Akk 416

New SX4 (AKK416)
New Car Features

Maintenance
Petrol engine oil change interval
15.000 km / 12 months
Classification:
API SL, SM or SN/ ILSAC GF-3, GF-4 or GF-5
Viscosity:
SAE 0W-20, 5W-30, 10W-30, 10W-40
CVT fluid:
Suzuki CVT fluid Green -2
P/N 99000-22B24-046
Manual transmission oil:

Suzuki gear oil 75W80
(P/N 99000-22B21-036)
Replacement interval
160 000 km / 96 months
Engine coolant:
Suzuki LLC Super (Blue) First time: 160 000 km / 96 months
(P/N:99000-99032-20X) Second time and after: 80 000 km / 48 months
Transportation (fuses)
Fuse location during shipment
For transportation the following fuses are

removed:
B/U (30A)
SECTION 1-1
ENGINE MECHANICAL
M16A
1. Engine general
2. Cylinder Block
49mmφ
AKK416 AZG416/AZH416
Model
All Spec. All Spec.
Part No 11210-61M00 11210-54LC0
Displacement(cc) 1586 1586
d: Bore (mm) 78.0 78.0
Stroke (mm) 83.0 83.0
p: Pitch (mm) 94.0 94.0
Journal bore (mm) 49.0 56.0
Piston Jet - Installed
AKK 416 Journal Bore diameter smaller than AZH416 Journal Bore
diameter
4. Piston
• Piston newly designed

exclusively for AKK416
RS416 AKK416
AZH416 (ALL)
(mm)
Material Forged aluminum
Top volume (cc) 5,65 4.90
Piston
Outer diameter 78.0 1. Resin coating
Height 59.50 2. Side relief groove
Pin to top 30.0 3. Hard almite® process
Outer diameter 20.0 4. Small groove finishing
Pin
Length 59.0
Compression ratio
Compression Ratio= 11.0
11,1 11.0
4.1. Piston Ring
RS416
AZG416 AKK416
1. 1st ring AZH416
2. 2nd ring Thickness [a] 1.0 1.0
3. Oil ring Width [b] 2.50 2.50
1st
Type Barrel face
Finishing Nitriding process
Thickness [c] 1.0 1.0
Width [d] 2.5 2.5
2nd
Type Taper undercut
Finishing Zinc phosphatization
Thickness [e] 2.0 2.0
Width [f] 2,2 2,25
Oil
Type Multi-piece steel
Finishing Nitriding process
5. Valve
AZG/AZH416 AKK416
Material Heat-resistant steel
Heat treatment Tufftride Process
Total Intake 100,7
Valve length(mm Exhaust 99.0
Valve stem diameter (mm) 5,5
Valve Intake 30.0
head Exhaust 25.0
Wire diameter(mm) 3,1 2,8
Valve Total number of turn 7,15 7.45
spring Total length (mm) 39,37 38,79
Pitch Variable
- Bee hive type

- Non-constant pitch
6. Camshaft
Intake camshaft Exhaust camshaft

Cam Number Cam Number
Valve lift Valve lift
height 12710- height 12720-
AKK416 45.300 8.300 54LE0 44.800 7.800 54LE0
RS416 45,504 8,504 57K00

AZH416 45.110 8.110 57K00
46.000 9.000 72L00
AZG416
Material Cast iron
Structure Hollow
5. Oil strainer
Steel strainer Plastic strainer

12. Oil Pump
Double step relief valve
Double relief port
AKK416
Valve opening @1250 rpm 150 kPa
pressure @4000 rpm 350 kPa
12. Oil Pump (Cont’d) 2
1
[a] At low engine speed
[b] At high engine speed
[A] Relief port 1 starts opening AKK416

[B] Relief port 2 start opening Valve opening @1250 rpm 150 kPa
[C] Oil discharge pressure pressure @4000 rpm 350 kPa
[D] Engine speed
1. Oil relief port 1
2. Oil relief port 2
3. Rotor plate
4. Suction
5. Relief valve
6. Relief valve spring
7. Single step relief valve
8. Double step relief valve
13. Engine Mounting
[Revised liquid seal mounting]

- 30% reduction of floor vibration
- Improved NVH features
- Better shock absorption
[Pendulum mechanism]
- 40% (6kg) weight reduction
- Simplified structure
- Less number of parts
SECTION 1-3
ENGINE CONTROL
1. General
[A]: Ignition switch model 12. Fuel pump

[B]: Keyless push start model 13. Knock sensor
27. APP sensor
[C]: Non-ENG A-STOP model 14. ECT sensor 28. CMP sensor
[D]: ENG A-STOP model 15. HO2S-1 29. CKP sensor
1. Air cleaner 16. HO2S-2 30. Brake light
2. IAT sensor 17. OCV 31. Brake light switch
3. TP sensor 18. ECM 32. Starting motor control relay
4. Throttle actuator 33. Ignition switch
19. Radiator cooling fan relay No.1, 2 and 3
5. IMT valve actuator 34. Keyless start control module
20. A/C compressor relay 35. IG1 relay
6. MAP sensor 21. A/C refrigerant pressure sensor 36. Main relay
7. Ignition coil assembly 22. Generator
8. Fuel injector 37. CPP No.1 switch (M/T) or transmission range sensor (CVT)
23. Fuel pomp relay 38. Starting motor
9. EVAP canister purge valve 24. Cruise control switch 39. Electric load current sensor
10. EVAP canister 25. CPP No.2 switch 40. Barometric pressure sensor
11. Tank vapor control valve 26. Brake switch 41. ENG A-STOP control module
42. Control modules/sensors by CAN
Information sensors
1. Electric load current sensor
2. CKP sensor
3. CMP sensor
4. Knock sensor
5. IAT sensor
6. TP sensor
7. ECT sensor
8. APP sensor
9. Brake light switch / brake switch
10. CPP No.1 switch
11. CPP No.2 switch
1. General (Cont’d)
12. A/C refrigerant pressure sensor

13. HO2S-1
14. HO2S-2
15. MAP sensor
Control devices
[a]: MIL
[b]: Immobilizer indicator light
[c]: EVAP canister purge valve
[d]: Fuel pump relay
[e]: Starting motor control relay
[f]: A/C compressor relay
[g]: Radiator cooling fan relay No.3
[h]: Radiator cooling fan relay No.1
[k]: Radiator cooling fan relay No.2
[m]: OCV
[n]: Fuel injector
[o]: Ignition coil assembly
[p]: Electric throttle body assembly
[q]: IMT valve actuator
[r]: Main relay
[s]: Generator
Others
[1]: ECM
[2]: DLC
[3]: Combination meter
[4]: Individual circuit fuse box No.1
1. General (cont.)
System Flow Diagram
2. Intake System (cont.)
1. Engine cover + air cleaner 5. IAT sensor

