to “Troubleshooting for Lost Communication”:
K15B Model in Section 10H (Page 10H-17). K15B Model in Section 10H (Page 10H-10).

DTC U0100 DTC U0126

AENJHB0B4604040 AENJHB0B4604042
Refer to “Troubleshooting for Lost Communication”: Refer to “Troubleshooting for Lost Communication”:
K15B Model in Section 10H (Page 10H-10). K15B Model in Section 10H (Page 10H-10).
4F-51 Electronic Stability Program:

DTC U0140 DTC U1082

AENJHB0B4604043 AENJHB0B4604045
Refer to “Troubleshooting for Lost Communication”: Refer to “Troubleshooting for Lost Communication”:
K15B Model in Section 10H (Page 10H-10). K15B Model in Section 10H (Page 10H-10).

DTC U0155
AENJHB0B4604044
Refer to “Troubleshooting for Lost Communication”:
K15B Model in Section 10H (Page 10H-10).

ESP® Control Module Power Supply and Ground Circuit Check

AENJHB0B4604046
Circuit Diagram

[A] E09
[a]
24 13
8 1
3 26
A1 2
4 15
RED E09-13 9 3
A2 27 16
5 4
1 GRN E09-24 10 28 17
5
29 18
6
19
7
6 30 20
8
B1 21
7
2 YEL E09-29 9
31 22
10
32
C1 11
33 23
BLK E09-25 12

25 14

IGSB0A460023-01

[A]: ESP® control module connector (View: [a]) 1. Lead to battery 6. J/B
A1: Solenoid valve power supply circuit 2. Ignition power supply 7. “ABS” fuse
A2: Pump motor power supply circuit 3. Relay box 8. ESP® control module
B1: Ignition power supply circuit 4. “ABS SOL” fuse 9. Lead to solenoid valve power supply relay
C1: ESP® control module ground circuit 5. “ABS MOT” fuse 10. Lead to pump motor relay

Circuit Description
When the ignition is set “ON”, power is supplied to ESP® control module. Then power is supplied to pump motor and
solenoid valve in other line by the switching function in ESP® control module.

Troubleshooting
Step Action Yes No
1 Fuse check Go to Step 2. Replace fuse and check
for short circuit to
Are “ABS SOL” fuse, “ABS MOT” fuse and “ABS” fuse in ground.
good condition?
2 ESP® control module power supply circuit check Go to Step 3. Repair or replace
1) Check that ignition is “OFF”. defective wire harness.
2) Disconnect “E09” and connector.
3) Check for proper terminal connection to “E09” connector.
4) If connection is OK, set ignition “ON”.
5) Check that voltage between “B1” circuit and ground is
battery voltage.

Is check result OK?

 Electronic Stability Program: 4F-52

Step Action Yes No

3 Pump motor and solenoid valve power supply circuit Go to Step 4. Repair or replace
check defective wire harness.
1) Set ignition “OFF”.
2) Check the following points.
• Voltage between “A1” circuit and ground is battery
voltage.
• Voltage between “A2” circuit and ground is battery
voltage.

Is check result OK?

4 ESP® control module ground circuit check ESP® control module Repair or replace
1) Check that ignition is “OFF”. power supply and defective wire harness.
ground circuit are in
2) Check that resistance between “C1” circuit and ground is
good condition.
less than 1 Ω.

Is check result OK?

Repair Instructions
ESP® Hydraulic Unit Operation Check 2) Connect SUZUKI scan tool to DLC (1).
AENJHB0B4606001
NOTE Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
• A false diagnosis may result if operation
check of the ESP® hydraulic unit is
performed without satisfying all of the
specified conditions below.
Check that all the following conditions are
met before performing operation check of
the ESP® hydraulic unit.
– Battery voltage is 12 V or more.
– No air is trapped in the brake system. 1
– Brakes do not drag.
– No DTC is stored in ESP® hydraulic unit /
control module.
• Operation check must be performed by 2
persons.
• DTC C1074, C1075, C1076 and C1078 are
detected, and ESP® warning light and ABS
warning light light up when ESP® hydraulic
unit / control module assembly (hydraulic
unit) is replaced. Perform ESP® hydraulic
unit operation check after sensor
calibration. (Sensor calibration of ESP®) (A)
• Lighting or blinking of warning light stops IJHA0A110021-01
when ignition is set “ON” after completing
3) Hoist vehicle until tire can be rotated.
ESP® hydraulic unit operation check.
4) Set transmission to neutral and release parking
1) Check that ignition is “OFF”. brake.
5) Set ignition “ON”, and select “Depressurization
check” / “Pressurization check” in “Hydraulic control
test” under “Utility” mode of SUZUKI scan tool.
Refer to Operator’s Manual of SUZUKI scan tool for
further details.
4F-53 Electronic Stability Program:
6) Perform the following checks with help of another
person.
• Depressurization check
Step on brake pedal and then select testing wheel
by SUZUKI scan tool and the wheel should be
turned by another person’s hand. At this time,
check whether the wheel rotates freely due to
brake depressurization.
• Pressurization check
Step off brake pedal and then select testing wheel
by SUZUKI scan tool and the wheel should be
turned by another person’s hand. At this time,
check whether the wheel is locked due to brake
pressurization.
NOTE
Pressurization / Depressurization by SUZUKI
scan tool is available for 0.5 seconds.
I8G001460007-01
7) Check all 4 wheels respectively.
8) Check that ABS warning light and ESP® warning
light are turned off after switching ignition from “OFF”
to “ON”. Check for DTC and repair problem if lights
are still lit.
9) If any faulty condition is found in Step 6) – 7), replace
ESP® hydraulic unit /control module assembly.
10) After completing the check, check that ignition is
“OFF” and then disconnect SUZUKI scan tool from
DLC.
Sensor Calibration
AENJHB0B4606002
NOTE
• If any DTC other than C1074, C1075, C1076
and C1078 is detected, repair the cause of
the detected DTC first.
• ESP® hydraulic unit / control module
assembly has reference values for master
cylinder pressure sensor and yaw rate / G
sensor stored. Also steering angle sensor
has its own reference point stored.
Traction control and stability control are
performed according to the variation of
these sensors from their reference points.
If a reference value is lost or shifted due to
the following maintenance, calibration is
needed.
Sensor Condition requiring calibration
• Replacement of steering angle
Steering angle sensor (C1075).
sensor • Replacement of ESP® hydraulic unit
/ control module assembly (C1075).
Master cylinder Replacement of ESP® hydraulic unit /
pressure sensor control module assembly (C1076).
Replacement or removal of ESP®
Yaw rate / G
hydraulic unit / control module
sensor
assembly (C1074 / C1078).
• All sensors are calibrated at once when
calibration is performed.
1) Park vehicle on level surface, apply parking brake,
set steering wheel in straight ahead position, stop
engine and release brake pedal.
NOTE
Keep condition of Step 1) until sensor
calibration is completed, in order to calibrate
sensor correctly.
 Electronic Stability Program: 4F-54

2) Connect SUZUKI scan tool to DLC (1) with ignition

“OFF”.
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)

(A)

IJHA0A110021-01

3) Set ignition “ON” and check that no DTC is detected

except C1074, C1075, C1076 and C1078. If any
DTC is detected, repair or replace trouble area.
4) Select menu “Sensor Calibration” under “Utility”
mode of SUZUKI scan tool and calibrate sensor with
ignition “ON”. Refer to Operator’s Manual of SUZUKI
scan tool for further details.
5) After completing the calibration, check DTC(s) is not
stored in ESP® hydraulic unit / control module
assembly.
6) Check that ignition is “OFF” and then disconnect
SUZUKI scan tool from DLC.
4F-55 Electronic Stability Program:

ESP® Hydraulic Unit / Control Module Assembly Components

AENJHB0B4606003

8 7 6 9

(a)

(a)
1

(b)

(d)

(b)
5

3 (c)

(d)

IJHA0A460008-01

1. ESP® hydraulic unit / control module assembly 6. To Right-front brake : 21 Nm (2.1 kgf-m, 15.5 lbf-ft)
2. Actuator bracket 7. To Left-front brake : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
3. Actuator mount bolt 8. To Right-rear brake : 26 Nm (2.7 kgf-m, 19.5 lbf-ft)
4. To master cylinder primary 9. To Left-rear brake
5. To master cylinder secondary : 16 Nm (1.6 kgf-m, 12.0 lbf-ft)

ESP® Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection
AENJHB0B4606004
• Check ESP® hydraulic unit / control module assembly
(1) for dents, crack, deformation and leakage.
• Check actuator bracket (2) and its mounting surface
for dents, crack and deformation.
• Check actuator mount bolts and actuator bracket nuts
for looseness.
• Check ESP® control module connector (ESP® control
module side and harness side) and its connector lock
mechanism for damage or crack.
• Check connector terminals for bend, corrosion or rust.
Repair or replace defective parts.
1 installation, check specified torque and
2
IJHA0A460009-01
Electronic Stability Program: 4F-56
ESP® Hydraulic Unit / Control Module
Assembly Removal and Installation
AENJHB0B4606005
NOTICE
• Performing the following prohibited
operations will affect the original
performance of ESP® hydraulic unit /
control module assembly.
– Do not disassemble the ESP® hydraulic
unit / control module assembly.
– Do not loosen the blind plug.
– Do not remove the motor.
– Regarding ESP® hydraulic unit / control
module assembly removal and
do not use impact tool.
– Use care not to allow dust to enter ESP®
hydraulic unit / control module.
– Do not place ESP® hydraulic unit /
control module on its side or upside
down.
– Do not give an impact to hydraulic unit.
• Brake fluid is extremely damaging to
painted surfaces. If brake fluid contacts
painted surfaces, immediately wipe it off
and flush the surfaces with water
thoroughly.
• The bracket of the ESP® hydraulic unit /
control module assembly may have some
burrs at the edge and may damage or
deform the bushing, resulting in abnormal
operation of the ESP® system.
Be careful not to scratch bushings with the
burr of the bracket when removing /
installing the ESP® hydraulic unit / control
module assembly from / to the bracket.
Removal
1) Remove battery and battery tray. (Page 1J-5)
2) Disconnect ESP® control module connector (1) by
pulling down the lock lever (2).
2 [a]
IFRA0A450024-02
[a]: Pull down to unlock.
4F-57 Electronic Stability Program:

3) Loosen flare nuts (1) using special tool and Installation

disconnect brake pipes from ESP® hydraulic unit / Reverse removal procedure noting the following points.
control module assembly (2). • Tighten brake pipe flare nuts (1), actuator mount bolt
(2) and actuator bracket nuts (3) (if removed) to
NOTE
specified torque.
Put bleeder plug cap or the like onto pipe to
prevent fluid from spilling. Tightening torque
Brake pipe flare nut (M10) (a): 16 N·m (1.6 kgf-m,
Special tool 12.0 lbf-ft)
(A): 09950M78220 Brake pipe flare nut (M12) (b): 21 N·m (2.1 kgf-m,
15.5 lbf-ft)
4) Remove actuator mount bolt (3). Actuator mount bolt (c): 9.0 N·m (0.92 kgf-m, 7.0
lbf-ft)
1
Actuator bracket nut (d): 26 N·m (2.7 kgf-m, 19.5
(A) lbf-ft)

2 1, (a)

3, (d)

1
1, (b)
3

IJHA0A460011-01 2, (c)
5) Remove ESP® hydraulic unit / control module
assembly from actuator bracket.
3, (d)
6) Remove actuator bracket, if necessary. (Page 4F- IJHA0A460012-01
55) • Bleed brake system. (Page 4A-4)
• Check for leakage of brake fluid and perform ESP®
hydraulic unit operation check. (Page 4F-52)

Front and Rear Wheel Speed Sensor On-Vehicle

Inspection
AENJHB0B4606006
Refer to “Front and Rear Wheel Speed Sensor On-
Vehicle Inspection” in Section 4E (Page 4E-40).

Front Wheel Speed Sensor Removal and

Installation
AENJHB0B4606007
Refer to “Front Wheel Speed Sensor Removal and
Installation” in Section 4E (Page 4E-41).

Rear Wheel Speed Sensor Removal and

Installation
AENJHB0B4606008
Refer to “Rear Wheel Speed Sensor Removal and
Installation” in Section 4E (Page 4E-42).

Front and Rear Wheel Speed Sensor Inspection

AENJHB0B4606009
Refer to “Front and Rear Wheel Speed Sensor
Inspection” in Section 4E (Page 4E-43).

Front Wheel Speed Sensor Encoder Removal
and Installation
AENJHB0B4606010
Refer to “Front Wheel Speed Sensor Encoder Removal
and Installation” in Section 4E (Page 4E-43).
Rear Wheel Speed Sensor Encoder Removal
and Installation
AENJHB0B4606011
Refer to “Rear Wheel Speed Sensor Encoder Removal
and Installation” in Section 4E (Page 4E-43).
Front and Rear Wheel Speed Sensor Encoder
Inspection
AENJHB0B4606012
Refer to “Front and Rear Wheel Speed Sensor Encoder
Inspection” in Section 4E (Page 4E-43).
Brake Master Cylinder Pressure Sensor On-
Vehicle Inspection
AENJHB0B4606013
1) Check basic brake system other than ESP®. (Page
4A-1)
2) Check that ignition is “OFF”.
3) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
1 as specified, replace ESP® hydraulic unit / control
(A)
IJHA0A110021-01
4) Set ignition “ON” and select “Data List” of SUZUKI
scan tool. Refer to Operator’s Manual of SUZUKI
scan tool for further details.
Electronic Stability Program: 4F-58
5) Check “Master Cyl Press” under “Data List” of
SUZUKI scan tool with brake pedal released.
If check result is not as specified, replace ESP®
hydraulic unit / control module assembly.
Master cylinder pressure specification
Brake pedal released: 0 ± 0.9 MPa (0 ± 9.2 kgf/
cm2, 0 ± 131 psi)
6) Hoist vehicle and remove left-side front wheel.
7) Remove bleeder plug from left-side front caliper and
install special tool to left-side front caliper.
Special tool
(A): 09956M02311
(A)
IJHA0A460013-01
8) With brake pedal depressed up to special tool gauge
reading 10 MPa (102.0 kgf/cm2, 1450 psi), check
“Master Cyl Press” under “Data List” of SUZUKI scan
tool.
If check result displayed on SUZUKI scan tool is not
module assembly.
Master cylinder pressure specification
Brake pedal depressed 10 MPa (102.0 kgf/cm2,
1450 psi): 10 ± 1.2 MPa (102.0 ± 12.2 kgf/cm2,
1450 ± 174 psi)
9) After completing the check, set ignition “OFF” and
disconnect SUZUKI scan tool from DLC.
10) Remove special tool, tighten bleeder plug and bleed
brake system. (Page 4A-5)
Tightening torque
Bleeder plug: 8.5 N·m (0.87 kgf-m, 6.5 lbf-ft)
11) Check brake fluid level in master cylinder reservoir.
(Page 4A-4)
Steering Angle Sensor On-Vehicle Inspection
AENJHB0B4606014
Refer to “Steering Angle Sensor On-Vehicle Inspection”
in Section 6B (Page 6B-6).
4F-59 Electronic Stability Program:

Steering Angle Sensor Removal and Installation Installation

AENJHB0B4606015 Reverse removal procedure.
Refer to “Steering Angle Sensor Removal and
Installation” in Section 6B (Page 6B-7).
ESP® OFF Switch Inspection
AENJHB0B4606018
Steering Angle Sensor Inspection Check ESP® OFF switch (1) for continuity between
AENJHB0B4606016 terminals at each switch position.
Refer to “Steering Angle Sensor Inspection” in Section If check result is not as specified, replace ESP® OFF
6B (Page 6B-7). switch.

ESP® OFF Switch Removal and Installation

AENJHB0B4606017 “4” “3”
Removal
1) Remove instrument panel switch bezel. (Page 9C-
37).
2) Disconnect ESP® OFF switch connector.
3) Remove ESP® OFF switch (1) from instrument panel “1” “2”
switch bezel.

5 4 3 2 1

IGSB0A460032-01

Terminal
Switch 1 4
position

OFF

ON

IGSB0A460033-01

IJHB0A460008-01

Specifications
Tightening Torque Specifications
AENJHB0B4607001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Brake pipe flare nut (M10) 16 1.6 12.0 (Page 4F-57)
Brake pipe flare nut (M12) 21 2.1 15.5 (Page 4F-57)
Actuator mount bolt 9.0 0.92 7.0 (Page 4F-57)
Actuator bracket nut 26 2.7 19.5 (Page 4F-57)
Bleeder plug 8.5 0.87 6.5 (Page 4F-58)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“ESP® Hydraulic Unit / Control Module Assembly Components” (Page 4F-55)
“Fasteners Information” in Section 0A (Page 0A-5)
 Electronic Stability Program: 4F-60

Special Tools and Equipment

Special Tool
AENJHB0B4608001
09950M78220 09956M02311
Flare nut wrench (10 x 12 Brake pressure gauge
mm)
(Page 4F-57) (Page 4F-58)

SUZUKI scan tool (Suzuki

SDT-II)
—
(Page 4F-14) /
(Page 4F-15) /
(Page 4F-52) /
(Page 4F-54) /
(Page 4F-58)
4F-61 Electronic Stability Program:

Section 5
Transmission / Transaxle
CONTENTS
Precautions .................................................5-1
Precautions............................................................. 5-1
Precautions for Transmission / Transaxle............. 5-1
Automatic Transmission/Transaxle....... 5A-1
Precautions...........................................................5A-1
Precautions for Diagnosing Trouble.................... 5A-1
Precautions for Disassembly and
Reassembly ...................................................... 5A-1
General Description .............................................5A-2
A/T Description ................................................... 5A-2
Description of Clutch / Brake / Planetary Gear
Functions .......................................................... 5A-5
Operation Table of A/T Component .................... 5A-6
Electronic Shift Control System Input / Output
Table ................................................................. 5A-8
A/T Diagnosis General Description ..................... 5A-8
OBD System Description .................................... 5A-8
Schematic and Routing Diagram......................5A-10
Electronic Shift Control System Input / Output
Diagram .......................................................... 5A-10
Electronic Shift Control System Circuit
Diagram .......................................................... 5A-11
Component Location .........................................5A-13
Electronic Shift Control System Component
Location .......................................................... 5A-13
Diagnostic Information and Procedures..........5A-15
A/T Control System Check................................ 5A-15
MIL Check ......................................................... 5A-17
Transmission Warning Light Check .................. 5A-17
DTC Check ....................................................... 5A-17
DTC Clearance ................................................. 5A-18
DTC Table......................................................... 5A-19
Fail-Safe Table.................................................. 5A-22
Scan Tool Data ................................................. 5A-29
Visual Inspection ............................................... 5A-33
A/T Basic Check ............................................... 5A-34
Road Test ......................................................... 5A-34
Manual Road Test............................................. 5A-40
Engine Brake Test ............................................ 5A-41
Stall Test ........................................................... 5A-41
Time Lag Test ................................................... 5A-42
Line Pressure Test ............................................ 5A-44
P Range Test .................................................... 5A-47
Table of Contents 5- i
A/T Symptom Diagnosis....................................5A-48
MIL Does Not Come ON with Ignition “ON”
and Engine Stopped (but Engine Can Be
Started) ...........................................................5A-49
MIL Remains ON after Engine Starts................5A-49
Transmission Warning Light Does Not Come
ON with Ignition ON ........................................5A-49
Transmission Warning Light Remains ON
with Ignition ON...............................................5A-49
DTC P0562 / P0563 / P1742 / P1743 ...............5A-49
DTC P0602 .......................................................5A-51
DTC P0604 / P062F / P1702 ............................5A-51
DTC P0705 .......................................................5A-52
DTC P0707 .......................................................5A-53
5
DTC P0711 .......................................................5A-55
DTC P0712 .......................................................5A-57
DTC P0713 .......................................................5A-58
DTC P0717 .......................................................5A-60
DTC P0722 .......................................................5A-61
DTC P072A .......................................................5A-63
DTC P0731 .......................................................5A-65
DTC P0741 .......................................................5A-67
DTC P0742 .......................................................5A-69
DTC P0746 / P0747 ..........................................5A-70
DTC P0751 .......................................................5A-73
DTC P0776 .......................................................5A-74
DTC P0777 .......................................................5A-76
DTC P0796 / P0797 ..........................................5A-78
DTC P0961 .......................................................5A-81
DTC P0962 .......................................................5A-82
DTC P0963 .......................................................5A-84
DTC P0965 .......................................................5A-85
DTC P0966 .......................................................5A-87
DTC P0967 .......................................................5A-88
DTC P0969 .......................................................5A-90
DTC P0970 .......................................................5A-91
DTC P0971 .......................................................5A-93
DTC P0973 .......................................................5A-94
DTC P0974 .......................................................5A-95
DTC P1706 .......................................................5A-97
DTC P1736 .......................................................5A-98
DTC P1737 .......................................................5A-99
DTC P1738 .....................................................5A-100
DTC P1739 .....................................................5A-101
DTC P2762 .....................................................5A-103
5-ii Table of Contents
DTC P2763 ..................................................... 5A-104
DTC P2764 ..................................................... 5A-106
DTC P2797 ..................................................... 5A-107
DTC P2798 / P2799 ........................................ 5A-108
DTC U0073 ..................................................... 5A-110
DTC U0100 ..................................................... 5A-110
DTC U0121 ..................................................... 5A-110
DTC U1082 ..................................................... 5A-110
Inspection of TCM and Its Circuits .................. 5A-110
TCM Power and Ground Circuit Check........... 5A-115
Repair Instructions ..........................................5A-116
TCM Learning Value Clearance...................... 5A-116
TCM Learning Value Initialization ................... 5A-116
ATF Level Check............................................. 5A-117
ATF Change.................................................... 5A-119
Select Lever Assembly Components .............. 5A-120
Select Lever Assembly Removal and
Installation ..................................................... 5A-121
Select Lever Assembly Disassembly and
Reassembly .................................................. 5A-121
Select Lever Assembly Inspection .................. 5A-126
O/D Off Switch Inspection ............................... 5A-126
Shift Lock Solenoid Inspection ........................ 5A-126
P Position Switch Inspection (Keyless Push
Start Model) .................................................. 5A-127
Manual Release of Shift Lock ......................... 5A-127
Select Cable Components .............................. 5A-128
Select Cable Removal and Installation ........... 5A-129
Select Cable Adjustment................................. 5A-130
Transmission Range Sensor Removal and
Installation ..................................................... 5A-130
Transmission Range Sensor Inspection and
Adjustment .................................................... 5A-131
Key Interlock Cable Removal and Installation
(Ignition Switch Model).................................. 5A-132
Key Interlock Cable Inspection (Ignition
Switch Model) ............................................... 5A-134
Output Shaft Speed Sensor Removal and
Installation ..................................................... 5A-134
Output Shaft Speed Sensor Inspection........... 5A-134
Input Shaft Speed Sensor Removal and
Installation ..................................................... 5A-135
Input Shaft Speed Sensor Inspection.............. 5A-135
A/T Oil Strainer Assembly Removal and
Installation ..................................................... 5A-136
A/T Oil Pan and Oil Strainer Assembly
Inspection...................................................... 5A-137
ATF Temperature Sensor Removal and
Installation ..................................................... 5A-137
ATF Temperature Sensor Inspection .............. 5A-138
Valve Body Assembly Removal and
Installation ..................................................... 5A-138
Solenoid Valve On-Vehicle Inspection ............ 5A-141
Solenoid Valve Inspection............................... 5A-142
TCM Removal and Installation ........................ 5A-143
Differential Side Oil Seal Replacement ........... 5A-144
ATF Cooler Hose Components ....................... 5A-145
ATF Cooler Hose Inspection ........................... 5A-145
ATF Cooler Hose Replacement ...................... 5A-146
A/T Assembly Components............................. 5A-146
A/T Assembly Dismounting and Remounting..5A-149
A/T Assembly Disassembly.............................5A-151
Oil Pump Assembly Components ...................5A-158
Oil Pump Assembly Disassembly and
Reassembly ..................................................5A-158
Oil Pump Assembly Inspection .......................5A-159
Direct Clutch Assembly Components..............5A-160
Direct Clutch Assembly Preliminary Check .....5A-161
Direct Clutch Assembly Disassembly and
Reassembly ..................................................5A-161
Direct Clutch Assembly Inspection..................5A-163
Forward and Reverse Clutch Assembly
Components..................................................5A-164
Forward and Reverse Clutch Assembly
Preliminary Check .........................................5A-164
Forward and Reverse Clutch Assembly
Disassembly and Reassembly ......................5A-165
Forward and Reverse Clutch Assembly
Inspection......................................................5A-168
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Components...........5A-169
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Disassembly and
Reassembly ..................................................5A-169
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Inspection...............5A-171
Countershaft Assembly Components..............5A-171
Countershaft Assembly Disassembly and
Reassembly ..................................................5A-171
Differential Assembly Components .................5A-173
Differential Assembly Disassembly and
Reassembly ..................................................5A-173
Differential Assembly Inspection .....................5A-175
Torque Converter Housing Disassembly and
Reassembly ..................................................5A-175
Transaxle Case Disassembly and
Reassembly ..................................................5A-177
A/T Assembly Inspection and Adjustment.......5A-179
A/T Assembly Reassembly .............................5A-182
Specifications ...................................................5A-195
Tightening Torque Specifications....................5A-195
Special Tools and Equipment .........................5A-196
Recommended Service Material .....................5A-196
Special Tool ....................................................5A-196
Manual Transmission/Transaxle ............ 5B-1
K15B Model..............................................................5B-1
General Description .............................................5B-1
Manual Transaxle Construction ..........................5B-1
Diagnostic Information and Procedures ............5B-5
Manual Transaxle Symptom Diagnosis...............5B-5
Repair Instructions ..............................................5B-8
Manual Transaxle Oil Level Check .....................5B-8
Manual Transaxle Oil Change.............................5B-8
Differential Side Oil Seal Replacement ...............5B-9
Gear Shift Control Lever and Cable
Components....................................................5B-10
Gear Shift Control Lever and Cable Removal
and Installation ................................................5B-11

Gear Select Control Cable Adjustment ............. 5B-13
Back Up Light Switch Removal and
Installation ....................................................... 5B-13
Back Up Light Switch Inspection....................... 5B-14
Neutral Position Switch Inspection.................... 5B-14
Manual Transaxle Unit Components................. 5B-15
Manual Transaxle Unit Dismounting and
Remounting..................................................... 5B-15
Gear Shift and Select Shaft Assembly
Components.................................................... 5B-17
Gear Shift and Select Shaft Assembly
Removal and Installation................................. 5B-17
Manual Transaxle Assembly Components........ 5B-19
5th Gear Disassembly and Reassembly ........... 5B-20
Manual Transaxle Assembly Disassembly
and Reassembly ............................................. 5B-24
Transaxle Right Case Disassembly and
Reassembly .................................................... 5B-28
Transaxle Left Case Disassembly and
Reassembly .................................................... 5B-30
Input Shaft and Countershaft Components....... 5B-32
Input Shaft Disassembly and Reassembly........ 5B-33
Countershaft Disassembly and Reassembly .... 5B-35
Gear Shift Shaft Components ........................... 5B-39
Gear Shift Shaft and Fork Inspection ................ 5B-39
Differential Components ................................... 5B-40
Differential Disassembly and Reassembly........ 5B-40
Specifications.....................................................5B-43
Tightening Torque Specifications...................... 5B-43
Special Tools and Equipment ...........................5B-43
Recommended Service Material ....................... 5B-43
Special Tool ...................................................... 5B-43
D13A Model............................................................5B-47
General Description ...........................................5B-47
Manual Transaxle Construction ........................ 5B-47
Diagnostic Information and Procedures..........5B-50
Manual Transaxle Symptom Diagnosis............. 5B-50
Repair Instructions ............................................5B-52
Manual Transaxle Oil Level Check ................... 5B-52
Manual Transaxle Oil Change .......................... 5B-53
Differential Side Oil Seal Replacement ............. 5B-54
Gear Shift Control Lever and Cable
Components.................................................... 5B-55
Gear Shift Control Lever and Cable Removal
and Installation ................................................ 5B-56
Gear Select Control Cable Adjustment ............. 5B-56
Back Up Light Switch Removal and
Installation ....................................................... 5B-56
Back Up Light Switch Inspection....................... 5B-56
Neutral Position Switch Inspection.................... 5B-56
Manual Transaxle Unit Components................. 5B-57
Manual Transaxle Unit Dismounting and
Remounting..................................................... 5B-58
Gear Shift and Select Shaft Assembly
Components.................................................... 5B-59
Gear Shift and Select Shaft Assembly
Removal and Installation................................. 5B-60
Table of Contents 5-iii
Manual Transaxle Assembly Components........5B-62
Fifth Gear Disassembly and Reassembly .........5B-63
Manual Transaxle Assembly Disassembly
and Reassembly .............................................5B-67
Transaxle Right Case Disassembly and
Reassembly ....................................................5B-71
Transaxle Left Case Disassembly and
Reassembly ....................................................5B-72
Input Shaft and Countershaft Components.......5B-74
Input Shaft Disassembly and Reassembly........5B-74
Countershaft Disassembly and Reassembly ....5B-77
Gear Shift Shaft Components ...........................5B-80
Gear Shift Shaft and Fork Inspection ................5B-80
Differential Components....................................5B-80
Differential Disassembly and Reassembly........5B-80
Specifications .....................................................5B-80
Tightening Torque Specifications......................5B-80
Special Tools and Equipment ...........................5B-81
Recommended Service Material .......................5B-81
Special Tool ......................................................5B-81
Clutch ....................................................... 5C-1
General Description .............................................5C-1
Clutch Construction.............................................5C-1
Diagnostic Information and Procedures ............5C-2
Clutch System Symptom Diagnosis ....................5C-2
Repair Instructions ..............................................5C-3
CPP No.1 Switch Removal and Installation ........5C-3
CPP No.1 Switch Inspection and Adjustment .....5C-3
CPP No.2 Switch Removal and Installation ........5C-4
CPP No.2 Switch Inspection and Adjustment .....5C-4
Clutch Pedal Inspection ......................................5C-5
Clutch Fluid Level Inspection ..............................5C-5
Air Bleeding of Clutch System.............................5C-5
Clutch Fluid Pipe and Hose Components ...........5C-6
Clutch Fluid Pipe Removal and Installation.........5C-7
Clutch Fluid Pipe and Hose Inspection ...............5C-7
Clutch Master Cylinder Removal and
Installation .........................................................5C-7
Clutch Master Cylinder Inspection ......................5C-8
Clutch Operating Cylinder Assembly
Removal and Installation...................................5C-8
Clutch Operating Cylinder Assembly
Inspection..........................................................5C-8
Clutch Pedal Assembly Components..................5C-9
Clutch Pedal Assembly Removal and
Installation .......................................................5C-10
Clutch Cover and Clutch Disc Components......5C-10
Clutch Cover and Clutch Disc Removal and
Installation .......................................................5C-11
Clutch Cover and Clutch Disc Inspection..........5C-12
Specifications .....................................................5C-12
Tightening Torque Specifications......................5C-12
Special Tools and Equipment ...........................5C-12
Recommended Service Material .......................5C-12
Special Tool ......................................................5C-13
5-1 Precautions:

Precautions
Transmission / Transaxle

Precautions
Precautions for Transmission / Transaxle
AENJHB0B5000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Caution for Fastener

Refer to “Caution for Fastener” in Section 00 (Page 00-5).

Warning for Air Bag

Refer to “Warning for Air Bag” in Section 00 (Page 00-7).

Reassembling Note for Wiring Harness

Observe “Reassembling Note for Wiring Harness” in Section 9A (Page 9A-142) whenever installing wiring harness.
Otherwise, electrical trouble may occur.
 Automatic Transmission/Transaxle: 5A-1

Automatic Transmission/Transaxle
Transmission / Transaxle

Precautions
Precautions for Diagnosing Trouble
AENJHB0B5100001
• Diagnostic information stored in TCM memory can be cleared as well as checked using SUZUKI scan tool or CAN
communication OBD generic scan tool. Before using scan tool, read its Operator’s Manual to know how to use it.
• When replacing TCM with used one, all learned values which are stored in TCM memory should be erased after
installation of used TCM referring to “TCM Learning Value Initialization” (Page 5A-116). Neglecting this initialization
may cause excessive shift shock.
• Read “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3) before inspection, and understand well
what is written there.
• TCM replacement
– When substituting a known-good TCM, check that all actuators have resistance of specified value.
Neglecting this check may result in damage to the known-good TCM.
• Communication of TCM and other control module is established by CAN. (For more detail of CAN communication
for TCM, refer to “CAN Communication System Diagnosis General Description”: K15B Model in Section 10H (Page
10H-3).) Therefore, handle CAN communication line with care referring to “Precautions for Electrical Circuit
Service” in Section 00 (Page 00-3).

Precautions for Disassembly and Reassembly

AENJHB0B5100002
When repairing Automatic Transaxle (A/T), it is necessary to conduct the on-vehicle test to investigate where the
cause of the trouble lies first.
Then whether overhaul should be done or not is determined. If the transaxle is disassembled without such preliminary
procedure, not only the cause of the trouble would be unknown, but also a secondary trouble may occur and
unexpectedly longer time would be wasted.
As the A/T consists of high precision component, the following cautions should be strictly observed when handling its
parts in disassembly and reassembly.
• Disassembly of valve body assembly is prohibited. Otherwise, disassembly will spoil its original performance.
• When component part of forward clutch, direct clutch and/or O/D and 2nd coast brake, namely clutch disc, brake
disc, retaining plate and/or separator plate have been replaced, all learned contents which have been stored in
TCM memory by executing learning control should be initialized. (Page 5A-116)
• Wash dirt off from the transaxle so that no such dirt will enter the transaxle during dismounting and remounting.
• When overhauling, select a clean place free from dust and dirt.
• Place a rubber mat on a workbench to protect parts from damage.
• When wiping internal parts of A/T, use lint-free paper, not cloth or rags.
• When separating the case joint, do not pry with a flat-bladed screwdriver or the like but tap with a plastic hammer
lightly.
• Wash the disassembled parts in ATF or kerosene (using care not to allow ATF or kerosene to get on your face etc.)
and check that each fluid passage is not clogged by blowing air into it. But use kerosene to wash the discs, resin
parts and rubber parts.
• Replace each gasket, oil seal and O-ring with a new one.
• Apply ATF to sliding or rotating parts before reassembly.
• Keep component parts in group for each subassembly and avoid mixing them up.
• Clean all parts with cleaning solvent thoroughly and air-dry them.
• Keep face and eyes away from solvent spray while air blowing parts.
• Check mating surface for irregularities and remove them, if any, and clean it again.
• Apply ATF to all O-rings.
• When installing seal ring, be careful so that it is not expanded excessively, extruded or caught.
• Replace oil seals that are removed and apply grease to their lips.
• Always use torque wrench when tightening bolts.
• A new disc should be soaked in ATF at least 2 hours before use.
5A-2 Automatic Transmission/Transaxle:

General Description
A/T Description
AENJHB0B5101001
This transaxle is electronic control full automatic transaxle with forward 3-speed plus overdrive (O/D) and reverse 1-
speed.
The torque converter is of a 3-element, 1-step and 2-phase type and is equipped with an automatically controlled lock-
up mechanism.
The gear change device consists of a Ravigneaux type planetary gear unit, 3 multiple-disc type clutches, 2 multiple-
disc type brakes and 1 one-way clutch.
The hydraulic pressure control device consists of a valve body assembly, 3 pressure control solenoid valves (linear
solenoid), shift solenoid valve, TCC solenoid valve (linear solenoid) and electro magnetic oil pump solenoid valve.
Employing the Ravigneaux type planetary gear unit and this clutch-to-clutch control system greatly simplifies the
construction to make possible a lightweight and compact transaxle.
A line pressure learning control is conducted to provide optimum shifting time at every upshifting with engine throttle
opened. If long upshifting time is detected, the subsequent line pressure applied during upshifting is intensified. On the
contrary, if short upshifting time is detected, the subsequent line pressure applied during upshifting is weakened.
Lock up control:
When the vehicle speed exceeds the specified value, the TCC solenoid valve fully engages the TCC upon receiving
control signal from TCM. This control helps to improve the power transaxle efficiency.
Slip controlled lock-up function:
Even at a lower speed than when the TCC is completely engaged, control over the TCC solenoid valve causes the
TCC to slip (to be engaged slightly) improving power transmission efficiency. While such slip control is being executed,
the fluid pressure applied to the TCC is controlled by the TCC solenoid valve so that the difference between the engine
speed and the input shaft speed becomes close to the specified value.
Also, during deceleration, the TCC is made to slip (be engaged slightly) to raise the engine speed and enlarge the fuel
cut operation range so that fuel consumption is reduced.
Due to this reason, it is absolutely necessary for the A/T to use ATF suitable for slip control. Use of any fluid other than
the specified ATF may cause juddering or other faulty condition to occur.
Reverse control:
In the reverse control, if the shift lever is shifted to R range while the vehicle is running forward, the TCM prevents
shifting to reverse to protect internal A/T parts from becoming damaged.
Slope shift control:
TCM distinguishes uphill according to the vehicle speed and accelerator position, and limits the gear to shift up.
 Automatic Transmission/Transaxle: 5A-3

Garage shift control:

The garage shift control controls gear shifting to D or R range from N range while the vehicle is at a standhill. The line
pressure applied to forward clutch or the reverse clutch is adjusted to reduce shift shock.

ICL80C510001-01

1. Drive plate 10. Output shaft speed sensor 19. Forward clutch (C1)
2. Torque converter clutch (TCC) 11. Reduction drive gear 20. Reverse clutch (C3)
3. Torque converter 12. Planetary carrier 21. Rear planetary sun gear
4. Input shaft 13. 1st and reverse brake (B3) 22. Front planetary sun gear
5. Oil pump 14. Planetary ring gear 23. Short planetary pinion gear
6. Direct clutch drum (doubles as sensor rotor 15. Long planetary pinion gear 24. Countershaft
for input shaft speed sensor)
7. Direct clutch (C2) 16. One-way clutch No.2 (F2) 25. Reduction driven gear
8. Input shaft speed sensor 17. O/D and 2nd coast brake (B1) 26. Differential case assembly
9. Parking lock gear 18. Intermediate shaft 27. Final gear
5A-4 Automatic Transmission/Transaxle:

Specifications
Item Specifications
3-element, 1-step, 2-phase type (with TCC (lock-up)
Type
Torque converter mechanism)
Stall torque ratio 1.85 to 2.05
Type Internal involute gear type oil pump (non crescent type)
Oil pump
Drive system Engine driven
Type Forward 4-step, reverse 1-step planetary gear type
P range Gear in neutral, output shaft fixed, engine start
R range Reverse
N range Gear in neutral, engine start
D range Forward 1st ↔ 2nd ↔ 3rd ↔ 4th automatic gear
(O/D ON) change
Shift position D range Forward 1st ↔ 2nd ↔ 3rd ← 4th automatic gear
(O/D OFF) change
Forward 1st ↔ 2nd ← 3rd ← 4th automatic gear
2 range
change
Gear change Forward 1st ← 2nd ← 3rd ← 4th reduction, and
L range
device fixed at 1st gear
1st 2.875 Front planetary sun gear: 24
2nd 1.568 Rear planetary sun gear: 30
Gear Number of
3rd 1.000 Long planetary pinion gear: 20
ratio teeth
4th (overdrive gear) 0.697 Short planetary pinion gear: 19
Reverse (reverse gear) 2.300 Planetary ring gear: 69
Wet type multiple-disc clutch... 3 sets
Control elements Wet type multiple-disc brake... 2 sets
One-way clutch... 1 set
Reduction gear ratio 1.023
Final gear reduction ratio 4.278
Lubrication Lubrication system Force feed system by oil pump
Cooling Cooling system Radiator assisted cooling (water-cooled)
Fluid used SUZUKI AT OIL AW-1
 Automatic Transmission/Transaxle: 5A-5

Description of Clutch / Brake / Planetary Gear Functions

AENJHB0B5101002

7
9
8
2 4 6 10 11

15
3 12 13 14

16

17

ICL80C510002-01

1. Input shaft and intermediate shaft 7. 1st and reverse brake (B3) 13. Front planetary sun gear
2. Direct clutch (C2) 8. One-way clutch No.2 (F2) 14. Rear planetary sun gear
3. Reduction drive gear 9. O/D and 2nd coast brake (B1) 15. Final drive gear
4. Planetary carrier 10. Reverse clutch (C3) 16. Reduction driven gear
5. Short planetary pinion gear 11. Forward clutch (C1) 17. Final driven gear
6. Long planetary pinion gear 12. Planetary ring gear

Functions
Part name Function
Forward clutch (C1) Meshes intermediate shaft and front planetary sun gear
Direct clutch (C2) Meshes input shaft and planetary carrier
Reverse clutch (C3) Meshes intermediate shaft and rear planetary sun gear
O/D and 2nd coast brake (B1) Fixes rear planetary sun gear
1st and reverse brake (B3) Fixes planetary carrier
One-way clutch No.2 (F2) Prevents planetary carrier from turning counterclockwise
5A-6 Automatic Transmission/Transaxle:

Operation Table of A/T Component

AENJHB0B5101003
Part
Selector Gear O/D and 1st and One-way
Forward Direct Reverse Condition
position position 2nd coast reverse clutch
clutch (C1) clutch (C2) clutch (C3)
brake (B1) brake (B3) No.2 (F2)
P Parking × × × × × ×
When vehicle is
traveling forwards at
× × × ×
9 km/h (6 mile/h) or
less
R Reverse
When vehicle is
traveling forwards at
× × × × ×
more than 9 km/h (6
mile/h)
N Neutral × × × × × ×
1st × × × ×
2nd × × × ×
2nd↔3rd ×→ × →× × ×
D
3rd × × × ×
3rd↔4th →× × ×→ × ×
4th × × × ×
1st × × × ×
2
2nd × × × ×
L 1st × × ×

: Applied
×: Release
 Automatic Transmission/Transaxle: 5A-7

Operation Table of Shift Solenoid Valve, Pressure Control Solenoid Valve and TCC Solenoid Valve
Solenoid valve
Pressure Pressure Pressure
Selector Gear TCC Shift
control control control Condition
position position solenoid solenoid
solenoid solenoid solenoid
valve valve “A”
valve “A” valve “B” valve “C”
P Parking × ×
When vehicle is traveling forwards
× ×
at 9 km/h (6 mile/h) or less
R Reverse
When vehicle is traveling forwards
×
at more than 9 km/h (6 mile/h)
N Neutral × ×
When vehicle is traveling forwards
( ) × ×
at 12 km/h (8 mile/h) or less
1st
When vehicle is traveling forwards
( ) × × ×
at more than 12 km/h (8 mile/h)
When vehicle is Lock-up
( )
traveling forwards at ON
12 km/h (8 mile/h) or Lock-up
( ) ×
less OFF
2nd
When vehicle is Lock-up
( ) ×
traveling forwards at ON
D
more than 12 km/h (8 Lock-up
( ) × ×
mile/h) OFF
( ) → →× × Lock-up ON
2nd↔3rd
( ) → →× × × Lock-up OFF
( ) × × Lock-up ON
3rd
( ) × × × Lock-up OFF
→ ( ) ×→ × Lock-up ON
3rd↔4th
→ ( ) ×→ × × Lock-up OFF
( ) × Lock-up ON
4th
( ) × × Lock-up OFF
When vehicle is traveling forwards
( ) × ×
at 12 km/h (8 mile/h) or less
1st
When vehicle is traveling forwards
( ) × × ×
at more than 12 km/h (8 mile/h)
When vehicle is Lock-up
( )
traveling forwards at ON
2
12 km/h (8 mile/h) or Lock-up
( ) ×
less OFF
2nd
When vehicle is Lock-up
( ) ×
traveling forwards at ON
more than 12 km/h (8 Lock-up
( ) × ×
mile/h) OFF
L 1st ( ) ×

: ON (Power ON)
×: OFF (Power OFF)
: Controlled
: Controlled (line pressure)
Valve status
Operates Does not operate
Pressure control solenoid valve “A” Close Open
Pressure control solenoid valve “B” Close Open
Pressure control solenoid valve “C” Open Close
TCC solenoid valve Open Close
Shift solenoid valve “A” Open Close
Electro magnetic oil pump solenoid valve Open Close
5A-8 Automatic Transmission/Transaxle:
Electronic Shift Control System Input / Output Table
A/T Diagnosis General Description
AENJHB0B5101005
This vehicle is equipped with TCM which controls the
automatic shift up and shift down timing, TCC operation,
etc. suitably to vehicle driving conditions.
TCM has an OBD system which detects a malfunction in
this system.
When diagnosing a trouble in transaxle including this
system, have full understanding of the outline of “OBD
System Description” (Page 5A-8) and each item in
“Precautions for Diagnosing Trouble” (Page 5A-1) and
execute diagnosis according to “A/T Control System
Check” (Page 5A-15) to obtain correct result smoothly.
AENJHB0B5101004
IJHB0A510027-01
OBD System Description
AENJHB0B5101006
For A/T control system, TCM has the following functions.
• When ignition is “ON” with no malfunction in A/T
control system detected, transmission warning light
(1) lights for about 2 seconds and then goes OFF for
bulb check.
• When TCM detects a malfunction in A/T control
system, it indicates transmission warning light and
stores DTC in its memory.
TCM detects a malfunction which gives an adverse
effect to vehicle emission in A/T control system while
the engine is running, TCM requires ECM to make the
MIL (2) turn ON.
• TCM stores the malfunction area (DTC according to
SAE J2012) in TCM memory. (If it judges that the
system is normal for 3 driving cycles continuously
warning light turn OFF although DTC stored in its
memory will remain.)
 Automatic Transmission/Transaxle: 5A-9

• It is possible to communicate with vehicle through

DLC (3) using not only SUZUKI scan tool (4) but also
CAN communication OBD generic scan tool which are
in compliance with SAE J1978. (Diagnostic
information can be accessed using a scan tool.)

2 1

IJHB0A510001-01

• For information about the following items, refer to

“OBD System Description”: K15B in Section 1A (Page
1A-1).
– Warm-up cycle
– Driving cycle
– 3 driving cycle detection logic
– Pending DTC
– Freeze frame data
5A-10 Automatic Transmission/Transaxle:

Schematic and Routing Diagram

Electronic Shift Control System Input / Output Diagram
AENJHB0B5102001

Electro magnetic oil pump solenoid

valve

ABS / ESP® control module

ABS / ESP® control module

ECM

CAN communincation

IJHB0A510002-01
 Automatic Transmission/Transaxle: 5A-11

Electronic Shift Control System Circuit Diagram

AENJHB0B5102002

12V 19
5V
20
2
WHT E15-16 E14-11 LT GRN
BLK E15-6 E14-12 BEG
12V
12V
21
3
PPL E15-14 E14-16 BRN
GRY E15-5 12V
22
E14-22 RED
4
E14-9 BLK
P
PNK E15-20 12V
23
5 R
BRN E15-1 E14-21 YEL
YEL E14-19 BLU
N 6 12V
BEG E15-8 24
D E14-4 GRY
BLU E15-7
E14-2 PPL
2 12V
PPL E15-19 25
L E14-5 LT BLU
LT GRN E15-18
E14-3 GRN
12V
26
E14-15 PNK
12V
7 E14-10 WHT
8
YEL E15-21

[B] 9
PPL 11

10 27
11 E14-6 WHT
WHT
BLK 28
30
29 31
E14-24 BLU

[A]
IG2
WHT E14-7 32
15 [B] IG1 33
RED E14-17
12 ST 34
WHT
14

12 15 4 35
RED P
13 BLK GRN
N
12V
YEL 38
37
16 17
36
18
E14-1 BLK
WHT
15
RED E14-23 BLK

IJHB0A510003-01
5A-12 Automatic Transmission/Transaxle:

[A]: Ignition switch model 13. Combination meter 27. “T/M” fuse
[B]: Keyless push start model 14. DLC 28. J/B
1. TCM 15. CAN driver 29. “IG1 SIG2” fuse
2. Input shaft speed sensor 16. MIL 30. “IG11” relay
3. Output shaft speed sensor 17. Transmission warning light 31. “IGN” fuse
4. Transmission range sensor 18. Meter driver 32. Ignition switch
5. To ignition power supply 19. A/T 33. “KEY” fuse
6. Back-up light 20. ATF temperature sensor 34. “KEY2” fuse
7. Select lever 21. Shift solenoid valve “A” 35. Starting motor control relay
8. O/D off switch 22. Pressure control solenoid valve “A” 36. Starting motor
9. P position switch 23. Pressure control solenoid valve “B” 37. “ST” fuse
10. Shift lock solenoid 24. Pressure control solenoid valve “C” 38. Main fuse box
11. To BCM 25. TCC solenoid valve
12. BCM 26. Electro magnetic oil pump solenoid valve

Terminal Arrangement of TCM Connector (Viewed from Harness Side)

NOTE
For circuit name and terminal voltage, refer to “Inspection of TCM and Its Circuits” (Page 5A-110).

[A]
E14 E15
[a]
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
IGRA0A511004-01

[A]: TCM connector (View: [a])

 Automatic Transmission/Transaxle: 5A-13

Component Location
Electronic Shift Control System Component Location
AENJHB0B5103001
5A-14 Automatic Transmission/Transaxle:

5
4 6

9
11
8
7
12

13
10

12
14

17
16
18
19
15

21

20
IJHB0A510004-01
 Automatic Transmission/Transaxle: 5A-15

1. Solenoid connector
2. Input shaft speed sensor
3. Output shaft speed sensor
4. Transmission range sensor
5. Shift solenoid “A”
6. TCC solenoid valve
7. Pressure control solenoid valve “A”
8. Pressure control solenoid valve “B” 15. Select lever
9. Pressure control solenoid valve “C” 16. TCM
10. Electro magnetic oil pump solenoid valve 17. BCM
11. ATF temperature sensor 18. O/D off switch
12. Combination meter 19. Shift lock release button
13. Transmission warning light 20. Shift lock solenoid
14. MIL 21. P position switch (keyless push start model)

Diagnostic Information and Procedures

A/T Control System Check
AENJHB0B5104001
Refer to the following items for the details of each step.
Step Action Yes No
1 Customer complaint analysis Go to Step 2. Perform customer
1) Perform customer complaint analysis. (Page 5A-16) complaint analysis.

Was customer complaint analysis performed?

2 DTC / freeze frame data check, record and clear Print DTC and freeze Go to Step 4.
1) Check for DTC (current and pending DTC). (Page 5A- frame data or write them
16) down and clear them
referring to “DTC
Is there any DTC(s)? Clearance” (Page 5A-
18), and go to Step 3.
3 Visual inspection Repair or replace faulty Go to Step 5.
1) Perform visual inspection. (Page 5A-16) part, and go to Step 11.

Is there any faulty condition?

4 Visual inspection Repair or replace faulty Go to Step 8.
1) Perform visual inspection. (Page 5A-16) part, and go to Step 11.

Is there any faulty condition?

5 Trouble symptom confirmation Go to Step 6. Go to Step 7.
1) Check trouble symptom. (Page 5A-17)

Is trouble symptom identified?

6 Recheck and record DTC / freeze frame data Go to Step 9. Go to Step 8.
1) Recheck for DTC (current and pending DTC) and freeze
frame data. (Page 5A-17)

Is there any DTC(s)?

7 Recheck and record DTC / freeze frame data Go to Step 9. Go to Step 10.
1) Recheck for DTC (current and pending DTC) and freeze
frame data. (Page 5A-17)

Is there any DTC(s)?

8 A/T basic check and A/T symptom diagnosis Check and repair faulty Go to Step 10.
1) Perform A/T basic check and A/T symptom diagnosis. part(s), and go to Step
(Page 5A-17) 11.

Is there any faulty condition?

9 Troubleshooting for DTC Go to Step 11. Check and repair faulty
1) Perform troubleshooting for applicable DTC. (Page part(s), and go to Step
5A-17) 11.

Are check and repair complete?

10 Intermittent problem check Repair or replace faulty Go to Step 11.
1) Check for intermittent problems. (Page 5A-17) part(s), and go to Step
11.
Is there any faulty condition?
5A-16 Automatic Transmission/Transaxle:

Step Action Yes No

11 Final confirmation test Go to Step 6. End.
1) Perform final confirmation test. (Page 5A-17)

Is there any problem symptom, DTC or abnormal condition?

Step 1: Customer Complaint Analysis

Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such an inspection form will facilitate collecting information required for proper analysis and
diagnosis.
Customer questionnaire form (Example)

I8C50B510014-01

Step 2: DTC / Freeze Frame Data Check, Record and
Clearance
First, check DTC (current and pending DTC). If DTC is
indicated, print DTC and freeze frame data or write them
down and then clear them. (Page 5A-18)
Steps 3 and 4: Visual Inspection
As a preliminary step, perform visual check of the items
that support proper function of engine and A/T. (Page
5A-33)
 Automatic Transmission/Transaxle: 5A-17

Step 5: Trouble Symptom Confirmation Transmission Warning Light Check

In case that there is no DTC at Step 2:
Based on information obtained in “Step 1: Customer
Complaint Analysis” (Page 5A-16) and “Step 2: DTC /
Freeze Frame Data Check, Record and Clearance”
(Page 5A-16), check trouble symptoms.
In case that there is any DTC at Step 2:
Recheck DTC according to “DTC Confirmation
Procedure” described in each DTC troubleshooting.
AENJHB0B5104003
1) Set ignition “ON”.
2) Check that transmission warning light (1) lights for
about 2 sec. and then goes OFF. If anything faulty is
found, refer to “Transmission Warning Light Does
Not Come ON with Ignition ON” (Page 5A-49) or
“Transmission Warning Light Remains ON with
Ignition ON” (Page 5A-49).

Steps 6 and 7: Rechecking and Record of DTC and

Freeze Frame Data
Refer to “DTC Check” (Page 5A-17) for checking 1
procedure.

Step 8: A/T Basic Check and A/T Symptom

Diagnosis
1) Perform A/T basic check. (Page 5A-34)
2) In case there is no faulty part found in inspection
procedure of “A/T Basic Check”, perform “A/T
Symptom Diagnosis” (Page 5A-48) based on IJHB0A510005-01
symptom found in vehicle checking in the following
items.
DTC Check
• Customer complaint analysis AENJHB0B5104004
NOTE
• Trouble symptom confirmation
In case that MIL turns on, the malfunction(s)
Step 9: Troubleshooting for DTC is detected in either ECM or TCM and it
Perform applicable DTC troubleshooting and repair or stores the trouble information (DTC, freeze
replace faulty parts. frame data, etc.) in its memory.

Step 10: Intermittent Problem Check 1) Set ignition “OFF”.

In case that there is no DTC at Step 2:
Check for intermittent problem. (Page 00-12)
In case that there is any DTC at Step 2:
Check parts related to detected DTC (e.g. wire harness,
connector, etc.). (Page 00-12)
Step 11: Final Confirmation Test
Check that the problem symptom has gone and the
vehicle is free from any abnormal conditions. If what has
been repaired is related to DTC, clear DTC once,
perform DTC confirmation procedure and check that no
DTC is indicated.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Read DTC, pending DTC and freeze frame data
according to instructions displayed on SUZUKI scan
tool and print them or write them down. Refer to
Operator's Manual of SUZUKI scan tool for further
details.

MIL Check
AENJHB0B5104002
Refer to “MIL Check”: K15B in Section 1A (Page 1A-23).
5A-18 Automatic Transmission/Transaxle:

NOTE DTC Clearance

If communication between SUZUKI scan tool
and TCM is not possible, perform the
following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-17)
• Check TCM power circuit and ground
circuit. (Page 5A-110)
1
AENJHB0B5104005
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Clear DTC and pending DTC according to
instructions displayed on SUZUKI scan tool. Refer to
Operator's Manual of SUZUKI scan tool for further
details.
NOTE
If communication between SUZUKI scan tool
and TCM is not possible, perform the
following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.) (Page
10H-17)
• Check TCM power circuit and ground
circuit. (Page 5A-110)

(A) 1

IJHA0A110011-01

(A)

IJHA0A110011-01
 Automatic Transmission/Transaxle: 5A-19

DTC Table
AENJHB0B5104006
NOTE
• DTC with in the following table cannot be read with CAN communication OBD-II generic scan
tool.
• For details of D/C (driving cycle), refer to “OBD System Description”: K15B in Section 1A (Page 1A-
1).

DTC
Transmission
DTC DTC name DTC detecting condition detection MIL
warning light
logic
P0562 Main power supply circuit voltage is
(Page System Voltage Low lower than specified value for 20 1 D/C Lights up Lights up
5A-49) sec.
P0563 Main power supply circuit voltage is
(Page System Voltage High higher than specified value for 20 1 D/C Lights up Lights up
5A-49) sec.
P0602
Control Module TCM internal failure (data
(Page — Off Off
Programming Error programming error).
5A-51)
P0604 Internal Control Module
(Page Random Access Memory TCM internal failure (RAM error). 1 D/C Lights up Lights up
5A-51) (RAM) Error
P062F
Internal Control Module TCM internal failure (EEPROM
(Page 1 D/C Lights up Lights up
EEPROM Error error).
5A-51)
P0705 Transmission Range
Multiple signals are input
(Page Sensor “A” Circuit (PRNDL 1 D/C Lights up Lights up
simultaneously for 4 sec.
5A-52) Input)
P0707
Transmission Range No sensor signal is input for 28
(Page 2 D/C Lights up Lights up
Sensor “A” Circuit Low sec.
5A-53)
Transmission Fluid ATF temperature sensor signal
P0711
Temperature Sensor “A” circuit voltage is unchanged for 600
(Page 2 D/C Lights up Lights up
Circuit Range / sec., after drive vehicle at 40 km/h
5A-55)
Performance (25 mile/h).
P0712 Transmission Fluid ATF temperature sensor signal
(Page Temperature Sensor “A” circuit voltage is lower than 2 D/C Lights up Lights up
5A-57) Circuit Low specified value for 5 sec.
P0713 Transmission Fluid ATF temperature sensor signal
(Page Temperature Sensor “A” circuit voltage is higher than 2 D/C Lights up Lights up
5A-58) Circuit High specified value for 5 sec.
P0717 Input shaft speed sensor signal is
Input / Turbine Speed
(Page not input even if output shaft speed 1 D/C Lights up Lights up
Sensor “A” Circuit No Signal
5A-60) sensor signal is input.
P0722 Output shaft speed sensor signal is
Output Speed Sensor
(Page not input even if input shaft speed 1 D/C Lights up Lights up
Circuit No Signal
5A-61) sensor signal is input.
Difference between engine speed
and input shaft speed is less than
P072A
specified value, and the gear
(Page Stuck in Neutral 1 D/C Lights up Lights up
commanded by TCM does not
5A-63)
match the actual gear when
driving.
P0731 The gear commanded by TCM
(Page Gear 1 Incorrect Ratio does not match the actual gear 2 D/C Lights up Off
5A-65) when driving.
5A-20 Automatic Transmission/Transaxle:

DTC
Transmission
DTC DTC name DTC detecting condition detection MIL
warning light
logic
Difference between engine speed
P0741 Torque Converter Clutch
and input shaft speed is more than
(Page Circuit Performance / Stuck 2 D/C Lights up Lights up
specified value even if TCC
5A-67) Off
solenoid valve is turned on.
Difference between engine speed
P0742
Torque Converter Clutch and input shaft speed is less than
(Page 2 D/C Lights up Off
Circuit Stuck On specified value even if TCC
5A-69)
solenoid valve is turned off.
P0746 The gear commanded by TCM
Pressure Control Solenoid
(Page does not match the actual gear 2 D/C Lights up Lights up
“A” Performance / Stuck Off
5A-70) when driving.
P0747 The gear commanded by TCM
Pressure Control Solenoid
(Page does not match the actual gear 2 D/C Lights up Lights up
“A” Stuck On
5A-70) when driving.
P0751 The gear commanded by TCM
Shift Solenoid “A”
(Page does not match the actual gear 2 D/C Lights up Off
Performance / Stuck Off
5A-73) when driving.
P0776 The gear commanded by TCM
Pressure Control Solenoid
(Page does not match the actual gear 2 D/C Lights up Lights up
“B” Performance / Stuck Off
5A-74) when driving.
P0777 The gear commanded by TCM
Pressure Control Solenoid
(Page does not match the actual gear 2 D/C Lights up Lights up
“B” Stuck On
5A-76) when driving.
P0796 The gear commanded by TCM
Pressure Control Solenoid
(Page does not match the actual gear 2 D/C Lights up Lights up
“C” Performance / Stuck Off
5A-78) when driving.
P0797 The gear commanded by TCM
Pressure Control Solenoid
(Page does not match the actual gear 2 D/C Lights up Lights up
“C” Stuck On
5A-78) when driving.
Difference between target electric
P0961 Pressure Control Solenoid current and measured current of
(Page “A” Control Circuit Range / pressure control solenoid valve “A” 1 D/C Lights up Lights up
5A-81) Performance drive circuit (+) is more than
specified value for 3 sec.
Measured electric current of
P0962
Pressure Control Solenoid pressure control solenoid valve “A”
(Page 1 D/C Lights up Lights up
“A” Control Circuit Low drive circuit (+) is lower than
5A-82)
specified value.
Measured electric current of
P0963
Pressure Control Solenoid pressure control solenoid valve “A”
(Page 1 D/C Lights up Lights up
“A” Control Circuit High drive circuit (+) is higher than
5A-84)
specified value.
Difference between target electric
P0965 Pressure Control Solenoid current and measured current of
(Page “B” Control Circuit Range / pressure control solenoid valve “B” 1 D/C Lights up Lights up
5A-85) Performance drive circuit (+) is more than
specified value for 3 sec.
Measured electric current of
P0966
Pressure Control Solenoid pressure control solenoid valve “B”
(Page 1 D/C Lights up Lights up
“B” Control Circuit Low drive circuit (+) is lower than
5A-87)
specified value.
Measured electric current of
P0967
Pressure Control Solenoid pressure control solenoid valve “B”
(Page 1 D/C Lights up Lights up
“B” Control Circuit High drive circuit (+) is higher than
5A-88)
specified value.
 Automatic Transmission/Transaxle: 5A-21

DTC
Transmission
DTC DTC name DTC detecting condition detection MIL
warning light
logic
Difference between target electric
P0969 Pressure Control Solenoid current and measured current of
(Page “C” Control Circuit Range / pressure control solenoid valve “C” 1 D/C Lights up Lights up
5A-90) Performance drive circuit (+) is more than
specified value for 3 sec.
Measured electric current of
P0970
Pressure Control Solenoid pressure control solenoid valve “C”
(Page 1 D/C Lights up Lights up
“C” Control Circuit Low drive circuit (+) is higher than
5A-91)
specified value.
Measured electric current of
P0971
Pressure Control Solenoid pressure control solenoid valve “C”
(Page 1 D/C Lights up Lights up
“C” Control Circuit High drive circuit (+) is lower than
5A-93)
specified value.
Shift solenoid valve “A” drive circuit
P0973
Shift Solenoid “A” Control voltage is lower than specified
(Page 1 D/C Lights up Lights up
Circuit Low value even if shift solenoid valve
5A-94)
“A” is turned on.
Shift solenoid valve “A” drive circuit
P0974
Shift Solenoid “A” Control voltage is higher than specified
(Page 1 D/C Lights up Lights up
Circuit High value even if shift solenoid valve
5A-95)
“A” is turned off.
P1702
Internal Control Module TCM internal failure (check sum
(Page 1 D/C Lights up Lights up
Memory Check Sum Error error).
5A-51)
P1706 Torque Request ECM detects abnormality of CAN
(Page Communication Error from communication data which TCM 1 D/C Off Off
5A-97) TCM transmits.
P1736 Output shaft speed sensor signal
Output Speed Sensor
(Page circuit voltage is lower than 1 D/C Lights up Lights up
Circuit Low
5A-98) specified value.
P1737 Output shaft speed sensor signal
Output Speed Sensor
(Page circuit voltage is higher than 1 D/C Lights up Lights up
Circuit High
5A-99) specified value.
P1738 Input shaft speed sensor signal
Input / Turbine Speed
(Page circuit voltage is lower than 1 D/C Lights up Lights up
Sensor “A” Circuit Low
5A-100) specified value.
P1739 Input shaft speed sensor signal
Input / Turbine Speed
(Page circuit voltage is higher than 1 D/C Lights up Lights up
Sensor “A” Circuit High
5A-101) specified value.
P1742
Auxiliary Transmission Fluid Main power supply circuit voltage is
(Page 1 D/C Lights up Off
Pump Supply Voltage Low lower than 9 V for 5 sec.
5A-49)
P1743
Auxiliary Transmission Fluid Main power supply circuit voltage is
(Page 1 D/C Lights up Off
Pump Supply Voltage High higher than 16 V for 5 sec.
5A-49)
Difference between target electric
Torque Converter Clutch
P2762 current and measured current of
Pressure Control Solenoid
(Page TCC solenoid valve drive circuit (+) 1 D/C Lights up Lights up
Control Circuit Range /
5A-103) is more than specified value for 3
Performance
sec.
P2763 Torque Converter Clutch Measured electric current of TCC
(Page Pressure Control Solenoid solenoid valve drive circuit (+) is 1 D/C Lights up Lights up
5A-104) Control Circuit High higher than specified value.
P2764 Torque Converter Clutch Measured electric current of TCC
(Page Pressure Control Solenoid solenoid valve drive circuit (+) is 1 D/C Lights up Lights up
5A-106) Control Circuit Low lower than specified value.
5A-22 Automatic Transmission/Transaxle:

DTC
Transmission
DTC DTC name DTC detecting condition detection MIL
warning light
logic
This DTC is detected if the
following conditions are met.
• Difference between input shaft
P2797 speed and output shaft speed is
Auxiliary Transmission Fluid
(Page more than 350 rpm. 2 D/C Lights up Off
Pump Performance
5A-107) • Difference between engine
speed and input shaft speed is
less than 1,000 rpm.
• P0731 is not detected.
P2798 Electro magnetic oil pump solenoid
Auxiliary Transmission Fluid
(Page valve drive circuit is shorted to 1 D/C Lights up Off
Pump Control Circuit Low
5A-108) ground.
P2799 Electro magnetic oil pump solenoid
Auxiliary Transmission Fluid
(Page valve drive circuit is open or 1 D/C Lights up Off
Pump Control Circuit High
5A-108) shorted to power supply.
U0073
Control Module
(Page 1 D/C Lights up Lights up
Communication Bus Off
5A-110)
U0100
Lost Communication With Refer to “CAN DTC (Lost
(Page 1 D/C Lights up Lights up
ECM Communication and
5A-110)
Communication Bus Off) Table”:
U0121
Lost Communication With K15B Model in Section 10H (Page
(Page 1 D/C Lights up Off
ABS / ESP® Control Module 10H-7).
5A-110)
U1082 Lost Communication With
(Page ENG A-STOP Control 1 D/C Lights up Off
5A-110) Module

Fail-Safe Table
AENJHB0B5104007
This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sensor or
its circuit fails. The following table shows the fail-safe function for each fail condition of sensor, solenoid or its circuit.
DTC DTC name Fail-safe operation
• Torque limitation is activated.
• Gear shifts to 3rd.
• Gear remains in R range when the failure occurs in R range.
• Reverse control is disabled.
P0562 • TCM stops the following control / function.
(Page 5A- System Voltage Low – Slip controlled lock-up function
49) – Lock-up function
– Learning control
– Garage shift control
– Slope shift control
– Engine auto stop and start control
 Automatic Transmission/Transaxle: 5A-23

DTC DTC name Fail-safe operation

P0563 • Torque limitation is activated
(Page 5A- System Voltage High • Remains in gear when the failure occurs, shifts to 2nd after
49) the vehicle has stopped.
• Gear remains in R range when the failure occurs in R range.
• TCM stops the following control / function.
P0604 – Slip controlled lock-up function
Internal Control Module Random
(Page 5A- – Lock-up function
Access Memory (RAM) Error
51)
– Learning control
– Garage shift control
– Slope shift control
P062F
(Page 5A- Internal Control Module EEPROM Error TCM controls with default value.
51)
• Selected range is set in priority order shown below.
D> 2> L> R> N> P
• Torque limitation is activated.
• Remains in gear when the failure occurs, shifts to 2nd after
the vehicle has stopped.
P0705
Transmission Range Sensor “A” Circuit • Gear remains in R range when the failure occurs in R range.
(Page 5A- • TCM stops the following control / function.
(PRNDL Input)
52)
– Slip controlled lock-up function
– Lock-up function
– Learning control
– Garage shift control
– Slope shift control
• TCM controls actuators assuming that selected range is D
range.
• Torque limitation is activated.
• Remains in gear when the failure occurs, shifts to 2nd after
the vehicle has stopped.
P0707 • Gear remains in R range when the failure occurs in R range.
Transmission Range Sensor “A” Circuit
(Page 5A- • TCM stops the following control / function.
Low
53)
– Slip controlled lock-up function
– Lock-up function
– Learning control
– Garage shift control
– Slope shift control
P0711
Transmission Fluid Temperature Sensor
(Page 5A- • TCM controls actuators assuming that ATF temperature is
“A” Circuit Range / Performance
55) 80 °C (176 °F).
P0712 • TCM stops the following control / function.
Transmission Fluid Temperature Sensor
(Page 5A-
“A” Circuit Low – Slip controlled lock-up function
57)
P0713 – Learning control
Transmission Fluid Temperature Sensor
(Page 5A- – Engine auto stop and start control
“A” Circuit High
58)
5A-24 Automatic Transmission/Transaxle:

DTC DTC name Fail-safe operation

• Torque limitation is activated.
• Remains in gear when the failure occurs, shifts to 2nd after
the vehicle has stopped.
• Gear remains in R range when the failure occurs in R range.
• TCM calculates input shaft speed by output shaft speed
sensor.
P0717
Input / Turbine Speed Sensor “A” Circuit • TCM stops the following control / function.
(Page 5A-
No Signal
60) – Slip controlled lock-up function
– Lock-up function
– Learning control
– Garage shift control
– Slope shift control
– Engine auto stop and start control
• Torque limitation is activated.
• Remains in gear when the failure occurs, shifts to 4th after
the vehicle has stopped.
• TCM calculates vehicle speed by input shaft speed sensor.
• TCM stops the following control / function.
P0722 – Slip controlled lock-up function
(Page 5A- Output Speed Sensor Circuit No Signal
– Lock-up function
61)
– Learning control
– Garage shift control
– Slope shift control
– Reverse control
– Engine auto stop and start control
• TCM stops the following control / function.
P072A – Slip controlled lock-up function
(Page 5A- Stuck in Neutral – Lock-up function
63) – Slope shift control
– Gear shifting
P0731 • TCM stops the following control / function.
(Page 5A- Gear 1 Incorrect Ratio – Learning control
65) – Slope shift control
• TCM stops the following control / function.
P0741 – Slip controlled lock-up function
Torque Converter Clutch Circuit
(Page 5A-
Performance / Stuck Off – Lock-up function
67)
– Learning control
• Torque limitation is activated in R range.
P0742 • TCM stops the following control / function.
Torque Converter Clutch Circuit Stuck
(Page 5A- – Learning control
On
69) – Slope shift control
– Engine auto stop and start control
 Automatic Transmission/Transaxle: 5A-25

DTC DTC name Fail-safe operation

• Torque limitation is activated.
• Remains in gear when the failure occurs, shifts to 2nd or 4th
after the vehicle has stopped.
P0746 • TCM stops the following control / function.
Pressure Control Solenoid “A”
(Page 5A- – Slip controlled lock-up function
Performance / Stuck Off
70) – Lock-up function
– Learning control
– Garage shift control
– Slope shift control
• Torque limitation is activated.
• Remains in gear when the failure occurs, shifts to 2nd after
the vehicle has stopped.
• TCM stops the following control / function.
P0747 – Slip controlled lock-up function
(Page 5A- Pressure Control Solenoid “A” Stuck On – Lock-up function
70) – Learning control
– Garage shift control
– Slope shift control
– Multiplex shifting
– Engine auto stop and start control
• During L range, shifts to 2nd.
P0751
Shift Solenoid “A” Performance / Stuck • TCM stops the following control / function.
(Page 5A-
Off – Learning control
73)
– Slope shift control
• Torque limitation is activated.
• Remains in gear when the failure occurs, shifts to 2nd after
the vehicle has stopped.
P0776 • TCM stops the following control / function.
Pressure Control Solenoid “B”
(Page 5A- – Slip controlled lock-up function
Performance / Stuck Off
74) – Lock-up function
– Learning control
– Garage shift control
– Slope shift control
• Torque limitation is activated.
• Remains in gear when the failure occurs, shifts to 3rd after
the vehicle has stopped.
• TCM stops the following control / function.
P0777 – Slip controlled lock-up function
(Page 5A- Pressure Control Solenoid “B” Stuck On – Lock-up function
76) – Learning control
– Garage shift control
– Slope shift control
– Multiplex shifting
– Engine auto stop and start control
5A-26 Automatic Transmission/Transaxle:

DTC DTC name Fail-safe operation

• Torque limitation is activated.
• Remains in gear when failure occurs, shifts to 3rd after the
vehicle has stopped.
P0796 • TCM stops the following control / function.
Pressure Control Solenoid “C”
(Page 5A- – Slip controlled lock-up function
Performance / Stuck Off
78) – Lock-up function
– Learning control
– Garage shift control
– Slope shift control
• Torque limitation is activated.
• Remains in gear when the failure occurs, shifts to 2nd after
the vehicle has stopped.
• TCM stops the following control / function.
P0797 – Slip controlled lock-up function
(Page 5A- Pressure Control Solenoid “C” Stuck On – Lock-up function
78) – Learning control
– Garage shift control
– Slope shift control
– Multiplex shifting
– Engine auto stop and start control
P0961
Pressure Control Solenoid “A” Control
(Page 5A-
Circuit Range / Performance
81)
P0962
Pressure Control Solenoid “A” Control
(Page 5A-
Circuit Low
82)
P0963
Pressure Control Solenoid “A” Control
(Page 5A-
Circuit High
84) • Power supply for all solenoid valve is cut off (3rd).
P0965
Pressure Control Solenoid “B” Control • Gear remains in R range when the failure occurs in R range.
(Page 5A-
Circuit Range / Performance • Reverse control is disabled.
85)
P0966 • TCM stops the following control / function.
Pressure Control Solenoid “B” Control
(Page 5A- – Slip controlled lock-up function
Circuit Low
87) – Lock-up function
P0967
Pressure Control Solenoid “B” Control – Learning control
(Page 5A-
Circuit High – Garage shift control
88)
P0969 – Slope shift control
Pressure Control Solenoid “C” Control
(Page 5A-
Circuit Range / Performance
90)
P0970
Pressure Control Solenoid “C” Control
(Page 5A-
Circuit Low
91)
P0971
Pressure Control Solenoid “C” Control
(Page 5A-
Circuit High
93)
 Automatic Transmission/Transaxle: 5A-27

DTC DTC name Fail-safe operation

P0973 • Torque limitation is activated.
(Page 5A- Shift Solenoid “A” Control Circuit Low • If failure occurs in 1st or 2nd, remains in the same gear
94) when failure occurs, shifts to 2nd when the vehicle has
stopped.
• If failure occurs in 3rd or 4th, shifts to 3rd, and then shifts to
2nd when the vehicle has stopped.
• Gear remains in R range when the failure occurs in R range.
P0974 • TCM stops the following control / function.
(Page 5A- Shift Solenoid “A” Control Circuit High
95) – Slip controlled lock-up function
– Lock-up function
– Learning control
– Garage shift control
– Slope shift control
• Torque limitation is activated.
• Remains in gear when the failure occurs, shifts to 2nd after
the vehicle has stopped.
• Gear remains in R range when the failure occurs in R range.
P1702
Internal Control Module Memory Check • TCM stops the following control / function.
(Page 5A-
Sum Error – Slip controlled lock-up function
51)
– Lock-up function
– Learning control
– Garage shift control
– Slope shift control
P1736 • Torque limitation is activated.
(Page 5A- Output Speed Sensor Circuit Low • Remains in gear when the failure occurs, shifts to 2nd after
98) the vehicle has stopped.
• Gear remains in R range when the failure occurs in R range.
• TCM calculates vehicle speed by input shaft speed sensor.
• TCM stops the following control / function.
– Slip controlled lock-up function
P1737
(Page 5A- Output Speed Sensor Circuit High – Lock-up function
99) – Learning control
– Garage shift control
– Slope shift control
– Reverse control
– Engine auto stop and start control
P1738 • Torque limitation is activated.
Input / Turbine Speed Sensor “A” Circuit
(Page 5A- • Remains in gear when the failure occurs, shifts to 2nd after
Low
100) the vehicle has stopped.
• Gear remains in R range when the failure occurs in R range.
• TCM calculates input shaft speed by output shaft speed
sensor.
• TCM stops the following control / function.
P1739
Input / Turbine Speed Sensor “A” Circuit – Slip controlled lock-up function
(Page 5A-
High – Lock-up function
101)
– Learning control
– Garage shift control
– Slope shift control
– Engine auto stop and start control
5A-28 Automatic Transmission/Transaxle:

DTC DTC name Fail-safe operation

P1742
Auxiliary Transmission Fluid Pump
(Page 5A-
Supply Voltage Low
49)
TCM stops engine auto stop and start control.
P1743
Auxiliary Transmission Fluid Pump
(Page 5A-
Supply Voltage High
49)
• Power supply for all solenoid valve is cut off (3rd).
• Gear remains in R range when the failure occurs in R range.
• Reverse control is disabled.
P2762 Torque Converter Clutch Pressure • TCM stops the following control / function.
(Page 5A- Control Solenoid Control Circuit Range / – Slip controlled lock-up function
103) Performance – Lock-up function
– Learning control
– Garage shift control
– Slope shift control
P2763 • Torque limitation is activated in R range.
Torque Converter Clutch Pressure
(Page 5A- • TCM stops the following control / function.
Control Solenoid Control Circuit High
104)
– Slip controlled lock-up function
– Lock-up function
P2764
Torque Converter Clutch Pressure – Learning control
(Page 5A-
Control Solenoid Control Circuit Low
106) – Slope shift control
– Engine auto stop and start control
P2797
Auxiliary Transmission Fluid Pump
(Page 5A-
Performance
107)
P2798
Auxiliary Transmission Fluid Pump
(Page 5A- TCM stops engine auto stop and start control.
Control Circuit Low
108)
P2799
Auxiliary Transmission Fluid Pump
(Page 5A-
Control Circuit High
108)
U0073 • TCM controls actuators assuming that engine speed is
(Page 5A- Control Module Communication Bus Off 7,000 rpm.
110) • TCM controls actuators assuming that ECT is 80 °C (176
U0100 °F).
(Page 5A- Lost Communication With ECM
• TCM controls actuators assuming that throttle position is
110)
0%.
• TCM controls actuators assuming that accelerator pedal
position is 0%.
• TCM controls actuators assuming that engine torque is
maximum.
• Torque limitation is activated.
• Remains in gear when the failure occurs, shifts to 2nd after
U0121 ® the vehicle has stopped.
Lost Communication With ABS / ESP
(Page 5A-
Control Module • Gear remains in R range when the failure occurs in R range.
110)
• TCM stops the following control / function.
– Slip controlled lock-up function
– Lock-up function
– Learning control
– Garage shift control
– Slope shift control
 Automatic Transmission/Transaxle: 5A-29

DTC DTC name Fail-safe operation

U1082
Lost Communication With ENG A-
(Page 5A- TCM stops engine auto stop and start control.
STOP Control Module
110)

Scan Tool Data

AENJHB0B5104008

NOTE
• If communication between SUZUKI scan tool and TCM is not possible, perform the following
checks:
– Check communication condition between PC and VCI using SUZUKI scan tool function.
– Check DLC power circuit and ground circuit.
– Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
– Check CAN communication system. (“Control Module Communication Bus Off” is detected in any
control module.) (Page 10H-17)
– Check TCM power circuit and ground circuit. (Page 5A-110)
• The following scan tool data related to A/T can be checked only by communicating with TCM.

