Programming ECU Suzuki

Suzuki Pass-Thru
Reprogramming Tool
Operators Manual
TABLE OF CONTENTS
SECTION
0
1
2
3
4
5
6
7
8
PAGE
Introduction 3
Precautions for Reprogramming ECU 4
Preparation 5
Installation 6
3.1 Installation of Suzuki Pass-Thru Reprogramming Tool software 6
3.2 Installation of database (ECU calibration files) 8
3.3 Installation of USB driver 10
<When using Windows 2000>.10
<When using Windows XP>.14
Uninstallation 17
Language Setting 17
How to check the Version of Suzuki Pass-Thru Reprogramming Tool
Software and Database
18
How to use Reprogramming Tool 18
Error Codes 29
<APPENDIX> 36
COPYRIGHT SUZUKI MOTOR CORPORATION 2005
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0. Introduction
The Suzuki Pass-Thru Reprogramming Tool (Reprogramming Tool hereinafter) consists of the SDS
interface box (1), Diagnosis cable (2), and USB cable (3).
The Reprogramming Tool is used in
combination with the PC to program the latest ECU calibration file onto the vehicle ECU. Please, keep in
mind that there is no guarantee that all problems related to the electric control system can be solved after
programming the latest ECU calibration file onto the vehicle ECU.
Before using the Reprogramming Tool, the diagnosis of the electric control system has to be performed
according to the service manual. If the Service Manual diagnostic flow chart suggests replacing the
ECU, first try programming the vehicle ECU by using the Reprogramming Tool with the latest calibration
file. Performing ECU reprogramming without the diagnosis of the electric control system may lead to the
misdiagnosis of the real problem and/or ECU damage.
This operators manual describes the cautions for the ECU reprogramming, the instructions for installing
the Reprogramming Software, etc. Therefore, read this operators manual carefully and have a clear
grasp of the contents before performing the ECU reprogramming using the Reprogramming Tool.
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1. Precautions for Reprogramming ECU
Read the following instructions carefully before executing the reprogramming of ECU.
Be sure the battery is fully charged. The battery voltage should be 11V or more.
Do not start the engine during the reprogramming process.
Do not attempt reprogramming ECU with the battery charger connected to the vehicle battery.
The battery charger may cause variation in the system voltage, which will cut off the execution of
the ECU reprogramming and cause damage to ECU.
Turn off all electric loads such as headlights and air conditioner. (If equipped with DRL, set the
parking brake. This turns off the DRL.)
Follow the instruction of the reprogramming software to turn on or off the ignition switch.
While the ECU reprogramming is executed by the reprogramming software, do not touch the
reprogramming tools including the communication cables.
If the cables used for the
communication with the vehicle and PC are disconnected, the ECU reprogramming may fail and
ECU may be damaged.
If you are using a portable (laptop) PC, be sure it is sitting on a hard stable surface, if you hold it
in your hands or on your lap the communication cables might be disconnected resulting in the
ECU damage.
Connect the communication cables securely.
Or, the communication cables might be
disconnected resulting in the ECU damage.
Perform the ECU reprogram when the ECU temperature is between 0 and 40 degrees Celsius
(between 32 and 104 degrees Fahrenheit). Or, the ECU reprogram may fail.
During the ECU reprogram, be sure to follow the steps below to prevent electrical noise from
affecting the ECU reprogram.
1) Stop any instrument with a built-in motor that may cause electrical noise.
2) Do not turn on or off any instrument such as an illumination lamp in the vehicle.
3) Do not start or race the engine of another vehicle near the vehicle for which the ECU
reprogram is performed.
When the ECU reprogram is completed, execute the following procedure.

1) Make sure that you have the latest Suzuki Tech2 Diagnostic Application.
2) Clear all diagnostic trouble codes of all electronic control systems (AT, ABS, etc.) by using Suzuki
scan tool (Tech2).
3) Make sure that the engine starts.
4) In case that TCM is reprogrammed, make sure that MIL does not turn on after operating shift
lever (P>R>N).
Be sure to read the APPENDIX for important instructions which have to be followed before and
after the ECU reprogram.
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2. Preparation
Items required for the ECU reprogramming are as follows:
PC
[Minimum specifications]
OS
CPU
Hard disc
Memory
Display
Other
Windows 2000, Windows XP