2. Intake manifold + IMT valve 6. MAP sensor
3. IMT valve actuator 7. EVAP purge valve
4. Electrical throttle body 8. PCV hose
3. Fuel System
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 (gauge) 13. EVAP canister purge valve
4. Delivery pipe 9. Fuel pump 14. Vapor control valve
5. Fuel injector 10. Fuel vapor line
4. Fuel System (cont’d)
- Plastic tank
- Fuel pump directly fitted on the tank
- Special tool 09941-51013
- Common tank between 2WD and 4WD
4. Charging system
1. Generator 6. Charge warning light

2. IC regulator 7. ECM
3. Stator coil 8. Battery
4. Diode 9. Electric load
5. Field coil (rotor coil)
5. Charging System (cont’d)
Starting control Voltage generation is suspended during starting

and for specified period after starting. After
specified time ellapsed, generated voltage is
raised to normal generator voltage.
Generator assist control In case of large increase in electrical load during
idling or low speed driving, engine speed will
drop due to increase in load of generator. ECM
Control
increases generation power by increasing duty
ratio of generator control signal.
Generator cut off control ECM decreases generation power of generator
by cutting off the generator control signal when
accelerating in order to reduce engine load. ECM
recovers generation power of generator when
decelerating.
6. Charging System (cont’d)
RW420 – 1 Aux belt AZH416 & AKK416

2 Aux belts
SECTION 2
SUSPENSION
CONTENTS
1. Wheel Alignment
2. Front Suspension
3. Rear Suspension
1. Front Wheel Alignment
Front Rear
Toe (total) : Coil spring with pink paint IN 4.5 +/- 2.6 mm
IN 1.0 +/-1.0 mm
"r"-"f" Coil spring with other color IN 5.2 +/- 2.6 mm
Coil spring with pink paint -0o10' +/- 1o
Camber "a" -1o00' +/-1o00'
Coil spring with other color -0o18' +/- 1o
Coil spring with pink paint 3o35' +/- 2o -
Caster "b"
Coil spring with other color 3o41' +/- 2o
King pin Coil spring with pink paint 12o04' +/- 2o
inclination "c" Coil spring with other color 12o18' +/- 2o
Side slip limit [mm/m] IN 3.0 to IN 0 -
Coil spring w ith Inside 38o 54'+/- 2o -
pink paint
Outside 32o 24'+/- 2o -
Steering angle
Coil spring w ith
Inside 38o 36'+/- 2o -
other color Outside 32o 12'+/- 2o -
Paint Coil spring Specification Destination

Light green x 1 41111-61M00 M16A 2WD Standard
Light green x 2 41111-61M10 M16A 4WD Standard P02, P22, P24,
Brown x 1 41111-61M50 D16AA 2WD Standard P43
Brown x 2 41111-61M60 D16AA 4WD Standard
Pink x 1 41111-61MA0 M16A 2WD H10 P06, P10, P37,
Pink x 2 41111-61MB0 M16A 4WD H10 P71, P90
F : Forward [A]: Camber (Front view)

S : Vehicle body center [B]: Caster (Side view)
T : Wheel center line “C” : 90o
2. Front Suspension (Cont’d)
-3.1kg
• Tightening
torque
increased
to 165 Nm
from 95 Nm
• Do not
reuse bolts
and nuts
1. Suspension arm
2. Suspension arm front bushing
3. Clip
[f]. Forward
(a) : 165 Nm
(b) : 55 Nm
x : Do not reuse
L+10mm
L
Patch Curl
1. Suspension arm front bushing
2. Front Suspension (Cont’d) 2. Hydraulic press
(A) : 09943-76311
(B) : 09913-75821
09943-76310 09943-76311
Diameter increased by 10%

Piston rod compared with RW series.
Diameter increased by 10%

Inner cylinder compared with RW series.
1. Rear coil spring
2. Rear spring lower seat
3. Rear spring upper seat
4. Rear axle
5. Rear wheel hub assembly
6. Rear brake disc dust cover
7. Rear shock absorber
8. Shock absorber upper bushing
9. Shock absorber upper washer
(a) : 88 Nm
(b) : 30 Nm
(c) : 78 Nm
(d) : 90 Nm
[f] : Forward
3. Rear Suspension
3. Rear Suspension
-4.4kg
No stabilizer bar
on AKK416.
3. Rear Suspension (Cont’d)
Side stopper
Load : + 60%
Soft (- 70%)
Hard (+ 30%)
1. Match mark ( before removing)

2. Protrusion
1 7
1.Coil spring
4.Torsion beam
7.Rear shock absorber
SECTION 3
DRIVELINE
1. i-AWD System
1. General Description
2. Input & Output
3. System Components
4. Circuit Diagram
5. Traction Modes
6. Control Details
7. Control Limitations
8. Maximum Current Regulation
9. i-AWD Coupling Operation
1-1. General Description
1. Crankshaft 13. ECM 9. Electromagnetic
2. CVT clutch
3. Front differential 12. TCM
4. Transfer 19. ESP cont.
6. Propeller shaft 11. 4WD
7. Coupling 18. P/S cont. control
module 5. Transfer
10. Rear differential
17. IPC temp. sensor
14. Traction
mode 15. BCM 8. Coupling air
switch temp. sensor
16. SASM
1-2. Input & Output
1-3. System Components
1. 4WD control
module
2. Transfer oil
temperature sensor
3. Rear drive
coupling assembly
4. Rear drive
coupling air
temperature sensor
5. Combination
meter
6. Information
display
7. 4WD warning
light
8. Driving mode
switch
1. Connector
2. 4WD control module
3. Bolt
1-3. System Components (cont’d)