Normal condition / Reference

Scan tool data Vehicle condition
value
Ignition ON and engine stopped 0 rpm
Input Shaft Revolution
At 60 km/h (37 mile/h) constant speed, D (O/D OFF) 2,300 rpm
(Page 5A-31)
range, 20% or less throttle opening and in 3rd gear (displayed in increments of 50 rpm)
At vehicle stop 0 rpm
Output Shaft Revolution
At 60 km/h (37 mile/h) constant speed, D (O/D OFF) 2,300 rpm
(Page 5A-31)
range, 20% or less throttle opening and in 3rd gear (displayed in increments of 50 rpm)
After driving at 60 km/h (37 mile/h) for 15 minutes or
ATF Temperature (Page
more, and ATF temperature around sensor reaches 70 to 80 °C
5A-31)
70 to 80 °C (158 to 176 °F)
Battery Voltage (Page Ignition: “ON” Battery voltage is displayed
5A-32) Engine: stopped (8 to 16 V)
A Solenoid (Com) (Page
Ignition “ON” Approx. 100 mA
5A-32)
B Solenoid (Com) (Page
Ignition “ON” Approx. 100 mA
5A-32)
C Solenoid (Com) (Page
Ignition “ON” Approx. 100 mA
5A-32)
TCC Solenoid (Com)
Ignition “ON” Approx. 100 mA
(Page 5A-32)
Electro Magnetic Oil Pump During engine auto stop and start control 40 to 50%
Solenoid Duty (Electro
Magnetic Oil Pump
Other than above condition 0%
Solenoid Duty (%))
(Page 5A-32)
A Solenoid (Mon) (Page
Ignition “ON” Approx. 100 mA
5A-32)
B Solenoid (Mon) (Page
Ignition “ON” Approx. 100 mA
5A-32)
C Solenoid (Mon) (Page
Ignition “ON” Approx. 100 mA
5A-32)
TCC Solenoid (Mon)
Ignition “ON” Approx. 100 mA
(Page 5A-32)
Engine Speed (Page Engine: Running at idle speed
Engine idle speed is displayed.
5A-32) Select lever: P range
5A-30 Automatic Transmission/Transaxle:

Normal condition / Reference

Scan tool data Vehicle condition
value
Ignition: “ON” 0 to 100% (Varies depending on
Accel Actual Position Accelerator pedal: Depressed depressed value)
(Page 5A-32) Ignition: “ON”
0%
Accelerator pedal: Released
Ignition: “ON” 0 to 100% (Varies depending on
Accel Effective Position Accelerator pedal: Depressed depressed value)
(Page 5A-32) Ignition: “ON”
0%
Accelerator pedal: Released
Engine coolant temperature is
ECT (Page 5A-32) Ignition: “ON”
displayed.
Ignition: “ON”
P
Select lever: P range
Ignition: “ON”
R
Select lever: R range
Ignition: “ON”
N
Transaxle Range (Page Select lever: N range
5A-32) Ignition: “ON”
D
Select lever: D range
Ignition: “ON”
2
Select lever: 2 range
Ignition: “ON”
L
Select lever: L range
Ignition: “ON”
P
Select lever: P range
Ignition: “ON”
R
Select lever: R range
Ignition: “ON”
N
Actual Gear Position Select lever: N range
(Page 5A-32) Ignition: “ON”
D
Select lever: D range
Ignition: “ON”
2nd
Select lever: 2 range
Ignition: “ON”
1st
Select lever: L range
Lock-up: Off Release
Torque Converter Clutch
Lock-up: Off ↔ On Slip
(Page 5A-32)
Lock-up: On Connect
Neutral Control Mode Neutral control: ON Neutral Control Active
(Neutral Control Mode Neutral control: In transition Entering Neutral Control
(Neutral Control Not Neutral control: In transition Exiting Neutral Control
Active / Entering Neutral
Control / Neutral Control
Other than above condition Neutral Control Not Active
Active / Exiting Neutral
Control)) (Page 5A-32)
Engine: Running at idle speed
15 to 70 rpm
Select lever: P range
Slip RPM (Page 5A-32) Engine: Running at idle speed
Vehicle: Stopped Engine speed is displayed.
Select lever: D range
Vehicle Speed (Page
Vehicle: Running The same value as speedometer
5A-32)
Ignition: “ON”
ON
Select lever: P range
P Range (Page 5A-32)
Ignition: “ON”
OFF
Select lever: P, R, D, 2, L range
 Automatic Transmission/Transaxle: 5A-31

Normal condition / Reference

Scan tool data Vehicle condition
value
Ignition: “ON”
ON
Select lever: R range
R Range (Page 5A-32)
Ignition: “ON”
OFF
Select lever: P, N, D, 2, L range
Ignition: “ON”
ON
Select lever: N range
N Range (Page 5A-32)
Ignition: “ON”
OFF
Select lever: P, R, D, 2, L range
Ignition: “ON”
ON
Select lever: D range
D Range (Page 5A-32)
Ignition: “ON”
OFF
Select lever: P, R, N, 2, L range
Ignition ON
ON
Select lever: 2 range
2 Range (Page 5A-32)
Ignition: “ON”
OFF
Select lever: P, R, N, D, L range
Ignition: “ON”
ON
Select lever: L range
L Range (Page 5A-32)
Ignition: “ON”
OFF
Select lever: P, R, N, D, 2 range
Ignition: “ON”
ON
3 Pos (O/D OFF) State Select lever: D (O/D OFF) range
(Page 5A-32) Ignition: “ON”
OFF
Select lever: D (O/D ON) range
Engine: Idle speed after warming up
Shift Solenoid A (Com) Vehicle: Stopped ON
(Page 5A-33) Select lever: P, R, N, D, 2 or L range
Gear position: 2nd, 3rd or 4th OFF
Engine: Idle speed after warming up
Shift Solenoid A (Mon) Vehicle: Stopped ON
(Page 5A-33) Select lever: P, R, N, D, 2 or L range
Gear position: 2nd, 3rd or 4th OFF
Neutral Control Inhibit Neutral control: ON Permit
(Neutral Control Inhibit
(Permit / Inhibit)) (Page Other than above condition Inhibit
5A-33)
Ignition: “ON”
ON
Brake Switch (Page 5A- Brake pedal: Fully depressed
33) Ignition: “ON”
OFF
Brake pedal: Released
Air Conditioner Signal Magnet clutch: ON ON
(Page 5A-33) Magnet clutch: OFF OFF
Ignition: “ON”
OFF
Transaxle Warning Light Transaxle warning light: OFF
(Page 5A-33) Ignition: “ON”
ON
Transaxle warning light: Lights up
MIL Request (MIL Ignition: “ON” ON
Request (OFF / ON)) Engine: Running with faulty condition ON
(Page 5A-33) Engine: Running without faulty condition OFF

Scan Tool Data Definitions Output Shaft Revolution (rpm)

Input Shaft Revolution (rpm)
Input shaft revolution calculated by reference pulses
coming from input shaft speed sensor on transmission
case.
Output shaft revolution calculated by reference pulses
coming from output shaft speed sensor on transmission
case.
ATF Temperature (°C)
ATF temperature calculated by signal from transmission
fluid temperature sensor installed in valve body.
5A-32 Automatic Transmission/Transaxle:
Battery Voltage (V)
This parameter indicates battery voltage inputted
through ignition switch to TCM.
A Solenoid (Com) (Pressure Control Solenoid A
Command, mA)
This parameter indicates control current value that TCM
outputs to pressure control solenoid valve “A”.
B Solenoid (Com) (Pressure Control Solenoid B
Command, mA)
This parameter indicates control current value that TCM
outputs to pressure control solenoid valve “B”.
C Solenoid (Com) (Pressure Control Solenoid C
Command, mA)
This parameter indicates control current value that TCM
outputs to pressure control solenoid valve “C”.
TCC Solenoid (Com) (TCC Solenoid Command, mA)
This parameter indicates control current value that TCM
outputs to TCC solenoid valve.
Electro Magnetic Oil Pump Solenoid Duty (%)
This parameter indicates solenoid duty ratio that TCM
outputs to electro magnetic oil pump solenoid valve.
A Solenoid (Mon) (Pressure Control Solenoid A
Monitor, mA)
This parameter indicates current value that flows to
pressure control solenoid valve “A”.
B Solenoid (Mon) (Pressure Control Solenoid B
Monitor, mA)
This parameter indicates current value that flows to
pressure control solenoid valve “B”.
C Solenoid (Mon) (Pressure Control Solenoid C
Monitor, mA)
This parameter indicates current value that flows to
pressure control solenoid valve “C”.
TCC Solenoid (Mon) (TCC Solenoid Monitor, mA)
This parameter indicates current value that flows to TCC
solenoid valve.
Engine Speed (rpm)
Engine speed calculated by signal through CAN
communication line fed from ECM.
Accel Actual Position (Accelerator Actual Position,
%)
Accelerator pedal position calculated by signal through
CAN communication line fed from ECM.
Accel Effective Position (Accelerator Effective
Position, %)
This parameter indicates accelerator pedal position
calculated by signal through CAN communication line
fed from ECM.
ECT (Engine Coolant Temperature, °C)
This parameter indicates engine coolant temperature
sent from ECM through CAN.
Transaxle Range (P, R, N, D, 2, L)
Transmission range detected by signal fed from
transmission range sensor.
Actual Gear Position (1st, 2nd, R, N, P, D)
This parameter indicates the gear position of A/T.
Torque Converter Clutch (Release, Slip, Connect)
This parameter indicates the state of lock-up clutch
output from TCM.
Neutral Control Mode (Neutral Control Not Active /
Entering Neutral Control / Neutral Control Active /
Exiting Neutral Control)
This parameter indicates the status of neutral control.
Slip RPM (rpm)
This parameter indicates slipping rotation in the torque
converter (speed difference between input shaft rotation
and engine rotation)
Vehicle Speed (km/h)
Vehicle speed calculated by signal through CAN
communication line fed from ECM.
P Range (OFF, ON)
This parameter indicates the state of P range switch in
transmission range sensor.
R Range (OFF, ON)
This parameter indicates the state of R range switch in
transmission range sensor.
N Range (OFF, ON)
This parameter indicates the state of N range switch in
transmission range sensor.
D Range (OFF, ON)
This parameter indicates the state of D range switch in
transmission range sensor.
2 Range (OFF, ON)
This parameter indicates the state of 2 range switch in
transmission range sensor.
L Range (OFF, ON)
This parameter indicates the state of L range switch in
transmission range sensor.
3 Pos (O/D OFF) State (OFF, ON)
This parameter indicates the state of O/D OFF output
from TCM.
 Automatic Transmission/Transaxle: 5A-33

Shift Solenoid A (Com) (Shift Solenoid Valve A Brake Switch (OFF, ON)
(Command), OFF, ON) Brake light switch position detected by signal through
ON: ON command is being outputted to shift solenoid CAN communication line fed from ECM.
valve “A”. ON: Brake pedal depressed
OFF: ON command not being outputted to shift solenoid OFF: Brake pedal released
valve “A”.
Air Conditioner Signal (ON/OFF)
Shift Solenoid A (Mon) (Shift Solenoid Valve A ON: Signal which inform that air conditioner compressor
(Monitor), OFF, ON) is turned ON.
ON: Electricity being passed to shift solenoid valve “A” OFF: Signal which inform that air conditioner
OFF: Electricity not being passed to shift solenoid valve compressor is turned OFF.
“A”
Transaxle Warning Light (OFF, ON)
Neutral Control Inhibit (Permit / Inhibit) This parameter indicates the state of transmission
This parameter indicates the permission status of neutral warning light.
control.
MIL Request (OFF / ON)
This parameter indicates the status of MIL.

Visual Inspection
AENJHB0B5104009
Visually check the following parts and systems.
Inspection item Referring
• ATF — level, leakage, color “ATF Level Check” (Page 5A-117)
• ATF hoses — disconnection, looseness, deterioration “ATF Cooler Hose Replacement” (Page 5A-146)
“Select Cable Removal and Installation” (Page 5A-
• A/T select cable — installation
129)
“Engine Oil and Filter Change”: K15B in Section 1E
• Engine oil — level, leakage
(Page 1E-4)
“Engine Cooling System Inspection”: K15B in
• Engine coolant — level, leakage
Section 1F (Page 1F-10)
“Engine Assembly Removal and Installation”: K15B
• Engine mountings — play, looseness, damage
in Section 1D (Page 1D-27)
“Suspension, Wheel and Tire Symptom Diagnosis”
• Suspension — play, looseness
in Section 2A (Page 2A-1)
“Front Drive Shaft Assembly On-Vehicle
• Drive shafts — damage
Inspection”: Front in Section 3A (Page 3A-3)
“Battery Inspection”: K15B in Section 1J (Page 1J-
• Battery — indicator condition, corrosion of terminal
2)
“Electronic Shift Control System Component
• Connectors of electric wire harness — disconnection, friction
Location” (Page 5A-13)
• Fuses — burning —
• Parts — installation, damage —
• Bolts — looseness —
• Other parts that can be checked visually —

Also check the following items at engine start, if possible.

Inspection item
• MIL — Operation
• Transmission warning light — Operation
• Charge warning light — Operation
• Engine oil pressure warning light — Operation
• Other parts that can be checked visually
Referring
“MIL Check”: K15B in Section 1A (Page 1A-23)
“Transmission Warning Light Check” (Page 5A-17)
“Generator Symptom Diagnosis”: K15B in Section
1J (Page 1J-3)
“Combination Meter Diagnosis” in Section 9C
(Page 9C-20)
“Combination Meter Diagnosis” in Section 9C
(Page 9C-20)
5A-34 Automatic Transmission/Transaxle:

A/T Basic Check

AENJHB0B5104010
This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in
“Visual Inspection” (Page 5A-33). Follow the flow carefully.
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Road test Go to Step 3. Repair or replace
1) Perform “Road Test” (Page 5A-34). defective part.

Is test result OK?

3 Manual road test Go to Step 4. Repair or replace
1) Perform “Manual Road Test” (Page 5A-40). defective part.

Is test result OK?

4 Engine brake test Go to Step 5. Repair or replace
1) Perform “Engine Brake Test” (Page 5A-41). defective part.

Is test result OK?

5 Stall test Go to Step 6. Repair or replace
1) Perform “Stall Test” (Page 5A-41). defective part.

Is test result OK?

6 Time lag test Go to Step 7. Repair or replace
1) Perform “Time Lag Test” (Page 5A-42). defective part.

Is test result OK?

7 Line pressure test Proceed to “A/T Repair or replace
1) Perform “Line Pressure Test” (Page 5A-44). Symptom Diagnosis” defective part.
(Page 5A-48).
Is test result OK?

Road Test
AENJHB0B5104011
This test is to check if upshift, downshift and lock-up take place at specified speeds while actually driving vehicle on a
level road.

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
Limit the driving speed permissible in road conditions and regulations.

1) Connect SUZUKI scan tool to DLC.

2) Select “Data list” mode on scan tool.
3) Drive vehicle so that ATF temperature reaches normal operating temperature (70 to 80 °C (158 to 176 °F)).
(Page 5A-29)

NOTE
Engine coolant temperature rises when revving engine in P or N range, but ATF temperature does not
rise in P or N range. Drive vehicle to raise ATF temperature.

4) While driving in D range, check if gear shift and lock-up occur properly as shown in “Automatic Gear Shift Table”
(Page 5A-35).
 Automatic Transmission/Transaxle: 5A-35

Automatic Gear Shift Table

Automatic gear shift schedule is shown in the following table. Test-drive the vehicle on a level road in the D (O/D ON),
D (O/D OFF) or 2 range.

1. Shift point in D (O/D ON), D (O/D OFF) or 2 range

Throttle Vehicle speed (km/h
Shift Remark
opening (mile/h))
1st → 2nd 46 – 50 (29 – 31) D (O/D ON), D (O/D OFF), 2 range
100% 2nd → 3rd 90 – 94 (56 – 58) D (O/D ON), D (O/D OFF) range
3rd → 4th 153 – 157 (95 – 98) D (O/D ON) range
1st → 2nd 33 – 37 (21 – 23) D (O/D ON), D (O/D OFF), 2 range
UP shift 50% 2nd → 3rd 63 – 67 (39 – 42) D (O/D ON), D (O/D OFF) range
3rd → 4th 102 – 106 (63 – 66) D (O/D ON) range
1st → 2nd 16 – 20 (10 – 12) D (O/D ON), D (O/D OFF), 2 range
20% 2nd → 3rd 34 – 38 (21 – 24) D (O/D ON), D (O/D OFF) range
3rd → 4th 51 – 55 (32 – 34) D (O/D ON) range
4th → 3rd 143 – 147 (89 – 91) D (O/D ON) range
100% 3rd → 2nd 80 – 84 (50 – 52) D (O/D ON), D (O/D OFF) range
2nd → 1st 38 – 42 (24 – 26) D (O/D ON), D (O/D OFF), 2 range
4th → 3rd 69 – 73 (43 – 45) D (O/D ON) range
DOWN shift 50% 3rd → 2nd 28 – 32 (17 – 20) D (O/D ON), D (O/D OFF) range
2nd → 1st 12 – 16 (7 – 10) D (O/D ON), D (O/D OFF), 2 range
4th → 3rd 44 – 48 (27 – 30) D (O/D ON) range
20% 3rd → 2nd 20 – 24 (12 – 15) D (O/D ON), D (O/D OFF) range
2nd → 1st 8 – 12 (5 – 7) D (O/D ON), D (O/D OFF), 2 range

2. Lock-up point in D (O/D ON), D (O/D OFF) or 2 range

Lock-up Throttle Vehicle speed (km/h
Remark
clutch status opening (mile/h))
100% — D (O/D ON), D (O/D OFF), 2 range
ON 50% — D (O/D ON), D (O/D OFF), 2 range
20% 33 – 37 (21 – 23) D (O/D ON), D (O/D OFF), 2 range
2nd gear lock-up
100% — D (O/D ON), D (O/D OFF), 2 range
OFF 50% — D (O/D ON), D (O/D OFF), 2 range
20% 32 – 36 (20 – 22) D (O/D ON), D (O/D OFF), 2 range
100% 32 – 36 (20 – 22) D (O/D ON), D (O/D OFF) range
ON 50% 32 – 36 (20 – 22) D (O/D ON), D (O/D OFF) range
20% 32 – 36 (20 – 22) D (O/D ON), D (O/D OFF) range
3rd gear lock-up
100% 30 – 34 (19 – 21) D (O/D ON), D (O/D OFF) range
OFF 50% 30 – 34 (19 – 21) D (O/D ON), D (O/D OFF) range
20% 30 – 34 (19 – 21) D (O/D ON), D (O/D OFF) range
100% 46 – 50 (29 – 31) D (O/D ON) range
ON 50% 46 – 50 (29 – 31) D (O/D ON) range
20% 46 – 50 (29 – 31) D (O/D ON) range
4th gear lock-up
100% 44 – 48 (27 – 30) D (O/D ON) range
OFF 50% 44 – 48 (27 – 30) D (O/D ON) range
20% 44 – 48 (27 – 30) D (O/D ON) range
5A-36 Automatic Transmission/Transaxle:

3. Slip lock-up point in D (O/D ON), D (O/D OFF) or 2 range

Slip lock-up Throttle Vehicle speed (km/h
Remark
clutch status opening (mile/h))
D (O/D ON), D (O/D OFF), 2 range and
Slip ON 15% 21 – 23 (13 – 14)
not locked-up
2nd gear
D (O/D ON), D (O/D OFF), 2 range and
Slip OFF 15% 18 – 20 (11 – 12)
not locked-up
D (O/D ON), D (O/D OFF) range and
Slip ON 15% 34 – 36 (21 – 22)
not locked-up
3rd gear
D (O/D ON), D (O/D OFF) range and
Slip OFF 15% 29 – 31 (18 – 19)
not locked-up
Slip ON 15% 49 – 51 (30 – 32) D (O/D ON) range and not locked-up
4th gear
Slip OFF 15% 45 – 47 (28 – 29) D (O/D ON) range and not locked-up

Troubleshooting
Condition Possible cause
Unable to run in D range Faulty TCM
Faulty shift solenoid valve “A”
Faulty pressure control solenoid valve
“A”
Faulty ATF
Faulty valve body component
Faulty oil pump
Faulty planetary gear
Faulty forward clutch
Faulty drive plate
Faulty torque converter
Unable to run in R range Faulty TCM
Faulty shift solenoid valve “A”
Faulty pressure control solenoid valve
“B”
Faulty ATF
Faulty valve body component
Faulty oil pump
Faulty planetary gear
Faulty reverse clutch
Faulty 1st and reverse brake
Faulty drive plate
Faulty torque converter
Correction / Reference Item
Substitute a known-good TCM and recheck
DTC.
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“ATF Level Check” (Page 5A-117)
“Valve Body Assembly Removal and
Installation” (Page 5A-138)
“Oil Pump Assembly Inspection” (Page 5A-
159)
Check planetary gear referring to “A/T
Assembly Reassembly” (Page 5A-182).
“Forward and Reverse Clutch Assembly
Preliminary Check” (Page 5A-164)
“Flywheel / Drive Plate Inspection”: K15B in
Section 1D (Page 1D-38)
Replace torque converter referring to “A/T
Assembly Reassembly” (Page 5A-182).
Substitute a known-good TCM and recheck
DTC.
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“ATF Level Check” (Page 5A-117)
“Valve Body Assembly Removal and
Installation” (Page 5A-138)
“Oil Pump Assembly Inspection” (Page 5A-
159)
Check planetary gear referring to “A/T
Assembly Reassembly” (Page 5A-182).
“Forward and Reverse Clutch Assembly
Preliminary Check” (Page 5A-164)
Check 1st and reverse brake referring to “A/T
Assembly Reassembly” (Page 5A-182).
“Flywheel / Drive Plate Inspection”: K15B in
Section 1D (Page 1D-38)
Replace torque converter referring to “A/T
Assembly Reassembly” (Page 5A-182).

Condition Possible cause
1 → 2 upshift fails Battery voltage is too low
Faulty TCM
Faulty input shaft speed sensor
Faulty output shaft speed sensor
Faulty ATF temperature sensor
Faulty pressure control solenoid valve
“A”
Faulty pressure control solenoid valve
“B”
Faulty pressure control solenoid valve
“C”
Faulty APP sensor
Faulty ATF
Faulty transmission range sensor
Faulty valve body component
Faulty O/D and 2nd coast brake
2 → 3 upshift fails Battery voltage is too low
Faulty TCM
Faulty input shaft speed sensor
Faulty output shaft speed sensor
Faulty transmission range sensor
Faulty ATF temperature sensor
Faulty shift solenoid valve “A”
Faulty pressure control solenoid valve
“A”
Faulty pressure control solenoid valve
“B”
Faulty pressure control solenoid valve
“C”
Faulty APP sensor
Faulty ATF
Faulty valve body component
Faulty direct clutch
Automatic Transmission/Transaxle: 5A-37
Correction / Reference Item
“Battery Inspection”: K15B in Section 1J (Page
1J-2)
Substitute a known-good TCM and recheck
DTC.
“Input Shaft Speed Sensor Inspection” (Page
5A-135)
“Output Shaft Speed Sensor Inspection” (Page
5A-134)
“ATF Temperature Sensor Inspection” (Page
5A-138)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
“ATF Level Check” (Page 5A-117)
“Transmission Range Sensor Inspection and
Adjustment” (Page 5A-131)
“Valve Body Assembly Removal and
Installation” (Page 5A-138)
Check O/D and 2nd coast brake referring to “A/
T Assembly Reassembly” (Page 5A-182).
“Battery Inspection”: K15B in Section 1J (Page
1J-2)
Substitute a known-good TCM and recheck
DTC.
“Input Shaft Speed Sensor Inspection” (Page
5A-135)
“Output Shaft Speed Sensor Inspection” (Page
5A-134)
“Transmission Range Sensor Inspection and
Adjustment” (Page 5A-131)
“ATF Temperature Sensor Inspection” (Page
5A-138)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
“ATF Level Check” (Page 5A-117)
“Valve Body Assembly Removal and
Installation” (Page 5A-138)
“Direct Clutch Assembly Preliminary Check”
(Page 5A-161)
5A-38 Automatic Transmission/Transaxle:
Condition Possible cause
3 → 4 upshift fails Battery voltage is too low
Faulty TCM
Faulty input shaft speed sensor
Faulty output shaft speed sensor
Faulty transmission range sensor
Faulty ATF temperature sensor
Faulty pressure control solenoid valve
“A”
Faulty pressure control solenoid valve
“B”
Faulty pressure control solenoid valve
“C”
Faulty APP sensor
Faulty ATF
Faulty valve body component
Faulty O/D and 2nd coast brake
Gear shift point is Abnormal engine condition
incorrect
Faulty TCM
Faulty pressure control solenoid valve
“A”
Faulty pressure control solenoid valve
“B”
Faulty APP sensor
4 → 3 downshift fails Faulty O/D off switch
Battery voltage is too low
Faulty TCM
Faulty input shaft speed sensor
Faulty output shaft speed sensor
Faulty transmission range sensor
Faulty ATF temperature sensor
Faulty pressure control solenoid valve
“A”
Faulty pressure control solenoid valve
“B”
Faulty pressure control solenoid valve
“C”
Faulty APP sensor
Faulty ATF
Correction / Reference Item
“Battery Inspection”: K15B in Section 1J (Page
1J-2)
Substitute a known-good TCM and recheck
DTC.
“Input Shaft Speed Sensor Inspection” (Page
5A-135)
“Output Shaft Speed Sensor Inspection” (Page
5A-134)
“Transmission Range Sensor Inspection and
Adjustment” (Page 5A-131)
“ATF Temperature Sensor Inspection” (Page
5A-138)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
“ATF Level Check” (Page 5A-117)
“Valve Body Assembly Removal and
Installation” (Page 5A-138)
Check O/D and 2nd coast brake referring to “A/
T Assembly Reassembly” (Page 5A-182).
“Engine Basic Inspection”: K15B in Section 1A
(Page 1A-54)
Substitute a known-good TCM and recheck
DTC.
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
“O/D Off Switch Inspection” (Page 5A-126)
“Battery Inspection”: K15B in Section 1J (Page
1J-2)
Substitute a known-good TCM and recheck
DTC.
“Input Shaft Speed Sensor Inspection” (Page
5A-135)
“Output Shaft Speed Sensor Inspection” (Page
5A-134)
“Transmission Range Sensor Inspection and
Adjustment” (Page 5A-131)
“ATF Temperature Sensor Inspection” (Page
5A-138)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
“ATF Level Check” (Page 5A-117)

Condition Possible cause
3 → 2 downshift fails Battery voltage is too low
Faulty TCM
Faulty input shaft speed sensor
Faulty output shaft speed sensor
Faulty transmission range sensor
Faulty ATF temperature sensor
Faulty shift solenoid valve “A”
Faulty pressure control solenoid valve
“A”
Faulty pressure control solenoid valve
“B”
Faulty pressure control solenoid valve
“C”
Faulty APP sensor
Faulty ATF
Faulty valve body component
Faulty O/D and 2nd coast brake
2 → 1 downshift fails Battery voltage is too low
Faulty TCM
Faulty input shaft speed sensor
Faulty output shaft speed sensor
Faulty transmission range sensor
Faulty ATF temperature sensor
Faulty pressure control solenoid valve
“A”
Faulty pressure control solenoid valve
“B”
Faulty pressure control solenoid valve
“C”
Faulty APP sensor
Faulty ATF
Faulty valve body component
Faulty one-way clutch No.2
Automatic Transmission/Transaxle: 5A-39
Correction / Reference Item
“Battery Inspection”: K15B in Section 1J (Page
1J-2)
Substitute a known-good TCM and recheck
DTC.
“Input Shaft Speed Sensor Inspection” (Page
5A-135)
“Output Shaft Speed Sensor Inspection” (Page
5A-134)
“Transmission Range Sensor Inspection and
Adjustment” (Page 5A-131)
“ATF Temperature Sensor Inspection” (Page
5A-138)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
“ATF Level Check” (Page 5A-117)
“Valve Body Assembly Removal and
Installation” (Page 5A-138)
Check O/D and 2nd coast brake referring to “A/
T Assembly Reassembly” (Page 5A-182).
“Battery Inspection”: K15B in Section 1J (Page
1J-2)
Substitute a known-good TCM and recheck
DTC.
“Input Shaft Speed Sensor Inspection” (Page
5A-135)
“Output Shaft Speed Sensor Inspection” (Page
5A-134)
“Transmission Range Sensor Inspection and
Adjustment” (Page 5A-131)
“ATF Temperature Sensor Inspection” (Page
5A-138)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
“ATF Level Check” (Page 5A-117)
“Valve Body Assembly Removal and
Installation” (Page 5A-138)
Check one-way clutch No.2 referring to “A/T
Assembly Disassembly” (Page 5A-151).
5A-40 Automatic Transmission/Transaxle:

Condition Possible cause Correction / Reference Item

TCC (lock-up) function Battery voltage is too low
pressure control does not
operate Faulty TCM
Faulty input shaft speed sensor
Faulty output shaft speed sensor
Faulty ATF temperature sensor
Faulty TCC solenoid valve
Faulty brake light switch
Faulty APP sensor
Faulty torque converter
Faulty valve body component
“Battery Inspection”: K15B in Section 1J (Page
1J-2)
Substitute a known-good TCM and recheck
DTC.
“Input Shaft Speed Sensor Inspection” (Page
5A-135)
“Output Shaft Speed Sensor Inspection” (Page
5A-134)
“ATF Temperature Sensor Inspection” (Page
5A-138)
“Solenoid Valve Inspection” (Page 5A-142)
“Brake Light Switch Inspection” in Section 4A
(Page 4A-11)
“APP Sensor On-Vehicle Inspection”: K15B in
Section 1C (Page 1C-6)
Replace torque converter referring to “A/T
Assembly Reassembly” (Page 5A-182).
“Valve Body Assembly Removal and
Installation” (Page 5A-138)

Manual Road Test 4) After warming up engine, set ignition “OFF” and
AENJHB0B5104012 disconnect solenoid connector (1).
! WARNING
1
If you do not select a suitable route and take
proper precautions when performing a road
test, an accident can occur.
• Select a level road with no traffic to
minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a
driver and a tester.

NOTE
Limit the driving speed permissible in road
conditions and regulations.
IJHA0A510006-01
This test checks the gears being used in L, 2, D (O/D
5) With select lever in L range, start vehicle and check
OFF) or D (O/D ON) range when driven with deactivated
that 3rd gear is being used referring to the following
gear shift control system. Test drive vehicle on a level
table.
road.
6) While vehicle is running, shift select lever to 2 range
NOTE and check that 3rd gear is being used.
Before this test, check DTC. 7) While vehicle is running, shift select lever to D range
and check that 3rd gear is being used.
1) Connect SUZUKI scan tool to DLC.
Vehicle speed at 1,000 rpm in engine speed
2) Select “Data list” mode on scan tool. under normal condition
3) Drive vehicle so that ATF temperature reaches Gear position Vehicle speed
normal operating temperature (70 to 80 °C (158 to 1st Approx. 8.9 km/h (5.5 mile/h)
176 °F)). (Page 5A-29) 2nd Approx. 16.4 km/h (10.2 mile/h)
NOTE 3rd Approx. 25.6 km/h (15.9 mile/h)
4th Approx. 36.8 km/h (22.9 mile/h)
Engine coolant temperature rises when Reverse Approx. 11.2 km/h (7.0 mile/h)
revving engine in P or N range, but ATF
temperature does not rise in P or N range. 8) After the checks, stop vehicle then set ignition
Drive vehicle to raise ATF temperature. “OFF”, and reconnect solenoid connector.
9) Clear DTC. (Page 5A-18)
 Automatic Transmission/Transaxle: 5A-41

Troubleshooting
Condition Possible cause Correction / Reference Item
Operated gear is not Faulty valve body component “Valve Body Assembly Removal and
correct Installation” (Page 5A-138)
Faulty clutch or brake Check clutch and brake referring to “A/T
Assembly Reassembly” (Page 5A-182).

Engine Brake Test

AENJHB0B5104013
! WARNING
There is the risk of a rear-end collision if there are vehicles behind you when you perform this test.
Check that there are no vehicles behind you when you perform this test.

1) While driving vehicle in 3rd gear of D range, shift down to 2 range and check if engine brake operates.
2) In the same way as in Step 1), check engine brake for operation when shifted down to L range.
3) Engine brake should operate.

Troubleshooting
Condition Possible cause Correction / Reference Item
Failure to operate when Faulty valve body component “Valve Body Assembly Removal and
shifted down to 2 range Installation” (Page 5A-138)
Faulty O/D and 2nd coast brake Check O/D and 2nd coast brake referring to “A/
T Assembly Reassembly” (Page 5A-182).
Failure to operate when Faulty valve body component “Valve Body Assembly Removal and
shifted down to L range Installation” (Page 5A-138)
Faulty 1st and reverse brake Check 1st and reverse brake referring to “A/T
Assembly Reassembly” (Page 5A-182).

Stall Test NOTICE

AENJHB0B5104014
This test is to check overall performance of A/T and
engine by measuring stall speed in D and R ranges.
Perform this test only when ATF is at normal operating
temperature and its level is between FULL and LOW
marks.
! WARNING
If you do not select a suitable route and take
proper precautions when performing a road
test, an accident can occur.
• Select a level road with no traffic to
minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a
driver and a tester.
If proper precautions are not taken when
performing stall tests, the A/T failure may
result due to an excessive rise in ATF
temperature.
• Do not continue running the engine for
longer than 5 seconds at stall speed.
• After performing a stall test, allow the
engine to run at idle for longer than 1
minute before performing another stall
test.
NOTE
• Limit the driving speed permissible in road
conditions and regulations.
• Repeat test 3 times and take average of
those data for final time lag data.

1) Connect SUZUKI scan tool to DLC.

2) Select “Data list” mode on scan tool.
3) Drive vehicle so that ATF temperature reaches
normal operating temperature (70 to 80 °C (158 to
176 °F)). (Page 5A-29)
5A-42 Automatic Transmission/Transaxle:

NOTE 7) Shift select lever to D range and depress accelerator

Engine coolant temperature rises when
revving engine in P or N range, but ATF
temperature does not rise in P or N range.
Drive vehicle to raise ATF temperature.
4) Apply parking brake and block wheels.
5) Start engine with select lever in P range.
6) Depress brake pedal fully.
pedal fully while watching tachometer. Read engine
rpm quickly when it has become constant (stall
speed).
8) Release accelerator pedal immediately after stall
speed is checked.
9) In the same way, check stall speed in R range.
10) Stall speed should be within the following
specification.
Engine stall speed
Standard: 2,200 – 2,600 rpm

Troubleshooting
Condition
Lower than standard level Engine output torque failure
in both D and R ranges
Faulty torque converter
Higher than standard
level in D range
Higher than standard
level in R range
Higher than standard
level in both D and R
ranges
Possible cause Correction / Reference Item
“Engine Basic Inspection”: K15B in Section 1A
(Page 1A-54)
Replace torque converter referring to “A/T
Assembly Reassembly” (Page 5A-182).
Malfunction of pressure control solenoid “Solenoid Valve Inspection” (Page 5A-142)
valve “A” (Low line pressure)
Faulty valve body component “Valve Body Assembly Removal and
Installation” (Page 5A-138)
Slippery forward clutch “Forward and Reverse Clutch Assembly
Preliminary Check” (Page 5A-164)
Faulty one-way clutch No.2 Check one-way clutch No.2 referring to “A/T
Assembly Disassembly” (Page 5A-151).
Malfunction of pressure control solenoid “Solenoid Valve Inspection” (Page 5A-142)
valve “B” (Low line pressure)
Faulty valve body component “Valve Body Assembly Removal and
Installation” (Page 5A-138)
Slippery reverse clutch “Forward and Reverse Clutch Assembly
Preliminary Check” (Page 5A-164)
Slippery 1st and reverse brake Check 1st and reverse brake referring to “A/T
Assembly Reassembly” (Page 5A-182).
Malfunction of pressure control solenoid “Solenoid Valve Inspection” (Page 5A-142)
valve “A” (Low line pressure)
Malfunction of pressure control solenoid “Solenoid Valve Inspection” (Page 5A-142)
valve “B” (Low line pressure)
Faulty valve body component “Valve Body Assembly Removal and
Installation” (Page 5A-138)
Clogged oil strainer “A/T Oil Strainer Assembly Removal and
Installation” (Page 5A-136)
Faulty oil pump “Oil Pump Assembly Inspection” (Page 5A-
159)

Time Lag Test ! WARNING

AENJHB0B5104015
This test is to check conditions of clutch, brake and fluid
pressure. “Time lag” means time elapsed since select
lever is shifted with engine idling till shock is felt.
If you do not select a suitable route and take
proper precautions when performing a road
test, an accident can occur.
• Select a level road with no traffic to
minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a
driver and a tester.
 Automatic Transmission/Transaxle: 5A-43

NOTE 5) With a stopwatch ready, shift select lever from N to D

Limit the driving speed permissible in road range and measure time from that moment till shock
conditions and regulations. is felt.
6) Similarly measure time lag by shifting select lever
1) Connect SUZUKI scan tool to DLC. from N to R range.
2) Select “Data list” mode on scan tool.
NOTE
3) Drive vehicle so that ATF temperature reaches
normal operating temperature (70 to 80 °C (158 to • When repeating this test, wait at least one
176 °F)). (Page 5A-29) minute after select lever is shifted back to
N range.
NOTE • Engine should be warmed up fully for this
Engine coolant temperature rises when test.
revving engine in P or N range, but ATF • Repeat test 3 times and take average of
temperature does not rise in P or N range. those data for final time lag data.
Drive vehicle to raise ATF temperature.
Gear shifting time lag
4) With chocks placed before and behind front and rear N → D: Less than 0.7 sec.
wheels respectively, depress brake pedal. N → R: Less than 1.2 sec.

Troubleshooting
Condition Possible cause
N → D time lag exceeds Faulty pressure control solenoid valve
specification “A”
Faulty pressure control solenoid valve
“B”
Faulty valve body component
Clogged oil strainer
Faulty oil pump
Faulty forward clutch
Faulty one-way clutch No.2
N → R time lag exceeds Faulty pressure control solenoid valve
specification “A”
Faulty pressure control solenoid valve
“B”
Faulty shift solenoid valve “A”
Faulty valve body component
Clogged oil strainer
Faulty oil pump
Faulty reverse clutch
Faulty 1st and reverse brake
Correction / Reference Item
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“Valve Body Assembly Removal and
Installation” (Page 5A-138)
“A/T Oil Strainer Assembly Removal and
Installation” (Page 5A-136)
“Oil Pump Assembly Inspection” (Page 5A-
159)
“Forward and Reverse Clutch Assembly
Preliminary Check” (Page 5A-164)
Check one-way clutch No.2 referring to “A/T
Assembly Disassembly” (Page 5A-151).
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“Solenoid Valve Inspection” (Page 5A-142)
“Valve Body Assembly Removal and
Installation” (Page 5A-138)
“A/T Oil Strainer Assembly Removal and
Installation” (Page 5A-136)
“Oil Pump Assembly Inspection” (Page 5A-
159)
“Forward and Reverse Clutch Assembly
Preliminary Check” (Page 5A-164)
Check 1st and reverse brake referring to “A/T
Assembly Reassembly” (Page 5A-182).
5A-44 Automatic Transmission/Transaxle:

Line Pressure Test 7) Attach oil pressure gauge to fluid pressure check
AENJHB0B5104016 hole (2) in transaxle rear cover.
Purpose of this test is to check operating conditions of
each part by measuring fluid pressure in fluid pressure NOTE
line.
After attaching oil pressure gauge, check that
Line pressure test requires the following conditions.
no fluid leakage exists.
• ATF is proper level (between FULL and LOW on
dipstick). Special tool
• A/C OFF (A): 09925M37811M001

! WARNING
If you do not select a suitable route and take
proper precautions when performing a road
test, an accident can occur.
• Select a level road with no traffic to
minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a
1
driver and a tester.

NOTE
(A)
Limit the driving speed permissible in road
conditions and regulations.

1) Connect SUZUKI scan tool to DLC. 2

2) Select “Data list” mode on scan tool.
3) Drive vehicle so that ATF temperature reaches
normal operating temperature (70 to 80 °C (158 to
176 °F)). (Page 5A-29)
ICL80C510013-02
NOTE
8) Start engine and run it at idle speed.
Engine coolant temperature rises when
revving engine in P or N range, but ATF 9) Shift to D range and check fluid pressure.
temperature does not rise in P or N range.
Drive vehicle to raise ATF temperature.
NOTE
4) Hoist vehicle.
Repeat test 3 times and take average of those
5) Remove left side engine under side cover. data for final time lag data.
6) Remove fluid pressure check hole bolt (1).

A/T line pressure

D range
At idle 240 – 350 kPa (2.4 – 3.6 kgf/cm2,
speed 35 – 50 psi, 2.4 – 3.5 bar)
 Automatic Transmission/Transaxle: 5A-45

10) Stop engine and disconnect special tool.
11) After applying ATF to new O-ring, fit it to fluid
pressure check hole bolt (1). Then install fluid
pressure check hole bolt to transaxle rear cover (2)
by tightening it to specified torque.
Tightening torque
Fluid pressure check hole bolt (a): 7.4 N·m (0.75
kgf-m, 5.5 lbf-ft)
14) Start engine and run it at idle speed.
15) Shift to R range and check fluid pressure.
NOTE
Repeat test 3 times and take average of those
data for final time lag data.

A/T line pressure

R range
At idle 420 – 560 kPa (4.3 – 5.7 kgf/cm2,
speed 61 – 81 psi, 4.2 – 5.6 bar)

16) Stop engine and disconnect special tool.

17) After applying ATF to new O-ring, fit it to fluid
pressure check hole bolt (1). Then install fluid
2 1, (a) pressure check hole bolt to transaxle rear cover (2)
ICL80C510014-01 by tightening it to specified torque.
12) Remove fluid pressure check hole bolt (1). Tightening torque
13) Attach oil pressure gauge to fluid pressure check Fluid pressure check hole bolt (a): 7.4 N·m (0.75
hole (2) in transaxle case. kgf-m, 5.5 lbf-ft)

NOTE
After attaching oil pressure gauge, check that
no fluid leakage exists.

Special tool
(A): 09925M37811M001

2 1, (a)

ICL80C510012-01

18) Install left side engine under side cover.

(A)

ICL80C510011-01
5A-46 Automatic Transmission/Transaxle:

Troubleshooting
Condition Possible cause Correction / Reference Item
Higher than standard Faulty pressure control solenoid valve “Solenoid Valve Inspection” (Page 5A-142)
level in each range “A”
Faulty pressure control solenoid valve “Solenoid Valve Inspection” (Page 5A-142)
“B”
Faulty valve body component “Valve Body Assembly Removal and
Installation” (Page 5A-138)
Lower than standard level Faulty pressure control solenoid valve “Solenoid Valve Inspection” (Page 5A-142)
in each range “A”
Faulty pressure control solenoid valve “Solenoid Valve Inspection” (Page 5A-142)
“B”
Faulty valve body component “Valve Body Assembly Removal and
Installation” (Page 5A-138)
Clogged oil strainer “A/T Oil Strainer Assembly Removal and
Installation” (Page 5A-136)
Faulty oil pump “Oil Pump Assembly Inspection” (Page 5A-
159)
Lower than standard level Faulty forward clutch Inspect forward clutch. If defect is found,
only in D range replace forward clutch.
Faulty valve body component “Valve Body Assembly Removal and
Installation” (Page 5A-138)
Lower than standard level Faulty reverse clutch Inspect reverse clutch. If defect is found,
only in R range replace reverse clutch.
Faulty 1st and reverse brake Inspect 1st and reverse brake. If defect is
found, replace 1st and reverse brake.
Faulty valve body component “Valve Body Assembly Removal and
Installation” (Page 5A-138)
Higher than standard Faulty pressure control solenoid valve “Solenoid Valve Inspection” (Page 5A-142)
level only in D range “A”
Faulty pressure control solenoid valve “Solenoid Valve Inspection” (Page 5A-142)
“B”
Higher than standard Faulty pressure control solenoid valve “Solenoid Valve Inspection” (Page 5A-142)
level only in R range “A”
Faulty pressure control solenoid valve “Solenoid Valve Inspection” (Page 5A-142)
“B”
Faulty valve body component “Valve Body Assembly Removal and
Installation” (Page 5A-138)
 Automatic Transmission/Transaxle: 5A-47

P Range Test
AENJHB0B5104017
! WARNING
If P range test is performed without checking that the area around the vehicle is clear of persons and
objects, there is a risk of severe personal injury or death.
Check that the downhill from and around the vehicle is clear of persons and objects before performing
the test.

1) Stop vehicle on a slope of 5 degrees or more, shift to P range and apply parking brake.
2) Stop engine, depress brake pedal and release parking brake.
3) Then, release brake pedal gradually and check that vehicle remains stationary.
4) Depress brake pedal and shift select lever to N range.
5) Then, release brake pedal gradually and check that vehicle moves.

Troubleshooting
Condition Possible cause Correction / Reference Item
Vehicle moves in P range Defective parking lock pawl or spring Check parking lock pawl and/or spring
or remains stationary in N referring to “A/T Assembly Reassembly” (Page
range 5A-182).
5A-48 Automatic Transmission/Transaxle:

A/T Symptom Diagnosis

AENJHB0B5104018

Engine Chassis Electrical system CAN ATF A/T

Diagnostic item

Drive system and body interference

Pressure control solenoid valve "C"

Pressure control solenoid valve "A"
Pressure control solenoid valve “B”

Engine coolant temperature signal

Water intrusion or different type of

Resonant exhaust pipe system

large deflection on drive shaft

range sensor misadjustment

Wear, looseness, scratches,

Suspension play, looseness

Transmission range sensor

Shift cable or transmission

Output shaft speed sensor

Accelerator position signal

Electro magnetic oil pump
Input shaft speed sensor

ATF temperature sensor

Shift solenoid valve "A"

Throttle position signal

Engine torque signal
Engine speed signal
TCC solenoid valve
Drive plate runout

Brake light switch

Torque converter
Engine mounting

Battery voltage
Tire unbalance

solenoid valve

ATF low level

ATF burning

fluid in ATF

Valve body
Oil seal
Gasket
Engine

O-ring
TCM

A/T
Symptom
Impossible to go
forward or slippage
in D range
Impossible or Impossible to go
start out backward or
slippage slippage in R
Slippage during
shifting or
acceleration
Excessive N → D time lag
Excessive N → R time lag
Starting motor does not operate in
P or N range
N→D
N→R
Engine stalls
During
acceleration
Poor acceleration
Poor 1st → 2nd
shift
Poor 2nd → 3rd
No gear shift
shift
Poor 3rd → 4th
shift
Non operate TCC (lock-up) system
Poor engine brake
No kickdown
Incorrect gear shift point
Shift lever movement hard /
too loose
No engine auto stop and start
Breather
Engine to T/A
housing mating
surface
Differential oil seal
Manual shaft oil
Oil leakage seal
T/A housing
Oil pan
Rear case
T/A case
O-ring
Oil cooler hose
N→D
N→R
Shift up
Excessive shift During coastdown
shock
During kickdown
When depressing
or releasing
accelerator (with
no shifting)
Abnormal During idling
vibration During driving
During idling
During garage shift

Abnormal noise During driving

During shifting
When depressing
or releasing
accelerator
(●: Applicable)
IJHB0A510028-01
 Automatic Transmission/Transaxle: 5A-49

MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)
AENJHB0B5104020
Refer to “MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)”: K15B in
Section 1A (Page 1A-65).

MIL Remains ON after Engine Starts

AENJHB0B5104021
Refer to “MIL Remains ON after Engine Starts”: K15B in Section 1A (Page 1A-65).

Transmission Warning Light Does Not Come ON with Ignition ON

AENJHB0B5104019
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Go to Step 2.
1) Check DTC related to CAN communication. for applicable DTC.

Is there CAN-DTC(s) detected?

2 DTC check Go to troubleshooting Substitute a known-
1) Check combination meter for DTC. for applicable DTC. good TCM and recheck
transmission warning
Is there any DTC(s)? light operation. (Page
5A-143)

Transmission Warning Light Remains ON with Ignition ON

AENJHB0B5104022
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Substitute a known-
1) Check DTC. (Page 5A-17) for applicable DTC. good combination meter
and recheck
Is there any DTC(s)? transmission warning
light operation. (Page
9C-34)
If transmission warning
light still remains ON,
substitute a known-
good TCM and recheck
transmission warning
light operation. (Page
5A-143)

DTC P0562 / P0563 / P1742 / P1743

AENJHB0B5104023
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0562: System Voltage Low • TCM power supply circuit and/or
Main power supply circuit voltage is lower than specified value for 20 sec. ground circuit
(1 D/C detection logic) • Charging system
P0563: System Voltage High
• TCM
Main power supply circuit voltage is higher than specified value for 20 sec.
(1 D/C detection logic)
P1742: Auxiliary Transmission Fluid Pump Supply Voltage Low
Main power supply circuit voltage is lower than 9 V for 5 sec.
(1 D/C detection logic)
P1743: Auxiliary Transmission Fluid Pump Supply Voltage High
Main power supply circuit voltage is higher than 16 V for 5 sec.
(1 D/C detection logic)
5A-50 Automatic Transmission/Transaxle:

Circuit Diagram

1
A1
2
E14-6 WHT

A2 8
3 7
6
E14-24 BLU
[B]
9

4 [A]

B1
E14-1 BLK
B2
E14-23 BLK

[C]
[a]
E14 E15

6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
IJHA0A510007-01

[A]: Ignition switch model B2: Ground circuit 6. “IGN” fuse

[B]: Keyless push start model 1. TCM 7. “IG11” relay
[C]: TCM connector (View: [a]) 2. “T/M” fuse 8. J/B
A1: Main power supply circuit 3. “IG1 SIG2” fuse 9. BCM
A2: Ignition on signal circuit 4. Ignition switch
B1: Ground circuit 5. Main fuse box

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– DTC P0717, P1738, P1739, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Start engine at idle for 30 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 TCM power supply and ground circuit check Go to Step 3. Repair TCM power
1) Check TCM power supply and ground circuits. (Page supply or ground circuit.
5A-115)

Is check result OK?

 Automatic Transmission/Transaxle: 5A-51

Step Action Yes No

3 TCM power supply voltage check Substitute a known- Check charging system.
1) Check power supply voltage for the following conditions. good TCM and recheck (Page 1J-3)
DTC. (Page 5A-143)
• Ignition ON
• Engine running at 3,000 rpm

Is voltage 10 to 15 V?

DTC P0602
AENJHB0B5104024
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0602: Control Module Programming Error TCM
TCM internal failure (data programming error).
(Transmission warning light does not light up)

DTC Confirmation Procedure

1) Start engine and run it at idle if possible.

NOTE
After reprogramming TCM, perform “TCM Learning Value Clearance” (Page 5A-116) and “TCM
Learning Value Initialization” (Page 5A-116).

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0602?
3 Reprogramming operation procedure check and Go to Step 4. Check the operation
equipment preparation procedures, SUZUKI
scan tool and DLC.
Is there a problem with reprogramming operation procedure,
SUZUKI scan tool or DLC?
4 TCM reprogramming Temporary failure. Replace TCM and
(Page 00-12) execute reprogramming
Was reprogramming of TCM executed? again. (Page 5A-143)

DTC P0604 / P062F / P1702

AENJHB0B5104025
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0604: Internal Control Module Random Access Memory (RAM) Error TCM
TCM internal failure (RAM error).
(1 D/C detection logic)
P062F: Internal Control Module EEPROM Error
TCM internal failure (EEPROM error).
(1 D/C detection logic)
P1702: Internal Control Module Memory Check Sum Error
TCM internal failure (check sum error).
(1 D/C detection logic)

DTC Confirmation Procedure

1) Set ignition “ON”.
5A-52 Automatic Transmission/Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0604, P062F or P1702?
3 DTC check Substitute a known- Temporary failure.
1) Clear DTC. (Page 5A-18) good TCM and recheck
DTC. (Page 5A-143)
2) Set ignition “OFF”.
3) Perform “DTC Confirmation Procedure”, and check
DTC. (Page 5A-17)

Is DTC P0604, P062F or P1702 still indicated?

DTC P0705
AENJHB0B5104026
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0705: Transmission Range Sensor “A” Circuit (PRNDL Input) • Select cable
Multiple signals are input simultaneously for 4 sec. • Transmission range sensor and/or its circuit
(1 D/C detection logic)
• TCM

Circuit Diagram

1
2

P A1
C166-6 PNK E15-20

R A2
IG1 C166-1 BRN E15-1
3
YEL A3
B1 N
C166-9 BEG E15-8

D A4
C166-7 BLU E15-7

2 A5
C166-3 PPL E15-19

L A6
C166-8 LT GRN E15-18

[A]
[B]
E14 E15 C166

6 5 4 3 2 1 6 5 4 3 2 1
4 3 2 1 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
9 8 7 6 5
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
IJHA0A510008-01

[A]: TCM connector (View: [a]) A3: Transmission range sensor (N range) circuit B1: Transmission range sensor power supply circuit
[B]: Transmission range sensor connector (View: [a]) A4: Transmission range sensor (D range) circuit 1. TCM
A1: Transmission range sensor (P range) circuit A5: Transmission range sensor (2 range) circuit 2. Transmission range sensor
A2: Transmission range sensor (R range) circuit A6: Transmission range sensor (L range) circuit 3. Back-up light
 Automatic Transmission/Transaxle: 5A-53

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• 10.2 V < Battery voltage < 15.5 V

1) Shift select lever to each of L, 2, D, N, R and P ranges for 10 seconds each.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Transmission range sensor circuit check using SUZUKI Temporary failure. Go to Step 3.
scan tool (Page 00-12)
1) With ignition “OFF”, connect SUZUKI scan tool to DLC.
2) Set ignition “ON” and check transmission range signal
(P, R, N, D, 2 or L) on scan tool when shifting select lever
to each range.

Is applicable range indicated?

3 Select cable adjustment check Go to Step 4. Adjust select cable and
1) Check select cable for adjustment. (Page 5A-130) recheck DTC.

Is it adjusted correctly?
4 Transmission range sensor adjustment check Go to Step 5. Adjust transmission
1) Check transmission range sensor for adjustment. range sensor and
(Page 5A-131) recheck DTC.

Is it adjusted correctly?
5 Transmission range sensor circuit check Go to Step 6. Repair or replace
1) Set ignition “OFF”. defective wire harness.
2) Disconnect “C166” and “E15” connectors.
3) Check for proper terminal connection to “C166” and
“E15” connectors.
4) If connections are OK, check the following points.
• Resistance between each of “A1”, “A2”, “A3”, “A4”,
“A5” and “A6” circuit terminals and other terminal at
“C166” connector: infinity
• Voltage of “A1”, “A2”, “A3”, “A4”, “A5” and “A6”
circuits: approx. 0 V (When ignition is “ON”)

Is check result OK?

6 Transmission range sensor check Substitute a known- Replace transmission
1) Check transmission range sensor. (Page 5A-131) good TCM and recheck range sensor. (Page
DTC. (Page 5A-143) 5A-130)
Is check result OK?

DTC P0707
AENJHB0B5104027
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0707: Transmission Range Sensor “A” Circuit Low • Select cable
No sensor signal is input for 28 sec. • Transmission range sensor and/or its circuit
(2 D/C detection logic)
• TCM
5A-54 Automatic Transmission/Transaxle:

Circuit Diagram

1
2

P A1
C166-6 PNK E15-20

R A2
IG1 C166-1 BRN E15-1
3
YEL A3
B1 N
C166-9 BEG E15-8

D A4
C166-7 BLU E15-7

2 A5
C166-3 PPL E15-19

L A6
C166-8 LT GRN E15-18

[A]
[B]
E14 E15 C166

6 5 4 3 2 1 6 5 4 3 2 1
4 3 2 1 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
9 8 7 6 5
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
IJHA0A510008-01

[A]: TCM connector (View: [a]) A3: Transmission range sensor (N range) circuit B1: Transmission range sensor power supply circuit
[B]: Transmission range sensor connector (View: [a]) A4: Transmission range sensor (D range) circuit 1. TCM
A1: Transmission range sensor (P range) circuit A5: Transmission range sensor (2 range) circuit 2. Transmission range sensor
A2: Transmission range sensor (R range) circuit A6: Transmission range sensor (L range) circuit 3. Back-up light

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0717, P0722, P0746, P0747, P0776, P0777, P0796, P0797,
P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Drive vehicle at 35 km/h (22 mile/h) or more in D (O/D ON) range for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
 Automatic Transmission/Transaxle: 5A-55

Step Action Yes No

2 Transmission range sensor circuit check using SUZUKI Intermittent connection • If all ranges are
scan tool and poor contact displayed OFF, go to
1) With ignition “OFF”, connect SUZUKI scan tool to DLC. trouble. (Page 00-12) Step 3.
2) Set ignition “ON”. • If specified range is
displayed OFF, go to
3) Check transmission range signal (P, R, N, D, 2, L) on
Step 4.
scan tool when shifting select lever to each range.

Is applicable range indicated?

3 Transmission range sensor power supply voltage check Go to Step 7. Repair or replace
1) With ignition “OFF”, disconnect “C166” connector. defective wire harness.
2) Check for proper terminal connection to “C166”
connector.
3) If connection is OK, set ignition “ON”.
4) Check that voltage between “B1” circuit and ground is
battery voltage.

Is check result OK?

4 Transmission range sensor signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C166” and “E15” defective wire harness.
connectors.
2) Check for proper terminal connection to “C166” and
“E15” connectors.
3) If connections are OK, check the following points.
• Resistance of “A1”, “A2”, “A3”, “A4”, “A5” and “A6”
circuits: less than 1 Ω
• Resistance between each of “A1”, “A2”, “A3”, “A4”,
“A5” and “A6” circuits and ground: infinity

Is check result OK?

5 Select cable adjustment check Go to Step 6. Adjust select cable and
1) Check select cable for adjustment. (Page 5A-130) recheck DTC.

Is it adjusted correctly?
6 Transmission range sensor adjustment check Go to Step 7. Adjust transmission
1) Check transmission range sensor for adjustment. range sensor and
(Page 5A-131) recheck DTC.

Is it adjusted correctly?
7 Transmission range sensor check
1) Check transmission range sensor. (Page 5A-131)
Is check result OK?
Substitute a known- Replace transmission
good TCM and recheck range sensor. (Page
DTC. (Page 5A-143) 5A-130)

DTC P0711
AENJHB0B5104028
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0711: Transmission Fluid Temperature Sensor “A” • ATF temperature sensor and/or its circuit
Circuit Range / Performance • TCM
ATF temperature sensor signal circuit voltage is unchanged
for 600 sec., after drive vehicle at 40 km/h (25 mile/h).
(2 D/C detection logic)
5A-56 Automatic Transmission/Transaxle:

Circuit Diagram

1
3

5V A1
2
E14-11 LT GRN C139-1

E14-12 BEG C139-7

A2

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1
6 5 4 3 2 1 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511009-01

[A]: TCM connector (View: [a]) A2: ATF temperature sensor ground circuit 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: ATF temperature sensor signal circuit 2. ATF temperature sensor

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0712, P0713, P0717, P0722, P0746, P0747, P0776,
P0777, P0796, P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973,
P0974, P1702, P1736, P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 45 km/h (28 mile/h) or more in D range.
3) Keep select lever position at D range for 12 min.
 Automatic Transmission/Transaxle: 5A-57

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 ATF temperature sensor signal circuit and ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) With ignition “OFF”, disconnect “C139” and “E14”
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 ATF temperature sensor check Substitute a known- Replace ATF
1) Check ATF temperature sensor. (Page 5A-138) good TCM and recheck temperature sensor.
DTC. (Page 5A-143) (Page 5A-137)
Is check result OK?

DTC P0712
AENJHB0B5104029
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0712: Transmission Fluid Temperature Sensor “A” Circuit Low • ATF temperature sensor and/or its circuit
ATF temperature sensor signal circuit voltage is lower than specified • TCM
value for 5 sec.
(2 D/C detection logic)

Circuit Diagram

1
3

5V A1
2
E14-11 LT GRN C139-1

E14-12 BEG C139-7

A2

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1
6 5 4 3 2 1 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511009-01

[A]: TCM connector (View: [a]) A2: ATF temperature sensor ground circuit 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: ATF temperature sensor signal circuit 2. ATF temperature sensor
5A-58 Automatic Transmission/Transaxle:

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• 10.2 V < Battery voltage < 15.5 V

1) Warm up engine to normal operating temperature.

2) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 ATF temperature sensor signal circuit check Go to Step 3. Replace defective wire
1) With ignition “OFF”, disconnect “C139” and “E14” harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity

Is check result OK?

3 ATF temperature sensor check Substitute a known- Repair or replace ATF
1) Check ATF temperature sensor. (Page 5A-138) good TCM and recheck temperature sensor.
DTC. (Page 5A-143) (Page 5A-137)
Is check result OK?

DTC P0713
AENJHB0B5104030
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0713: Transmission Fluid Temperature Sensor “A” • ATF temperature sensor and/or its circuit
Circuit High • TCM
ATF temperature sensor signal circuit voltage is higher
than specified value for 5 sec.
(2 D/C detection logic)
 Automatic Transmission/Transaxle: 5A-59

Circuit Diagram

1
3

5V A1
2
E14-11 LT GRN C139-1

E14-12 BEG C139-7

A2

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1
6 5 4 3 2 1 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511009-01

[A]: TCM connector (View: [a]) A2: ATF temperature sensor ground circuit 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: ATF temperature sensor signal circuit 2. ATF temperature sensor

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702,
P1736, P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 ATF temperature sensor signal circuit and ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) With ignition “OFF”, disconnect “C139” and “E14”
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

5A-60 Automatic Transmission/Transaxle:

Step Action Yes No

3 ATF temperature sensor check Substitute a known- Replace ATF
1) Check ATF temperature sensor. (Page 5A-138) good TCM and recheck temperature sensor.
DTC. (Page 5A-143) (Page 5A-137)
Is check result OK?

DTC P0717
AENJHB0B5104031
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0717: Input / Turbine Speed Sensor “A” Circuit No Signal • Input shaft speed sensor and/or its circuit
Input shaft speed sensor signal is not input even if output shaft • Direct clutch
speed sensor signal is input.
• TCM
(1 D/C detection logic)

Circuit Diagram

12V
A1
2
C44-2 WHT E15-16

C44-1 BLK E15-6

A2

[A] [B]
C44
E14 E15
2 1
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18 [a]

IGRA0A511010-01

[A]: TCM connector (View: [a]) A1: Input shaft speed sensor power supply circuit 1. TCM
[B]: Input shaft speed sensor connector (View: [a]) A2: Input shaft speed sensor signal circuit 2. Input shaft speed sensor

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0722, P0746, P0747, P0776, P0777, P0796, P0797,
P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
 Automatic Transmission/Transaxle: 5A-61

1) Drive vehicle at 30 km/h (19 mile/h) or more in D (O/D ON) range for 5 min. (keep throttle valve opening constant
in this step.)

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Input shaft speed sensor power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C44” connector. defective wire harness.
2) Check for proper terminal connection to “C44”
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

3 Input shaft speed sensor signal circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “E15” connector. defective wire harness.
2) Check for proper terminal connection to “E15” connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C44” connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

4 Input shaft speed sensor check Go to Step 5. Replace input shaft
1) Check input shaft speed sensor. (Page 5A-135) speed sensor. (Page
5A-135)
Is check result OK?
5 Input shaft speed sensor teeth visual check Intermittent connection Replace direct clutch.
1) Check input shaft speed sensor teeth (1) visually. and poor contact • Removal: (Page
trouble. (Page 00-12) 5A-151)
1 If OK, substitute a • Installation: (Page
known-good TCM and 5A-182)
recheck DTC. (Page
5A-143)

ICL80C510227-01

Is check result OK?

DTC P0722
AENJHB0B5104032
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0722: Output Speed Sensor Circuit No Signal • Output shaft speed sensor and/or its circuit
Output shaft speed sensor signal is not input even if input • Reduction drive gear
shaft speed sensor signal is input.
• TCM
(1 D/C detection logic)
5A-62 Automatic Transmission/Transaxle:

Circuit Diagram

12V
A1
2
C45-2 PPL E15-14

C45-1 GRY E15-5

A2

[A] [B]
C45
E14 E15
2 1
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18 [a]

IGRA0A511011-01

[A]: TCM connector (View: [a]) A1: Output shaft speed sensor power supply circuit 1. TCM
[B]: Output shaft speed sensor connector (View: [a]) A2: Output shaft speed sensor signal circuit 2. Output shaft speed sensor

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0746, P0747, P0776, P0777, P0796, P0797,
P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Drive vehicle at 15 km/h (9 mile/h) or more in D (O/D ON) range for 5 min.
 Automatic Transmission/Transaxle: 5A-63

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Output shaft speed sensor power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C45” connector. defective wire harness.
2) Check for proper terminal connection to “C45”
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

3 Output shaft speed sensor signal circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “E15” connector. defective wire harness.
2) Check for proper terminal connection to “E15” connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C45” connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

4 Output shaft speed sensor check Go to Step 5. Replace output shaft
1) Check output shaft speed sensor. (Page 5A-134) speed sensor. (Page
5A-134)
Is check result OK?
5 Output reduction drive gear visual check Intermittent connection Replace reduction drive
1) Check reduction drive gear (1) visually. and poor contact gear.
trouble. (Page 00-12) • Removal: (Page
1 If OK, substitute a 5A-151)
known-good TCM and • Installation: (Page
recheck DTC. (Page 5A-182)
5A-143)

ICL80C510228-01

Is check result OK?

DTC P072A
AENJHB0B5104033
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P072A: Stuck in Neutral • Valve body assembly
Difference between engine speed and input shaft speed is • A/T (clutch, brake or gear etc.)
less than specified value, and the gear commanded by
• TCM
TCM does not match the actual gear when driving.
(1 D/C detection logic)
5A-64 Automatic Transmission/Transaxle:

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– ATF temperature ≥ 20 °C (68 °F)
– DTC P0562, P0563, P0604, P0705, P0707, P0711, P0712, P0713, P0717, P0961, P0962, P0963,
P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738, P1739, P2762,
U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Drive vehicle with 1st gear for 10 sec.
3) Drive vehicle with 2nd gear for 10 sec.
4) Drive vehicle with 3rd gear for 10 sec.
5) Drive vehicle with 4th gear for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Valve body assembly replacement Check A/T mechanical End.
1) Replace valve body assembly. (Page 5A-138) systems. (clutch, brake
or gear etc.)
2) Check DTC.
If OK, substitute a
Is DTC P072A still indicated? known-good TCM and
recheck DTC. (Page
5A-143)
 Automatic Transmission/Transaxle: 5A-65

DTC P0731
AENJHB0B5104034
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0731: Gear 1 Incorrect Ratio • Pressure control solenoid valve “A” and/or its circuit
The gear commanded by TCM does not match the actual • Pressure control solenoid valve “B” and/or its circuit
gear when driving.
• TCC solenoid valve and/or its circuit
(2 D/C detection logic)
• Valve body assembly
• A/T (clutch, brake or gear etc.)
• TCM

Circuit Diagram

1 5
12V
A1 2
E14-22 RED C139-6
A2
E14-9 BLK C139-13
12V
3
B1
E14-21 YEL C139-5
B2
E14-19 BLU C139-12
12V
4
C1
E14-5 LT BLU C139-3
C2
E14-3 GRN C139-9

[B] C139
[A]
E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511012-01

[A]: TCM connector (View: [a])
[B]: Solenoid connector (View: [a])
A1: Pressure control solenoid valve “A” drive circuit (+)
A2: Pressure control solenoid valve “A” drive circuit (–)
B1: Pressure control solenoid valve “B” drive circuit (+)
B2: Pressure control solenoid valve “B” drive circuit (–) 3. Pressure control solenoid valve “B”
C1: TCC solenoid valve drive circuit (+) 4. TCC solenoid valve
C2: TCC solenoid valve drive circuit (–) 5. A/T
1. TCM
2. Pressure control solenoid valve “A”

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.
5A-66 Automatic Transmission/Transaxle:

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– ATF temperature ≥ 20 °C (68 °F)
– DTC P0562, P0563, P0604, P0705, P0707, P0711, P0712, P0713, P0717, P0722, P0751, P0797,
P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737,
P1738, P1739, P2762, P2763, P2764, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Drive vehicle at more than 35 km/h (22 mile/h) in “L” range.

2) Release accelerator pedal, and keep vehicle coasting for 20 sec. with engine brakes applied.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Solenoid valve drive circuit check Go to Step 3. Repair or replace
1) Check the following circuits. defective wire harness.
• Pressure control solenoid valve “A” drive circuit (+)
and (–): (Page 5A-81)
• Pressure control solenoid valve “B” drive circuit (+)
and (–): (Page 5A-85)
• TCC solenoid valve drive circuit (+) and (–): (Page
5A-103)

Is check result OK?

3 Solenoid valve circuit check Go to Step 5. Go to Step 4.
1) Check the following circuits. (Page 5A-141)
• Pressure control solenoid valve “A”
• Pressure control solenoid valve “B”
• TCC solenoid valve drive

Is check result OK?

4 Solenoid valve check for resistance Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check the following solenoid valve for resistance.
(Page 5A-142)
• Pressure control solenoid valve “A”
• Pressure control solenoid valve “B”
• TCC solenoid valve drive

Is check result OK?

5 Solenoid valve check for operation Go to Step 6. Replace valve body
1) Check the following solenoid valve for operation. assembly. (Page 5A-
(Page 5A-142) 138)
• Pressure control solenoid valve “A”
• Pressure control solenoid valve “B”
• TCC solenoid valve drive

Is check result OK?

 Automatic Transmission/Transaxle: 5A-67

Step Action Yes No

6 Valve body assembly replacement Check A/T mechanical End.
1) Replace valve body assembly. (Page 5A-138) systems. (clutch, brake
or gear etc.)
2) Check DTC.
If OK, substitute a
Is DTC P0731 still indicated? known-good TCM and
recheck DTC. (Page
5A-143)

DTC P0741
AENJHB0B5104035
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0741: Torque Converter Clutch Circuit Performance / Stuck Off • Shift solenoid valve “A” and/or its circuit
Difference between engine speed and input shaft speed is more than • TCC solenoid valve and/or its circuit
specified value even if TCC solenoid valve is turned on.
• Valve body assembly
(2 D/C detection logic)
• A/T (clutch, brake or gear etc.)
• TCM

Circuit Diagram

1
4

12V
A1 2
E14-16 BRN C139-10

12V
3
B1
E14-5 LT BLU C139-3

B2
E14-3 GRN C139-9

[B] C139
[A]
E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511013-01

[A]: TCM connector (View: [a]) B1: TCC solenoid valve drive circuit (+) 2. Shift solenoid valve “A”
[B]: Solenoid connector (View: [a]) B2: TCC solenoid valve drive circuit (–) 3. TCC solenoid valve
A1: Shift solenoid valve “A” drive circuit 1. TCM 4. A/T

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.
5A-68 Automatic Transmission/Transaxle:

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0711, P0712, P0713, P0717, P0961, P0962, P0963,
P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738, P1739, P2762,
P2763, P2764, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Drive vehicle with 4th gear in D range for 1 min. (keep throttle valve opening constant in this step.)

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Solenoid valve drive circuit check Go to Step 3. Repair or replace
1) Check the following circuits. defective wire harness.
• Shift solenoid valve “A” drive circuit
– Short to ground: (Page 5A-94)
– Open and short to power supply circuit: (Page
5A-95)
• TCC solenoid valve drive circuit (+) and (–): (Page
5A-103)

Is check result OK?

3 Solenoid valve circuit check Go to Step 5. Go to Step 4.
1) Check the following circuits. (Page 5A-141)
• Shift solenoid valve “A”
• TCC solenoid valve drive

Is check result OK?

4 Solenoid valve check for resistance Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check the following solenoid valve for operation.
(Page 5A-142)
• Shift solenoid valve “A”
• TCC solenoid valve drive

Is check result OK?

5 Solenoid valve check for operation Go to Step 6. Replace valve body
1) Check the following solenoid valve for operation. assembly. (Page 5A-
(Page 5A-142) 138)
• Shift solenoid valve “A”
• TCC solenoid valve drive

Is check result OK?

6 Valve body assembly replacement Check A/T mechanical End.
1) Replace valve body assembly. (Page 5A-138) systems. (clutch, brake
or gear etc.)
2) Check DTC.
If OK, substitute a
Is DTC P0741 still indicated? known-good TCM and
recheck DTC. (Page
5A-143)
 Automatic Transmission/Transaxle: 5A-69

DTC P0742
AENJHB0B5104036
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0742: Torque Converter Clutch Circuit Stuck On • TCC solenoid valve and/or its circuit
Difference between engine speed and input shaft speed is less • Valve body assembly
than specified value even if TCC solenoid valve is turned off.
• A/T (clutch, brake or gear etc.)
(2 D/C detection logic)
• TCM

Circuit Diagram

1
3

12V
2
A1
E14-5 LT BLU C139-3

A2
E14-3 GRN C139-9

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511014-01

[A]: TCM connector (View: [a]) A2: TCC solenoid valve drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: TCC solenoid valve drive circuit (+) 2. TCC solenoid valve

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0711, P0712, P0713, P0717, P0961, P0962, P0963,
P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738, P1739, P2762,
P2763, P2764, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Drive vehicle and increase vehicle speed to 80 km/h (50 mile/h) with 50% throttle opening.
2) Close throttle and decrease vehicle speed to 30 km/h (18 mile/h).
3) Repeat Steps 1) to 2) 5 times or more.
5A-70 Automatic Transmission/Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 TCC solenoid valve drive circuit check Go to Step 3. Repair or replace
1) Check TCC solenoid valve drive circuit (+) and (–). defective wire harness.
(Page 5A-103)

Is check result OK?

3 TCC solenoid valve circuit check Go to Step 5. Go to Step 4.
1) Check TCC solenoid valve drive circuit. (Page 5A-141)

Is check result OK?

4 TCC solenoid valve check for resistance Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check TCC solenoid valve for resistance. (Page 5A-
142)

Is check result OK?

5 TCC solenoid valve check for operation Go to Step 6. Replace valve body
1) Check TCC solenoid valve for operation. (Page 5A- assembly. (Page 5A-
142) 138)

Is check result OK?

6 Valve body assembly replacement Check A/T mechanical End.
1) Replace valve body assembly. (Page 5A-138) systems. (clutch, brake
or gear etc.)
2) Check DTC.
If OK, substitute a
Is DTC P0742 still indicated? known-good TCM and
recheck DTC. (Page
5A-143)

DTC P0746 / P0747

AENJHB0B5104037
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0746: Pressure Control Solenoid “A” Performance / Stuck Off • Pressure control solenoid valve “A”
The gear commanded by TCM does not match the actual gear when driving. and/or its circuit
(2 D/C detection logic) • Valve body assembly
P0747: Pressure Control Solenoid “A” Stuck On
• A/T (clutch, brake or gear etc.)
The gear commanded by TCM does not match the actual gear when driving.
(2 D/C detection logic) • TCM
 Automatic Transmission/Transaxle: 5A-71

Circuit Diagram

1
3

12V
2
A1
E14-22 RED C139-6

A2
E14-9 BLK C139-13

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511015-01

[A]: TCM connector (View: [a]) A2: Pressure control solenoid valve “A” drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: Pressure control solenoid valve “A” drive circuit (+) 2. Pressure control solenoid valve “A”

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

P0746

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– ATF temperature ≥ 20 °C (68 °F)
– DTC P0562, P0563, P0604, P0705, P0707, P0711, P0712, P0713, P0717, P0722, P0747, P0961,
P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738,
P1739, P2762, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Drive vehicle with 1st gear for 10 sec.
3) Drive vehicle with 2nd gear for 10 sec.
4) Drive vehicle with 3rd gear for 10 sec.
5) Drive vehicle with 4th gear for 10 sec.
5A-72 Automatic Transmission/Transaxle:

P0747

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– ATF temperature ≥ –20 °C (–4 °F)
– DTC P0562, P0563, P0604, P0705, P0707, P0711, P0712, P0713, P0717, P0722, P0961, P0962,
P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738, P1739,
P2762, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Drive vehicle with 4th gear in D range for 20 sec. (keep throttle valve opening constant in this step.)

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Pressure control solenoid valve “A” drive circuit check Go to Step 3. Repair or replace
1) Check pressure control solenoid valve “A” circuit (+) and defective wire harness.
(–). (Page 5A-81)

Is check result OK?

3 Pressure control solenoid valve “A” circuit check Go to Step 5. Go to Step 4.
1) Check pressure control solenoid valve “A” circuit.
(Page 5A-141)

Is check result OK?

4 Pressure control solenoid valve “A” check for Replace solenoid Replace valve body
resistance harness. (Page 5A- assembly. (Page 5A-
1) Remove valve body assembly. (Page 5A-138) 137) 138)
2) Check pressure control solenoid valve “A” for resistance.
(Page 5A-142)

Is check result OK?