Pentium 4 1.3 GHz or more
Empty space (20 Gbyte or more)
256 Mbyte or more
SVGA (800-600) or more, 256 colors or more
USB 1.1 or more
Suzuki Pass-Thru Reprogramming Tool (P/N: 09910-06520 or 09910-06521) consisting of the

following parts:
1. SDS interface box (P/N: 09904-41011-001 or 09904-41012-001)
2. Diagnosis cable (P/N: 09910-06520-002)
3. USB cable (P/N: 09910-06520-003 or 09910-06521-003)
Suzuki Pass-Thru Reprogramming Tool software provided by Suzuki Pit Stop found under
OBD/OBDII DIAGNOSTICS or Pass-Thru Reprogramming Software.
The software serial number that activates your software is provided in a letter via U.S. Mail service.
Database File (Contains ECU calibration files) provided by Suzuki Pit Stop found under
OBD/OBDII DIAGNOSTICS or Pass-Thru Reprogramming Software.
Reprogram Label (P/N: 99963-01501-224) refer to applicable TSB for details.
3. Installation
When you install the Suzuki Pass-Thru Reprogramming Tool software (Reprogramming Software
hereinafter), Database and USB driver for the first time, install the Reprogramming Software first, then
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Database and then the USB driver. When updating the Reprogramming Software and Database, install the
Reprogramming Software first, then the Database. When updating the Database only, download and install
the Database.
NOTE:
If the software is installed verify the version referring to section 6, you may not need to
download and install the software if you have the latest version.
3.1.
Installation of Suzuki Pass-Thru Reprogramming Tool software
Install the Reprogramming Software to the PC according to the following procedure.

1) Start up the PC.
NOTE:
- To install the Reprogramming Software, use the administrators account for logging on
to the PC. (If you are able to install any type of software, you have an administrators
account.)
- Before starting the installation, terminate the operation of any currently running
programs and application software in the active mode such as virus scanning software,
etc.
2) In the Suzuki Pass-Thru Reprogramming Software screen download the Software by clicking
Download Now. You will get a File Download window. Click Open in Windows 2000 and XP
service pack 1 or Run in Windows XP service pack 2.
3) The next window will show the download progress.
4) When the download is finished a security warning may appear depending on your operating
system. Click Run.
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5) The Pass-Thru Reprogramming Tool Install will appear. Click on Yes
NOTE:
After clicking Yes, it might take some time for the next screen to show up depending
on your PC performance.
6) When the InstallShield Wizard screen opens up. Click Next.
NOTE:
After clicking Next the following screen may appear if the latest software is already
installed.
Click on Cancel and continue to the database installation.
Otherwise
continue to step 7.
7) Now enter your
name, company
name and the serial number. The serial number is sent through U.S. Mail. Click Next.
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8) Click Next again at the next screen.
DO NOT CHANGE THE DEFAULT INSTALLATION
LOCATION.
9) When the installation is completed, click the Finish button.
NOTE:
AFTER installing or updating the Reprogramming Software, be sure to install the database
because the database is removed during the installation of the Reprogramming Software.
For the installation method, refer to the item 3.2.
3.2.
Installation of Database (ECU calibration files)
Install the Database to the PC according to the following procedure:

1) Start up the PC.
2) In the Suzuki Pass-Thru Reprogramming Software screen download the Database Calibration
Files by clicking Download Now. You will get a File Download window. Click Open in
Windows 2000 and XP service pack 1 or Run in Windows XP service pack 2.
3) The next window will show the download progress.
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4) When the download is finished a security warning may appear depending on your operating
system. Click Run.
5) The Database installation will appear. Click on Yes

NOTE:
After clicking Yes, it might take some time for the next screen to show up depending on
your PC performance.
6) At the Precautions before installing the database window, click Next.
7) Now type in the serial number used for the software installation exactly how it is shown on the
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letter. Click Next.
8) After the installation progress window completes click Finish at the Wizard complete window.
3.3.
Installation of USB driver
The installation method varies depending on the version of Windows. Start the installation of USB
driver referring to the procedures described below. Skip this section if are already using your PC to
reprogram Suzuki vehicles.
NOTE:
- Before the installation, make sure that the voltage of the vehicle battery is 11V or more.
- The USB driver installation procedure needs to be performed only once for PC in use.
- The Driver will already be installed if your computer is already being used for reprogramming.
-
<When using Windows 2000>