1-3. System Components (cont’d)
Terminal Measurement
Resistance
position condition
[a]: AUTO switch
55.6 - 58.5Ω
pushed
[b]: Mode dial
208.1 - 214.3Ω
turned to SPORT
1-2 [c]: Mode dial
514.0 - 526.4Ω
turned to SNOW
[d]: LOCK switch
1127.8 - 1152.6Ω
is pushed
Except above 3503.8 - 3574.6Ω
1-3. System Components
(cont’d)
i-AWD coupling air
temperature sensor
i-AWD coupling
electromagnetic coil connector
[A]: Ignition switch model
1-4. Circuit Diagram [B]: Keyless push start model
1. Rear drive coupling unit
2. Rear drive coupling air temperature sensor
3. Transfer oil temperature sensor
4. Each control module
5. 4WD control module
6. “IG1 SIG” fuse
7. Ignition switch
8. IG1 relay
9. “4WD” fuse
ECM TCM
1-5. Traction Modes ESP EPS
- Mode switching OK/NG signal - Mode signal

- Mode signal
Mode signal Mode signal
LOCK OK/NG signal Indicator blink request

4WD BCM IPC
Mode switching OK/NG signal Information display request
Mode signal
- Mode switching request

- CAN bus
- Single wire 4WD Switch
1-6. Control Details
1. Vehicle Take-Off Control

2. Acceleration Control
3. Steering Stability Control
4. VDSC
5. Traction Mode Comparison
1-6-1. Vehicle Take-Off Control
⊿ω:Front wheel slip speed

TP : Throttle Position
I : Coupling current
1-6-2. Acceleration Control
When TP is increasing at high VSS

1-6-3. Steering Stability Control
Coupling
Front wheel slip
current
t
Stepping on
Accelerator Pedal Coupling
current
t
t : Time
1-6-4. VDSC Throttle valve
Wheel speed i-AWD coupling Ignition coil

EPS motor
YAW rate Wheel
4WD control module
ECM
Steering angle EPS control module ESP HU
Vehicle Dynamics Electronic Stability

Safety Synthetic Control Program Control
zone Zone Zone
(BCM control zone) (ESP control zone)
Grip zone Slip zone
Mild Severe Tire

understeer understeer grip
/ oversteer / oversteer limit
Skid ratio
: Before control
: After control
1-6-4. Vehicle Dynamics Synthetic Control (cont’d)
[Mild oversteer]
[Mild understeer]
1-6-5. Traction Mode Comparison
4WD mode
Control AUTO SPORT SNOW LOCK
Feed-back control : When Applicable (Larger torque to
wheel spin is detected, Applicable: Same as Applicable: Same as rear wheels than
Applicable
torque is transmitted to AUTO AUTO AUTO/SPORT/SNOW all
rear wheels. the time)
Feed-forward control : Applicable (Larger torque to
Torque is transmitted to Applicable: same as rear wheels than
4WD Applicable at low VSS. Applicable
rear wheels depending on SPORT AUTO/SPORT/SNOW all
APP before wheel slip. the time)
Feed-forward control :
Torque is transmitted to
Not applicable Not applicable Applicable Not applicable
rear wheels depending on
steering angle.
Larger engine torque at
ECM Standard same APP as Standard Standard
AUTO/SNOW/LOCK
Lower gear than
CVT Standard Standard Standard
AUTO/SNOW/LOCK
Torque reduction is Torque reduction is largerTorque reduction is smaller
Traction control by engine
Standard smaller than AUTO. (More than AUTO. (Less engine than AUTO and same as
torque reduction
engine torque than AUTO) torque and AUTO) SPORT.
Traction control by active Much larger than AUTO
ESP Standard Larger than AUTO Almost the same as AUTO
brake at vehicle start-up (almost double the SPORT)
Stability control in severe
Coupling fixed at 2WD.
oversteering or
Engine torque reduction and active brake appllied.
understeering
ABS Coupling fixed at 2WD. ABS in operation.
4WD coupling and EPS
assistance control in mild BCM does not send torque
VDSC Standard Standard Standard
oversteering or reduction request to 4WD.
understeering
1-6-5. Traction Modes (Cont’d)
4WD mode
Applicable
steering angle.
- Feel back control available to all modes to avoid wheel spin.

- “Pre-Torque control is applied to LOCK mode
4WD mode
Applicable
steering angle.
- Feed-forward control : Torque is transmitted to rear wheels in

response to accelerator pedal position, even if there is no speed
difference between front and rear wheels.
- Available in AUTO mode as well, when vehicle starts to move.
- Available in SPORT/SNOW/LOCK modes in all vehicle speed
range.
4WD mode
Applicable
steering angle.
- Feed-forward control by steering angle: Applicable to SNOW

mode.
Beneficial to low-friction road where one front wheel spin tends to
occur while turning.
4WD mode
AUTO/SNOW/LOCK
Lower gear than
AUTO/SNOW/LOCK
Torque reduction is Torque reduction is larger
Torque reduction is smaller
torque reduction
oversteering or
understeering
understeering
M16A : Throttle position

Ignition advance
4WD mode
AUTO/SNOW/LOCK
Lower gear than
AUTO/SNOW/LOCK
torque reduction
oversteering or
understeering
understeering
Pulley ratio shifted to lower gear side

4WD mode
AUTO/SNOW/LOCK
Lower gear than
AUTO/SNOW/LOCK
torque reduction
oversteering or
understeering
understeering
S-mode switch ON:

Minimum primary pulley speed line is
shifted upward.
1. Primary pulley speed
2. Vehicle speed
3. Transmission range
4. The lowest gear ratio
5. The highest gear ratio
4WD mode
AUTO/SNOW/LOCK
Lower gear than
AUTO/SNOW/LOCK
torque reduction
oversteering or
understeering
understeering
[SPORT]
Engine torque is not significantly reduced, to obtain sporty driving
with high rpm.
[SNOW]
Engine torque is significantly reduced for stability on a snowy road.
[LOCK]
Same as SPORT for better escape performance.
4WD mode
AUTO/SNOW/LOCK
Lower gear than
AUTO/SNOW/LOCK
torque reduction
oversteering or
understeering
understeering
Active brake is applied especially when the vehicle starts up to

avoid wheel spin.
[SPORT] Larger than AUTO for better vehicle startability.
[SNOW] The same level as AUTO is sufficient as engine torque is
significantly reduced.
[LOCK] Almost double the SPORT, as large torque is distributed to
rear wheels in LOCK mode.
4WD mode
AUTO/SNOW/LOCK
Lower gear than
AUTO/SNOW/LOCK
torque reduction
oversteering or
understeering
understeering
ESP and ABS operations have priority.