5 Pressure control solenoid valve “A” check for operation Go to Step 6. Replace valve body
1) Check pressure control solenoid valve “A” for operation. assembly. (Page 5A-
(Page 5A-142) 138)

Is check result OK?

6 Valve body assembly replacement Check A/T mechanical End.
1) Replace valve body assembly. (Page 5A-138) systems. (clutch, brake
or gear etc.)
2) Check DTC.
If OK, substitute a
Is DTC P0746 / P0747 still indicated? known-good TCM and
recheck DTC. (Page
5A-143)
 Automatic Transmission/Transaxle: 5A-73

DTC P0751
AENJHB0B5104038
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0751: Shift Solenoid “A” Performance / Stuck Off • Shift solenoid valve “A” and/or its circuit
The gear commanded by TCM does not match the actual • Valve body assembly
gear when driving.
• A/T (clutch, brake or gear etc.)
(2 D/C detection logic)
• TCM

Circuit Diagram

1
3

12V
A1 2
E14-16 BRN C139-10

[B] C139
[A]
E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511016-01

[A]: TCM connector (View: [a]) A1: Shift solenoid valve “A” drive circuit 2. Shift solenoid valve “A”
[B]: Solenoid connector (View: [a]) 1. TCM 3. A/T

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– ATF temperature ≥ 20 °C (68 °F)
– DTC P0562, P0563, P0604, P0705, P0707, P0711, P0712, P0713, P0717, P0722, P0961, P0962,
P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738, P1739,
P2762, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Repeat acceleration at 50% throttle opening and deceleration between 10 and 35 km/h (6 and 22 mile/h) in L
range for more than 5 times.
5A-74 Automatic Transmission/Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Shift solenoid valve “A” drive circuit check Go to Step 3. Repair or replace
1) Check shift solenoid valve “A” drive circuit. defective wire harness.
• Short to ground: (Page 5A-94)
• Open and short to power supply circuit: (Page 5A-
95)

Is check result OK?

3 Shift solenoid valve “A” circuit check Go to Step 5. Go to Step 4.
1) Check shift solenoid valve “A” circuit. (Page 5A-141)

Is check result OK?

4 Shift solenoid valve “A” check for resistance Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check shift solenoid valve “A” for resistance. (Page
5A-142)

Is check result OK?

5 Shift solenoid valve “A” check for operation Go to Step 6. Replace valve body
1) Check shift solenoid valve “A” for operation. (Page 5A- assembly. (Page 5A-
142) 138)

Is check result OK?

6 Valve body assembly replacement Check A/T mechanical End.
1) Replace valve body assembly. (Page 5A-138) systems. (clutch, brake
or gear etc.)
2) Check DTC.
If OK, substitute a
Is DTC P0751 still indicated? known-good TCM and
recheck DTC. (Page
5A-143)

DTC P0776
AENJHB0B5104039
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0776: Pressure Control Solenoid “B” Performance / Stuck Off • Shift solenoid valve “A” and/or its circuit
The gear commanded by TCM does not match the actual gear when • Pressure control solenoid valve “B” and/or its
driving. circuit
(2 D/C detection logic)
• Valve body assembly
• A/T (clutch, brake or gear etc.)
• TCM
 Automatic Transmission/Transaxle: 5A-75

Circuit Diagram

1
4

12V
A1 2
E14-16 BRN C139-10

12V
3
B1
E14-21 YEL C139-5

B2
E14-19 BLU C139-12

[B] C139
[A]
E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511017-01

[A]: TCM connector (View: [a]) B1: Pressure control solenoid valve “B” drive circuit (+) 2. Shift solenoid valve “A”
[B]: Solenoid connector (View: [a]) B2: Pressure control solenoid valve “B” drive circuit (–) 3. Pressure control solenoid valve “B”
A1: Shift solenoid valve “A” drive circuit 1. TCM 4. A/T

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– ATF temperature ≥ 20 °C (68 °F)
– DTC P0562, P0563, P0604, P0705, P0707, P0711, P0712, P0713, P0717, P0722, P0747, P0961,
P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738,
P1739, P2762, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Drive vehicle with 1st gear for 10 sec.
3) Drive vehicle with 2nd gear for 10 sec.
4) Drive vehicle with 3rd gear for 10 sec.
5) Drive vehicle with 4th gear for 10 sec.
5A-76 Automatic Transmission/Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Solenoid valve drive circuit check Go to Step 3. Repair or replace
1) Check the following circuits. defective wire harness.
• Shift solenoid valve “A” drive circuit
– Short to ground: (Page 5A-94)
– Open and short to power supply circuit: (Page
5A-95)
• Pressure control solenoid valve “B” drive circuit (+)
and (–): (Page 5A-85)

Is check result OK?

3 Solenoid valve circuit check Go to Step 5. Go to Step 4.
1) Check the following circuits. (Page 5A-141)
• Shift solenoid valve “A”
• Pressure control solenoid valve “B”

Is check result OK?

4 Solenoid valve check for resistance Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check the following solenoid valve for resistance.
(Page 5A-142)
• Shift solenoid valve “A”
• Pressure control solenoid valve “B”

Is check result OK?

5 Solenoid valve check for operation Go to Step 6. Replace valve body
1) Check the following solenoid valve for operation. assembly. (Page 5A-
(Page 5A-142) 138)
• Shift solenoid valve “A”
• Pressure control solenoid valve “B”

Is check result OK?

6 Valve body assembly replacement Check A/T mechanical End.
1) Replace valve body assembly. (Page 5A-138) systems. (clutch, brake
or gear etc.)
2) Check DTC.
If OK, substitute a
Is DTC P0776 still indicated? known-good TCM and
recheck DTC. (Page
5A-143)

DTC P0777
AENJHB0B5104040
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0777: Pressure Control Solenoid “B” Stuck On • Pressure control solenoid valve “B” and/or its circuit
The gear commanded by TCM does not match the actual • Valve body assembly
gear when driving.
• A/T (clutch, brake or gear etc.)
(2 D/C detection logic)
• TCM
 Automatic Transmission/Transaxle: 5A-77

Circuit Diagram

1
3

12V
2
A1
E14-21 YEL C139-5

A2
E14-19 BLU C139-12

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511018-01

[A]: TCM connector (View: [a]) A2: Pressure control solenoid valve “B” drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: Pressure control solenoid valve “B” drive circuit (+) 2. Pressure control solenoid valve “B”

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– ATF temperature ≥ 20 °C (68 °F)
– DTC P0562, P0563, P0604, P0705, P0707, P0711, P0712, P0713, P0717, P0722, P0746, P0747,
P0776, P0796, P0797, P0961, 0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973,
P0974, P1702, P1736, P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Repeat acceleration at 50% throttle opening and deceleration between 10 and 35 km/h (6 and 22 mile/h) in L
range for more than 5 times.
2) Drive vehicle in 2 range for 1 min. (keep throttle valve opening constant in this step.)

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
5A-78 Automatic Transmission/Transaxle:

Step Action Yes No

2 Pressure control solenoid valve “B” drive circuit check Go to Step 3. Repair or replace
1) Check pressure control solenoid valve “B” circuit (+) and defective wire harness.
(–). (Page 5A-85)

Is check result OK?

3 Pressure control solenoid valve “B” circuit check Go to Step 5. Go to Step 4.
1) Check pressure control solenoid valve “B” circuit.
(Page 5A-141)

Is check result OK?

4 Pressure control solenoid valve “B” check for Replace solenoid Replace valve body
resistance harness. (Page 5A- assembly. (Page 5A-
1) Remove valve body assembly. (Page 5A-138) 137) 138)
2) Check pressure control solenoid valve “B” for resistance.
(Page 5A-142)

Is check result OK?

5 Pressure control solenoid valve “B” check for operation Go to Step 6. Replace valve body
1) Check pressure control solenoid valve “B” for operation. assembly. (Page 5A-
(Page 5A-142) 138)

Is check result OK?

6 Valve body assembly replacement Check A/T mechanical End.
1) Replace valve body assembly. (Page 5A-138) systems. (clutch, brake
or gear etc.)
2) Check DTC.
If OK, substitute a
Is DTC P0777 still indicated? known-good TCM and
recheck DTC. (Page
5A-143)

DTC P0796 / P0797

AENJHB0B5104041
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0796: Pressure Control Solenoid “C” Performance / Stuck Off • Pressure control solenoid valve “C”
The gear commanded by TCM does not match the actual gear when driving. and/or its circuit
(2 D/C detection logic) • Valve body assembly
P0797: Pressure Control Solenoid “C” Stuck On
• A/T (clutch, brake or gear etc.)
The gear commanded by TCM does not match the actual gear when driving.
(2 D/C detection logic) • TCM
 Automatic Transmission/Transaxle: 5A-79

Circuit Diagram

1
3

12V
2
A1
E14-4 GRY C139-4

A2
E14-2 PPL C139-11

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511019-01

[A]: TCM connector (View: [a]) A2: Pressure control solenoid valve “C” drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: Pressure control solenoid valve “C” drive circuit (+) 2. Pressure control solenoid valve “C”

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

P0796

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– ATF temperature ≥ 20 °C (68 °F)
– DTC P0562, P0563, P0604, P0705, P0707, P0711, P0712, P0713, P0717, P0722, P0777, P0961,
P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738,
P1739, P2762, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Drive vehicle with 1st gear for 10 sec.
3) Drive vehicle with 2nd gear for 10 sec.
4) Drive vehicle with 3rd gear for 10 sec.
5) Drive vehicle with 4th gear for 10 sec.
5A-80 Automatic Transmission/Transaxle:

P0797

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– ATF temperature ≥ 20 °C (68 °F)
– DTC P0562, P0563, P0604, P0705, P0707, P0711, P0712, P0713, P0717, P0722, P0961, P0962,
P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738, P1739,
P2762, U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Repeat acceleration at 50% throttle opening and deceleration between 10 and 35 km/h (6 and 22 mile/h) in L
range for more than 5 times.
2) Drive vehicle with 3rd gear for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Pressure control solenoid valve “C” drive circuit check Go to Step 3. Repair or replace
1) Check pressure control solenoid valve “C” circuit (+) and defective wire harness.
(–). (Page 5A-90)

Is check result OK?

3 Pressure control solenoid valve “C” circuit check Go to Step 5. Go to Step 4.
1) Check pressure control solenoid valve “C” circuit.
(Page 5A-141)

Is check result OK?

4 Pressure control solenoid valve “C” check for Replace solenoid Replace valve body
resistance harness. (Page 5A- assembly. (Page 5A-
1) Remove valve body assembly. (Page 5A-138) 137) 138)
2) Check pressure control solenoid valve “C” for resistance.
(Page 5A-142)

Is check result OK?

5 Pressure control solenoid valve “C” check for operation Go to Step 6. Replace valve body
1) Check pressure control solenoid valve “C” for operation. assembly. (Page 5A-
(Page 5A-142) 138)

Is check result OK?

6 Valve body assembly replacement Check A/T mechanical End.
1) Replace valve body assembly. (Page 5A-138) systems. (clutch, brake
or gear etc.)
2) Check DTC.
If OK, substitute a
Is DTC P0796 / P0797 still indicated? known-good TCM and
recheck DTC. (Page
5A-143)
 Automatic Transmission/Transaxle: 5A-81

DTC P0961
AENJHB0B5104042
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0961: Pressure Control Solenoid “A” Control Circuit • Pressure control solenoid valve “A” and/or its circuit
Range / Performance • Valve body assembly
Difference between target electric current and measured
• TCM
current of pressure control solenoid valve “A” drive circuit
(+) is more than specified value for 3 sec.
(1 D/C detection logic)

Circuit Diagram

1
3

12V
2
A1
E14-22 RED C139-6

A2
E14-9 BLK C139-13

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511015-01

[A]: TCM connector (View: [a]) A2: Pressure control solenoid valve “A” drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: Pressure control solenoid valve “A” drive circuit (+) 2. Pressure control solenoid valve “A”

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.5 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

5A-82 Automatic Transmission/Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Pressure control solenoid valve “A” drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “E14” defective wire harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C139” connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 Pressure control solenoid valve “A” circuit check Substitute a known- Go to Step 4.
1) Check resistance of pressure control solenoid valve “A” good TCM and recheck
circuit. (Page 5A-141) DTC. (Page 5A-143)

Is check result OK?

4 Pressure control solenoid valve “A” check Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check pressure control solenoid valve “A”. (Page 5A-
142)

Is check result OK?

DTC P0962
AENJHB0B5104043
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0962: Pressure Control Solenoid “A” Control Circuit Low • Pressure control solenoid valve “A” and/or its
Measured electric current of pressure control solenoid valve “A” circuit
drive circuit (+) is lower than specified value. • Valve body assembly
(1 D/C detection logic)
• TCM
 Automatic Transmission/Transaxle: 5A-83

Circuit Diagram

1
3

12V
2
A1
E14-22 RED C139-6

A2
E14-9 BLK C139-13

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511015-01

[A]: TCM connector (View: [a]) A2: Pressure control solenoid valve “A” drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: Pressure control solenoid valve “A” drive circuit (+) 2. Pressure control solenoid valve “A”

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0961, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Pressure control solenoid valve “A” drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “E14” defective wire harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C139” connector: infinity

Is check result OK?

5A-84 Automatic Transmission/Transaxle:

Step Action Yes No

3 Pressure control solenoid valve “A” circuit check Substitute a known- Go to Step 4.
1) Check resistance of pressure control solenoid valve “A” good TCM and recheck
circuit. (Page 5A-141) DTC. (Page 5A-143)

Is check result OK?

4 Pressure control solenoid valve “A” check Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check pressure control solenoid valve “A”. (Page 5A-
142)

Is check result OK?

DTC P0963
AENJHB0B5104044
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0963: Pressure Control Solenoid “A” Control Circuit High • Pressure control solenoid valve “A” and/or its
Measured electric current of pressure control solenoid valve “A” circuit
drive circuit (+) is higher than specified value. • Valve body assembly
(1 D/C detection logic)
• TCM

Circuit Diagram

1
3

12V
2
A1
E14-22 RED C139-6

A2
E14-9 BLK C139-13

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511015-01

[A]: TCM connector (View: [a]) A2: Pressure control solenoid valve “A” drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: Pressure control solenoid valve “A” drive circuit (+) 2. Pressure control solenoid valve “A”

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0961, P0962, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

 Automatic Transmission/Transaxle: 5A-85

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Pressure control solenoid valve “A” drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “E14” defective wire harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C139” connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 Pressure control solenoid valve “A” circuit check Substitute a known- Go to Step 4.
1) Check resistance of pressure control solenoid valve “A” good TCM and recheck
circuit. (Page 5A-141) DTC. (Page 5A-143)

Is check result OK?

4 Pressure control solenoid valve “A” check Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check pressure control solenoid valve “A”. (Page 5A-
142)

Is check result OK?

DTC P0965
AENJHB0B5104045
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0965: Pressure Control Solenoid “B” Control Circuit • Pressure control solenoid valve “B” and/or its circuit
Range / Performance • Valve body assembly
Difference between target electric current and measured
• TCM
current of pressure control solenoid valve “B” drive circuit
(+) is more than specified value for 3 sec.
(1 D/C detection logic)
5A-86 Automatic Transmission/Transaxle:

Circuit Diagram

1
3

12V
2
A1
E14-21 YEL C139-5

A2
E14-19 BLU C139-12

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511018-01

[A]: TCM connector (View: [a]) A2: Pressure control solenoid valve “B” drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: Pressure control solenoid valve “B” drive circuit (+) 2. Pressure control solenoid valve “B”

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.5 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0961, P0962, P0963, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Pressure control solenoid valve “B” drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “E14” defective wire harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C139” connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

 Automatic Transmission/Transaxle: 5A-87

Step Action Yes No

3 Pressure control solenoid valve “B” circuit check Substitute a known- Go to Step 4.
1) Check resistance of pressure control solenoid valve “B” good TCM and recheck
circuit. (Page 5A-141) DTC. (Page 5A-143)

Is check result OK?

4 Pressure control solenoid valve check Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check pressure control solenoid valve “B”. (Page 5A-
142)

Is check result OK?

DTC P0966
AENJHB0B5104046
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0966: Pressure Control Solenoid “B” Control Circuit Low • Pressure control solenoid valve “B” and/or its
Measured electric current of pressure control solenoid valve “B” circuit
drive circuit (+) is lower than specified value. • Valve body assembly
(1 D/C detection logic)
• TCM

Circuit Diagram

1
3

12V
2
A1
E14-21 YEL C139-5

A2
E14-19 BLU C139-12

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511018-01

[A]: TCM connector (View: [a]) A2: Pressure control solenoid valve “B” drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: Pressure control solenoid valve “B” drive circuit (+) 2. Pressure control solenoid valve “B”

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0961, P0962, P0963, P0965, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

5A-88 Automatic Transmission/Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Pressure control solenoid valve “B” drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “E14” defective wire harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C139” connector: infinity

Is check result OK?

3 Pressure control solenoid valve “B” circuit check Substitute a known- Go to Step 4.
1) Check resistance of pressure control solenoid valve “B” good TCM and recheck
circuit. (Page 5A-141) DTC. (Page 5A-143)

Is check result OK?

4 Pressure control solenoid valve check Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check pressure control solenoid valve “B”. (Page 5A-
142)

Is check result OK?

DTC P0967
AENJHB0B5104047
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0967: Pressure Control Solenoid “B” Control Circuit High • Pressure control solenoid valve “B” and/or its
Measured electric current of pressure control solenoid valve “B” circuit
drive circuit (+) is higher than specified value. • Valve body assembly
(1 D/C detection logic)
• TCM
 Automatic Transmission/Transaxle: 5A-89

Circuit Diagram

1
3

12V
2
A1
E14-21 YEL C139-5

A2
E14-19 BLU C139-12

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511018-01

[A]: TCM connector (View: [a]) A2: Pressure control solenoid valve “B” drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: Pressure control solenoid valve “B” drive circuit (+) 2. Pressure control solenoid valve “B”

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0961, P0962, P0963, P0965, P0966, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Pressure control solenoid valve “B” drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “E14” defective wire harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C139” connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

5A-90 Automatic Transmission/Transaxle:

Step Action Yes No

3 Pressure control solenoid valve “B” circuit check Substitute a known- Go to Step 4.
1) Check resistance of pressure control solenoid valve “B” good TCM and recheck
circuit. (Page 5A-141) DTC. (Page 5A-143)

Is check result OK?

4 Pressure control solenoid valve check Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check pressure control solenoid valve “B”. (Page 5A-
142)

Is check result OK?

DTC P0969
AENJHB0B5104048
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0969: Pressure Control Solenoid “C” Control Circuit • Pressure control solenoid valve “C” and/or its circuit
Range / Performance • Valve body assembly
Difference between target electric current and measured
• TCM
current of pressure control solenoid valve “C” drive circuit
(+) is more than specified value for 3 sec.
(1 D/C detection logic)

Circuit Diagram

1
3

12V
2
A1
E14-4 GRY C139-4

A2
E14-2 PPL C139-11

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511019-01

[A]: TCM connector (View: [a]) A2: Pressure control solenoid valve “C” drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: Pressure control solenoid valve “C” drive circuit (+) 2. Pressure control solenoid valve “C”

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.
 Automatic Transmission/Transaxle: 5A-91

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.5 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0970, P0971, P0973, P0974, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Drive vehicle in D range at 2nd for 10 sec.

2) Drive vehicle in D range at 4th for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Pressure control solenoid valve “C” drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “E14” defective wire harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C139” connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 Pressure control solenoid valve “C” circuit check Substitute a known- Go to Step 4.
1) Check resistance of pressure control solenoid valve “C” good TCM and recheck
circuit. (Page 5A-141) DTC. (Page 5A-143)

Is check result OK?

4 Pressure control solenoid valve check Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check pressure control solenoid valve “C”. (Page 5A-
142)

Is check result OK?

DTC P0970
AENJHB0B5104049
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0970: Pressure Control Solenoid “C” Control Circuit Low • Pressure control solenoid valve “C” and/or its
Measured electric current of pressure control solenoid valve “C” circuit
drive circuit (+) is higher than specified value. • Valve body assembly
(1 D/C detection logic)
• TCM
5A-92 Automatic Transmission/Transaxle:

Circuit Diagram

1
3

12V
2
A1
E14-4 GRY C139-4

A2
E14-2 PPL C139-11

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511019-01

[A]: TCM connector (View: [a]) A2: Pressure control solenoid valve “C” drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: Pressure control solenoid valve “C” drive circuit (+) 2. Pressure control solenoid valve “C”

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0971, P0973, P0974, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Pressure control solenoid valve “C” drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “E14” defective wire harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C139” connector: infinity

Is check result OK?

 Automatic Transmission/Transaxle: 5A-93

Step Action Yes No

3 Pressure control solenoid valve “C” circuit check Substitute a known- Go to Step 4.
1) Check resistance of pressure control solenoid valve “C” good TCM and recheck
circuit. (Page 5A-141) DTC. (Page 5A-143)

Is check result OK?

4 Pressure control solenoid valve check Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check pressure control solenoid valve “C”. (Page 5A-
142)

Is check result OK?

DTC P0971
AENJHB0B5104050
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0971: Pressure Control Solenoid “C” Control Circuit High • Pressure control solenoid valve “C” and/or its
Measured electric current of pressure control solenoid valve “C” circuit
drive circuit (+) is lower than specified value. • Valve body assembly
(1 D/C detection logic)
• TCM

Circuit Diagram

1
3

12V
2
A1
E14-4 GRY C139-4

A2
E14-2 PPL C139-11

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511019-01

[A]: TCM connector (View: [a]) A2: Pressure control solenoid valve “C” drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: Pressure control solenoid valve “C” drive circuit (+) 2. Pressure control solenoid valve “C”

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0973, P0974, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

5A-94 Automatic Transmission/Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Pressure control solenoid valve “C” drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “E14” defective wire harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C139” connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 Pressure control solenoid valve “C” circuit check Substitute a known- Go to Step 4.
1) Check resistance of pressure control solenoid valve “C” good TCM and recheck
circuit. (Page 5A-141) DTC. (Page 5A-143)

Is check result OK?

4 Pressure control solenoid valve check Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check pressure control solenoid valve “C”. (Page 5A-
142)

Is check result OK?

DTC P0973
AENJHB0B5104051
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0973: Shift Solenoid “A” Control Circuit Low • Shift solenoid valve “A” and/or its circuit
Shift solenoid valve “A” drive circuit voltage is lower than • Valve body assembly
specified value even if shift solenoid valve “A” is turned on.
• TCM
(1 D/C detection logic)

Circuit Diagram

1
3

12V
A1 2
E14-16 BRN C139-10

[B] C139
[A]
E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511016-01
 Automatic Transmission/Transaxle: 5A-95

[A]: TCM connector (View: [a]) A1: Shift solenoid valve “A” drive circuit 2. Shift solenoid valve “A”
[B]: Solenoid connector (View: [a]) 1. TCM 3. A/T

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0974, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Shift solenoid valve “A” drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “E14” defective wire harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity

Is check result OK?

3 Shift solenoid valve “A” circuit check Substitute a known- Go to Step 4.
1) Check resistance of shift solenoid valve “A” circuit. good TCM and recheck
(Page 5A-141) DTC. (Page 5A-143)

Is check result OK?

4 Shift solenoid valve “A” check Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check shift solenoid valve “A”. (Page 5A-142)

Is check result OK?

DTC P0974
AENJHB0B5104052
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0974: Shift Solenoid “A” Control Circuit High • Shift solenoid valve “A” and/or its circuit
Shift solenoid valve “A” drive circuit voltage is higher than • Valve body assembly
specified value even if shift solenoid valve “A” is turned off.
• TCM
(1 D/C detection logic)
5A-96 Automatic Transmission/Transaxle:

Circuit Diagram

1
3

12V
A1 2
E14-16 BRN C139-10

[B] C139
[A]
E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511016-01

[A]: TCM connector (View: [a]) A1: Shift solenoid valve “A” drive circuit 2. Shift solenoid valve “A”
[B]: Solenoid connector (View: [a]) 1. TCM 3. A/T

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Drive vehicle at 15 km/h (9 mile/h) or more in D range for 10 sec.

 Automatic Transmission/Transaxle: 5A-97

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Shift solenoid valve “A” drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “E14” defective wire harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Voltage of “A1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

3 Shift solenoid valve “A” circuit check Substitute a known- Go to Step 4.
1) Check resistance of shift solenoid valve “A” circuit. good TCM and recheck
(Page 5A-141) DTC. (Page 5A-143)

Is check result OK?

4 Shift solenoid valve “A” check Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check shift solenoid valve “A”. (Page 5A-142)

Is check result OK?

DTC P1706
AENJHB0B5104053
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1706: Torque Request Communication Error from TCM • TCM
ECM detects abnormality of CAN communication data which TCM transmits. • ECM
(1 D/C detection logic but transmission warning light and MIL does not light up)

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC U0073, U0100 or U0121 is not detected.
– ECM: DTC P0335 or P0340 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Start engine at idle for 30 sec.

DTC Troubleshooting
Step Action Yes No
1 DTC check Go to applicable DTC Go to Step 2.
troubleshooting.
Is there any DTC(s) other than P1706?
2 DTC check of ECM Go to applicable DTC Substitute a known-
1) Check DTC of ECM. (Page 1A-23) troubleshooting. good TCM and recheck
DTC. (Page 5A-143)
Is there any DTC(s)?
5A-98 Automatic Transmission/Transaxle:

DTC P1736
AENJHB0B5104054
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1736: Output Speed Sensor Circuit Low • Output shaft speed sensor and/or its circuit
Output shaft speed sensor signal circuit voltage is lower • TCM
than specified value.
(1 D/C detection logic)

Circuit Diagram

12V
A1
2
C45-2 PPL E15-14

C45-1 GRY E15-5

A2

[A] [B]
C45
E14 E15
2 1
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18 [a]

IGRA0A511011-01

[A]: TCM connector (View: [a]) A1: Output shaft speed sensor power supply circuit 1. TCM
[B]: Output shaft speed sensor connector (View: [a]) A2: Output shaft speed sensor signal circuit 2. Output shaft speed sensor

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• 10.2 V < Battery voltage < 15.5 V

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Output shaft speed sensor power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C45” connector. defective wire harness.
2) Check for proper terminal connection to “C45”
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

 Automatic Transmission/Transaxle: 5A-99

Step Action Yes No

3 Output shaft speed sensor signal circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “E15” connector. defective wire harness.
2) Check for proper terminal connection to “E15” connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C45” connector: infinity

Is check result OK?

4 Output shaft speed sensor check Intermittent connection Replace output shaft
1) Check output shaft speed sensor. (Page 5A-134) and poor contact speed sensor. (Page
trouble. (Page 00-12) 5A-134)
Is check result OK?
If OK, substitute a
known-good TCM and
recheck DTC. (Page
5A-143)

DTC P1737
AENJHB0B5104055
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1737: Output Speed Sensor Circuit High • Output shaft speed sensor and/or its circuit
Output shaft speed sensor signal circuit voltage is higher • TCM
than specified value.
(1 D/C detection logic)

Circuit Diagram

12V
A1
2
C45-2 PPL E15-14

C45-1 GRY E15-5

A2

[A] [B]
C45
E14 E15
2 1
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18 [a]

IGRA0A511011-01

[A]: TCM connector (View: [a]) A1: Output shaft speed sensor power supply circuit 1. TCM
[B]: Output shaft speed sensor connector (View: [a]) A2: Output shaft speed sensor signal circuit 2. Output shaft speed sensor

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• 10.2 V < Battery voltage < 15.5 V

1) Set ignition “ON” for 10 sec.

5A-100 Automatic Transmission/Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Output shaft speed sensor signal circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “E15” connector. defective wire harness.
2) Check for proper terminal connection to “E15” connector.
3) If connections are OK, check the following points.
• Resistance between “A2” circuit terminal and other
terminal at “C45” connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

3 Output shaft speed sensor check Intermittent connection Replace output shaft
1) Check output shaft speed sensor. (Page 5A-134) and poor contact speed sensor. (Page
trouble. (Page 00-12) 5A-134)
Is check result OK?
If OK, substitute a
known-good TCM and
recheck DTC. (Page
5A-143)

DTC P1738
AENJHB0B5104056
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1738: Input / Turbine Speed Sensor “A” Circuit Low • Input shaft speed sensor and/or its circuit
Input shaft speed sensor signal circuit voltage is lower • TCM
than specified value.
(1 D/C detection logic)

Circuit Diagram

12V
A1
2
C44-2 WHT E15-16

C44-1 BLK E15-6

A2

[A] [B]
C44
E14 E15
2 1
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18 [a]

IGRA0A511010-01

[A]: TCM connector (View: [a]) A1: Input shaft speed sensor power supply circuit 1. TCM
[B]: Input shaft speed sensor connector (View: [a]) A2: Input shaft speed sensor signal circuit 2. Input shaft speed sensor
 Automatic Transmission/Transaxle: 5A-101

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
10.2 V < Battery voltage < 15.5 V

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Input shaft speed sensor power supply circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C44” connector. defective wire harness.
2) Check for proper terminal connection to “C44”
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

3 Input shaft speed sensor signal circuit check Go to Step 4. Repair or replace
1) With ignition “OFF”, disconnect “E15” connector. defective wire harness.
2) Check for proper terminal connection to “E15” connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C44” connector: infinity

Is check result OK?

4 Input shaft speed sensor check Intermittent connection Replace input shaft
1) Check input shaft speed sensor. (Page 5A-135) and poor contact speed sensor. (Page
trouble. (Page 00-12) 5A-135)
Is check result OK?
If OK, substitute a
known-good TCM and
recheck DTC. (Page
5A-143)

DTC P1739
AENJHB0B5104057
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1739: Input / Turbine Speed Sensor “A” Circuit High • Input shaft speed sensor and/or its circuit
Input shaft speed sensor signal circuit voltage is higher • TCM
than specified value.
(1 D/C detection logic)
5A-102 Automatic Transmission/Transaxle:

Circuit Diagram

12V
A1
2
C44-2 WHT E15-16

C44-1 BLK E15-6

A2

[A] [B]
C44
E14 E15
2 1
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18 [a]

IGRA0A511010-01

[A]: TCM connector (View: [a]) A1: Input shaft speed sensor power supply circuit 1. TCM
[B]: Input shaft speed sensor connector (View: [a]) A2: Input shaft speed sensor signal circuit 2. Input shaft speed sensor

DTC Confirmation Procedure

NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• 10.2 V < Battery voltage < 15.5 V

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 Input shaft speed sensor signal circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “E15” connector. defective wire harness.
2) Check for proper terminal connection to “E15” connector.
3) If connections are OK, check the following points.
• Resistance between “A2” circuit terminal and other
terminal at “C44” connector: infinity
• Voltage of “A2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

3 Input shaft speed sensor check Intermittent connection Replace input shaft
1) Check input shaft speed sensor. (Page 5A-135) and poor contact speed sensor. (Page
trouble. (Page 00-12) 5A-135)
Is check result OK?
If OK, substitute a
known-good TCM and
recheck DTC. (Page
5A-143)
 Automatic Transmission/Transaxle: 5A-103

DTC P2762
AENJHB0B5104058
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2762: Torque Converter Clutch Pressure Control Solenoid • TCC solenoid valve and/or its circuit
Control Circuit Range / Performance • Valve body assembly
Difference between target electric current and measured current of TCC
• TCM
solenoid valve drive circuit (+) is more than specified value for 3 sec.
(1 D/C detection logic)

Circuit Diagram

1
3

12V
2
A1
E14-5 LT BLU C139-3

A2
E14-3 GRN C139-9

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511014-01

[A]: TCM connector (View: [a]) A2: TCC solenoid valve drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: TCC solenoid valve drive circuit (+) 2. TCC solenoid valve

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.5 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702,
P1736, P1737, P1738, P1739, P2763, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Drive vehicle with 1st gear for 10 sec.

2) Drive vehicle with 2nd gear for 10 sec.
3) Drive vehicle with 3rd gear for 10 sec.
4) Drive vehicle with 4th gear for 10 sec.
5A-104 Automatic Transmission/Transaxle:

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 TCC solenoid valve drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “E14” defective wire harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C139” connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 TCC solenoid valve circuit check Substitute a known- Go to Step 4.
1) Check resistance of TCC solenoid valve circuit. (Page good TCM and recheck
5A-141) DTC. (Page 5A-143)

Is check result OK?

4 TCC solenoid valve check Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check TCC solenoid valve. (Page 5A-142)

Is check result OK?

DTC P2763
AENJHB0B5104059
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2763: Torque Converter Clutch Pressure Control • TCC solenoid valve and/or its circuit
Solenoid Control Circuit High • Valve body assembly
Measured electric current of TCC solenoid valve drive
• TCM
circuit (+) is higher than specified value.
(1 D/C detection logic)
 Automatic Transmission/Transaxle: 5A-105

Circuit Diagram

1
3

12V
2
A1
E14-5 LT BLU C139-3

A2
E14-3 GRN C139-9

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511014-01

[A]: TCM connector (View: [a]) A2: TCC solenoid valve drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: TCC solenoid valve drive circuit (+) 2. TCC solenoid valve

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702,
P1736, P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 TCC solenoid valve drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “E14” defective wire harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C139” connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

5A-106 Automatic Transmission/Transaxle:

Step Action Yes No

3 TCC solenoid valve circuit check Substitute a known- Go to Step 4.
1) Check resistance of TCC solenoid valve circuit. (Page good TCM and recheck
5A-141) DTC. (Page 5A-143)

Is check result OK?

4 TCC solenoid valve check Replace solenoid Replace TCC solenoid
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- valve. (Page 5A-138)
137)
2) Check TCC solenoid valve. (Page 5A-142)

Is check result OK?

DTC P2764
AENJHB0B5104060
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2764: Torque Converter Clutch Pressure Control • TCC solenoid valve and/or its circuit
Solenoid Control Circuit Low • Valve body assembly
Measured electric current of TCC solenoid valve drive
• TCM
circuit (+) is lower than specified value.
(1 D/C detection logic)

Circuit Diagram

1
3

12V
2
A1
E14-5 LT BLU C139-3

A2
E14-3 GRN C139-9

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IGRA0A511014-01

[A]: TCM connector (View: [a]) A2: TCC solenoid valve drive circuit (–) 3. A/T
[B]: Solenoid connector (View: [a]) 1. TCM
A1: TCC solenoid valve drive circuit (+) 2. TCC solenoid valve

DTC Confirmation Procedure

NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– DTC P0562, P0563, P0604, P0705, P0707, P0717, P0722, P0746, P0747, P0776, P0777, P0796,
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702,
P1736, P1737, P1738, P1739, P2762, U0073, U0100 or U0121 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

 Automatic Transmission/Transaxle: 5A-107

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 TCC solenoid valve drive circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “E14” defective wire harness.
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C139” connector: infinity

Is check result OK?

3 TCC solenoid valve circuit check Substitute a known- Go to Step 4.
1) Check resistance of TCC solenoid valve circuit. (Page good TCM and recheck
5A-141) DTC. (Page 5A-143)

Is check result OK?

4 TCC solenoid valve check Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check TCC solenoid valve. (Page 5A-142)

Is check result OK?

DTC P2797
AENJHB0B5104061
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2797: Auxiliary Transmission Fluid Pump Performance • Electro magnetic oil pump solenoid valve
This DTC is detected if the following conditions are met. • Valve body assembly
• Difference between input shaft speed and output shaft • A/T (forward clutch)
speed is more than 350 rpm.
• TCM detects abnormal gear ratio.
(2 D/C detection logic)

DTC Confirmation Procedure

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.
5A-108 Automatic Transmission/Transaxle:

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– DTC P0717, P0722, P1736, P1737, P1738, P1739, U0073 or U0100 is not detected.
– ECM: DTC P0335 is not detected.
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Drive vehicle at approx. 50 to 80 km/h (31 to 50 mile/h) in D range for 1 minute. (Keep accelerator pedal position
constant in this step.)

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
2 ATF check Go to Step 3. Refill or change ATF.
1) Check ATF for level and deterioration. (Page 5A-117) (Page 5A-119)

Is check result OK?

3 Line pressure check Go to Step 4. Repair or replace
1) Check for line pressure. (Page 5A-44) defective parts.

Is check result OK?

4 Electro magnetic oil pump solenoid valve check Go to Step 5. Replace valve body
1) Remove valve body assembly. (Page 5A-138) assembly. (Page 5A-
138)
2) Check electro magnetic oil pump solenoid valve.
(Page 5A-142)

Is check result OK?

5 Valve body check Check A/T mechanical Clean or replace valve
1) Check that fluid passage is not clogged in valve body system (forward clutch). body assembly. (Page
assembly. 5A-138)

Is check result OK?

DTC P2798 / P2799

AENJHB0B5104062
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2798: Auxiliary Transmission Fluid Pump Control Circuit Low • Electro magnetic oil pump solenoid valve
Electro magnetic oil pump solenoid valve drive circuit is shorted to and/or its circuit
ground. • Valve body assembly
(1 D/C detection logic)
• TCM
P2799: Auxiliary Transmission Fluid Pump Control Circuit High
Electro magnetic oil pump solenoid valve drive circuit is open or
shorted to power supply.
(1 D/C detection logic)
 Automatic Transmission/Transaxle: 5A-109

Circuit Diagram

1
3

12V
2
A1
E14-15 PNK C139-5

A2
E14-10 WHT C139-12

[A] [B] C139

E14 E15

6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
13 12 11 10 9 8 7 [a]
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

IJHB0A510006-01

[A]: TCM connector (View: [a]) A2: Electro magnetic oil pump solenoid valve 3. A/T
drive circuit (–)
[B]: Solenoid connector (View: [a]) 1. TCM
A1: Electro magnetic oil pump solenoid valve 2. Electro magnetic oil pump solenoid valve
drive circuit (+)

DTC Confirmation Procedure

P2798

! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and a tester.

NOTE
• Limit the driving speed permissible in road conditions and regulations.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– DTC U0073 or U0100 is not detected.

1) Execute engine auto stop control.

P2799
1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-15).
5A-110 Automatic Transmission/Transaxle:

Step Action Yes No

2 Electro magnetic oil pump solenoid valve drive circuit Go to Step 3. Repair or replace
check defective wire harness.
1) With ignition “OFF”, disconnect “C139” and “E14”
connectors.
2) Check for proper terminal connection to “C139” and
“E14” connectors.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at “C139” connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at “C139” connector: infinity
• Voltage of “A1” and “A2” circuit: approx. 0 V (when
ignition is “ON”)

Is check result OK?

3 Electro magnetic oil pump solenoid valve and solenoid Substitute a known- Go to Step 4.
harness check good TCM and recheck
1) Check electro magnetic oil pump solenoid valve and DTC. (Page 5A-143)
solenoid harness. (Page 5A-141)

Is check result OK?

4 Solenoid valve check for resistance Replace solenoid Replace valve body
1) Remove valve body assembly. (Page 5A-138) harness. (Page 5A- assembly. (Page 5A-
137) 138)
2) Check electro magnetic oil pump solenoid valve for
resistance. (Page 5A-142)

Is check result OK?

DTC U0073
AENJHB0B5104063
Refer to “Troubleshooting for Communication Bus Off”: K15B Model in Section 10H (Page 10H-17).

DTC U0100
AENJHB0B5104064
Refer to “Troubleshooting for Lost Communication”: K15B Model in Section 10H (Page 10H-10).

DTC U0121
AENJHB0B5104065
Refer to “Troubleshooting for Lost Communication”: K15B Model in Section 10H (Page 10H-10).

DTC U1082
AENJHB0B5104066
Refer to “Troubleshooting for Communication Bus Off”: K15B Model in Section 10H (Page 10H-17).

Inspection of TCM and Its Circuits

AENJHB0B5104067
TCM and its circuits can be checked at TCM wiring connectors by measuring voltage, pulse signal and resistance.

NOTICE
If you connect a voltmeter or an ohmmeter directly to the TCM terminals by removing the TCM
connectors, you can damage the TCM.
Never connect a voltmeter or an ohmmeter directly to any terminal on the TCM by disconnecting the
TCM connectors.

1) Remove TCM (1) from vehicle. (Page 5A-143)

2) Connect TCM connectors (2) to TCM.
 Automatic Transmission/Transaxle: 5A-111

3) Check voltage and/or pulse signal using voltmeter (3) and oscilloscope (4).

NOTE
• As each terminal voltage is affected by battery voltage, check that it is 12 V or more when ignition is
“ON”.
• Voltage with asterisk(*) cannot be measured by voltmeter because it is pulse signal. Check it with
oscilloscope if necessary.

[A] [B]

6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18

[a]
2

I8C50B510028-01

[A]: TCM connector “E14” (View: [a]) [B]: TCM connector “E15” (View: [a])

“E14” connector
Terminal Normal
Wire color Circuit Condition
No. voltage
E14-1 BLK Ground circuit Approx. 0 V Constantly
Pressure control solenoid valve “C” drive
E14-2 PPL Approx. 0 V Constantly
circuit (–)
E14-3 GRN TCC solenoid valve drive circuit (–) Approx. 0 V Constantly
Refer to reference waveform.
Pressure control solenoid valve “C” drive
E14-4* GRY “Pressure Control Solenoid Valve “A”, “B”, “C” and
circuit (+)
TCC Solenoid Valve Signal” (Page 5A-113)
Refer to reference waveform.
E14-5* LT BLU TCC solenoid valve drive circuit (+) “Pressure Control Solenoid Valve “A”, “B”, “C” and
TCC Solenoid Valve Signal” (Page 5A-113)
E14-6 WHT Main power supply circuit 10 to 14 V Constantly
Refer to reference waveform.
E14-7* WHT CAN communication line (Low) circuit
“CAN Communication Signal” (Page 5A-113)
E14-8 — — — —
Pressure control solenoid valve “A” drive
E14-9 BLK Approx. 0 V Constantly
circuit (–)
Electro magnetic oil pump solenoid valve
E14-10 WHT Approx. 0 V Constantly
drive circuit (–)
Ignition: “ON”
2.9 to 3.1 V
ATF temperature: 20 °C (68 °F)
E14-11 LT GRN ATF temperature sensor signal circuit
Ignition: “ON”
0.3 to 0.5 V
ATF temperature: 100 °C (212 °F)
E14-12 BEG ATF temperature sensor ground circuit Approx. 0 V Constantly
E14-13 — — — —
E14-14 — — — —
Electro magnetic oil pump solenoid valve 10.5 to 16 V Engine auto stop control operating
E14-15 PNK
drive circuit (+) 0V Other than above condition
Ignition: “ON”
E14-16 BRN Shift solenoid valve “A” drive circuit 9.5 to 14 V
Select lever position: P range
5A-112 Automatic Transmission/Transaxle:

Terminal Normal
Wire color Circuit Condition
No. voltage
Refer to reference waveform.
E14-17* RED CAN communication line (High) circuit
“CAN Communication Signal” (Page 5A-113)
E14-18 — — — —
Pressure control solenoid valve “B” drive
E14-19 BLU Approx. 0 V Constantly
circuit (–)
E14-20 — — — —
Refer to reference waveform.
Pressure control solenoid valve “B” drive
E14-21* YEL “Pressure Control Solenoid Valve “A”, “B”, “C” and
circuit (+)
TCC Solenoid Valve Signal” (Page 5A-113)
Refer to reference waveform.
Pressure control solenoid valve “A” drive
E14-22* RED “Pressure Control Solenoid Valve “A”, “B”, “C” and
circuit (+)
TCC Solenoid Valve Signal” (Page 5A-113)
E14-23 BLK Ground circuit Approx. 0 V Constantly
10 to 14 V Ignition: “ON”
E14-24 BLU Ignition ON signal circuit
Approx. 0 V Other than above condition

“E15” connector
Terminal Normal
Wire color Circuit Condition
No. voltage
Ignition: “ON”
Transmission range sensor (R range) 8.4 to 14 V
E15-1 BRN Select lever position: R range
circuit
Approx. 0 V Other than above condition
E15-2 — — — —
E15-3 — — — —
E15-4 — — — —
Refer to reference waveform.
E15-5* GRY Output shaft speed sensor signal circuit
“Output Shaft Speed Sensor Signal” (Page 5A-114)
Refer to reference waveform.
E15-6* BLK Input shaft speed sensor signal circuit
“Input Shaft Speed Sensor Signal” (Page 5A-114)
Ignition: “ON”
Transmission range sensor (D range) 8.4 to 14 V
E15-7 BLU Select lever position: D range
circuit
Approx. 0 V Other than above condition
Ignition: “ON”
Transmission range sensor (N range) 8.4 to 14 V
E15-8 BEG Select lever position: N range
circuit
Approx. 0 V Other than above condition
E15-9 — — — —
E15-10 — — — —
E15-11 — — — —
E15-12 — — — —
E15-13 — — — —
Output shaft speed sensor power supply 8.4 to 14 V Ignition: “ON”
E15-14 PPL
circuit Approx. 0 V Ignition: 5 sec. after ignition “OFF”
E15-15 — — — —
Input shaft speed sensor power supply 8.4 to 14 V Ignition: “ON”
E15-16 WHT
circuit Approx. 0 V Ignition: 5 sec. after ignition “OFF”
E15-17 — — — —
Ignition: “ON”
Transmission range sensor (L range) 8.4 to 14 V
E15-18 LT GRN Select lever position: L range
circuit
Approx. 0 V Other than above condition
Ignition: “ON”
Transmission range sensor (2 range) 8.4 to 14 V
E15-19 PPL Select lever position: 2 range
circuit
Approx. 0 V Other than above condition
Ignition: “ON”
Transmission range sensor (P range) 8.4 to 14 V
E15-20 PNK Select lever position: P range
circuit
Approx. 0 V Other than above condition
 Automatic Transmission/Transaxle: 5A-113

Terminal Normal
Wire color Circuit Condition
No. voltage
Ignition: “ON”
8.4 to 14 V
O/D off switch: Released
E15-21 YEL O/D off switch signal circuit
Ignition: “ON”
Approx. 0 V
O/D off switch: Pushed
E15-22 — — — —
E15-23 — — — —
E15-24 — — — —
E15-25 — — — —
E15-26 — — — —

Reference Waveform Measurement condition

• Engine: Idle speed after warming up
NOTE
• Select lever position: P range
• How to read waveforms is shown below.

IEL10B510015-02

[A]: Waveform of channel 1
[B]: Ground level of each channel
Measurement condition
I8T401111066-01
• Engine: Idle speed after warming up
[C]: VOLT/DIV of each channel
• Select lever position: L range
[D]: TIME/DIV

• Waveform varies depending on

measurement condition and vehicle spec.

Pressure Control Solenoid Valve “A”, “B”, “C” and

TCC Solenoid Valve Signal

Pressure control solenoid valve “C” signal (1):

Channel Probe Terminal No.
+ E14-4
1
– E14-1
ICL80C510027-01
TCC solenoid valve signal (2):
Channel Probe Terminal No. CAN Communication Signal
+ E14-5
2
– E14-1 CAN communication signal (Low) (1):
Channel Probe Terminal No.
Pressure control solenoid valve “B” signal (3): + E14-7
Channel Probe Terminal No. 2
– E14-1
+ E14-21
3
– E14-1 CAN communication signal (High) (2):
Channel Probe Terminal No.
Pressure control solenoid valve “A” signal (4): + E14-17
Channel Probe Terminal No. 1
– E14-1
+ E14-22
4
– E14-1
5A-114 Automatic Transmission/Transaxle:

Measurement condition
• Engine: Stopped
• Ignition: “ON”

I9P60A510016-01

Output Shaft Speed Sensor Signal

Channel Probe Terminal No.
+ E15-5
1
– E14-1

Measurement condition
• Vehicle: Drive vehicle at 40 km/h (25 mile/h)

ICL80C510028-01

Input Shaft Speed Sensor Signal

Channel Probe Terminal No.
+ E15-6
1
– E14-1

Measurement condition
• Engine: Idle speed after warming up
• Select lever position: P range

ICL80C510029-01
 Automatic Transmission/Transaxle: 5A-115

TCM Power and Ground Circuit Check

AENJHB0B5104068
Circuit Diagram

1
A1
2
E14-6 WHT

A2 8
3 7
6
E14-24 BLU
[B]
9

4 [A]

B1
E14-1 BLK
B2
E14-23 BLK

[C]
[a]
E14 E15

6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
IJHA0A510007-01

[A]: Ignition switch model B2: Ground circuit 6. “IGN” fuse

[B]: Keyless push start model 1. TCM 7. “IG11” relay
[C]: TCM connector (View: [a]) 2. “T/M” fuse 8. J/B
A1: Main power supply circuit 3. “IG1 SIG2” fuse 9. BCM
A2: Ignition on signal circuit 4. Ignition switch
B1: Ground circuit 5. Main fuse box

Troubleshooting
Step Action Yes No
1 Main power supply circuit check Go to Step 2. Repair or replace
1) Set ignition “OFF” and disconnect connectors from TCM. defective wire harness.
2) Check for proper terminal connection to TCM
connectors.
3) If connections are OK, check that voltage between main
power supply circuit (A1) and ground is battery voltage.

Is check result OK?

2 Ignition ON signal circuit check Go to Step 3. Repair or replace
1) Set ignition “ON”. defective wire harness.
2) Check that voltage between Ignition ON signal circuit
(A2) and ground is battery voltage.

Is check result OK?

5A-116 Automatic Transmission/Transaxle:

Step Action Yes No

3 TCM ground circuit check TCM power supply and Repair or replace
1) Set ignition “OFF”. ground circuits are in defective wire harness.
good condition.
2) Check that resistance between each TCM ground circuit
1 (B1) and ground circuit 2 (B2) and ground is less than
1 Ω.

Is check result OK?

Repair Instructions
TCM Learning Value Clearance NOTICE
AENJHB0B5106001
NOTICE If TCM learning value initialization is not
performed after one of the following
If TCM learning value initialization is not
operations has been performed, there is a
performed after one of the following
possibility that the vehicle will not be able to
operations has been performed, there is a
move.
possibility that the vehicle will not be able to
Perform TCM learning value initialization
move.
whenever one of the following operations
Perform TCM learning value initialization
has been performed:
whenever one of the following operations
has been performed: • TCM is removed or replaced.
• TCM is removed or replaced. • TCM software is reprogrammed.
• TCM software is reprogrammed. • Valve body assembly is removed or
replaced.
• Valve body assembly is removed or
replaced. • A/T assembly is disassembled or replaced.
• A/T assembly is disassembled or replaced.
NOTE
1) With ignition “OFF”, connect SUZUKI scan tool to • Limit the driving speed permissible in road
DLC. conditions and regulations.
Special tool • If TCM learning value initialization is not
: SUZUKI scan tool (Suzuki SDT-II) completed, excessive shift shock could be
felt.
2) Set ignition “ON”.
3) Select “A/T Learned Initialize” in “Active test” menu,
and follow instructions displayed on SUZUKI scan
tool.
4) Set ignition “OFF”.

TCM Learning Value Initialization

AENJHB0B5106002
! WARNING
If you do not select a suitable route and take
proper precautions when performing a road
test, an accident can occur.
• Select a level road with no traffic to
minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a
driver and a tester.

1) With ignition “OFF”, shift select lever to P range and
connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
1
2
(A)
IJHA0A110011-01
2. VCI
2) Display “Data List” mode on SUZUKI scan tool.
3) Drive vehicle so that ATF temperature reaches
normal operating temperature (65 to 110 °C (149 to
230 °F)).
NOTE
Engine coolant temperature rises when
racing engine at P or N range. But ATF
temperature does not rise at P or N range.
Drive vehicle to raise ATF temperature.
4) Perform garage shift learning as follows:
a) Stop vehicle with engine running and place it
horizontally.
b) Keep engine idling, depress brake pedal fully
and shift select lever to N range for 3 seconds.
c) Shift select lever to D range for 3 seconds.
d) Repeat Step b) – c) 5 times.
e) Shift select lever to N range for 3 seconds, and
then shift select lever to R range for 3 seconds.
f) Repeat Step e) 4 times.
5) Perform gear shift control learning as follows:
a) Accelerate vehicle up to practicable maximum
speed in D range with accelerator pedal
depressed 25 – 35%.
Automatic Transmission/Transaxle: 5A-117
NOTE
Insufficient driving speed may cause
remaining shift shock. However, the shock
will be solved by self-learning during driving
after that.
b) Decelerate vehicle with engine brake releasing
accelerator pedal and stop vehicle.
c) Repeat Step a) – b) 9 times.
ATF Level Check
AENJHB0B5106003
NOTICE
Failure to take the following precautions
when checking the ATF may cause failure of
the A/T.
• Do not use any fluid other than the
specified ATF. Use of any other fluids may
cause juddering or other faulty conditions.
• Avoid overfilling the A/T. If the A/T is filled
with too much fluid, the fluid can foam and
flow out through the breather.
The resulting loss of fluid may cause
slippage and failure of the A/T.
• Use only lint-free paper for wiping. Do not
use cloth or rags.
• Do not reuse ATF.
NOTE
• Perform ATF level check before checking
any service on A/T.
• Do not add or drain ATF before each test.
Level Check at Normal Operating (Hot) Temperature
– Hot Check
1) Drive vehicle so that ATF temperature reaches
normal operating temperature (70 to 80 °C (158 to
176 °F)).
NOTE
Engine coolant temperature rises when
racing engine at P or N range. But ATF
temperature does not rise at P or N range.
Drive vehicle to raise ATF temperature.
2) Stop vehicle with engine running and place it
horizontally.
3) With select lever in P range, apply parking brake and
block wheels.
4) Connect SUZUKI scan tool to DLC and check that
“ATF Temperature” is 70 to 80 °C (158 to 176 °F).
5) Keep engine idling, depress brake pedal fully and
shift select lever slowly to L and back to P range.
6) With engine idling and A/C switch turned off, pull out
fluid level gauge (1), wipe it off with lint-free paper
towel and put it back into place.
5A-118 Automatic Transmission/Transaxle:

7) Pull out fluid level gauge again and check fluid level Level Check at Room (Cold) Temperature – Cold
indicated on it. Lowest fluid level should be between Check
“FULL HOT” (2) and “LOW HOT” (3). If it is below Fluid level can be checked temporarily at room (cold)
“LOW HOT”, add specified ATF up to “FULL HOT”. temperature which corresponds to 20 to 30 °C (68 to 86
°F). This level check is considered as preparation before
NOTE performing level check under normal operating (hot)
• Do not race engine while checking fluid temperature. Checking procedure itself is the same as
level, even after engine start. that described in “Level Check at Normal Operating
(Hot) Temperature – Hot Check” (Page 5A-117). If fluid
• Do not overfill. Overfilling can cause
level is between “FULL COLD” (4) and “LOW COLD” (5),
foaming and loss of fluid through breather.
proceed to test drive. And when ATF temperature has
Then slippage and transaxle failure can
reached 70 to 80 °C (158 to 176 °F), check fluid level
result.
again and adjust it if necessary.
• Bringing level from “LOW HOT” to “FULL
HOT” requires 0.4 liters (0.85 / 0.70 US/Imp.
pt).
• If vehicle was driven under high load such
as pulling trailer, fluid level should be
checked about half an hour after it is
stopped.
• Check lower position of fluid on both sides
of level gauge.

ATF specification
: SUZUKI AT OIL AW-1
1

3 2

5 4
1
IJHA0A510009-02

1. Fluid level gauge 3. “LOW HOT”

1 2. “FULL HOT”

3 2

5 4
1
IJHA0A510009-02

4. “FULL COLD” 5. “LOW COLD”

 Automatic Transmission/Transaxle: 5A-119

ATF Change 7) Check fluid level. (Page 5A-117)

AENJHB0B5106004
NOTICE ATF specification
: SUZUKI AT OIL AW-1
Failure to take proper precautions when
replacing ATF can cause failure of the A/T. ATF capacity
• Do not use any fluid other than the When draining from drain plug hole: 2.7 liters
specified ATF. Use of any other fluid may (5.71 / 4.75 US/Imp. pt.)
cause juddering or other faulty conditions. When overhauling: 5.0 liters (10.57 / 8.80 US/Imp.
• Avoid overfilling the A/T. If the A/T is filled pt.)
with too much fluid, the fluid can foam and
flow out through the breather.
The resulting loss of fluid may cause
slippage and failure of the transaxle.
• Replace ATF when the A/T is replaced and
also when the vehicle has been driven
under excessively high load.

1) Hoist vehicle.
2) Remove left side engine under side cover.
3) When engine is cool, remove ATF drain plug (1) from
A/T oil pan (2) and drain ATF. 1

NOTE
ATF does not drain completely from drain
plug.
3 2
4) Install ATF drain plug with new gasket (3) and then
tighten it to specified torque.
Tightening torque
ATF drain plug (a): 17 N·m (1.7 kgf-m, 12.5 lbf-ft) 5 4
1
IJHA0A510009-02

1. Fluid level gauge 4. “FULL COLD”

2. “FULL HOT” 5. “LOW COLD”
3. “LOW HOT”

2
1, (a)

IJHA0A510010-01

5) Install left side engine under side cover.

6) Lower vehicle and replenish transaxle with proper
amount of specified ATF.
5A-120 Automatic Transmission/Transaxle:

Select Lever Assembly Components

AENJHB0B5106005

9 A
11
4 (b)
13 12

10

14 (a)
IJHB0A510008-01

1. Shift lock solenoid
2. Select lever
3. Select lever connector
4. Select lever knob screw
5. Select lever knob assembly
6. Select lever indicator
7. Select position plate 13. Select lever illumination light assembly
8. Select lever boot 14. Select lever nut
9. Shift lock release button : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
: Apply grease 99000-25011 to sliding surface.
10. Spring : 2.2 Nm (0.22 kgf-m, 2.0 lbf-ft)
11. Bulb filter : Do not reuse.
12. Bulb
 Automatic Transmission/Transaxle: 5A-121

Select Lever Assembly Removal and Installation

Installation Reverse removal procedure noting the following points.
AENJHB0B5106006
• Tighten select lever nuts (1) to specified torque.
Removal
1) Remove floor console box. (Page 9H-34) Tightening torque
2) Disconnect select cable (1) from select lever Select lever nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf-ft)
assembly (2) as shown in figure.

1, (a)
4

IFAE0A510018-01

3. Select lever bracket 4. Select lever pin 1, (a)

IJHA0A510012-01

3) For ignition switch model, disconnect key interlock
cable end and detach cable casing cap from select
lever assembly. (Page 5A-132)
4) Disconnect select lever connector and clamp.
5) Remove select lever nuts (1), and then remove
select lever assembly (2) from floor panel.
1
• After installing select lever assembly, adjust select
cable. (Page 5A-130)
• After installing select lever assembly, check that
ignition can be turned from “ON” to “OFF” when
releasing select lever button in P range and that
ignition cannot be turned from “ON” to “OFF” when
releasing select lever button in N range.
• After installing select lever assembly, check select
lever operation. (Page 5A-126)

Select Lever Assembly Disassembly and

Reassembly
AENJHB0B5106007

Disassembly
1) While pushing locks (1), pull down select lever boot
(2).
2

IJHA0A510011-01
2

IEL10C510040-01
5A-122 Automatic Transmission/Transaxle:

2) Remove select lever knob screws (1). a) Pull up terminal lock (1) approx. 1.0 mm (0.039
in.).

1 1

IGSB0A550034-01

IDAA0A550025-01 b) Insert terminal release tool (3) or flat-bladed

3) Disconnect select lever connector clamp (1).
4) Disconnect O/D off switch terminals (2) and select
lever illumination light terminals (3) from select lever
connector (4) according to the following procedure.
NOTICE
precision screwdriver (4) between connector
claw (1) and terminal (2), and then lift up
connector claw slightly to release terminal.
NOTE
Use the tool shown in figure below.

• Connector claws may be deformed if [A]

terminals are disconnected improperly
from connector, causing terminals coming
off the connector during connector
assembly.
Be careful not to deform connector claws.
• Terminals may be deformed if terminals “b”
are disconnected improperly from
connector, causing poor contact. “a”
Be careful not to deform terminals.
“a”

[B]

4 1
“a”
IDP60A510017-01
[A]
[A]: Terminal release tool “a”: Approx. 1.0 mm (0.039 in.)
5 4 3 2 1 [B]: Flat-bladed precision screwdriver “b”: Approx. 2.5 mm (0.098 in.)

10 9 8 7 6

3 2
[a]

IJHB0A510009-01

[A]: Select lever connector (View: [a])

 Automatic Transmission/Transaxle: 5A-123

7) Releasing claws (3), remove select lever indicator

1 1
(1) with select lever boot (2).
4 3

2 2
3

2
3

IGSB0A550035-01

c) Pull wiring to remove terminal (1) from connector

(2).

2 IJHB0A510011-01
1
8) Remove select lever illumination light assembly (1).

IDP60A510019-01 1

5) Release fixing of O/D off switch harness.

6) Checking released state of O/D off switch harness,
pull out select lever knob assembly (1). IJHB0A510012-01

9) Releasing claws (1), remove shift lock release button

(2) and spring.

IJHB0A510010-01

IJHB0A510013-01
5A-124 Automatic Transmission/Transaxle:

Reassembly 5) Install select lever knob assembly (1), select lever

1) Apply grease to sliding surface of shift lock release indicator (2) and select lever boot (3) all together
button (1). passing O/D off switch harness (4) through the
original route.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A) 1

2) Push shift lock release button along with spring (2)

3
until claws lock in place to install them.

1
2

4
“A”

IJHB0A510015-01

6) Place select lever in P range and fix O/D off switch

harness (1).

IJHB0A510014-01

3) Check that select lever can be shifted from P range

to other ranges when shift lock release button is
pushed.
4) Install select lever illumination light assembly (1) and
fix harness to select lever as shown in figure.

IFRA0A550037-01

7) Check O/D off switch harness for the following items,

shifting select lever from P range to L range and
from L range to P range. If any malfunction is found,
adjust the fixing position.
• Excessive stress given to the harness.
• Excessive slag in the harness.
8) Connect O/D off switch terminals (1) and select lever
illumination light terminals (2) to select lever
connector (3) in positions shown in figure according
to the following procedure.
IFRA0A550035-01
 Automatic Transmission/Transaxle: 5A-125

NOTE c) Push terminal lock (1) into connector until it is

Polarity of select lever illumination light flush with connector surface.
terminals and O/D off switch terminals does
not affect their performance. Therefore,
connection of select lever illumination light
1
terminals “4”, “9” and O/D off switch
terminals “3”, “8” can be either positive or
negative.

IGSB0A550051-01

9) Connect select lever connector clamp.

3 10) Tighten new select lever knob screws (1) to specified
torque.
[A] Tightening torque
Select lever knob screw (a): 2.2 N·m (0.22 kgf-
5 4 3 2 1 m, 2.0 lbf-ft)
10 9 8 7 6

2 1
[a]

1, (a)
IJHB0A510016-01

[A]: Select lever connector (View: [a])

a) Align protrusions (2) on terminal with slots (1) in

connector, and then push terminals into
connector until they click into place.

IDAA0A550033-01

11) Pull up select lever boot (1) to lower end of select

2 lever knob assembly (2) and lock the position.

IGSB0A550050-01

b) Pull wirings slightly to check that terminals are

firmly locked in place.
1

IDAA0A550034-01

12) After installing select lever assembly, check select

lever operation. (Page 5A-126)
5A-126 Automatic Transmission/Transaxle:

Select Lever Assembly Inspection

AENJHB0B5106008 1
Check the following items. 2
• Select lever button operates smoothly without noise. BLK L101-8 L101-3 YEL 3

• Select lever shifts from P range to R range correctly IGRA0A511023-01

when shift lock release button and select lever button
3. To TCM
are pushed.
• Select lever operates smoothly.
Shift Lock Solenoid Inspection
• Select lever position matches combination meter AENJHB0B5106010
display. NOTICE
• O/D off indicator on meter changes when O/D off Short circuit or an improper connection will
switch is pressed with ignition “ON”. damage the shift lock solenoid.
• Select lever illumination light comes on when Confirm that the power supply voltage and
clearance light is turned on. test connections are both correct.

1) Remove floor console box. (Page 9H-34)

O/D Off Switch Inspection
AENJHB0B5106009 2) Disconnect select lever connector (1).
1) Remove floor console box. (Page 9H-34) 3) Check that shift lock solenoid rod moves smoothly
2) Disconnect select lever connector. and returns when positive terminal of battery is
connected to terminal “5” and negative terminal of
3) Check for continuity between terminals “3” and “8” of
battery is connected to terminal “10”.
select lever connector (1).
Replace select lever assembly, if solenoid rod does
If check result is not as specified, replace select
not move smoothly.
lever assembly.
O/D off switch specification
Condition Specification
With O/D off switch (2) pressed
Continuity
exists
With O/D off switch (2) released
No continuity
exists
1

2
5 4 3 2 1
10 9 8 7 6

IJHA0A510021-01

1
2
BLK L101-10 L101-5 WHT 3

5 4 3 2 1 IGRA0A511025-01
10 9 8 7 6
2. Shift lock solenoid 3. To BCM

IJHA0A510020-01
 Automatic Transmission/Transaxle: 5A-127

P Position Switch Inspection (Keyless Push Manual Release of Shift Lock

AENJHB0B5106012
Start Model)
AENJHB0B5106011 1) For ignition switch model, set ignition “ACC”.
1) Remove floor console box. (Page 9H-34) 2) While pushing down shift lock release button (1)
2) Disconnect select lever connector (1). using a flat-bladed screwdriver (2), press the select
3) Check for continuity between terminals “2” and “7” of lever button (3). Check that select lever (4) can be
select lever connector. shifts to other than P range.
If check result is not as specified, replace select If faulty condition is found, replace select lever
lever assembly. assembly.

P position switch specification 4

Condition Specification 3
P range and select lever is released Continuity
Other than P range No continuity

IJHA0A510023-01
1

5 4 3 2 1
10 9 8 7 6

IJHA0A510022-01

2
BLK L101-7 L101-2 PPL 3

IGRA0A511027-01

2. P position switch 3. To BCM

5A-128 Automatic Transmission/Transaxle:

Select Cable Components

AENJHB0B5106013

11
7 10
8 A

(d) 9

(d)

(b)
(c)

(a)
(a)

3
A A (e)
IGRA0A511028-02

1. Select lever assembly 7. Casing cap : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
: Check that claw of the casing cap fit
completely to the select lever assembly.
2. Select cable 8. Select lever pin : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
: After completing installation, adjust select cable. : Apply lithium grease 99000-25011.
(Page 5A-130)
3. Clip 9. Adjuster case : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
4. Select cable bracket 10. Lock : 12 Nm (1.2 kgf-m, 9.0 lbf-ft)
5. Manual select lever 11. Select cable clamp
6. Manual select lever pin : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: Apply lithium grease 99000-25011.
 Automatic Transmission/Transaxle: 5A-129

Select Cable Removal and Installation 6) Remove select cable (1) from select cable bracket
AENJHB0B5106014 (2) pushing lock on select cable clip (3) in arrow
! CAUTION direction.

Touching a hot exhaust system component

will cause a burn.
Do not perform any service work on the
select cable until the exhaust system is cool.

Removal
1) Disable air bag system. (Page 8B-48)
2) Remove floor console box. (Page 9H-34) 3

3) Remove SDM. (Page 8B-49)

4) Disconnect select cable from select lever assembly.
(Page 5A-121) 2
5) Remove clip (1) from manual select lever pin (2).
(Page 5A-128)

IJHA0A510025-01

7) Remove select cable from floor tunnel.

Installation
1
2 Reverse removal procedure noting the following points.
• Apply grease to pin and cable joint. (Page 5A-128)
• Fit select cable in select cable bracket securely and
check that the lock on select cable clip has come up.
IJHA0A510024-01
• Tighten bolts and nuts to specified torque. (Page
5A-128)
• Adjust select cable. (Page 5A-130)
• Enable air bag system. (Page 8B-48)
5A-130 Automatic Transmission/Transaxle:

Select Cable Adjustment 13) Slide lock plate (4) in arrow direction [b] as shown in
AENJHB0B5106015 figure until it gets over the claw (5).
1) Apply parking brake and block wheels.
2) Set ignition “ON”, shift select lever to N range.
3) Remove floor console box. (Page 9H-34)
4) Set ignition “ON” and shift select lever to N range.
5) Remove adjuster case (cable end) from select lever 1, “A”
2 5 4
pin of select lever assembly. (Page 5A-128)
6) Release lock plate (1) which restricts moving of lock
piece (2).
7) Pull out lock piece from adjuster case (3) using pliers [b]

to disengage cable. 3 [a] 4

IFAE0A510022-01

14) After installing select cable, check the following

points.
• Perform “P Range Test” (Page 5A-47).
3
1 • Check back-up light turns ON when shifting select
2 lever to R range.
• Check shift position indicated information display
is consistent with select lever range.
• Check engine can start in P and N ranges and
cannot start in other ranges.
15) Install floor console box. (Page 9H-34)

3 2
Transmission Range Sensor Removal and
Installation
I8C50B510062-01 AENJHB0B5106016
8) Check that neutral position of select lever is suitable NOTICE
position. If the transmission range sensor is removed
9) Shift select lever to N range. and reinstalled, a gap will be created between
10) Check that needle direction shaped on manual the sensor and the manual select lever shaft.
select lever (2) and N reference line (1) on This gap prevents the transmission range
transmission range sensor are aligned. sensor from correctly identifying the selected
transaxle range.
Do not reuse any removed transmission
range sensor.

Removal
1 1) Remove clip and disconnect select cable from
manual select lever. (Page 5A-128)
2 2) Shift manual select lever (1) to N position.

“D”
“R” “N” “2”
“P” “L”

ICL80C510034-01

11) Apply grease to select lever pin (1), and then install
adjuster case (2) into select lever pin securely.
1
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
12) Push lock piece (3) in arrow direction [a] as shown in
figure.
ICL80C510035-01
 Automatic Transmission/Transaxle: 5A-131

3) Disconnect transmission range sensor connector Tightening torque

(1). Transmission range sensor bolt (a): 5.4 N·m (0.55
kgf-m, 4.0 lbf-ft)
Manual select lever nut (b): 12 N·m (1.2 kgf-m, 9.0
lbf-ft)

(a)

(a)
1 (b)
IEL10A510015-02 ICL80C510038-01

4) Remove manual select lever nut (1) and manual

select lever (2). Transmission Range Sensor Inspection and
5) Remove transmission range sensor mounting bolts Adjustment
AENJHB0B5106017
(3) and transmission range sensor (4).
1) Apply parking brake and block wheels.
2) With ignition “ON”, shift select lever to N range.
3) Check that needle direction shaped (2) on manual
3
select lever (4) and N reference line (1) on
transmission range sensor are aligned. If not, loosen
4 sensor bolts (3) and align them.
4) Tighten sensor bolts to specified torque.
Tightening torque
Transmission range sensor bolt (a): 5.4 N·m (
0.55 kgf-m, 4.0 lbf-ft)
3
1 2
ICL80C510037-01

3, (a)
Installation
Reverse removal procedure noting the following points.
1
• Use new transmission range sensor.
• Adjust select cable. (Page 5A-130) 2

• Tighten transmission range sensor mounting bolts

and manual select lever nut to specified torque. 4

3, (a)
ICL80C510039-01
5A-132 Automatic Transmission/Transaxle:

5) Check that engine can start with select lever in N or Key Interlock Cable Removal and Installation
P ranges but not D, 2, L or R range. Also, check that (Ignition Switch Model)
back-up light lights in R range. AENJHB0B5106018

If faulty condition cannot be corrected by adjustment, NOTE

disconnect transmission range sensor connector If interlock cable is bent excessively, the
and check that continuity exists as shown by moving cable will lose correct operation.
manual select lever. Do not bend interlock cable excessively
when removing and installing it.

4 3 2 1 Removal
9 8 7 6 5 1) Disable air bag system. (Page 8B-48)
2) Remove steering column lower cover. (Page 6B-2)
3) Turn ignition switch to “ACC” position.
1 2 3 4 5 6 7 8 9 4) Pull out key interlock cable (1) from key cylinder
cover (2) while pressing check hook with a flat-
P bladed screwdriver or the like (3).

L 1
I9P60A510070-01

6) Check transmission range sensor for the following 2

points.
3
• Vehicle should not move in P range even when I7V10A510031-02

pushed. 5) Turn ignition switch to “LOCK” position.

• Check engine can start in P and N ranges, and
cannot start in other ranges.
• Check back-up light turns ON only when shifting
select lever to R range.
6) Remove floor console box. (Page 9H-34)
7) Detach cable end (1) from interlock cam (2) while
pressing claws (3) of interlock cam boss.
At this time, be careful not to cause damage to its
claws.
8) Detach cable casing cap (4) from selector bracket
(5) while pressing check hook.
9) Remove interlock cable.

4
1

3 4

5
I9P60A510034-03
 Automatic Transmission/Transaxle: 5A-133

Installation 4) Pull out lock button (1) of selector side cable end (2).
1) Lay interlock cable to its original cabling route as
shown in figure.

2
1

1
I2RH01510086-01
1
5) Shift select lever to N range.
6) Positioning white mark (3) on cable casing cap (1)
2 upward, fit casing cap into selector bracket (2).
7) Connect cable end (4) to interlock cam (5) with
ignition switch turned to “ACC” position.
8) Drive lock button (6) in cable end until it locks cable
4 movement.
3

IJHA0A510026-01 5 3
2
1. Key interlock cable 4. Select lever assembly
2. Clamp 5. Accelerator pedal harness 4
3. Steering lock assembly

2) Turn ignition switch to “ACC” position.

3) Insert cable casing cap (1) into key cylinder cover (2)
6 1
securely.

IJHA0A510027-01

9) Check key interlock cable function. (Page 5A-134)

10) Install floor console box. (Page 9H-34)
11) Install steering column lower cover. (Page 6B-2)
1 12) Enable air bag system. (Page 8B-48)

IDAA0A550073-01
5A-134 Automatic Transmission/Transaxle:

Key Interlock Cable Inspection (Ignition Switch Installation

Model) 1) Apply ATF to output shaft speed sensor O-ring.
AENJHB0B5106019
2) Install output shaft speed sensor (1) to A/T case and
1) Shift select lever to P range and set ignition switch to
tighten bolt to specified torque.
“ACC”.
2) While pushing shift lock release button (1), press the Tightening torque
select lever button (2). Output shaft speed sensor bolt (a): 5.4 N·m (
0.55 kgf-m, 4.0 lbf-ft)
2 3) Connect output shaft speed sensor connector to
output shaft speed sensor.

IJHA0A510028-01

3) At the condition in Step 2), check that ignition switch

cannot be turned from “ACC” to “LOCK” position.
1

(a)
IJHA0A510030-01

Output Shaft Speed Sensor Inspection

I9P60A510071-01 AENJHB0B5106021

4) Release the select lever button. Check that ignition 1) Remove output shaft speed sensor. (Page 5A-
switch can be turned from “ACC” to “LOCK” position. 134)
If faulty condition is found, adjust key interlock cable. 2) Check the following points:
(Page 5A-132) • O-ring is free of damage.
• End face of sensor is free of any metal particles
and damage.
3) Check output shaft speed sensor as follows. If faulty
condition is found, replace output shaft speed
I9P60A510072-01
sensor. (Page 5A-134)
a) Connect battery (1), resistance and ammeter (3)
Output Shaft Speed Sensor Removal and to output shaft speed sensor (4) as shown in
Installation figure.
AENJHB0B5106020 b) Check that current through output shaft speed
Removal sensor changes to specified value when
1) Disconnect output shaft speed sensor connector. ferromagnetic material (iron) (5) passes in front
2) Remove output shaft speed sensor (1) by removing of output shaft speed sensor.
its bolt.
NOTE
Keep approximately 5 mm (0.2 in.) gap “a”
between ferromagnetic material (iron) and
end face of output shaft speed sensor.

1
IJHA0A510029-01
 Automatic Transmission/Transaxle: 5A-135

Output shaft speed sensor current 3) Connect input shaft speed sensor connector to input
Current alternates between 4 – 8 mA and 12 – 16 shaft speed sensor.
mA
(a) 1

4
5

“a”

2
3
1
IGRA0A511030-01
IJHA0A510032-01
2. Resistance (100 Ω)

Input Shaft Speed Sensor Removal and Input Shaft Speed Sensor Inspection
AENJHB0B5106023
Installation 1) Remove input shaft speed sensor. (Page 5A-135)
AENJHB0B5106022
Removal 2) Check the following points:
1) Disconnect input shaft speed sensor connector. • O-ring is free of damage.
2) Remove input shaft speed sensor (1) by removing its • End face of sensor is free of any metal particles
bolt. and damage.
3) Check input shaft speed sensor as follows. If faulty
1
condition is found, replace input shaft speed sensor.
(Page 5A-135)
a) Connect battery (1), resistance and ammeter (3)
to input shaft speed sensor (4) as shown in
figure.
b) Check that current through input shaft speed
sensor changes to specified value when
ferromagnetic material (iron) (5) passes in front
of input shaft speed sensor.

NOTE
Keep approximately 5 mm (0.2 in.) gap “a”
IJHA0A510031-01
between ferromagnetic material (iron) and
end face of input shaft speed sensor.
Installation
Input shaft speed sensor current
1) Apply ATF to input shaft speed sensor O-ring. Current alternates between 4 – 8 mA and 12 – 16
2) Install input shaft speed sensor (1) to A/T case and mA
tighten bolt to specified torque.
Tightening torque 4
Input shaft speed sensor bolt (a): 5.4 N·m (0.55
kgf-m, 4.0 lbf-ft) 4
5

“a”

2
3
1
IGRA0A511030-01

2. Resistance (100 Ω)
5A-136 Automatic Transmission/Transaxle:

A/T Oil Strainer Assembly Removal and Installation

Installation Reverse removal procedure noting the following points.
AENJHB0B5106024
• When overhauling A/T, replace oil strainer (1) and its
Removal
O-ring (2) with new one.
1) Hoist vehicle.
• Use new oil pan gasket (3) for A/T oil pan (4).
2) Remove left side engine under side cover.
• Tighten oil pan bolts to specified torque.
3) Drain A/T fluid. (Page 5A-119)
4) Remove A/T oil pan (1) and oil pan gasket (2). Tightening torque
Oil pan bolt (a): 7.0 N·m (0.71 kgf-m, 5.5 lbf-ft)
NOTE
When removing A/T oil pan, tap around it
lightly with plastic hammer. Do not force it off
using flat-bladed screwdriver or the like.

5) Remove oil strainer assembly (3) and O-ring.

1
3

4
2

(a)
1 ICL80C510048-01

• Replenish transaxle with ATF. (Page 5A-119)

• Check fluid level. (Page 5A-117)
• Check for fluid leakage after warming up A/T.