1) Start up the PC.
NOTE:
- Use the administrators account for logging on to the PC.
- Before starting the installation, terminate the operation of resident programs and
application software in the active mode such as virus scanning software, etc.
2) Download the USB Driver from Suzuki Pit Stop.
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In the Suzuki Pass-Thru Reprogramming
Software screen download the USB Driver by clicking Download Now. You will get a File
Download window. Click Open or Run.
3) After the file download completes you will see the WinZip window open. Click on Unzip.
4) Click OK and click Close.
5) Connect the SDS interface box to the DLC and PC, referring to Step 3) under When using
Windows 98.
6) Windows detects the USB device, and then Found New Hardware Wizard is started. Click next.
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7) Select Search for a suitable driver for my device (recommended) for the specification of the
retrieval method, and then click the Next button.
8) Select only Specify a location on the Locate Driver Files screen and click the Next button.
(Cancel check marks for the floppy disc drive or CD-ROM drive etc.)
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9) Type in (C:\passthruSetup\Driver) in the box under Copy manufacturers files from: Click the OK
button.
7) Click Next
8) Click Finish
9) The USB Driver is now installed.
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<When using Windows XP>

1) Start up the PC.
NOTE:
- Use the administrators account for logging on to the PC.
- Before starting the installation, terminate the operation of resident programs and
application software in the active mode such as virus scanning software, etc.
2) Follow steps 1) thru 4) under When Using Windows 2000 in this section to download and install
the USB driver. After installation is complete return to this section and continue to step 3)
3) Connect the SDS interface box to the DLC and PC, referring to step 3) under When using
Windows 98. Continue to step 4).
4) Windows detects the USB device, and then Found New Hardware Wizard is started. Select
the radial button No, not at this time, click Next.
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5) Select the radial button Install from list or specific location (Advanced) for the installation
method, and then click the Next button.
6) Select the radial button Search for the best driver in these locations. Check the box next to
Include this location in the search: (Do not check box Search removable media (floppy, CDROM).)
Enter (C:\passthruSetup\Drivers) in the space next to the Browse button, click Next.
\passthruSetup\Drivers
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7) As Windows logo test confirmation screen appears, click the Continue Anyway button.
8) After clicking Continue Anyway, the driver will be loaded. Click Finish
9) Now the PC is ready for reprogramming.
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4. Uninstallation
It is not necessary to remove or reinstall the software and database. When new software or database is
available the installation automatically overrides the old software or database. However if the software
needs to be removed, perform the following procedure:
1) Make sure that the Reprogramming Software is closed.
2) Start the Add/Remove Programs. (Start>Settings>Control Panel>Add/Remove Programs)
3) In theAdd/Remove Programs window, scroll down to the Suzuki Pass-Thru Reprogramming
Tool and select it.
4) Click the Change/Remove button.
5) In the next window, select the Remove and click the Next button.
6) Select the OK button at the confirmation window.
7) When the operation is completed, click the Finish button.
8) Open C drive of the PC in use and open the Program Files folder.
9) If the folder named Suzuki is there, delete the folder.
10) Open the C drive and delete the passthruSetup folder if it is there.
11) Empty the recycle bin to assure the complete removal.
5. Language Setting
You can select one language from the list for the Reprogramming Software.
Perform the following
procedure.
1) Execute
the
language
setting
software
by
selecting
Programs,
Reprogramming Tool, and Setup Tool in the start menu in order.

2) Select one language from the list.
3) After selecting one language, click the OK button.

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Suzuki
Pass-Thru
6. How to check the Version of Suzuki Pass-Thru Reprogramming Tool

Software and Database
Check the version of the Reprogramming Software and Database according to the following procedure.
1)
Start the Reprogramming Software by selecting Programs, Suzuki Pass-Thru Reprogramming

Tool, and Reprogramming Tool in the start menu in order.
NOTE:
Before executing the Reprogramming Software, terminate the operation of all the other
application software and stop the screen saver as well.
2)
Left-click the icon at the upper-left corner of the Reprogramming Software and choose About
Pass-Thru Reprogramming
7. How to use Reprogramming Tools