In ESP or ABS operation, traction mode is fixed at 2WD.
4WD mode
4WD coupling and EPS BCM does not
assistance control in mild send torque
oversteering or reduction request
understeering to 4WD.
: Before control
: After control
In “mild” oversteering is detected by

BCM, BCM sends torque down
request to 4WD control module.
In 4WD “LOCK” mode, this request is

not sent.
[Mild oversteer] Rear wheel torque has a priority.
1-7. Control Limitations
Coupling current is set 0 when:
• Coupling air temperature is too high

• Transfer oil temperature is too high
• Estimated coupling fluid temperature is too high
• Coupling air temperature increase is too fast
• Tire size difference is too large
• ⊿N during 2WD→4WD switching is too large
• While ABS is in operation
1-7. Control Limitations (Cont’d)
“4WD MODE UNSELECTABLE, AUTO MODE ON”
- One of the following modules sends 4WD shift inhibit request to IPC:
 ECM, TCM, ESP, EPS and 4WD control module.
“LOCK MODE CANNOT BE SET”
- LOCK button is pressed over 60 km/h

“NOT LOCKABLE, SET TO SNOW MODE FIRST”
- LOCK button is pressed with traction mode at AUTO and SPORT.

1-8. Maximum Current Regulation
Max. current is 2A in
RW420 model
1-10. Parameters on Scan Tool (Cont’d)
System : BCM
Parameter Reference value Driving mode switch
0.3 - 0.7 V Held at AUTO position
1.3 - 1.8 V Held at SPORT position
Driving Mode Switch 2.3 - 2.9 V Held at SNOW position
3.2 - 3.9 V Hed at LOCK position
4.1 - 4.7 V Released
2. Transfer
1. General
2. Transfer Oil Temperature Sensor
3. Oil Pump
4. Oil Strainer
5. Oil Seals
6. Shim Selection
[A] Transmission side
[B] Front right drive shaft side
1. Reduction drive gear 2-1. General
2. Reduction driven gear
3. Input bevel gear
4. Output bevel pinion
5. Intermediate shaft
6. Oil pump rotor assembly
7. Transfer oil temperature sensor
8. Transfer left case
9. Transfer right case
10. Retainer
11. Flange
12. Spacer
Kizashi SX4
A6B424 AKK416 AKK416D
29111- 57L10 57L00 57L20
Reduction
Reduction ratio 1.172(34/29)
drive gear
Total length [mm] 188.5 184.5 201.0
27311- 57L90
Bevel gear
Gear/Pinion ratio 0.297(11/37)
2-2. Transfer Oil Temperature Sensor
[A] Standard value

[B] Sensor resistance
[C] Temperature
2-3. Oil Pump
32
12 13
12. Reduction driven gear
13. Reduction driven gear right bearing
32. Oil pump drive pin
28. Oil pump cover
28
2-3. Oil Pump
2-3. Oil Pump (cont’d)
2-3. Oil Pump (cont’d)
2-4. Oil Strainer
3. Front Brake (Cont’d)
Caution:
When removing pads from caliper, do not move them toward
brake disc side. Otherwise return springs would be
damaged.
Do not remove return springs and pad clips from the caliper.
Otherwise they would be deformed.
Pad removal
Pad removal
- Slide the inner pad along the clips fitted on the caliper.
Pad removal 3. Front Brake (Cont’d)
- Slide the outer pad along the clips fitted on the caliper.
1 Front Brake (Cont’d)
3.
1
1
1. Return spring and clip 1
- No periodical maintenance as long
as the spring is not deformed.
- Not necessary to replace the spring
when replacing brake pads
Clip
Return spring
Do not remove from the

caliper
3. Front Brake (Cont’d) Return spring force applied point
3. Front Brake (Cont’d) Brake pad fitting
: Outer pad, leading side first!
3. Front Brake (Cont’d) Wrong example
6. Rear Brake (Cont’d)
Steel Aluminium alloy
-2.25 kg
6. Rear Disc Brake (cont’d)
[Brake pad installation : SWIFT RS416, SX4 RW420]
- Turn brake caliper piston clockwise to obtain
clearance between brake disc and pads.
Special Tool (A) : 09945-16060
[Brake pad installation : SWIFT AZG/AZH, SX4 AKK]

- Turn brake caliper piston clockwise to obtain
clearance between brake disc and pads.
Special Tool (A) : 09945-16030

SECTION 4F
ESP® :
ELECTRONIC
STABILITY
PROGRAM
1. Component Location (Cont’d)
ESP control module
If ESP control module is replaced,

Calibration is required:
- Master cylinder pressure sensor

- Yaw rate / G sensor
- Steering angle sensor
2. Steering Angle Sensor (Cont’d)
[On-Vehicle Calibration]
Drive the vehicle at 15 km/h or higher for a several seconds.
 Not available in SX4 AKK416/416D, Kizashi

Steering angle sensor calibration is required if one of the following conditions is met.
-Steering angle sensor is replaced
-Steering angle sensor is removed and reinstalled
-ESP control module is replaced
Battery disconnection does not affect sensor calibration
Steering wheel at neutral
Vehicle on a level surface

Brake pedal released
3. Wheel Speed Sensor (Cont’d)
Rear
5. Hill Hold Control
[Up Hill hold control start conditions] All of the following conditions:
- Longitudinal G > 0
- Engine running
- Parking brake released
- M/T neutral switch is OFF
- CPP1 is ON (Clutch pedal is fully depressed)
- Back up lamp switch OFF
- For two seconds after releasing the brake pedal
[Down Hill hold control start conditions] All of the following conditions:
- Longitudinal G < 0
- Engine running
- Parking brake released
- M/T neutral switch is OFF
- CPP1 is ON (Clutch pedal is fully depressed)
- Back up lamp switch ON
- For two seconds after releasing the brake pedal
[Hill Hold control end condition]

- When one of the conditions above is not met except CPP1 status.
NOTE:
CPP1 switch is used to recognize the driver present at driver’s seat.
Even if the clutch pedal is released within two seconds during hill hold
control in operation, the hill hold control continues.
6. μ–Split Control - Braking
[Friction-split control in braking]
Steering assistance force in low friction

surface direction
[A] High friction surface

[B] Low friction surface (slippery road)
6. μ–Split Control - Accelerating
[Friction-split control in accelerating]
Steering assistance force in high friction

surface direction
[A] High friction surface

[B] Low friction surface (slippery road)
7. Relation with 4WD System
Traction control by active brake:

LOCK>SPORT>SNOW≒AUTO
Traction control by engine torque reduction:

SNOW>AUTO>SPORT≒LOCK
ESP Operation in severe oversteering or understeering:

4WD system is fixed at 2WD mode. ESP has a priority.
See “Section 3. Driveline” for more details.