ICL80C510046-01
 Automatic Transmission/Transaxle: 5A-137

A/T Oil Pan and Oil Strainer Assembly ATF Temperature Sensor Removal and
Inspection Installation
AENJHB0B5106025 AENJHB0B5106026
• Check that the oil cleaner magnets (1) are free from Removal
metal particles. If not, clean. 1) Hoist vehicle.
• Check A/T oil pan (2) for crack, deformation, and 2) Drain A/T fluid. (Page 5A-119)
damage. 3) Install ATF drain plug. (Page 5A-119)
• Check oil strainer assembly for crack, deformation, 4) Remove A/T oil pan and oil strainer assembly.
and damage. (Page 5A-136)
5) Remove valve body assembly. (Page 5A-138)
6) Lower vehicle.
1 7) Remove battery tray, if necessary. (Page 1J-5)
8) Remove solenoid connector (1) with solenoid
harness (2).

NOTE

2
When pulling solenoid harness out of
transaxle case, take care not to damage ATF
temperature sensor at narrow exit of case.
Careless sensor treatment might cause
sensor malfunction.
1

ICL80C510049-01 1

IJHB0A510017-01
5A-138 Automatic Transmission/Transaxle:

Installation ATF Temperature Sensor Inspection

Reverse removal procedure noting the following points. AENJHB0B5106027
1) Warm up ATF temperature sensor (2).
• For details of valve body assembly and solenoid valve
connectors installation, refer to “Valve Body Assembly 2) Check resistance between terminals of solenoid
Removal and Installation” (Page 5A-138). connector (1). Check if its resistance decreases as
its temperature increases.
• Tighten ATF temperature sensor plate bolt to specified
If measured resistance is out of specified resistance,
torque.
replace ATF temperature sensor.
Tightening torque
ATF temperature sensor resistance
ATF temperature sensor plate bolt (a): 6.8 N·m (
10 °C (50 °F): 5.63 – 7.30 kΩ
0.69 kgf-m, 5.0 lbf-ft)
110 °C (230 °F): 224 – 271 Ω
145 °C (293 °F): 102 – 121 Ω

6 5 4 3 2 1
13 12 11 10 9 8 7

(a)
1

IJHB0A510018-01

• For details of A/T oil pan installation, refer to “A/T Oil

Strainer Assembly Removal and Installation” (Page
3
5A-136).
Use new oil pan gasket.
• Apply ATF to new solenoid harness O-ring. 2
• Tighten solenoid connector bolt to specified torque.
Tightening torque ICL80C510053-01
Solenoid connector bolt (a): 5.4 N·m (0.55 kgf-m,
3. ATF
4.0 lbf-ft)

(a) Valve Body Assembly Removal and Installation

AENJHB0B5106028
Removal
1) Remove A/T oil pan and oil strainer assembly.
(Page 5A-136)
2) Disconnect each connector (1) from solenoid valves.

ICL80C510052-01

• Replenish transaxle with ATF and check fluid level.

(Page 5A-119)
• Check for fluid leakage after warming up A/T.
 Automatic Transmission/Transaxle: 5A-139

3) Remove ATF temperature sensor (2). 6) Remove solenoid connector (1) with harness.

1 1 1 1 1 1 NOTE
When pulling solenoid harness (2) out of
transaxle case, take care not to damage ATF
temperature sensor at narrow exit of case.
Careless sensor treatment might cause
2
sensor malfunction.

IJHB0A510019-01

4) Remove valve body assembly bolts.

NOTE
• Be careful not to let manual valve fall off
when removing valve body assembly.
• There are two kinds of bolts (bolts A (1)
and B (2)) for fixing valve body assembly.

1 1
1

2
2

2 2

IJHB0A510017-01

7) Remove governor No.1 gasket (1).

2 2 1

2
2
2

IJHB0A510020-01

5) Remove valve body assembly (1).

ICL80C510058-01

ICL80C510056-01
5A-140 Automatic Transmission/Transaxle:

8) Remove C3 accumulator piston (1) and No.1 spring 3) Install C3 accumulator piston and spring referring to
(2), position rag on piston to catch piston. To remove the following table.
piston, force low-pressure compressed air (100 kPa,
Accumulator piston identification
1.0 kgf/cm2, 14.5 psi max) into hole (3) as shown in
figure, and pop piston into rag. Identification as
Piston name embossed letters on
NOTE piston
Do not push accumulator piston with fingers C3 accumulator piston (3) SC-3A
or anything when removing them.
Accumulator spring identification
Pushing them may cause compressed fluid
in accumulator to spew out of hole and get to Color of
your face and clothes. Spring name Length “a” identification
paint
C3 accumulator No.1 65.40 mm
Yellow
spring (4) (2.575 in.)

1
3
“a”
2

I7V10A510047-02

1
3
2
4

ICL80C510059-01

Installation
1) Select new O-rings referring to the following table.
Accumulator O-ring dimension
Inside Section
O-ring name
diameter diameter
Large C3 accumulator 24.6 mm 2.62 mm
ICL80C510060-01
O-ring (1) (0.969 in.) (0.103 in.)
Small C3 accumulator 21.8 mm 2.62 mm 4) After applying ATF to new governor No.1 gasket (1),
O-ring (2) (0.858 in.) (0.103 in.) install it to transaxle case.

1
2) Install new O-rings to accumulator piston and apply
A/T fluid to them.

NOTE
Check that O-rings are not twisted or caught
when installing.

ICL80C510058-01

5) Install solenoid harness to transaxle case. (Page

5A-137)
 Automatic Transmission/Transaxle: 5A-141

6) Install manual valve rod (1) to manual valve lever (3) 9) Install ATF temperature sensor (7).
and then install valve body assembly (2) to transaxle
Tightening torque
case.
ATF temperature sensor plate bolt (a): 6.8 N·m (
0.69 kgf-m, 5.0 lbf-ft)

1 2 3 4 5 6

ICL80C510061-01

7) Tighten valve body bolts to specified torque,

referring to the following table and figure.
(a)
Valve body bolt length
Bolt Length “a” Pieces
1 20 mm (0.79 in.) 3
2 36 mm (1.4 in.) 8 IJHB0A510022-01

10) Install A/T oil pan and oil strainer assembly. (Page
Tightening torque 5A-136)
Valve body bolt: 11 N·m (1.1 kgf-m, 8.5 lbf-ft) 11) Lower vehicle.
1 12) Replenish transaxle with proper amount of specified
1 1
ATF. (Page 5A-2)
13) Check fluid level. (Page 5A-117)
14) Perform “TCM Learning Value Clearance” (Page 5A-
2
116).
2
15) Perform “TCM Learning Value Initialization” (Page
2 5A-116).

Solenoid Valve On-Vehicle Inspection

AENJHB0B5106029
2 Resistance Check
2
1) Set ignition “OFF”.
2
2 2) Remove battery and battery tray. (Page 1J-5)
2
3) Disconnect solenoid connector from A/T.
4) Check for proper terminal connection to solenoid
“a” connector (1).
5) Check resistance of each solenoid valve circuit as
follows.
IJHB0A510021-01 Shift solenoid valve “A” resistance: [A]
8) Connect solenoid connectors identifying their Between (10) terminal of solenoid connector and
installing positions by wire color. transaxle: 11 to 15 Ω at 20 °C (68 °F)
Solenoid valve Wire color Pressure control solenoid valve “A” resistance: [B]
Shift solenoid valve “A” (1) RED Between (6) and (13) terminals of solenoid
TCC solenoid valve (2) BLU, YEL connector: 5.0 to 5.6 Ω at 20 °C (68 °F)
Pressure control solenoid valve “C” (3) GRY, LT BLU Between (6) terminal of solenoid connector and
Pressure control solenoid valve “B” (4) GRN, BRN transaxle: Infinity
Pressure control solenoid valve “A” (5) WHT, BLK
Electro magnetic oil pump solenoid Pressure control solenoid valve “B” resistance: [C]
PPL, LT GRN Between (5) and (12) terminals of solenoid
valve (6)
connector: 5.0 to 5.6 Ω at 20 °C (68 °F)
Between (5) terminal of solenoid connector and
transaxle: Infinity
5A-142 Automatic Transmission/Transaxle:

Pressure control solenoid valve “C” resistance: [D]

Between (4) and (11) terminals of solenoid [A] [B]
1 1
connector: 5.0 to 5.6 Ω at 20 °C (68 °F)
Between (4) terminal of solenoid connector and
transaxle: Infinity
TCC solenoid valve resistance: [E]
Between (3) and (9) terminals of solenoid connector:
5.0 to 5.6 Ω at 20 °C (68 °F)
Between (3) terminal of solenoid connector and
transaxle: Infinity [C] [D]
1 1
Electro magnetic oil pump solenoid valve
resistance: [F]
Between (2) and (8) terminals of solenoid connector:
5.0 to 5.6 Ω at 20 °C (68 °F)
Between (2) terminal of solenoid connector and
transaxle: Infinity

1
[E] [F]
1
1

IJHB0A510023-01

Solenoid Valve Inspection

AENJHB0B5106030
Shift Solenoid Valve “A”
Resistance check
Check shift solenoid valve “A”.
Shift solenoid valve “A” resistance
IGRA0A511032-01
Standard: 11 to 15 Ω at 20 °C (68 °F)

ICL80C510067-01
 Automatic Transmission/Transaxle: 5A-143

Operation check Operation check

Check that shift solenoid valve “A” (1) makes a clicking
sound when voltage is applied to each terminal as
shown in figure.
Check that pressure control solenoid valve “A” (1), “B”
(2), “C” (3), TCC pressure solenoid valve (4) and electro
magnetic oil pump solenoid valve (5) operates with click
sound when voltage is applied to each terminal as
shown in figure.

4
3

1 1

ICL80C510068-01

2. 12 V battery

Pressure Control Solenoid Valve “A”, “B”, “C” and

6
TCC Solenoid Valve
Resistance check
Measure resistance pressure control solenoid valve “A”
(1), “B” (2), “C” (3), TCC pressure control solenoid valve
(4) and electro magnetic oil pump solenoid valve (5). 7

Pressure control solenoid valve “A”

Standard: 5.0 to 5.6 Ω at 20 °C (68 °F) IJHB0A510025-01

Pressure control solenoid valve “B” 6. 12 V - 21 W bulb 7. 12 V battery

Standard: 5.0 to 5.6 Ω at 20 °C (68 °F)
Pressure control solenoid valve “C”
Standard: 5.0 to 5.6 Ω at 20 °C (68 °F)
TCC pressure control solenoid valve
Standard: 5.0 to 5.6 Ω at 20 °C (68 °F)
Electro magnetic oil pump solenoid valve
Standard: 5.0 to 5.6 Ω at 20 °C (68 °F)
4
3 NOTE
2 When the TCM is replaced, perform “TCM
1
5
TCM Removal and Installation
AENJHB0B5106031
NOTICE
As the TCM consists of precision parts, the
TCM will be damaged if it is exposed to an
excessively large impact.
Handle the TCM carefully so as not to impact
it.
Learning Value Clearance” (Page 5A-116) and
“TCM Learning Value Initialization” (Page 5A-
116). Neglecting this initialization may cause
excessive shift shock.
Removal
1) Disconnect negative (–) cable at battery.
2) Remove glove box and passenger side instrument
panel undercover. (Page 9C-35)
3) Disconnect connectors (1) from TCM (2).

IJHB0A510024-01
5A-144 Automatic Transmission/Transaxle:

4) Remove TCM by removing screws (3). 5) Apply grease to new differential side oil seal lips.
: Grease 99000–25030 (SUZUKI Super Grease C)
3 6) Using special tool, install new differential side oil
seals (1) at specified position as shown in figure.
2
Special tool
(A): 09944M88220
(B): 09924M74510
(C): 09951M16091
Differential side oil seal installing depth
“a”: 2.6 to 3.6 mm (0.10 to 0.14 in.)

3
IGSB0A550027-01

Installation
Reverse removal procedure noting the following points.
• Perform “TCM Learning Value Clearance” (Page 5A-
116).
• Perform “TCM Learning Value Initialization” (Page 5A-
116).

Differential Side Oil Seal Replacement

AENJHB0B5106032
1) Hoist vehicle and drain ATF. (Page 5A-119)
2) Remove front drive shaft assembly. (Page 3A-3)
3) Remove drive intermediate shaft assembly. (Page
3A-11)
4) Remove differential side oil seal (1) using flat-bladed
screwdriver or the like.

IGRA0A511033-01

[A]: Right side [B]: Left side

7) Install drive intermediate shaft assembly. (Page

3A-11)
8) Install front drive shaft assembly. (Page 3A-3)
9) Replenish transaxle with proper amount of ATF.
(Page 5A-119)
I7V10A510055-02
10) Check fluid level. (Page 5A-117)
[a]: Forward
 Automatic Transmission/Transaxle: 5A-145

ATF Cooler Hose Components

AENJHB0B5106033

(b)

(a)

1
4

IJHA0A510033-01

1. A/T assembly 4. Fluid cooler pipe : 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
2. Inlet hose 5. To radiator : Do not reuse.
3. Outlet hose : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)

ATF Cooler Hose Inspection

AENJHB0B5106034
Check ATF cooler hoses (1) for fluid leakage, crack,
damage and deterioration. Replace hose and/or clamp if
any faulty condition is found.

1
IJHA0A510034-01
5A-146 Automatic Transmission/Transaxle:

ATF Cooler Hose Replacement

AENJHB0B5106035
Rubber hoses for ATF cooler should be checked at
specified interval. If replacing them, note the following
items.
• If there is matchmark on each of hose and pipe, install
the hose aligning matchmark on hose with matchmark
on pipe and then install each clamp in proper position.
2
• Replace clamps at the same time
• Insert hose as far as its limit mark
• Clamp clamps securely
1
IJHA0A510035-01

1. Inlet hose (Inlet to ATF cooler)

2. Outlet hose (Outlet from ATF cooler)

A/T Assembly Components

AENJHB0B5106036

IJHA0A510036-01

[A]: Positioning type 2. Taper : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)

[B]: Standard type 3. Drive plate : 83 Nm (8.5 kgf-m, 61.5 lbf-ft)
1-1. Drive plate to torque converter No.1 bolt 4. Drive plate bolt : 54 Nm (5.5 kgf-m, 40.0 lbf-ft)
: For tightening order, refer to “Remounting” under “A/
T Assembly Dismounting and Remounting” (Page
5A-149).
1-2. Drive plate to torque converter No.2 bolt 5. Torque converter
: For tightening order, refer to “Remounting” under “A/ : Apply grease 99000-25011 to mating
T Assembly Dismounting and Remounting” (Page surface to drive plate.
5A-149).
 Automatic Transmission/Transaxle: 5A-147

Inner Parts

(d) 30
(d) 29 FLD 19 FLD
23 18 FLD
24
22 27 15 FLD
13 FLD
26 FLD
25 FLD
12 21 FLD
28 20
9 FLD 10

25 FLD 17 FLD
16 61 FLD
7 FLD
(c)
4 (a) 14 FLD 63 FLD
59 FLD
11 FLD
FLD
3 FLD 57 FLD
3
55 FLD 62 FLD
3 FLD 52 FLD
1 A
8
48 FLD 60 FLD
5 FLD 49
6 FLD 58 FLD

3 FLD 56 FLD
46 FLD
2
(d) 44 FLD 54 FLD

3 FLD 53 FLD
32 (b)
42 FLD 51 FLD
31 50
(d) 127 91 93 FLD
33 35 36
87 FLD 89
(f) 47 FLD 85 FLD
34
FLD
FLD
40 45
39 1216B 92 FLD
3 FLD 83 FLD
81 FLD 90 FLD
(e) 43 FLD
79 FLD
FLD 88 FLD
41 FLD 78 FLD 86

38 76 84 100 1216B
3 FLD
37 (d)
3 FLD
74 82 FLD
3 FLD 126 (a)
75 80 99 FLD
(e) (g)
70 98 FLD
64 FLD 71 125 (a) 77 FLD
LD
96
72 (c) 73 (c)
(c)
113 FLD 94
101 FLD
3 FLD
77 FLD
3 FLD 3 FLD
65 3 FLD

(l) 3 FLD 126 (a)

95 97 FLD
3 FLD 104 FLD
66
67
106
114 117 FLD
68 102 FLD 118 119
(h) 115
103
69 (j)
104 FLD
108 FLD 116 121 122
102 FLD
107 FLD 123
111
(k)
109 112 (i) 105 FLD
120 FLD
110 (m) 124 FLD
103
ICL80C510077-02
5A-148 Automatic Transmission/Transaxle:
1. Torque converter
: Apply grease 99000-25011 to mating
surface of drive plate.
2. Torque converter housing
3. O-ring
4. Torque converter housing plug
5. Oil seal
6. Input shaft seal ring
7. Input shaft front thrust bearing
8. Input shaft subassembly
9. Direct clutch piston
10. Direct clutch return spring subassembly
11. Direct clutch balancer
12. Shaft snap ring
13. Direct clutch separator plate
14. Direct clutch disc
15. Direct clutch retaining plate
16. Direct clutch retaining plate snap ring
17. Input shaft rear thrust bearing
18. Input shaft rear thrust bearing race
19. Direct clutch hub
20. Reduction drive gear nut
: Tighten reduction drive gear nut gradually
so as rotational torque of reduction drive
gear to be in specified value. (Page 5A-
182)
21. Reduction drive gear
22. Fluid reservoir plate
23. Lubrication tube clamp
24. Lubrication tube
25. Bearing cap
26. Countershaft right bearing
27. Countershaft
28. Reduction driven gear
29. Countershaft left bearing
30. Countershaft bearing shim
31. Solenoid harness
32. Breather hose plug
33. Breather hose
34. Breather union
35. Input shaft speed sensor
36. Output shaft speed sensor
37. Fluid reservoir left plate No.1
38. Fluid reservoir left plate No.2
39. Transaxle case
: Apply sealant 99000-31230 to mating
surface to torque converter housing.
40. 1st and reverse brake piston
41. 1st and reverse brake spring subassembly
42. 1st and reverse brake separator plate
43. 1st and reverse brake disc
44. 1st and reverse brake retaining plate
45. 1st and reverse brake retaining plate snap
ring
46. Planetary ring gear subassembly
47. Planetary gear assembly
48. One-way clutch No.2 assembly
49. One-way clutch outer race retainer
50. O/D and 2nd coast brake retaining plate
snap ring
51. O/D and 2nd coast brake retaining plate
52. O/D and 2nd coast brake disc
53. O/D and 2nd coast brake separator plate
54. O/D and 2nd coast brake rear plate
55. Planetary gear thrust bearing
56. Front sun gear thrust bearing race
57. Front planetary sun gear
58. Rear planetary sun gear subassembly
59. Rear sun gear thrust bearing
60. Forward clutch hub
61. Intermediate shaft thrust bearing front race
62. Intermediate shaft thrust bearing
63. Intermediate shaft thrust bearing rear race
64. Governor gasket No.2
65. Valve body assembly
: Do not disassemble.
66. A/T oil strainer assembly
67. Oil pan gasket
68. Oil cleaner magnet
69. A/T oil pan
70. C3 accumulator No.1 spring
71. C3 accumulator piston
72. Fluid filler tube union
73. Fluid cooler pipe union
74. Transmission range sensor
75. Manual select lever
76. Reverse clutch plate snap ring
77. Reverse clutch retaining plate
78. Reverse clutch disc
79. Reverse clutch cushion plate
80. Forward clutch plate snap ring
81. Forward clutch retaining plate
82. Forward clutch disc
83. Forward clutch separator plate
84. Balancer snap ring
85. Forward clutch balancer
86. Forward clutch return spring subassembly
87. Forward clutch piston
88. Forward clutch piston O-ring
89. Forward clutch drum
90. Forward clutch drum O-ring
91. Forward and reverse clutch assembly
92. Intermediate shaft seal ring
93. Reverse clutch drum thrust bearing
94. O/D and 2nd coast brake return spring
subassembly snap ring
95. O/D and 2nd coast brake return spring
subassembly
96. O/D and 2nd coast brake piston
97. O/D and 2nd coast brake piston
front O-ring
98. O/D and 2nd coast brake piston
rear O-ring
99. Rear cover seal ring
100. Transaxle rear cover
: Apply sealant 99000-31230 to
mating surface to transaxle case.
101. Governor gasket No.1
102. Differential side oil seal
103. Side bearing shim
104. Side bearing cup
105. Differential side right bearing
106. Differential case subassembly
107. Final driven gear
108. Differential side left bearing
109. Over flow plug gasket
110. Over flow plug
111. ATF drain plug gasket
112. ATF drain plug
113. Reverse clutch separator plate
114. Parking lock pawl rod
115. Parking lock pawl bracket
116. Manual detent spring
117. Parking lock pawl shaft
118. Parking lock pawl
119. Parking lock pawl spring
120. Manual valve lever
121. Manual valve lever pin
122. Manual shift shaft spacer
123. Manual shift shaft
124. Manual shift shaft oil seal
125. Transaxle case plug
126. Transaxle rear cover plug
127. ATF temperature sensor plate
: Do not reuse.
: Apply ATF.
: 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)
: 29 Nm (3.0 kgf-m, 21.5 lbf-ft)
: 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: 5.4 Nm (0.55 kgf-m, 4.0 lbf-ft)
: 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
: 6.8 Nm (0.69 kgf-m, 5.0 lbf-ft)
: 12 Nm (1.2 kgf-m, 9.0 lbf-ft)
: 78 Nm (8.0 kgf-m, 57.5 lbf-ft)
: 17 Nm (1.7 kgf-m, 12.5 lbf-ft)
: 7.4 Nm (0.75 kgf-m, 5.5 lbf-ft)
: 9.8 Nm (1.0 kgf-m, 7.5 lbf-ft)
: 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: 24 Nm (2.4 kgf-m, 18.0 lbf-ft)
 Automatic Transmission/Transaxle: 5A-149

A/T Assembly Dismounting and Remounting a) Insert flat-bladed screwdriver or the like (1) to
AENJHB0B5106037 torque converter case.
! CAUTION b) Lock drive plate by engaging flat-bladed
screwdriver or the like with gear of drive plate.
If the A/T assembly is tilted with the torque
converter end down, the torque converter
can fall off the A/T assembly, which could
cause personal injury.
Keep the A/T assembly horizontal or tilted
with the torque converter end up throughout
the operation.

NOTE
When A/T assembly is replaced, perform
“TCM Learning Value Clearance” (Page 5A- 1
116) and “TCM Learning Value Initialization” ICL80C510078-02
(Page 5A-116).
c) Remove torque converter locating bolt (1) or
Dismounting torque converter bolts (2) through installation
hole of starting motor.
1) Remove battery and battery tray. (Page 1J-5)
2) Hoist vehicle.
3) Remove engine under side covers.
4) Drain coolant. (Page 1F-11)
5) Drain ATF. (Page 5A-119)
6) Disconnect the following electric wires/connectors
and each clamp.
• Input shaft speed sensor (1)
• Output shaft speed sensor (2)
• Transmission range sensor (3)
• Solenoid connector (4)
7) Remove battery ground cable bolt (5).

2 1 1 2
IFAE0A510047-01

d) Turn crankshaft by 60° by turning crankshaft

3 5
4 19) Support engine assembly, using shackle, engine
IEL10A510020-01
8) Disconnect select cable. (Page 5A-129)
9) Remove radiator outlet hose.
10) Disconnect ATF cooler hose. (Page 5A-146)
11) Remove front drive shaft assembly. (Page 3A-3)
12) Remove drive intermediate shaft assembly. (Page
3A-11)
13) Remove exhaust No.1 pipe. (Page 1K-4)
14) Remove starting motor. (Page 1I-4)
15) Remove torque converter locating bolt and torque
converter bolts as follows.
pulley bolt using wrench.
e) Repeat Step a) – d) 5 times.
16) Loosen bolts and nuts fastening engine and A/T
assembly.
17) Remove air cleaner assembly. (Page 1D-9)
18) Remove left side apron lower member bracket.
(Page 9H-5)
hook, chain hoist or the like. Refer to Step 29) of
removal procedure in (Page 1D-27).
20) Remove the following parts. (Page 1D-26)
• Engine left mounting bracket
• Engine rear torque rod bracket
21) Support A/T assembly with transmission jack.
22) Remove bolts and nuts fastening engine and A/T
assembly, and then detach A/T assembly from
engine.
5A-150 Automatic Transmission/Transaxle:

NOTE Tightening torque

When dismounting A/T assembly from Torque converter bolt (b): 23 N·m (2.3 kgf-
engine, move it in parallel with crankshaft m, 17.0 lbf-ft)
and use care so as not to apply excessive
force to drive plate and torque converter.

Remounting
1) Check that torque converter is installed correctly to
transaxle. (Page 5A-182)
2) Tighten bolts and nuts fastening engine and A/T
assembly to specified torque. (Page 5A-146)
3) Install the following parts. (Page 1D-26)
• Engine left mounting bracket
• Engine rear torque rod bracket 3

4) Lower transmission jack.

5) Remove chain hoist from engine assembly.
1, (a) 2, (b)
6) Install left side apron lower member bracket.
(Page 9H-5) IFAE0A510051-02

7) Install air cleaner assembly. (Page 1D-9)
8) Tighten torque converter locating bolt and torque
converter bolts as follows.
NOTE
Torque converter locating bolt is used for
accurate positioning.
Tighten torque converter locating bolt first so
that bolt holes for torque converter and drive
plate are positioned properly, and that torque
converter bolts are tightened securely.
One torque converter locating bolt and five
torque converter bolts are required to secure
torque converter and drive plate.
a) Lock drive plate by engaging flat-bladed
screwdriver or the like (1) with drive plate gear.
3. Taper
d) Repeat Step c) 4 times.
9) Install starting motor. (Page 1I-4)
10) Install drive intermediate shaft assembly. (Page
3A-11)
11) Install front drive shaft assembly. (Page 3A-3)
12) Install exhaust No.1 pipe. (Page 1K-4)
13) Connect ATF cooler hose. (Page 5A-146)
14) Connect select cable. (Page 5A-129)
15) Install radiator outlet hose.
16) Connect the following electric wires/connectors and
each clamp:
• Input shaft speed sensor (1)
• Output shaft speed sensor (2)
• Transmission range sensor (3)
• Solenoid connector (4)
17) Tighten battery ground cable bolt (5) to specified
torque.
Tightening torque
Battery ground cable bolt (a): 25 N·m (2.5 kgf-
m, 18.5 lbf-ft)

2 1
1

ICL80C510078-02

b) Tighten torque converter locating bolt (1) to

specified torque.
Tightening torque
Torque converter locating bolt (a): 23 N·m (
2.3 kgf-m, 17.0 lbf-ft)
c) Turn crankshaft 60° by turning crankshaft pulley
bolt using wrench and tighten torque converter
3 5, (a)
bolt (2) to specified torque. 4
IEL10A510022-01
 Automatic Transmission/Transaxle: 5A-151

18) Refill cooling system with coolant. (Page 1F-11) 4) Remove engine hook (1).
19) Refill A/T assembly with ATF. (Page 5A-119)
1
20) Check ATF level. (Page 5A-117)
21) Install engine under side covers.
22) Install battery and battery tray. (Page 1J-5)
23) Perform “TCM Learning Value Clearance” (Page 5A-
116), if A/T assembly is replaced.
24) Perform “TCM Learning Value Initialization” (Page
5A-116), if A/T assembly is replaced.
ICL80C510082-01

A/T Assembly Disassembly 5) Remove transmission range sensor. (Page 5A-

AENJHB0B5106038 130)
NOTICE 6) Remove output shaft speed sensor (1) and input
Contamination and rough handling of the shaft speed sensor (2).
transaxle may cause premature wear,
functional problems and damage to parts. 2

• Thoroughly clean the exterior of the

transaxle before disassembling it.
• Keep workbench, tools and hands clean
during the service operation.
1
• Use special care when handling aluminum
parts so as not to damage them.
• Keep removed parts free of dust and other
foreign matter.
ICL80C510083-01
NOTE 7) Remove fluid cooler pipe (1), gaskets (2), fluid cooler
When A/T internal part(s) is replaced, perform pipe unions (3) and O-rings (4).
“TCM Learning Value Clearance” (Page 5A- 8) Remove fluid level gauge (5), fluid filler tube (6) and
116) and “TCM Learning Value Initialization” O-ring (7).
(Page 5A-116). 9) Remove fluid filler tube union (8) and O-ring (9).
1) Drain ATF. (Page 5A-119)
6
2) Remove torque converter (1) by pulling it out of the
transaxle as straight as possible to prevent oil seal 5 7
lip from damage. 6

9
1

2
1
2
1 3

ICL80C510081-01 ICL80C510084-02

3) Remove harness bracket with select cable clamp. 10) Remove A/T oil pan, oil pan gasket and oil strainer
(Page 5A-146) assembly. (Page 5A-136)
5A-152 Automatic Transmission/Transaxle:

NOTE 16) Remove torque converter housing (1) while tapping

For removal of A/T oil pan, do not turn around it lightly with plastic hammer.
transaxle over as this will contaminate valve
body with foreign materials in bottom of A/T
oil pan.

11) Remove valve body assembly. (Page 5A-138)

12) Remove solenoid connector. (Page 5A-137)
13) Remove governor gasket No.1 (1).

ICL80C510085-01

17) Remove breather hose (1) and breather union (2).

2
ICL80C510058-01

14) Remove C3 accumulator piston (1) and No.1 spring

(2), position rag on piston to catch piston. To remove
piston, force low-pressure compressed air (100 kPa,
1.0 kgf/cm2, 14.5 psi, max) into hole (3) as shown in
figure, and pop piston into rag.
ICL80C510086-01
NOTE
18) Remove oil pump bolts (2) then remove oil pump
Do not push accumulator piston with fingers assembly (1).
or anything before removing them. Pushing
them may cause compressed fluid in 1
accumulator to spew out of hole and get to
2
your face and clothes.

1
3

2
ICL80C510087-01

19) Remove direct clutch assembly (1).

ICL80C510059-01

15) Remove torque converter housing bolts (2).

ICL80C510088-01
 Automatic Transmission/Transaxle: 5A-153

20) Remove input shaft front thrust bearing (1). 24) Remove governor gasket No.2 (1).

NOTE 1

If input shaft front thrust bearing is not

found, it may have been taken out with oil
pump assembly.

1
1

ICL80C510092-01

25) Remove bolts (1) then remove fluid reservoir left

plate No.1 (2) and No.2 (3).

3
1

ICL80C510089-02

21) Remove input shaft rear thrust bearing (1) and thrust
bearing race (2). 2
1
ICL80C510093-01
NOTE
26) Turn over transaxle and remove bolts (1) then
If input shaft rear thrust bearing is not found, remove rear cover assembly (2).
it may have been taken out with direct clutch
assembly.
2 1
22) Remove direct clutch hub (3).

1
ICL80C510094-01

27) Remove 2nd brake gaskets (1).

ICL80C510090-01

23) Remove differential assembly (1) and countershaft

assembly (2).

2
1
ICL80C510095-01

28) Remove reverse clutch drum thrust bearing (1).

NOTE
If reverse clutch drum thrust bearing is not
found, it may have been taken out with rear
ICL80C510091-01
cover assembly.
5A-154 Automatic Transmission/Transaxle:

29) Remove forward and reverse clutch assembly (2). NOTE

If rear sun gear thrust bearing is not found on
forward clutch hub, it may have been left in
transaxle.

ICL80C510096-01

30) Remove intermediate shaft thrust bearing front race

(1), thrust bearing (2) and rear race (3) from forward
and reverse clutch assembly (4).
ICL80C510099-01
NOTE
33) Remove rear sun gear thrust bearing race (1).
If intermediate shaft thrust bearing and/or
races are not found on forward and reverse 34) Remove rear planetary sun gear subassembly (2).
clutch assembly, they may have been left in
transaxle.

I2RH0B510112-01

31) Remove forward clutch hub (1). ICL80C510100-01

35) Remove planetary gear thrust bearing (1).

NOTE
If planetary gear thrust bearing is not found
on rear planetary sun gear assembly, it may
have been left in transaxle.

ICL80C510098-01

32) Remove rear sun gear thrust bearing (1) from

forward clutch hub.

ICL80C510101-01
 Automatic Transmission/Transaxle: 5A-155

36) Remove O/D and 2nd coast brake rear plate (1), 39) Remove front sun gear thrust bearing race (2) from
discs (2), separator plates (3) and retaining plate (4). front planetary sun gear (1).

ICL80C510104-01

40) Remove one-way clutch outer race retainer (1).

ICL80C510097-01

37) Remove O/D and 2nd coast brake retaining plate

snap ring (1).

1
ICL80C510105-01

41) Check one-way clutch No.2 as follows.

• Ensure planetary carrier (1) rotates only
counterclockwise direction [a], never clockwise
direction [b].
If planetary carrier rotates both ways or does not
rotate either way, one-way clutch No.2 assembly
will need to be replaced with new one-way clutch
ICL80C510102-01
No.2 assembly.
38) Remove front planetary sun gear (1).

ICL80C510106-01

42) Remove planetary gear assembly (1) with one-way

clutch No.2 assembly (2).

ICL80C510103-01

ICL80C510107-01
5A-156 Automatic Transmission/Transaxle:

43) Remove one-way clutch No.2 assembly (1). Special tool

(A): 09927M26010

ICL80C510108-01 ICL80C510111-01

44) Turn over transaxle and release caulking from 46) Screwing in bolts of 30 mm (1.2 in.) in length (1),
reduction drive gear nut (1). remove reduction drive gear (2).

NOTICE
If three bolts are screwed on unevenly, the
reduction drive gear will be pulled out at an
angle, resulting in damage to the reduction
drive gear, the bearing and the transaxle
case.
Screw three bolts on gradually and evenly so
that the reduction drive gear remains straight
when pulled out.
I2RH0B510136-01

45) Secure reduction drive gear (1) with parking lock Reduction drive gear screwing bolt length
pawl (2), then remove reduction drive gear nut. 40 to 80 mm (1.6 to 3.1 in.)

ICL80C510110-01

NOTE
It is recommended that this operation should
be carried out on rubber mat to prevent
damaging transaxle case.

ICL80C510113-01

47) Remove snap ring while 1st and reverse brake

piston return springs are compressed using special
tool and hydraulic press.
 Automatic Transmission/Transaxle: 5A-157

NOTICE 51) Remove inner O-ring (1) and outer O-ring (2) from
Pushing down the 1st and reverse brake 1st and revered brake piston.
return spring subassembly over 0.8 mm (0.03
in.) will damage to the return spring
subassembly, the discs, the plates and/or the
piston.
Do not push down the 1st and reverse brake
return spring subassembly over 0.8 mm (0.03
in.).

Special tool
(A): 09926M97620
ICL80C510116-01

52) Remove bolts (1), and then remove parking lock

pawl bracket (2).

I2RH0B510134-01

48) Remove 1st and reverse brake retaining plate (1),

discs (2) and separator plates (3).
1
49) Remove 1st and reverse brake return spring ICL80C510115-01
subassembly (4). 53) Remove parking lock pawl shaft, and then remove
spring (2) and parking lock pawl (1).

ICL80C510109-01

50) Blowing compressed air from oil hole (1) of oil pump,
remove 1st and reverse brake piston (2).
ICL80C510112-01

54) Remove manual detent spring (1).

ICL80C510117-01

ICL80C510114-01
5A-158 Automatic Transmission/Transaxle:

55) With chisel (1), brake manual valve lever spacer (2) 59) Remove manual shift shaft oil seal (1).
and remove it.

ICL80C510122-01

ICL80C510118-01

56) Using spring pin remover (1) with 3 mm (0.1 in.) in Oil Pump Assembly Components
AENJHB0B5106039
diameter and hammer, remove manual valve lever
pin.

ICL80C510119-01 3
57) Remove manual shift shaft (1). 2 FLD
1 C
ICL80C510123-01

1. Oil seal
: Apply grease 99000-25030 to oil seal lip.
2. O-ring
3. Oil pump assembly
: Apply ATF.

: Do not reuse.

Oil Pump Assembly Disassembly and

Reassembly
AENJHB0B5106040
ICL80C510120-01
NOTICE
58) Remove parking lock pawl rod (2) from manual valve
lever (1). The oil pump assembly will lose its original
performance if it disassembled.
Do not disassemble the oil pump assembly.

ICL80C510121-01
 Automatic Transmission/Transaxle: 5A-159

Disassembly Oil Pump Assembly Inspection

AENJHB0B5106041
1) Remove O-ring from oil pump body.
1) Using special tool, measure inside diameter of stator
2) Remove oil seal (1) using special tool. shaft bushing (1).
Special tool If check result is not as specified, replace oil pump
(A): 09913M50121 assembly.
Special tool
(A): 09900M20605
Stator shaft bushing inside diameter “a”
Standard: 18.424 to 18.450 mm (0.7254 to 0.7264
in.)

I2RH0B510150-01

2. Oil pump assembly

Reassembly
1) Install new oil seal (1) to oil pump body (2).
Use special tool and hammer to install it, and then
apply grease to its lip portion. ICL80C510125-01

Special tool 2) Install direct clutch assembly (1) to stator shaft

(A): 09913M85210 assembly, then ensure that direct clutch assembly
turns smoothly.
“A”: Grease 99000–25030 (SUZUKI Super If unsmooth rotation or noise are found in oil pump
Grease C) assembly (2), replace oil pump assembly with new
one. This check should also be done to input shaft
assembly and replace input shaft assembly if
necessary.

I2RH0B510151-01

2) After applying ATF to new O-ring, install it to oil pump

body. I2RH0B510158-01
3) Check drive gear for smooth rotation using torque
converter (1).

I4RS0A510043-01
5A-160 Automatic Transmission/Transaxle:

3) Using special tool, measure inside diameter of oil

pump body bushing (1).
If check result is not as specified, replace oil pump
assembly. Torque converter also needs to be
checked. Replace torque converter, if necessary.
Special tool
(A): 09900M20605
Oil pump body bushing inside diameter “a”
Standard: 38.113 to 38.138 mm (1.5005 to 1.5015
in.)

ICL80C510127-01

Direct Clutch Assembly Components

AENJHB0B5106042

ICL80C510126-01

1. Input shaft front thrust bearing 6. Direct clutch piston 11. Direct clutch disc
2. Input shaft seal ring 7. Direct clutch return spring subassembly 12. Direct clutch retaining plate
3. Input shaft subassembly 8. Direct clutch balancer 13. Plate snap ring
4. Inner O-ring 9. Shaft snap ring : Apply ATF.

5. Outer O-ring 10. Direct clutch separator plate : Do not reuse.

 Automatic Transmission/Transaxle: 5A-161

Direct Clutch Assembly Preliminary Check NOTICE

AENJHB0B5106043
Pushing down the direct clutch return spring
1) Install direct clutch assembly (1) to oil pump
subassembly over 0.7 mm (0.03 in.) will
assembly (2).
damage to the direct clutch return spring
2) Install special tools to upper surface of direct clutch subassembly and/or the piston.
piston. Blow in air (400 to 800 kPa, 4.1 to 8.2 kgf/ Do not push down the direct clutch return
cm2, 58.0 to 116 psi) through oil hole (3) of oil pump spring subassembly over 0.7 mm (0.03 in.).
assembly, and measure piston stroke of direct
clutch. Special tool
If piston stroke exceeds specified value, (A): 09926M95420
disassemble, check and replace inner parts.
(A)
Special tool
(A): 09900M20607
(B): 09900M20701 1

Direct clutch piston stroke

0.4 to 0.7 mm (0.016 to 0.028 in.)

ICL80C510131-01

3) Remove clutch No.2 balancer (1) and direct clutch

return spring subassembly (2).

ICL80C510128-01

Direct Clutch Assembly Disassembly and

Reassembly
AENJHB0B5106044

Disassembly
1) Remove plate snap ring (1), and then remove direct
clutch retaining plate, discs and separator plates.
ICL80C510130-01

4) Using finger to block an oil hole (1), apply

compressed air (400 to 800 kPa, 4.1 to 8.2 kgf/cm2,
58.0 to 116 psi) to opposite oil hole, to assist removal
of clutch piston.

IJHB0A510026-02

2) Using special tool and hydraulic press, compress

direct clutch return spring subassembly, and remove
shaft snap ring (1).

I2RH0B510164-01
5A-162 Automatic Transmission/Transaxle:

5) Remove outer O-ring (1) from direct clutch piston (2). Reassembly
Reverse disassembly procedure noting the following
points.
• Use new seal rings and O-rings. Apply ATF before
installation.
• Apply ATF to direct clutch balancer.
• Use new shaft snap ring.
• Do not damage direct clutch balancer (1) and piston
ICL80C510132-01 by pressing in direct clutch balancer passing through
6) Remove inner O-ring (2) from input shaft its original installing position over 0.7 mm (0.03 in.).
subassembly (1).
Special tool
(A): 09926M95420

(A)

ICL80C510133-01

7) Remove input shaft seal rings (1) from input shaft

subassembly.

ICL80C510135-01

• Apply ATF to direct clutch separator plates (4), discs

(3) and retaining plate (2).
• Before assembling discs, soak them in ATF for at
least two hours.
• Install direct clutch separator plates, discs, retaining
ICL80C510134-01 plate and new plate snap ring (1) to input shaft
subassembly.

4
1

ICL80C510136-01
 Automatic Transmission/Transaxle: 5A-163

• Install new plate snap ring so that its both ends would Direct Clutch Assembly Inspection
be positioned in correct location as shown in figure. AENJHB0B5106045

Clutch Disc, Separator Plate and Retaining Plate

Check that sliding surfaces of clutch discs, separator
plates and retaining plate are not worn hard or burnt.
If necessary, replace.

NOTE
If disc lining is exfoliated or discolored,
replace all discs.

I2RH0B510172-01

I2RH0B510170-01
Direct Clutch Return Spring Subassembly
[A]: Correct [B]: Incorrect Measure free length of direct clutch return spring.
If measured length is out of reference value greatly,
• Measure direct clutch piston stroke. (Page 5A-161) replace direct clutch assembly.
When piston stroke is out of specification, select direct
clutch retaining plate with suitable thickness from NOTE
among the following table and replace it.
• Do not apply excessive force when
Available direct clutch retaining plate thickness measuring spring free length.
Thickness Identification mark • Perform measurement at several points.
2.8 mm (0.110 in.) 1
3.0 mm (0.118 in.) 2 Reference free length of direct clutch return spring
3.2 mm (0.126 in.) 3 “a”: 23.74 mm (0.9346 in.)

ICL80C510137-01
5A-164 Automatic Transmission/Transaxle:

Forward and Reverse Clutch Assembly Components

AENJHB0B5106046

ICL80C510138-02

1. Forward clutch balancer
2. Forward clutch return spring subassembly
3. Forward clutch piston
4. Forward clutch piston O-ring
5. Forward clutch drum
8. Intermediate shaft seal ring
9. Reverse clutch plate snap ring
10. Reverse clutch retaining plate
11. Reverse clutch separator plate
12. Reverse clutch disc
15. Forward clutch retaining plate
16. Forward clutch disc
17. Forward clutch separator plate
18. Balancer snap ring
: Apply ATF.

6. Forward clutch drum O-ring 13. Reverse clutch cushion plate : Do not reuse.
7. Intermediate shaft subassembly 14. Forward clutch plate snap ring

Forward and Reverse Clutch Assembly

Preliminary Check
AENJHB0B5106047
1) Install forward and reverse clutch assembly (1) to
transaxle rear cover (2).
2) Install special tools to upper surface of reverse
clutch retaining plate (3).
Blow in compressed air (400 to 800 kPa, 4.1 to 8.2
kgf/cm2, 58.0 to 116 psi) through oil hole (4) of
transaxle rear cover and measure reverse clutch
piston stroke.
 Automatic Transmission/Transaxle: 5A-165

If piston stroke exceeds specified value, Forward and Reverse Clutch Assembly
disassemble, check and replace inner parts. Disassembly and Reassembly
AENJHB0B5106048
Special tool
(A): 09900M20607
(B): 09900M20701 Disassembly
Reverse clutch piston stroke 1) Remove reverse clutch plate snap ring (1).
0.52 to 1.12 mm (0.0205 to 0.0441 in.) 2) Remove reverse clutch retaining plates, discs,
separator plate and clutch cushion plate from
intermediate shaft subassembly.

ICL80C510139-01
I7V10A510075-01
3) Blow in compressed air (400 – 800 kPa, 4.1 – 8.2 3) Remove forward clutch plate snap ring (1).
kgf/cm2, 58.0 – 116 psi) through oil hole (1) of
4) Remove forward clutch retaining plate, discs and
transaxle rear cover with special tool attached on
separator plates from forward clutch drum.
upper surface of forward clutch retaining plate, and
measure forward clutch piston stroke.
If piston stroke exceeds specified value,
disassemble, check and replace inner parts.
Special tool
(A): 09900M20607
(B): 09900M20701
(C): 09952M06020
Forward clutch piston stroke
0.8 to 1.0 mm (0.031 to 0.039 in.)
I7V10A510076-01

5) Using special tool and hydraulic press, compress

forward clutch balancer (1) and remove balancer
snap ring.

NOTICE
Pushing down the forward clutch balancer
over 1.5 mm (0.06 in.) will damage to the
forward clutch return spring subassembly
and/or the balancer.
Do not push down the forward clutch
balancer over 1.5 mm (0.06 in.).
ICL80C510140-01
5A-166 Automatic Transmission/Transaxle:

Special tool 9) Apply compressed air (400 to 800 kPa, 4.1 to 8.2
(A): 09926M97610 kgf/cm2, 58.0 to 116 psi) to oil hole (1) of transaxle
rear cover to remove forward clutch drum (2).

I2RH0B510180-01
ICL80C510146-01
6) Remove forward clutch balancer (1).
10) Remove forward clutch piston O-ring (1) from
7) Remove forward clutch return spring subassembly
intermediate shaft subassembly (2).
(2) from intermediate shaft subassembly (3).

ICL80C510141-01 ICL80C510144-01
8) Install intermediate shaft subassembly (1) to 11) Remove forward clutch drum O-ring (1) from forward
transaxle rear cover (2). Apply compressed air (400 clutch drum (2).
to 800 kPa, 4.1 to 8.2 kgf/cm2, 58.0 to 116 psi) to oil
hole (3) of transaxle rear cover to remove forward
clutch piston (4).

ICL80C510145-01

12) Remove intermediate shaft seal ring (1) from

intermediate shaft subassembly (2).
IJHA0A510037-01

I2RH0B510186-01
 Automatic Transmission/Transaxle: 5A-167

Reassembly • Install new forward clutch plate snap ring so that its
Reverse disassembly procedure noting the following both ends would be positioned in correct location as
points. shown in figure.
• Use new O-rings and seal ring. Apply ATF before
installation.
• Use new balancer snap ring.
• Apply ATF to forward clutch piston and forward clutch
balancer.
• Do not damage forward clutch return spring
subassembly and balancer (1) by pressing forward
clutch return spring subassembly passing through its
original installing position over 1.0 mm (0.039 in.).
Special tool
(A): 09926M97610

ICL80C510148-01

[A]: Correct [B]: Incorrect

I2RH0B510180-01 • Measure forward clutch piston stroke. (Page 5A-

• Apply ATF to forward clutch separator plates (1), discs 164)
(2) and retaining plate (3). When piston stroke is out of specification, select
• Before assembling discs, soak them in ATF for two forward clutch retaining plate with suitable thickness
hours or more. from among the following table and replace it.
• Install forward clutch separator plates, discs and Available forward clutch retaining plate thickness
retaining plate, then new forward clutch plate snap Thickness Identification mark
ring (4) to forward clutch drum. 3.0 mm (0.118 in.) 1
3.1 mm (0.122 in.) 2
4
3.2 mm (0.126 in.) 3
3
3.3 mm (0.130 in.) 4
2 3.4 mm (0.134 in.) 5
1 3.5 mm (0.138 in.) 6
3.6 mm (0.142 in.) 7
3.7 mm (0.146 in.) 8
3.8 mm (0.150 in.) 9

• Install reverse clutch cushion plate (1) in correct

direction as shown in figure.
• Apply ATF to reverse clutch cushion plate, reverse
ICL80C510147-01
clutch separator plate (2), discs (3) and retaining
plates (4).
• Before assembling discs, soak them in ATF for two
hours or more.
5A-168 Automatic Transmission/Transaxle:

• Install reverse clutch cushion plate, reverse clutch Forward and Reverse Clutch Assembly
separator plate, discs, retaining plate and then snap Inspection
ring (5) to intermediate shaft subassembly. AENJHB0B5106049

Clutch Disc, Separator Plate and Retaining Plate

Check that sliding surfaces of clutch discs, separator
plate and retaining plates are not worn hard or burnt.
If necessary, replace.

NOTE
If disc lining is exfoliated or discolored,
replace all discs.

ICL80C510149-01

• Install new reverse clutch plate snap ring so that its

both ends would be positioned in correct location as
shown in figure.

I2RH0B510192-01

Forward Clutch Return Spring Subassembly

Measure free length of forward clutch return spring.
If measured length is out of reference value greatly,
replace forward and reverse clutch assembly.

NOTE
• Do not apply excessive force when
measuring spring free length.
• Perform measurement at several points.

Reference free length of forward clutch return spring

“a”: 20.88 mm (0.8220 in.)

I2RH0B510190-01

[A]: Correct [B]: Incorrect

• Measure reverse clutch piston stroke. (Page 5A-

164)
When piston stroke is out of specification, select
reverse clutch retaining plate with suitable thickness
from among the following table and replace it.
Available reverse clutch retaining plate thickness
Thickness Identification mark
ICL80C510150-01
3.0 mm (0.118 in.) 1
3.2 mm (0.126 in.) 2
3.4 mm (0.134 in.) 3
3.6 mm (0.142 in.) 4
 Automatic Transmission/Transaxle: 5A-169

Forward Clutch Piston Lip and Forward Clutch Forward Clutch Drum Lip
Balancer Lip Check its lip for wear, deformation, cut and/or hardening.
Check each lip for wear, deformation, cut and/or If necessary, replace.
hardening. If necessary, replace.

ICL80C510151-01 I2RH0B510195-01

Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components
AENJHB0B5106050

ICL80C510152-02

1. Snap ring 5. O/D and 2nd coast brake piston 9. Rear cover plug O-ring
2. O/D and 2nd coast brake return spring 6. Rear cover seal ring : Apply ATF.
subassembly
3. O/D and 2nd coast brake piston front O-ring 7. Transaxle rear cover : Do not reuse.
: Apply sealant 99000-31230 to mating
surface to transaxle case.
4. O/D and 2nd coast brake piston rear O-ring 8. Rear cover plug : 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)

Transaxle Rear Cover (O/D and 2nd Coast Brake

Piston) Assembly Disassembly and
Reassembly
AENJHB0B5106051

Disassembly
1) Remove O/D and 2nd coast brake return spring
subassembly snap ring (1). 1
2) Remove O/D and 2nd coast brake return spring
subassembly (2).
2

ICL80C510232-01
5A-170 Automatic Transmission/Transaxle:

3) Apply compressed air (400 to 800 kPa, 4.1 to 8.2 Reassembly

kgf/cm2, 58.0 to 116 psi) to oil hole (2) of transaxle
rear cover (1) to remove O/D and 2nd coast brake
piston.
Reverse disassembly procedure noting the following
points.
• Use new seal rings and O-rings. Apply ATF to seal
rings and O-rings before installation.
• Tighten rear cover plugs to specified torque. (Page
5A-169)
• First, tighten seal ring to 5 mm (0.2 in.), and then
install seal ring.
• Do not open rear cover seal ring too wide to attach.

ICL80C510153-01

4) Remove O/D and 2nd coast brake piston front O-ring

(1) and rear O-ring (2) from O/D and 2nd coast brake
piston.

ICL80C510156-01

1. Transaxle rear cover

• Install new O/D and 2nd coast brake return spring

subassembly snap ring so that its both ends are
positioned in correct location as shown in figure.
ICL80C510154-01

5) Remove rear cover seal rings (1) from rear cover. Snap ring installation position
“a”: More than 3 mm (0.12 in.)

[A]

“a” “a”
[B]

ICL80C510155-01

6) Remove rear cover plugs (1) from rear cover.

ICL80C510158-01

[A]: Correct [B]: Incorrect

1 1
1
ICL80C510157-01
 Automatic Transmission/Transaxle: 5A-171

Transaxle Rear Cover (O/D and 2nd Coast Brake Countershaft Assembly Disassembly and
Piston) Assembly Inspection Reassembly
AENJHB0B5106052 AENJHB0B5106054

O/D and 2nd Coast Brake Return Spring Disassembly

Subassembly 1) Remove countershaft left bearing (1) and reduction
Measure free length of O/D and 2nd coast brake return driven gear (2) together using special tool and
spring. hydraulic press.
If measured length is out of specified length, replace
transaxle rear cover. Special tool
(A): 09925M98221
NOTE
• Do not apply excessive force when
measuring spring free length.
• Perform measurement at several points.

O/D and 2nd coast brake return spring free length

“a”: 12.63 mm (0.4972 in.)

I7V10A510080-01

2) Remove countershaft right bearing (1) using special

tools.
Special tool
(A): 09913M61510
ICL80C510159-01
(B): 09926M58010

Countershaft Assembly Components

AENJHB0B5106053

I2RH0B510211-01

ICL80C510233-01

1. Countershaft right bearing 5. Bearing cup

2. Countershaft 6. Countershaft bearing shim
3. Countershaft left bearing : Apply ATF.

4. Reduction driven gear : Do not reuse.

5A-172 Automatic Transmission/Transaxle:

Reassembly 3) Press-fit countershaft left bearing (1) using special

1) Press-fit new countershaft right bearing (1) using tools and hydraulic press.
special tool and hydraulic press. Special tool
NOTE (A): 09913M84510
(B): 09925M88210
Replace countershaft right bearing together
with bearing cup as a set.

Special tool
(A): 09913M84510

I2RH0B510214-01

I2RH0B510212-01

2) Press-fit reduction driven gear (1) using special tools

and hydraulic press.
Special tool
(A): 09913M84510
(B): 09925M88210

I2RH0B510213-01
 Automatic Transmission/Transaxle: 5A-173

Differential Assembly Components

AENJHB0B5106055

ICL80C510160-02

1. Differential side right bearing 4. Differential side left bearing : Apply ATF.

2. Differential case subassembly 5. Side bearing cup : Do not reuse.

3. Final driven gear 6. Side bearing shim : 78 Nm (8.0 kgf-m, 57.5 lbf-ft)

Differential Assembly Disassembly and 2) Remove differential side right bearing using special
Reassembly tools.
AENJHB0B5106056
Special tool
Disassembly (A): 09926M37610
1) Remove final gear bolts (1) and final driven gear (2). (B): 09926M37610M001
(C): 09926M37610M003
(D): 09926M37610M002

ICL80C510161-01

ICL80C510162-01
5A-174 Automatic Transmission/Transaxle:

3) Remove differential side left bearing using special 2) Facing groove (2) side upward, install final driven
tools. gear (1) to differential case as shown in figure.
Special tool
(A): 09926M37610
(B): 09926M37610M001
(C): 09926M37610M003
(D): 09926M37610M002

ICL80C510163-01

3) Tighten final gear bolts (1) to specified torque.

NOTE
To avoid rust, apply ATF to final driven gear
after installation.

I2RH0B510228-01 Tightening torque

Final gear bolt (a): 78 N·m (8.0 kgf-m, 57.5 lbf-ft)
Reassembly

! CAUTION
Failure to take proper precautions when
handling the warmed final driven gear can
result in serious burns.
• Use tongs or the like to remove warmed
final driven gear from a container.
• Wear heat-resistant gloves, such as leather
glove, when grabbing warmed final driven
I2RH0B510231-01
gear.
2. Final driven gear

NOTICE
4) After applying ATF to new differential side right
If the final driven gear is excessively warmed, bearing (1), press-fit it to differential case
there is a danger that its strength will be subassembly using special tool and hydraulic press.
reduced. Do not leave final driven gear in
boiling water for longer than 5 minutes. NOTE
Replace differential side right bearing
1) Put final driven gear in water vessel, heat and
together with bearing cup as a set.
remove when it boils, and then remove moisture.

NOTE Special tool

(A): 09913M70123
After removing moisture on final driven gear,
install final driven gear to differential case as
quickly as possible.

ICL80C510164-01

I2RH0B510229-01
 Automatic Transmission/Transaxle: 5A-175

5) After applying ATF to new differential side left Torque Converter Housing Disassembly and
bearing (1), install it to differential case subassembly Reassembly
using special tool and hydraulic press. AENJHB0B5106058

NOTE Disassembly
Replace differential side left bearing together 1) Remove fluid reservoir plate (1) and lubrication tube
with bearing cup as a set. clamp (2).
2) Remove lubrication tube (3).
Special tool
(A): 09913M70123 NOTE
Do not bend lubrication tube with excessive
force.

I2RH0B510234-01

Differential Assembly Inspection

AENJHB0B5106057 1
1) Hold differential case subassembly with soft jawed
vise and set special tools as shown. ICL80C510165-01

Special tool 3) Remove differential side oil seal (1) using a flat-
(A): 09900M20607 bladed screwdriver or the like.
(B): 09900M20701
2) Measure differential side gear thrust play.
Differential side gear thrust play
Standard: 0.06 to 0.22 mm (0.0024 to 0.0087 in.)

I7V10A510084-01

4) Remove countershaft right bearing cup using special

tools.
Special tool
(A): 09944M96013
I2RH0B510235-01
(B): 09942M15511
3) If check result is not as specified, replace differential (C): 09921M26010
case subassembly.

(B) (C)
(A)

ICL80C510166-02
5A-176 Automatic Transmission/Transaxle:

5) Remove differential side right bearing cup using Reassembly

special tools. 1) After applying ATF to new O-rings, fit them to
Special tool housing plugs. Then install plugs to torque converter
(A): 09925M16510 housing.
(B): 09924M74510 Tightening torque
Torque converter housing plug (a): 7.5 N·m (
0.76 kgf-m, 5.5 lbf-ft)
(B)

(A)

(a)

(a)
ICL80C510234-01 ICL80C510170-01
6) Remove torque converter housing plugs (1).
(a)

ICL80C510171-01
1
ICL80C510168-01 2) Using special tools, install shim and differential side
right bearing cup.

NOTE
Use shim with the same thickness as
removed one.

Special tool
(A): 09924M74510
(B): 09944M88220

(A)
1
ICL80C510169-01

(B)
ICL80C510172-01
 Automatic Transmission/Transaxle: 5A-177

3) Using special tool, install new countershaft right Tightening torque

bearing cup. Fluid reservoir plate bolt (a): 5.4 N·m (0.55 kgf-
m, 4.0 lbf-ft)
Special tool
Lubrication tube clamp bolt (b): 5.4 N·m (0.55
(A): 09924M74510
kgf-m, 4.0 lbf-ft)
(B): 09944M68510
(b)
3

(a)
(A)

1
(B)

ICL80C510173-01 2
4) Using special tools, install new differential side oil
seal to torque converter housing evenly at specified (a)
ICL80C510175-01
position shown in figure.
Special tool Transaxle Case Disassembly and Reassembly
(A): 09924M74510 AENJHB0B5106059

(B): 09944M88220
Disassembly
Differential side oil seal installing depth 1) Remove differential side oil seal (1) using a flat-
“a”: 2.6 to 3.6 mm (0.10 to 0.14 in.) bladed screwdriver or the like.
5) Apply grease to oil seal lip.
: Grease 99000–25030 (SUZUKI Super Grease C)

(A)

(B)

I7V10A510085-01

2) Remove countershaft left bearing cup and shim

using special tools.
Special tool
(A): 09944M96013
(B): 09942M15511
(C): 09921M26010

“a”

ICL80C510174-01

6) Install lubrication tube (1).

7) Install fluid reservoir plate (2) and lubrication tube
clamp (3) by tightening their mounting bolts to
specified torque.
ICL80C510235-01

3) Remove differential side left bearing cup and shim

using special tools.
5A-178 Automatic Transmission/Transaxle:

Special tool Reassembly

(A): 09913M75520 1) After applying ATF to new O-rings, fit them to
transaxle case plugs. Then install plugs to transaxle
(A) case.
Tightening torque
Transaxle case plug (a): 7.5 N·m (0.76 kgf-m, 5.5
lbf-ft)

(a)

ICL80C510176-02

4) Remove transaxle case plugs (1).

1
(a)
ICL80C510238-01

(a)

1
ICL80C510236-01
ICL80C510239-01

2) Using special tools, assemble shim and differential

1 side left bearing cup.

NOTE
Use shim with the same thickness as
removed one.

Special tool
(A): 09924M74510
(B): 09944M88220
ICL80C510237-01

(A)

(B)

ICL80C510177-01
 Automatic Transmission/Transaxle: 5A-179

3) Using special tools, install shim and countershaft left A/T Assembly Inspection and Adjustment
bearing cup. AENJHB0B5106060

NOTE Inspection
Use shim with the same thickness as Brake disc
removed one. Dry and check them for pitting, burn, flaking, significant
wear, glazing, cracking, charring and chips or metal
Special tool particles imbedded in lining.
(A): 09924M74510 If discs show any of above conditions, replacement is
(B): 09944M88220 required.

(A)
NOTE
• If disc lining is exfoliated or discolored,
replace all discs.
(B)
• Before assembling new discs, soak them
in ATF for at least two hours.

ICL80C510178-01

4) Using special tools, install new differential side oil

seal to transaxle case evenly at specified position
shown in figure.
Special tool I2RH01510147-01
(A): 09924M74510
(B): 09951M16091 Brake separator plate and retaining plate
Dry plates and check for discoloration. If plate surface is
Differential side oil seal installing depth
smooth and even color smear is indicated, plate should
“a”: 2.6 to 3.6 mm (0.10 to 0.14 in.)
be reused. If severe heat spot discoloration or surface
5) Apply grease to oil seal lip. scuffing is indicated, plate must be replaced.
: Grease 99000–25030 (SUZUKI Super Grease C)

I2RH0B510253-01

Brake return spring subassembly

Measure brake return springs.
Evidence of extreme heat or burning in area of clutch
may have caused springs to take heat set and would
require their replacement.
1st and reverse brake return spring free length
“a”: 22.57 mm (0.8886 in.)

ICL80C510179-01
5A-180 Automatic Transmission/Transaxle:

NOTE 4) Measure bearing preload at a speed of 100 rpm

• Do not apply excessive force when
measuring spring free length.
• Perform measurement at several points.
using a small torque wrench and special tool.
Special tool
(A): 09928M06050
Differential side bearing preload (a) measured as
starting torque
In case of new bearing: 0.78 to 1.37 Nm (8.0 to
14.0 kgf-cm, 0.58 to 1.01 lbf-ft)
In case of reused bearing: 0.39 to 0.69 Nm (4.0 to
7.0 kgf-cm, 0.29 to 0.51 lbf-ft)

ICL80C510180-01

Adjustment
Differential side bearing preload
I2RH0B510256-01
1) After applying ATF to differential assembly, fit it to
transaxle case. 5) If check result is not as specified, select shim with
suitable thickness from among the following table
2) Install torque converter housing to transaxle case,
and replace it. Then adjust differential side bearing
then tighten torque converter housing bolts (1) to
preload within specification.
specified torque.
Tightening torque NOTE
Torque converter housing bolt (a): 29 N·m (3.0 Record measured differential side bearing,
kgf-m, 21.5 lbf-ft) because it is necessary to adjust
countershaft bearing preload.

Available shim thickness

Thickness Identification mark
1.80 mm (0.0709 in.) A
1.85 mm (0.0728 in.) B
1.90 mm (0.0748 in.) C
1.95 mm (0.0768 in.) D
2.00 mm (0.0787 in.) E
2.05 mm (0.0807 in.) F
2.08 mm (0.0819 in.) G
2.11 mm (0.0831 in.) H
ICL80C510181-01 2.14 mm (0.0843 in.) J
3) Turn differential assembly more than 3 revolutions 2.17 mm (0.0854 in.) K
using special tool. 2.20 mm (0.0866 in.) L
2.23 mm (0.0878 in.) M
Special tool 2.26 mm (0.0890 in.) N
(A): 09928M06050 2.29 mm (0.0902 in.) P
2.32 mm (0.0913 in.) Q
2.35 mm (0.0925 in.) R
2.40 mm (0.0945 in.) S
2.45 mm (0.0965 in.) T
2.50 mm (0.0984 in.) U
2.55 mm (0.1004 in.) V
2.60 mm (0.1024 in.) W
2.65 mm (0.1043 in.) X
2.70 mm (0.1063 in.) Y

6) Remove differential assembly.

 Automatic Transmission/Transaxle: 5A-181

Countershaft bearing preload Countershaft bearing preload (b) measured as

1) After applying ATF to countershaft assembly (1) and starting torque
differential assembly (2), fit them. In case of new bearing: 0.33 to 0.76 Nm (3.4 to
7.7 kgf-cm, 0.24 to 0.56 lbf-ft)
2 In case of reused bearing: 0.17 to 0.38 Nm (1.8 to
3.8 kgf-cm, 0.13 to 0.28 lbf-ft)
1

ICL80C510182-01

2) Install torque converter housing to transaxle case,

I3RM0B510067-01
then tighten torque converter housing bolts (1) to
specified torque. 5) If check result is not as specified, select shim with
suitable thickness from among the following table
Tightening torque and replace it. Then adjust countershaft bearing
Torque converter housing bolt (a): 29 N·m (3.0 preload within specification.
kgf-m, 21.5 lbf-ft)
Available shim thickness
Thickness Identification mark
1.70 mm (0.0669 in.) 1
1.75 mm (0.0689 in.) 2
1.80 mm (0.0709 in.) 3
1.85 mm (0.0728 in.) 4
1.90 mm (0.0748 in.) 5
1.93 mm (0.0760 in.) 6
1.96 mm (0.0772 in.) 7
1.99 mm (0.0783 in.) A
2.02 mm (0.0795 in.) B
2.05 mm (0.0807 in.) C
ICL80C510181-01 2.08 mm (0.0819 in.) D
3) Turn differential assembly more than 3 revolutions 2.11 mm (0.0831 in.) E
using special tool. 2.14 mm (0.0843 in.) F
2.17 mm (0.0854 in.) G
Special tool 2.20 mm (0.0866 in.) H
(A): 09928M06050 2.25 mm (0.0886 in.) K
4) Measure bearing preload at a speed of 100 rpm 2.30 mm (0.0906 in.) L
using a small torque wrench and special tool. 2.35 mm (0.0925 in.) M
2.40 mm (0.0945 in.) N
Special tool 2.45 mm (0.0965 in.) P
(A): 09928M06050 2.50 mm (0.0984 in.) Q
Countershaft bearing (b) – Differential side bearing 2.55 mm (0.1004 in.) R
=
preload preload (a) 2.60 mm (0.1024 in.) S
2.65 mm (0.1043 in.) U
2.70 mm (0.1063 in.) W

6) Remove differential assembly and countershaft

assembly.
5A-182 Automatic Transmission/Transaxle:

A/T Assembly Reassembly 2) Install manual detent spring (1) to transaxle case
AENJHB0B5106061 and tighten manual detent spring bolt to specified
! CAUTION torque.

Failure to take proper precautions when Tightening torque

reassembling the A/T can result in oil leakage Manual detent spring bolt (a): 9.8 N·m (1.0 kgf-
or lose their original performance. m, 7.5 lbf-ft)
• Clean all parts with compressed air. Never
use wiping cloths or rags.
• Before assembling new clutch or brake
discs, soak them in ATF for at least 2
hours.
• Lubricate O-rings with ATF.
• Apply ATF on sliding or rotating surfaces
of parts before assembly.
• Use SUZUKI Super Grease C to retain parts
in place.
ICL80C510183-01
• Install thrust bearings and races in correct
direction and position. 3) Install parking lock pawl rod (2) to new manual valve
lever (1).
• Check that snap ring ends are not aligned
with one of cut outs and are installed in
groove correctly.
• Do not use adhesive cements on gaskets
and similar parts.
• Tighten each bolt and nut to specified
torque.

1) Install new manual shift shaft oil seal to transaxle ICL80C510121-01

case evenly at specified position as shown in figure.
4) After applying ATF to new manual valve lever (1),
Use special tool and hammer it to install oil seal,
install new manual shift shaft (4), new spacer (3) and
then apply ATF to its lip portion.
manual valve lever to transaxle case.
Special tool
(A): 09925M98210
Manual shift shaft oil seal installing depth
“a”: 0.75 to 1.25 mm (0.030 to 0.0492 in.)

“a”

(A)

ICL80C510242-01
 Automatic Transmission/Transaxle: 5A-183

5) After installing new manual valve lever pin (2) using 7) After applying ATF to new O-rings, install them to 1st
spring pin remover with 3 mm (0.1 in.) in diameter (5) and reverse brake piston (3).
and hammer, turn spacer to set position as shown in
figure. Then caulk spacer with punch (6).

I2RH0B510263-01

1. Inner O-ring 2. Outer O-ring

ICL80C510184-01
8) Install 1st and reverse brake piston (1) to transaxle
case (2).

NOTE
Be careful not to damage O-ring when
installing 1st and reverse brake piston.

ICL80C510185-01

6) Install parking lock pawl bracket (1) to transaxle case

by tightening its mounting bolt to specified torque.
Tightening torque
Parking lock pawl bracket bolt (a): 7.4 N·m (0.75
kgf-m, 5.5 lbf-ft)
I2RH0B510264-01

9) After applying ATF to 1st and reverse brake return

spring subassembly (1), install it to transaxle case
(2).

(a)
ICL80C510186-01

I2RH0B510265-01
5A-184 Automatic Transmission/Transaxle:

10) Apply ATF to 1st and reverse brake discs (2), 12) Install new 1st and reverse brake snap ring so that
separator plates (3) and retaining plate (1), and then its both ends would be positioned in correct location
install them to transaxle case. as shown in figure.

I2RH0B510266-01

11) Compress 1st and reverse brake return spring

subassembly using special tool and hydraulic press,
then attach new snap ring.

NOTICE
Pushing down the 1st and reverse brake
return spring subassembly over 0.8 mm (0.03
in.) from its original installing position will
damage to the return spring subassembly,
the discs, the plates and/or the piston.
Do not push down the 1st and reverse brake
return spring subassembly over 0.8 mm (0.03 I2RH0B510268-01
in.) from its original installing position. [A]: Correct [B]: Incorrect

Special tool
13) Measure 1st and reverse brake piston stroke.
(A): 09926M97620
If piston stroke exceeds specified value,
disassemble, check and replace discs and plates.
• Using special tool, measure 1st and reverse brake
piston stroke when compressed air (400 – 800
kPa, 4.1 – 8.2 kgf/cm2, 58.0 – 116 psi) is blown
through oil hole.
Special tool
(A): 09900M20607
(B): 09900M20701
(C): 09952M06020
I2RH0B510267-01 1st and reverse brake piston stroke
Standard: 0.791 to 1.489 mm (0.03114 to 0.05862
in.)

ICL80C510187-01
 Automatic Transmission/Transaxle: 5A-185

14) Press-fit reduction drive gear (1) to transaxle case 16) Press-fit new planetary ring gear subassembly (1) to
(3) using special tools and hydraulic press as shown reduction drive gear (3) using special tools and
in figure. hydraulic press as shown in figure.

NOTICE NOTICE
Failure to take proper precautions during the Failure to take proper precautions during the
press-fitting of a reduction drive gear can press-fitting of a planetary ring gear
cause damage to the reduction drive gear subassembly can cause damage to the
bearing. reduction drive gear bearing.
• Do not use the transaxle case as • Do not reuse a planetary ring gear
groundwork to press-fit reduction drive subassembly.
gear. • Do not use the transaxle case as
• Do not apply load more than 20 kN (2039.4 groundwork to press-fit the planetary ring
kgf, or 4496.2 lbf) with hydraulic press. gear subassembly.
• Do not apply load more than 20 kN (2039.4
NOTE kgf, or 4496.2 lbf) with hydraulic press.
When replacing reduction drive gear, replace
it together with reduction driven gear as a Special tool
set. (A): 09951M18211
(B): 09944M78210
Special tool
(A): 09951M18211
(B): 09944M78210

I2RH0B510272-01

2. Stand that can slightly lift transaxle case.

17) Install new reduction drive gear nut.

I2RH0B510270-01

2. Stand that can slightly lift transaxle case.

15) Install parking lock pawl (1) and spring (2). Apply
ATF to parking lock pawl shaft, then insert it into
transaxle case.

ICL80C510112-01
5A-186 Automatic Transmission/Transaxle:

18) Measure preload by turning counter drive gear at a 21) Check for correct installation of planetary gear
speed of 100 rpm using a small torque wrench. assembly as follows.
If measured preload is out of specification preload, Measure distance “a” using vernier caliper (1) and
replace the following parts. straightedge (2). If check result is not as specified,
• A/T case remove planetary gear assembly and reinstall it
properly.
• Reduction drive gear
• Planetary ring gear sub assembly Distance between planetary gear assembly and
mating surface of transaxle case
• Reduction drive gear nut
“a”: 30.3 to 32.3 mm (1.20 to 1.27 in.)
Special tool
(A): 09927M26010
Reduction drive gear bearing preload measured
as starting torque
Standard: 0.05 to 0.35 Nm (0.5 to 3.5 kgf-cm, 0.04
to 0.26 lbf-ft)

ICL80C510188-01

19) Using chisel or the like, caulk planetary ring gear

subassembly (1).

ICL80C510191-01

22) Apply ATF to one-way clutch No.2 assembly (1), and

install it to planetary gear assembly. After that,
ensure that planetary carrier (2) rotates only
counterclockwise direction [a], not clockwise
ICL80C510189-01 direction [b].
20) Apply ATF to planetary gear assembly (1), and fit it to
planetary ring gear assembly.

ICL80C510192-01

ICL80C510190-01
 Automatic Transmission/Transaxle: 5A-187

23) Install one-way clutch outer race retainer (1). 27) After applying ATF to O/D and 2nd coast brake
retaining plate (4), separator plates (3), discs (2) and
rear plate (1), install them to transaxle case (5).

1
ICL80C510105-01

24) Install new O/D and 2nd coast brake retaining plate
snap ring (1).

ICL80C510201-01

28) After applying ATF to planetary gear thrust bearing

(1), install it to rear planetary sun gear subassembly
(2) in direction shown in figure.

1
ICL80C510102-01
2
25) After applying ATF to front sun gear thrust bearing
race (2), install it to front planetary sun gear (1) in
direction shown in figure.

ICL80C510194-01

2 29) After applying ATF to rear planetary sun gear

subassembly (1), install them in transaxle case (2).

ICL80C510104-01

26) After applying ATF to front planetary sun gear (1),

install it to planetary gear assembly (2).

ICL80C510195-01

ICL80C510193-01
5A-188 Automatic Transmission/Transaxle:
30) After applying ATF to rear sun gear thrust bearing
race (1), install it to rear planetary sun gear (2) in
direction shown in figure.
ICL80C510196-01
31) After applying ATF to rear sun gear thrust bearing
(1), install it to forward clutch hub (2) in direction
shown in figure.
ICL80C510197-01
32) After applying ATF to forward clutch hub (1), install it
in transaxle case.
ICL80C510198-01
33) After applying ATF to intermediate shaft thrust
bearing rear race (3), thrust bearing (2) and front
race (1), install them to forward and reverse clutch
assembly (4).
I2RH0B510294-01
34) Apply ATF to forward and reverse clutch assembly
(1).
Install forward and reverse clutch assembly while
rotating clockwise and counterclockwise frequently
to fit clutch discs to mating hubs.
NOTE
Before installation, align teeth of forward and
reverse clutch discs to facilitate installation.
ICL80C510199-01
 Automatic Transmission/Transaxle: 5A-189

35) Check for correct installation of forward and reverse Available O/D and 2nd coast brake rear plate
clutch assembly as follows. thickness
Measure distance “a” using vernier caliper (1) and Thickness Identification mark
straightedge (2). If check result is not as specified, 1.8 mm (0.071 in.) 1
remove forward and reverse clutch assembly, 2.0 mm (0.079 in.) 2
forward clutch hub, rear planetary sun gear 2.2 mm (0.087 in.) 3
subassembly, and reinstall them properly. 2.4 mm (0.094 in.) 4
Distance between forward and reverse clutch 2.6 mm (0.102 in.) 5
assembly and mating surface of transaxle case
“a”: 32.9 to 36.3 mm (1.30 to 1.43 in.)

ICL80C510202-01

ICL80C510209-01

37) After applying ATF to new 2nd brake gaskets (1),

ICL80C510200-01 install them to transaxle case (2).
36) Measure O/D and 2nd coast brake piston stroke.
• Measure dimension “a” from end face of transaxle
case to O/D and 2nd coast brake rear plate (1)
using straightedge and vernier caliper.
• Measure dimension “b” from O/D and 2nd coast
brake piston (2) to rear cover assembly mating
surface using straightedge and vernier caliper.
• Calculate piston stroke from measured value of 2
1
dimensions “a” and “b”. ICL80C510204-01
• Piston stroke = “a” – “b”
O/D and 2nd coast brake piston stroke
Standard: 0.65 – 1.05 mm (0.026 – 0.041 in.)
If check result is not as specified, select O/D and 2nd
coast brake rear plate with suitable thickness from
among the following table and replace it.
5A-190 Automatic Transmission/Transaxle:

38) After applying ATF to reverse clutch drum thrust Tightening torque
bearing (1), install it to forward and reverse clutch Fluid reservoir left plate bolt No.1 (a): 10 N·m (
assembly (2) in direction shown in figure. 1.0 kgf-m, 7.5 lbf-ft)
Fluid reservoir left plate bolt No.2 (b): 10 N·m (
1.0 kgf-m, 7.5 lbf-ft)

2
(b)

ICL80C510210-01

39) Remove sealant attached to mating surface of 1

(a)
transaxle rear cover (1) completely. ICL80C510208-01

40) Apply sealant to mating surface of transaxle rear 43) After applying ATF to new governor gasket No.2 (1),
cover (1) as shown in figure. install it to transaxle case.
“A”: Sealant 99000–31230 (SUZUKI Bond 1
No.1216B)

“a”

“a”

“A”
1 ICL80C510092-01

44) After applying ATF to differential assembly (1) and

countershaft assembly (2), install them to transaxle
case.
ICL80C510206-01
1
a: 1.2 mm (0.047 in.)

2
41) Install transaxle rear cover assembly (1) on transaxle
case (2) and tighten rear cover bolts (3) to specified
torque.
Tightening torque
Rear cover bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-
ft)
ICL80C510091-01
1
45) After applying ATF to direct clutch hub (1), install it to
3, (a) planetary gear assembly.