Execute the reprogramming of the vehicle ECU according to the following procedure:
1) Start up the PC on which the USB Driver and Reprogramming Software and database are
installed.
2) Execute the Reprogramming Software by selecting Start, Programs, Suzuki Pass-Thru
Reprogramming Tool, and Reprogramming Tool in the start menu in order.
NOTE:
Before executing the Reprogramming Software, terminate the operation of all the other
application software and stop the screen saver as well.
3) If you would like to check the version of the Reprogramming Software, left-click the icon at the
upper-left
corner
of
the
Reprogramming
Reprogramming If not, skip this step.
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Software
and
choose
About
Pass-Thru
4) The screen, which shows you the distributor (dealer) code and date, is displayed.
If the distributor (dealer) code is wrong or not displayed, enter the correct code. Click the Next
button after confirming the distributor (dealer) code and date. If the date is incorrect, the clock on
the PC is not set correctly. Please set the clock correctly and start again.
Note:
For retail customers enter your name in the Distributor Code area.
5) Select the target system from the screen displayed.
Click the Next button after selecting the target system.
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6) The screen, which prompts you to select the Pass-Thru device, is displayed.
Check if the selected device is Pass-Thru PDIB32 Hitachi Car Engineering Co., Ltd. If correct,
click the Next button.
7) The screen, which prompts you to prepare the Pass-Thru device, is displayed.
8) Connect the SDS interface box with the Diagnosis Cable to the vehicle subject to the ECU
reprogramming.
Then connect the PC and SDS interface box with the USB cable.
following screen appears after you connect the SDS Interface to the PC, click OK:
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If the
At the next screen enter at the C:\passthruSetup\Drivers as shown below. And click OK
The driver should automatically install from this point. Continue to step 9)
9) Check if the vehicle conditions are as follows:
a) The battery is fully charged. The battery voltage is 11 or more.
b) The engine is not running.
c) The ignition switch is turned on.
d) The shift lever position is P in case AT (CVT) is selected in Step 5).
After checking the above, click the Next button.
10) The SDS interface box is initialized, and then the initialization of the vehicle ECU for
communication is executed. The screen as shown below is displayed during the initializations.
When the initializations of the SDS interface box and the vehicle ECU are successful, the
operation advances to Step 12) automatically.
An error message will be displayed if an error
occurs, if so check for the following conditions and start the process again.
a)
Is the USB driver installed? (See the section 3.3.)
b)
Are the SDS interface box and PC connected properly with the USB cable?
c)
Are the SDS interface box and the vehicle subject to the ECU reprogramming
connected properly with the diagnosis system cable?
d)
Has Pass-Thru PDIB32 Hitachi Car Engineering Co., Ltd. been selected on the
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screen, which prompts you to select the Pass-Thru device?

e)
In the Select Pass-Thru Device to reprogram screen, pictured in step 6, click the
setup button and make sure the communication port is set to USB
f)
Is the vehicle subject to the ECU reprogramming? (See the ECU List for the
Reprogramming)
Manual mode:
When retrying the ECU reprogramming after a failure, the pop-up message shown below is
displayed. Make sure that the displayed part number is suitable for the target ECU. If suitable,
click the OK button. (CAUTION: If the OK button is clicked when it is not suitable, the
target ECU may be damaged.) If unsuitable, contact the S.M.A.R.T. Hotline.
NOTE:
The displayed part number might be different from the ECU label if the ECU has been
reprogrammed in the past.
In this case, make sure that the displayed part number
matches the number found on the TSB. If it doesnt match call the S.M.A.R.T. Hotline.
In the case of a blank ECU (calibration or software installed), the below message will be
displayed. Input the part number found on the appropriate TSB. Then click the OK button.
Caution: Do not input the wrong part number. This may damage the ECU.
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Firmware update for the SDS interface box:

In case that the firmware in the SDS interface box is old, the firmware update is automatically
started without moving to Step 11). At this point, the pop-up message shown below is displayed.
Start the firmware update according to the instructions on the display.
NOTE:
After the firmware update, the instruction to disconnect the diagnosis cable from the
vehicles DLC is displayed. Be sure to follow the instruction. or, the SDS interface box will
not reset. Then reconnect the SDS tool and restart the Pass-Thru reprogramming.
11) When the initialization is successful, the screen which prompts you to make sure the ECU part
number and software version is displayed. Depending on the ECU type, this screen might not be
displayed.
Displayed on the screen are the part number of the target ECU installed in the vehicle and vehicle
identification number (VIN). Check each item, and then click the Next button.
To stop the ECU reprogramming, click the Cancel button.
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12) The screen, which shows you the reprogramming information, is displayed.
Check that the displayed information is correct and click the Next button to start the
reprogramming. If the vehicle identification number (VIN) is wrong, click the Back button and
change the VIN. Or, click the Cancel button and start all over from the beginning. For the
setting procedure of the date of the PC, refer to the instruction manual of the PC in use or
Windows Help, etc.
Manual mode:
After clicking the Next button on the screen in the manual mode, a message might be displayed
prompting you to check the battery voltage, engine speed and vehicle speed. Check the vehicle
conditions and if the check result is satisfactory, click Yes. If the vehicle conditions fail to meet
the required conditions, click No to stop the ECU reprogramming.
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13) The ECU reprogramming is executed automatically. It takes 7 to 15 minutes. When the ECU
reprogramming has been completed successfully, the operation advances to Step 14)
automatically.
This
screen
might
be
different
depending
on
the
ECU
type.
NOTE:
Avoid touching the PC, cables, etc. during the ECU reprogramming, this may cause the
cables used for communication with the vehicle and PC to disconnect and the ECU
reprogramming will fail.
If an error occurs, the error message will be displayed. Troubleshoot the cause and start the
process again from the beginning.
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14) When the ECU reprogramming has been performed successfully, the screen, which prompts you
to turn off the ignition switch, is displayed.
Turn off the ignition switch of the vehicle subject to the ECU reprogramming, and then click the
Nextbutton.
15) In order to initialize the ECU, it is necessary to wait for one minute after the ignition switch is
turned off. During that time, a one minute count down will be displayed. After one minute, the
operation advances to Step 17) automatically.
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16) One minute after Step 16), the screen, which prompts you to turn on the ignition switch, is
displayed.
Turn on the ignition switch of the vehicle subject to the ECU reprogramming, and then click the
Next button.
17) The procedure to terminate the ECU reprogramming is executed automatically.
If an error occurs, the error message is displayed.
Troubleshoot the cause and restart the
procedure from the beginning. During the terminating procedure, the Reprogramming Software
checks if any diagnostic trouble code (DTC) is detected.
When any DTC is detected, the
operation advances to Step 19). When no DTC is detected, the operation advances to Step 20).
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18) When any DTC is detected during the terminating procedure in Step 18), the screen, which lists
the detected DTC, is displayed.
Check the detected DTC, and then click the Next button. After clicking the Next button, the
Reprogramming Software clears the detected DTC automatically. And, the operation advances to
Step 20).
19) The screen, which tells you that the ECU reprogramming is successful, is displayed.
Displayed on the screen are the ECU part number and software version after the ECU
reprogramming.
Click the Finish button.
This closes the Reprogramming Software and
completes the ECU reprogramming procedure.
20) Turn off the ignition switch and disconnect the reprogramming tool from the vehicle.
21) Place a Reprogram Label in the glove box that indicates the ECU programming has been
performed on the ECU. Refer to the APPENDIX for post reprogramming procedures.
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8. Error Codes
Code
102
Error Message
File cannot be opened.
Cause
The ECU data file does not exist.
103
Error occurred while reading file.
Reading the ECU data file failed.
105
4001
The file's format is invalid.

The Pass-Thru device cannot be opened.
4002
Receiving ECU messages has failed.
The data in the ECU data file is invalid.

Suzuki Pass-Thru Reprogramming Tool software
has not been installed properly on the PC.
Reception of the ECU message failed.
4003
Sending tester message has failed.
Transmission of the tester message failed.
4004
Received ECU messages are invalid.
The format of the ECU response message is invalid.
4005
Negative response from ECU is received.
An error was received from ECU.
4011
The reprogramming cannot be performed while the

engine
is
running.
Stop the engine to retry.
Battery
voltage
is
out
of
specified
range.
The reprogramming cannot be performed.
ECU already has the latest version.
The engine speed was detected when starting the

ECU reprogramming.
Remedy
Check if the ECU data file (*.enc) exists in the
folder where Suzuki Pass-Thru Reprogramming
Tool software was installed. If not, execute the
installation.
Check if the ECU data file (*.enc) is used in any
program other than Suzuki Pass-Thru
Reprogramming Tool software.
Install the ECU data file again.
Install Suzuki Pass-Thru Reprogramming Tool
software again.
Check if the vehicle is subject to the ECU
reprogramming.
Check if the diagnosis system cable and USB
cable are connected properly.
reprogramming.
reprogramming.
reprogramming.
Check to ensure that the engine at stop and the
battery voltage is within the specified range (11V 14V).
Stop the engine and start all over from the
beginning.
The battery voltage was out of the specified range