8. Messages
Fault in ESP System switched Fault in hill hold

system OFF during service system
8. Messages (Cont’d)
[SERVICE ESP SYSTEM]

ESP-related DTC detected.
[HILL HOLD DISABLE]

- Brake switch is stuck ON
- Clutch pedal position sensor abnormal
- Neutral switch abnormal
- Back-up lamp switch abnormal
- Transmission range sensor abnormal
- Communication error between ESP and EASS
control modules
- ESP-related DTC detected
11. ESP Function Setting
11. ESP Function Setting (Cont’d)
SECTION 5B1
TRANSMISSION
5M/T
1. General
Model SX4 AKK416 • Transmission type is

Type MF70 MF70, designed and
1st 3.545 (39/11) manufactured by
2nd 1.904 (40/21) Suzuki Motor
3rd 1.258 (39/31) Corporation.
4th 0.911 (31/34)
5th 0.725 (29/40)
• MF70 is widely used
REV 3.250 (39/12)
Final 4.352 (74/17)
for 1.5- and 1.6- litre
engines.
2. Gear Indicator
New feature
NOTE:
• The gearshift indicator is not indicated when the gear position is in “N” (Neutral).
• If clutch pedal is depressed while UP/DOWN arrow is indicated, the indication

disappears.
• If accelerator pedal is released while UP arrow is indicated, the indication will

display the currently selected gear position.
• The indication of gearshift indicator timing may differ depending on the vehicle
condition and/or driving situation even in the same vehicle speed and engine
revolution.
2. Gear Indicator (Cont’d)
Lower gear position is selected for the vehicle speed and/or

engine revolution. Changing to a higher gear position
is recommended.
• In this case, shifting up to 4th gear position is recommended.
Current gear position is optimal for the vehicle speed and/or

engine revolution.
• In this case, 3rd gear position is the best.
Higher gear position is selected for the vehicle speed and/or

engine revolution. Changing to a lower gear position
is recommended.
• In this case, shifting down to 2nd gear position is recommended.
SECTION 5C1
CLUTCH
- FOR M16A ENGINE
5. Clutch Pedal (Cont’d)
CPP1
CPP2
CPP1
CPP2
CPP2 CPP2
Rod pushed in Rod released
Clutch pedal released Clutch pedal depressed
CPP1
Rod released CPP1
5. Clutch Pedal (cont’d) Rod pushed in
1. CPP switch for cruise (CPP2)
2. CPP switch for start (CPP1)
[CPP2]
Clutch pedal pulled
“a” : LHD---1.4-1.9mm
RHD---1.4-1.9mm
(a) : 7.5Nm
[CPP1]
Clutch pedal depressed
“a” : LHD---3.6-4.1mm
RHD---4.3-4.8mm
5. Clutch Pedal (cont’d) (a) : 7.5Nm
Destination ENG A- M/T clutch IG switch Cruise
5. Clutch Pedal (cont’d) Engine Hill hold ESP
Code Region STOP start / Push start control
M16A - - IG YES - YES
M16A - - IG - - YES
M16A YES YES IG YES YES YES
M16A - YES Push start YES YES YES
P22 EU
M16A YES YES Push start YES YES YES
D16AA YES YES Push start YES YES YES
D16AA YES YES IG YES YES YES
M/T model system configurations
D16AA - YES Push start YES YES YES

M16A - YES IG - - YES
M16A - YES IG YES - YES
M16A YES YES Push start YES YES YES
P02 UK, etc.
M16A YES YES IG YES YES YES
D16AA - YES Push start YES YES YES
D16AA YES YES Push start YES YES YES
D16AA - YES IG YES - YES
P24 ADR (Australia, NZ, etc.) M16A - YES Push start YES YES YES
D16AA - - IG YES - YES
M16A - - IG YES - -
P10 South America (Chile, etc.) M16A - YES Push start YES - -
P43 Middle East (Saudi Arabia, etc.) M16A - - IG YES - YES
P90 Russia
P37 Brasil M16A - YES Push start YES YES YES
P71 Mexico M16A - - IG - - -
P06 RSA
P38 Taiwan M16A (Only CVT)
5. CPP Switch (cont’d)
Clutch pedal pulled

Clutch pedal depressed
1. CPP switch for cruise (CPP2)

2. CPP switch for start (CPP1)
Switch Clutch pedal CPP switch rod Continuity

CPP2 Released [A] Pushed in NO
To detect half clutch Depressed [B] Released YES
CPP1 Released [B] Released NO
To detect complete clutch release Depressed [A] Pushed in YES
5. CPP Switch (cont’d)
1. Clutch pedal
2. Clutch pedal arm
1. Clutch pedal 3. Master cylinder
2. CPP No.2 switch Clutch pedal free travel
Clearance between end of thread and clutch “b” : 2 – 8 mm
pedal arm 4. Release point
“a” : 1.4 – 1.9 mm 5. Full stroke point
Tightening torque Clutch release margin
CPP No.2 switch lock nut (a) : 7.5 Nm “c” : 25 – 40 mm
SECTION 5E-1
TRANSMISSION
CVT
PART 1
Auxiliary Transmission Components
4
2
LB: Low Brake

RB: Reverse Brake
HC: High Clutch
1
1 5
1. Secondary pulley
2. Front sun gear
3. Rear sun gear
4. Long pinion
5. Short pinion
6. Planetary carrier
7. Ring gear
8. Reduction gear
Operating range
High torque is obtained to
give great off-the-line
acceleration
Automatically
switched
Engine speed
Vehicle speed
Engine speed is lower at any
vehicle speed to improve high-
speed fuel economy.
Operating range
A : Auxiliary transmission shift up point
TCM shifts pulley ratio to low gear side

Overview of components
LB: Low Brake

RB: Reverse Brake
HC: High Clutch
1. Secondary pulley
2. Front sun gear
3. Rear sun gear
4. Long pinion
5. Short pinion
6. Planetary carrier
7. Ring gear
8. Reduction gear
1
4 4a
4a
1. P range detection switch