3, (a)

2
3, (a)
ICL80C510207-01

42) Install fluid reservoir left plate No.1 (1) and No.2 (2)
and then tighten fluid reservoir left plate No.1 bolt
and No.2 bolt to specified torque. ICL80C510211-01
 Automatic Transmission/Transaxle: 5A-191

46) After applying ATF to input shaft rear thrust bearing Distance between direct clutch assembly and
(1) and thrust bearing race (2), install them into direct mating surface of transaxle case
clutch hub (3) in direction shown in figure. “a”: 10.4 to 12.2 mm (0.409 to 0.480 in.)

ICL80C510212-01

47) After applying ATF to direct clutch assembly (1),

install it while rotating clockwise and
counterclockwise frequently to fit clutch discs to
mating hub.

NOTE
Before installation, align teeth of direct clutch
discs to facilitate installation.

48) After applying ATF to input shaft front thrust bearing

(2), install it to direct clutch assembly in direction
shown in figure.
ICL80C510213-01
2 2
50) Install oil pump assembly (1) to transaxle case and
tighten oil pump assembly bolts to specified torque.
1 Tightening torque
Oil pump assembly bolt (a): 25 N·m (2.5 kgf-m,
18.5 lbf-ft)

(a)

ICL80C510203-02

49) Check for correct installation of direct clutch

assembly as follows.
Measure distance “a” using vernier caliper (1) and ICL80C510205-02
straightedge (2). If check result is not as specified, 51) Check that input shaft (1) turns smoothly.
remove direct clutch assembly, direct clutch hub and
reinstall them properly.
1

ICL80C510214-02
5A-192 Automatic Transmission/Transaxle:

52) Measure input shaft thrust play by applying dial 57) Install torque converter housing to transaxle case.
gauge onto input shaft end (1). a) Apply sealant to threads of four bolts (1).
Special tool “A”: Sealant 99000–31230 (SUZUKI Bond
(A): 09900M20607 No.1216B)
(B): 09900M20701
b) Tighten bolts to specified torque.
Input shaft thrust play
0.3 to 0.9 mm (0.01 to 0.04 in.) Tightening torque
Torque converter housing bolt (a): 29 N·m (
3.0 kgf-m, 21.5 lbf-ft)
(A)

1 (B)

ICL80C510215-01
ICL80C510218-01
53) After applying ATF to new O-ring, fit it to breather
58) Install new O-rings to accumulator piston and apply
union (2). Then install breather union to transaxle
ATF to them referring to the following table.
case.
54) Install breather hose (1). NOTE
Check that O-rings are not twisted or caught
when installing.

1 Accumulator O-ring dimension

2 Inside Section
O-ring name
diameter diameter
Large C3 accumulator 24.6 mm 2.62 mm
O-ring (1) (0.969 in.) (0.103 in.)
Small C3 accumulator 21.8 mm 2.62 mm
O-ring (2) (0.858 in.) (0.103 in.)

ICL80C510086-01 59) Install C3 accumulator piston and spring referring to

55) Wipe off and clean mating surface between the following table.
transaxle case (1) and torque converter housing.
Accumulator piston identification
56) Apply sealant to transaxle case as shown in figure.
Identification as
“A”: Sealant 99000–31230 (SUZUKI Bond Piston name embossed letters on
No.1216B) piston
C3 accumulator piston (3) SC-3A

ICL80C510217-01

“a”: 1.2 mm (0.047 in.)

 Automatic Transmission/Transaxle: 5A-193

Accumulator spring identification 65) After applying ATF to new O-ring (6), fit it to fluid filler
Color of identification tube (7). Then install fluid filler tube to transaxle case
Spring name and tighten fluid filler tube bolt to specified torque.
paint
C3 accumulator No.1 Tightening torque
Yellow
spring (4) Fluid filler tube bolt (e): 11 N·m (1.1 kgf-m, 8.5
lbf-ft)

1
3
2
4 6
7

3, (b)

(c)
(e)
5

(d) 4
ICL80C510060-01
5
60) After applying ATF to new governor gasket No.1 (1),
install it to transaxle case. 2, (a)

1 1
ICL80C510220-02

66) After applying ATF to O-ring of each sensor, install

input shaft speed sensor (1) (color: green) and
output shaft speed sensor (2) (color: white) and
tighten each mounting bolts to specified torque.
Tightening torque
Input shaft speed sensor bolt (a): 5.4 N·m (0.55
kgf-m, 4.0 lbf-ft)
Output shaft speed sensor bolt (b): 5.4 N·m (
0.55 kgf-m, 4.0 lbf-ft)
ICL80C510058-01

61) Install solenoid connector and valve body assembly.

(Page 5A-138) 1 (a)

62) Install A/T oil pan and oil strainer assembly. (Page (b)
5A-136)
63) After applying ATF to new O-rings (1), fit them to fluid 2
cooler pipe unions (2) and (3) respectively. Then
install the unions to transaxle case and tighten each
one to specified torque.
Tightening torque
Fluid cooler pipe union (a): 25 N·m (2.5 kgf-m,
18.5 lbf-ft) ICL80C510221-01

Fluid filler tube union (b): 25 N·m (2.5 kgf-m, 67) Install transmission range sensor. (Page 5A-130)
18.5 lbf-ft)
64) Install fluid cooler pipe (4) with new gaskets (5) and
tighten fluid cooler union bolts and fluid cooler pipe
bracket bolt to specified torque.
Tightening torque
Fluid cooler pipe union bolt (c): 35 N·m (3.6 kgf-
m, 26.0 lbf-ft)
Fluid cooler pipe bracket bolt (d): 11 N·m (1.1
kgf-m, 8.5 lbf-ft)
5A-194 Automatic Transmission/Transaxle:

68) Install hook (1) and tighten hook nut to specified • Apply grease around cup (6) at the center of
torque. torque converter.
Tightening torque “A”: Grease 99000–25011 (SUZUKI Super
Hook nut (a): 25 N·m (2.5 kgf-m, 18.5 lbf-ft) Grease A)

(a)
1

ICL80C510224-01

ICL80C510222-01

69) Install harness brackets and select cable clamp.

(Page 5A-146)
70) Install torque converter (3) noting the following
points.

NOTICE
Failure to take proper precautions before and
during installation of the torque converter
can cause damage to other parts.
• Check the pump hub portion carefully
before installing the torque converter. A
torque converter having nicks, burrs or
other damage at the pump hub portion will
damage the oil seal, causing oil leakage. If
the hub portion is damaged in any way,
replace the torque converter.
• Do not drop the torque converter when
installing it. If you drop the torque
converter, it will damage the oil pump gear
and cause a critical defect in the operation
of the A/T.
ICL80C510223-01

• Install torque converter while aligning grooves (1) 4. Flange nut 5. Torque converter housing
of torque converter with projections (2) of oil pump
drive gear.
• Install torque converter using care not to damage
oil seal of oil pump.
• After installing torque converter check that
distance “a” is within specification.
Torque converter installing position
“a”: More than 29.9 mm (1.18 in.)
• Check torque converter for smooth rotation.
 Automatic Transmission/Transaxle: 5A-195

Specifications
Tightening Torque Specifications
AENJHB0B5107001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Fluid pressure check hole bolt (Page 5A-45) /
7.4 0.75 5.5
(Page 5A-45)
ATF drain plug 17 1.7 12.5 (Page 5A-119)
Select lever nut 13 1.3 9.5 (Page 5A-121)
Select lever knob screw 2.2 0.22 2.0 (Page 5A-125)
Transmission range sensor bolt (Page 5A-131) /
5.4 0.55 4.0
(Page 5A-131)
Manual select lever nut 12 1.2 9.0 (Page 5A-131)
Output shaft speed sensor bolt (Page 5A-134) /
5.4 0.55 4.0
(Page 5A-193)
Input shaft speed sensor bolt (Page 5A-135) /
5.4 0.55 4.0
(Page 5A-193)
Oil pan bolt 7.0 0.71 5.5 (Page 5A-136)
ATF temperature sensor plate bolt (Page 5A-138) /
6.8 0.69 5.0
(Page 5A-141)
Solenoid connector bolt 5.4 0.55 4.0 (Page 5A-138)
Valve body bolt 11 1.1 8.5 (Page 5A-141)
Torque converter locating bolt 23 2.3 17.0 (Page 5A-150)
Torque converter bolt 23 2.3 17.0 (Page 5A-150)
Battery ground cable bolt 25 2.5 18.5 (Page 5A-150)
Final gear bolt 78 8.0 57.5 (Page 5A-174)
Torque converter housing plug 7.5 0.76 5.5 (Page 5A-176)
Fluid reservoir plate bolt 5.4 0.55 4.0 (Page 5A-177)
Lubrication tube clamp bolt 5.4 0.55 4.0 (Page 5A-177)
Transaxle case plug 7.5 0.76 5.5 (Page 5A-178)
Torque converter housing bolt (Page 5A-180) /
29 3.0 21.5 (Page 5A-181) /
(Page 5A-192)
Manual detent spring bolt 9.8 1.0 7.5 (Page 5A-182)
Parking lock pawl bracket bolt 7.4 0.75 5.5 (Page 5A-183)
Rear cover bolt 25 2.5 18.5 (Page 5A-190)
Fluid reservoir left plate bolt No.1 10 1.0 7.5 (Page 5A-190)
Fluid reservoir left plate bolt No.2 10 1.0 7.5 (Page 5A-190)
Oil pump assembly bolt 25 2.5 18.5 (Page 5A-191)
Fluid cooler pipe union 25 2.5 18.5 (Page 5A-193)
Fluid filler tube union 25 2.5 18.5 (Page 5A-193)
Fluid cooler pipe union bolt 35 3.6 26.0 (Page 5A-193)
Fluid cooler pipe bracket bolt 11 1.1 8.5 (Page 5A-193)
Fluid filler tube bolt 11 1.1 8.5 (Page 5A-193)
Hook nut 25 2.5 18.5 (Page 5A-194)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Select Lever Assembly Components” (Page 5A-120)
“Select Cable Components” (Page 5A-128)
“ATF Cooler Hose Components” (Page 5A-145)
“A/T Assembly Components” (Page 5A-146)
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components” (Page 5A-169)
“Differential Assembly Components” (Page 5A-173)
“Fasteners Information” in Section 0A (Page 0A-5)
5A-196 Automatic Transmission/Transaxle:

Special Tools and Equipment

Recommended Service Material
AENJHB0B5108001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 (Page 5A-124) / (Page
5A-130) / (Page 5A-194)
SUZUKI Super Grease C P/No.: 99000–25030 (Page 5A-144) / (Page
5A-159) / (Page 5A-177) /
(Page 5A-179)
Sealant SUZUKI Bond No.1216B P/No.: 99000–31230 (Page 5A-190) / (Page
5A-192) / (Page 5A-192)

NOTE
Required service material(s) is also described in:
“Select Lever Assembly Components” (Page 5A-120)
“Select Cable Components” (Page 5A-128)
“A/T Assembly Components” (Page 5A-146)
“Oil Pump Assembly Components” (Page 5A-158)
“Direct Clutch Assembly Components” (Page 5A-160)
“Forward and Reverse Clutch Assembly Components” (Page 5A-164)
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components” (Page 5A-169)
“Countershaft Assembly Components” (Page 5A-171)
“Differential Assembly Components” (Page 5A-173)

Special Tool
AENJHB0B5108002
09900M20605 09900M20607
Dial calipers (1/100 mm, 10 - Dial gauge
34 mm)
(Page 5A-159) / (Page 5A-161) /
(Page 5A-160) (Page 5A-165) /
(Page 5A-165) /
(Page 5A-175) /
(Page 5A-184) /
(Page 5A-192)
09900M20701 09913M50121
Magnetic stand Oil seal remover
(Page 5A-161) / (Page 5A-159)
(Page 5A-165) /
(Page 5A-165) /
(Page 5A-175) /
(Page 5A-184) /
(Page 5A-192)
09913M61510 09913M70123
Bearing puller Bearing installer
(Page 5A-171) (Page 5A-174) /
(Page 5A-175)

09913M75520 09913M84510
Bearing installer Bearing installer
(Page 5A-178) (Page 5A-172) /
(Page 5A-172) /
(Page 5A-172)
 Automatic Transmission/Transaxle: 5A-197

09913M85210 09921M26010
Bearing installer Bearing outer race remover
collar
(Page 5A-159) (Page 5A-175) /
(Page 5A-177)

09924M74510 09925M16510
Bearing and oil seal handle Oil seal installer
(Page 5A-144) / (Page 5A-176)
(Page 5A-176) /
(Page 5A-176) /
(Page 5A-177) /
(Page 5A-177) /
(Page 5A-178) /
(Page 5A-179) /
(Page 5A-179)
09925M37811M001 09925M88210
Oil pressure gauge Bearing puller attachment
(Page 5A-44) / (Page 5A-172) /
(Page 5A-45) (Page 5A-172)

09925M98210 09925M98221
Input shaft bearing installer Bearing installer
(Page 5A-182) (Page 5A-171)

09926M37610 09926M37610M001
Bearing remover Bearing puller
(Page 5A-173) / (Page 5A-173) /
(Page 5A-174) (Page 5A-174)

09926M37610M002 09926M37610M003
Bearing puller attachment Bearing remover attachment
(Page 5A-173) / (Page 5A-173) /
(Page 5A-174) (Page 5A-174)

09926M58010 09926M95420
Bearing remover attachment Clutch spring compressor
(Page 5A-171) (Page 5A-161) /
(Page 5A-162)
5A-198 Automatic Transmission/Transaxle:

09926M97610 09926M97620
Spring compressor Spring compressor
(Page 5A-166) / (Page 5A-157) /
(Page 5A-167) (Page 5A-184)

09927M26010 09928M06050
Counter drive gear socket Differential preload adapter
(Page 5A-156) / (Page 5A-180) /
(Page 5A-186) (Page 5A-180) /
(Page 5A-181) /
(Page 5A-181)

09942M15511 09944M68510
Sliding hammer Bearing installer attachment
(Page 5A-175) / (Page 5A-177)
(Page 5A-177)

09944M78210 09944M88220
Bearing installer support Oil seal installer
(Page 5A-185) / (Page 5A-144) /
(Page 5A-185) (Page 5A-176) /
(Page 5A-177) /
(Page 5A-178) /
(Page 5A-179)
09944M96013 09951M16091
Bearing outer race remover Oil seal installer
(Page 5A-175) / (Page 5A-144) /
(Page 5A-177) (Page 5A-179)

09951M18211 09952M06020
Oil seal remover & installer Dial gauge plate No.2
No. 2
(Page 5A-185) / (Page 5A-165) /
(Page 5A-185) (Page 5A-184)

SUZUKI scan tool (Suzuki

SDT-II)
—
(Page 5A-17) /
(Page 5A-18) /
(Page 5A-116) /
(Page 5A-117)
 Manual Transmission/Transaxle: K15B Model 5B-1

Manual Transmission/Transaxle
Transmission / Transaxle

K15B Model
General Description
Manual Transaxle Construction
AENJHB0B5211001
The transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three
shafts: input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a
sliding idler gear arrangement.
The low speed synchronizer sleeve & hub is mounted on countershaft and engaged with countershaft 1st gear or 2nd
gear, while the high speed synchronizer sleeve & hub is mounted on input shaft and engaged with input shaft 3rd gear
or 4th gear. The 5th speed sleeve & hub on input shaft is engaged with input shaft 5th gear mounted on the input shaft.
To prevent the cracking noise from the reverse gear when shifting transaxle gear into the reverse gear, the reverse
shift braking device is used. This device utilizes the 5th synchromesh, which is the lever synchro type, to apply the
brake on the input shaft rotation.
The double cone synchronizing mechanism is provided to 1st and 2nd gear synchromesh devices to improve shift
feeling of 1st and 2nd gears.
For servicing, it is necessary to use genuine sealant or its equivalent on mating surfaces of transaxle case which is
made of aluminum. The case fastening bolts must be tightened to specified torque by means of torque wrench. It is
also important that all parts are thoroughly cleaned with cleaning fluid and air-dried before reassembling.
5B-2 Manual Transmission/Transaxle: K15B Model

Further, care must be taken to adjust preload of countershaft taper roller bearings. New synchronizer rings are
inhibited from being lapped with respective gear cones using lapping compound before they are assembled.

IFRA0B521001-01

1. Input shaft 8. Reverse gear shaft 15. Countershaft 3rd gear

2. 5th speed sleeve & hub
3. Input shaft 5th gear
4. Input shaft 4th gear
5. High speed synchronizer sleeve & hub
6. Input shaft 3rd gear
7. Left case
9. Reverse idler gear
10. Right case
11. Countershaft
12. Side cover
13. Countershaft 5th gear
14. Countershaft 4th gear
16. Countershaft 2nd gear
17. Low speed synchronizer sleeve & hub
18. Countershaft 1st gear
19. Final gear
20. Differential case
 Manual Transmission/Transaxle: K15B Model 5B-3

Gear Shift Mechanism

The gear shifting control system consists of the following main parts. Movement of gear shift control lever is
transmitted to gear shift & select shaft through gear shift and gear select cables.

2
4 13

11
5

3
5

10

12

6
7
8 9

IJHB0B521001-01

1. Gear shift control cable
2. Gear select control cable
3. Select cable lever
4. Shift cable lever
5. 5th gear shift fork
6. 5th & reverse gear shift shaft
7. Gear shift & select lever
8. Low speed gear shift shaft
9. High speed gear shift shaft
10. Reverse gear shift lever
11. Gear shift & select shaft assembly
12. Gear shift interlock bolt
13. Gear shift control lever assembly
5B-4 Manual Transmission/Transaxle: K15B Model

Reverse Shift Prevention Mechanism
Construction
In the gear shift lever case, the reverse shift limit yoke
(2) which turns around reverse shift limit yoke retainer is
provided.
This reverse shift limit yoke restricts the movement of
gear shift & select lever (1) to prevent erroneous reverse
shifting.
2) The cubic part of the gear shift & select lever (1)
pushes the projection of the reverse shift limit yoke
(2). The reverse shift limit yoke rotates and pushes
the gear shift & select lever toward the neutral
position.
[a]

3 1 2

[c] [b]

IAP70A520035-02

[a]: 5th [c]: 4th

[b]: Reverse
1 2
3) If the reverse shifting force is still applied to the shift
lever, the cubic part of the gear shift & select lever
(1) rides over the projection of the reverse shift limit
yoke (2), and the gear is shifted into the 4th. The
reverse shift limit yoke returns to its original position.

[a]

1
I9P60A521054-01

3. Gear shift & select shaft assembly

[c] [b]

Operation
1) If shifting directly from 5th [a] to reverse [b] is
attempted, the cubic part of the gear shift & select
lever (1) is blocked by the projection of the reverse
IAP70A520034-02
shift limit yoke (2).
[a]: 5th [c]: 4th
[a] [a] [b]: Reverse
1 1

2 2

[c] [b] [c] [b]

IAP70A520033-02

[c]: 4th
 Manual Transmission/Transaxle: K15B Model 5B-5
Diagnostic Information and Procedures
Manual Transaxle Symptom Diagnosis
Condition Possible cause
Gears slipping out of Worn shift shaft
mesh
Worn shift fork or synchronizer sleeve
Weak or damaged locating springs
Worn bearings on input shaft or
countershaft
Worn chamfered tooth on sleeve and
gear
AENJHB0B5214001
Correction / Reference Item
Replace shift shaft.
• Low speed gear shift shaft: (Page 5B-24)
• High speed gear shift shaft: (Page 5B-24)
• 5th & reverse gear shift shaft: (Page 5B-
24)
Replace shift fork, shift shaft or synchronizer
sleeve & hub.
• Low speed gear shift shaft: (Page 5B-24)
• High speed gear shift shaft: (Page 5B-24)
• 5th gear shift fork: (Page 5B-39)
• Low speed synchronizer sleeve & hub:
(Page 5B-35)
• High speed synchronizer sleeve & hub:
(Page 5B-33)
• 5th speed synchronizer sleeve & hub:
(Page 5B-20)
Replace gear shift & select shaft assembly.
(Page 5B-17)
Replace input shaft bearing or output shaft
bearing.
• Countershaft left bearing
– Inner race: (Page 5B-35)
– Outer race: (Page 5B-24)
• Countershaft right bearing
– Inner race: (Page 5B-35)
– Outer race: (Page 5B-28)
• Input shaft left bearing and right bearing:
(Page 5B-33)
Replace synchronizer sleeve & hub and gear.
• Countershaft 1st gear and 2nd gear:
(Page 5B-35)
• Input shaft 3rd gear and 4th gear: (Page
5B-33)
• Input shaft 5th gear: (Page 5B-20)
• Low speed synchronizer sleeve & hub:
(Page 5B-35)
• High speed synchronizer sleeve & hub:
(Page 5B-33)
• 5th speed synchronizer sleeve & hub:
(Page 5B-20)
5B-6 Manual Transmission/Transaxle: K15B Model
Condition Possible cause
Hard shifting Inadequate lubricant
Improper clutch pedal free travel
Distorted or broken clutch disc
Damaged clutch pressure plate
Worn synchronizer ring
Worn chamfered tooth on sleeve and
gear
Worn gear shift control shaft joint
bushing
Distorted shift shaft
Broken gear shift / select control cables Replace gear shift and select cable. (Page
Correction / Reference Item
Add manual transaxle oil.
Replace clutch pedal arm or clutch master
cylinder.
• Clutch pedal arm: (Page 5C-5)
• Clutch master cylinder: (Page 5C-7)
Replace clutch disc. (Page 5C-11)
Replace clutch cover. (Page 5C-11)
Replace synchronizer ring.
• Low speed synchronizer ring and 2nd gear
synchronizer ring: (Page 5B-35)
• High speed synchronizer ring: (Page 5B-
33)
• 5th speed synchronizer ring: (Page 5B-
20)
Replace synchronizer sleeve & hub and gear.
• Countershaft 1st gear and 2nd gear:
(Page 5B-35)
• Input shaft 3rd gear and 4th gear: (Page
5B-33)
• Input shaft 5th gear: (Page 5B-20)
• Low speed synchronizer sleeve & hub:
(Page 5B-35)
• High speed synchronizer sleeve & hub:
(Page 5B-33)
• 5th speed synchronizer sleeve & hub:
(Page 5B-20)
Replace gear shift & select shaft assembly.
(Page 5B-17)
Replace shift fork or shift shaft.
• Low speed gear shift shaft: (Page 5B-24)
• High speed gear shift shaft: (Page 5B-24)
• 5th & reverse gear shift shaft: (Page 5B-
24)
5B-11)
 Manual Transmission/Transaxle: K15B Model 5B-7
Condition Possible cause
Noise Inadequate or insufficient lubricant
Damaged or worn bearing(s)
Damaged or worn gear(s)
Damaged or worn synchronizer parts
Correction / Reference Item
Add manual transaxle oil.
Replace bearing.
• Countershaft left bearing
– Inner race: (Page 5B-35)
– Outer race: (Page 5B-24)
• Countershaft right bearing
– Inner race: (Page 5B-35)
– Outer race: (Page 5B-28)
• Input shaft left bearing and right bearing:
(Page 5B-33)
• Differential side bearing
– Inner race: (Page 5B-40)
– Right side outer race: (Page 5B-28)
– Left side outer race: (Page 5B-30)
• Needle bearing
– Countershaft 1st gear and 2nd gear:
(Page 5B-33)
– Input shaft 3rd gear and 4th gear:
(Page 5B-35)
– 5th gear: (Page 5B-20)
Replace gear.
• Countershaft 1st gear, 2nd gear, 3rd gear
and 4th gear: (Page 5B-35)
• Input shaft 1st gear, 2nd gear, 3rd gear and
4th gear: (Page 5B-33)
• Input shaft 5th gear and countershaft 5th
gear: (Page 5B-20)
Replace synchronizer parts.
• Low speed synchronizer parts: (Page 5B-
35)
• High speed synchronizer parts: (Page 5B-
33)
• 5th speed synchronizer parts: (Page 5B-
20)
5B-8 Manual Transmission/Transaxle: K15B Model

Repair Instructions
Manual Transaxle Oil Level Check
AENJHB0B5216001
1) Hoist vehicle and remove left side engine under side
cover.
2) Check manual transaxle for oil leakage. Repair leaky
point, if any.
3) Remove oil level / filler plug (1). Check oil
contamination and check that oil level reaches lower
end of oil level / filler plug hole (2).
If oil is excessively dirty or insufficient, change oil or
add specified oil up to plug hole.
4) Apply sealant to thread of oil level / filler plug, and
then tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (a): 21 N·m (2.1
kgf-m, 15.5 lbf-ft)
Manual Transaxle Oil Change
AENJHB0B5216002
1) Before changing oil, stop engine and hoist vehicle
horizontally.
2) Remove left side engine under side cover.
3) Check manual transaxle for oil leakage. Repair leaky
point, if any.
4) Remove oil level / filler plug (2).
5) Remove drain plug (1), and drain oil.
6) Apply sealant to thread of drain plug, and tighten it to
specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m,
15.5 lbf-ft)
7) Add new specified oil until oil level reaches lower
end of oil level / filler plug hole (3) as shown in figure.

NOTE
It is highly recommended to use “SUZUKI
GEAR OIL 75W”.

Manual transaxle oil specification

: SUZUKI GEAR OIL 75W 99000–22B27–036
: API GL-4 (For SAE classification, refer to
viscosity chart.)
Manual transaxle oil capacity (reference)
IJHA0A520002-01 : 2.6 liters (5.49/4.58 US/Imp. pt)
Viscosity chart

75W

C - 30 - 20 - 10 0 10 20 30 40
F - 22 -4 14 32 50 68 86 104
[a]
IFFA0B521002-01

IAP70A320003-01 [a]: Temperature

 Manual Transmission/Transaxle: K15B Model 5B-9

8) Apply sealant to thread of oil level / filler plug, and
then tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (b): 21 N·m (2.1
kgf-m, 15.5 lbf-ft)
5) Install new oil seal (1) to specified position using
special tool.
NOTE
• When installing oil seal, face its spring
side inward.
• Check that oil seal is installed horizontally
to surface of case after installing oil seal.

Special tool
(A): 09944M66010
(B): 09944M88220
(C): 09924M74510
2, (b), “A”
Distance from case end face to right oil seal
“a”: 9.5 – 10.5 mm (0.37 – 0.41 in.)
Distance from case end face to left oil seal
“c”: 0 – 1.0 mm (0 – 0.04 in.)
6) Apply grease to oil seal lip. Then, check drive shaft
1, (a), “A”
IJHA0A520003-01
where oil seal contacts and check its smoothness.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)

“c” “a”

(C)
(C)

IAP70A320006-01

Differential Side Oil Seal Replacement (B) (A)

AENJHB0B5216003
1) Hoist vehicle and drain transaxle oil. (Page 5B-8)
2) Remove front drive shaft. (Page 3A-3)
1, “A”
3) Remove drive intermediate shaft. (Page 3A-11) IGSB0A521005-01

4) Remove oil seal (1) using special tool. 7) Install drive intermediate shaft. (Page 3A-11)
8) Install front drive shaft. (Page 3A-3)
Special tool
(A): 09913M50121 9) Add transaxle oil. (Page 5B-8)

(A)
1
I9P60A522004-01
5B-10 Manual Transmission/Transaxle: K15B Model

Gear Shift Control Lever and Cable Components

AENJHB0B5216004

(d)
3

5
1

(a)
(b) 4
7

(c)

A
A

IJHA0A520004-01

1. Gear shift control lever knob 5. Cable bracket : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
: For removal refer to “Gear Shift Control
Lever and Cable Removal and Installation”:
K15B Model (Page 5B-11).
2. Gear shift control cable 6. Gear shift and select shaft assembly : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
: Apply grease 99000-25011 to pivot.
3. Gear select control cable 7. Shift control lever boot : 21 Nm (2.1 kgf-m, 15.5 lbf-ft)
4. Gear shift control lever assembly : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft) : Do not reuse.
: Apply grease 99000-25011 to pivot.
 Manual Transmission/Transaxle: K15B Model 5B-11

Gear Shift Control Lever and Cable Removal b) Cut inner ring (1) at two places along 3-4 line (2)
and Installation using nippers or the like, and remove the ring.
AENJHB0B5216005

! CAUTION
Touching a hot exhaust system component
will cause a burn. 2

Do not perform any service work on the

select cable until the exhaust system is cool.

Removal
1) Disable air bag system. (Page 8B-48)
2) Remove floor console box. (Page 9H-34)
3) Remove gear shift control lever knob from gear shift 1
control lever as follows, if necessary.
IHSB0A521002-02

NOTICE c) Cut lock ring (1) using nippers or the like.

When removing gear shift control lever knob,
if inside plastic cap on top of the gear shift
lever is damaged, new knob may not be fixed
firmly.
Carefully remove the knob not to damage the
plastic cap.

NOTE
• If new gear shift control lever knob cannot
be fixed tightly, it is necessary to replace
gear shift control lever assembly.
1
• The inside of the gear shift control lever IHSB0A521003-02
knob is composed of double structure
d) While releasing lock expanding rock ring (1),
plastic parts and is fitted to gear shift
remove gear shift control lever knob (2) by
control lever with the lock shape (ring).
pulling it in arrow direction.
a) Cut off outer shell (1) of gear shift control lever
knob at the bottom approx. 20 mm (0.79 in.)
using knife or the like.

“a” 1 1

IHSB0A521001-01
IHSB0A521004-01
“a”: Approx. 20 mm (0.79 in.)
4) Remove shift control lever boot if necessary.
5) Remove SDM. (Page 8B-49)
6) Disconnect end (5) of gear shift control cable from
pivot (6) of gear shift control lever assembly (2).
7) Disconnect end (7) of gear select control cable from
pivot (8) of gear shift control lever assembly.
5B-12 Manual Transmission/Transaxle: K15B Model

8) Disconnect gear shift and select control cables (1)
from gear shift control lever assembly while pulling
quick joints (4) in arrow direction as shown in figure.
9) Remove nuts (3) and remove gear shift control lever
assembly from floor panel.
12) Remove cable grommet bolts (2) and cable nuts (3),
and then remove gear shift and select control cables
from floor panel.

2
5

1 3 2

3
4 3
1
IFRA0A522002-01
2

3 assembly and gear shift control lever. (Page 5B-10)
7 8
IDL10A520006-01
10) Disconnect cable end (2) of gear shift control / gear
select control from joint pivot on gear shift & select
shaft assembly (1) as follows.
a) Insert special tool between gear shift & select
shaft assembly and cable end.
Special tool
(A): 09922M75230
Installation
Reverse removal procedure noting the following points.
• Apply grease to pivot of gear shift and select shaft
• Tighten each bolt and nut to specified torque. (Page
5B-10)
• Adjust gear select control cable. (Page 5B-13)
• Install new gear shift control lever knob, if removed.
• After installation, check that gear shift control lever
knob does not come off the gear shift control lever
assembly.
• Enable air bag system. (Page 8B-48)

b) Pry cable end away pushing special tool in arrow

direction.

(A)

1
IJHB0A522008-01

11) Disconnect gear shift and gear select control cables

from transaxle while puling up quick joint (1) in arrow
direction.
 Manual Transmission/Transaxle: K15B Model 5B-13

Gear Select Control Cable Adjustment 5) Slide lock plate (3) in direction [c], until it gets over
AENJHB0B5216006 the claw (4) of cable end holder.
1) Release lock plate (1) which restricts moving of
cable end holder (2).
1
2) Push cable end holder out from adjuster (4) using
appropriate tool (3) to disengage cable.

[b]

5, “A”
3 4 1

[c]
3
[a] 2

IFRA0A521032-01

Back Up Light Switch Removal and Installation

Removal
I4RS0A520004-01
3) Apply grease to pivot (5) of gear shift control lever,
and then install adjuster (1) into pin of gear shift
control lever securely.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
4) Push cable end holder (2) in direction [a].
AENJHB0B5216007
1) Remove battery and battery tray. (Page 1J-5)
2) Support transaxle with transmission jack.
3) Remove engine left mounting bracket. (Page 1D-
26)
4) Disconnect back up light switch connector (1).
5) Remove back up light switch (2).

NOTE
1
Do not apply force to adjuster in cable
operation direction [b].

IFRA0A522003-01
5B-14 Manual Transmission/Transaxle: K15B Model

Installation Neutral Position Switch Inspection

AENJHB0B5216009
1) Apply oil to new O-ring (1) and tighten back up light Check neutral position switch (1) function using
switch (2) to specified torque. ohmmeter.
Tightening torque Replace gear shift & select shaft assembly if switch does
Back up light switch (a): 19 N·m (1.9 kgf-m, 14.0 not operate as specified.
lbf-ft) Neutral position switch specification
Neutral position: Continuity exists
1 2, (a)
1st gear position: No continuity

I3RH0A520006-01

2) Connect back up light switch connector.

3) Install engine left mounting bracket. (Page 1D-26)
4) Install battery and battery tray. (Page 1J-5)

Back Up Light Switch Inspection

AENJHB0B5216008
Check back up light switch function using ohmmeter.
Replace back up light switch if defective.
Back up light switch specification
Switch ON (Push): Continuity exists
IJHB0A521002-01
Switch OFF (Release): No continuity

I4RS0A520011-01
 Manual Transmission/Transaxle: K15B Model 5B-15

Manual Transaxle Unit Components

AENJHB0B5216010

(a)

(a)

(b)

(a)
(a)
IJHA0A520005-01

1. Engine : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)

2. Transaxle : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)

Manual Transaxle Unit Dismounting and 5) Remove ground terminal bolt (1) and engine harness
Remounting clamps (2).
AENJHB0B5216011
Dismounting
1) Remove battery and battery tray. (Page 1J-5)
2) Remove air cleaner assembly. (Page 1D-9)
3) Disconnect gear shift and gear select control cables
from transaxle. (Page 5B-11)
4) Remove engine harness bracket (1) from transaxle
case and clamp.

1 2

IJHB0A521003-01

6) Drain transaxle oil. (Page 5B-8)

7) Remove exhaust pipe. (Page 1K-4)
8) Remove front drive shaft assembly. (Page 3A-3)
9) Remove drive intermediate shaft assembly. (Page
3A-11)
IJHA0A520009-01
10) Remove starting motor. (Page 1I-4)
5B-16 Manual Transmission/Transaxle: K15B Model

11) Remove clutch fluid pipe from clutch pipe joint.
(Page 5C-7)
12) Loosen bolts and nuts fastening engine.
13) Open hood as wide as possible and hold it using
rope.
14) Remove front suspension frame. (Page 2B-13)
15) Support engine assembly, referring to “Engine
Assembly Removal and Installation”: K15B in
Section 1D (Page 1D-27).
16) Support transaxle with transmission jack.
17) Disconnect neutral position switch connector (1).
1
• Tighten the following bolts and nuts to specified
torque.
– Transaxle to engine bolt and nut: (Page 5B-15)
– Front drive shaft: (Page 3A-3)
– Intermediate shaft assembly: (Page 3A-11)
– Front suspension frame: (Page 2B-13)
– Starting motor: (Page 1I-4)
– Engine left mounting bracket, engine rear torque
rod and engine rear torque rod bracket: (Page
1D-26)
– Exhaust pipe: (Page 1K-4)
• Putting ground cable end lug against rib on case,
tighten engine harness ground bolt (1) to specified
torque.
Tightening torque
Engine harness ground bolt (a): 25 N·m (2.5 kgf-
m, 18.5 lbf-ft)

IJHB0A521004-01

18) Disconnect back up light switch connector and

clamps. (Page 5B-13)
1, (a)
19) Remove engine rear torque rod bracket. (Page
1D-26)
20) Remove bolts and nut fastening engine and IJHB0A521005-01
transaxle and then detach transaxle from engine. • Set each clamp for wiring securely.
• Add transaxle oil. (Page 5B-8)
Remounting
Reverse dismounting procedure noting the following • Bleed clutch system. (Page 5C-5)
points. • Check function of engine, clutch and transaxle.
NOTICE • Check that there is no oil leakage and fluid leakage at
each connection.
Failure to take proper precautions when
remounting the manual transaxle can cause
damage to parts.
• When installing the transaxle, be careful
not to let the drive shaft scratch the oil
seal.
Oil leakage may occur if the oil seal lip is
scratched by the drive shaft.
• Do not use a hammer when installing the
drive shaft joint into the differential gear.
Hitting the drive shaft joint with a hammer
will damage the joint.
 Manual Transmission/Transaxle: K15B Model 5B-17

Gear Shift and Select Shaft Assembly Components

AENJHB0B5216012

3 (a)

2 (a)

5 3 (a)
(a)

2 (a)

1217G 1 3 (a)

4 (a)

4 (a)

IJHB0B521002-01

1. Gear shift & select shaft assembly
: Apply sealant 99000-31260.
For details, refer to “Gear Shift and Select
Shaft Assembly Removal and Installation”:
K15B Model (Page 5B-17).
2. Gear shift guide case No.1 bolt
3. Gear shift guide case No.2 bolt
4. Gear shift guide case No.3 bolt : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
5. Gear shift interlock bolt : Do not reuse.
: For tightening order, refer to “Gear Shift
and Select Shaft Assembly Removal and
Installation”: K15B Model (Page 5B-17).
6. Neutral position switch

Gear Shift and Select Shaft Assembly Removal

and Installation
AENJHB0B5216013
1

Removal
1) Disconnect gear shift and gear select control cables
from transaxle. (Page 5B-11)
2) Remove engine harness bracket (1) from transaxle
case and clamp.

IJHA0A520009-01

3) Remove gear shift interlock bolt (1) from transaxle

case.
5B-18 Manual Transmission/Transaxle: K15B Model

4) Remove gear shift guide case bolts (2) and gear shift d) Install new washer (2) and gear shift interlock
& select shaft assembly (3). bolt, and then tighten it to specified torque.
Tightening torque
2 3 Gear shift interlock bolt (c): 23 N·m (2.3 kgf-
2 m, 17.0 lbf-ft)

(b)

(a)

(a)

3
1
IJHA0A520010-01

Installation
1 2
NOTICE
(c)
The fastener is pre-coated with friction IJHA0A520012-01

stabilizer. If the fastener is reused, it may 2) Install engine harness bracket (1) to transaxle case
work loose. and clamp.
Replace the fastener pre-coated with friction
stabilizer with a new one.
1
1) Install gear shift & select shaft assembly in the
following procedure.
a) Clean sealing surface between gear shift &
select shaft assembly and transaxle.
b) Apply specified amount of sealant to left case as
shown in figure.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
IJHA0A520009-01
Sealant amount for transaxle left case
3) Connect gear shift and gear select control cables to
“a”: 1.5 mm (0.059 in.)
transaxle. (Page 5B-11)

“a”
“A” “a”

IJHA0A520011-02

c) Install gear shift and select shaft assembly (1) to

left case and tighten gear shift guide case No.1
bolts and new gear shift guide case No.2 bolts to
specified torque.
Tightening torque
Gear shift guide case No.1 bolt (a): 23 N·m (
2.3 kgf-m, 17.0 lbf-ft)
Gear shift guide case No.2 bolt (b): 23 N·m (
2.3 kgf-m, 17.0 lbf-ft)
 Manual Transmission/Transaxle: K15B Model 5B-19

Manual Transaxle Assembly Components

AENJHB0B5216014

3 1217G

6 (b)

OIL
7
33
30
(a) 2 1217G
25 A

31
32

34
(d)
(d)
27

(a) 26

8
35
(d) 9 1217G
OIL

7 (c)
26

1
28 (a)

(a)

10 1217G (c) 17 (f)

16

5 1217G
23
18 (a)
25 A
OIL

11
10 1217G (c) 14 (f)
13
OIL

19
OIL

12
4

20

29 (e)
15

36

23
(d)
24
OIL

22
21
(d)
IJHB0B521003-01
5B-20 Manual Transmission/Transaxle: K15B Model

1. Transaxle right case 16. Countershaft 5th gear 31. Breather hose
2. Transaxle left case 17. Countershaft nut 32. Breather union
: Apply sealant 99000-31260 to mating : After tightening nut to specified torque,
surface of left case and right case. caulk nut securely.
3. Gear shift and select shaft assembly 18. 5th gear shift fork 33. Breather cover plate
: For details, refer to “Gear Shift and Select
Shaft Assembly Removal and Installation”:
K15B Model (Page 5B-17).
: Apply sealant 99000-31260 to mating
surface of gear shift & select shaft
assembly and left case.
4. Transaxle left case plate 19. Needle bearing 34. Transaxle hook
5. Transaxle side cover 20. Input shaft 5th gear 35. Cap
: Apply sealant 99000-31260 to mating
surface of side cover and left case.
6. Back up light switch 21. Reverse gear shift lever 36. Gasket
7. O-ring 22. Reverse gear shaft : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
8. Differential assembly 23. Washer : 19 Nm (1.9 kgf-m, 14.0 lbf-ft)
: For details, refer to “Differential
Disassembly and Reassembly”: K15B
Model (Page 5B-40).
9. Oil level / filler plug 24. Reverse idler gear : 21 Nm (2.1 kgf-m, 15.5 lbf-ft)
: Apply sealant 99000-31260 to threads.
10. Oil drain plug 25. Oil seal : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: Apply sealant 99000-31260 to threads. : Apply grease 99000-25011 to oil seal lip.
11. 5th speed synchronizer ring 26. Outer race : 31 Nm (3.2 kgf-m, 23.0 lbf-ft)
12. 5th speed synchronizer lever 27. Differential side shim : 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
: For adjustment, refer to “Transaxle Left
Case Disassembly and Reassembly”:
K15B Model (Page 5B-30).
13. 5th speed synchronizer sleeve & hub 28. Input oil gutter : Apply transaxle oil.
: For assembly, refer to “5th Gear
Disassembly and Reassembly”: K15B
Model (Page 5B-20).
14. Input shaft nut 29. Input shaft & countershaft assembly : Do not reuse.
: After tightening nut to specified torque, : For details, refer to “Input Shaft and
caulk nut securely. Countershaft Components”: K15B Model
(Page 5B-32).
15. Bearing set shim 30. Breather plug
: For adjustment, refer to “Manual
Transaxle Assembly Disassembly and
Reassembly”: K15B Model (Page 5B-24).

5th Gear Disassembly and Reassembly

AENJHB0B5216015

Disassembly 1
1) Remove gear shift & select shaft assembly. (Page
5B-17)
2) Remove side cover bolts and take off transaxle side
cover (1) using special tool.

NOTICE
Oil leakage will occur if side cover is
distorted. 1
Be careful not to distort side cover when it is
removed from transaxle left case.
(A)
Special tool
(A): 09921M96510

I9P60A522015-01

3) Unfasten caulking of input shaft nut (3).

 Manual Transmission/Transaxle: K15B Model 5B-21

4) Arrange a double-gear-engagement shifting both low 8) Remove special tool, input shaft 5th gear, needle
speed gear shift shaft (1) and high speed gear shift bearing and then countershaft 5th gear (1). Gear
shaft (2) in arrow direction, and then remove input puller (2) is necessary if spline fitting of countershaft
shaft nut and washer. 5th gear is tight.

I9P60A522016-01
3

Reassembly
1) Clean all components thoroughly, check them for
IDAA0A521019-01
any abnormal condition and replace defective parts
5) Remove 5th gear shift fork bolt (1).
with new ones if necessary.
6) Remove 5th gear shift fork (2) and 5th gear all
2) Check clearance “a” between 5th speed
together. Use gear puller for removal if spline fitting
synchronizer ring (2) and input shaft 5th gear (1),
of hub is tight.
and replace defective part with new one. Also, check
2
gear teeth for damage.
1
Clearance “a” between 5th speed synchronizer
ring and input shaft 5th gear
Standard: 0.40 – 1.40 mm (0.0158 – 0.0551 in.)
Limit: 0.4 mm (0.0158 in.)

IDAA0A521020-01

7) Unfasten caulking of countershaft nut (2), install

input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut.
Special tool
(A): 09927M76060

(A)

IJHA0A520020-01

I4RH01520016-01
5B-22 Manual Transmission/Transaxle: K15B Model

3) Install countershaft 5th gear (1) to countershaft as 9) Assemble 5th speed synchronizer sleeve (1), 5th
shown in figure. speed synchronizer hub (2), 5th speed synchronizer
levers (3) and 5th speed synchronizer ring (4) as
follows.
[c]
[b]

[a]

IAP70A520014-01

[a]: Countershaft side [c]: Short boss (Outside)

[b]: Long boss (Inside)

4) Apply transaxle oil to needle bearing (3), and install it I4RH01520054-01

to input shaft.
a) Install 5th speed synchronizer hub (1) to 5th
5) Install input shaft 5th gear (1) to input shaft. speed synchronizer sleeve (2) in specified
6) Install special tool to stop shaft rotation. direction as shown in figure.
Special tool [b] 1
(A): 09927M76060
7) Tighten new countershaft nut (2) to specified torque, [a]
and caulk nut securely.
2
NOTICE
• Once countershaft nut is removed, it will
no longer have necessary fastening
IAP70A520016-02
performance.
Never reuse the countershaft nut. [a]: Chamfered side [b]: Long boss

• If caulking part (4) of countershaft nut is

cracked while caulking, the nut will spoil b) Fit 5th speed synchronizer levers (1) to 5th
locking performance. speed synchronizer hub (2) by aligning
Replace the nut with new one again. protrusion (3) of 5th speed synchronizer levers
with groove of 5th speed synchronizer hub.
Tightening torque
3
Countershaft nut (a): 100 N·m (10.2 kgf-m, 74.0
lbf-ft)
1
3

I9P60A522047-01

IAP70A520015-01

8) Remove special tool.

 Manual Transmission/Transaxle: K15B Model 5B-23

c) Install 5th speed synchronizer ring (1) to 5th 14) Tighten input shaft nut to specified torque, and then
speed synchronizer hub (2) in specified direction caulk nut securely.
as shown in figure.
NOTICE
1
• Once input shaft nut is removed, it will no
longer have necessary fastening
performance.
Never reuse the input shaft nut.
2 • If caulking part of input shaft nut is
cracked while caulking, the nut will spoil
locking performance.
Replace the nut with new one again.

I4RH01520055-01 Tightening torque

10) Fit 5th gear shift fork (1) to 5th speed synchronizer Input shaft nut (b): 100 N·m (10.2 kgf-m, 74.0 lbf-
sleeve (3) and 5th speed synchronizer hub (2) ft)
assembly, and install them into input shaft and gear
shift shaft by aligning punch mark (4) with 3
matchmark (5) on input shaft.
1, (a)

4 5

4, (b)

IDAA0A521022-01

2 15) Install side cover (1) to left case as follows.

1
a) Clean mating surfaces of left case and side
3
cover.
b) Apply specified amount of sealant to side cover
as shown in figure.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for side cover
IFL80A520007-01
“a”: 1.5 mm (0.059 in.)
11) Tighten new 5th gear shift fork bolt (1) to specified
torque. c) Mate side cover with left case.
d) Tighten side cover bolts to specified torque.
NOTICE
Tightening torque
5th gear shift fork bolt is pre-coated with
Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
adhesive. If the bolt is reused, it may work
loose. 1
Replace the 5th gear shift fork bolt with new
one once it is removed.
“A”

Tightening torque
5th gear shift fork bolt (a): 10 N·m (1.0 kgf-m, 7.5 “A”
lbf-ft)
(a)
12) Arrange a double-gear-engagement shifting both low
speed gear shift shaft (2) and high speed gear shift IAP70A520017-01
shaft (3) in arrow direction. 16) Install gear shift & select shaft assembly. (Page
13) Install washer and new input shaft nut (4). 5B-17)
5B-24 Manual Transmission/Transaxle: K15B Model

Manual Transaxle Assembly Disassembly and 8) Remove transaxle case bolts (1).
Reassembly
AENJHB0B5216016

Disassembly
1) Remove gear shift & select shaft assembly. (Page
1
5B-17)
2) Remove input shaft 5th gear and countershaft 5th
gear. (Page 5B-20)
3) Remove left case plate bolts (3).
4) Remove left case plate (1) and bearing set shim (2).
5) Remove snap ring (6) using snap ring pliers (4).

IDAA0A521024-01

9) Remove transaxle left case (1) from transaxle right

case (2) using special tool.
3
Special tool
(A): 09912M34510
3

IDAA0A521023-01 1

)A(
2
5 4

6
2
IDAA0A521025-01

IEL70B520043-01
10) Remove reverse gear shift lever bolts (4) and
reverse gear shift lever (5).
5. Input shaft 7. Input shaft left bearing
11) Pull out reverse gear shaft (1) with washer (2), and
6) Remove back up light switch. (Page 5B-13) then take off reverse idler gear (3).
7) Remove reverse gear shaft bolt (1) with gasket. 12) Pull out 5th & reverse gear shift shaft (6).

I9P60A522021-01
 Manual Transmission/Transaxle: K15B Model 5B-25

NOTE Reassembly
When removing 5th & reverse gear shift NOTE
shaft, push up high speed gear shift shaft
and shift it to 4th to facilitate removal of 5th & The differential side bearing is of a tapered
reverse shift shaft. roller type. When reassembling the transaxle,
select a differential side bearing shim
referring to “Transaxle Left Case
6 Disassembly and Reassembly”: K15B Model
(Page 5B-30).
1
1) Install differential assembly into transaxle right case.
2
2) Join input shaft (5), countershaft (4), low speed gear
3
shift shaft (2) and high speed gear shift shaft (3)
assemblies all together, and then install them into
transaxle right case (1).
5
NOTE
• Do not damage oil seal by input shaft
spline while installing.
4
• Check that countershaft is engaged with
final gear.
IDAA0A521026-01

13) Remove countershaft left bearing outer race (1) from

transaxle left case (2) using special tool.
Special tool
(A): 09913M70123

2
(A)
I2RH01520080-01
1 3) Install 5th & reverse gear shift shaft (1) into transaxle
right case (2). At the same time, join reverse gear
shift arm (4) and reverse gear shift lever (3).

1
4

I9P60A522025-01

14) By tapping input shaft end with plastic hammer, push

it out as assembly from case a little, and then 2
remove input shaft assembly (1), countershaft
assembly (2), high speed gear shift shaft (3) and low
speed gear shift shaft (4) all together.
3

IDAA0A521027-01

4) Mate reverse idler gear (1) with reverse gear shift

lever (2), insert reverse gear shaft (3) and washer (6)
I2RH01520035-01 into case (4) through idler gear and then align bolt
15) Remove differential assembly from transaxle right hole (7) on shaft with notch (8) on case.
case. 5) Tighten reverse gear shift lever bolts (5) to specified
torque.
5B-26 Manual Transmission/Transaxle: K15B Model

NOTE c) Mate right case with left case.

Check that reverse gear shift lever end has 7) Tighten transaxle case bolts to specified torque.
clearance “a” to idle gear groove. Tightening torque
Transaxle case bolt (a): 23 N·m (2.3 kgf-m, 17.0
Clearance between lever end and idle gear
lbf-ft)
groove
“a”: 0.5 – 1.0 mm (0.02 – 0.04 in)
Tightening torque
Reverse gear shift lever bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lbf-ft)
(a)

(a)

IDAA0A521029-01

6 8) Install new reverse gear shaft bolt (1) and new

gasket, and tighten it to specified torque.

NOTICE
1
Reverse gear shaft bolt is pre-coated with
adhesive. If the bolt is reused, it may work
2 loose.
2
“a”
Replace the reverse gear shaft bolt with new
one once it is removed.
5, (a)
Tightening torque
IDAA0A521028-02 Reverse gear shaft bolt (a): 23 N·m (2.3 kgf-m,
6) Install right case to left case as follows. 17.0 lbf-ft)
a) Clean mating surfaces of right case and left
case.
b) Apply specified amount of sealant to left case (1)
as shown in figure.
1,(a)
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for left case
“a”: 1.5 mm (0.059 in.)

I9P60A522030-01

IAP70A520020-01
 Manual Transmission/Transaxle: K15B Model 5B-27

9) Install new snap ring (1) using snap ring pliers (4). Available shim thickness
Clearance Applicable shim
2 4 0.42 – 0.47 mm
0.65 mm (0.0255 in.)
(0.0166 – 0.0185 in.)
3
0.48 – 0.52 mm
0.70 mm (0.0275 in.)
(0.0189 – 0.0204 in.)
0.53 – 0.57 mm
0.75 mm (0.0295 in.)
(0.0209 – 0.0224 in.)
0.58 – 0.62 mm
0.80 mm (0.0314 in.)
1 (0.0229 – 0.0244 in.)
0.63 – 0.67 mm
0.85 mm (0.0334 in.)
(0.0249 – 0.0263 in.)
0.68 – 0.72 mm
IEL70B520045-01 0.90 mm (0.0354 in.)
(0.0268 – 0.0283 in.)
2. Input shaft 3. Input shaft left bearing
0.73 – 0.77 mm
0.95 mm (0.0374 in.)
(0.0288 – 0.0303 in.)
10) To seat countershaft left bearing outer race (1) to 0.78 – 0.82 mm
bearing cone, tap countershaft left bearing outer 1.00 mm (0.0393 in.)
(0.0308 – 0.0322 in.)
race using special tool and plastic hammer (3). 0.83 – 0.87 mm
1.05 mm (0.0413 in.)
Special tool (0.0327 – 0.0342 in.)
(A): 09913M70123 0.88 – 0.92 mm
1.10 mm (0.0433 in.)
(0.0347 – 0.0362 in.)
0.93 – 0.97 mm
1.15 mm (0.0452 in.)
(0.0367 – 0.0381 in.)
3 0.98 – 1.02 mm
1.20 mm (0.0472 in.)
(0.0386 – 0.0401 in.)

2 c) Put the applicable spare part shim on bearing

outer race and install left case plate (2).
d) Tighten used bolts (1) to specified torque.

1
Tightening torque
I9P60A522031-01 Left case plate bolt (a): 31 N·m (3.2 kgf-m,
2. Input shaft 23.0 lbf-ft)
e) Turn countershaft (3) 10 times or more.
11) Select countershaft 5th gear shim as follows.
a) Push down bearing outer race and measure
1, (a)
clearance “a” between transaxle left case and 3
bearing outer race using straightedge (1) and
feeler gauge (2).
4

1, (a)

1, (a)

1 IDAA0A521030-01

2 4. Input shaft

“a” f) Remove left case plate.

I9P60A521037-01

b) Select a shim which fits the clearance measured

above.
5B-28 Manual Transmission/Transaxle: K15B Model

g) Place straightedge (1) over shim (3) and Tightening torque

compress it by hand through straightedge, and Left case plate bolt (a): 31 N·m (3.2 kgf-m, 23.0
measure “a” using feeler gauge (2). lbf-ft)
Clearance between case surface and
straightedge 1, (a)
3
“a”: 0.18 – 0.22 mm (0.0070 – 0.0086 in.)
h) If clearance “a” is out of specification, select
suitable shim which adjusts clearance “a” to 4
specification and put it on bearing outer race.

NOTE
1, (a)
Insert 0.1 mm (0.003 in.) feeler to check
whether or not a shim fulfills specification.
1, (a)

IDAA0A521030-01

4. Input shaft

13) Install input shaft 5th gear and countershaft 5th gear.
(Page 5B-20)
14) Install gear shift & select shaft assembly. (Page
5B-17)
15) Install back up light switch. (Page 5B-13)
16) Check input shaft for rotation in each gear position.
17) Check back up light switch for continuity with gears
I9P60A521048-02
in reverse position using ohmmeter.
12) Install left case plate (2), and then tighten new left
case plate bolts (1) to specified torque. Transaxle Right Case Disassembly and
Reassembly
NOTICE AENJHB0B5216017

Left case plate bolt is pre-coated with Disassembly

adhesive. If the bolt is reused, it may work
1) Remove differential side oil seal from transaxle right
loose.
case. (Page 5B-9)
Replace the left case plate bolt with new one
once it is removed. 2) Remove differential side bearing outer race (1) using
brass bar (2), if necessary.
NOTE
2
After tightening bolts, check that
countershaft (3) can be rotated by hand with
certain load.

I9P60A522034-01
 Manual Transmission/Transaxle: K15B Model 5B-29

3) Remove input shaft oil seal (1) using special tool, if Reassembly
necessary. 1) Install input shaft oil seal (1) using special tool and
Special tool hammer. Apply grease to oil seal lip.
(A): 09913M50121 “A”: Grease 99000–25011 (SUZUKI Super
Grease A)
(A)
Special tool
(A): 09913M84510
Distance from case surface to input shaft oil seal
“a”: 5.4 – 6.0 mm (0.21 – 0.23 in.)

(A)
1 1, “A”

IDLA0A520045-01

4) Pull out countershaft right bearing outer race using

special tools, if necessary. 1

Special tool
“a”
(A): 09930M30104
(B): 09941M64511

(A)
IGSB0A521023-01

(B) 2) Install countershaft right bearing outer race (1) using

special tools and hammer.
Special tool
(A): 09913M75821
(B): 09924M84510M004

I5RW0A520027-01 (A)

(B)

1
I9P60A522037-01

3) Install differential side bearing outer race using

special tool and hammer.
Special tool
(A): 09924M74510
(B): 09925M14520

(A)

(B)

I9P60A522038-01
5B-30 Manual Transmission/Transaxle: K15B Model

4) Install new differential side oil seal to transaxle right Tightening torque
case. (Page 5B-9) Oil gutter bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
Breather cover plate bolt (b): 10 N·m (1.0 kgf-m,
Transaxle Left Case Disassembly and 7.5 lbf-ft)
Reassembly
AENJHB0B5216018 (a)

Disassembly 1
(b)
1) Remove oil gutter (1) and breather cover plate (2), if
2
necessary.

1
2

IAP70A520023-01

2) Calculate clearance “c” for selection of applicable

differential side shim as follows.
a) Install differential side bearing outer race to
transaxle right case. (Page 5B-28)
b) Install differential assembly (2) to transaxle right
IAP70A520022-01
case (1).
2) Remove differential side oil seal from transaxle left
case. (Page 5B-9) c) Install differential side bearing outer race of
transaxle left case side (3) to differential
3) Remove differential side bearing outer race (1) using assembly.
special tools, and then remove shim.
d) Keep pushing differential side bearing outer race
Special tool with force of 34 N (3.5 kgf, 7.6 lbf) by hand and
(A): 09942M15511 turn differential assembly 10 times or more.
(B): 09944M96013
(C): 09921M26010 3
1 2

(A) (C)

(B)

1
IDAA0A521033-01

Reassembly IGSB0A521025-01

1) Install oil gutter (1) and breather cover plate (2), if

removed.

NOTICE
The oil gutter bolts and breather cover plate
bolts are pre-coated with adhesive. If these
bolts are reused, they may work loose.
Replace the oil gutter bolts and breather
cover plate bolts with new ones whenever
they are removed.
 Manual Transmission/Transaxle: K15B Model 5B-31

e) Measure distance “a” from mating surface of Available shim thickness

transaxle right case (1) to differential side Clearance “c” Applicable shim
bearing outer race (2). 0.800 – 0.839 mm
1.00 mm (0.0393 in.)
(0.03150 – 0.03303 in.)
0.840 – 0.879 mm
“a” 2 1.04 mm (0.0409 in.)
(0.03307 – 0.03460 in.)
0.880 – 0.919 mm
1.08 mm (0.0425 in.)
(0.03465 – 0.03618 in.)
0.920 – 0.959 mm
1.12 mm (0.0440 in.)
(0.03622 – 0.03775 in.)
1
0.960 – 0.999 mm
1.16 mm (0.0456 in.)
(0.03780 – 0.03933 in.)
1.000 – 1.039 mm
1.20 mm (0.0472 in.)
(0.03938 – 0.04090 in.)
1.040 – 1.079 mm
1.24 mm (0.0488 in.)
IGSB0A521026-01 (0.04095 – 0.04248 in.)
f) Measure depth “b” from mating surface of 1.080 – 1.119 mm
1.28 mm (0.0503 in.)
transaxle left case (1) to installation position of (0.04252 – 0.04405 in.)
differential side bearing outer race. 1.120 – 1.159 mm
1.32 mm (0.0519 in.)
(0.04410 – 0.04562 in.)
1 1.160 – 1.199 mm
1.36 mm (0.0535 in.)
(0.04567 – 0.04720 in.)
1.200 – 1.239 mm
1.40 mm (0.0551 in.)
(0.04725 – 0.04877 in.)
1.240 – 1.279 mm
1.44 mm (0.0566 in.)
(0.04882 – 0.05035 in.)
1.280 – 1.319 mm
1.48 mm (0.0582 in.)
(0.05040 – 0.05192 in.)
1.320 – 1.359 mm
1.52 mm (0.0598 in.)
(0.05197 – 0.05350 in.)
“b” 1.360 – 1.399 mm
1.56 mm (0.0614 in.)
(0.05354 – 0.05507 in.)
1.400 – 1.439 mm
1.60 mm (0.0629 in.)
(0.05512 – 0.05665 in.)
1.440 – 1.479 mm
1 1.64 mm (0.0645 in.)
(0.05670 – 0.05822 in.)
IGSB0A521027-01 1.480 – 1.529 mm
1.68 mm (0.0661 in.)
g) Calculate clearance “c” by the following formula. (0.05827 – 0.06019 in.)
Clearance “c” = depth “b” – distance “a”
4) Put shim, and then install differential side bearing
outer race using special tools.
Special tool
“c” (A): 09924M74510
(B): 09925M14520
“b” “a”
(A)
(B)

IGSB0A521028-01
I5RW0A520032-01
3) Select shim closest to calculated shim thickness 5) Install new differential side oil seal to transaxle left
from the following available sizes. case. (Page 5B-9)
5B-32 Manual Transmission/Transaxle: K15B Model

Input Shaft and Countershaft Components

AENJHB0B5216019

OIL
31
30

28 29

27

22

OIL
25
OIL

24

OIL
20

OIL
5
OIL

23

OIL
18
17 26

21

16

OIL
19
OIL

15
OIL

13
12 14
11
9
OIL

5
10
7
OIL

6 8

4
OIL

6
OIL

5
2 A
1
OIL

3
IJHB0B521004-01

1. Input shaft 12. Input shaft left bearing 23. 2nd gear synchronizer outer ring
2. Oil seal 13. Snap ring 24. 2nd gear synchronizer center cone
: Apply grease 99000-25011 to oil seal lip.
3. Input shaft right bearing 14. 5th gear spacer 25. 2nd gear synchronizer inner ring
4. Input shaft 3rd gear 15. Countershaft right bearing 26. Circlip
5. Needle bearing 16. Countershaft 27. Countershaft 2nd gear
6. High speed synchronizer ring 17. Countershaft 1st gear 28. Countershaft 3rd gear
7. High speed synchronizer spring 18. Low speed synchronizer inner ring 29. 3rd & 4th gear spacer
8. High speed synchronizer sleeve & hub 19. Low speed synchronizer center cone 30. Countershaft 4th gear
: For assembly, refer to “Input Shaft
Disassembly and Reassembly”: K15B Model
(Page 5B-33).
9. High speed synchronizer key 20. Low speed synchronizer outer ring 31. Countershaft left bearing
10. Circlip 21. Low speed synchronizer sleeve & hub : Do not reuse.
: For assembly, refer to “Countershaft
Disassembly and Reassembly”: K15B Model
(Page 5B-35).
11. Input shaft 4th gear 22. Low speed synchronizer key : Apply transaxle oil.
 Manual Transmission/Transaxle: K15B Model 5B-33

Input Shaft Disassembly and Reassembly 5) Remove high speed synchronizer sleeve & hub
AENJHB0B5216020 assembly (2) together with 3rd gear (3) using
! CAUTION bearing puller (4) and hydraulic press.

Using an inappropriate hydraulic press or

bearing puller could cause personal injury.
Use the hydraulic press and bearing puller
which are capable of safely bearing a load of
at least 5 tons (11,000 lbs).

NOTICE
Supporting the gear on the concave side of
I2RH01520097-01
the puller can cause damage to the gear.
Support the gear on the flat side of the puller. 1. Input shaft

Disassembly 6) Remove 3rd gear needle bearing from input shaft.

1) Remove input shaft right bearing (2) from input shaft
(1) using bearing puller (3) and hydraulic press.
Reassembly
I4RH01520029-01
2) Remove 5th gear spacer (2), left bearing (3) and 4th
gear (4) all together using bearing puller (5) and
hydraulic press.
7) Disassemble synchronizer sleeve & hub assembly.
1) Clean all components thoroughly, check them for
any abnormal condition and replace defective parts
with new ones if necessary.
2) Check clearance “a” between synchronizer ring (2)
and gear (1), key slot width “b” in synchronizer ring
and replace defective part with new one. Also, check
gear teeth for damage.
Clearance “a” between synchronizer ring and
gear
Standard: 0.40 – 1.50 mm (0.0158 – 0.0590 in.)
Limit: 0.4 mm (0.0158 in.)
Key slot width “b”
Standard: 10.00 – 10.20 mm (0.3937 – 0.4015 in.)
Limit: 10.45 mm (0.4114 in.)

I3RH0A520018-01

1. Input shaft

3) Remove 4th gear needle bearing and high speed

synchronizer ring.
4) Using snap ring pliers (2), remove circlip (1).

I5JB0A520054-01

I7RW01520007-01
5B-34 Manual Transmission/Transaxle: K15B Model

3) To ensure lubrication of input shaft (1), blow air into 5) Install right bearing (1) to input shaft (2) using special
oil holes (2) as shown in figure and check that they tool and hydraulic press.
are free from any obstruction.
Special tool
(A): 09913M80113

I2RH01520049-01

4) Fit high speed synchronizer sleeve (4) to hub (3),

insert 3 keys (2) in it and then set springs at
specified position (1) as shown in figure.
NOTE
Assemble sleeve and hub in correct
direction. (No direction is specified to each
key.)
Synchronizer key installation position
“a” = “b”
I3RH0A520019-01
6) Install 3rd gear needle bearing (4), apply oil to it, and
then install 3rd gear (1) and synchronizer ring (2).
7) Install high speed synchronizer sleeve & hub
assembly (3) using special tool and hydraulic press.
NOTE
• Check that synchronizer ring key slots are
aligned with keys (5) in sleeve & hub
assembly.
• Check free rotation of 3rd gear after press-
fitting sleeve & hub assembly.

Special tool
(A): 09922M59420

[c]
3 [a]

(A)

IAP70A520026-01

[a]: 4th gear side [c]: Projecting end

[b]: Short boss side

4 [b] 2
IAP70A520027-01

[a]: 3rd gear side [c]: Long boss side

[b]: Key way

8) Install new circlip (1) to groove securely.

 Manual Transmission/Transaxle: K15B Model 5B-35

9) Install 4th gear needle bearing (2), apply oil to it and NOTICE
then install synchronizer ring (3) and 4th gear (4). Supporting the gear on the concave side of
the puller can cause damage to the gear.
Support the gear on the flat side of the puller.

Disassembly
1) Remove left bearing cone (2) with 4th gear (3) using
bearing puller (4) and hydraulic press.

I2RH01520052-01

5. Input shaft

10) Press-fit left bearing (2) using special tool and

hydraulic press.
Special tool I2RH01520054-01

(A): 09913M80113 1. Countershaft

11) Using the same special tool as in Step 10), install 5th
gear spacer (1). 2) Apply bearing puller (5) to 2nd gear (4), and remove
3rd & 4th gear spacer (2) and 3rd gear (3) together
NOTICE with 2nd gear using hydraulic press. Needle bearing
Press-fitting left bearing and 5th gear spacer would come out with 2nd gear.
together can cause distortion of spacer.
Do not press-fit left bearing using spacer.

I2RH01520055-01

1. Countershaft

3) Remove 2nd synchronizer outer ring, center cone

and inner ring.
4) Using snap ring pliers (3), remove circlip (1).
I3RH0A520020-01

Countershaft Disassembly and Reassembly

AENJHB0B5216021

! CAUTION
Using an inappropriate hydraulic press or
bearing puller could cause personal injury.
Use the hydraulic press and bearing puller
which are capable of safely bearing a load of
at least 5 tons (11,000 lbs).
I7RW01520008-01

2. Low speed synchronizer sleeve

5B-36 Manual Transmission/Transaxle: K15B Model

5) Apply bearing puller (3) to 1st gear (2) and remove Reassembly
low speed synchronizer sleeve & hub assembly (1)
with 1st gear using hydraulic press.
I2RH01520057-01
1) Clean all components thoroughly, check them for
any abnormal condition and replace defective parts
with new ones if necessary.
2) Check the following items.
• Difference between outer ring (1) and inner ring
(3)
Difference between synchronizer outer ring
and inner ring “a”
Standard: 0.40 – 1.25 mm (0.0158 – 0.0492 in.)
Limit: 0.4 mm (0.0158 in.)

6) Disassemble synchronizer sleeve & hub assembly.

7) Remove 1st gear needle bearing from shaft.
8) To remove right bearing (1) from countershaft, grind
with a grinder (2) one part “a” of right bearing as
illustrated till it becomes thin.

NOTICE
The shaft (3) will be damaged if the bearing is
ground too much.
Limit the grinding to a minimum necessary
IAP70A520028-01
amount if necessary.
2. Center cone

• Key protrusion width in outer ring

Key protrusion width “b”
Standard: 10.10 – 10.30 mm (0.3976 – 0.4055
2
in.)
3
Limit: 9.85 mm (0.3878 in.)
1 “a”
3
1

I5RW0A520035-01
“b”
9) Remove right bearing (2) by breaking at thin point
IGSB0A521031-01
with a chisel (1) if necessary.
• Each chamfered tooth of gear and synchronizer
ring for abnormal wear and damage
1
Replace it with new one if necessary.
3) To ensure lubrication of countershaft (1), blow air
into oil holes (2) as shown in figure and check that
they are free from any obstruction.

2
I5RW0A520036-01

IGSB0A521042-01
 Manual Transmission/Transaxle: K15B Model 5B-37

4) Fit low speed synchronizer sleeve (1) to hub (2) and 8) Install low speed synchronizer sleeve & hub
3 keys (3) as shown in figure. assembly (1) using special tools and hydraulic press.

NOTE NOTE
No specific direction is assigned to low • Support shaft with special tool as shown in
speed synchronizer hub and each key but it figure so that retainer of bearing cone will
is assigned as assembly. be free from compression.
• Check that synchronizer ring key slots are
Synchronizer key installation position aligned with keys (5) while press-fitting
sleeve & hub assembly.
• Check free rotation of 1st gear (3) after
press-fitting sleeve & hub assembly.
3

Special tool
2
(A): 09922M76340
(B): 09913M85210
[b]
(C): 09940M54910
(D): 09924M07710

[a]

[a]

2
IJHB0B521005-01

[a]: 2nd gear side [b]: Key way

5) Install right bearing cone (1) to countershaft (2) using

special tools and hydraulic press.
Special tool
(A): 09941M74910
IGSB0A521033-03

[a]: 1st gear side [c]: Short flange

[b]: Key slots
(A)

1 9) Install new circlip (1) to groove securely.

10) Install needle bearing (2) and apply oil to needle
2 bearing.

IGSB0A521032-01

6) Install 1st gear needle bearing (4), apply oil to it, and
then install 1st gear (3).
7) Install synchronizer outer ring (2), center cone (6)
and inner ring (7).
5B-38 Manual Transmission/Transaxle: K15B Model

11) Install 2nd gear (6) with synchronizer outer ring (3), 13) Press-fit 4th gear (2) using the same procedure as in
center cone (4) and inner ring (5) as shown in figure. Step 12).
14) Install left bearing cone (1) using special tools and
hydraulic press.

NOTE
For protection of bearing cone (3), support
shaft with special tool as shown in figure.

Special tool
(A): 09922M76340
(B): 09913M80113

IAP70A520031-01

[A]: Section [a] – [a]

12) Press-fit 3rd gear (2) and spacer (1) using special
tools and hydraulic press. IFRA0B521014-01

NOTE
It is recommended to press-fit spacer and 3rd
gear first, and then 4th gear later separately
so that countershaft will not be compressed
excessively.

Special tool
(A): 09922M76340
(B): 09913M85210

I4RH01520036-01

3. 2nd gear
 Manual Transmission/Transaxle: K15B Model 5B-39

Gear Shift Shaft Components

AENJHB0B5216022

5 (a)
1

7 (b)
2
4

IJHB0A521011-01

1. Low speed gear shift shaft 5. Reverse gear shift lever bolt 9. Spring pin
2. High speed gear shift shaft 6. Reverse gear shift lever : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
3. 5th & reverse gear shift shaft 7. 5th gear shift fork bolt : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
4. 5th gear shift fork 8. Reverse gear shift arm : Do not reuse.

Gear Shift Shaft and Fork Inspection

AENJHB0B5216023
1) Using feeler gauge, check clearance between fork
(1) and sleeve (2) and replace those parts if it
exceeds specified value.
Clearance “a” between fork and sleeve
Position Standard Limit
0.40 – 1.25 mm
Low speed
(0.0157 – 0.0492 in.)
0.40 – 1.50 mm 0.40 mm
High speed
(0.0157 – 0.0590 in.) (0.0157 in.)
0.40 – 1.40 mm
5th
(0.0157 – 0.0551 in.)

I2RH01520068-01

2) Insert each gear shift shaft into case and check that
it moves smoothly. If not, correct burns or dents with
oilstone, reamer or the like.
5B-40 Manual Transmission/Transaxle: K15B Model

Differential Components
AENJHB0B5216024

OIL
4

OIL
OIL
1 3

8 (a)
2
10

OIL
1

OIL
9
OIL

3
OIL

4 5
7

5
IJHA0A520015-01

1. Differential pinion washer 6. Differential case : 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
2. Differential pinion 7. Final gear : Apply transaxle oil.

3. Differential side gear 8. Final gear bolt : Do not reuse.

4. Side gear washer 9. Differential pinion shaft
5. Differential side bearing 10. Differential pinion shaft pin

Differential Disassembly and Reassembly 2) Remove left bearing (1) using special tool, bearing
AENJHB0B5216025 puller (2) and hydraulic press.
Disassembly Special tool
1) Support differential case with soft jawed vise (1) and (A): 09913M84510
remove final gear bolts (2), and then remove final
gear (3).
(A)
2

IFRA0B522009-01

3) Remove right bearing in the same manner as in Step

1
IFP80A540096-01 2).
4) Support differential case (1) with soft jawed vise.
 Manual Transmission/Transaxle: K15B Model 5B-41

5) Remove differential pinion shaft pin using special b) Move side gear up and down by hand or flat-
tool and hammer, and then disassemble bladed screwdriver (4) and read dial gauge.
components parts.
Differential side gear thrust play
Special tool 0.03 – 0.31 mm (0.001 – 0.012 in.)
(A): 09922M85811
[A]
(A)
2
2
3

1
(B)

(C)
1

I6RS0E520013-01 [B] (A)

2. Differential side gear
2
4
Reassembly 1
Judging from abnormality noted before reassembly and
what is found through visual check of component parts 3
2
after disassembly, prepare replacing parts and proceed (B)
to reassembly. Check that all parts are clean.
4
1) Install differential pinions, differential side gears (1),
washers and pinion shaft to differential case (2), and 1
IJHB0A521010-01
measure thrust play of differential side gear using
special tools as follows. [A]: Right side [B]: Left side

If measured value is out of specification, select

suitable side gear washer (3) and check again. Available side gear washer thickness
Thickness mm (in.) Thickness mm (in.)
Special tool
0.85 mm (0.0334 in.) 1.05 mm (0.0413 in.)
(A): 09900M20607
0.90 mm (0.0354 in.) 1.10 mm (0.0433 in.)
(B): 09900M20701
0.95 mm (0.0374 in.) 1.15 mm (0.0452 in.)
(C): 09952M06010
1.00 mm (0.0393 in.) 1.20 mm (0.0472 in.)
a) Hold differential assembly with soft jawed vise
and apply measuring tip of dial gauge to side 2) Install new differential pinion shaft pin (1) from left
gear as shown in figure. side until depth “a” becomes 0.2 – 2.2 mm (0.007 –
0.086 in.) as shown using special tool.
Special tool
(A): 09922M85811

(A)

“a”

IGSB0A521043-01
5B-42 Manual Transmission/Transaxle: K15B Model

3) Press-fit right side bearing (1) using special tools 5) Support differential case with soft jawed vise (3),
and hydraulic press. install final gear (2) and then tighten final gear bolts
(1) to specified torque.
Special tool
(A): 09951M76010 Tightening torque
(B): 09925M16010 Final gear bolt (a): 100 N·m (10.2 kgf-m, 74.0 lbf-
ft)

1, (a)

(A)
(B)

1 2

3
IFP80A540097-01
IFRA0B522010-01

4) Press-fit left side bearing (1) using special tools and

hydraulic press.
Special tool
(A): 09951M76010
(B): 09925M16510
(C): 09913M85230

(A)
(B)

(C)

IFRA0B522011-01
 Manual Transmission/Transaxle: K15B Model 5B-43

Specifications
Tightening Torque Specifications
AENJHB0B5217001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Transaxle oil level / filler plug (Page 5B-8) /
21 2.1 15.5
(Page 5B-9)
Transaxle oil drain plug 21 2.1 15.5 (Page 5B-8)
Back up light switch 19 1.9 14.0 (Page 5B-14)
Engine harness ground bolt 25 2.5 18.5 (Page 5B-16)
Gear shift guide case No.1 bolt 23 2.3 17.0 (Page 5B-18)
Gear shift guide case No.2 bolt 23 2.3 17.0 (Page 5B-18)
Gear shift interlock bolt 23 2.3 17.0 (Page 5B-18)
Countershaft nut 100 10.2 74.0 (Page 5B-22)
5th gear shift fork bolt 10 1.0 7.5 (Page 5B-23)
Input shaft nut 100 10.2 74.0 (Page 5B-23)
Side cover bolt 10 1.0 7.5 (Page 5B-23)
Reverse gear shift lever bolt 23 2.3 17.0 (Page 5B-26)
Transaxle case bolt 23 2.3 17.0 (Page 5B-26)
Reverse gear shaft bolt 23 2.3 17.0 (Page 5B-26)
Left case plate bolt (Page 5B-27) /
31 3.2 23.0
(Page 5B-28)
Oil gutter bolt 10 1.0 7.5 (Page 5B-30)
Breather cover plate bolt 10 1.0 7.5 (Page 5B-30)
Final gear bolt 100 10.2 74.0 (Page 5B-42)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Gear Shift Control Lever and Cable Components”: K15B Model (Page 5B-10)
“Manual Transaxle Unit Components”: K15B Model (Page 5B-15)
“Gear Shift and Select Shaft Assembly Components”: K15B Model (Page 5B-17)
“Manual Transaxle Assembly Components”: K15B Model (Page 5B-19)
“Gear Shift Shaft Components”: K15B Model (Page 5B-39)
“Differential Components”: K15B Model (Page 5B-40)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Recommended Service Material
AENJHB0B5218001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 (Page 5B-9) / (Page 5B-
13) / (Page 5B-29)
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 (Page 5B-8) / (Page 5B-
8) / (Page 5B-9) / (Page
5B-18) / (Page 5B-23) /
(Page 5B-26)

NOTE
Required service material(s) is also described in:
“Gear Shift Control Lever and Cable Components”: K15B Model (Page 5B-10)
“Gear Shift and Select Shaft Assembly Components”: K15B Model (Page 5B-17)
“Manual Transaxle Assembly Components”: K15B Model (Page 5B-19)
“Input Shaft and Countershaft Components”: K15B Model (Page 5B-32)
“Differential Components”: K15B Model (Page 5B-40)

Special Tool
AENJHB0B5218002
5B-44 Manual Transmission/Transaxle: K15B Model

09900M20607 09900M20701
Dial gauge Magnetic stand
(Page 5B-41) (Page 5B-41)

09912M34510 09913M50121
Case separator Oil seal remover
(Page 5B-24) (Page 5B-9) /
(Page 5B-29)

09913M70123 09913M75821
Bearing installer Bearing installer attachment
(Page 5B-25) / (Page 5B-29)
(Page 5B-27)

09913M80113 09913M84510
Bearing installer Bearing installer
(Page 5B-34) / (Page 5B-29) /
(Page 5B-35) / (Page 5B-40)
(Page 5B-38)

09913M85210 09913M85230
Bearing installer Bearing remover tool
(Page 5B-37) / (Page 5B-42)
(Page 5B-38)

09921M26010 09921M96510
Bearing outer race remover Oil pan seal cutter
collar
(Page 5B-30) (Page 5B-20)

09922M59420 09922M75230
Installer handle Gear shift cable remover
(Page 5B-34) (Page 5B-12)

09922M76340 09922M85811
Bevel pinion rear collar Spring pin remover (4.5 mm)
(Page 5B-37) / (Page 5B-41) /
(Page 5B-38) / (Page 5B-41)
(Page 5B-38)
 Manual Transmission/Transaxle: K15B Model 5B-45

09924M07710 09924M74510
Synchronizer hub installer Bearing and oil seal handle
(Page 5B-37) (Page 5B-9) /
(Page 5B-29) /
(Page 5B-31)

09924M84510M004 09925M14520
Bearing installer attachment Bearing and oil seal installer
(80 x 50 mm)
(Page 5B-29) (Page 5B-29) /
(Page 5B-31)

09925M16010 09925M16510
Drive gear bearing installer Oil seal installer
(Page 5B-42) (Page 5B-42)

09927M76060 09930M30104
Gear holder Sliding shaft
(Page 5B-21) / (Page 5B-29)
(Page 5B-22)

09940M54910 09941M64511
Front fork oil seal install Bearing and oil seal remover
driver (30 mm min.)
(Page 5B-37) (Page 5B-29)

09941M74910 09942M15511
Steering stem bearing Sliding hammer
remover and installer
(Page 5B-37) (Page 5B-30)

09944M66010 09944M88220
Oil seal installer Oil seal installer
(Page 5B-9) (Page 5B-9)

09944M96013 09951M76010
Bearing outer race remover Bearing installer
(Page 5B-30) (Page 5B-42) /
(Page 5B-42)
5B-46 Manual Transmission/Transaxle: K15B Model

09952M06010
Dial gauge plate No.1
(Page 5B-41)
 Manual Transmission/Transaxle: D13A Model 5B-47

D13A Model
General Description
Manual Transaxle Construction
AENJHB0B5221001
The transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three
shafts: input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a
sliding idler gear arrangement.
The low speed synchronizer sleeve & hub is mounted on countershaft and engaged with countershaft 1st gear or 2nd
gear, while the high speed synchronizer sleeve & hub is mounted on input shaft and engaged with input shaft 3rd gear
or 4th gear. The 5th speed sleeve & hub on input shaft is engaged with input shaft 5th gear mounted on the input shaft.
To prevent the cracking noise from the reverse gear when shifting transaxle gear into the reverse gear, the reverse
shift braking device is used. This device utilizes the 5th synchromesh, which is the lever synchro type, to apply the
brake on the input shaft rotation.
The double cone synchronizing mechanism is provided to 1st and 2nd gear synchromesh devices to improve shift
feeling of 1st and 2nd gears.
For servicing, it is necessary to use genuine sealant or its equivalent on mating surfaces of transaxle case which is
made of aluminum. The case fastening bolts must be tightened to specified torque by means of torque wrench. It is
also important that all parts are thoroughly cleaned with cleaning fluid and air-dried before reassembling.
Further, care must be taken to adjust preload of countershaft taper roller bearings. New synchronizer rings are
inhibited from being lapped with respective gear cones using lapping compound before they are assembled.