(11V 14V) when starting the ECU reprogramming.
The program in ECU has already been reprogrammed
to the new version.
Charge the battery or replace it with a new one and

start all over from the beginning.
The ECU program of the vehicle needs not be
reprogrammed.
4018
4028
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Code
4031
Error Message
Error
occurred
in
The reprogramming is aborted.
communication.
Cause
An error occurred in communication with ECU.
4032
Error
occurred
in
communication.
4033
Error
occurred
in
communication.
4034
The
verification
4035
Error
occurred
in
has
failed.
communication.
Verification of the ECU reprogramming failed.
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Remedy
reprogramming.
reprogramming.
reprogramming.
reprogramming.
reprogramming.
Code
4036
Error Message
Error
occurred
in
communication.
Cause
4037
Error
occurred
in
communication.
4040
Error
occurred
while
rewriting.
4041
Error
occurred
while
rewriting.
4043
Cannot erase the Flash ROM

4045
The reprogramming cannot be performed when the

vehicle
is
running.
Stop the vehicle to retry.
on
the
ECU.
Erasing of the Flash ROM on ECU failed.
The engine speed was detected when starting the

ECU reprogramming.
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Remedy
reprogramming.
reprogramming.
reprogramming.
reprogramming.
reprogramming.
Stop the engine and start all over from the
beginning.
Code
4046
Error Message
Error occurred in the Pass-Thru device.
Cause
An error occurred in the SDS interface box.
4054
Vehicles ECU does not match with the reprogramming

data.
Error
occurred
in
communication.
The vehicle is not subject to the ECU reprogramming.
4056
Error
occurred
in
4058
Error
occurred
while
rewriting.
Writing of the Flash ROM on ECU failed.
4059
Error
occurred
while
rewriting.
4055
communication.
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Remedy
reprogramming.
reprogramming.
reprogramming.
reprogramming.
reprogramming.
Code
4060
Error Message
The DTC related to the reprogramming is detected.
Cause
The ECU reprogramming failed.
4061
Error occurred while initializing the Pass-Thru device.
An error occurred in communication with the SDS

interface box.
4062
Error occurred while configurating the Pass-Thru device.

interface box.
4064

interface box.
Remedy
reprogramming.
software again.
software again.
Check if the diagnosis system cable and USB cable

are connected properly.

software again.
4065

interface box.
Check if the diagnosis system cable and USB cable

are connected properly.

software again.
5014
ECU does not correspond to a Seed&Key file.
ECU does not correspond to a Seed&Key file.
5601
A database is not found.

Please check if the database is installed in a correct
location.
Database search is failed.
5603

5604

5602
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Check if ECU corresponds to a Seed&Key

file.
Check if the database is installed in the location
where the Reprogramming Software (Reprog.exe) is
installed.
Check if the database exists.
Check if the database corresponds to the
database.
database.
database.
Code
5605
Error Message
Cause
5606

5800
Error
occurred
while
rewriting.
5801
Error
occurred
while
rewriting.
5802
Error
occurred
in
communication.
5803
Error
occurred
in
communication.
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Remedy
database.
database.
reprogramming.
reprogramming.
reprogramming.
reprogramming.
Code
5804
Error Message
Error
occurred
in
5805
Error
occurred
5820
The shift lever position is not P.

Please make the position into P and start all over again.
The term of validity has run out.
Please download the newest software.
5821
while
communication.
rewriting.
Cause
The shift lever position is not P.
5900
Error
occurred
in
communication.
The term of validity for using Suzuki Pass-Thru

Reprogramming Tool software is expired.
5901
Error
occurred
in
communication.
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Remedy
reprogramming.
reprogramming.
Change the shift lever position to P and star all
over again.
Install the newest Suzuki Pass-Thru
Reprogramming Tool software on PC in use.

reprogramming.
Check to ensure that the engine at stop and
the battery voltage is within the specified range
(11V - 14V).
reprogramming.
(11V - 14V).
Code
5902
Error Message
Error
occurred
in
communication.
Cause
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Remedy

reprogramming.
(11V - 14V).
<APPENDIX>
A) When the ECM reprogram is completed for the following models, execute the following
procedures referring to the applicable service manual.
Model
Procedure
Verona (RP625)
Idle Learn Procedure
Forenza (RQ420)
Idle Learn Procedure