2. Manual release lever
3 3. Shift lock solenoid
4. M range switch
4a. Manual shift down (M-) switch
3. Shift Lever Mechanism 4b. Manual shift up (M+) switch
3. Shift Lever Mechanism (cont’d)
Shift with the knob button pressed in and the

brake pedal depressed.
Shift with the knob button pressed in.
Shift with the knob button released.
(1) : knob button

4. Shift Paddle
Paddle switch
4. Shift Paddle (cont’d)
[Paddle switch specification]
[Paddle switch removal] Free : No continuity

Pulled : Continuity
- Remove steering wheel
- Disconnect paddle switch connector (1)
- Loosen screws (2)
- Remove paddle switch (3)
4. Connector
TCM Slope sensor
TCM
Keyless start control module

Gear shift Control
1. Engine brake : Large

[Down hill control] 2. Engine brake : Small
- Shift down to apply engine brake. a : Large gradient
b : Small gradient
[Up hill control]
- High gear zone is inhibited for a better acceleration.
[Acceleration control]
- Down shifting value varies with accelerator pedal position change.
12. Protection Control
General description
- In case of trouble that may damage TCM and transaxle safety occurs,
TCM temporally enters safety mode to protect TCM and transaxle.
TCM comes back to normal mode when safety is assured.
- Protection controls of TCM are as follows.
- Reverse inhibit control

Reverse gear is inhibited if the range is switched from D to R above
10km/h.
- Control under high temperature

17. On-Vehicle Service
1. CVT Fluid Inspection

2. CVT Fluid Change
3. Line Pressure Test
4. Stall Test
5. Setting after Replacement
17-1. CVT Fluid Inspection
(1) Drive the vehicle until the CVT fluid temperature

reaches 70 oC (158 oF).
(2) Park the vehicle on a level surface with engine idling.
(3) Move the selector lever PRNDMDNRP.
(4) After wiping dirt off around the CVT fluid level gauge, pull out the
CVT fluid level gauge to check the fluid state.
(5) Check fluid level. The level should be within “HOT” range.
H : Fluid level
T : Fluid temperature
1. CVT fluid level gauge
Fluid status Possible cause Required process

CVT fluid is deteriorated due to Change CVT fluid. Check transmission
"Varnish" state
extremely high temperature condition. assembly, harness and cooling pipes etc.
Change CVT fluid. Check if there is any
"Milky white" state CVT fluid contains water.
point where water filters into transmission.
Change transmission assembly.
Metal powder mixed Transmission internal parts are worn.
Clean CVT fluid cooler circuit.
17-2. CVT Fluid Change
(1) Drain the fluid from oil pan drain plug.  It is recommended to measure volume of drained fluid.
(2) Install drain plug to oil pan with new gasket. Tighten plug to 34 Nm.
(3) Pour a proper amount of CVT fluid.  The volume could be the same as measured value at (1).
(4) Drive the vehicle until the CVT fluid temperature reaches 70 oC (158 oF).
(After warming up the engine, drive the vehicle on the road for approximately 10 minutes. If the
outside air temperature is 20 oC (68 oF), CVT fluid temperature reaches 50 to 80 oC (122 to 176 oF).
(5) Check fluid level and status. If the fluid is dirty, repeat from step (1).
CAUTION:
- Use specified fluid : SUZUKI GREEN-2
- Do not reuse drained fluid.
- Use wiping paper to wipe the fluid level gauge. Do not use wiping cloth.
- After the fluid change, perform fluid leak check.
17-3. Line Pressure Test
(1) Check engine oil level. Refill if required.
(2) Warm up the CVT fluid until the fluid temperature reaches 70 oC (158 oF).
(3) Park the vehicle on a level surface. Engage the parking brake fully. Lock the wheels with blocks.
(4) Attach oil pressure gauge to the pressure test port.
(5) Measure the line pressure at engine idle speed and stall speed respectively.
(6) Detach the oil pressure gauge. Then fit the bolt to the pressure test port and tighten it to 13 Nm.
17-3. Line Pressure Test (cont’d)
Line pressure At idle At stall

(MPa) 0.5 to 1.0 -
P or N (kg/cm2) 5.1 to 10.1 -
range (psi) 72.5 to 145 -
(bar) 5 to 10 -
(MPa) 0.5 to 1.0 4.18 to 4.68
R or D (kg/cm2) 5.1 to 10.1 42.7 to 47.7
range (psi) 72.5 to 145 607 to 678
(bar) 5 to 10 42 to 46
17-4. Stall Test
(1) Check engine oil level. Refill if required.
(2) Attach oil pressure gauge to the pressure test port.
(3) Warm up the CVT fluid until the fluid temperature reaches 70 to oC (158 oF). (After warming up the
engine, drive the vehicle on the road for approximately 10 minutes. If the outside air temperature is
20 oC (68 oF), CVT fluid temperature reaches 50 to 80 oC (122 to 176 oF).
(4) Park the vehicle on a level surface. Engage the parking brake fully. Lock the wheels with blocks.
(5) Depress the accelerator pedal fully in D range with brake pedal firmly depressed.
(6) Rapidly read the stall speed. Then immediately release the accelerator pedal.
(7) In the same way, check the stall speed in R range.
(8) Move the selector lever to N range. Leave the engine running at idle for 1 minute or longer.
Engine Stall speed (rpm)

M16A 2350-2950
17-5. Setting after Replacement
0. Summary
1. Case 1
2. Case 2
3. Case 3
4. Learning Value Initialization
5. Slope Sensor Calibration
17-5-0. Summary
TCM Valve body or transmission assembly Setting Procedure

Not replaced Case 1
Replaced with a new one
Replaced with new or used assembly Case 1 or 3(*)
Not replaced Replaced with new or used assembly Case 2
Not replaced
Replaced with a used one Case 3
Replaced with new or used assembly
(*) : When replacing TCM first, perform initialization procedure [Ca

17-5-1. Case 1

Not replaced Case 1
Replaced with a new one
Replaced with new or used assembly Case 1 or 3(*)
Setting Procedure:
1) Set the selector lever at P range.
2) Turn ignition key to ON position and leave ignition in ON for 10 sec.
3) Check that transmission warning light does not come ON and DTC is not detected in TCM.
4) Perform slope sensor calibration.
IMPORTANT:
New TCM : Valve body ROM data is written in the new TCM at first ignition cycle.
After that, the data stored in the TCM cannot be cleared or overwritten until the TCM data is
cleared by Scan Tool.
17-5-2. Case 2

Not replaced Replaced with new or used assembly Case 2
Setting Procedure:
1) Set the selector lever at P range.
2) Turn ignition key to ON position and leave ignition in ON for 10 sec.
3) Perform “Learning Value Initialization” by Suzuki Scan Tool.