IDAA0A521002-01
5B-48 Manual Transmission/Transaxle: D13A Model

1. Input shaft 8. Reverse gear shaft 15. Countershaft 3rd gear

2. 5th speed sleeve & hub
3. Input shaft 5th gear
4. Input shaft 4th gear
5. High speed synchronizer sleeve & hub
6. Input shaft 3rd gear
7. Left case
9. Reverse idler gear 16. Countershaft 2nd gear
10. Right case 17. Low speed synchronizer sleeve & hub
11. Countershaft 18. Countershaft 1st gear
12. Side cover 19. Final gear
13. Countershaft 5th gear 20. Differential case
14. Countershaft 4th gear

Gear Shift Mechanism

The gear shifting control system consists of the following main parts. Movement of gear shift control lever is
transmitted to gear shift & select shaft through gear shift and gear select cables.

2
13

11

5
3
5

10

12

6 7
8 9
IDL10A520001-01

1. Gear shift control cable
2. Gear select control cable
3. Select cable lever
4. Shift cable lever
5. 5th gear shift fork
6. 5th & reverse gear shift shaft
7. Gear shift & select lever
8. Low speed gear shift shaft
9. High speed gear shift shaft
10. Reverse gear shift lever
11. Gear shift & select shaft assembly
12. Gear shift interlock bolt
13. Gear shift control lever assembly
 Manual Transmission/Transaxle: D13A Model 5B-49

Reverse Shift Prevention Mechanism
Construction
In the gear shift lever case, the reverse shift limit yoke
(2) which turns around reverse shift limit yoke retainer is
provided.
This reverse shift limit yoke (2) restricts the movement of
gear shift & select lever (1) to prevent erroneous reverse
2) The cubic part of the gear shift & select lever (1)
pushes the projection of the reverse shift limit yoke
(2). The reverse shift limit yoke (2) rotates and
pushes the gear shift & select lever (1) toward the
neutral position.
[a]

shifting.
2

3
1

[c] [b]

IAP70A520034-02

[a]: 5th [c]: 4th

[b]: Reverse

1 2
3) If the reverse shifting force is still applied to the shift
lever, the cubic part of the gear shift & select lever
(1) rides over the projection of the reverse shift limit
yoke (2), and the gear is shifted into the 4th. The
reverse shift limit yoke (2) returns to its original
position.

[a]

1 2
I9P60A521054-01

3. Gear shift & select shaft assembly

[c] [b]
Operation
1) If shifting directly from 5th [a] to reverse [b] is
attempted, the cubic part of the gear shift & select
lever (1) is blocked by the projection of the reverse
shift limit yoke (2).
IAP70A520035-02

1 [a] 1 [a] [a]: 5th [c]: 4th

[b]: Reverse

2 2

[c] [b] [c] [b]

IAP70A520033-02

[c]: 4th
5B-50 Manual Transmission/Transaxle: D13A Model
Diagnostic Information and Procedures
Manual Transaxle Symptom Diagnosis
Condition Possible cause
Gears slipping out of Worn shift fork shaft
mesh
Worn shift fork or synchronizer sleeve
Weak or damaged locating springs
Worn bearings on input shaft or
countershaft
Worn chamfered tooth on sleeve and
gear
AENJHB0B5224001
Correction / Reference Item
Replace shift fork or shift shaft.
• Low speed gear shift shaft: (Page 5B-67)
• High speed gear shift shaft: (Page 5B-67)
• 5th & reverse gear shift shaft: (Page 5B-
67)
Replace shift fork, shift shaft or synchronizer
sleeve & hub.
• Low speed gear shift shaft: (Page 5B-67)
• High speed gear shift shaft: (Page 5B-67)
• 5th gear shift fork: (Page 5B-80)
• Low speed synchronizer sleeve & hub:
(Page 5B-77)
• High speed synchronizer sleeve & hub:
(Page 5B-74)
• 5th speed synchronizer sleeve & hub:
(Page 5B-63)
Replace gear shift & select shaft assembly.
(Page 5B-60)
Replace input shaft bearing or output shaft
bearing.
• Countershaft left bearing:
– Inner race: (Page 5B-77)
– Outer race: (Page 5B-67)
• Countershaft right bearing:
– Inner race: (Page 5B-77)
– Outer race: (Page 5B-71)
• Input shaft left bearing and right bearing:
(Page 5B-74)
Replace synchronizer sleeve & hub and gear.
• Countershaft 1st gear and 2nd gear:
(Page 5B-77)
• Input shaft 3rd gear and 4th gear: (Page
5B-74)
• Input shaft 5th gear: (Page 5B-63)
• Low speed synchronizer sleeve & hub:
(Page 5B-77)
• High speed synchronizer sleeve & hub:
(Page 5B-74)
• 5th speed synchronizer sleeve & hub:
(Page 5B-63)
 Manual Transmission/Transaxle: D13A Model 5B-51
Condition Possible cause
Hard shifting Inadequate lubricant
Improper clutch pedal free travel
Distorted or broken clutch disc
Damaged clutch pressure plate
Worn synchronizer ring
Worn chamfered tooth on sleeve and
gear
Worn gear shift control shaft joint
bushing
Distorted shift shaft
Broken gear shift / select control cables Replace gear shift and select cable. (Page
Correction / Reference Item
Add manual transaxle oil.
Replace clutch pedal arm or clutch master
cylinder.
• Clutch pedal arm: (Page 5C-5)
• Clutch master cylinder: (Page 5C-7)
Replace clutch disc. (Page 5C-11)
Replace clutch cover. (Page 5C-11)
Replace synchronizer ring.
• Low speed synchronizer ring and 2nd gear
synchronizer ring: (Page 5B-77)
• High speed synchronizer ring: (Page 5B-
74)
• 5th speed synchronizer ring: (Page 5B-
63)
Replace synchronizer sleeve & hub and gear.
• Countershaft 1st gear and 2nd gear:
(Page 5B-77)
• Input shaft 3rd gear and 4th gear: (Page
5B-74)
• Input shaft 5th gear: (Page 5B-63)
• Low speed synchronizer sleeve & hub:
(Page 5B-77)
• High speed synchronizer sleeve & hub:
(Page 5B-74)
• 5th speed synchronizer sleeve & hub:
(Page 5B-63)
Replace gear shift & select shaft assembly.
(Page 5B-59)
Replace shift fork or shift shaft.
• Low speed gear shift shaft: (Page 5B-67)
• High speed gear shift shaft: (Page 5B-67)
• 5th & reverse gear shift shaft: (Page 5B-
67)
5B-56)
5B-52 Manual Transmission/Transaxle: D13A Model

Condition Possible cause Correction / Reference Item

Noise Inadequate or insufficient lubricant
Damaged or worn bearing(s)
Damaged or worn gear(s)
Damaged or worn synchronizer parts
Add manual transaxle oil.
Replace bearing.
• Countershaft left bearing:
– Inner race: (Page 5B-77)
– Outer race: (Page 5B-67)
• Countershaft right bearing:
– Inner race: (Page 5B-77)
– Outer race: (Page 5B-71)
• Input shaft left bearing and right bearing:
(Page 5B-74)
• Differential side bearing:
– Inner race: (Page 5B-80)
– Right side outer race: (Page 5B-71)
– Left side outer race: (Page 5B-72)
• Needle bearing:
– Countershaft 1st gear and 2nd gear:
(Page 5B-74)
– Input shaft 3rd gear and 4th gear:
(Page 5B-77)
– 5th gear: (Page 5B-63)
Replace gear.
• Countershaft 1st gear, 2nd gear, 3rd gear
and 4th gear: (Page 5B-77)
• Input shaft 1st gear, 2nd gear, 3rd gear and
4th gear: (Page 5B-74)
• Input shaft 5th gear and countershaft 5th
gear: (Page 5B-63)
Replace synchronizer parts.
• Low speed synchronizer parts: (Page 5B-
77)
• High speed synchronizer parts: (Page 5B-
74)
• 5th speed synchronizer parts: (Page 5B-
63)

Repair Instructions
Manual Transaxle Oil Level Check
AENJHB0B5226001
1) Hoist vehicle and remove left side engine under side
cover.
2) Check manual transaxle for oil leakage.
Repair leaky point, if any.
3) Remove oil level / filler plug (1). Check oil
contamination and check that oil level reaches lower
end of oil level / filler plug hole (2).
If oil is excessively dirty or insufficient, change oil or
add specified oil up to plug hole.
 Manual Transmission/Transaxle: D13A Model 5B-53

4) Apply sealant to thread of level / filler plug, and then 8) Add new specified oil until oil level reaches lower
tighten it to specified torque. end of oil filler plug hole (3) as shown in figure.
“A”: Sealant 99000–31260 (SUZUKI Bond NOTE
No.1217G)
It is highly recommended to use “SUZUKI
Tightening torque GEAR OIL 75W”.
Transaxle oil level / filler plug (a): 21 N·m (2.1
kgf-m, 15.5 lbf-ft) Manual transaxle oil specification
: SUZUKI GEAR OIL 75W 99000–22B27–036
1, (a), “A” : API GL-4 (For SAE classification, refer to
viscosity chart.)
Manual transaxle oil capacity
Reference: 2.6 liters (5.49/4.58 US/Imp. pt.)
Viscosity chart

75W

C - 30 - 20 - 10 0 10 20 30 40
F - 22 -4 14 32 50 68 86 104
IDL10A520002-01 [a]
IFFA0B521002-01

[a]: Temperature

9) Apply sealant to thread of oil level / filler plug, and

then tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
IAP70A320003-01
Tightening torque
Transaxle oil level / filler plug (b): 21 N·m (2.1
Manual Transaxle Oil Change kgf-m, 15.5 lbf-ft)
AENJHB0B5226002
1) Before changing oil, stop engine and hoist vehicle
2, (b), “A”
horizontally.
2) Remove left side engine under side cover.
3) Check manual transaxle for oil leakage.
Repair leaky point, if any.
4) Remove oil level / filler plug (2).
5) Cover suspension frame with a board (4) to protect it
from dripping oil.
6) Remove drain plug (1), and drain oil.
7) Apply sealant to thread of drain plug, and tighten it to 4
specified torque. 1, (a), “A”
IDL10A520003-01
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m,
15.5 lbf-ft)

IAP70A320006-01
5B-54 Manual Transmission/Transaxle: D13A Model

Differential Side Oil Seal Replacement

AENJHB0B5226003
1) Hoist vehicle and drain transaxle oil. (Page 5B-53)
2) Remove front drive shaft. (Page 3A-3)
3) Remove drive intermediate shaft. (Page 3A-3)
4) Remove oil seal (1) using special tool.
Special tool
(A): 09913M50121

(A)
1
I9P60A522004-01

5) Install new oil seal (1) using special tool.

NOTE
• When installing oil seal, face its spring
side inward.
• Check that oil seal is installed horizontally
to surface of case after installing oil seal.

Special tool
(A): 09944M66010
(B): 09944M88220
(C): 09924M74510
Distance from case end face to right oil seal
“a”: 0 – 1.0 mm (0 – 0.04 in.)
Distance from case end face to left oil seal
“c”: 0 – 1.0 mm (0 – 0.04 in.)
6) Apply grease to oil seal lip. Then, check drive shaft
where oil seal contacts and check its smoothness.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)

“c” “a”

(C)
(C)

(B) (A)

1, “A”
IGSB0A521005-01

7) Install drive intermediate shaft. (Page 3A-11)

8) Install front drive shaft. (Page 3A-3)
9) Add transaxle oil. (Page 5B-53)
 Manual Transmission/Transaxle: D13A Model 5B-55

Gear Shift Control Lever and Cable Components

AENJHB0B5226004

(d)
2

6
1
3

(d)
5
8
(b)
(a)
4

(c)

A A

IJHB0A523001-01

1. Gear shift control lever knob
: For removal, refer to “Gear Shift Control Lever
and Cable Removal and Installation”: D13A
Model (Page 5B-56).
2. Gear shift control cable
3. Gear select control cable
4. Gear shift control lever assembly
: Apply grease 99000-25011 to pivot.
5. Cable bracket
6. Harness bracket : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
7. Gear shift and select shaft assembly : 21 Nm (2.1 kgf-m, 15.5 lbf-ft)
: Apply grease 99000-25011 to pivot.
8. Shift control lever boot : Do not reuse.
: 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
: 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
5B-56 Manual Transmission/Transaxle: D13A Model

Gear Shift Control Lever and Cable Removal Back Up Light Switch Inspection
AENJHB0B5226008
and Installation Check back up light switch function using ohmmeter.
AENJHB0B5226005
Refer to “Gear Shift Control Lever and Cable Removal Replace back up light switch if defective.
and Installation”: K15B Model (Page 5B-11).
Back up light switch specification
Switch ON (Push): Continuity exists
Gear Select Control Cable Adjustment Switch OFF (Release): No continuity
AENJHB0B5226006
Refer to “Gear Select Control Cable Adjustment”: K15B
Model (Page 5B-13).

Back Up Light Switch Removal and Installation

AENJHB0B5226007
Removal
1) Remove battery and battery tray. (Page 1J-16)
2) Support transaxle with transmission jack.
3) Remove engine left mounting bracket. (Page 1D-
98)
4) Disconnect back up light switch connector (1). I4RS0A520011-01

5) Remove back up light switch (2).

Neutral Position Switch Inspection
AENJHB0B5226009
Check neutral position switch (1) function using
ohmmeter.
Replace gear shift & select shaft assembly if switch does
1
not operate as specified.
Neutral position switch specification
Neutral position: Continuity exists
1st gear position: No continuity
2

IFRA0A522003-01

Installation
1) Apply oil to new O-ring (1) and tighten back up light
switch (2) to specified torque.
Tightening torque
Back up light switch (a): 19 N·m (1.9 kgf-m, 14.0
lbf-ft)

1 2, (a)

IJHB0A523002-01

I3RH0A520006-01

2) Connect back up light switch connector.

3) Install engine left mounting bracket. (Page 1D-98)
4) Install battery and battery tray. (Page 1J-16)
 Manual Transmission/Transaxle: D13A Model 5B-57

Manual Transaxle Unit Components

AENJHB0B5226010

(b)
(b)

(a)

(a)
(b)
IDL10A520010-01

1. Engine : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)

2. Transaxle : 85 Nm (8.7 kgf-m, 63.0 lbf-ft)
5B-58 Manual Transmission/Transaxle: D13A Model

Manual Transaxle Unit Dismounting and 7) Remove injector harness clamps (1) from bracket.
Remounting
AENJHB0B5226011
Dismounting
1) Remove battery and battery tray. (Page 1J-16)
2) Remove air cleaner assembly. (Page 1D-82) 1

3) Disconnect gear shift and gear select control cables

from transaxle. (Page 5B-56)
4) Remove gear shift & select shaft assembly. (Page
5B-60)
5) Remove engine harness clamps (1) from bracket.

1
IJHB0A523005-01

1 8) Drain transaxle oil. (Page 5B-53)

9) Remove exhaust pipe. (Page 1K-8)
10) Remove front drive shaft assembly. (Page 3A-3)
11) Remove drive intermediate shaft assembly. (Page
3A-11)
12) Remove starting motor. (Page 1I-19)
13) Remove clutch fluid pipe. (Page 5C-7)
14) Loosen bolts and nuts fastening engine.
1 15) Open hood as wide as possible and hold it using
1
IJHB0A523003-01
rope.
6) Remove back up light switch wire clamp (1) from 16) Remove front suspension frame. (Page 2B-13)
bracket. 17) Support engine assembly, refer to “Engine Assembly
Removal and Installation”: D13A in Section 1D
(Page 1D-99).
18) Support transaxle with transmission jack.
19) Disconnect neutral position switch connector (1).

IJHB0A523004-01 IJHB0A523006-01

20) Disconnect back up light switch connector and

clamps. “Back Up Light Switch Removal and
Installation”: D13A Model (Page 5B-56)
21) Remove engine rear torque rod bracket. (Page
1D-98)
22) Remove bolts fastening engine and transaxle and
then detach transaxle from engine.
 Manual Transmission/Transaxle: D13A Model 5B-59

Remounting – Transaxle to engine bolts: (Page 5B-57)

Reverse dismounting procedure noting the following – Front drive shaft: (Page 3A-3)
points.
– Intermediate shaft assembly: (Page 3A-11)
NOTICE – Front suspension frame: (Page 2B-13)
Failure to take proper precautions when – Starting motor: (Page 1I-19)
remounting the manual transaxle can cause – Engine left mounting bracket, engine rear torque
damage to parts. rod and engine rear torque rod bracket: (Page
• When installing the transaxle, be careful 1D-98)
not to let the drive shaft scratch the oil – Exhaust pipe: (Page 1K-8)
seal. • Set each clamp for wiring securely.
Oil leakage may occur if the oil seal lip is
scratched by the drive shaft. • Add transaxle oil. (Page 5B-53)
• Do not use a hammer when installing the • Bleed clutch system. (Page 5C-5)
drive shaft joint into the differential gear. • Check function of engine, clutch and transaxle.
Hitting the drive shaft joint with a hammer • Check that there is no oil leakage and fluid leakage at
will damage the joint. each connection.

• Tighten the following bolts and nuts to specified

torque.

Gear Shift and Select Shaft Assembly Components

AENJHB0B5226012

2 (a)

2 (a)

3 (a)
4 (a)

2 (a)

1217G 1

3 (a)

3 (a)

IJHB0A523007-01

1. Gear shift & select shaft assembly 4. Gear shift interlock bolt
: Apply sealant 99000-31260 : For tightening order, refer to “Gear Shift and Select Shaft
For details, refer to “Gear Shift and Select Shaft Assembly Assembly Removal and Installation”: D13A Model (Page 5B-60).
Removal and Installation”: D13A Model (Page 5B-60)
2. Gear shift guide case No.1 bolt : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
3. Gear shift guide case No.2 bolt : Do not reuse.
5B-60 Manual Transmission/Transaxle: D13A Model

Gear Shift and Select Shaft Assembly Removal Installation

and Installation
AENJHB0B5226013 NOTICE
The fastener is pre-coated with friction
Removal stabilizer. If the fastener is reused, it may
1) Remove battery and battery tray. (Page 1J-16) work loose.
2) Disconnect gear shift and gear select control cables Replace the fastener pre-coated with friction
from transaxle. (Page 5B-56) stabilizer with a new one.
3) Remove engine harness bracket (1) from transaxle
1) Install gear shift & select shaft assembly in the
case and clamp.
following procedure.
a) Clean sealing surface between gear shift &
select shaft assembly and transaxle. Remove oil,
1
old sealant and dust from sealing surface.
b) Apply sealant “A” to left case as shown in figure.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for left case
“a”: 1.5 mm (0.059 in.)

IJHA0A520009-01

4) Remove gear shift interlock bolt (1) from transaxle

case.
5) Remove gear shift guide case bolts (2) and gear shift
& select shaft assembly (3).

2
“a”
2 “A” “a”

IJHA0A520011-02

c) Install gear shift and select shaft assembly (1) to

left case and tighten gear shift guide case No.1
bolts and new gear shift guide case No.2 bolts to
specified torque.
Tightening torque
Gear shift guide case No.1 bolt (a): 23 N·m (
2.3 kgf-m, 17.0 lbf-ft)
Gear shift guide case No.2 bolt (b): 23 N·m (
2.3 kgf-m, 17.0 lbf-ft)

3 1
IFRA0A522004-01
 Manual Transmission/Transaxle: D13A Model 5B-61

d) Install new washer (2) and gear shift interlock

bolt, and then tighten it to specified torque.
Tightening torque
Gear shift interlock bolt (c): 23 N·m (2.3 kgf-
m, 17.0 lbf-ft)

(a)

(b)

1 2 (c)
IJHB0A523008-01

2) Install engine harness bracket (1) to transaxle case

and clamp.

IJHA0A520009-01

3) Connect gear shift and gear select control cables to

transaxle. (Page 5B-56)
4) Install battery and battery tray. (Page 1J-16)
5B-62 Manual Transmission/Transaxle: D13A Model

Manual Transaxle Assembly Components

AENJHB0B5226014

3 1217G

6 (e)

38

OIL
7 33 A

14 (b) 2 1217G
10 1217G (a)
39

40

41
42 (c)
46 (c)

43
45
35 44 (b)

8 34
OIL

34
9 1217G (a)

14 (b)

36 13 (c)

11 (c)
21 (d)

20
5 1217G
29
1 23 22 (c)
33 A
OIL

15
18 (d)
17
OIL

24
OIL

16
4

25

37

12 (f)
19

32

29
31 (b)
30
OIL

28
26
27 (b)
IJHB0A523009-01
 Manual Transmission/Transaxle: D13A Model 5B-63

1. Transaxle right case 28. Reverse gear shaft

2. Transaxle left case 29. Washer
: Apply sealant 99000-31260 to mating surface of left case and right case.
3. Gear shift & select shaft assembly 30. Reverse idler gear
: For details, refer to “Gear Shift and Select Shaft Assembly Removal and
Installation”: D13A Model (Page 5B-60).
: Apply sealant 99000-31260 to mating surface of gear shift & select shaft
assembly and left case.
4. Transaxle left case plate 31. Reverse gear shaft bolt
5. Transaxle side cover 32. Gasket
: Apply sealant 99000-31260 to mating surface of side cover and left case.
6. Back up light switch 33. Oil seal
: Apply grease 99000-25011 to oil seal lip.
7. O-ring 34. Outer race
8. Differential assembly 35. Differential side shim
: For details, refer to “Differential Disassembly and Reassembly”: D13A : For adjustment, refer to “Transaxle Left Case
Model (Page 5B-80). Disassembly and Reassembly”: D13A Model (Page
5B-72).
9. Oil level / filler plug 36. Input oil gutter
: Apply sealant 99000-31260 to threads.
10. Oil drain plug 37. Input shaft & countershaft assembly
: Apply sealant 99000-31260 to threads. : For details, refer to “Input Shaft and Countershaft
Components”: D13A Model (Page 5B-74).
11. Oil gutter bolt 38. Breather plug
12. Left case plate bolt 39. Breather hose
13. Side cover bolt 40. Breather union
14. Transaxle case bolt 41. Breather cover plate
15. 5th speed synchronizer ring 42. Breather cover plate bolt
16. 5th speed synchronizer lever 43. Transaxle hook
17. 5th speed synchronizer sleeve & hub 44. Transaxle hook bolt
18. Input shaft nut 45. Cap
: After tightening nut to specified torque, caulk nut securely.
19. Bearing set shim 46. Cap bolt
: For adjustment, refer to “Manual Transaxle Assembly Disassembly and
Reassembly”: D13A Model (Page 5B-67).
20. Countershaft 5th gear : 21 Nm (2.1 kgf-m, 15.5 lbf-ft)
21. Countershaft nut : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: After tightening nut to specified torque, caulk nut securely.
22. 5th gear shift fork bolt : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
23. 5th gear shift fork : 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
24. Needle bearing : 19 Nm (1.9 kgf-m, 14.0 lbf-ft)
25. Input shaft 5th gear : 31 Nm (3.2 kgf-m, 23.0 lbf-ft)
26. Reverse gear shift lever : Do not reuse.
27. Reverse gear shift lever bolt : Apply transaxle oil.

Fifth Gear Disassembly and Reassembly

AENJHB0B5226015

Disassembly 1
1) Remove gear shift & select shaft assembly. (Page
5B-60)
2) Remove side cover bolts and take off transaxle side
cover (1) using special tool.

NOTICE
Oil leakage will occur if side cover is
distorted. 1
Be careful not to distort side cover when it is
removed from transaxle left case.
(A)
Special tool
(A): 09921M96510

I9P60A522015-01

3) Unfasten caulking of input shaft nut (3).

5B-64 Manual Transmission/Transaxle: D13A Model

4) Arrange a double-gear-engagement shifting both low 8) Remove input shaft 5th gear, needle bearing and
speed gear shift shaft (1) and high speed gear shift then countershaft 5th gear (1). Gear puller (2) is
shaft (2) in arrow direction, and then remove input necessary if spline fitting of countershaft 5th gear is
shaft nut (3) and washer. tight.

I9P60A522016-01
3

Reassembly
1) Clean all components thoroughly, check them for
IDAA0A521019-01
any abnormal condition and replace defective parts
5) Remove 5th gear shift fork bolt (1).
with new ones if necessary.
6) Remove 5th gear shift fork (2) and 5th gear all
2) Check clearance “a” between 5th speed
together. Use gear puller for removal if spline fitting
synchronizer ring (2) and input shaft 5th gear (1),
of hub is tight.
and replace defective part with new one. Also, check
2
gear teeth for damage.
1
Clearance “a” between 5th speed synchronizer
ring and input shaft 5th gear
Standard: 0.40 – 1.40 mm (0.0158 – 0.0551 in.)
Limit: 0.4 mm (0.0158 in.)

IDAA0A521020-01

7) Unfasten caulking of countershaft nut (2), install

input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2).
Special tool
(A): 09927M76060

(A)

2
IJHA0A520020-01

I4RH01520016-01
 Manual Transmission/Transaxle: D13A Model 5B-65

3) Install countershaft 5th gear (1) to countershaft as 9) Assemble 5th speed synchronizer sleeve (1), 5th
shown in figure. speed synchronizer hub (2), 5th speed synchronizer
levers (3) and 5th speed synchronizer ring (4) as
follows.
[c]
[b]

[a]

IAP70A520014-01

[a]: Countershaft side [c]: Short flange (Outside)

[b]: Long flange (Inside)

4) Apply transaxle oil to needle bearing (3), and install it I4RH01520054-01

to input shaft.
a) Install 5th speed synchronizer hub (1) to 5th
5) Install input shaft 5th gear (1) to input shaft. speed synchronizer sleeve (2) in specified
6) Install special tool to stop shaft rotation. direction as shown in figure.
Special tool [b] 1
(A): 09927M76060
7) Tighten new countershaft nut (2) to specified torque, [a]
and caulk nut securely.
2
NOTICE
• Once countershaft nut is removed, it will
no longer have necessary fastening
IAP70A520016-02
performance.
Never reuse the countershaft nut. [a]: Chamfered side [b]: Long boss

• If caulking part (4) of countershaft nut is

cracked while caulking, the nut will spoil b) Fit 5th speed synchronizer levers (1) to 5th
locking performance. speed synchronizer hub (2) by aligning
Replace the nut with new one again. protrusion (3) of 5th speed synchronizer levers
(1) with groove of 5th speed synchronizer hub
Tightening torque (2).
Countershaft nut (a): 100 N·m (10.2 kgf-m, 74.0
3
lbf-ft)

1
3

I9P60A522047-01

IAP70A520015-01

8) Remove special tool.

5B-66 Manual Transmission/Transaxle: D13A Model

c) Install 5th speed synchronizer ring (1) to 5th
speed synchronizer hub (2) in specified direction
as shown in figure.
1
12) Arrange a double-gear-engagement shifting both low
speed gear shift shaft (2) and high speed gear shift
shaft (3) in arrow direction.
13) Install washer and new input shaft nut (4).
14) Tighten input shaft nut to specified torque, and then
caulk nut securely.

NOTICE
2 • Once input shaft nut is removed, it will no
longer have necessary fastening
performance.
Never reuse the input shaft nut.
• If caulking part of input shaft nut is
I4RH01520055-01
cracked while caulking, the nut will spoil
10) Fit 5th gear shift fork (1) to 5th speed synchronizer locking performance.
sleeve (3) and 5th speed synchronizer hub (2) Replace the nut with new one again.
assembly, and install them into input shaft and gear
shift shaft by aligning punch mark (4) with Tightening torque
matchmark (5) on input shaft. Input shaft nut (b): 100 N·m (10.2 kgf-m, 74.0 lbf-
ft)

4
3
5

1, (a)

2
3

4, (b)

IDAA0A521022-01

2 15) Install side cover (1) to left case as follows.

1
a) Clean mating surfaces of left case and side
3 cover.
b) Apply specified amount of sealant to side cover
as shown in figure.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for side cover
IFRA0A522007-02 “a”: 1.5 mm (0.059 in.)
11) Tighten 5th gear shift fork bolt (1) to specified torque.
c) Mate side cover with left case.
NOTICE d) Tighten side cover bolts to specified torque.
5th gear shift fork bolt is pre-coated with
adhesive. If the bolt is reused, it may work
loose.
Replace the 5th gear shift fork bolt with new
one once it is removed.

Tightening torque
5th gear shift fork bolt (a): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)
 Manual Transmission/Transaxle: D13A Model 5B-67

Tightening torque 6) Remove back up light switch. (Page 5B-56)

Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft) 7) Remove reverse gear shaft bolt (1) with gasket.

“A”

“A”

(a)

IAP70A520017-01

16) Install gear shift & select shaft assembly. (Page

I9P60A522021-01
5B-60)
8) Remove transaxle case bolts (1).
Manual Transaxle Assembly Disassembly and
Reassembly 1
AENJHB0B5226016

Disassembly
1) Remove gear shift & select shaft assembly. (Page
5B-60)
1
2) Remove input shaft 5th gear and countershaft 5th
gear. (Page 5B-63)
3) Remove left case plate bolts (3).
4) Remove left case plate (1) and bearing set shim (2).
5) Remove snap ring (6) using snap ring pliers (4).

IDL10A520015-01
5 9) Remove transaxle left case (1) from transaxle right
case (2) using special tool.
Special tool
3
(A): 09912M34510

3
1

)A(
IDAA0A521023-01

2
5 4

2
IDL10A520016-01

6
10) Remove reverse gear shift lever bolts (4) and
reverse gear shift lever (5).
11) Pull out reverse gear shaft (1) with washer (2), and
IEL70B520043-01
then take off reverse idler gear (3).
5. Input shaft 7. Input shaft left bearing
5B-68 Manual Transmission/Transaxle: D13A Model

12) Pull out 5th & reverse gear shift shaft (6). Reassembly

NOTE NOTE
When removing 5th & reverse gear shift The differential side bearing is of a tapered
shaft, push up high speed gear shift shaft roller type. When reassembling the transaxle,
and shift it to 4th to facilitate removal of 5th & select a differential side bearing shim
reverse shift shaft. referring to “Transaxle Left Case
Disassembly and Reassembly”: D13A Model
(Page 5B-72).
6 1) Install differential assembly into transaxle right case.
1
2) Join input shaft (5), countershaft (4), low speed gear
2 shift shaft (2) and high speed gear shift shaft (3)
assemblies all together, and then install them into
3
transaxle right case (1).

NOTE
5
• Do not damage oil seal by input shaft
spline while installing.
• Check that countershaft is engaged with
4
final gear.
IDL10A520017-01

13) Remove countershaft left bearing outer race (1) from

transaxle left case (2) using special tool.
Special tool
(A): 09913M70123

2
(A) I2RH01520080-01

1
3) Install 5th & reverse gear shift shaft (1) into transaxle
right case (2). At the same time, join reverse gear
shift arm (4) and reverse gear shift lever (3).

1 4

I9P60A522025-01

14) Remove differential side oil seal. (Page 5B-54)

15) By tapping input shaft end with plastic hammer, push 2

it out as assembly from case a little, and then

remove input shaft assembly (1), countershaft
3
assembly (2), high speed gear shift shaft (3) and low
speed gear shift shaft (4) all together.

IDL10A520018-01

4) Mate reverse idler gear (1) with reverse gear shift

lever (2), insert reverse gear shaft (3) and washer (6)
into case (4) through idler gear and then align bolt
hole (7) on shaft with notch (8) on case.
5) Tighten reverse gear shift lever bolts (5) to specified
I2RH01520035-01 torque.
16) Remove differential assembly from transaxle right
case.
 Manual Transmission/Transaxle: D13A Model 5B-69

NOTE 7) Tighten transaxle case bolts to specified torque.

Check that reverse gear shift lever end has Tightening torque
clearance “a” to idle gear groove. Transaxle case bolt (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)
Clearance between lever end and idle gear
groove
(a)
“a”: 0.5 – 1.0 mm (0.02 – 0.04 in)
Tightening torque
Reverse gear shift lever bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lbf-ft)

(a)
7

IDL10A520021-01
6 8) Install new reverse gear shaft bolt (1) and new
gasket, and tighten it to specified torque.

NOTICE
Reverse gear shaft bolt is pre-coated with
1 adhesive. If the bolt is reused, it may work
loose.
2 Replace the reverse gear shaft bolt with new
“a” one once it is removed.
2
Tightening torque
5, (a)
Reverse gear shaft bolt (a): 23 N·m (2.3 kgf-m,
IDL10A520019-01
17.0 lbf-ft)
6) Install right case to left case as follows.
a) Clean mating surfaces of right case and left
case.
b) Apply specified amount of sealant to left case (1)
as shown in figure.
1,(a)
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for left case
“a”: 1.5 mm (0.059 in.)

I9P60A522030-01

IAP70A520020-01

c) Mate right case with left case.

5B-70 Manual Transmission/Transaxle: D13A Model

9) Install new snap ring (1) using snap ring pliers (4). Available shim thickness
Clearance Applicable shim
2 4 0.42 – 0.47 mm
0.65 mm (0.0255 in.)
(0.0166 – 0.0185 in.)
3
0.48 – 0.52 mm
0.70 mm (0.0275 in.)
(0.0189 – 0.0204 in.)
0.53 – 0.57 mm
0.75 mm (0.0295 in.)
(0.0209 – 0.0224 in.)
0.58 – 0.62 mm
0.80 mm (0.0314 in.)
1 (0.0229 – 0.0244 in.)
0.63 – 0.67 mm
0.85 mm (0.0334 in.)
(0.0249 – 0.0263 in.)
0.68 – 0.72 mm
IEL70B520045-01 0.90 mm (0.0354 in.)
(0.0268 – 0.0283 in.)
2. Input shaft 3. Input shaft left bearing
0.73 – 0.77 mm
0.95 mm (0.0374 in.)
(0.0288 – 0.0303 in.)
10) To seat countershaft left bearing outer race (1) to 0.78 – 0.82 mm
bearing cone, tap countershaft left bearing outer 1.00 mm (0.0393 in.)
(0.0308 – 0.0322 in.)
race (1) using special tool and plastic hammer (3). 0.83 – 0.87 mm
1.05 mm (0.0413 in.)
Special tool (0.0327 – 0.0342 in.)
(A): 09913M70123 0.88 – 0.92 mm
1.10 mm (0.0433 in.)
(0.0347 – 0.0362 in.)
0.93 – 0.97 mm
1.15 mm (0.0452 in.)
(0.0367 – 0.0381 in.)
3 0.98 – 1.02 mm
1.20 mm (0.0472 in.)
(0.0386 – 0.0401 in.)

2 c) Put the thickest spare part shim on bearing outer

race and install left case plate (2).
d) Tighten used bolts (1) to specified torque.

1
Tightening torque
I9P60A522031-01 Left case plate bolt (a): 31 N·m (3.2 kgf-m,
2. Input shaft 23.0 lbf-ft)
e) Turn countershaft (3) 10 times or more.
11) Select countershaft 5th gear shim as follows.
a) Push down bearing outer race and measure
1, (a)
clearance “a” between transaxle right case and 3
bearing outer race using straightedge (1) and
feeler gauge (2).
4

1, (a)

1, (a)

1 IDAA0A521030-01

2 4. Input shaft

“a” f) Remove left case plate.

I9P60A521037-01

b) Select a shim which fits the clearance measured

above.
 Manual Transmission/Transaxle: D13A Model 5B-71

g) Place straightedge (1) over shim (3) and Tightening torque

compress it by hand through straightedge, and Left case plate bolt (a): 31 N·m (3.2 kgf-m, 23.0
measure “a” using feeler gauge (2). lbf-ft)
Clearance between case surface and
straightedge 1, (a)
3
“a”: 0.18 – 0.22 mm (0.0071 – 0.0086 in.)
h) If clearance “a” is out of specification, select
suitable shim which adjusts clearance “a” to 4
specification and put it on bearing outer race.

NOTE
1, (a)
Insert 0.2 mm (0.008 in.) feeler to check
whether or not a shim fulfills specification.
1, (a)

IDAA0A521030-01

4. Input shaft

13) Install input shaft 5th gear and countershaft 5th gear.
(Page 5B-63)
14) Install gear shift & select shaft assembly. (Page
5B-60)
15) Install back up light switch. (Page 5B-56)
16) Check input shaft for rotation in each gear position.
17) Check back up light switch for continuity with gears
I9P60A521048-02
in reverse position using ohmmeter.
12) Install left case plate (2), and then tighten new left
case plate bolts (1) to specified torque. Transaxle Right Case Disassembly and
Reassembly
NOTICE AENJHB0B5226017

Left case plate bolt is pre-coated with Disassembly

adhesive. If the bolt is reused, it may work
loose.
Replace the left case plate bolt with new one
once it is removed.
1) Remove differential side oil seal. (Page 5B-54)
2) Remove differential side bearing outer race (1) using
brass bar (2), if necessary.

NOTE 2

After tightening bolts, check that

countershaft (3) can be rotated by hand with
certain load.

I9P60A522034-01
5B-72 Manual Transmission/Transaxle: D13A Model

3) Remove input shaft oil seal (1), if necessary. 2) Install countershaft right bearing outer race (1) using
special tools and hammer.
Special tool
(A): 09913M75821
(B): 09924M84510M004

(A)

1
(B)

IAP70B520016-02
1
4) Pull out countershaft right bearing outer race using I9P60A522037-01
special tools, if necessary.
3) Install differential side bearing outer race using
Special tool special tool and hammer.
(A): 09930M30104
Special tool
(B): 09941M64511
(A): 09924M74510
(A)
(B): 09925M14520

(B)

(A)

(B)

I5RW0A520027-01

I9P60A522038-01
Reassembly
4) Install differential side oil seal. (Page 5B-54)
1) Install input shaft oil seal (1) using special tool and
hammer. Apply grease to oil seal lip.
Transaxle Left Case Disassembly and
: Grease 99000–25011 (SUZUKI Super Grease A) Reassembly
AENJHB0B5226018
Special tool
(A): 09913M84510 Disassembly
Distance from case surface to input shaft oil seal 1) Remove oil gutter (1) and breather cover plate (2), if
“a”: 2.7 – 3.3 mm (0.107 – 0.108 in.) necessary.

(A)
1 1
2

“a”

IAP70A520022-01

2) Remove differential side oil seal. (Page 5B-54)

IDL10A520025-01
 Manual Transmission/Transaxle: D13A Model 5B-73

3) Remove differential side bearing outer race (1) using d) Keep pushing differential side bearing outer race
special tools, and then remove shim. with force of 34 N (3.5 kgf, 7.6 lbf) by hand and
turn differential assembly 10 times or more.
Special tool
(A): 09942M15511 3
(B): 09944M96013 1 2
(C): 09921M26010

(A) (C)

(B)

1
IDAA0A521033-01 IGSB0A521025-01

e) Measure distance “a” from mating surface of

Reassembly
transaxle right case (1) to differential side
1) Install oil gutter (1) and breather cover plate (2), if bearing outer race (2).
removed.

NOTICE
“a” 2
The oil gutter bolts and breather cover plate
bolts are precoated with adhesive. If these
bolts are reused, they may work loose.
Replace the oil gutter bolts and breather
cover plate bolts with new ones whenever 1
they are removed.

Tightening torque
Oil gutter bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
Breather cover plate bolt (b): 10 N·m (1.0 kgf-m,
IGSB0A521026-01
7.5 lbf-ft)
f) Measure depth “b” from mating surface of
(a)
transaxle left case (1) to installation position of
differential side bearing outer race.
1
(b)
1
2

IAP70A520023-01

2) Calculate clearance “c” for selection of applicable

differential side shim as follows. “b”
a) Install differential side bearing outer race to
transaxle right case. “Transaxle Right Case
Disassembly and Reassembly”: D13A Model
(Page 5B-71) 1
b) Install differential assembly (2) to transaxle right
IGSB0A521027-01
case (1).
c) Install differential side bearing outer race of
transaxle left case side (3) to differential
assembly.
5B-74 Manual Transmission/Transaxle: D13A Model

g) Calculate clearance “c” by the following formula. 4) Put shim, and then install differential side bearing
Clearance “c” = depth “b” – distance “a” outer race using special tools.
Special tool
(A): 09924M74510
(B): 09925M14520
“c”

(A)
(B)
“b” “a”

I5RW0A520032-01

IGSB0A521028-01
5) Install differential side oil seal. (Page 5B-54)
3) Select shim closest to calculated shim thickness
from the following available sizes. Input Shaft and Countershaft Components
AENJHB0B5226019
Available shim thickness Refer to “Input Shaft and Countershaft Components”:
Calculated shim K15B Model (Page 5B-32).
Applicable shim
thickness
0.800 – 0.839 mm Input Shaft Disassembly and Reassembly
1.00 mm (0.0393 in.) AENJHB0B5226020
(0.03150 – 0.03303 in.)
0.840 – 0.879 mm ! CAUTION
1.04 mm (0.0409 in.)
(0.03307 – 0.03460 in.)
0.880 – 0.919 mm Using an inappropriate hydraulic press or
1.08 mm (0.0425 in.) bearing puller could cause personal injury.
(0.03465 – 0.03618 in.)
0.920 – 0.959 mm Use the hydraulic press and bearing puller
1.12 mm (0.0440 in.) which are capable of safely bearing a load of
(0.03622 – 0.03775 in.)
0.960 – 0.999 mm at least 5 tons (11,000 lbs).
1.16 mm (0.0456 in.)
(0.03780 – 0.03933 in.)
1.000 – 1.039 mm NOTICE
1.20 mm (0.0472 in.)
(0.03938 – 0.04090 in.) Supporting the gear on the concave side of
1.040 – 1.079 mm the puller can cause damage to the gear.
1.24 mm (0.0488 in.)
(0.04095 – 0.04248 in.) Support the gear on the flat side of the puller.
1.080 – 1.119 mm
1.28 mm (0.0503 in.)
(0.04252 – 0.04405 in.) Disassembly
1.120 – 1.159 mm 1) Remove input shaft right bearing (2) from input shaft
1.32 mm (0.0519 in.)
(0.04410 – 0.04562 in.) (1) using bearing puller (3) and hydraulic press.
1.160 – 1.199 mm
1.36 mm (0.0535 in.)
(0.04567 – 0.04720 in.)
1.200 – 1.239 mm
1.40 mm (0.0551 in.)
(0.04725 – 0.04877 in.)
1.240 – 1.279 mm
1.44 mm (0.0566 in.)
(0.04882 – 0.05035 in.)
1.280 – 1.319 mm
1.48 mm (0.0582 in.)
(0.05040 – 0.05192 in.)
1.320 – 1.359 mm
1.52 mm (0.0598 in.)
(0.05197 – 0.05350 in.)
1.360 – 1.399 mm
1.56 mm (0.0614 in.)
(0.05354 – 0.05507 in.) I4RH01520029-01

1.400 – 1.439 mm
1.60 mm (0.0629 in.)
(0.05512 – 0.05665 in.)
1.440 – 1.479 mm
1.64 mm (0.0645 in.)
(0.05670 – 0.05822 in.)
1.480 – 1.529 mm
1.68 mm (0.0661 in.)
(0.05827 – 0.06019 in.)

2) Remove 5th gear spacer (2), left bearing (3) and 4th
gear (4) all together using puller (5) and hydraulic
press.
I3RH0A520018-01
1. Input shaft
3) Remove 4th gear needle bearing and high speed
synchronizer ring.
4) Using snap ring pliers (2), remove circlip (1).
I7RW01520007-01
5) Remove high speed synchronizer sleeve & hub
assembly (2) together with 3rd gear (3) using puller
(4) and hydraulic press.
I2RH01520097-01
1. Input shaft
6) Remove 3rd gear needle bearing from input shaft.
7) Disassemble synchronizer sleeve & hub assembly.
Manual Transmission/Transaxle: D13A Model 5B-75
Reassembly
1) Clean all components thoroughly, check them for
any abnormal condition and replace defective parts
with new ones if necessary.
2) Check clearance “a” between synchronizer ring (2)
and gear (1), key slot width “b” in synchronizer ring
and replace defective part with new one, if
necessary. Also, check gear teeth for damage.
Clearance “a” between synchronizer ring and
gear
Standard: 0.40 – 1.50 mm (0.0158 – 0.0590 in.)
Limit: 0.4 mm (0.0158 in.)
Key slot width “b”
Standard: 10.00 – 10.20 mm (0.3937 – 0.4015 in.)
Limit: 10.45 mm (0.4114 in.)
I5JB0A520054-01
3) To ensure lubrication of input shaft (1), blow air into
oil holes (2) as shown in figure and check that they
are free from any obstruction.
I2RH01520049-01
5B-76 Manual Transmission/Transaxle: D13A Model

4) Fit high speed synchronizer sleeve (4) to hub (3), 7) Install high speed synchronizer sleeve & hub
insert 3 keys (2) in it and then set springs at assembly (3) using special tool and hydraulic press.
specified position (1) as shown in figure.
NOTE
NOTE
• Check that synchronizer ring key slots are
Assemble sleeve and hub in correct aligned with keys (5) in sleeve & hub
direction. (No direction is specified to each assembly.
key.)
• Check free rotation of 3rd gear after press-
Synchronizer key installation position fitting sleeve & hub assembly.
“a” = “b”
Special tool
(A): 09922M59420

[c]
3 [a]

(A)

5
IAP70A520026-01

[a]: 4th gear side [c]: Projecting end

[b]: Short flange side

4 [b] 2
5) Install right bearing (1) to input shaft (2) using special IAP70A520027-01
tool and hydraulic press.
[a]: 3rd gear side [c]: Long flange
Special tool [b]: Key way
(A): 09913M80113
8) Install new circlip (1) to groove securely.
9) Install needle bearing (2), apply oil to it and then
install synchronizer ring (3) and 4th gear (4).

I3RH0A520019-01

6) Install 3rd gear needle bearing (4), apply oil to it, and
then install 3rd gear (1) and synchronizer ring (2). I2RH01520052-01

5. Input shaft
 Manual Transmission/Transaxle: D13A Model 5B-77

10) Press-fit left bearing (2) using special tool and 2) Apply puller (5) to 2nd gear (4), and remove 3rd &
hydraulic press. 4th gear spacer (2) and 3rd gear (3) together with
2nd gear using hydraulic press. Needle bearing
Special tool
would come out with 2nd gear.
(A): 09913M80113
11) Using the same special tool as in Step 10), install 5th
gear spacer (1).

NOTICE
Press-fitting left bearing (2) and 5th gear
spacer (1) together can cause distortion of
spacer.
Do not press-fit left bearing using spacer.

I2RH01520055-01

1. Countershaft

3) Remove 2nd synchronizer outer ring, center cone

and inner ring.
4) Using snap ring pliers (3), remove circlip (1).

I3RH0A520020-01

Countershaft Disassembly and Reassembly

AENJHB0B5226021

! CAUTION I7RW01520008-01

Using an inappropriate hydraulic press or 2. Low speed synchronizer sleeve

bearing puller could cause personal injury.
Use the hydraulic press and bearing puller 5) Apply puller (3) to 1st gear (2) and remove low
which are capable of safely bearing a load of speed synchronizer sleeve & hub assembly (1) with
at least 5 tons (11,000 lbs). 1st gear using hydraulic press.

NOTICE
Supporting the gear on the concave side of
the puller can cause damage to the gear.
Support the gear on the flat side of the puller.

Disassembly
1) Remove left bearing cone (2) with 4th gear (3) using
puller (4) and hydraulic press.
I2RH01520057-01

6) Disassemble synchronizer sleeve & hub assembly.

7) Remove 1st gear needle bearing from shaft.

I2RH01520054-01

1. Countershaft
5B-78 Manual Transmission/Transaxle: D13A Model

8) To remove right bearing (1) from countershaft, grind Reassembly

with a grinder (2) one part “a” of right bearing (1) as
illustrated till it becomes thin.
NOTICE
The shaft (3) will be damaged if the bearing is
ground too much.
Limit the amount of grinding to the minimum
amount if necessary.
1) Clean all components thoroughly, check them for
any abnormal condition and replace defective parts
with new ones if necessary.
2) Check the following items.
• Difference between outer ring (1) and inner ring
(3)
Difference between synchronizer outer ring
and inner ring “a”
Standard: 0.40 – 1.25 mm (0.0158 – 0.0492 in.)
Limit: 0.40 mm (0.0158 in.)

3 2

1 “a”
3
1

I5RW0A520035-01

9) Break right bearing (2) at thin point with a chisel (1)

to remove it. IAP70A520028-01

2. Center cone

1 • Key protrusion width “b” in outer ring

Key slot width “b”
Standard: 10.10 – 10.30 mm (0.3976 – 0.4055
in.)
Limit: 9.85 mm (0.3878 in.)

2
I5RW0A520036-01

“b”

IGSB0A521031-01

• Each chamfered tooth of gear and synchronizer

ring for abnormal wear and damage
Replace it with new one if necessary.
3) To ensure lubrication of countershaft (1), blow air
into oil holes (2) as shown in figure and check that
they are free from any obstruction.

I2RH01520060-01
 Manual Transmission/Transaxle: D13A Model 5B-79

4) Fit low speed synchronizer sleeve (1) to hub (2) and 8) Install low speed synchronizer sleeve & hub
3 keys (3) as shown in figure. assembly (1) using special tools and hydraulic press.

NOTE NOTE
No specific direction is assigned to low • Support shaft with special tool as shown in
speed synchronizer hub and each key but it figure so that retainer of bearing cone will
is assigned as assembly. be free from compression.
• Check that synchronizer ring key slots are
Synchronizer key installation position aligned with keys (5) while press-fitting
sleeve & hub assembly.
• Check free rotation of 1st gear (3) after
press-fitting sleeve & hub assembly.
3

Special tool
2
(A): 09922M76340
(B): 09913M85210
[b]
(C): 09940M54910
(D): 09924M07710

[a]

[a]

2
IJHB0B521005-01

[a]: 2nd gear side [b]: Key way

5) Install right bearing cone (1) to countershaft (2) using

special tools and hydraulic press.
Special tool
(A): 09941M74910
IGSB0A521033-03

[a]: 1st gear side [c]: Short flange

[b]: Key slots
(A)

1 9) Install new circlip (1) to groove securely.

10) Install needle bearing (2) and apply oil to needle
2 bearing.

IGSB0A521032-01

6) Install needle bearing (4), apply oil to it, and then

install 1st gear (3).
7) Install synchronizer outer ring (2), center cone (6)
and inner ring (7).
5B-80 Manual Transmission/Transaxle: D13A Model

11) Install 2nd gear (6) with synchronizer outer ring (3), 13) Press-fit 4th gear (2) using the same procedure as in
center cone (4) and inner ring (5) as shown in figure. Step 12).
14) Install left bearing cone (1) using special tool and
hydraulic press.

NOTE
For protection of bearing cone (3), support
shaft with special tool as shown in figure.

Special tool
(A): 09922M76340
(B): 09913M80113

IAP70A520031-01

[A]: Section [a] – [a]

12) Press-fit 3rd gear (2) and spacer (1) using special
tools and hydraulic press. IFRA0B521014-01

NOTE Gear Shift Shaft Components

AENJHB0B5226022
It is recommended to press-fit spacer and 3rd
Refer to “Gear Shift Shaft Components”: K15B Model
gear first, and then 4th gear later separately
(Page 5B-39).
so that countershaft will not be compressed
excessively.
Gear Shift Shaft and Fork Inspection
AENJHB0B5226023
Special tool Refer to “Gear Shift Shaft and Fork Inspection”: K15B
(A): 09922M76340 Model (Page 5B-39).
(B): 09913M85210
Differential Components
AENJHB0B5226024
Refer to “Differential Components”: K15B Model (Page
5B-40).

Differential Disassembly and Reassembly

AENJHB0B5226025
Refer to “Differential Disassembly and Reassembly”:
K15B Model (Page 5B-40).

I4RH01520036-01

3. 2nd gear

Specifications
Tightening Torque Specifications
AENJHB0B5227001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Transaxle oil level / filler plug (Page 5B-53) /
21 2.1 15.5
(Page 5B-53)
Transaxle oil drain plug 21 2.1 15.5 (Page 5B-53)
Back up light switch 19 1.9 14.0 (Page 5B-56)
 Manual Transmission/Transaxle: D13A Model 5B-81

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Gear shift guide case No.1 bolt 23 2.3 17.0 (Page 5B-60)
Gear shift guide case No.2 bolt 23 2.3 17.0 (Page 5B-60)
Gear shift interlock bolt 23 2.3 17.0 (Page 5B-61)
Countershaft nut 100 10.2 74.0 (Page 5B-65)
5th gear shift fork bolt 10 1.0 7.5 (Page 5B-66)
Input shaft nut 100 10.2 74.0 (Page 5B-66)
Side cover bolt 10 1.0 7.5 (Page 5B-67)
Reverse gear shift lever bolt 23 2.3 17.0 (Page 5B-69)
Transaxle case bolt 23 2.3 17.0 (Page 5B-69)
Reverse gear shaft bolt 23 2.3 17.0 (Page 5B-69)
Left case plate bolt (Page 5B-70) /
31 3.2 23.0
(Page 5B-71)
Oil gutter bolt 10 1.0 7.5 (Page 5B-73)
Breather cover plate bolt 10 1.0 7.5 (Page 5B-73)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Gear Shift Control Lever and Cable Components”: D13A Model (Page 5B-55)
“Manual Transaxle Unit Components”: D13A Model (Page 5B-57)
“Gear Shift and Select Shaft Assembly Components”: D13A Model (Page 5B-59)
“Manual Transaxle Assembly Components”: D13A Model (Page 5B-62)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Recommended Service Material
AENJHB0B5228001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 (Page 5B-54) / (Page
5B-72)
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 (Page 5B-53) / (Page
5B-53) / (Page 5B-53) /
(Page 5B-60) / (Page
5B-66) / (Page 5B-69)

NOTE
Required service material(s) is also described in:
“Gear Shift Control Lever and Cable Components”: D13A Model (Page 5B-55)
“Gear Shift and Select Shaft Assembly Components”: D13A Model (Page 5B-59)
“Manual Transaxle Assembly Components”: D13A Model (Page 5B-62)

Special Tool
AENJHB0B5228002
09912M34510 09913M50121
Case separator Oil seal remover
(Page 5B-67) (Page 5B-54)
5B-82 Manual Transmission/Transaxle: D13A Model

09913M70123 09913M75821
Bearing installer Bearing installer attachment
(Page 5B-68) / (Page 5B-72)
(Page 5B-70)

09913M80113 09913M84510
Bearing installer Bearing installer
(Page 5B-76) / (Page 5B-72)
(Page 5B-77) /
(Page 5B-80)

09913M85210 09921M26010
Bearing installer Bearing outer race remover
collar
(Page 5B-79) / (Page 5B-73)
(Page 5B-80)

09921M96510 09922M59420
Oil pan seal cutter Installer handle
(Page 5B-63) (Page 5B-76)

09922M76340 09924M07710
Bevel pinion rear collar Synchronizer hub installer
(Page 5B-79) / (Page 5B-79)
(Page 5B-80) /
(Page 5B-80)

09924M74510 09924M84510M004
Bearing and oil seal handle Bearing installer attachment
(Page 5B-54) / (Page 5B-72)
(Page 5B-72) /
(Page 5B-74)

09925M14520 09927M76060
Bearing and oil seal installer Gear holder
(80 x 50 mm)
(Page 5B-72) / (Page 5B-64) /
(Page 5B-74) (Page 5B-65)

09930M30104 09940M54910
Sliding shaft Front fork oil seal install
driver
(Page 5B-72) (Page 5B-79)
 Manual Transmission/Transaxle: D13A Model 5B-83

09941M64511 09941M74910
Bearing and oil seal remover Steering stem bearing
(30 mm min.) remover and installer
(Page 5B-72) (Page 5B-79)

09942M15511 09944M66010
Sliding hammer Oil seal installer
(Page 5B-73) (Page 5B-54)

09944M88220 09944M96013
Oil seal installer Bearing outer race remover
(Page 5B-54) (Page 5B-73)
5C-1 Clutch:

Clutch
Transmission / Transaxle

General Description
Clutch Construction
AENJHB0B5301001
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.
The clutch cover is secured to the flywheel, and carries
the diaphragm spring in such a way that the peripheral
edge part of the spring pushes on the pressure plate
against the flywheel (with the disc in between), when the
clutch release bearing (incorporated in clutch operating
cylinder assembly) is held back. This is the engaged
condition of the clutch.
Depressing the clutch pedal causes the release bearing
(incorporated in clutch operating cylinder assembly) to
advance and pushes on the tips of the tapered fingers of
the diaphragm spring. When this happens, the drive
straps (connecting clutch cover and pressure plate) pull
the pressure plate away from the flywheel, thereby
interrupting the flow of drive from flywheel through clutch
disc to transaxle input shaft. Clutch fluid is supplied from
brake fluid reservoir. Clutch fluid level can be checked by
brake fluid level of brake fluid reservoir.

IHSB0A530001-01

1. Crankshaft 5. Clutch cover

2. Flywheel 6. Diaphragm spring
3. Clutch disc 7. Clutch operating cylinder assembly
4. Pressure plate 8. Input shaft

Diagnostic Information and Procedures
Clutch System Symptom Diagnosis
Condition Possible cause
Slipping Improper clutch pedal free travel
Worn or oily clutch disc facing
Warped disc, pressure plate or flywheel Replace clutch disc, cover or flywheel.
surface
Weakened diaphragm spring
Master cylinder piston or seal cup not Replace clutch master cylinder. (Page 5C-7)
returning
Dragging clutch Improper clutch pedal free travel
Weakened diaphragm spring or worn
spring tip
Rusted input shaft spline
Damaged or worn spline of transaxle
input shaft
Excessively wobbly clutch disc
Broken clutch facing or dirty clutch
facing with oil
Fluid leakage
Clutch vibration Glazed (glass-like) clutch facings
Dirty clutch facing with oil
Release bearing does not slide
smoothly
Wobbly clutch disc or poor facing
contact
Weakened torsion springs in clutch disc Replace clutch disc. (Page 5C-11)
Clutch disc rivets loose
Distorted pressure plate or flywheel
surface
Weakened engine mounting or loosened Replace engine mounting or retighten engine
engine mounting bolt(s) / nut(s)
Clutch: 5C-2
AENJHB0B5304001
Correction / Reference Item
Replace clutch pedal arm and/or clutch master
cylinder.
• Clutch pedal arm: (Page 5C-10)
• Clutch master cylinder: (Page 5C-7)
Replace clutch disc. (Page 5C-11)
• Clutch disk and cover: (Page 5C-11)
• Flywheel
– K15B model: (Page 1D-37)
– D13A model: (Page 1D-105)
Replace clutch cover. (Page 5C-11)
Replace clutch pedal arm and/or clutch master
cylinder.
• Clutch pedal arm: (Page 5C-10)
• Clutch master cylinder: (Page 5C-7)
Replace clutch cover. (Page 5C-11)
Lubricate clutch disc spline.
Replace input shaft.
• K15B model: (Page 5B-33)
• D13A model: (Page 5B-74)
Replace clutch disc. (Page 5C-11)
Replace clutch disc. (Page 5C-11)
Repair or replace clutch system.
Repair or replace clutch disc. (Page 5C-11)
Replace clutch disc. (Page 5C-11)
Replace clutch operating cylinder assembly.
(Page 5C-8)
Replace clutch disc. (Page 5C-11)
Replace clutch disc. (Page 5C-11)
Replace clutch cover or flywheel.
• Clutch cover: (Page 5C-11)
• Flywheel
– K15B model: (Page 1D-37)
– D13A model: (Page 1D-105)
mounting bolts / nuts.
• K15B model: (Page 1D-26)
• D13A model: (Page 1D-98)
5C-3 Clutch:

Condition Possible cause Correction / Reference Item

Noisy clutch Worn or broken release bearing Replace clutch operating cylinder assembly.
(Page 5C-8)
Input shaft right bearing worn down Replace input shaft right bearing.
• K15B model: (Page 5B-33)
• D13A model: (Page 5B-74)
Excessive rattle of clutch disc hub Replace clutch disc. (Page 5C-11)
Cracked clutch disc Replace clutch disc. (Page 5C-11)
Rattle of pressure plate and diaphragm Replace clutch cover. (Page 5C-11)
spring
Grabbing clutch Clutch disc facings soaked with oil Replace clutch disc. (Page 5C-11)
Clutch disc facing excessively worn Replace clutch disc. (Page 5C-11)
Rivet heads protrude from clutch disc Replace clutch disc. (Page 5C-11)
facing surface
Weakened torsion springs Replace clutch disc. (Page 5C-11)

Repair Instructions
CPP No.1 Switch Removal and Installation
AENJHB0B5306001
Removal
1) Remove steering column. (Page 6B-8)
2) Disconnect connector of CPP No.1 switch (1).
3) Remove CPP No.1 switch from clutch pedal bracket.
1
CPP No.1 Switch Inspection and Adjustment
AENJHB0B5306002
Inspection
Measure resistance between terminals under each
condition below. If check result is not as specified,
replace switch.
CPP No.1 switch resistance
When switch shaft is pushed [A]: Continuity exists
When switch shaft is free [B]: No continuity

IFRA0A532001-01

Installation
1) Install CPP No.1 switch to clutch pedal bracket.
2) Adjust switch position. (Page 5C-3)
3) Connect connector to CPP No.1 switch securely.
4) Install steering column. (Page 6B-8)
I5JB0AA10009-01
Adjustment
With clutch pedal (1) depressed, adjust switch (2)
position so that clearance “a” between end of thread and
clutch pedal arm is within specification. Then tighten lock
nut to specified torque.
 Clutch: 5C-4

Clearance between end of thread and clutch pedal CPP No.2 Switch Inspection and Adjustment
arm AENJHB0B5306004

“a”: 3.0 – 4.0 mm (0.118 – 0.157 in.)

Inspection
Tightening torque Measure resistance between terminals under each
CPP No.1 switch lock nut (a): 7.5 N·m (0.76 kgf-m, condition below. If check result is not as specified,
5.5 lbf-ft) replace switch.
CPP No.2 switch resistance
(a) When switch shaft is pushed [A]: No continuity
When switch shaft is free [B]: Continuity exists
“a”
2

IGSB0A530001-01
I5JB0AA10009-01

CPP No.2 Switch Removal and Installation

AENJHB0B5306003
Removal
1) Remove steering column. (Page 6B-8)
2) Disconnect connector of CPP No.2 switch (1).
3) Remove CPP No.2 switch from clutch pedal bracket.
1 Tightening torque
Adjustment
With clutch pedal (1) pulled toward driver’s seat, adjust
switch (2) position so that clearance “a” between end of
thread and clutch pedal arm is within specification. Then
tighten lock nut to specified torque.
Clearance between end of thread and clutch pedal
arm
“a”: 1.0 – 2.0 mm (0.039 – 0.078 in.)
CPP No.2 switch lock nut (a): 7.5 N·m (0.76 kgf-m,
5.5 lbf-ft)

(a)

“a”

IFRA0A532003-01

1
Installation
1) Install CPP No.2 switch to clutch pedal bracket.
2) Adjust switch position. (Page 5C-4)
3) Connect connector to CPP No.2 switch securely.
IGSB0A530002-01
4) Install steering column. (Page 6B-8)
5C-5 Clutch:

Clutch Pedal Inspection Upon completion of above inspection, start engine

AENJHB0B5306005 and check clutch for proper operation.
Clutch Pedal Height
Measure distance between free position (1) and fully Clutch release margin
depressed position (2) on clutch pedal which is shown “b”: 20 – 40 mm (0.78 – 1.57 in.)
by “a” in figure. If clutch pedal height is out of
specification, replace pedal arm and/or clutch master
cylinder (3).
Clutch pedal height
“a”: 135 mm (5.31 in.)

3
2
4 1

3
1 5 “a”
2 “b”

IHSB0A530009-01

Clutch Fluid Level Inspection

“a”
IHSB0A530008-01
Clutch Pedal Free Travel
Depress clutch pedal (1), stop it when clutch resistance
is felt, and measure how much pedal has moved (clutch
pedal free travel) as represented by “a” in the figure.
If “a” is not within specification, check pedal arm (2) and
master cylinder (3) and replace defective part.
Clutch pedal free travel “a”
: MAX. 10 mm (0.39 in.)
Clutch Release Margin
1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral
gear position.
3) Without clutch pedal depressed, slightly push the
shift lever to reverse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress
clutch pedal, and at gear contact noise died position
(release point) stop depressing.
5) Measure distance between release point (4) and full
stroke point (5) on clutch pedal which is shown by “b”
in the figure.
If “b” is not within specification, it is possible that air
is trapped in this system. If suspected so, bleed air.
(Page 5C-5)
AENJHB0B5306006
1) Check clutch system for crack, damage and fluid
leakage.
If any defect is found, repair or replace.
2) Check fluid level. (Page 4A-4)
Clutch fluid specification
: Refer to brake fluid reservoir cap.
Air Bleeding of Clutch System
AENJHB0B5306007
NOTICE
• Brake fluid is extremely damaging to
painted surfaces.
If brake fluid contacts painted surfaces,
immediately wipe it off and flush the
surfaces with water thoroughly.
• If the clutch pedal is pumped continuously
to bleed the clutch system, the oil seal of
the operating cylinder may be damaged,
resulting in fluid leakage.
After releasing the clutch pedal, wait at
least 1 second before depressing it again.
Bleed hydraulic clutch system of air as follows whenever
air enters hydraulic clutch system.
1) Fill master cylinder reservoir with brake fluid and
keep the reservoir at least one-half full of fluid during
bleeding operation.
Clutch fluid specification
: Refer to brake fluid reservoir cap.
 Clutch: 5C-6

2) Remove bleeder plug cap. Attach a vinyl tube (1) to 4) When fluid pressure in cylinder is completely
bleeder plug, and insert the other end into container released, retighten bleeder plug.
(2). 5) Repeat Step 3) – 4) until there are no more air
3) Depress clutch pedal several times, and then while bubbles in hydraulic line.
holding it depressed, loosen bleeder plug (3) about 6) When air bubbles disappear from fluid flowing into
one-half a turn. container, hold clutch pedal depressed, and tighten
bleeder plug until the lock clicks.
7) Attach bleeder plug cap.
8) After completing bleeding operation, apply fluid
3 pressure to clutch line and check for leakage.
9) Replenish master cylinder reservoir with fluid up to
specified level.
10) Check clutch pedal for operation. If spongy condition
is felt, repeat entire procedure of bleeding.

IFRA0A532005-01

Clutch Fluid Pipe and Hose Components

AENJHB0B5306008

(b)

1 Si
4

2
6
3

(a) 6

IJHA0A530001-01

1. Clutch master cylinder 4. Brake master cylinder reservoir 7. Clutch pipe joint
: Apply grease 99000-25100 to push rod tip.
2. Clutch fluid pipe 5. Clutch operating cylinder assembly : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
3. Clutch reservoir hose 6. Clamp : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
5C-7 Clutch:

Clutch Fluid Pipe Removal and Installation Installation

AENJHB0B5306009 Reverse removal procedure noting the following points.
NOTICE
• Install each clamp securely.
Brake fluid is extremely damaging to painted
• After installation, bleed air from clutch system.
surfaces.
(Page 5C-5)
If brake fluid contacts painted surfaces,
immediately wipe it off and flush the surfaces • After installation, check clutch pedal free travel.
with water thoroughly. (Page 5C-5)
• Check fluid leakage.
Removal • Add fluid to MAX level of reservoir.
1) Remove dust and dirt from each joint of pipe to be
disconnected and clean around brake master Clutch Fluid Pipe and Hose Inspection
cylinder reservoir cap. AENJHB0B5306010

2) Remove air cleaner assembly.
• K15B model: (Page 1D-9)
• D13A model: (Page 1D-82)
3) For K15B model, remove ECM. (Page 1C-2)
4) For D13A model, remove engine assembly.(Page
1D-99)
5) Remove battery and battery tray.
• K15B model: (Page 1J-5)
6) Take out fluid from brake master cylinder reservoir
with syringe or the like.
7) Remove clutch fluid pipe (2) as follows.
a) Pull out clamp (1) of clutch master cylinder (3).
b) Pull out clamp (5) of pipe joint (4).
Check clutch fluid pipe and hose for damage, abrasions
and leakage. If check result is not OK, replace clutch
fluid pipe and hose.
Clutch Master Cylinder Removal and
Installation
AENJHB0B5306011
Removal
1) Clean around brake master cylinder reservoir cap
and take out fluid from brake master cylinder
reservoir with syringe or the like.
2) Disconnect clutch fluid pipe from clutch master
cylinder. (Page 5C-7)
3) Disconnect clutch reservoir hose (1).

1 IJHA0A530003-01

4) Remove clutch pedal assembly. (Page 5C-10)

IJHA0A530002-01
5) Remove clutch master cylinder.

Installation
Reverse removal procedure noting the following points.
2 • Apply grease to push rod tip.
4

“A”: Grease 99000–25100 (SUZUKI Silicone

Grease)
5

“A”

IFRA0A532008-01

IGSB0A530019-01
 Clutch: 5C-8

• Install each clamp securely. Installation

• After installation, bleed air from clutch system.
(Page 5C-5)
• After installation, check clutch pedal free travel.
(Page 5C-5)
Clutch Master Cylinder Inspection
AENJHB0B5306012
Check clutch master cylinder for damage and leakage.
Replace clutch master cylinder if defective.
1) Install clutch operating cylinder assembly (1) to
transaxle. Tighten mounting bolts to specified torque.
Tightening torque
Clutch operating cylinder assembly mounting
bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
2) Connect fluid pipe joint (2) to clutch operating
cylinder assembly and install clamp (3).

Clutch Operating Cylinder Assembly Removal

and Installation
AENJHB0B5306013
2
NOTICE
• Brake fluid is extremely damaging to
painted surfaces.
If brake fluid contacts painted surfaces, 3
immediately wipe it off and flush the
surfaces with water thoroughly.
• The clutch operating cylinder may lose its
original performance if it is disassembled
and reassembled.
Do not disassemble and repair the clutch
operating cylinder.
1
(a)
Removal
1) Clean around brake master cylinder reservoir cap
and take out fluid from brake master cylinder
reservoir with syringe or the like. IDL10A530013-01

2) Dismount transaxle assembly. 3) Remount transaxle assembly.

• K15B model: (Page 5B-15) • K15B model: (Page 5B-15)
• D13A model: (Page 5B-58) • D13A model: (Page 5B-58)
3) Pull out clamp (1) of clutch operating cylinder and 4) Bleed clutch system and check clutch pedal free
disconnect fluid pipe joint (2). travel.
4) Remove clutch operating cylinder assembly (3). • Bleed air clutch system: (Page 5C-5)
• Clutch pedal free travel: (Page 5C-5)

Clutch Operating Cylinder Assembly Inspection

AENJHB0B5306014
2
NOTICE
If the clutch operating cylinder is washed, the
grease contained within the bearing of clutch
operating cylinder may be washed away,
1
causing the bearing to seize up.
Do not wash the clutch operating cylinder.

Check clutch fluid leakage, spring for damage and

bearing for smooth rotation. If malfunction is found,
replace clutch operating cylinder assembly.

IDL10A530012-01
5C-9 Clutch:

Clutch Pedal Assembly Components

AENJHB0B5306015

10, “2” (a) 8

9
1

(c)

(c)

6
6

(b)

2 E
3

2 E
6 Si
7 E

10, “1” (a)

10, “1” (a)

IJHB0A531001-01

1. Clutch pedal bracket 6. Cushion : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)

2. Pedal boss bushing 7. Spring : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: Apply grease 99000-25050 to all surfaces : Apply grease 99000-25050 to all surface
of bushings. of spring.
3. Clutch pedal shaft spacer 8. CPP No.1 switch : 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)
4. Clutch pedal 9. CPP No.2 switch
: Apply grease 99000-25100 to all surface
of pin.
5. Clutch pedal pad 10. Clutch pedal nut
: For tightening order, refer to “Clutch Pedal
Assembly Removal and Installation” (Page
5C-10).
 Clutch: 5C-10

Clutch Pedal Assembly Removal and Installation

AENJHB0B5306016
Removal • Apply grease to push rod tip.
1) Remove steering column. (Page 6B-8) “A”: Grease 99000–25100 (SUZUKI Silicone
2) Disconnect CPP No.1 switch connector. Grease)
3) Disconnect CPP No.2 switch connector.
1, “2”, (a)
4) Remove push rod (5) from clutch pedal. (Page 5C-
7)
5) Disconnect harness clamps (1).
6) Remove clutch master cylinder bolts (2).
7) Remove clutch pedal nuts (3), and then remove
clutch pedal assembly (4).

3 “A”

2, (b)

1, “1”, (a)
4

1 1, “1”, (a)

IJHA0A530006-01
5

Clutch Cover and Clutch Disc Components

AENJHB0B5306017
2

IJHA0A530005-01

8) Remove CPP No.1 switch, if necessary. (Page 5C-

3)
9) Remove CPP No.2 switch, if necessary. (Page 5C-
4)

Installation 3 (a)
Reverse removal procedure noting the following points.
• Tighten clutch pedal nut in (1) numerical order (“1” –
“2”) to specified torque. 1

Tightening torque 2
IGRA0B531002-01
Clutch pedal nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf-ft)
1. Clutch cover 3. Clutch cover bolt
• Tighten clutch master cylinder bolts (2) to specified : For tightening order, refer to
“Clutch Cover and Clutch Disc
torque. Removal and Installation” (Page
5C-11).
Tightening torque 2. Clutch disc : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
Clutch master cylinder bolt (b): 23 N·m (2.3 kgf-
m, 17.0 lbf-ft)
5C-11 Clutch:

Clutch Cover and Clutch Disc Removal and Tightening torque

Installation Clutch cover bolt (a): 23 N·m (2.3 kgf-m, 17.0
AENJHB0B5306018 lbf-ft)

Removal 4, “4”, (a)

1) Dismount manual transaxle.
• K15B model: (Page 5B-15) 3, “2”, (a)
1
• D13A model: (Page 5B-58)
2) Hold flywheel with special tool and remove clutch 3, “1”, (a)
cover (1) and clutch disc. (B)

Special tool
4, “5”, (a)
(A): 09924M17811 2

(A)

4, “6”, (a)

3, “3”, (a)
IGSB0A530018-01

4) Apply a light coating of grease to clutch disc spline.