(04MY/05MY vehicles only)
TEC Learn Procedure
Swift + (RR416)
B) When the TCM reprogram is completed for the following models, execute the
following procedure referring to the applicable service manual.
Model
Procedure
Verona (RP625)
TCM Initialization Procedure
Forenza (RQ420)
C) In case that the ECM reprogram is performed for the following models,
perform the following registration referring to the applicable service manual.
Model
Registration
Jimny (SN415D, Euro4, VIN: 300001-)

ECM Registration
Grand Vitara (JB419D)
D) In case that the ECM reprogram is performed for the following models, follow
the instructions below.
Model
Grand Vitara
(SQ416/ 420/ 625)
VIN
ABS Actuator Assembly Part#

56100-65D20, 56100-65D21, 56100-65D22
See the VIN

table below.
Esteem/ Baleno
(SY413/ 416/ 418)
56100-69G00, 56100-69GB0
1) Turn off the ignition switch.

2) Disconnect the negative cable from the battery.
3) Disconnect the connector from the ABS actuator assembly.
4) Connect the negative cable to the battery.
5) Perform the ECM reprogram referring to the operator.s manual .Suzuki
Pass-Thru Reprogramming Tool Operator.s Manual..
6) After the ECM reprogram is successful, turn the ignition switch off.
7) Disconnect the negative cable from the battery.
8) Connect the connector to the ABS actuator assembly.
9) Connect the negative cable to the battery.
37 of 40
Grand Vitara (SQ416/ 420/ 625)

2S2GTA03C004700012S2GTA03C004900012S2GTA03C006000012S2GTA03C007000012S2GTA03C104700012S2GTA03C164700012S2GTA52C004700012S2GTA52C004900012S2GTA52C006000012S2GTA52C007000012S2GTA52C104700012S3TA03C 161000012S3TA52C 161000012S3TA52C 26100001JS3TA03V 14150001JS3TA03V 24150001JS3TA03V 34100001JS3TA03V 34150001JS3TA03V 44100001JS3TA52V 14150001JS3TA52V 24150001JS3TB03V 14150001JS3TB03V 24150001JS3TB03V 34100001JS3TB03V 34150001JS3TB03V 44100001JS3TB52V 14150001JS3TB52V 24150001JS3TB52V 34100001JS3TB52V 34150001JS3TB52V 44100001JS3TD62V 14150001-
JS3TD62V 24150001JS3TD62V 34100001JS3TD62V 34150001JS3TD62V 44100001JS3TD62V 54100001JS3TD83V 54100001JS3TL52V 14150001JS3TL52V 24150001JS3TL52V 34100001JS3TL52V 34150001JS3TL52V 44100001JS3TL52V 54100001JSAFTA03V00150001JSAFTA03V00200001JSAFTA03V10150001JSAFTA03V14150001JSAFTA03V20150001JSAFTA03V24150001JSAFTA03V30150001JSAFTA03V30200001JSAFTA03V34150001JSAFTA03V40200001JSAFTA52V00150001JSAFTA52V14150001JSAFTA52V24150001JSAFTB03V00150001JSAFTB03V00200001JSAFTB03V10150001JSAFTB03V14150001JSAFTB03V20150001JSAFTB03V24150001JSAFTB03V30150001-
H:\My docs\pass thru stuff\Suzuki Pass-Thru Operators Manual 11106a.doc
JSAFTB52V00150001JSAFTB52V00200001JSAFTB52V14150001JSAFTB52V24150001JSAFTB52V34150001JSAFTB83V00100001JSAFTD02V00200001JSAFTD32V00150001JSAFTD32V10150001JSAFTD62V00150001JSAFTD62V00200001JSAFTD62V10150001JSAFTD62V14150001JSAFTD62V24150001JSAFTD62V34150001JSAFTD62V34200001JSAFTD62V44200001JSAFTD82V00100001JSAFTD82V10100001JSAFTD83V00100001JSAFTL52V00150001JSAFTL52V00200001JSAFTL52V10150001JSAFTL52V14150001JSAFTL52V20150001JSAFTL52V24150001JSAFTL52V30150001JSAFTL52V34150001JSAFTL52V34200001JSAFTL52V44200001-
Baleno/ Esteem (SY413/ 416/ 418)