(Learned parameter is cleared at this step) See “16-5-4. Learning Value Initialization”.
4) Perform “CVT pressure control learning described in next page.
17-5-2. Case 2 (cont’d)
[CVT pressure control learning]
Step Item Procedure

Park the vehicle at a relatively cool place and stop the engine. Wait
1 CVT fluid cooling
until CVT fluid temperature drops down to the room temperature.
1) CVT fluid temperature Using Scan Tool, confirm that the CVT fluid temperature is almost the
measurement same as outside air temperature.
- Start the engine. Move the shift lever between N and D and between
N and R twice or three times. If the shock has become small, go to "3)
Line pressure and shift control learning".
- If the shift shock is still big, repeat garage shifting (up to 10 times,
Learning at 2) Garage shift learning respectively).
2 cold CAUTION:
temperature In garage shifting, keep each position (N, D or R) for 2 or more
seconds. Especially in N range, wait until the engine speed is
sufficiently stabilized.
3) Line pressure and shift control
Leave the vehicle with engine idling in D range for 20 seconds.
learning
Warm the CVT fluid up to 40oC (104 F).
o
4) Hydraulic pressure adjustment
5) Lock up control learning Drive the vehicle at 40-50km/h (64-80mph) in D range for 5 seconds.
o o
Warm the CVT fluid up to 80 C (176 F).
1) CVT fluid temperature CAUTION:
measurement
Learning at If it is hard to warm the CVT fluid up to 80oC (176oF) at cold region,
3 warm warm it up to as high temperature as possible.
temperature 2) Garage shift learning Same procedure as "2 Learning at cold temperature".
3) Line pressure and shift control
Same procedure as "2 Learning at cold temperature".
learning
4) Lock up control learning Same procedure as "2 Learning at cold temperature".
17-5-3. Case 3
Replaced with a new one Replaced with new or used assembly Case 1 or 3(*)
Not replaced
Replaced with a used one Case 3
Replaced with new or used assembly
Setting Procedure:
1) First replace valve body assembly or transmission assembly.
2) Then replace TCM.
3) Perform the same working procedure as “Case 1”.
IMPORTANT:
It is highly recommended to replace valve body or transmission assembly first.
If the TCM is replaced with a new one before replacing the valve body or transmission assembly
and the ignition key is turned to ON position, the valve body ROM data is written in the new TCM.
In this case, “Case 2” must be performed after replacing the valve body or transmission assembly with
another one because another one contains a different valve body ROM.
Used TCM : Valve body ROM data has been already written in the TCM.
If the valve body or transmission assembly is replaced with another (new or used) one,
TCM data does not match another one’s ROM data.
TCM data cannot be cleared simply by disconnecting negative cable at battery.
TCM data must be once cleared by Scan Tool as shown above.
17-5-4. Learning Value Initialization
17-5-4. Learning Value Initialization (Cont’d)
17-5-5. Slope Sensor Calibration
Setting Procedure:
1) Adjust air pressure of all tires to specified value.
2) When ignition is OFF, connect SUZUKI scan tool to DLC.
3) Perform “DTC Check” and confirm that DTC other than P1708 is not detected. If DTC other than P1708 is
detected, perform troubleshooting for applicable DTC.
4) Park vehicle on level surface, apply parking brake and stop engine with ignition ON.
5) Select menu “Slope Sensor Calibration” under “Utility” mode of SUZUKI scan tool and calibrate sensor with
ignition ON. Refer to scan tool operator’s manual for further details.
6) Confirm that ignition is OFF and then disconnect SUZUKI scan tool from DLC.
17-5-5. Slope Sensor Calibration (cont’d)
17-5-5. Slope Sensor Calibration (cont’d)
SECTION 6
STEERING
1. Description
1. Upper steering column

2. Steering column support member
3. P/S motor with P/S control module
4. Torque sensor
5. Lower steering column
6. Dash panel
7. Steering gear case
8. Tie rod
1. Description (cont’d)
SWIFT RS SWIFT AZG/AZH SX4 RW SX4 AKK Kizashi
Assist type Pinion Column Pinion Column Pinion
Steering column SHOWA NSK NSK NSK MANDO
Torque sensor SHOWA NSK NSK NSK NSK
EPS motor Mitsubishi Elec. Mitsubishi Elec. Mitsubishi Elec. Mitsubishi Elec.
Mitsubishi Elec.
EPS control module Mitsubishi Elec. Mitsubishi Elec. Mitsubishi Elec. Mitsubishi Elec.
4-1. Components Location (cont’d)
4-1. Components Location (cont’d)
EPS motor with control module
Torque sensor
4-1.Components Location
(cont’d)
79: P/S fuse (80A)

4-2. Components Function
Component Function
It outputs the voltage to EPS control module according to
Torque
the steering torque and direction detected by 2 sensors :
sensor
main and sub.
Voltage corresponding to actual EPS motor angular

Resolver
position is sent to EPS control module.
Steering column Motor assists steering operation by generating torque
assembly corresponding to the current supplied by EPS control
EPS
module.
motor
-Control module determines motor current value and
with EPS
direction according to the torque sensor output voltage,
control
resolver output voltage and vehicle speed.
module
-Control module detects engine state (running / at a stop)
according to the engine speed signal.
EPS warning light It turns on when the system is abnormal.
4-3. Torque Sensor (cont’d)
4-4. EPS Motor with
Control Module
4-4. EPS Motor with Control Module (cont’d)
1. Rotor
Column Upper Section 2. Stator
3. Inverter
[A] : Steering wheel neutral

[B] : Streeing wheel turned
1. EPS motor signal 1
[Advantage of brushless motor]