I7V20A532013-01
NOTE
When installing a new clutch disc,
Installation application of grease is not required.
NOTE “A”: Grease 99000–25210 (SUZUKI Super
Before assembling, check the following Grease I)
items.
• Contact surfaces of flywheel, pressure
plate and clutch disk are clean and dry.
• Old grease and dust are removed from
input shaft and clutch disk hub spline.
“A”

1) Hold flywheel with special tool (A).

2) Align clutch disc with crankshaft center using special
tool (B) and install clutch cover (1).
3) Install and tighten clutch cover bolts using the
following procedure:
a) Tighten 3 bolts (3) by hand.
b) Tighten other bolts (4) evenly and gradually to
5.0 Nm (0.51 kgf-m, 4.0 lbf-ft).
c) Fully tighten all bolts evenly and gradually to
specified torque in numerical order (“1” – “6”)
starting from bolt nearby strap plate rivet (2).

NOTE IJHA0A530007-01

For centering of clutch disc spline, tighten 5) Join manual transaxle with engine.
clutch cover bolts while pushing clutch disc • K15B model: (Page 5B-15)
with special tool. • D13A model: (Page 5B-58)
Special tool NOTE
(A): 09924M17811 When inserting transaxle input shaft to clutch
(B): 09923M36320 disc, turn crankshaft little by little to match
the splines.
 Clutch: 5C-12

Clutch Cover and Clutch Disc Inspection

AENJHB0B5306019

Clutch Disc
At clutch cover side of clutch disc, measure depth “a” of
rivet head depression, i.e. distance between rivet head
and facing surface.
If depression is found to have reached service limit at
any of rivet holes, replace clutch disc.
I4RS0B540166-03
Rivet head depth
Model Standard Limit Clutch Cover
1.35 mm 0.50 mm Check clutch cover as follows.
K15B model
Clutch (0.053 in.) (0.019 in.) • Check diaphragm spring (1) for abnormal wear or
cover side 0.80 mm 0 mm damage.
D13A model
(0.031 in.) (0 in.)
• Check pressure plate (2) for wear or heat spots.
1.15 mm 0.30 mm
K15B model
Flywheel (0.045 in.) (0.011 in.)
side 0.90 mm 0 mm
D13A model
(0.035 in.) (0 in.)

I3RM0A530015-01

Specifications
Tightening Torque Specifications
AENJHB0B5307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
CPP No.1 switch lock nut 7.5 0.76 5.5 (Page 5C-4)
CPP No.2 switch lock nut 7.5 0.76 5.5 (Page 5C-4)
Clutch operating cylinder assembly mounting (Page 5C-8)
10 1.0 7.5
bolt
Clutch pedal nut 13 1.3 9.5 (Page 5C-10)
Clutch master cylinder bolt 23 2.3 17.0 (Page 5C-10)
Clutch cover bolt 23 2.3 17.0 (Page 5C-11)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Clutch Fluid Pipe and Hose Components” (Page 5C-6)
“Clutch Pedal Assembly Components” (Page 5C-9)
“Clutch Cover and Clutch Disc Components” (Page 5C-10)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Recommended Service Material
AENJHB0B5308001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Silicone Grease P/No.: 99000–25100 (Page 5C-7) / (Page 5C-
10)
SUZUKI Super Grease I P/No.: 99000–25210 (Page 5C-11)
5C-13 Clutch:

NOTE
Required service material(s) is also described in:
“Clutch Fluid Pipe and Hose Components” (Page 5C-6)
“Clutch Pedal Assembly Components” (Page 5C-9)

Special Tool
AENJHB0B5308002
09923M36320 09924M17811
Clutch center guide (15 mm) Flywheel holder
(Page 5C-11) (Page 5C-11) /
(Page 5C-11)

Section 6
Steering
CONTENTS
Precautions .................................................6-1
Precautions............................................................. 6-1
Precautions for Steering ....................................... 6-1
Steering General Diagnosis.................... 6A-1
Precautions...........................................................6A-1
Precautions for Steering General Diagnosis ....... 6A-1
Diagnostic Information and Procedures............6A-1
Steering Symptom Diagnosis.............................. 6A-1
Steering Wheel and Column................... 6B-1
Precautions...........................................................6B-1
Precautions for Steering Wheel and Column ...... 6B-1
General Description .............................................6B-1
Steering Wheel and Column Construction .......... 6B-1
Diagnostic Information and Procedures............6B-1
Checking Steering Column for Accident
Damage ............................................................ 6B-1
Repair Instructions ..............................................6B-2
Steering Wheel and Column Components.......... 6B-2
Steering Wheel Removal and Installation ........... 6B-3
Contact Coil Assembly Removal and
Installation ......................................................... 6B-4
Centering of Contact Coil Assembly ................... 6B-6
Contact Coil Assembly Inspection....................... 6B-6
Steering Angle Sensor On-Vehicle Inspection .... 6B-6
Steering Angle Sensor Removal and
Installation ......................................................... 6B-7
Steering Angle Sensor Inspection....................... 6B-7
Steering Column Removal and Installation ......... 6B-8
Steering Shaft Joint On-Vehicle Inspection ...... 6B-10
Steering Column Inspection .............................. 6B-10
Steering Lower Shaft Inspection ....................... 6B-11
Steering Lock Removal and Installation............ 6B-11
Steering Lock Disassembly and Reassembly
(Ignition Switch Model).................................... 6B-12
Steering Lock Inspection (Ignition Switch
Model) ............................................................. 6B-12
Auto Steering Lock Inspection (Keyless Push
Start Model) .................................................... 6B-13
Ignition Switch Removal and Installation
(Ignition Switch Model).................................... 6B-13
Ignition Switch Inspection (Ignition Switch
Model) ............................................................. 6B-14
Table of Contents 6- i
Steering Lower Shaft Removal and
Installation .......................................................6B-14
Steering Gear Case Assembly Components ....6B-16
Tie-Rod End Boot On-Vehicle Inspection .........6B-17
Tie-Rod End Removal and Installation..............6B-17
Tie-Rod End Inspection.....................................6B-18
Steering Gear Case Assembly Removal and
Installation .......................................................6B-18
Steering Rack Boot Inspection..........................6B-19
Tie-Rod / Rack Boot Removal and Installation ..6B-19
Pinion Shaft Rotation Torque Inspection...........6B-21
Pinion Shaft Rotation Torque Adjustment .........6B-21
Specifications .....................................................6B-22
Tightening Torque Specifications......................6B-22
Special Tools and Equipment ...........................6B-22
Recommended Service Material .......................6B-22
Special Tool ......................................................6B-22
Power Assisted Steering System........... 6C-1 6
Precautions...........................................................6C-1
Precautions for Diagnosing Trouble....................6C-1
General Description .............................................6C-1
P/S System Description ......................................6C-1
Description of EPS System Component
Function ............................................................6C-2
P/S Control Module Input / Output Diagram........6C-5
OBD System Description ....................................6C-5
Description of Sensor Calibrating Condition .......6C-5
Schematic and Routing Diagram ........................6C-6
P/S System Diagram...........................................6C-6
Component Location ...........................................6C-7
Power Steering Control System Component
Location.............................................................6C-7
Diagnostic Information and Procedures ............6C-9
P/S System Check ..............................................6C-9
P/S Warning Light Check ..................................6C-12
DTC Check........................................................6C-12
DTC Clearance .................................................6C-13
DTC Table.........................................................6C-14
Fail-Safe Table..................................................6C-15
Scan Tool Data .................................................6C-16
Visual Inspection ...............................................6C-17
P/S System Symptom Diagnosis ......................6C-18
6-ii Table of Contents
P/S Warning Light Does Not Come ON with
Ignition “ON” before Engine Starts ..................6C-18
P/S Warning Light Remains ON Steady after
Engine Starts ..................................................6C-19
DTC C1111 / C1113 / C1114 / C1115 ..............6C-19
DTC C1131 .......................................................6C-21
DTC C1141 / C1142 / C1143 / C1145 / C1146 ..6C-22
DTC C1152 / C1154..........................................6C-23
DTC C1153 / C1155..........................................6C-24
DTC C1160 .......................................................6C-24
DTC C1161 / C1162 / C1166 ............................6C-25
DTC C1163 .......................................................6C-26
DTC C116A.......................................................6C-26
DTC C116B.......................................................6C-27
DTC C116C / C116D ........................................6C-28
DTC U0073 .......................................................6C-28
DTC U0100 .......................................................6C-28
DTC U0121 .......................................................6C-29
DTC U0126 .......................................................6C-29
DTC U0140 .......................................................6C-29
DTC U0155 .......................................................6C-29
DTC U1082 .......................................................6C-29
P/S Control Module Power Supply and
Ground Circuit Check......................................6C-29
Inspection of P/S Control Module and Its
Circuits ............................................................6C-30
Steering Wheel Play Check ..............................6C-32
Steering Force Check .......................................6C-32
Repair Instructions ............................................6C-33
Sensor Calibration.............................................6C-33
Torque Sensor and Its Circuit Inspection ..........6C-33
Special Tools and Equipment ...........................6C-35
Special Tool ......................................................6C-35
 Precautions: 6-1

Precautions
Steering

Precautions
Precautions for Steering
AENJHB0B6000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Caution for Fastener

Refer to “Caution for Fastener” in Section 00 (Page 00-5).

Warning for Air Bag

Refer to “Warning for Air Bag” in Section 00 (Page 00-7).

Warning for Vehicle Equipped with Supplemental Restraint (Air Bag) System
Refer to “Warning for Vehicle Equipped with Supplemental Restraint (Air Bag) System” in Section 00 (Page 00-7).

Reassembling Note for Wiring Harness

Observe “Reassembling Note for Wiring Harness” in Section 9A (Page 9A-142) whenever installing wiring harness.
Otherwise, electrical trouble may occur.

Warning for P/S System

Refer to “Warning for P/S System” in Section 00 (Page 00-6).
6A-1 Steering General Diagnosis:
Steering General Diagnosis
Steering
Precautions
Precautions for Steering General Diagnosis
Since the problems in steering involve several systems, such possibilities should be fully considered when diagnosing
a complaint. To avoid being misled by an unclear symptom, always perform the road test first. Proceed with the
following preliminary inspection and correct defects if any.
1) Check tires for proper pressure and uneven wear.
2) Hoist vehicle and check steering system for loose or damaged parts.
3) Spin front wheels. Check for out-of-round tires, out-of-balance tires, bent rims, loose and/or rough wheel bearings.
Diagnostic Information and Procedures
Steering Symptom Diagnosis
Condition Possible cause
Hard steering Insufficient tire pressure
Binding tie-rod end ball joint
Binding suspension arm ball joint
Binding steering column
Improper tooth contact between rack
and pinion
Malfunction of power steering system
Disturbed front wheel alignment
Too much play in steering Loose or rattle steering wheel
Worn wheel bearing(s)
Loose steering gear case bolt
Worn joint of steering column
Worn tie-rod end or tie-rod ball joint
Worn suspension arm joint
Improper tooth contact between rack
and pinion
Faulty steering gear case assembly
AENJHB0B6100001
AENJHB0B6104001
Correction / Reference Item
Adjust tire pressure.
Replace tie-rod end. (Page 6B-17)
Replace suspension arm. (Page 2B-8)
Replace steering column assembly. (Page
6B-8)
Check pinion shaft rotation torque or replace
steering gear case assembly.
• Pinion shaft rotation torque: (Page 6B-21)
• Steering gear case assembly: (Page 6B-
18)
Check and correct. (Page 6C-9)
Check and adjust front wheel alignment.
(Page 2B-2)
Check steering wheel play. (Page 6C-32)
Replace wheel bearing(s). (Page 3A-17)
Tighten steering gear case bolt. (Page 6B-
18)
Replace steering column assembly. (Page
6B-8)
Replace tie-rod end or tie-rod.
• Tie-rod end: (Page 6B-17)
• Tie-rod: (Page 6B-19)
Replace suspension arm. (Page 2B-8)
Check pinion shaft rotation torque or replace
steering gear case assembly.
• Pinion shaft rotation torque: (Page 6B-21)
• Steering gear case assembly: (Page 6B-
18)
Replace steering gear case assembly. (Page
6B-18)

Condition Possible cause
Poor return ability Insufficient tire pressure
Binding tie-rod end ball joint
Binding suspension arm joint
Binding steering column
Improper tooth contact between rack
and pinion
Malfunction of power steering system
Faulty steering gear case assembly
Disturbed front wheel alignment
Steering noise (Rattle or Broken or damaged wheel bearing(s)
chuckle) Worn tie-rod end or tie-rod ball joint Replace tie-rod end or tie-rod.
Loose steering gear case bolt
Improper tooth contact between rack
and pinion
Faulty steering column
Faulty steering gear case assembly
Wander or poor steering Mismatched tire or uneven tire pressure Replace or adjust tire pressure. (Page 2D-3)
stability Loose suspension arm joint and tie-rod Replace suspension arm or tie-rod end.
end
Faulty front strut assembly or mounting Replace front strut assembly or repair
Broken or sagging coil spring
Loose stabilizer bar
Improper tooth contact between rack
and pinion
Malfunction of power steering system
Faulty steering gear case assembly
Disturbed front wheel alignment
Steering General Diagnosis: 6A-2
Correction / Reference Item
Adjust tire pressure.
Replace tie-rod end. (Page 6B-17)
Replace suspension arm. (Page 2B-8)
Replace steering column. (Page 6B-8)
Check pinion shaft rotation torque or replace
steering gear case assembly.
• Pinion shaft rotation torque: (Page 6B-21)
• Steering gear case assembly: (Page 6B-
18)
Check and correct. (Page 6C-9)
Replace steering gear case assembly. (Page
6B-18)
Check and adjust front wheel alignment.
(Page 2B-2)
Replace wheel bearing(s). (Page 3A-17)
• Tie-rod end: (Page 6B-17)
• Tie-rod: (Page 6B-19)
Tighten steering gear case bolt. (Page 6B-
18)
Check pinion shaft rotation torque or replace
steering gear case assembly.
• Pinion shaft rotation torque: (Page 6B-21)
• Steering gear case assembly: (Page 6B-
18)
Replace steering column assembly. (Page
6B-8)
Replace steering gear case assembly. (Page
6B-18)
• Suspension arm: (Page 2B-8)
• Tie-rod end: (Page 6B-17)
mounting. (Page 2B-4)
Replace coil spring. (Page 2B-6)
Tighten or replace stabilizer bar or bushing.
(Page 2B-13)
Check pinion shaft rotation torque or replace
steering gear case assembly.
• Pinion shaft rotation torque: (Page 6B-21)
• Steering gear case assembly: (Page 6B-
18)
Check and correct. (Page 6C-9)
Replace steering gear case assembly. (Page
6B-18)
Check and adjust front wheel alignment.
(Page 2B-2)
6A-3 Steering General Diagnosis:

Condition Possible cause Correction / Reference Item

Erratic steering when Uneven tire pressure Adjust tire pressure.
braking Worn wheel bearing(s) Replace wheel bearing(s). (Page 3A-17)
Brakes not working in unison Check and repair brake system. (Page 4A-1)
Front brake disc stained with brake fluid Clean and check brake disc and caliper.
• Brake disc: (Page 4B-2)
• Brake caliper: (Page 4B-9)
Warped brake disc Replace brake disc. (Page 4B-4)
Badly worn brake pad Replace brake pad. (Page 4B-2)
Broken or sagging coil spring Replace coil spring. (Page 2B-6)
Faulty front strut assembly (shock Replace front strut assembly (shock absorber).
absorber) (Page 2B-6)
Disturbed front wheel alignment Check and adjust front wheel alignment.
(Page 2B-2)
Steering lock does not Faulty steering lock (ignition switch Check steering lock / auto steering lock.
operate (not locked or model) / auto steering lock (keyless • Steering lock: (Page 6B-12)
released) push start model)
• Auto steering lock: (Page 6B-13)
 Steering Wheel and Column: 6B-1

Steering Wheel and Column

Steering

Precautions
Precautions for Steering Wheel and Column
AENJHB0B6200001
For service precautions, refer to “Precautions for Handling and Storage of Air Bag System Components” in Section 8B
(Page 8B-1).

General Description
Steering Wheel and Column Construction
AENJHB0B6201001
• The steering column is of a collapsible tube type. The column contracts in the event of a heavy frontal collision to
absorb impact energy and thus helps reduce injuries to the driver. The steering column also has the following
features:
– The steering column is provided with a tilt adjustment mechanism. This mechanism allows step-less adjustment
of the whole steering column in up-and-down directions.
– The steering column incorporates a steering lock to help prevent theft. On the ignition switch model, the ignition
switch is installed on the steering column together with the steering lock.
When servicing the steering column, it is important that only the specified fasteners be used and they are tightened
exactly to the specified torques to keep the collapsible steering column and other features fully workable. It is also
important to carefully handle the steering column during and after its removal from the vehicle, such as preventing the
use of a steering wheel puller and avoiding hammering the end of the steering shaft, leaning the removed steering
column assembly against the wall or any other object, or dropping the assembly. These precautions should be
observed to prevent the capsules that keep the designed length and position of the steering column from being
loosened.
• The steering wheel has the driver air bag (inflator) module of the supplemental restraint (air bag) system installed at
the center. During service operations on the steering wheel, the air bag (inflator) module should be handled
carefully while observing all instructions in “Precautions for Air Bag System Service” in Section 8B (Page 8B-1) to
prevent accidental deployment.

Diagnostic Information and Procedures

Checking Steering Column for Accident Damage
AENJHB0B6204001
Refer to “Steering Column Inspection” (Page 6B-10).
6B-2 Steering Wheel and Column:

Repair Instructions
Steering Wheel and Column Components
AENJHB0B6206001

[B]
19 3

6 7

14 [A]
13
19
12 (b)

11 (b)

15
10 (c)

9 (c) 16

17

20

18 (a)

1
IJHB0A620001-01
 Steering Wheel and Column: 6B-3

[A]: Keyless push start model
[B]: Ignition switch model
1. Driver air bag (inflator) module
2. Steering wheel
3. Steering column upper cover
4. Steering column lower cover
5. Contact coil assembly
: Center contact coil cable assembly.
(Page 6B-6)
6. Steering column
7. Steering lower shaft
8. Steering column assembly
9. Steering column nut
: For tightening order, refer to “Steering
Column Removal and Installation” (Page
6B-8).
10. Steering column lower bolt
: For tightening order, refer to “Steering
Column Removal and Installation” (Page
6B-8).
11. Steering column joint bolt
: For tightening order, refer to “Steering
Lower Shaft Removal and Installation”
(Page 6B-14).
12. Steering lower shaft joint bolt
: For tightening order, refer to “Steering
Lower Shaft Removal and Installation”
(Page 6B-14).
13. Ignition switch
14. Steering lock
15. Ignition switch cylinder
16. Steering joint cover
17. Auto steering lock
18. Steering shaft nut
19. Steering lock bolt
: For tightening and loosening procedures of
steering lock bolt, refer to “Steering Lock
Removal and Installation” (Page 6B-11).
20. Steering angle sensor
: For installation, refer to “Steering Angle
Sensor Removal and Installation” (Page 6B-
7).
: 33 Nm (3.4 kgf-m, 24.5 lbf-ft)
: 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
: 14 Nm (1.4 kgf-m, 10.5 lbf-ft)
: Do not reuse.

Steering Wheel Removal and Installation 6) Remove steering shaft nut and then make alignment
AENJHB0B6206002 marks (1) across steering wheel and shaft for correct
NOTICE reinstallation.

• The coil in the contact coil assembly will

break if the contact coil is turned too
much.
Do not turn contact coil more than about
two and a half turns in either direction from
the neutral position.
• The impact energy absorbing function of
the steering column assembly may be
impaired if the steering column assembly
receives an excessively large force.
Be careful not to strongly impact the I4RS0A620005-01

steering column assembly when removing 7) Remove steering wheel using special tool.
and installing steering wheel.
Special tool
Removal (A): 09944M36011
1) Park vehicle on a level surface, apply parking brake,
set steering wheel in straight ahead position and set
ignition “OFF”.
2) Disconnect negative (–) cable at battery.
3) Disable air bag system. (Page 8B-48)
4) Remove driver air bag (inflator) module from
steering wheel. (Page 8B-50)
5) Disconnect steering switch connector (if equipped). (A)
IFRA0A620002-01
6B-4 Steering Wheel and Column:

Installation 3) Remove tapping screws (3), and then detach

steering column upper cover (4).
NOTICE
If the operations in Step 1) – 3) are omitted or 4
3
not performed as instructed, the contact coil
assembly will break when the steering wheel
is turned.
Perform Step 1) – 3) exactly as instructed.

1) Check that vehicle’s front wheels are at straight

ahead position.
2) If contact coil is turned after removing steering
wheel, center contact coil assembly. (Page 6B-6)
3) Install steering wheel to steering shaft with 2 grooves 2

(1) in contact coil assembly fitted on 2 lugs (2) on 1

back side of steering wheel, while aligning marks (3) I9P60A620004-02
on steering wheel and steering shaft each other. 4) Disconnect contact coil assembly connector (1) as
4) Tighten steering shaft nut (4) to specified torque. follows.
Tightening torque a) Release locking slider (2) by sliding it in arrow
Steering shaft nut (a): 33 N·m (3.4 kgf-m, 24.5 direction “1”.
lbf-ft) b) After unlocking, disconnect contact coil
assembly connector by pulling it in arrow
3 direction “2”.
Without steering switch

4,(a)
3

“1”
2 2

“2” 1
1
I9P60A620003-01

5) Connect steering switch connector (if equipped).

6) Install driver air bag (inflator) module to steering
IFKA0P620009-01
wheel. (Page 8B-50)
7) Connect negative (–) cable at battery.
With steering switch
8) Enable air bag system. (Page 8B-48)

Contact Coil Assembly Removal and

Installation 3
AENJHB0B6206003

NOTICE
The coil in the contact coil assembly will
break if the contact coil is turned too much. “2”
1
Do not turn the contact coil more than about
two and a half turns in either direction from “1”
the neutral position. 2

IFKA0P620010-01
Removal
3. Contact coil assembly
1) Remove steering wheel from steering column.
(Page 6B-3)
5) Disconnect horn connector (1) and steering angle
2) Remove standard screw (1), and then detach sensor connector (2).
steering column lower cover (2).
 Steering Wheel and Column: 6B-5

6) Release claws (3) and remove contact coil assembly 5) Connect steering angle sensor connector (4) to
(4). steering angle sensor (5).

3 3 5

2 1
1 2 4
IGSB0A620004-01
IFKA0P620011-01

7) Remove steering angle sensor from contact coil
assembly. (Page 6B-7)
Installation
1) Check that vehicle’s front wheels are in straight
ahead position.
2) Install steering angle sensor to contact coil
assembly. (Page 6B-7)
3) Install contact coil assembly (1) with steering angle
sensor to lighting switch securely.
6) Install steering column upper cover (4) with tapping
screws (3).
7) Install steering column lower cover (2) with standard
screw (1).
NOTICE
Lead wires will be damaged if they get
pinched when you install the covers.
Check that there is no wire caught between
the covers before securing the covers.

NOTE
4
New contact coil assembly is supplied with 3

contact coil set and held at its center position

with a lock pin (2). Remove this lock pin after
installing contact coil assembly to lighting
switch.

1
I9P60A620004-02

8) Install steering wheel to steering column. (Page

6B-3)
I9P60A620008-01

4) Connect contact coil assembly connector (1) and

horn connector (2) to contact coil assembly (3)
securely. Check that contact coil assembly connector
is locked.
6B-6 Steering Wheel and Column:

Centering of Contact Coil Assembly Contact Coil Assembly Inspection

AENJHB0B6206004 AENJHB0B6206005
1) Remove steering wheel. (Page 6B-3) Refer to “Contact Coil and Its Circuit Check” in Section
8B (Page 8B-44).
2) Check that ignition is “OFF”.
3) Turn contact coil counterclockwise slowly with a light
Steering Angle Sensor On-Vehicle Inspection
force till contact coil will not turn any further. AENJHB0B6206006

NOTE 1) Connect SUZUKI scan tool to DLC (1) with ignition

“OFF”.
Contact coil can turn about 5 turns at
maximum, that is, if it is at the center Special tool
position, it can turn about two and a half (A): SUZUKI scan tool (Suzuki SDT-II)
turns both clockwise and counterclockwise.

IDL10A620002-01

4) From the position of Step 3), turn contact coil

assembly clockwise to place connector (1) at top
position within one rotation.
5) Turn rotation part (2) two turns clockwise to place
connector at top position. Check that triangle mark
(4) on rotation part is aligned with that on stationary
part (3) and flat cable (6) is visible in hole (5) as (A)

shown in figure. IJHA0A110021-01

2) Set ignition “ON” and select “Data List” of SUZUKI

6 scan tool.
Refer to Operator’s Manual of SUZUKI scan tool for
5
further details.
1
3) Check “Steering Angle Sensor” under “Data List” of
SUZUKI scan tool in the following steering wheel
conditions.
• Front wheels are in straight ahead position.
• Rotate steering wheel once clockwise from
straight ahead position.
• Rotate steering wheel once counterclockwise
from straight ahead position.
2 Replace steering angle sensor if check result is not
as specified.

3
IDL10A620003-01
 Steering Wheel and Column: 6B-7

Steering angle specification Installation

Vehicle condition Steering angle Reverse removal procedure noting the following points.
Front wheels in straight ahead • Install steering angle sensor to contact coil after
0 ± 3°
position performing centering of contact coil assembly.
Rotate steering wheel once (Page 6B-6)
360 ± 3°
clockwise • Do not rotate rotor of removed steering angle sensor
Rotate steering wheel once (1) until steering angle sensor is reinstalled to contact
–360 ± 3°
counterclockwise coil (2).

NOTE
A new steering angle sensor is secured by a
lock pin. After installing new steering angle
sensor to contact coil, remove the lock pin
from the steering angle sensor.

• Fit wide groove (3) to wide projection (4) and narrow

groove (5) to narrow projection (6).

4
I6JB01460032-01 1
2 3

Steering Angle Sensor Removal and Installation

AENJHB0B6206007

NOTE
If you rotate the rotor of the steering angle
sensor with the sensor removed, DTC may be
set even though the steering angle sensor
status is normal.
5
Do not rotate the rotor when removing and 6
installing the steering angle sensor. IGRA0A620003-01

Removal Steering Angle Sensor Inspection

1) Remove steering wheel. (Page 6B-3) AENJHB0B6206008

2) Remove contact coil assembly. (Page 6B-4)
3) Remove steering angle sensor (1) from contact coil
assembly (2) while opening fitting engagement
hooks (3) of contact coil assembly.
1
• Check sensor for dents, crack or deformation.
• Check sensor connectors (sensor side and harness
side) and sensor connector lock mechanism for
damage.
• Check connector terminals for bend, corrosion or rust.
Replace steering angle sensor (1) if defective.

3
3

3 2
IGRA0A620002-01

IFRA0P460022-01
6B-8 Steering Wheel and Column:

Steering Column Removal and Installation 7) Disconnect P/S control module connectors (1).
AENJHB0B6206009

NOTICE
The steering column assembly can be easily
damaged during and after removal.
To avoid damaging the steering column 1
assembly, take the following precautions
when removing it and when setting it down
after removal:
• Do not release tilt lever with steering
column nuts loosened or steering column
removed from vehicle. Doing so may
increase operating force for tilt motion.
• The impact energy absorbing function of
IJHA0A620010-01
the steering column assembly may be
impaired if the steering column assembly 8) For keyless push start model, disconnect auto
receives an excessively large force. steering lock connector (1).
Be careful not to strongly impact the For ignition switch model, disconnect both key
steering column assembly when removing reminder switch connector (3) and ignition switch
and installing it. connector (4).
• Never drop the steering column assembly 9) Detach steering column harness clamps (2).
on its end. This could collapse the steering 10) Remove steering column nuts (5) and steering
shaft or loosen capsules that maintain the column lower bolt (6).
design length of the column. Ignition switch model
• Do not lean the steering column assembly
against something. This could cause it to
bend or deform.
• Do not loosen the steering column nuts
when the steering lower shaft is still 2

installed. This could cause damage to the

shaft joint bearing. 4 3

Removal
1) Remove contact coil assembly. (Page 6B-4)
2) For ignition switch model, remove immobilizer 5 5
control module from steering lock. (Page 10C-16)
3) Remove lighting switch and wiper switch. 2
• Lighting switch: (Page 9B-12)
• Wiper switch: (Page 9D-9)
6
4) Remove steering column hole cover. (Page 9C-35)
5) For A/T model with ignition switch, disconnect key
interlock cable from steering lock. (Page 5A-132)
IFRA0A620017-01
6) Remove steering lower shaft. (Page 6B-14)
 Steering Wheel and Column: 6B-9

Keyless push start model Ignition switch model

6
2

5 4

5 5 2, (b) 2, (b)

2 6

6 1, (a)

IFRA0A620018-01 IFRA0A620019-01

11) Remove steering column.

Keyless push start model
Installation

NOTICE
Tightening the fasteners in the wrong order
may cause damage to the steering shaft joint
of steering column. 6
Tighten the steering column lower bolt and
nuts in this order before installing the
steering lower shaft.
3

1) Check that vehicle’s front wheels are in straight

ahead position. 2, (b) 2, (b)

2) Install steering column.

3) Tighten steering column lower bolt (1) to specified 6
torque.
4) Tighten steering column nuts (2) to specified torque.
1, (a)
Tightening torque
Steering column lower bolt (a): 14 N·m (1.4 kgf-
m, 10.5 lbf-ft)
IFRA0A620020-01
Steering column nut (b): 14 N·m (1.4 kgf-m, 10.5
lbf-ft) 8) Connect P/S control module connectors (1).

5) Check that tilt function operates smoothly when the

lever is released, and the function are securely fixed
when lever is locked.
6) For keyless push start model, connect auto steering
1
lock connector (3).
For ignition switch model, connect both key reminder
switch connector (4) and ignition switch connector
(5).
7) Attach steering column harness clamps (6) in place.

IJHA0A620010-01
6B-10 Steering Wheel and Column:

9) Install steering lower shaft. (Page 6B-14) • Check steering column assembly for looseness in
10) For A/T model with ignition switch, connect key arrow directions [a] and [b] in figure with tilt lever
interlock cable to steering lock. (Page 5A-132) locked.
11) Install lighting switch and wiper switch.
• Lighting switch: (Page 9B-12)
• Wiper switch: (Page 9D-9)
12) For ignition switch model, install immobilizer control [a]

module to steering lock. (Page 10C-16)

[b]
13) Install contact coil assembly. (Page 6B-4)
14) Install steering column hole cover. (Page 9C-35)
15) Enable air bag system. (Page 8B-48)
IFRA0A620005-01

Steering Shaft Joint On-Vehicle Inspection • Check that distances “a”, “b” and “c” shown in figure
AENJHB0B6206010
are as specified.
Check steering shaft joint for wear, breakage and any
other damage. Replace steering column assembly with Power steering column length
new one if defective. “a”: 461.6 mm (18.17 in.)
“b”: 243.6 mm (9.590 in.)
“c”: 85.7 mm (3.374 in.)

“a”

I9P60A620041-01

Steering Column Inspection

AENJHB0B6206011

NOTE
Steering column assembly should be
checked if vehicle was involved in an
accident and steering column assembly was
exposed to impact or air bag deployed.

Perform the following checks if damage to steering “b”

column assembly is suspected. If check result is not OK,
replace steering column assembly with new one.
“c”
• Check that two capsules (1) are attached to steering
column bracket securely.
IFRA0A620006-01
1

IFRA0A620004-01
 Steering Wheel and Column: 6B-11

Steering Lower Shaft Inspection 3) Loosen steering lock bolt(s) (2) using chisel, and
AENJHB0B6206012 then remove auto steering lock (3) or steering lock
• Adjust distance “a” between yoke centers of steering (4) from steering column.
lower shaft bearing to 249.5 mm (9.822 in.).
• Then check that steering lower shaft retracts by 25 [A] [B]

mm (0.98 in.) and extends by 5 mm (0.19 in.) from

distance “a”. 4
1
1
3
[a]

[b]

2
1 IFRA0A620007-01
1
“a” [A]: Ignition switch model [B]: Keyless push start model
IAP70A620006-01

[a]: Retracts by 25 mm (0.98 in.) 1. Yoke Installation

[b]: Extends by 5 mm (0.19 in.) 1) For ignition switch model: Align oblong hole (2) in
steering shaft (3) with center of hole (1) in steering
• Check steering lower shaft for smooth rotation. column.
Turn ignition key to “LOCK” position and pull it out,
Steering Lock Removal and Installation and then align lug of steering lock with hole in
AENJHB0B6206013 steering shaft.
Removal

! WARNING
Steering lock is made of magnesium.
Drilling, cutting or filing the steering lock
3
may spark to ignite magnesium powder,
causing a fire or burn.
1
Do not perform drilling, cutting or filing
magnesium powder on the steering lock.
2
NOTICE
Failure to take the following precautions
when removing or installing the steering lock
can cause failure of the steering lock.
• Do not drop or otherwise expose the IFRA0A620008-01
steering lock to large shock. Any steering
lock that has received large shock should
be replaced.
• Keep the steering column and/or the
steering lock free of oil, water, dust or
other foreign materials.

1) Remove steering column (1). (Page 6B-8)

2) Hold steering column using vise.
6B-12 Steering Wheel and Column:

2) For ignition switch model: Install steering lock to Steering Lock Disassembly and Reassembly
steering shaft with key cylinder (1) toward steering (Ignition Switch Model)
wheel. AENJHB0B6206014

For keyless push start model: Install auto steering NOTE

lock with the column cover mounting screw hole (2)
toward P/S motor side. Ignition switch and ignition switch cylinder
can be replaced without removing steering
lock.
[A]
1
When removing steering lock, refer to
“Steering Lock Removal and Installation”
(Page 6B-11).
[a]
Disassembly
1) Remove ignition switch (1). (Page 6B-13)
2) Turn ignition key to “ACC”, and then push lock button
(4) on ignition switch cylinder using a rod (2) of about
2 mm (0.08 in) in diameter inserted through hole (3).
[B] 3) Pull out ignition switch cylinder (5) from steering lock
(6).

[b] 1

2
IFRA0A620009-01

[A]: Ignition switch model [a]: Steering wheel side

[B]: Keyless push start model [b]: P/S motor side 3

3) Tighten new steering lock bolts (1) until head of each

bolt is broken off.

5
I9P60A620032-02

Reassembly
IFRA0A620010-01
Reverse removal procedure noting the following points.
4) Install steering column. (Page 6B-8)
• Turn ignition key to “ACC”, and then insert ignition
5) Set ignition to “ACC” or “ON” and check that steering switch cylinder into steering lock securely.
shaft rotates smoothly. Then set ignition to “LOCK”
• If ignition switch cylinder has been replaced, register
(“OFF”) (and pull out key for ignition switch model)
ignition key transponder code in BCM after completing
and check that steering wheel is locked.
installation. (Page 10B-57)
6) For ignition switch model: If ignition switch cylinder
has been replaced, register ignition key transponder
Steering Lock Inspection (Ignition Switch
code in BCM after completing installation. (Page
9F-14)
Model)
AENJHB0B6206015
7) Check steering column and torque sensor after Key Reminder Switch Inspection
installation. If faulty condition is found, replace 1) Disconnect key reminder switch connector (1) from
steering column. steering lock (2).
• Steering column: (Page 6B-10)
• Torque sensor: (Page 6C-33)
 Steering Wheel and Column: 6B-13

2) Check continuity between terminals of key reminder check auto steering lock wire harness for open or
switch connector. short and if auto steering lock wire harness is in
If check result is not as specified, replace steering good condition, replace auto steering lock (1).
lock. (Page 6B-11)

2 NOTE
*: Voltage can be checked only for a short
time while locking or releasing auto steering
lock.
1

Auto steering lock unit terminal voltage

Normal
Terminal Condition
voltage
2
• Any door opened or closed
1
10 – 14 V with ignition “OFF”*
1
• Ignition “OFF” → “ACC”*
I9P60A620033-05 0–1V Other than above condition
Key reminder switch continuity • Any door opened or closed
10 – 14 V with ignition “OFF”*
2
[A] • Ignition “OFF” → “ACC”*
1 2
[B] 0–1V Other than above condition
[C]
• Any door opened or closed
10 – 14 V with ignition “OFF”*
[D] 3
I9P60A620034-02 • Ignition “OFF” → “ACC”*
0–1V Other than above condition
[A]: Terminal [C]: Key inserted
[B]: Condition [D]: Key pulled out
4 0–1V Ignition is in any mode.
5 0–1V Ignition is in any mode.
Steering Lock Inspection
1) Insert ignition key (1). 1
2) Check lock shaft (2) for operation as follows.
a) Lock shaft moves in arrow direction “1”, when
turning ignition key to “ACC” or “ON”.
b) Lock shaft moves in arrow direction “2”, when
turning ignition key to “LOCK” and pulling out
ignition key.
If faulty condition is found, replace steering lock.

2
“2” “1”
1
[A]

[a]
654321

IDL10A620014-01

[A]: Connector “G146” (View: [a])

IAP70A620007-01

Ignition Switch Removal and Installation

Auto Steering Lock Inspection (Keyless Push (Ignition Switch Model)
Start Model) AENJHB0B6206017
AENJHB0B6206016 Removal
1) Remove steering column lower cover and steering 1) Disconnect negative (–) cable at battery.
column hole cover. 2) Remove steering column upper cover and lower
• Steering column lower cover: (Page 6B-2) cover. (Page 6B-2)
• Steering column hole cover: (Page 9C-35) 3) Check that ignition key is removed.
2) Measure voltage between terminals “1” – “5” and 4) Disconnect connector (1) from ignition switch (2).
ground respectively under conditions described in
the table below. If check result is not as specified,
6B-14 Steering Wheel and Column:

5) Remove screws (4), and then remove ignition switch Steering Lower Shaft Removal and Installation
from steering lock (3). AENJHB0B6206019

NOTICE
3
If the steering wheel is turned with the
2
steering lower shaft removed, the neutral
4 2
setting of the contact coil may be disturbed.
3 If it is turned in either direction more than
about two and a half turns, the contact coil
1 will break.
Never turn the steering wheel with the
steering lower shaft removed.

Removal
1) Turn steering wheel so that vehicle’s front wheels
I9P60A620036-06
are at straight ahead position.
Installation 2) Set ignition “LOCK”. For ignition switch model,
Reverse removal procedure. remove key.
3) Remove steering joint cover. (Page 6B-2)
Ignition Switch Inspection (Ignition Switch 4) Make matchmarks (1) on the following parts for
Model) correct reinstallation.
AENJHB0B6206018
Check for continuity between terminals at each switch • Steering lower shaft (2) with serrations and joint
position. If check result is not as specified, replace yoke (3) under steering column
ignition switch. • Lower joint yoke on steering lower shaft and
pinion shaft (4)

3 2 1 NOTE
Turn steering wheel a little for removal of
steering lower shaft joint bolt.
6 5 4

5) Remove steering column joint bolt (6) and steering

lower shaft joint bolt (5).
6) Remove steering lower shaft.

6
I9P60A620037-05 1
2
Ignition switch continuity
3

Terminal
1 2 3 4 5 6
Position
2
LOCK

ACC 1

5 4
ON

I9P60A620039-01

START

I9P60A620038-01
 Steering Wheel and Column: 6B-15

Installation 4) Install steering joint cover (1) as shown inserting left

end of the cover under floor carpet (2) through slit of
NOTICE the carpet.
• The steering lower shaft joint bolts are
precoated with friction stabilizer. If the
bolts are reused, they may work loose.
Never reuse the steering lower shaft joint
bolts. 1
2
• Insufficient insertion of shaft serrations
into joint yoke at upper side and lower side
of steering lower shaft spoils strength of
the connection.
Fully insert shaft serrations into joint
yokes.

1) Check that vehicle’s front wheels are in straight

ahead position. IFRA0B620002-01

2) Aligning matchmarks (4), insert steering lower shaft

(1) with serrations into joint yoke (2) under steering
column, and fit lower joint yoke on steering lower
shaft onto pinion shaft (3) fully.

NOTE
• Insert steering lower shaft joint bolt and
steering column joint bolt to each bolt hole
in joint yoke from the side without thread.
• Turn steering wheel a little for installation
of steering lower shaft joint bolt.

3) Tighten new steering lower shaft joint bolt and new

steering column joint bolt to specified torque in
numerical order (“1” – “2”) as shown in figure.
Tightening torque
Steering lower shaft joint bolt* (a): 35 N·m (3.6
kgf-m, 26.0 lbf-ft)
Steering column joint bolt* (b): 35 N·m (3.6 kgf-
m, 26.0 lbf-ft)

“2”, (b)

1
2

3
“1”, (a)
IJHB0A620002-01
6B-16 Steering Wheel and Column:

Steering Gear Case Assembly Components

AENJHB0B6206020

(c)

10

9
11 (d) (c)

8 (a)

(a)

1
5
7

6
E

3 (b)

4 2

E
2

3 (b) 5

[f]
(a) 9
4
8 (a)

6
7
IJHB0B620001-02

[f]: Forward 6. Rack boot clip : 45 Nm (4.6 kgf-m, 33.5 lbf-ft)
1. Steering gear case 7. Tie-rod end : 84 Nm (8.6 kgf-m, 62.0 lbf-ft)
2. Tie-rod lock washer 8. Tie-rod end nut : 80 Nm (8.2 kgf-m, 59.0 lbf-ft)
: For removing and installing procedure of
tie-rod lock washer, refer to “Tie-Rod / Rack
Boot Removal and Installation” (Page 6B-
19).
3. Tie-rod 9. Clip : 69 Nm (7.0 kgf-m, 51.0 lbf-ft)
4. Band 10. Steering gear packing : Do not reuse.
5. Boot 11. Steering rack damper screw lock nut : Apply grease 99000-25050.
 Steering Wheel and Column: 6B-17

Tie-Rod End Boot On-Vehicle Inspection 3) Disconnect tie-rod end (1) from steering knuckle (2)
AENJHB0B6206021 using special tool.
Check boot for crack and damage.
Replace tie-rod end, if defective. Special tool
(A): 09913M65210

(A)

I9P60A630016-01

IJHA0A620002-01
4) To facilitate adjustment after installation, make mark
(1) of tie-rod end lock nut (2) position on tie-rod end
thread. Then, loosen lock nut and remove tie-rod
Tie-Rod End Removal and Installation
AENJHB0B6206022 end (3) from tie-rod (4).

Removal
1) Hoist vehicle, and then remove front wheel. (Page
2D-3)
2) Remove clip (2) and tie-rod end nut (1) from tie-rod 2
end.

1 4

IDAA0A630014-01

Installation
1) Install tie-rod end lock nut (2) and tie-rod end (3) to
2
tie-rod (4). Align lock nut with mark (1) on tie-rod
thread.
1
IJHA0A620003-01

1 4

IDAA0A630014-01
6B-18 Steering Wheel and Column:

2) Connect tie-rod end to steering knuckle. Tighten tie- Steering Gear Case Assembly Removal and
rod end nut (1) to specified torque. Installation
AENJHB0B6206024
Tightening torque
Tie-rod end nut (a): 45 N·m (4.6 kgf-m, 33.5 lbf- NOTICE
ft) Failure to take proper precautions before
3) Install new clip (2). starting the procedure below can result in
damage to the contact coil of the air bag
system.
Before starting the procedure below, set the
front wheels in straight ahead position and
then lock the steering wheel by changing
ignition mode to “OFF” or removing ignition
key at “LOCK” position.

Removal
1) Remove front suspension frame with steering gear
case assembly. (Page 2B-13)
2 2) Remove steering gear packing (1) after detaching its
claws (3) from gear case.
3) Remove steering gear case bolts (4), and then
1, (a) remove steering gear case assembly (2) from front
IJHA0A620004-01
suspension frame.
4) Install front wheel. (Page 2D-3)
5) Check for toe. (Page 2B-2)
6) After checking that toe is as specified, tighten tie-rod
end lock nut to specified torque. 1

Tightening torque
Tie-rod end lock nut: 45 N·m (4.6 kgf-m, 33.5 lbf-
2
ft) 3

Tie-Rod End Inspection

AENJHB0B6206023 2

• Check tie-rod end ball joint for play.

• Check tie-rod ball joint for play.
If result of either inspection is not OK, replace with
new one.
4
IJHA0A620005-01

Installation
1) Mount steering gear case assembly (1) to front
suspension frame.
2) Install new steering gear case bolts (2) to specified
I9P60A630019-01 torque.

NOTICE
The steering gear case bolts are pre-coated
with friction stabilizer. If these bolts are
reused, they may work loose.
Never reuse the steering gear case bolts.

Tightening torque
Steering gear case bolt (a): 80 N·m (8.2 kgf-m,
59.0 lbf-ft)
 Steering Wheel and Column: 6B-19

3) Aligning protrusion on new steering gear packing (3) Tie-Rod / Rack Boot Removal and Installation
with notch on steering gear case assembly at AENJHB0B6206026

specified position (4), install steering gear packing to

steering gear case. Removal
1) Remove steering gear case assembly. (Page 6B-
NOTICE 18)
Once steering gear packing use, the packing 2) Remove tie-rod end. (Page 6B-17)
part transforms. If this cover is reused, water 3) Remove band (2) and rack boot clip (1).
may enter into gearbox.
4) Remove boot (3) from tie-rod.
Never reuse the steering gear packing.

4) Check that steering gear packing is fastened

2
securely with its claws (5).

4 3

1
1

IJHA0A620007-01

5) Unbend bent parts of tie-rod lock washer (1).

6) Hold steering rack end (4) using vise (2) with suitable
2, (a) spacers (3) as shown and remove tie-rod (5) from
IJHA0A620006-01 steering rack (6).
5) Install front suspension frame with steering gear
case assembly. (Page 2B-13)
4 3

Steering Rack Boot Inspection

AENJHB0B6206025
Check the steering rack boot for the following points.
Repair or replace steering rack boot if defective.
“b”
• Check steering rack boot (3) for deformation,
deterioration or crack. “a”

• Check steering rack boot clip (1) and band (2) for
fitting.

2
5

6
1
IDL10A630030-01
3
“a”: 5 mm (0.19 in.) “b”: 10 mm (0.39 in.) or more

1
I9P60A630026-02
6B-20 Steering Wheel and Column:

Installation 4) Fasten new band (1) using special tool, and install
1) Install tie-rod (1) and new tie-rod lock washer (3) to rack boot clip (2).
rack (2), and then tighten tie-rod to specified torque. Boot band fastening distance
Tightening torque “a”: 1.5 mm (0.059 in.)
Tie-rod (a): 84 N·m (8.6 kgf-m, 62.0 lbf-ft) Special tool
(A): 09943M55010

1 “a”

1, (a)

2
2
3

IDL10A630025-01

2) Bend lock washer (1) at 2 places as shown in figure. (A)

IGSB0A620019-02

5) Install tie-rod end. (Page 6B-17)

6) Install steering gear case assembly. (Page 6B-18)
1

I9P60A630029-02

3) Apply grease to section “A” of tie-rod indicated in

figure. Position boot properly in grooves of steering
gear case and tie-rod.
Check that boot is free from twist and dent.
“A”: Grease 99000–25050 (SUZUKI Super
Grease E)

“A”

IDAA0A630021-01
 Steering Wheel and Column: 6B-21

Pinion Shaft Rotation Torque Inspection 7) Using special tool and 24 mm hexagon bit with an
AENJHB0B6206028 extension, tighten rack damper screw lock nut while
1) Remove steering gear case assembly. (Page 6B- holding rack damper screw.
18)
Tightening torque
2) Remove steering rack boots. (Page 6B-19)
Rack damper screw lock nut (a): 69 N·m (7.0
3) Check pinion shaft rotation torque with rack position kgf-m, 51.0 lbf-ft)
centered using special tool.
Check that rack as a whole moves smoothly. NOTE
If check result is not as specified, adjust pinion shaft When tightening rack damper screw lock nut
rotation torque. with torque wrench connected to arm portion
Special tool of special tool, reading value is smaller than
(A): 09944M16810 the nut torque. Reading value should be
calculated using the formula below.
Rotation torque specification
1.15 – 2.05 Nm (0.117 – 0.209 kgf-m, 1.0 – 1.5 lbf- Formula for reading value of torque wrench.
ft) M = T x L / (L + “a”)
Rotation torque specification (with steering rack • M: Reading value using the special tool
boots) (Reference) • T: Specified torque
Rotation angle Rotation torque • L: Torque wrench length
1.45 – 2.35 Nm • “a”: Dimension of special tool (60 mm (2.3 in.))
0° – 180°
(0.147 – 0.239 kgf-m, 1.0 – 2.0 lbf-ft)

(A)

L
1, (a)
3

2, “A”

(A)

“a”
IHSE0A620011-01

Pinion Shaft Rotation Torque Adjustment

AENJHB0B6206029
1) Remove steering gear case assembly. (Page 6B-
18) IJHB0B620002-02
2) Remove steering rack boots. (Page 6B-19) 8) Recheck pinion shaft rotation torque is as specified.
3) Set steering rack position in center of steering rack (Page 6B-21)
stroke. 9) Install steering rack boots. (Page 6B-19)
4) Using special tool, remove rack damper screw lock 10) Install steering gear case assembly. (Page 6B-18)
nut (1).
Special tool
(A): 09941M75410
5) Tighten or loosen rack damper screw (2) to adjust
pinion shaft rotation torque to specified torque using
24 mm hexagon bit (3). (Page 6B-21)
6) Apply sealant “A” to rack damper screw.
“A”: Sealant 99000–31110 (SUZUKI Bond
No.1215)
6B-22 Steering Wheel and Column:

Specifications
Tightening Torque Specifications
AENJHB0B6207001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Steering shaft nut 33 3.4 24.5 (Page 6B-4)
Steering column lower bolt 14 1.4 10.5 (Page 6B-9)
Steering column nut 14 1.4 10.5 (Page 6B-9)
Steering lower shaft joint bolt* 35 3.6 26.0 (Page 6B-15)
Steering column joint bolt* 35 3.6 26.0 (Page 6B-15)
Tie-rod end nut 45 4.6 33.5 (Page 6B-18)
Tie-rod end lock nut 45 4.6 33.5 (Page 6B-18)
Steering gear case bolt 80 8.2 59.0 (Page 6B-18)
Tie-rod 84 8.6 62.0 (Page 6B-20)
Rack damper screw lock nut 69 7.0 51.0 (Page 6B-21)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Steering Wheel and Column Components” (Page 6B-2)
“Steering Gear Case Assembly Components” (Page 6B-16)
“Fasteners Information” in Section 0A (Page 0A-5)

Special Tools and Equipment

Recommended Service Material
AENJHB0B6208001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease E P/No.: 99000–25050 (Page 6B-20)
Sealant SUZUKI Bond No.1215 P/No.: 99000–31110 (Page 6B-21)

NOTE
Required service material(s) is also described in:
“Steering Gear Case Assembly Components” (Page 6B-16)

Special Tool
AENJHB0B6208002
09913M65210 09941M75410
Tie-rod end remover Lock nut wrench outer
(Page 6B-17) (Page 6B-21)

09943M55010 09944M16810
Boot clamp pliers Pinion torque checking
socket
(Page 6B-20) (Page 6B-21)
 Steering Wheel and Column: 6B-23

09944M36011 SUZUKI scan tool (Suzuki

SDT-II)
Steering wheel remover —
(Page 6B-3) (Page 6B-6)
6C-1 Power Assisted Steering System:

Power Assisted Steering System

Steering

Precautions
Precautions for Diagnosing Trouble
AENJHB0B6300001
! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test using 2 persons, a driver and a tester.

NOTE
Limit the driving speed permissible in road conditions and regulations.

• Before using scan tool, read its Operator’s Manual to know how to use it.
• After completion of repair, clear DTC and confirm that no DTC is stored in P/S control module. (Page 6C-13)

General Description
P/S System Description
AENJHB0B6301001
Power steering system employs an electronic power steering (EPS) system that is of a column assist type.
EPS system consists of P/S control module incorporated in P/S motor, and torque sensor. All of them are included in
steering column assembly.
The controllability of assisting steering force is optimized in all vehicle speed ranges.
For location of EPS system components, refer to “Power Steering Control System Component Location” (Page 6C-7).
Control item Control function
Electric current value to assist steering is determined based on steering torque information
Steering assist control from torque sensor and vehicle speed information through CAN communication. This is basic
control of P/S system.
Friction in steering system affects return feeling of the steering wheel especially at low speed
of the vehicle. The compensation current based on “Steering angle signal” transmitted from
Steering return control
the steering angle sensor is applied to assist the motor rotation in steering return direction and
improves return feeling of the steering wheel.
Steering converging At high speed running, steering damping performance becomes worse. Therefore, the
control compensation current is supplied for improvement of vehicle high speed stability.
If the steering wheel is kept at fully turned position with engine running, maximum current for
Maximum electric full steering assist is continuously being supplied to P/S motor causing the motor and P/S
current limit control control module to overheat. To prevent this, the control module reduces the current gradually
when the maximum current is supplied for specified time continuously.
P/S control module is equipped with fail-safe relay in its power supply circuit. When the system
is operating normally, the relay is “ON” and the control module can supply electric power to P/
Fail-safe control
S motor. However, once any malfunction is detected by self-diagnosis in P/S control system,
the relay is set to “OFF” and the power supply is cut off to stop the power assist system.
 Power Assisted Steering System: 6C-2

Description of EPS System Component Function

AENJHB0B6301002
EPS system components Function
Using two circuits (i.e. main and sub circuits), torque sensor outputs
Torque sensor voltages proportional to steering input torque and direction to P/S control
module.
P/S motor produces steering assist torque that corresponds to electric
P/S motor
current from P/S control module.
Rotation angle sensor consists of an energized coil and a pair of fixed
Steering Rotation
detector coils, and outputs signals proportional to motor rotation angle to
column P/S control angle sensor
P/S control module.
assembly module / • P/S control module controls P/S motor drive current by determining its
motor amount and direction of assistance based on voltage signal from torque
assembly sensor, vehicle speed and other data which are received via CAN
P/S control
module communication.
• P/S control module judges whether engine is running or not using
engine speed signal from CAN.
ECM transmits “Vehicle speed signal” and “Engine speed signal” to P/S
ECM
control module through CAN communication.
® control module (with ESP®) ESP® control module transmits “Yaw rate signal” and “Wheel speed signal”
ESP
to P/S control module through CAN communication.
Steering angle sensor transmits “Steering angle signal” to P/S control
Steering angle sensor
module through CAN communication.
Refer to “OBD System Description” (Page 6C-5) for operation of the P/S
P/S warning light
warning light.

Steering Column Assembly

Steering column assembly mainly consists of torque sensor shaft (input shaft) from steering wheel, worm wheel shaft
(output shaft) to steering gear case, torsion bar connecting the input and output shafts, torque sensor and P/S control
module / motor assembly and rotation angle sensor.

Torque sensor
Torque sensor adopts a hall IC-aided torque sensing system and consists of stationary magnet on input shaft,
stationary yoke on output shaft and stationary magnetic flux focusing ring (including hall IC) in torque sensor housing.
The magnet provides magnetic flux, the yoke adjusts the magnetic flux and the torque sensor detects fluctuation of
magnetic flux in the magnetic flux focusing ring. Further, the magnetic flux focusing ring consists of dual circuit, hall IC
1 and hall IC 2. This enables the P/S control module to compute steering assist torque corresponding to steering
wheel handling force based on signal from hall IC 1 (main signal). And hall IC 2 (sub signal) is used to check if hall IC
1 (main signal) is normal.

Torque sensing principle

1) At neutral point of the steering wheel (with no handling force applied), each tooth of yoke is positioned at
intermediate point between S and N poles. Therefore, magnetic flux does not pass through hall IC in this state.
2) When handling force is applied to steering wheel (input shaft) against sensor shaft (output shaft), which is
stationary with road friction, torsion occurs in torsion bar and a phase deviation relative to the torsion angle is
generated between yoke teeth and magnet.
3) Upon generation of the relative phase deviation between yoke teeth and magnet, each tooth of yoke is positioned
on S or N pole. Therefore, magnetic flux passes through yoke, magnetic flux focusing ring and hall IC.
4) Magnetic flux which passes through hall IC varies according to the steering direction and, density of the magnetic
flux varies according to the steering wheel handling force (steering torque). Hall IC converts the detected variation
of the magnetic flux on its direction and density to electrical signal and outputs to P/S control module.
6C-3 Power Assisted Steering System:

5) Output voltage of hall IC 1 (main torque sensor) and hall IC 2 (sub torque sensor) is 2.5 V at steering wheel neutral
point. In this position, P/S control module computes steering handling torque at zero. However, when steering
wheel is rotated with handling force, P/S control module controls the steering based on signal from hall IC 1 (main
torque sensor) according to the level of the handling force. When output voltage of hall IC 1 (main torque sensor)
exceeds 2.5 V, P/S control module assists the steering to the right. On the other hand, when the voltage is below
2.5 V, the control module assists the steering to the left.

[A] [B] [C]

1
4 3 2

6
6

8
5
7

7 4 7 7
9 9 9

5V 5V 5V
S N S N S S N S N S S N S N S
10 10 10
8 5 8 8

[D] [E] [F]

13
14
[G]
V

10 9

11 2.5V
12
15
[A] [H] [C]
1

4
IGSB0A630001-01

[A]: Left side steering 1. Magnet 9. Main signal

[B]: Neutral point 2. N pole 10. Sub signal
[C]: Right side steering 3. S pole 11. Sensor shaft (output shaft)
[D]: Pass of magnetic flux to hall IC upper side 4. Magnetic flux focusing ring 12. Torsion bar
[E]: No pass of magnetic flux to hall IC 5. Yoke teeth 13. Yoke
[F]: Pass of magnetic flux to hall IC lower side 6. Magnetic flux 14. Torque sensor housing
[G]: Torque sensor output characteristics 7. Hall IC1 15. Input shaft
[H]: Steering wheel neutral point (steering wheel handling torque) 8. Hall IC2
 Power Assisted Steering System: 6C-4

P/S motor • Receiving the induced electromotive force from each

When the steering wheel is turned to right or left, P/S detector coil, P/S control module calculates rotation
control module feeds an alternating current to transistors angle of the P/S motor.
in the P/S control module appropriate to the necessary
torque based on the signals from the torque sensor and 1 4
2
rotation angle sensor.
(+)
Receiving the alternating current, the six transistors are (+)
switched ON or OFF and feed the alternating current to a
three-phase stator coil (1) in P/S motor to create a
(-)
current circuit. The current circuit alternates the three- (-)
phase stator coil to plus and minus phases, thus the
inside rotor (permanent magnet) (2) is rotated to assist
5
steering. 3
(-) (+)
2 IFRA0B630013-01
3
1
Handling of steering when P/S system stops
N The system has a fail-safe function, which works as
S
manual steering without power assist when engine is
stopped or power steering system is malfunctioning.
When steering wheel is rotated by hand under these
IFRA0B630012-01 conditions, torsion bar (1) is twisted but steering assist is
3. Inverter not available without supply of electricity. Therefore,
steering torque sensor shaft (input shaft) (2) in steering
Rotation angle sensor column bumps against manual stopper (4) in worm
Rotation angle sensor consists of an energized coil (1) to wheel shaft (output shaft) (3) and torque sensor shaft
generate a magnetic field and a pair of detector coils to (input shaft) rotates worm wheel shaft (output shaft)
generate a current for detecting motor rotation angle, directly.
and the rotor (2) is off-center positioned from the center
of the motor shaft (3). And, the rotation angle sensor
calculates the motor rotation angle as follows. 2

• Magnetic field generated by energized coil is “a”

modulated corresponding to rotation of rotor with P/S
motor.
1
• Induced electromotive force in each of detector coil 1
3
(4) and detector coil 2 (5) is fluctuated corresponding
4
to change of the magnetic field. IDMAKPF60003-01

“a”: Maximum torsional angle of torsion bar

P/S Control Module

P/S control module determines basic assist power based on steering assist control and improves feeling of the
steering by using steering return control and steering converging control. Further, the P/S control module controls
motor current to harmonize target current with actual current in accordance with computing result of each control and
maximum current limit control.
And, the P/S control module communicates with ECM, BCM, ESP® control module (with ESP®), steering angle sensor
and combination meter through CAN communication.
6C-5 Power Assisted Steering System:

P/S Control Module Input / Output Diagram

AENJHB0B6301003

P/S control module

Torque sensor
Steering
assist control
Motor angular speed
(detected value) P/S motor
Steering
return control
Electric current of motor
(measured value)
Steering
converging control

Maximum
ECM CAN Target electric Motor electric CAN Combination meter
electric current
current computation current control
limit control

ESP® control module CAN communication

CAN function
(with ESP®)

Fail-safe control

Steering angle sensor CAN

IJHB0B630001-01

OBD System Description

AENJHB0B6301004 [A]
The P/S control module has an on-board self-diagnostic
function which detects a malfunction in this system.
Have full understanding of “OBD System Description”
and each item in “Precautions for Diagnosing Trouble”
(Page 6C-1), before executing diagnosis according to
“P/S System Check” (Page 6C-9).
The P/S control module performs on-board diagnosis
(self-diagnosis) on the system and operates the P/S
warning light (1) as follows.
1
• The P/S warning light turns on when the ignition is
“ON” (but the engine at stop) regardless of the
condition of the P/S control system. This is only to
check if the P/S warning light operates properly.
• When the engine is started, on-board diagnosis (self- [B]
diagnosis) is performed and the P/S warning light
turns off if no trouble is found.
• When the P/S control module detects a trouble, the P/
S warning light comes on to warn the driver of the
trouble. At the same time, a DTC is stored in the
module.

IJHB0A630002-01

[A]: Segment display type [B]: Dot display type

Description of Sensor Calibrating Condition

AENJHB0B6301005
Without ESP®
When the following conditions are met, steering angle sensor calibration should be performed since the original
calibration data are deleted.
 Power Assisted Steering System: 6C-6

Sensor to be calibrated Condition requiring calibration

Steering angle sensor • Steering angle sensor is replaced.
• P/S control module (steering column assembly) is replaced.
• Steering wheel is replaced.
• Adjustment of front wheel alignment.

Perform sensor calibration according to “Sensor Calibration” (Page 6C-33).

With ESP®
Refer to “Description of Sensor Calibrating Condition” in Section 4F (Page 4F-5).

Schematic and Routing Diagram

P/S System Diagram
AENJHB0B6302001

1
10 4
5V
11 21
12 WHT E61-1

BLK E61-2 E11-6 RED

13
14 E11-5 WHT
16 GRN G10-3
15
2
YEL 17
E11-7 YEL
18
RED G10-5
19 3 3
WHT G10-6
BLK E11-8 BLK
RED G10-7
20
RED WHT WHT G10-8

20

12V

7
9

IJHA0A630002-01

1. P/S control module / motor assembly 8. Rotation angle sensor exciter circuit 15. “MTR” fuse
2. CPU 9. Rotation angle sensor signal receive circuit 16. To ignition power supply
6C-7 Power Assisted Steering System:

3. CAN driver 10. Main fuse box 17. Combination meter

4. Torque sensor 11. “P/S” fuse 18. P/S warning light
5. Fail-safe relay 12. To continuous power supply 19. Meter driver
6. P/S motor 13. J/B 20. To other control modules by CAN
7. Rotation angle sensor 14. “IG1 SIG2” fuse 21. Torque sensor connector

Terminal Arrangement of P/S Control Module Connector (Viewed from Harness Side)

NOTE
For circuit name and terminal voltage, refer to “Inspection of P/S Control Module and Its Circuits”
(Page 6C-30).

[A] E11 [A] E61

[A] G10
[a]
1 4 3 2 1
2 1 8 7 6 5 4 3 2 1
8 7 6 5

IJHA0A630003-01

[A]: P/S control module connector (View: [a]) 1. P/S control module

Component Location
Power Steering Control System Component Location
AENJHB0B6303001
 Power Assisted Steering System: 6C-8

[A] [B]

2
1 1

12

7
6

10

11

IJHB0A630003-01
6C-9 Power Assisted Steering System:

[A]: Segment display type 4. “MTR” fuse 9. ECM (K15B model)

[B]: Dot display type
1. Combination meter
2. P/S warning light
3. BCM
5. “IG1 SIG” fuse 10. ECM (D13A model)
6. P/S control module / motor assembly 11. ESP® control module (with ESP®)
7. Steering column assembly (including P/S control 12. Steering angle sensor
module / motor assembly and torque sensor)
8. Steering gear case assembly

Diagnostic Information and Procedures

P/S System Check
AENJHB0B6304001
! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform the test extremely carefully.
• Perform the road test using 2 persons, a driver and a tester.

NOTE
Limit the driving speed permissible in road conditions and regulations.

Refer to the following items for the details of each step.

Step Action Yes No
1 Customer complaint analysis Go to Step 2. Perform customer
1) Perform “Step 1: Customer Complaint Analysis” (Page complaint analysis.
6C-11).

Was customer complaint analysis performed?

2 DTC check, record and clearance Print DTC or write it Go to Step 4.
1) Check for DTC (including pending DTC). (Page 6C-11) down and clear it
referring to “DTC
Is there any DTC? Clearance” (Page 6C-
13), and then go to Step
3.
3 Visual inspection Repair or replace Go to Step 5.
1) Perform “Steps 3 and 4: Visual Inspection” (Page 6C- defective part, and then
11). go to Step 11.

Is there any faulty condition?

4 Visual inspection Repair or replace Go to Step 8.
1) Perform “Steps 3 and 4: Visual Inspection” (Page 6C- defective part, and then
11). go to Step 11.

Is there any faulty condition?

5 Trouble symptom confirmation Go to Step 6. Go to Step 7.
1) Check trouble symptom. (Page 6C-11)

Is trouble symptom identified?

6 Rechecking and record of DTC Go to Step 9. Go to Step 8.
1) Recheck for DTC. (Page 6C-11)

Is there any DTC(s)?

7 Rechecking and record of DTC Go to Step 9. Go to Step 10.
1) Recheck for DTC. (Page 6C-11)

Is there any DTC(s)?

 Power Assisted Steering System: 6C-10

Step Action Yes No

8 Steering symptom diagnosis and P/S system symptom Go to Step 11. Check and repair
diagnosis defective part, and then
1) Check and repair. (Page 6C-12) go to Step 10.
• Steering symptom diagnosis: (Page 6A-1)
• P/S system symptom diagnosis: (Page 6C-18)

Are check and repair complete?

9 Troubleshooting for DTC Go to Step 11. Check and repair
1) Check and repair. (Page 6C-12) defective part, and then
go to Step 11.
Are check and repair complete?
10 Intermittent problem check Repair or replace Go to Step 11.
1) Check for intermittent problems. (Page 6C-12) defective part, and then
go to Step 11.
Is there any faulty condition?
11 Final confirmation test Go to Step 6. End.
1) Clear DTC if any.
2) Perform “Step 11: Final Confirmation Test” (Page 6C-
12).

Is there any problem symptom, DTC or abnormal condition?

6C-11 Power Assisted Steering System:

Step 1: Customer Complaint Analysis

Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose,
use of such a questionnaire form shown below will facilitate collecting information for proper analysis and diagnosis.
Check if the problem described in “Customer questionnaire” occurs actually in the vehicle if necessary.
(This step should be performed with the customer if possible.)

NOTE
This form is a standard sample. It should be modified according to conditions characteristic of each
market.

Customer questionnaire form (Example)

IAP70A630004-01

Step 2: DTC Check, Record and Clearance
Check DTC (current and pending DTC) referring to “DTC
Check” (Page 6C-12).
If DTC is indicated, print or write down the DTC and then
clear the DTC referring to “DTC Clearance” (Page 6C-
13).
Step 5: Trouble Symptom Confirmation
Based on “Step 1: Customer Complaint Analysis” (Page
6C-11) and “Step 2: DTC Check, Record and Clearance”
(Page 6C-11), check trouble symptoms. Also, check
trouble symptoms by performing test drive and turning
steering wheel fully to right and left with vehicle stopped.

Steps 3 and 4: Visual Inspection Steps 6 and 7: Rechecking and Record of DTC
Visually check P/S warning light for proper operation, Refer to “DTC Check” (Page 6C-12) for checking
connectors for proper condition and each part condition procedure.
referring to “Visual Inspection” (Page 6C-17).
 Power Assisted Steering System: 6C-12

Step 8: Steering Symptom Diagnosis and P/S P/S Warning Light Check
System Symptom Diagnosis AENJHB0B6304002

Perform basic steering system check first. (Page 6A-1)
Near the end of flow, check the parts of the system
suspected as a possible cause referring to “P/S System
Symptom Diagnosis” (Page 6C-18) and based on
symptoms appearing on the vehicle (symptoms obtained
through steps of customer complaint analysis, trouble
symptom confirmation and/or basic P/S system check).
Repair or replace faulty parts.
Step 9: Troubleshooting for DTC
Perform applicable DTC troubleshooting and repair or
replace faulty parts.
1) Set ignition “ON” (without running engine) and check
if the P/S warning light (1) comes on. If the P/S
warning light does not come on, go to “P/S Warning
Light Does Not Come ON with Ignition “ON” before
Engine Starts” (Page 6C-18) of the diagnostic flows.
2) Start engine and check if the P/S warning light turns
OFF. If P/S warning light remains ON and no DTC is
stored in P/S control module, go to “P/S Warning
Light Remains ON Steady after Engine Starts” (Page
6C-19) for troubleshooting.
[A]

Step 10: Intermittent Problems Check

Check parts that are prone to cause intermittent problem
(e.g. wire harness, connector, etc.), referring to
“Intermittent Connection and Poor Contact Inspection” in
Section 00 (Page 00-12) and related circuit of DTC
recorded in Step 2.

Step 11: Final Confirmation Test 1

Check that the problem symptom has disappeared and
the P/S system is free from any abnormal conditions. If
what has been repaired is related to the DTC, clear the
DTC once, perform DTC confirmation procedure and
check that no DTC is indicated. [B]

IJHB0A630002-01

[A]: Segment display type [B]: Dot display type

DTC Check
AENJHB0B6304003
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Read DTC according to instructions displayed on
SUZUKI scan tool and print it or write it down. Refer
to Operator's Manual of SUZUKI scan tool for further
details.
6C-13 Power Assisted Steering System:
NOTE
If communication between SUZUKI scan tool
and P/S control module is not possible,
perform the following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.)
– K15B model: (Page 10H-17)
– D13A model: (Page 10H-38)
• Check P/S control module power circuit
and ground circuit. (Page 6C-29)
1
(A)
IJHA0A110011-01
5) After completing the check, set ignition “OFF” and
disconnect SUZUKI scan tool from DLC.
DTC Clearance
AENJHB0B6304004
1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1).
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”.
4) Clear DTC according to instructions displayed on
SUZUKI scan tool. Refer to Operator's Manual of
SUZUKI scan tool for further details.
NOTE
If communication between SUZUKI scan tool
and P/S control module is not possible,
perform the following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
• Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.)
– K15B model: (Page 10H-17)
– D13A model: (Page 10H-38)
• Check P/S control module power circuit
and ground circuit. (Page 6C-29)
1
(A)
IJHA0A110011-01
5) After completing DTC clearance, set ignition “OFF”
and disconnect SUZUKI scan tool from DLC.
 Power Assisted Steering System: 6C-14

DTC Table
AENJHB0B6304005
NOTE
• If you do not perform the “P/S System Check” (Page 6C-9) before starting the DTC diagnosis, the
diagnosis will show a false result.
Perform “P/S System Check” (Page 6C-9) before starting the diagnosis.
• *D/C (Driving Cycle) is a duration from engine start to the following engine shutoff.
– 1 D/C: When a malfunction is detected in 1st driving cycle, DTC is detected as current DTC.

P/S
DTC DTC name DTC detecting condition *D/C warning
light
Voltage of torque sensor signal (main) circuit is
C1111 (Page Torque Sensor (Main)
higher than specified value (4.7 V) or lower than 1 Lights up
6C-19) Circuit Malfunction
specified value (0.3 V) for more than specified time.
Voltage difference between torque sensor signal
C1113 (Page Torque Sensor (Main and
(main) circuit and torque sensor signal (sub) circuit 1 Lights up
6C-19) Sub) Signal Difference
remains too large for more than specified time.
Torque Sensor Power Power supply voltage (5 V) for torque sensor circuit
C1114 (Page
Supply (5 V) Circuit is higher than specified value (5.5 V) or lower than 1 Lights up
6C-19)
Malfunction specified value (4.5 V) for more than specified time.
Voltage of torque sensor signal (sub) circuit is
C1115 (Page Torque Sensor (Sub) Circuit
higher than specified value (4.7 V) or lower than 1 Lights up
6C-19) Malfunction
specified value (0.3 V) for more than specified time.
C1131 (Page Rotation Angle Sensor Rotation angle sensor output signal error continues
1 Lights up
6C-21) Signal Malfunction for more than specified period.
Measured motor drive circuit voltage is higher than
C1141 (Page P/S Motor Circuit Voltage
normal voltage by 0.3 V or more, or motor drive 1 Lights up
6C-22) Malfunction
circuit is defective.
C1142 (Page P/S Motor Circuit Current Measured motor drive current is more than target
1 Lights up
6C-22) Malfunction 1 value by 10 A or more.
C1143 (Page P/S Motor Circuit Current
Measured motor drive current is more than 137 A. 1 Lights up
6C-22) Too Big
C1145 (Page P/S Motor Circuit Current Target motor drive current is more than 4 A or
1 Lights up
6C-22) Malfunction 2 measured motor drive current is less than 2 A.
C1146 (Page P/S Motor Voltage Motor voltage calculated in P/S control module is
1 Lights up
6C-22) Malfunction abnormal.
Measured voltage at fail-safe relay contact is higher
C1152 (Page Fail-Safe Relay Malfunction
than 5.5 V even though fail-safe relay-off is 1 Lights up
6C-23) (Melting Stuck)
commanded.
Measured voltage of fail-safe relay contact is lower
C1153 (Page Power Supply Voltage Too than 9 V even if engine speed is more than 600 rpm
1 Lights up
6C-24) Low or Too High and fail-safe relay ON is commanded, or voltage at
fail-safe relay contact is higher than 19.2 V.
Measured voltage at fail-safe relay contact is lower
C1154 (Page Fail-Safe Relay Malfunction
than 4 V even though fail-safe relay-on is 1 Lights up
6C-23) (Contact)
commanded.
C1155 (Page P/S Control Module Internal
P/S control module internal failure. 1 Lights up
6C-24) Failure
C1160 (Page
Assist Map Signal Failure Assist map data is not set in P/S control module. 1 Lights up
6C-24)
C1161 (Page CAN Invalid Data from
Invalid vehicle speed data is received from ECM. 1 Lights up
6C-25) Vehicle Speed
C1162 (Page CAN Invalid Data from
Invalid engine speed data is received from ECM. 1 Lights up
6C-25) Engine Speed
C1163 (Page CAN Invalid Data from Invalid data of steering angle is received from
1 Lights up
6C-26) Steering Angle Sensor steering angle sensor.
C1166 (Page Reliability Defect Of Vehicle Invalid data about vehicle speed reliability is
1 Lights up
6C-25) Speed Data received from ECM.
6C-15 Power Assisted Steering System:

P/S
DTC DTC name DTC detecting condition *D/C warning
light
C116A (Page Steering Angle Sensor Incomplete calibration signal of steering angle is
1 Lights up
6C-26) Calibration Incomplete received from steering angle sensor.
C116B (Page Steering Angle Sensor
Steering angle sensor detects calibration defect. 1 Lights up
6C-27) Calibration Defect
C116C (Page Steering Angle Sensor CPU in steering angle sensor detects internal
1 Lights up
6C-28) Circuit Performance defect.
C116D (Page Steering Angle Sensor
Steering angle sensor detects unconfirmed failure. 1 Lights up
6C-28) Specification Unregistered
U0073 (Page Control Module Transmitting and receiving error of P/S control
1 Off
6C-28) Communication Bus Off module is detected for specified time continuously.
U0100 (Page Lost Communication With CAN communication data from ECM cannot be
1 Lights up
6C-28) ECM received.
U0121 (Page Lost Communication With CAN communication data cannot be received from
1 Off
6C-29) ABS / ESP® Control Module ABS / ESP® control module.
Lost Communication With
U0126 (Page CAN communication data cannot be received from
Steering Angle Sensor 1 Lights up
6C-29) steering angle sensor.
Module
U0140 (Page Lost Communication With CAN communication data cannot be received from
1 Off
6C-29) Body Control Module BCM.
Lost Communication With
U0155 (Page CAN communication data cannot be received from
Instrument Panel Cluster 1 Off
6C-29) combination meter.
(IPC) Control Module
Lost Communication With
U1082 (Page CAN communication data cannot be received from
ENG A-STOP Control 1 Off
6C-29) ECM.
Module

Fail-Safe Table
AENJHB0B6304006
When any of the following DTCs is detected, P/S control module enters fail-safe mode as long as malfunction
continues to exist but that mode is cancelled when the following cancel conditions are met.
DTC Fail-safe operation Fail-safe operation cancel condition
C1111 (Page 6C-19)
C1113 (Page 6C-19)
C1114 (Page 6C-19)
C1115 (Page 6C-19)
C1131 (Page 6C-21)
P/S motor and fail-safe relay turned off. Ignition is set to “OFF”.
C1141 (Page 6C-22)
C1142 (Page 6C-22)
C1143 (Page 6C-22)
C1145 (Page 6C-22)
C1146 (Page 6C-22)
C1152 (Page 6C-23)
If one of the following conditions is met:
P/S motor turned off or assist value is • Voltage at fail-safe relay contact is higher than
C1153 (Page 6C-24)
decreased to minimum. 10 V or lower than 18.2 V.
• Ignition is set to “OFF”.
C1154 (Page 6C-23) P/S motor turned off.
Recovery from malfunction or ignition is set to
P/S motor turned off or P/S motor and
C1155 (Page 6C-24) “OFF”.
fail-safe relay turned off.
C1160 (Page 6C-24) Default assist map is applied. Setting of correct assist map.
Receiving invalid data, stops steering
Normal data is received and ignition is set to “OFF”.
return control.
C1161 (Page 6C-25)
Receiving invalid data, decreases the
Normal data is received or ignition is set to “OFF”.
assist value to minimum level.
C1162 (Page 6C-25) Assist is stopped. Normal data is received or ignition is set to “OFF”.
Receiving vehicle information, stops
C1163 (Page 6C-26) Ignition is set to “OFF”.
steering return control.
 Power Assisted Steering System: 6C-16

DTC Fail-safe operation Fail-safe operation cancel condition

Receiving invalid data, stops steering
C1166 (Page 6C-25) return control and decreases the assist Normal data is received or ignition is set to “OFF”.
value to minimum level.
Corrected calibration signal of steering angle is
C116A (Page 6C-26)
received or ignition is set to “OFF”.
Receiving vehicle information, stops Corrected calibration signal of steering angle is
C116B (Page 6C-27)
steering return control. received.
C116C (Page 6C-28)
Ignition is set to “OFF”.
C116D (Page 6C-28)
U0073 (Page 6C-28) —
Stops assist control, or decreases the
assist value to minimum level and stops
U0100 (Page 6C-28)
steering return control by signal from
ECM.
U0121 (Page 6C-29) — Normal data is received or ignition is set to “OFF”.
Receiving vehicle information, stops
U0126 (Page 6C-29)
steering return control.
U0140 (Page 6C-29) —
U0155 (Page 6C-29) —
U1082 (Page 6C-29) —

Scan Tool Data

AENJHB0B6304007

NOTE
• If communication between SUZUKI scan tool and P/S control module is not possible, perform the
following checks:
– Check communication condition between PC and VCI using SUZUKI scan tool function.
– Check DLC power circuit and ground circuit
– Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
– Check CAN communication system. (“Control Module Communication Bus Off” is detected in any
control module)
– K15B model: (Page 10H-17)
– D13A model: (Page 10H-38)
– Check P/S control module power circuit and ground circuit. (Page 6C-29)
• *1: Turn steering wheel fully and hold it with force applied.
• *2: The voltage and current of motor decrease gradually after few seconds when steering wheel is
turned.