GA11S-200001GC11S-200001GC11S-400001GC31S-200001GC31S-400001GC31W-200001GC31W-400001JS2GA11S 15200001JS2GA11S 25400001JS2GA21W 25400001JS2GA31S 15200001JS2GA31S 25400001JS2GA31W 15200001JS2GA31W 25400001JS2GA41S 15200001JS2GA41W 15200001JS2GA41W 25400001JS2GB31S 15200001JS2GB31S 15200001JS2GB31S 25400001JS2GB31S X5160001JS2GB31S Y5180001JS2GB31W 15200001JS2GB31W 15200001JS2GB31W 25400001JS2GB31W X5160001JS2GB41S 15200001JS2GB41S 25400001JS2GB41S X5160001JS2GB41S Y5180001JS2GB41W 15200001JS2GB41W 25400001JS2GB41W X5160001JS2GB41W Y5180001-
JSAEGA11S00200001JSAEGA11S00400001JSAEGA31S00200001JSAEGA31S00400001JSAEGA41S00200001JSAEGA41S00400001JSAEGB31S00200001JSAEGB31S00400001JSAEGC11S00200001JSAEGC11S00400001JSAEGC11W00200001JSAEGC31S00200001JSAEGC31S00400001JSAEGC31S10200001JSAEGC31S15200001JSAEGC31S20400001JSAEGC31W00200001JSAEGC31W00400001JSAEGC31W10200001JSAEGC31W15200001JSAEGC31W20400001JSAEGC41S00200001JSAEGC41W00200001JSAEGC41W00400001JSAEGC51S00200001JSAEGC51S00300001JSAEGC51S10200001JSAEGC51W00200001JSAEGC51W00300001JSAEGC51W10200001JSAEGD31S00200001JSAEGD31W00200001JSAEGD31W00400001-
Prepared by
Service & Parts Readiness Department

Service Readiness Group
Version 11156
1st Ed. March, 2001

40

Programming ECU Suzuki

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Programming ECU Suzuki

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Suzuki Pass-Thru

COPYRIGHT SUZUKI MOTOR CORPORATION 2005

The Reprogramming Tool is used in

1. Precautions for Reprogramming ECU

Do not start the engine during the reprogramming process.

If the cables used for the

Connect the communication cables securely.

Or, the communication cables might be

disconnected resulting in the ECU damage.

When the ECU reprogram is completed, execute the following procedure.

Windows 2000, Windows XP

Suzuki Pass-Thru Reprogramming Tool (P/N: 09910-06520 or 09910-06521) consisting of the

Reprogram Label (P/N: 99963-01501-224) refer to applicable TSB for details.

Installation of Suzuki Pass-Thru Reprogramming Tool software

Install the Reprogramming Software to the PC according to the following procedure.

3) The next window will show the download progress.

5) The Pass-Thru Reprogramming Tool Install will appear. Click on Yes

Click on Cancel and continue to the database installation.

7) Now enter your

8) Click Next again at the next screen.

DO NOT CHANGE THE DEFAULT INSTALLATION

Installation of Database (ECU calibration files)

Install the Database to the PC according to the following procedure:

3) The next window will show the download progress.

5) The Database installation will appear. Click on Yes

6) At the Precautions before installing the database window, click Next.

letter. Click Next.

Installation of USB driver

<When using Windows 2000>

In the Suzuki Pass-Thru Reprogramming

4) Click OK and click Close.

9) The USB Driver is now installed.

<When using Windows XP>

the radial button No, not at this time, click Next.

method, and then click the Next button.

9) Now the PC is ready for reprogramming.

Perform the following

Reprogramming Tool, and Setup Tool in the start menu in order.

3) After selecting one language, click the OK button.

6. How to check the Version of Suzuki Pass-Thru Reprogramming Tool

Start the Reprogramming Software by selecting Programs, Suzuki Pass-Thru Reprogramming

7. How to use Reprogramming Tools

Reprogramming If not, skip this step.

Click the Next button after selecting the target system.

An error message will be displayed if an error

Is the USB driver installed? (See the section 3.3.)

screen, which prompts you to select the Pass-Thru device?

In this case, make sure that the displayed part number

Firmware update for the SDS interface box:

17) The procedure to terminate the ECU reprogramming is executed automatically.

If an error occurs, the error message is displayed.

Troubleshoot the cause and restart the

When any DTC is detected, the

Click the Finish button.

This closes the Reprogramming Software and

completes the ECU reprogramming procedure.

Error occurred while reading file.

Reading the ECU data file failed.

The file's format is invalid.

Receiving ECU messages has failed.

The data in the ECU data file is invalid.

Sending tester message has failed.

Transmission of the tester message failed.

Received ECU messages are invalid.