Normal condition /
Scan tool data Vehicle condition
Reference value
Battery Voltage Approx. 12 to 14 V Engine running at idle speed
Sensor Power Supply Approx. 5 V Engine running at idle speed
Engine running at idle speed
Approx. ±0 Nm
Steering wheel at neutral
Engine running at idle speed
Sensor (Main) Torque 7.2 to 12.6 Nm
Vehicle stationary and steering wheel turned fully to right *1
Engine running at idle speed
–7.2 to –12.6 Nm
Vehicle stationary and steering wheel turned fully to left *1
Engine running at idle speed
Approx. ±0 Nm
Steering wheel at neutral
Engine running at idle speed
Sensor (Sub) Torque –7.2 to –12.6 Nm
Vehicle stationary and steering wheel turned fully to right *1
Engine running at idle speed
7.2 to 12.6 Nm
Vehicle stationary and steering wheel turned fully to left *1
6C-17 Power Assisted Steering System:

Normal condition /
Scan tool data Vehicle condition
Reference value
Engine running at idle speed
Approx. ±0 Nm
Steering wheel at neutral
Engine running at idle speed
Control Torque Approx. 7 Nm
Vehicle stationary and steering wheel turned fully to right *1
Engine running at idle speed
Approx. –7 Nm
Vehicle stationary and steering wheel turned fully to left *1
Engine running at idle speed
0.0 A
Steering wheel at neutral
Target Motor Current
Engine running at idle speed
Approx. 50 A
Vehicle stationary and steering wheel turned fully to right or left *1, *2
Engine running at idle speed
0.0 A
Steering wheel at neutral
Measured MOT Current
Engine running at idle speed
Approx. 50 A
Vehicle stationary and steering wheel turned fully to right or left *1, *2
Drive vehicle at 40 km/h using chassis dynamometer or while
Vehicle Speed Approx. 40 km/h
checking speedometer
0 rpm Set ignition “ON”
Engine Speed
Specified idle speed Engine running at idle speed after warming up
ON Set ignition “ON”
IGN Switch Status
OFF Other than above condition
ON Current flowing to P/S control module power supply
System Power Status
OFF Other than above condition
ON Power steering system operates normally
Fail Safe FET Status
OFF Performing fail-safe operation
0 ± 3° Front wheels in straight ahead position
Steering Angle Sensor 360° ± 3° Rotate steering wheel once clockwise
–360° ± 3° Rotate steering wheel once counterclockwise

Visual Inspection
AENJHB0B6304008
Visually check the following parts and systems.
Inspection item Referring section
• K15B model: “Battery Description”: K15B in
Section 1J (Page 1J-2)
Battery Fluid level, leakage indicator
• D13A model: “Battery Description”: D13A in
Section 1J (Page 1J-12)
“Intermittent Connection and Poor Contact
Connectors of electric wire harness Disconnection, friction
Inspection” in Section 00 (Page 00-12)
Fuses Blowout
P/S warning light Operation “P/S Warning Light Check” (Page 6C-12)
Other parts that can be checked visually
 Power Assisted Steering System: 6C-18

P/S System Symptom Diagnosis

AENJHB0B6304009
This section describes trouble diagnosis of the P/S system parts whose troubles are not indicated using SUZUKI scan
tool. When no malfunction is indicated by SUZUKI scan tool and steering basic parts as described in “Steering
Symptom Diagnosis” in Section 6A (Page 6A-1) are all in good condition, check the following power steering system
parts which may be possible causes for each trouble symptom of steering.

NOTE
Perform “Steering Force Check” (Page 6C-32) and “Front Wheel Alignment Inspection and
Adjustment” in Section 2B (Page 2B-2) before diagnosis.

Condition Possible cause Correction / Reference Item

Steering wheel feels Improper installation of steering wheel
heavy Poor performance of torque sensor
Poor performance of P/S motor
Malfunction of steering gear case
assembly
Vehicle speed data provided through
CAN communication
Steering wheel feels Malfunction of steering gear case
heavy momentarily when assembly
turning it to left or right
Poor recovery from turns Poor performance of torque sensor
Malfunction of steering gear case
assembly
Vehicle pulls to one side Poor performance of torque sensor
during straight driving Malfunction of steering gear case
assembly
Abnormal noise Malfunction of P/S motor (built in
steering column assembly)
Install steering wheel correctly. (Page 6B-3)
Check torque sensor. (Page 6C-33)
Check P/S motor. (Page 6C-16)
Replace steering gear case assembly. (Page
6B-18)
Check vehicle speed data. (Page 6C-16)
Replace steering gear case assembly. (Page
6B-18)
Check torque sensor. (Page 6C-33)
Replace steering gear case assembly. (Page
6B-18)
Check torque sensor. (Page 6C-33)
Replace steering gear case assembly. (Page
6B-18)
Replace steering column. (Page 6B-8)

P/S Warning Light Does Not Come ON with Ignition “ON” before Engine Starts
AENJHB0B6304010
Troubleshooting
Step Action Yes No
1 P/S warning light check Go to Step 2. Go to Step 4.
1) Set ignition “ON”.

Do other warning lights come ON?

2 DTC check Go to troubleshooting Go to Step 3.
1) Connect scan tool to DLC with ignition “OFF”. for applicable DTC.
2) When ignition is “ON”, check DTC.

Is DTC U0073 or U0155 detected?

3 Combination meter check Replace steering End.
1) Replace combination meter. (Page 9C-34) column assembly.
(Page 6B-8)
2) Set ignition “ON”.

Does P/S warning light stay OFF?

4 Fuse check Go to Step 5. Replace “MTR” fuse
and check for short
Is “MTR” fuse in good condition? circuit to ground.
5 CAN communication circuit check Go to Step 6. Repair or replace
1) Check CAN communication circuit between combination defective wire harness.
meter and P/S control module.
• K15B model: (Page 10H-17)
• D13A model: (Page 10H-38)

Is check result OK?

6C-19 Power Assisted Steering System:

Step Action Yes No

6 Combination meter power supply and ground circuit Replace combination Repair or replace
check meter and recheck defective wire harness.
1) Check combination meter power supply and ground warning light operation.
circuits. (Page 9C-29) If P/S warning light does
not come ON, replace
Is check result OK? steering column
assembly and recheck
warning light operation.
• Combination meter:
(Page 9C-34)
• Steering column
assembly: (Page
6B-8)

P/S Warning Light Remains ON Steady after Engine Starts

AENJHB0B6304011
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Go to Step 2.
1) Start engine and recheck DTC of P/S control module. for applicable DTC.

Is DTC(s) detected?
2 P/S control module check Replace combination End.
1) Replace steering column assembly. (Page 6B-8) meter. (Page 9C-34)
2) Set ignition “ON”.

Does P/S warning light stay ON?

DTC C1111 / C1113 / C1114 / C1115

AENJHB0B6304012
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1111: Torque Sensor (Main) Circuit Malfunction • Torque sensor (steering column assembly)
Voltage of torque sensor signal (main) circuit is higher than • Torque sensor circuit / connector
specified value (4.7 V) or lower than specified value (0.3 V) for
• P/S control module (steering column assembly)
more than specified time.
C1113: Torque Sensor (Main and Sub) Signal Difference
Voltage difference between torque sensor signal (main) circuit
and torque sensor signal (sub) circuit remains too large for more
than specified time.
C1114: Torque Sensor Power Supply (5 V) Circuit Malfunction
Power supply voltage (5 V) for torque sensor circuit is higher than
specified value (5.5 V) or lower than specified value (4.5 V) for
more than specified time.
C1115: Torque Sensor (Sub) Circuit Malfunction
Voltage of torque sensor signal (sub) circuit is higher than
specified value (4.7 V) or lower than specified value (0.3 V) for
more than specified time.
 Power Assisted Steering System: 6C-20

Circuit Diagram

1 [A]
5V 3
10
4 3 2 1
5V
A1
6 8 7 6 5
B1
7 E11-6 RED
4 WHT E61-1 [B]

A2
2 1
E11-5 WHT
8 B2
2
9
5 GRN G10-3 [C]
A3

E11-7 YEL
8 7 6 5 4 3 2 1

A4

B3 E11-8 BLK [a]

BLK E61-2

IJHA0A630005-01

[A]: Torque sensor connector “E11” (View [a]) B1: P/S control module power supply circuit 5. To ignition power supply
[B]: P/S control module connector “E61” (View [a]) B2: IG1 power supply circuit 6. Main fuse box
[C]: P/S control module connector “G10” (View [a]) B3: P/S control module ground circuit 7. “P/S” fuse
A1: 5 V power supply for torque sensor circuit 1. P/S control module / motor assembly 8. J/B
A2: Torque sensor signal (main) circuit 2. CPU 9. “IG1 SIG2” fuse
A3: Torque sensor signal (sub) circuit 3. Torque sensor 10. Torque sensor connector
A4: Torque sensor ground circuit 4. To continuous power supply

DTC Confirmation Procedure

Upon completion of initial check, turn steering wheel in both directions fully with vehicle stopped, and then handle
steering while driving.

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-9).
2 P/S control module power supply and ground circuit Go to Step 3. Repair or replace
check defective wire harness.
1) Check P/S control module power supply and ground
circuits. (Page 6C-29)

Is check result OK?

3 P/S control module check Go to Step 4. Replace steering
1) With ignition “OFF”, disconnect “E11” connector. column assembly.
(Page 6B-8)
2) Check for proper connection to “E11” connector.
3) If connections are OK, set ignition “ON”.
4) Check voltage between “E11-6” terminal and “E11-8”
terminal is approx. 5 V.

Is check result OK?

4 Torque sensor check Substitute a known- Replace steering
1) Check torque sensor. (Page 6C-33) good steering column column assembly.
assembly and recheck (Page 6B-8)
Is the sensor in good condition? DTC. (Page 6B-8)
6C-21 Power Assisted Steering System:

DTC C1131
AENJHB0B6304013
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1131: Rotation Angle Sensor Signal Malfunction • Rotation angle sensor (steering column assembly)
Rotation angle sensor output signal error continues for • P/S control module (steering column assembly)
more than specified period.

Circuit Diagram

7
[a]
3
A1
4
1 WHT E61-1

[A]
5 8 10
A2
6
2 GRN G10-3 9
2 1
11

[B]

8 7 6 5 4 3 2 1
A3
BLK E61-2

IJHA0A630006-01

[A]: P/S control module connector “E61” (View: [a]) 2. To ignition power supply 8. CPU
[B]: P/S control module connector “G10” (View: [a]) 3. Main fuse box 9. Rotation angle sensor
A1: P/S control module power supply circuit 4. “P/S” fuse 10. Rotation angle sensor exciter circuit
A2: IG1 power supply circuit 5. J/B 11. Rotation angle sensor signal receive circuit
A3: P/S control module ground circuit 6. “IG1 SIG2” fuse
1. To continuous power supply 7. P/S control module / motor assembly

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 P/S control module power supply and ground circuit Substitute a known- Repair or replace
check good steering column defective wire harness.
1) Check P/S control module power supply and ground assembly and recheck
circuits. (Page 6C-29) DTC. (Page 6B-8)

Is check result OK?

 Power Assisted Steering System: 6C-22

DTC C1141 / C1142 / C1143 / C1145 / C1146

AENJHB0B6304014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1141: P/S Motor Circuit Voltage Malfunction • P/S motor (steering column assembly)
Measured motor drive circuit voltage is higher than normal voltage by 0.3 • P/S control module (steering column
V or more, or motor drive circuit is defective. assembly)
C1142: P/S Motor Circuit Current Malfunction 1
Measured motor drive current is more than target value by 10 A or more.
C1143: P/S Motor Circuit Current Too Big
Measured motor drive current is more than 137 A.
C1145: P/S Motor Circuit Current Malfunction 2
Target motor drive current is more than 4 A or measured motor drive
current is less than 2 A.
C1146: P/S Motor Voltage Malfunction
Motor voltage calculated in P/S control module is abnormal.

Circuit Diagram

7
[a]
3
A1 12V
4
1 WHT E61-1
10
[A]
5 8
A2 9
6
2 GRN G10-3
2 1

[B]

8 7 6 5 4 3 2 1
A3
BLK E61-2

IJHA0A630007-01

[A]: P/S control module connector “E61” (View: [a]) 1. To continuous power supply 6. “IG1 SIG2” fuse
[B]: P/S control module connector “G10” (View: [a]) 2. To ignition power supply 7. P/S control module / motor assembly
A1: P/S control module power supply circuit 3. Main fuse box 8. CPU
A2: IG1 power supply circuit 4. “P/S” fuse 9. P/S motor
A3: P/S control module ground circuit 5. J/B 10. Fail-safe relay

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 P/S control module power supply and ground circuit Substitute a known- Repair or replace
check good steering column defective wire harness.
1) Check P/S control module power supply and ground assembly and recheck
circuits. (Page 6C-29) DTC. (Page 6B-8)

Is check result OK?

6C-23 Power Assisted Steering System:

DTC C1152 / C1154

AENJHB0B6304015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1152: Fail-Safe Relay Malfunction (Melting Stuck) P/S control module (steering column assembly)
Measured voltage at fail-safe relay contact is higher than
5.5 V even though fail-safe relay-off is commanded.
C1154: Fail-Safe Relay Malfunction (Contact)
Measured voltage at fail-safe relay contact is lower than 4
V even though fail-safe relay-on is commanded.

Circuit Diagram

7
[a]
3
A1 12V
4
1 WHT E61-1
10
[A]
5 8
A2 9
6
2 GRN G10-3
2 1

[B]

8 7 6 5 4 3 2 1
A3
BLK E61-2

IJHA0A630007-01

[A]: P/S control module connector “E61” (View: [a]) 1. To continuous power supply 6. “IG1 SIG2” fuse
[B]: P/S control module connector “G10” (View: [a]) 2. To ignition power supply 7. P/S control module / motor assembly
A1: P/S control module power supply circuit 3. Main fuse box 8. CPU
A2: IG1 power supply circuit 4. “P/S” fuse 9. P/S motor
A3: P/S control module ground circuit 5. J/B 10. Fail-safe relay

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Start engine.

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 P/S control module power supply and ground circuit Substitute a known- Repair or replace
check good steering column defective wire harness.
1) Check P/S control module power supply and ground assembly and recheck
circuits. (Page 6C-29) DTC. (Page 6B-8)

Is check result OK?

 Power Assisted Steering System: 6C-24

DTC C1153 / C1155

AENJHB0B6304016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1153: Power Supply Voltage Too Low or Too High • Charging system
Measured voltage of fail-safe relay contact is lower than 9 V even if • P/S control module (steering column
engine speed is more than 600 rpm and fail-safe relay ON is assembly)
commanded, or voltage at fail-safe relay contact is higher than 19.2 V.
C1155: P/S Control Module Internal Failure
P/S control module is internal failure.

Circuit Diagram

[a]
3 A1
4
5 WHT E61-1 2

A2 [A]

BLK E61-2
2 1

IJHA0A630008-01

[A]: P/S control module connector “E61” (View [a]) 1. P/S control module / motor assembly 4. “P/S” fuse
A1: P/S control module power supply circuit 2. CPU 5. To continuous power supply
A2: P/S control module ground circuit 3. Main fuse box

DTC Confirmation Procedure

Run engine at idle speed for more than 5 seconds.

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 P/S control module power supply and ground circuit Go to Step 3. Repair or replace
check defective wire harness.
1) Check P/S control module power supply and ground
circuits. (Page 6C-29)

Is check result OK?

3 P/S control module power supply voltage check Substitute a known- Check charging system.
1) Measure battery voltage with engine running at 3000 good steering column • K15B model: (Page
rpm. assembly and recheck 1J-3)
DTC. (Page 6B-8)
Is voltage between 9 V and 15 V? • D13A model: (Page
1J-15)

DTC C1160
AENJHB0B6304017
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1160: Assist Map Signal Failure P/S control module (steering column assembly)
Assist map data is not set in P/S control module.
6C-25 Power Assisted Steering System:

Circuit Diagram

7
[a]
3
A1
4
1 WHT E61-1

5 [A]
A2
8
6
2 GRN G10-3
2 1

[B]
A3
8 7 6 5 4 3 2 1
BLK E61-2

IJHA0A630009-01

[A]: P/S control module connector “E61” (View: [a]) 1. To continuous power supply 6. “IG1 SIG2” fuse
[B]: P/S control module connector “G10” (View: [a]) 2. To ignition power supply 7. P/S control module / motor assembly
A1: P/S control module power supply circuit 3. Main fuse box 8. CPU
A2: IG1 power supply circuit 4. “P/S” fuse
A3: P/S control module ground circuit 5. J/B

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Set ignition “OFF”.
3) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 P/S control module power supply and ground circuit Substitute a known- Repair or replace
check good steering column defective wire harness.
1) Check P/S control module power supply and ground assembly and recheck
circuits. (Page 6C-29) DTC. (Page 6B-8)

Is check result OK?

DTC C1161 / C1162 / C1166

AENJHB0B6304018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1161: CAN Invalid Data from Vehicle Speed • CAN communication circuit
Invalid vehicle speed data is received from ECM. • ECM
C1162: CAN Invalid Data from Engine Speed
• P/S control module (steering column assembly)
Invalid engine speed data is received from ECM.
C1166: Reliability Defect Of Vehicle Speed Data
Invalid data about vehicle speed reliability is received from ECM.

DTC Confirmation Procedure

C1161 / C1166
Refer to “DTC Confirmation Procedure” for DTC P0500 Vehicle Speed Sensor “A”.
• K15B model: (Page 1A-122)
• D13A model: (Page 1A-265)
 Power Assisted Steering System: 6C-26

C1162
Refer to “DTC Confirmation Procedure” for DTC P0335 Crankshaft Position Sensor “A” Circuit.
• K15B model: (Page 1A-106)
• D13A model: (Page 1A-254)

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 DTC check Go to troubleshooting Substitute a known-
1) Check ECM for DTC. (Page 6C-12) for applicable DTC. good steering column
(ECM-related faulty) assembly and recheck
Is DTC(s) detected? • K15B model: (Page DTC. (Page 6B-8)
1A-25)
• D13A model: (Page
1A-182)

DTC C1163
AENJHB0B6304019
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1163: CAN Invalid Data from Steering Angle Sensor • Steering angle sensor
Invalid data of steering angle is received from steering • ESP® control module (with ESP®)
angle sensor.
• P/S control module (steering column assembly)

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Without ESP®: Go Step Go to “P/S System
3. Check” (Page 6C-9) and
With ESP®: Go Step 2. recheck DTC.
2 DTC check Go to troubleshooting Go Step 3.
1) Check ESP control module for DTC. (Page 4F-14)
® for applicable DTC.

Is DTC(s) detected?
3 DTC check Go to troubleshooting Replace steering angle
1) Perform “DTC Check” (Page 6C-12). for applicable DTC. sensor and recheck
DTC. If DTC C1163 is
Is other DTC(s) than C1163 detected? still detected, substitute
a known-good steering
column assembly and
recheck DTC.
• Steering angle
sensor: (Page 6B-
7)
• Steering column
assembly: (Page
6B-8)

DTC C116A
AENJHB0B6304020
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C116A: Steering Angle Sensor Calibration Incomplete • Steering angle sensor
Incomplete calibration signal of steering angle is received • ESP® control module (with ESP®)
from steering angle sensor.
• P/S control module (steering column assembly)
6C-27 Power Assisted Steering System:

DTC Confirmation Procedure

With ESP®
Refer to “DTC Confirmation Procedure” in “DTC C1074 / C1075 / C1076 / C1078” in Section 4F (Page 4F-47).

Without ESP®
1) Set ignition “ON” and “OFF”.
2) Set ignition “ON” again.

DTC Troubleshooting (With ESP®)

Step Action Yes No
1 Was “P/S System Check” performed? Go Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 DTC check Go to troubleshooting Go to Step 3.
1) Check ESP® control module for DTC. (Page 4F-14) for applicable DTC.

Is DTC(s) detected?
3 Sensor calibration Substitute a known- End.
1) Perform sensor calibration. (Page 4F-53) good steering column
assembly and recheck
2) Check DTC. (Page 6C-12)
DTC. (Page 6B-8)
Is DTC C116A still detected?

DTC Troubleshooting (Without ESP®)

Step Action Yes No
1 Was “P/S System Check” performed? Go Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 6C-12). for applicable DTC.

Is other DTC(s) than C116A detected?

3 Sensor calibration Replace steering angle End.
1) Perform sensor calibration. (Page 6C-33) sensor and recheck
DTC. If C116A is still
2) Check DTC. (Page 6C-12)
detected, substitute a
Is DTC C116A still detected? known-good steering
column assembly and
recheck DTC.
• Steering angle
sensor: (Page 6B-
7)
• Steering column
assembly: (Page
6B-8)

DTC C116B
AENJHB0B6304021
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C116B: Steering Angle Sensor Calibration Defect • Steering angle sensor
Steering angle sensor detects calibration defect. • P/S control module (steering column assembly)

DTC Confirmation Procedure

1) Set ignition “ON” and “OFF”.
2) Set ignition “ON” again.
 Power Assisted Steering System: 6C-28

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 DTC check Go to troubleshooting Go to Step 3.
1) Perform “DTC Check” (Page 6C-12). for applicable DTC.

Is other DTC(s) than C116B detected?

3 Sensor calibration Replace steering angle End.
1) Perform sensor calibration. (Page 6C-33) sensor and recheck
DTC. If C116B is still
2) Check DTC. (Page 6C-12)
detected, substitute a
Is DTC C116B still detected? known-good steering
column assembly and
recheck DTC.
• Steering angle
sensor: (Page 6B-
7)
• Steering column
assembly: (Page
6B-8)

DTC C116C / C116D

AENJHB0B6304022
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C116C: Steering Angle Sensor Circuit Performance • Steering angle sensor
CPU in steering angle sensor detects internal defect. • P/S control module (steering column assembly)
C116D: Steering Angle Sensor Specification Unregistered
Steering angle sensor detects unconfirmed failure.

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go Step 2. Go to “P/S System
Check” (Page 6C-9) and
recheck DTC.
2 DTC check Go to troubleshooting Replace steering angle
1) Perform “DTC Check” (Page 6C-12). for applicable DTC. sensor and recheck
DTC. If C116C or
Is other DTC(s) than C116C or C116D detected? C116D is still detected,
substitute a known-
good steering column
assembly and recheck
DTC.
• Steering angle
sensor: (Page 6B-
7)
• Steering column
assembly: (Page
6B-8)

DTC U0073 DTC U0100

AENJHB0B6304023 AENJHB0B6304024
Refer to “Troubleshooting for Communication Bus Off”. Refer to “Troubleshooting for Lost Communication”.
• K15B model: (Page 10H-17) • K15B model: (Page 10H-10)
• D13A model: (Page 10H-38) • D13A model: (Page 10H-32)
6C-29 Power Assisted Steering System:

DTC U0121 • K15B model: (Page 10H-10)

AENJHB0B6304025
Refer to “Troubleshooting for Lost Communication”. • D13A model: (Page 10H-32)
• K15B model: (Page 10H-10)
DTC U0155
• D13A model: (Page 10H-32) AENJHB0B6304028
Refer to “Troubleshooting for Lost Communication”.
DTC U0126 • K15B model: (Page 10H-10)
AENJHB0B6304026
Refer to “Troubleshooting for Lost Communication”. • D13A model: (Page 10H-32)
• K15B model: (Page 10H-10)
DTC U1082
• D13A model: (Page 10H-32) AENJHB0B6304029
Refer to “Troubleshooting for Lost Communication”.
DTC U0140 • K15B model: (Page 10H-10)
AENJHB0B6304027
Refer to “Troubleshooting for Lost Communication”. • D13A model: (Page 10H-32)

P/S Control Module Power Supply and Ground Circuit Check

AENJHB0B6304030
Circuit Diagram

7
[a]
3
A1
4
1 WHT E61-1

5 [A]
A2
8
6
2 GRN G10-3
2 1

[B]
A3
8 7 6 5 4 3 2 1
BLK E61-2

IJHA0A630009-01

[A]: P/S control module connector “E61” (View: [a]) 1. To continuous power supply 6. “IG1 SIG2” fuse
[B]: P/S control module connector “G10” (View: [a]) 2. To ignition power supply 7. P/S control module / motor assembly
A1: P/S control module power supply circuit 3. Main fuse box 8. CPU
A2: IG1 power supply circuit 4. “P/S” fuse
A3: P/S control module ground circuit 5. J/B

Troubleshooting
Step Action Yes No
1 Circuit fuse check Go to Step 2. Replace fuse(s) and
1) Check that ignition is “OFF”. check for short to
ground in circuits
2) Disconnect “E61” and “G10” connectors.
connected to fuse(s).
3) Check for proper connection to “G10-3” and “E61-1”
terminals.
4) If connections are OK, check “P/S” fuse and “IG1 SIG2”
fuse for blowing.

Is check result OK?

2 P/S control module power supply circuit check Go to Step 3. “A1” circuit is open.
1) Check voltage between “E61-1” terminal and ground.

Is voltage 10 – 14 V?
 Power Assisted Steering System: 6C-30

Step Action Yes No

3 IG1 power supply circuit check Go to Step 4. “A2” circuit is open.
1) Set ignition “ON”.
2) Check voltage between “G10-3” terminal and ground.

Is voltage 10 – 14 V?
4 P/S control module ground circuit check P/S control module “A3” circuit is open or
1) Set ignition “OFF”. power supply and too high in resistance.
ground circuit are in
2) Check for proper connection to “E61-2” terminal.
good condition.
3) Check resistance between “E61-2” terminal and ground.

Is resistance 1 Ω or less?

Inspection of P/S Control Module and Its Circuits

AENJHB0B6304031
P/S control module (1) and its circuits can be checked at P/S control module wiring connectors by measuring voltage
and resistance.

NOTICE
If you connect a voltmeter or an ohmmeter directly to the P/S control module with the P/S control
module connectors disconnected, the P/S control module will be damaged.
Never connect a voltmeter or an ohmmeter directly to any terminal on the P/S control module with the
P/S control module connectors disconnected.

[C] [B]

8 7 6 5 4 3 2 1 4 3 2 1
8 7 6 5

[A] [a]
1

2 1

IJHA0A630012-01

[A]: P/S control module connector “E61” (View: [a]) [B]: Torque sensor connector “E11” (View: [a]) [C]: P/S control module connector “G10” (View: [a])

Voltage Check
1) Remove steering column hole cover. (Page 9C-35)
2) Measure voltage at each terminal with connectors connected to the P/S control module.

NOTE
• As each terminal voltage is affected by the battery voltage, check that the battery voltage is 12 V or
more when ignition is “ON”.
• *1: Turn steering wheel fully and hold it with force applied.
6C-31 Power Assisted Steering System:

“E61” connector
Terminal Circuit Wire color Normal voltage Condition
Main power supply for P/S control
E61-1 WHT Approx. 12 V Ignition in any position / mode
module
E61-2 Ground for P/S control module BLK 0V Ignition in any position / mode

“G10” connector
Terminal Circuit Wire color Normal voltage Condition
IG1 power supply for P/S control
G10-3 GRN Approx. 12 V Ignition “ON”
module
Refer to Oscilloscope Display.
G10-5 CAN (HI1) communication circuit RED
“CAN communication signal” (Page 6C-32)
Refer to Oscilloscope Display.
G10-6 CAN (LO1) communication circuit WHT
“CAN communication signal” (Page 6C-32)
Refer to Oscilloscope Display.
G10-7 CAN (HI2) communication circuit RED
“CAN communication signal” (Page 6C-32)
Refer to Oscilloscope Display.
G10-8 CAN (LO2) communication circuit WHT
“CAN communication signal” (Page 6C-32)

“E11” connector
Terminal Circuit Wire color Normal voltage Condition
Engine: Idle speed
Approx. 2.5 V
Steering wheel at neutral
Engine: Idle speed
Approx. 4 V Vehicle stationary and steering
E11-5 Torque sensor signal (Main) WHT
wheel turned fully to right *1
Engine: Idle speed
Approx. 1 V Vehicle stationary and steering
wheel turned fully to left *1
5 V reference power supply for
E11-6 RED Approx. 5 V Engine: Idle speed
torque sensor
Engine: Idle speed
Approx. 2.5 V
Steering wheel at neutral
Engine: Idle speed
Approx. 1 V Vehicle stationary and steering
E11-7 Torque sensor signal (Sub) YEL
wheel turned fully to right *1
Engine: Idle speed
Approx. 4 V Vehicle stationary and steering
wheel turned fully to left *1
E11-8 Ground for torque sensor BLK 0V Ignition in any position / mode
 Power Assisted Steering System: 6C-32

Reference Waveform Steering Wheel Play Check

AENJHB0B6304032
Oscilloscope display
Shown below is typical waveform display provided by • Check steering wheel for looseness or rattle by
oscilloscope. moving it in axial and lateral directions.
If check result is not OK, repair or replace steering
NOTE wheel.
• Display includes the following types of • Check steering wheel for play, holding vehicle in
data: straight ahead position on the ground with engine
stopped.
If steering wheel play is not as specified, check the
following components and replace any of them if
defective.
– Tie-rod end and tie-rod ball joint for wear
– Suspension arm joint for wear
– Steering shaft joint for wear
– Steering pinion or rack gear for wear or breakage
– Each part for looseness
Steering wheel play “a”
: 0 – 30 mm (0.00 – 1.18 in.)

I8T401111066-01

[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel

[B]: Ground level of each channel [D]: TIME/DIV
“a”

• Waveform varies depending on

measurement condition and vehicle spec.

CAN communication signal

I8C50A630015-02
Channel Probe Terminal No.
G10-5
+ Steering Force Check
CH1 G10-7 AENJHB0B6304033
– Ground 1) Place vehicle on level road and set steering wheel at
G10-6 straight ahead position.
+
CH2 G10-8
2) Check that tire inflation pressure is as specified
– Ground
referring to the “Tire Placard”.
Measurement condition 3) Start engine.
• Ignition mode: “ON” 4) With engine idling, measure steering force using
spring balance (1).
Steering force
: 30 N (3.1 kgf, 6.7 lbf) or less

IAW101630008-01
1
[a]: CH1 1. CAN communication signal I8C50A630016-01
[b]: CH2
6C-33 Power Assisted Steering System:

Repair Instructions
Sensor Calibration 3) Set ignition “ON” and check that no DTC is detected
AENJHB0B6306001 except C116A and C116B. If any DTC is detected,
Without ESP®
repair or replace trouble area.
NOTE 4) Select menu “Sensor Calibration” under “Utility”
mode of SUZUKI scan tool and calibrate sensor with
• If any DTC other than C116A and C116B is ignition “ON”. Refer to Operator’s Manual of SUZUKI
detected, repair the cause of the detected scan tool for further details.
DTC first.
5) After completing the calibration, check DTC(s) is not
• P/S control module has reference values stored P/S control module.
for power steering and steering angle
sensor has its own reference point stored. 6) Check that ignition is “OFF” and then disconnect
SUZUKI scan tool from DLC.
Sensor Condition requiring calibration
Steering angle • Steering angle sensor is replaced. With ESP®
sensor Refer to “Sensor Calibration” in Section 4F (Page 4F-
• P/S control module (steering column 53).
assembly) is replaced.
• Steering wheel is replaced. Torque Sensor and Its Circuit Inspection
• Adjustment of front wheel alignment. AENJHB0B6306002
Using SUZUKI Scan Tool
1) Park vehicle on level surface, release parking brake, 1) Connect SUZUKI scan tool to DLC (1).
set steering wheel in straight ahead position and
Special tool
stop engine.
(A): SUZUKI scan tool (Suzuki SDT-II)
NOTE
Keep condition of Step 1) until sensor
calibration is completed, in order to calibrate
sensor correctly.

2) Connect SUZUKI scan tool to DLC (1) with ignition

“OFF”.
Special tool
1
(A): SUZUKI scan tool (Suzuki SDT-II)

(A)

IJHA0A110011-01

2. VCI

2) Start engine and select “Sensor (Main) Torque” and

“Sensor (Sub) Torque” in “Data list” mode on
SUZUKI scan tool.

(A)

IJHA0A110021-01
 Power Assisted Steering System: 6C-34

3) Check each of “Sensor (Main) Torque” and “Sensor Using Voltmeter

(Sub) Torque” changes linearly as specified in the 1) Remove steering column hole cover. (Page 9C-35)
following graph.
2) Start engine and measure voltage between terminals
[A]
“E11-5” – “E11-8” and “E11-7” – “E11-8” at torque
[F] [V] sensor connector (1) connected to P/S control
module / motor assembly (2).
Approx. 4 V

Approx. 2.5 V [A]

[a]
Approx. 1 V 2
4 3 2 1
8 7 6 5
[H] [E] [H]

[C] [D]
[B]
[G] [V]

Approx. 4 V

Approx. 2.5 V 1

Approx. 1 V

[H] [E] [H]

[C] [D]
IHSE0A630004-01 2
[A]: Main signal
IJHB0A630004-01
[B]: Sub signal
[C]: Steering force at left turn [A]: P/S control module connector “E11” (View: [a])
[D]: Steering force at right turn
[E]: Steering wheel at straight ahead position
[F]: “Sensor (Main) Torque” in “Data List” displayed on scan tool
[G]: “Sensor (Sub) Torque” in “Data List” displayed on scan tool
[H]: Turn steering wheel fully and hold it with force applied.

4) If check result is not as specified, repair or replace

any of the following items.
• Torque sensor harness and connector
• Torque sensor (steering column assembly)
• P/S control module (steering column assembly)
6C-35 Power Assisted Steering System:

3) Check voltage changes linearly in main signal and 4) If check result is not as specified, repair or replace
sub signal as specified in the following graph. any of the following items.
• Torque sensor harness and connector
[A]
[F] [V] • Torque sensor (steering column assembly)
• P/S control module (steering column assembly)
Approx. 4 V

Approx. 2.5 V

Approx. 1 V

[H] [E] [H]

[C] [D]
[B]
[G] [V]

Approx. 4 V

Approx. 2.5 V

Approx. 1 V

[H] [E] [H]

[C] [D]
IHSE0A630005-01

[A]: Main signal

[B]: Sub signal
[C]: Steering force at left turn
[D]: Steering force at right turn
[E]: Steering wheel at straight ahead position
[F]: “Sensor (Main) Torque” measured voltage by volt meter
[G]: “Sensor (Sub) Torque” measured voltage by volt meter
[H]: Turn steering wheel fully and hold it with force applied.

Special Tools and Equipment

Special Tool
AENJHB0B6308001
SUZUKI scan tool (Suzuki
SDT-II)
—
(Page 6C-12) /
(Page 6C-13) /
(Page 6C-33) /
(Page 6C-33)

Section 7
HVAC
CONTENTS
Precautions .................................................7-1
Precautions............................................................. 7-1
Precautions for HVAC ........................................... 7-1
A/C System Caution.............................................. 7-1
Precautions for Servicing A/C System .................. 7-1
HVAC System........................................... 7B-1
Manual A/C Single Type .........................................7B-1
General Description .............................................7B-1
HVAC System Description .................................. 7B-1
Sub-Cool A/C System Description ...................... 7B-3
Compressor Drive Belt Description (K15B
Model) ............................................................... 7B-3
A/C Operation Description (K15B Model) ........... 7B-4
A/C Operation Description (D13A Model) ........... 7B-5
Schematic and Routing Diagram........................7B-6
Manual A/C Electronic Control Input / Output
Block Diagram................................................... 7B-6
Manual A/C System Circuit Diagram................... 7B-7
Component Location ...........................................7B-8
Manual A/C Control System Component
Location ............................................................ 7B-8
Diagnostic Information and Procedures............7B-9
A/C System Performance Inspection .................. 7B-9
Trouble Diagnosis for Abnormal Pressure ........ 7B-15
A/C System Symptom Diagnosis ...................... 7B-18
Abnormal Noise Symptom Diagnosis of
HVAC System ................................................. 7B-21
Air Conditioning System Check......................... 7B-22
Visual Inspection ............................................... 7B-24
Inspection of HVAC Control Unit and Its
Circuit.............................................................. 7B-24
Inspection of A/C System Circuits at ECM........ 7B-25
Repair Instructions ............................................7B-26
Operation Procedure for Refrigerant Charge .... 7B-26
A/C System Components.................................. 7B-32
Radiator Cooling Fan Removal and
Installation ....................................................... 7B-33
Radiator Cooling Fan Inspection....................... 7B-33
Condenser Assembly On-Vehicle Inspection.... 7B-34
Condenser Assembly Removal and
Installation ....................................................... 7B-34
HVAC Unit Components ................................... 7B-35
HVAC Unit Removal and Installation ................ 7B-36
Table of Contents 7- i
Blower Motor Removal and Installation.............7B-37
Blower Motor Inspection....................................7B-38
Blower Motor Resistor Removal and
Installation .......................................................7B-38
Blower Motor Resistor Inspection .....................7B-38
Evaporator Removal and Installation ................7B-39
Evaporator Inspection .......................................7B-39
Evaporator Temperature Sensor Removal
and Installation (If Equipped) ..........................7B-40
Evaporator Temperature Sensor Inspection
(If Equipped)....................................................7B-40
Heater Core Removal and Installation ..............7B-41
Expansion Valve Removal and Installation .......7B-42
Expansion Valve Inspection ..............................7B-42
HVAC Control Unit Components.......................7B-42
HVAC Control Unit Removal and Installation....7B-43
Blower Speed Selector Inspection ....................7B-45
A/C Refrigerant Pressure Sensor and Its
Circuit Inspection.............................................7B-45
A/C Refrigerant Pressure Sensor Removal
and Installation ................................................7B-45
Ventilation Duct Removal and Installation.........7B-46
Center Ventilation Louver Removal and 7
Installation .......................................................7B-46
Side Ventilation Louver Removal and
Installation .......................................................7B-47
Cup Holder Duct Removal and Installation .......7B-47
HVAC Air Filter Removal and Installation .........7B-47
HVAC Air Filter Inspection ................................7B-47
A/C Switch Inspection .......................................7B-48
HVAC System Relay Inspection........................7B-48
Compressor Drive Belt Inspection.....................7B-48
Compressor Drive Belt Removal and
Installation .......................................................7B-49
Compressor Assembly Removal and
Installation .......................................................7B-50
Compressor Assembly Components.................7B-52
Magnet Clutch Inspection..................................7B-53
Magnet Clutch Removal and Installation...........7B-54
Relief Valve Inspection......................................7B-57
Relief Valve Removal and Installation (K15B
Model) .............................................................7B-57
Specifications .....................................................7B-58
Tightening Torque Specifications......................7B-58
Special Tools and Equipment ...........................7B-58
7-ii Table of Contents
Recommended Service Material ....................... 7B-58
Special Tool ......................................................7B-58
Manual A/C Dual Type ..........................................7B-59
General Description ...........................................7B-59
HVAC System Description ................................ 7B-59
Sub-Cool A/C System Description .................... 7B-60
Compressor Drive Belt Description (K15B
Model) .............................................................7B-62
A/C Operation Description (K15B Model) .........7B-62
A/C Operation Description (D13A Model) .........7B-62
Schematic and Routing Diagram......................7B-62
Manual A/C Electronic Control Input / Output
Block Diagram................................................. 7B-62
Manual A/C System Circuit Diagram................. 7B-63
Component Location .........................................7B-64
Manual A/C Control System Component
Location .......................................................... 7B-64
Diagnostic Information and Procedures..........7B-66
A/C System Performance Inspection ................ 7B-66
Trouble Diagnosis for Abnormal Pressure ........7B-74
A/C System Symptom Diagnosis ......................7B-77
Abnormal Noise Symptom Diagnosis of
HVAC System ................................................. 7B-77
Air Conditioning System Check.........................7B-77
Visual Inspection ...............................................7B-77
Inspection of HVAC Control Unit and Its
Circuit .............................................................. 7B-77
Inspection of A/C System Circuits at ECM........7B-77
Repair Instructions ............................................7B-78
Operation Procedure for Refrigerant Charge .... 7B-78
A/C System Components..................................7B-84
Radiator Cooling Fan Removal and
Installation ....................................................... 7B-87
Radiator Cooling Fan Inspection....................... 7B-87
Condenser Assembly On-Vehicle Inspection.... 7B-87
Condenser Assembly Removal and
Installation ....................................................... 7B-87
HVAC Unit Components ...................................7B-87
HVAC Unit Removal and Installation ................ 7B-87
Blower Motor Removal and Installation............. 7B-87
Blower Motor Inspection.................................... 7B-87
Blower Motor Resistor Removal and
Installation ....................................................... 7B-87
Blower Motor Resistor Inspection .....................7B-87
Evaporator Removal and Installation ................ 7B-88
Evaporator Inspection ....................................... 7B-88
Evaporator Temperature Sensor Removal
and Installation (If Equipped) .......................... 7B-88
Evaporator Temperature Sensor Inspection
(If Equipped) ...................................................7B-88
Heater Core Removal and Installation .............. 7B-88
Expansion Valve Removal and Installation ....... 7B-88
Expansion Valve Inspection .............................. 7B-88
HVAC Control Unit Components....................... 7B-88
HVAC Control Unit Removal and Installation.... 7B-88
Blower Speed Selector Inspection .................... 7B-88
A/C Refrigerant Pressure Sensor and Its
Circuit Inspection ............................................7B-88
A/C Refrigerant Pressure Sensor Removal
and Installation ................................................7B-88
Ventilation Duct Removal and Installation.........7B-88
Center Ventilation Louver Removal and
Installation .......................................................7B-88
Side Ventilation Louver Removal and
Installation .......................................................7B-88
Cup Holder Duct Removal and Installation .......7B-88
HVAC Air Filter Removal and Installation .........7B-88
HVAC Air Filter Inspection ................................7B-88
Rear Cooling Unit Removal and Installation .....7B-89
Rear Cooling Unit Inspection ............................7B-90
Rear Blower Speed Selector Removal and
Installation .......................................................7B-91
Rear Blower Speed Selector Inspection ...........7B-91
Rear Ventilation Louver Removal and
Installation .......................................................7B-92
A/C Switch Inspection .......................................7B-92
HVAC System Relay Inspection........................7B-92
Compressor Drive Belt Inspection.....................7B-92
Compressor Drive Belt Removal and
Installation .......................................................7B-92
Compressor Assembly Removal and
Installation .......................................................7B-92
Compressor Assembly Components.................7B-92
Magnet Clutch Inspection..................................7B-92
Magnet Clutch Removal and Installation...........7B-92
Relief Valve Inspection......................................7B-92
Relief Valve Removal and Installation (K15B
Model) .............................................................7B-92
Specifications .....................................................7B-93
Tightening Torque Specifications......................7B-93
Special Tools and Equipment ...........................7B-93
Recommended Service Material .......................7B-93
Automatic A/C Dual Type .....................................7B-94
Precautions.........................................................7B-94
Precautions for Diagnosing Trouble ..................7B-94
General Description ...........................................7B-94
Auto A/C System Description............................7B-94
HVAC Control Description.................................7B-94
Sub-Cool A/C System Description ....................7B-95
Compressor Drive Belt Description (K15B
Model) .............................................................7B-95
A/C Operation Description (K15B Model) .........7B-95
A/C Operation Description (D13A Model) .........7B-95
OBD System Description ..................................7B-95
CAN Communication System Description.........7B-95
Schematic and Routing Diagram ......................7B-96
Auto A/C Electronic Control Input / Output
Block Diagram.................................................7B-96
Auto A/C System Circuit Diagram .....................7B-97
Component Location .........................................7B-98
Auto A/C Control System Component
Location...........................................................7B-98
Diagnostic Information and Procedures ........7B-100
A/C System Performance Inspection ..............7B-100
Trouble Diagnosis for Abnormal Pressure ......7B-100
A/C System Symptom Diagnosis ....................7B-100

Abnormal Noise Symptom Diagnosis of A/C
System .......................................................... 7B-102
Air Conditioning System Check....................... 7B-102
Visual Inspection ............................................. 7B-104
DTC Check ..................................................... 7B-104
DTC Clearance ............................................... 7B-104
DTC Table....................................................... 7B-105
Fail-Safe Table................................................ 7B-106
Scan Tool Data ............................................... 7B-107
DTC B1508 ..................................................... 7B-111
DTC B1509 ..................................................... 7B-112
DTC B150A ..................................................... 7B-113
DTC B150B ..................................................... 7B-115
DTC B150C / B1519 / B151B ......................... 7B-116
DTC B150D / B151A / B151C ......................... 7B-118
DTC B1513 / B1514 / B1531 .......................... 7B-120
DTC B1546 ..................................................... 7B-121
DTC B1549 / U2005........................................ 7B-122
DTC B1563 ..................................................... 7B-123
DTC B1570 ..................................................... 7B-124
DTC B1571 ..................................................... 7B-124
DTC U0073 ..................................................... 7B-124
DTC U0100 ..................................................... 7B-124
DTC U0155 ..................................................... 7B-124
Inspection of Auto A/C Panel and Its Circuit ... 7B-125
Inspection of A/C System Circuits at BCM...... 7B-126
Inspection of A/C System Circuits at ECM...... 7B-126
Repair Instructions ..........................................7B-126
Operation Procedure for Refrigerant Charge .. 7B-126
A/C System Components................................ 7B-126
Radiator Cooling Fan Removal and
Installation ..................................................... 7B-126
Radiator Cooling Fan Inspection..................... 7B-126
Condenser Assembly On-Vehicle Inspection.. 7B-126
Condenser Assembly Removal and
Installation ..................................................... 7B-126
HVAC Unit Components ................................. 7B-127
HVAC Unit Removal and Installation .............. 7B-128
Auto A/C Panel Removal and Installation ....... 7B-128
Blower Motor Removal and Installation........... 7B-128
Blower Motor Inspection ................................. 7B-128
Blower Motor Controller Removal and
Installation ..................................................... 7B-128
Blower Motor Controller Inspection ................. 7B-128
Evaporator Removal and Installation .............. 7B-129
Evaporator Inspection ..................................... 7B-129
Evaporator Temperature Sensor Removal
and Installation .............................................. 7B-129
Evaporator Temperature Sensor Inspection ... 7B-129
Heater Core Removal and Installation ............ 7B-129
Expansion Valve Removal and Installation ..... 7B-129
Expansion Valve Inspection ............................ 7B-129
A/C Refrigerant Pressure Sensor and Its
Circuit Inspection .......................................... 7B-129
Table of Contents 7-iii
A/C Refrigerant Pressure Sensor Removal
and Installation ..............................................7B-129
Temperature Control Actuator Removal and
Installation .....................................................7B-129
Temperature Control Actuator Inspection .......7B-130
Air Flow Control Actuator Removal and
Installation .....................................................7B-130
Air Flow Control Actuator Inspection...............7B-131
Air Intake Control Actuator Removal and
Installation .....................................................7B-131
Air Intake Control Actuator Inspection.............7B-132
Actuator Linkage Inspection............................7B-132
Sunload Sensor Removal and Installation ......7B-132
Sunload Sensor Inspection .............................7B-133
Outside Air Temperature Sensor Removal
and Installation ..............................................7B-133
Outside Air Temperature Sensor Inspection ...7B-133
Inside Air Temperature Sensor Removal and
Installation .....................................................7B-133
Inside Air Temperature Sensor Inspection......7B-134
Ventilation Duct Removal and Installation.......7B-134
Center Ventilation Louver Removal and
Installation .....................................................7B-134
Side Ventilation Louver Removal and
Installation .....................................................7B-134
Cup Holder Duct Removal and Installation .....7B-134
HVAC Air Filter Removal and Installation .......7B-134
HVAC Air Filter Inspection ..............................7B-134
Rear Cooling Unit Removal and Installation ...7B-134
Rear Cooling Unit Inspection ..........................7B-134
Rear Blower Speed Selector Removal and
Installation .....................................................7B-134
Rear Blower Speed Selector Inspection .........7B-134
Rear Ventilation Louver Removal and
Installation .....................................................7B-134
HVAC System Relay Inspection......................7B-134
Compressor Drive Belt Inspection...................7B-134
Compressor Drive Belt Removal and
Installation .....................................................7B-135
Compressor Assembly Removal and
Installation .....................................................7B-135
Compressor Assembly Components...............7B-135
Magnet Clutch Inspection................................7B-135
Magnet Clutch Removal and Installation.........7B-135
Relief Valve Inspection....................................7B-135
Relief Valve Removal and Installation (K15B
Model) ...........................................................7B-135
Specifications ...................................................7B-135
Tightening Torque Specifications....................7B-135
Special Tools and Equipment .........................7B-135
Recommended Service Material .....................7B-135
Special Tool ....................................................7B-135
7-1 Precautions:
Precautions
HVAC
Precautions
Precautions for HVAC
AENJHB0B7000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-
1).
Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3).
Caution for Fastener
Refer to “Caution for Fastener” in Section 00 (Page 00-
5).
Warning for Air Bag
Refer to “Warning for Air Bag” in Section 00 (Page 00-7).
Reassembling Note for Wiring Harness
Observe “Reassembling Note for Wiring Harness” in
Section 9A (Page 9A-142) whenever installing wiring
harness.
Otherwise, electrical trouble may occur.
Precautions for Ignition Mode
Refer to “Ignition Modes and Ignition Switch Positions” in
Section 0A (Page 0A-5).
A/C System Caution
AENJHB0B7000002
NOTICE
The A/C system of this vehicle uses HFC-
134a (R-134a) refrigerant. The compressor oil
and parts used in the system are also made
of materials compatible with each refrigerant.
If this system is serviced using compressor
oils or parts that are not appropriate for each
refrigerant, refrigerant leakage and damage
or other faulty conditions will occur in the A/
C system. This will also cause damage to or
faulty operation of the servicing equipment.
Check which refrigerant is used before any
service work including inspection and
maintenance. Use compatible refrigerant,
specified compressor oil and replacement
parts for respective refrigerant type. In
addition, use applicable manifold gauge set,
leak detector and refrigerant recovery and
recycling equipment respectively.
Precautions for Servicing A/C System
AENJHB0B7000003
Handling HFC-134a (R-134a) Refrigerant and
Specified Compressor Oil
! WARNING
• If HFC-134a (R-134a) is exposed to high
temperatures, it turns into a poisonous
gas.
Take the following precautions to prevent
health problems caused by HFC-134a (R-
134a) gas.
– Do not handle refrigerant in or near any
area where welding or steam cleaning is
performed.
– Keep refrigerant in a cold and dark
place. Avoid storing it under direct
sunlight, in a place close to fire or inside
a vehicle.
– If HFC-134a (R-134a) is burned, avoid
breathing fumes.
• Contact of liquid HFC-134a (R-134a)
refrigerant with skin and eyes will cause
frostbite. The refrigerant cools the surface
coming in contact with it to a temperature
much lower than the freezing point of
water.
Avoid contact with HFC-134a (R-134a)
refrigerant and wear goggles and gloves
whenever handling the refrigerant. Should
the refrigerant happen to contact your
eyes or skin, immediately take action as
described below to prevent aggravating
the condition:
– In the event of eye contact, do not touch
the eye with your hand. Instead, pour
fresh cold water over the eye to raise
gradually the temperature. After
washing the eye thoroughly with water,
receive medical attention as soon as
possible.
– If liquid HFC-134a (R-134a) contacts
your skin, wash the affected area
thoroughly with water. Since the skin
may have been frostbitten, receive
medical attention.
 Precautions: 7-2

NOTE Refrigerant Recovery

When discharging refrigerant out of A/C system, always
• Do not discharge HFC-134a (R-134a)
recover it using refrigerant recovery and recycling
refrigerant into atmosphere.
equipment because discharging HFC-134a (R-134a)
• The specified compressor oil for HFC-134a refrigerant into atmosphere would cause adverse effect
(R-134a) is highly hygroscopic. Keep to environment. For the method, refer to “Recovery” in
internal parts of air conditioning free from “Operation Procedure for Refrigerant Charge”.
moisture and dirt. When disconnecting any
• Manual A/C
line from system, install a blind plug or cap
to the fitting immediately. – Single type: (Page 7B-26)
• If pipes or hoses are replaced, replenish – Dual type: (Page 7B-78)
compressor with specified amount of • Automatic A/C
compressor oil from suction side referring – Dual type: (Page 7B-126)
to “Replenishing Compressor Oil” in
“Operation Procedure for Refrigerant Refrigerant Charge
Charge”. After performing compressor oil replenishment and
– Manual A/C evacuation, charge the A/C system with a proper amount
– Single type: (Page 7B-26) of refrigerant referring to “Charge” in “Operation
Procedure for Refrigerant Charge”.
– Dual type: (Page 7B-78)
• Manual A/C
– Automatic A/C
– Single type: (Page 7B-26)
– Dual type: (Page 7B-126)
– Dual type: (Page 7B-78)
• Automatic A/C
Handling A/C Cycle Parts and Tooling
– Dual type: (Page 7B-126)
NOTE
• Route drain hose so that drained water
does not adhere to vehicle components.
• When connecting hoses and pipes, apply a
few drops of compressor oil (refrigerant
oil) to O-ring.
• Replace O-ring with new one, once hoses,
pipes or parts are disconnected.
• For locations of high pressure service
valve and low pressure service valve, refer
to “A/C System Components”.
– Manual A/C
– Single type: (Page 7B-32)
– Dual type: (Page 7B-84)
– Automatic A/C
– Dual type: (Page 7B-126)
• Check local governmental regulations
regarding working with refrigerator
systems and its tooling.
7B-1 HVAC System: Manual A/C Single Type

HVAC System
HVAC

Manual A/C Single Type

General Description
HVAC System Description
AENJHB0B7211001
• This HVAC system is of a manually controlled air conditioning type.
• Settings of air flow mode, temperature control and air inlet mode are possible using air flow selector, temperature
selector and air intake selector respectively. When these selectors are set in desired positions, the corresponding
cables move air flow control door, temperature control door and air intake door accordingly.
• Air flow rate can be adjusted by blower speed selector. Four positions are available: LO, ML, MH and HI.
• A/C switch turns on and off the A/C system. Signal from the A/C switch is transmitted to ECM via BCM through CAN
communication system. The ECM circuits related to the A/C system control A/C compressor relay and radiator
(condenser) cooling fan relay according to the signal. Refer to “A/C Operation Description (K15B Model)”: Manual
A/C Single Type (Page 7B-4) or “A/C Operation Description (D13A Model)”: Manual A/C Dual Type (Page 7B-62)
for details.
• The ECM circuits related to the A/C system also control evaporator temperature depending on the data from
evaporator temperature sensor. Refer to “A/C Operation Description (K15B Model)”: Manual A/C Single Type (Page
7B-4) or “A/C Operation Description (D13A Model)”: Manual A/C Dual Type (Page 7B-62) for details. On the other
hand, compressor can adjust the flow rate of refrigerant, monitoring the A/C refrigerant pressure mechanically. This
also helps to keep the evaporator temperature at an optimum level.
• The A/C system uses an A/C refrigerant pressure sensor that is capable of detecting linear changes in refrigerant
pressure.
• HVAC unit incorporates blower motor unit, heater core unit and evaporator unit. The HVAC unit also incorporates an
air filter.
• Each side ventilator has a shutter mechanism.
• The condenser is of a sub-cool type. It is integral with the receiver / dryer and mounted on the vehicle body in a
floating manner.
• For further information on manual A/C system, refer to “Manual A/C Control System Component Location”: Manual
A/C Single Type (Page 7B-8), “A/C System Components”: Manual A/C Single Type (Page 7B-32) and “Manual A/C
Electronic Control Input / Output Block Diagram”: Manual A/C Single Type (Page 7B-6).
 HVAC System: Manual A/C Single Type 7B-2

HVAC System Construction

9 13

10 14
14

12

9
25 24

1 20

21

23

15
16

19 11 11
18
17
22

4
7
6
5
2 : [A]
3 : [B]

: [C]

IJHB0A721001-01

[A]: Air flow 8. Expansion valve 18. Air intake door

[B]: Refrigerant flow 9. Side ventilation air 19. Temperature control door
[C]: Engine coolant flow 10. Center ventilation air 20. Air flow control door
1. HVAC unit 11. Front foot air 21. Heater core
2. Compressor 12. Cup holder air 22. HVAC air filter
3. Condenser assembly 13. Defroster air 23. Engine
4. Receiver / dryer 14. Demister air 24. Radiator
5. Discharge hose 15. Fresh air 25. Reservoir
6. Suction hose 16. Recirculation air
7. Liquid hose 17. Evaporator
7B-3 HVAC System: Manual A/C Single Type

Sub-Cool A/C System Description

AENJHB0B7211002
In the sub-cool A/C system (condenser incorporating receiver / dryer), the inside of the condenser is divided into the
condensation part and the sub-cooler part, and the receiver / dryer is located between these parts. In the receiver /
dryer, the refrigerant is separated into vapor refrigerant and liquid refrigerant. Only the liquid refrigerant is delivered to
the sub-cooler part of the condenser. The refrigerant is supercooled by the sub-cooler part of the condenser.

IFRA0A721002-01

[A]: Liquid 4. Receiver/dryer 10. Desiccant

[B]: Vapor 5. A/C refrigerant pressure sensor 11. Filter
[C]: Superheated vapor 6. Expansion valve 12. Vapor refrigerant
1. Compressor 7. Evaporator 13. Liquid refrigerant
2. Magnet clutch 8. Condensation part
3. Condenser 9. Sub-cooler part

Compressor Drive Belt Description (K15B Model)

AENJHB0B7211003
The compressor drive belt is a stretch-type belt. It stretches itself to maintain the belt tension. Therefore, a tension
pulley, which is used to adjust the belt tension, or components for adjusting the clearance between the crankshaft
pulley and the magnet clutch pulley are not necessary. When removing or installing the stretch-type belt, use the
special tool to prevent the belt from being damaged.
 HVAC System: Manual A/C Single Type 7B-4

A/C Operation Description (K15B Model)

AENJHB0B7211004
Upon receiving A/C switch ON signal from HVAC control unit, ECM control A/C compressor relay and radiator
(condenser) cooling fan relay as described in the table below.
The A/C switch ON signal is sent from the HVAC control unit to BCM. Then it is transmitted to ECM as A/C request
signal through CAN. For CAN communication system, refer to “Communication System Description”: K15B Model in
Section 10H (Page 10H-1).
Input sensor
Control item Description
(or signal)
ECM controls compressor by turning A/C compressor relay ON/
Evaporator
Evaporator OFF according to request signal from BCM. BCM sends the signal
temperature
temperature based on the signal from evaporator temperature sensor to
sensor
prevent evaporator from freezing.
Control during ECM stops compressor by turning A/C compressor relay OFF
low engine according to signal from CKP sensor (engine rpm) to prevent
speed engine from stalling while engine speed is low.
Control during ECM stops compressor by turning A/C compressor relay OFF
high engine CKP sensor according to signal from CKP sensor (engine rpm) to prevent
speed (engine rpm) compressor from over-revolution while engine speed is high.
ECM stops compressor temporarily by turning A/C compressor
Control at relay OFF according to signals from CKP sensor (engine rpm)
engine start and others to stabilize engine idling speed immediately after
engine start.
• ECM stops compressor by turning A/C compressor relay OFF
Control at according to signal from A/C refrigerant pressure sensor to
A/C compressor abnormal A/C refrigerant
relay control protect system when refrigerant pressure is abnormal.
refrigerant pressure sensor
pressure • ECM stops compressor by turning A/C compressor relay OFF
when A/C refrigerant pressure sensor malfunctions.
• ECM stops compressor temporarily by turning A/C compressor
relay OFF according to signal from APP sensor to provide
enough acceleration while accelerator pedal is fully depressed
APP sensor and regardless of vehicle speed.
Control during
wheel speed
acceleration • ECM stops compressor temporarily by turning A/C compressor
sensor
relay OFF according to signal from throttle position sensor to
provide enough acceleration when accelerator pedal is
depressed more than specification while vehicle speed is low.
• ECM stops compressor by turning A/C compressor relay OFF
Control at high according to signal from ECT sensor to prevent overheating
engine coolant ECT sensor when engine coolant temperature is higher than specified level.
temperature • ECM stops compressor by turning A/C compressor relay OFF
when ECT sensor malfunctions.
ECM drives radiator cooling fan in low or high speed mode under
the following conditions by turning radiator cooling fan relays
No.1, No.2 and No.3 ON/OFF according to signals from A/C
refrigerant pressure sensor and wheel speed sensor when A/C
compressor relay is ON.
A/C refrigerant • Low speed mode (Radiator cooling fan relay No.1 ON)
Radiator (condenser) cooling fan pressure sensor – Vehicle speed is less than specified value.
relay control and wheel
– Vehicle speed is more than specified value and refrigerant
speed sensor
pressure more than specified value.
– Wheel speed sensor malfunction is not detected.
• High speed mode (Radiator cooling fan relays No.1, No.2 and
No.3 ON)
– Refrigerant pressure more than specified value.
7B-5 HVAC System: Manual A/C Single Type

A/C Operation Description (D13A Model)

AENJHB0B7211005
Upon receiving A/C switch ON signal from HVAC control unit, ECM controls A/C compressor relay and radiator
(condenser) cooling fan relay as described in the following table.
The A/C switch ON signal is sent from the HVAC control unit to BCM. Then it is transmitted to ECM as A/C request
signal through CAN. For CAN communication system, refer to “Communication System Description”: D13A Model in
Section 10H (Page 10H-24).
Input sensor (or
Control item Description
signal)
ECM controls compressor by turning A/C compressor relay
Evaporator
Evaporator ON/OFF according to request signal from BCM. BCM sends
temperature sensor
temperature the signal based on the signal from evaporator temperature
(if equipped)
sensor to prevent evaporator from freezing.
ECM stops compressor by turning A/C compressor relay
Control during low
OFF according to signal from CKP sensor (engine rpm) so
engine speed
as to prevent engine from stalling while engine speed is low.
CKP sensor (engine
ECM stops compressor by turning A/C compressor relay
rpm)
Control during high OFF according to signal from CKP sensor (engine rpm) so
engine speed as to prevent compressor from over-revolution while engine
speed is high.
• ECM stops compressor by turning A/C compressor relay
OFF according to signal from A/C refrigerant pressure
Control at abnormal A/C refrigerant sensor so as to protect system when refrigerant pressure
refrigerant pressure pressure sensor is abnormal.
A/C • ECM stops compressor by turning A/C compressor relay
compressor OFF when A/C refrigerant pressure sensor malfunctions.
relay control • ECM stops compressor temporarily by turning A/C
compressor relay OFF according to signal from
accelerator pedal position sensor so as to ensure
acceleration while accelerator pedal is fully depressed
Accelerator pedal regardless of vehicle speed.
Control during
position sensor and
acceleration • ECM stops compressor temporarily by turning A/C
wheel speed sensor
compressor relay OFF according to signal from throttle
position sensor so as to ensure acceleration when
accelerator pedal is depressed more than specification
while vehicle speed is low.
• ECM stops compressor by turning A/C compressor relay
OFF according to signal from ECT sensor so as to
Control at high prevent overheating when engine coolant temperature is
engine coolant ECT sensor higher than specified level.
temperature
• ECM stops compressor by turning A/C compressor relay
OFF when ECT sensor malfunctions.
ECM drives radiator cooling fan in low or high speed mode
Radiator (condenser) cooling fan A/C refrigerant by turning radiator cooling fan relays No.1, No.2 and No.3
relay control pressure sensor ON/OFF according to signal from A/C refrigerant pressure
sensor.
 HVAC System: Manual A/C Single Type 7B-6

Schematic and Routing Diagram

Manual A/C Electronic Control Input / Output Block Diagram
AENJHB0B7212001

Input sensor (or signal) Control module Output actuator (or signal)

ECM (A/C control area)

A/C refrigerant
pressure sensor A/C compressor relay A/C compressor relay
control
Accelerator pedal
position sensor Compressor
Radiator (condenser)
ECT sensor cooling fan relay control
Radiator cooling fan relay
CKP sensor

Wheel speed sensor Radiator cooling fan

ABS control module

Evaporator temperature
sensor (if equipped)

BCM

HVAC control unit

Blower motor
A/C switch

Blower speed selector Blower motor resistor

CAN communication
IJHB0A721002-01
7B-7 HVAC System: Manual A/C Single Type

Manual A/C System Circuit Diagram

AENJHB0B7212002

18

2
3

YEL
17 4

24

5
19

6 G155-5 RED
9

G155-4 YEL
7
G155-3 25
BLK 20
G155-1 GRY

G155-6 G155-2 WHT

8
GRN
10 21
G154-1 G154-7 BLU 27
22 12V 5V
11 28
YEL G154-11
12

G154-12 BLK
13
30 31
14

15
26
12V 23
LT GRN G154-3 G154-9 RED
16 29

30 31
IJHB0A721003-01

1. J/B 12. APP sensor (main) 23. Illumination light

2. Relay box 13. APP sensor (sub) 24. Blower motor
3. Blower motor relay 14. ECT sensor 25. Blower motor resistor
4. Main relay 15. A/C refrigerant pressure sensor 26. To J/B
5. Radiator cooling fan relay No.1 16. CKP sensor 27. BCM
6. Radiator cooling fan relay No.2 17. To continuous power supply 28. Evaporator temperature sensor (if equipped)
7. Radiator cooling fan relay No.3 18. To ignition power supply 29. Combination meter
8. A/C compressor relay 19. HVAC control unit 30. CAN driver
9. Radiator cooling fan 20. Blower speed selector 31. To other control module and DLC connected by CAN
10. Compressor 21. A/C switch
11. ECM 22. “A/C” indicator light
 HVAC System: Manual A/C Single Type 7B-8

Component Location
Manual A/C Control System Component Location
AENJHB0B7213001

5 6
7

2 8

3
1

9
11

10

IJHB0A721004-01
7B-9 HVAC System: Manual A/C Single Type

[A] 14

13 15
12

16 17 18

[B] 14

20 16 15

19
21
22 13 17 18

IJHB0A721005-01

[A]: K15B model 7. Temperature selector 15. A/C compressor relay

[B]: D13A model 8. Air intake selector 16. Radiator cooling fan relay No.2
1. BCM 9. Blower motor 17. Radiator cooling fan relay No.1
2. HVAC unit 10. Blower motor resistor 18. Blower motor relay
3. HVAC control unit 11. Evaporator temperature sensor (if equipped) 19. Compressor
4. Air flow selector 12. ECM 20. Condenser assembly
5. Blower speed selector 13. Main relay 21. Radiator cooling fan
6. A/C switch 14. Radiator cooling fan relay No.3 22. A/C refrigerant pressure sensor

Diagnostic Information and Procedures

A/C System Performance Inspection
AENJHB0B7214001
1) Check that vehicle and environmental conditions are as follows.
• Vehicle is put indoors.
• Ambient temperature is within 25 – 45 °C (77 – 113 °F).
• Relative humidity is within 30 – 70%.
• There is no wind indoors.
• HVAC unit is normal.
• Blower motor is normal.
• There is no air leakage from air ducts.
• Condenser fins are clean.
• HVAC air filter is not clogged with dirt and dust.
• Battery voltage is about 12 V or more (battery in good condition).
• Radiator cooling fan operates normally.
2) Check that high pressure valve (1) and low pressure valve (2) of manifold gauge are firmly closed.
 HVAC System: Manual A/C Single Type 7B-10

3) Connect high pressure charging hose (3) to high pressure service valve (4) and low pressure charging hose (5) to
low pressure service valve (6).

NOTE
For locations of high pressure service valve and low pressure service valve, refer to “A/C System
Components”: Manual A/C Single Type (Page 7B-32).

2 1

5
3

IELA0A722038-01

4) Warm up engine to normal operating temperature and keep it at specified idle speed.
5) Turn A/C switch ON, and then set blower speed selector to maximum speed position, temperature selector to
maximum cold position, air flow selector to face position, air intake selector to recirculation mode and side
ventilation louvers to open position. (Check that compressor and radiator cooling fan are working.)
6) Wait for ten minutes to stabilize A/C operation.
7) Open all door windows, front doors and hood.
8) Put about 20 mm (0.79 in.) of dry-bulb thermometer (1) in front of center ventilation louver (2). Put wet-and-dry-
bulb thermometer (3) near air inlet of HVAC unit.

3
ICN10P720004-01
7B-11 HVAC System: Manual A/C Single Type

9) Check for each pressure of low side and high side if it is within shaded range in the cooling inspection graph. If
each gauge reading is out of specified pressure, correct defective part referring to the following table.
When diagnosing troubles of abnormal pressure on the low side and high side more specifically, refer to “Trouble
Diagnosis for Abnormal Pressure”: Manual A/C Single Type (Page 7B-15).

NOTE
• If radiator fan changes speed between Low and High while checking the pressure, wait for another
ten minutes to stabilize A/C operation.
• Cooling inspection graph shows a measured value under relative humidity of 30 – 70%. Outlet air
temperature has a decreasing tendency when the humidity is 30% and an increasing tendency when
the humidity is 70%.
• Outlet air temperature may vary according to relative humidity under the same conditions of inlet air
temperature, low pressure value and high pressure value.

Cooling inspection graph (High and low pressure gauge)

[A]
psi kPa kgf/cm2 %
355.6 2500 25
341.4 2400 24 70
327.1 2300 23
312.9
2200 22
298.7
2100 21
30
284.4
2000 20
270.2
1900 19
256.0
1800 18
“f”
241.7
1700 17
[e]
227.5
1600 16
213.3 1500 15
[a] 199.1 1400 14
184.9 1300 13
“g ”
170.6 1200 12 [d ]
151.4 1100 11
142.2 1000 10
128.0 900 9
113.8 800 8
99.5 700 7
85.3 600 6
70
71.1 500 5 “h ”
56.9 400 4 30
[e]
42.7 300 3
[b] “i”
28.4 200 2
14.2 100 1
0
25 30 35 40 45°C
77 86 95 104 113°F
[c ]
IJHB0A721031-01
 HVAC System: Manual A/C Single Type 7B-12

[B]
psi kPa kgf/cm2 %
355.6 2500 25
341.4 2400 24
327.1 2300 23 70
312.9 2200 22
298.7 2100 21
284.42000 20 30
270.21900 19
256.01800 18 “f”
241.71700 17
[e]
227.51600 16
213.3 1500 15
199.1 1400 14
[a ] 184.9 1300 13 “g ”
170.6 1200 12 [d ]
151.4 1100 11
142.2 1000 10
128.0 900 9
113.8 800 8
99.5 700 7
85.3 600 6
71.1 500 5
70
56.9 400 4 “h ”
[e] 30
42.7 300 3
[b] 28.4 200 2 “i”
14.2 100 1
0
25 30 35 40 45°C
77 86 95 104 113°F
[c ]
IJHB0A721032-01

[A]: K15B model [b]: Pressure on low pressure gauge [e]: Acceptable range
[B]: D13A mode [c]: Ambient temperature
[a]: Pressure on high pressure gauge [d]: Humidity

Measuring result and cooling inspection graph, normal example is shown (ambient temperature at 30 °C
(86 °F))
K15B model D13A model
Pressure on high pressure 1230 – 1540 kPa (12.5 – 15.7 kgf/cm2) 1250 – 1650 kPa (12.7 – 16.8 kgf/cm2)
gauge (HI) (178 – 223 psi) (181 – 239 psi)
Pressure on low pressure 260 – 350 kPa (2.7 – 3.6 kgf/cm2) (37.7 230 – 310 kPa (2.3 – 3.2 kgf/cm2) (33.3
gauge (LO) – 50.7 psi) – 44.9 psi)

High pressure gauge

Condition Possible cause Correction
Refrigerant overcharged Recharge.
Expansion valve frozen or clogged Check expansion valve.
Clogged refrigerant passage of high pressure side Clean or replace.
Radiator cooling fan malfunction (insufficient cooling
Check radiator cooling fan.
Pressure is higher of condenser)
than acceptable Dirty or bent condenser fins (insufficient cooling of
Clean or repair.
range (“f” area) condenser)
Compressor malfunction (insufficient oil etc.) Check compressor.
Check engine cooling system.
Engine overheat • K15B model: (Page 1F-5)
• D13A model: (Page 1F-22)
Insufficient refrigerant (insufficient charge or Check for leakage, repair if necessary
Pressure is lower
leakage) and recharge.
than acceptable
Expansion valve malfunction (valve opens too wide) Check expansion valve.
range (“g” area)
Compressor malfunction (insufficient compression) Check compressor.
7B-13 HVAC System: Manual A/C Single Type

Low pressure gauge

Condition Possible cause Correction
Pressure is higher Expansion valve malfunction (valve opens too wide) Check expansion valve.
than acceptable
Compressor malfunction (insufficient compression) Check compressor.
range (“h” area)
Check for leakage, repair if
Pressure is lower Insufficient refrigerant (insufficient charge or leakage)
necessary and recharge.
than acceptable
Expansion valve malfunction (valve opens too narrow) Check expansion valve.
range (“i” area)
Clogged refrigerant passage (crashed pipe) Repair or replace.

10) Check correlation between inlet port temperature and outlet port temperature using the graph. For example, if
temperature near air inlet of HVAC unit is 35 °C (95.0 °F) and the one at air outlet of center ventilation louver is 20
°C (68.0 °F), their crossing point is within acceptable range as shown in the graph. In this case, cooling
performance is satisfactory and proper.
11) If crossing point is out of acceptable range, diagnose trouble referring to the following table.
Cooling inspection graph (Thermometer at center ventilation louver)

[A]
°F °C %
96.8 36
70
95.0 35
93.2 34
91.4 33
89.6 32
87.8 31
86.0 30
84.2 29 [c]
82.4 28
80.6 27
78.8 26
77.0 25
75.2 24 “f”
30
73.4 23
71.6 22 [d ]
[a] 69.8 21
68.0 20 [e]
66.2 19
64.4 18
62.6 17
60.8 16
59.0 15
57.2 14 “g”
55.4 13
53.6 12
51.8 11
50.0 10
48.2 9
46.4 8
44.6 7
25 30 35 40 45°C
77 86 95 104 113°F
[b ]
IJHB0A721033-01
 HVAC System: Manual A/C Single Type 7B-14

[B]
°F °C %
96.8 36
70
95.0 35
93.2 34
91.4 33
89.6 32
87.8 31 [c]
86.0 30
84.2 29
82.4 28
80.6 27
78.8 26
77.0 25 30
75.2 24 “f”
73.4 23
[d ]
71.6 22
[a] 69.8 21
68.0 20 [e]
66.2 19
64.4 18
62.6 17
60.8 16 “g”
59.0 15
57.2 14
55.4 13
53.6 12
51.8 11
50.0 10
48.2 9
46.4 8
44.6 7
25 30 35 40 45°C
77 86 95 104 113°F
[b ]
IJHB0A721034-01

[A]: K15B model [b]: Temperature near air inlet of HVAC unit [e]: Crossing point
[B]: D13A model [c]: Humidity
[a]: Temperature at outlet of center ventilation louver [d]: Acceptable range

Thermometer at center ventilation louver

Condition Possible cause Correction
Insufficient or excessive charge of refrigerant Check refrigerant pressure.
Dirty or bent evaporator fins Clean or repair.
Crossing point is higher
Air leakage from cooling (heater) unit or air duct Repair or replace.
than acceptable range
Malfunctioning, switch over function of door in cooling
(“f” area) Repair or replace.
(heater) unit
Compressor malfunction Check compressor.
Crossing point is lower Insufficient air volume from center ventilation louver
Check blower motor and fan.
than acceptable range (heater blower malfunction)
(“g” area) Compressor malfunction Check compressor.

12) After completion of repair, check the system performance again.

7B-15 HVAC System: Manual A/C Single Type

Trouble Diagnosis for Abnormal Pressure

AENJHB0B7214002
K15B Model

NOTE
Normal pressure for high pressure gauge (HI) and low pressure gauge (LO) in the following table are
those measured when the ambient temperature is about 30 °C (86 °F). As normal pressure for both
gauges vary depending on the ambient temperature, perform the following steps before starting
diagnosis of troubles.
1. Measure the ambient temperature and using that temperature, read the normal high and low
pressure from the graph given in Step 9 of “A/C System Performance Inspection”: Manual A/C
Single Type (Page 7B-9).
2. Use these values in place of the normal pressure in the following table.

Condition
Manifold gauge (kPa (kgf/cm2) (psi)) Possible cause Correction
Detail
LO HI
260 – 350 (2.7 – 3.6) 1230 – 1540 (12.5 – Normal condition
— —
(37.7 – 50.7) 15.7) (178 – 223)
Negative pressure 500 – 600 LO gauge reads Dust particles Replace expansion
(5.1 – 6.1) negative pressure, accumulate or water valve.
(72.6 – 87.0) while HI gauge reads droplets are frozen Replace condenser
extremely low inside expansion assembly.