- Long life
- No electrical noise
- No brush metal particles
- High speed rotation possible
- Low inertia
- Efficient cooling
[Disadvantage of brushless motor]
- High cost
- Precision parts integrated
[Resolver] 4-4. EPS Motor with Control Module (cont’d)
Column Upper Section
1. Motor shaft
2. Rotor
3. Exciting coil
4. Detecting coil 1
5. Detecting coil 2
No contact motor
 CPU should know the rotor position to
alternate the polarity precisely.
 Resolver (rotation angle sensor) is required.
4-5. [A]: CVT model
[B]: ENG A-STOP model
1. P/S control module / motor
Wiring assembly
2. CPU
3. CAN driver
Diagram 4. 9 V regulator
5. Torque sensor
6. Torque sensor (main) circuit
7. Torque sensor (sub) circuit
8. Torque sensor amplifier
9. Power supply relay
10. P/S motor
11. Rotation angle sensor
exciter circuit
signal receive circuit
14. Main fuse box
15. “P/S” fuse
16. To continuous power
supply
17. J/B
18. “IG1 SIG” fuse
19. “Meter” fuse
20. To ignition power supply
21. Combination meter
22. “P/S” warning light
23. Meter driver
24. DLC
25. To other control modules
by CAN
26. BCM
27. TCM (if equipped)
28. ENG A-STOP control
module (if equipped)
29. ABS/ESP® control module
30. ECM
4-6. Input / Output Flow
4-7. Indicator
4-8. DTC
DTC Diagnosis Condition DC EPS lamp
C1111 Main torque sensor circuit faulty Main torque sensor output voltage above 4.5V or below 0.5V. 1 YES
Torque sensor (Main and Sub) circuit Voltage difference between main signal and sub signal is above
C1113 1 YES
correlation specification.
C1115 Sub torque sensor circuit faulty Sub torque sensor output voltage above 4.5V or below 0.5V. 1 YES
C1116 Torque sensor 9V power circuit faulty Torque sensor power voltage below 7.0V. 1 YES
C1131 Resolver signal faulty Resolver signal abnormal 1 YES
Motor circuit voltage is higher than standard voltage by 0.3V or more, or
C1141 P/S motor voltage abnormal 1 YES
motor driving circuit is abnormal.
C1142 P/S motor current abnormal 1 Motor current is bigger than standard voltage by 10A or more. 1 YES
C1143 P/S motor current too large Measured motor drive current is bigger than 97 A. 1 YES
C1145 P/S motor current abnormal 2 Target motor current is much bigger than measured motor current. 1 YES
C1146 P/S motor voltage abnormal Motor voltage calculated by P/S control module is abnormal. 1 YES
C1152 Fail safe relay melted stuck Fail safe relay contact is melted and stuck 1 YES
Battery voltage is below 9 V while voltage at fail-safe relay contact is
C1153 Power supply voltage too low above 19.2V or engine speed is above 600rpm and commanded fail-safe 1 YES
relay ON.
Relay contact voltage below 4V while engine speed above 600rpm and
C1154 Fail safe relay contact faulty 1 YES
fail safe relay ON is commanded.
C1155 P/S control module internal failure P/S control module internal failure 1 YES
C1160 Assist map information not determined Assist map information is not written in P/S control module 1 YES
C1161 Vehicle speed signal abnormal in CAN Invalid vehicle speed signal from ECM. 1 NO
C1162 Engine speed signal abnormal in CAN Invalid engine speed signal from ECM. 1 YES
Invalid data from BCM (steering assist torque request) or steering assist
C1164 BCM signal abnormal in CAN 1 NO
torque request from BCM longs for 30 sec or more.
C1166 Reliability defect of vehicle speed data Invalid data from ECM (vehicle speed reliability) 1 NO
U0073 CAN Bus Off Impossible to transmit/receive CAN communication data 1 NO
U0100 CAN lost communication with ECM CAN communication data cannot be received from ECM. 1 YES
U0121 CAN lost communication with ABS/ESP CAN communication data cannot be received from ABS/ESP 1 YES
U0140 CAN lost communication with BCM CAN communication data cannot be received from BCM. 1 YES
U0155 CAN lost communication with IPC CAN communication data cannot be received from combination meter. 1 YES
U1082 CAN lost communication with EASS CAN communication data cannot be received from ENG A-STOP cont. 1 YES
4-9. Fail Safe
DTC Fail-safe operation Fail-safe operation cancel condition
C1111
C1113
C1115
C1116
C1131
C1141 P/S motor and fail-safe relay turned off. Ignition is set to "OFF".
C1142
C1143
C1145
C1146
C1152
C1153 P/S motor turned off or assist value is minimized. Voltage as fail-safe relay contact becomes
between 10 and 18.2 V or ignition is set to
P/S motor turned off or P/S motor and fail-safe relay
C1155 "OFF".
turned off.
C1160 Derault assist map information is applied. Correct assist map is set.
C1161 Assist value is minimized
C1162 Assist is suspended.
Normal data is received or ignition is set to
C1164 VDSC is suspended.
"OFF".
C1166 Assist value is minimized
U0100 Assist is suspended or assist value is minimized.
1. AUTO A/C Panel
1. Left side temperature dial
2. Right side temperature dial
3. DUAL switch and indicator
4. Blower fan speed switch
5. FRE/REC switch
6. Air outlet MODE switch
7. Front defroster switch and indicator
8. A/C switch and indicator
9. AUTO switch
10. OFF switch
11. VFD (Vacuum Fluorescent Display)
“AUTO” indicator flashing shows current malfunction.
How to enter “DUAL” mode:
- Press DUAL switch

or
- Turn passenger side temperature dial
5. AUTO A/C Component
Layout (cont’d)
Auto A/C Panel

2. Air Filter location
A/C filter
Thermistor
Thermistor position 2. HVAC Unit

(cont’d)
Ventilation Outlet
3. Ventilation System (cont’d)
5. AUTO A/C Component Layout (cont’d)
Outside Air Temperature Sensor

5. HVAC control module
HVAC Control Module

6. Sun Load sensor
5. AUTO A/C Component
Layout (cont’d)
7. Evaporator
thermistor
connector
8. Drain hose
Ensure drain hose is not blocked!

9. Inside air temp. sensor
10. Communication protocol
Auto LIN HVAC

A/C control CAN
bus
panel module
11. HVAC - Restart control
If the engine is stopped once and restarted within a short time,

outside temperature of last ignition cycle is used for control.
[Reason]
To avoid detecting heat radiating from the engine.
12. HVAC - Compressor Control
Control item Input Detail

Evaporator ECM turns OFF the compressor relay when the temperature of evaporator thermistor
thermistor is too low to prevent freezing.
ECM turns OFF the compressor relay according to the engine speed to prevent engine
Engine speed
stall at low rpm and to prevent compressor from overrunning at high rpm.
Compressor Refrigerant ECM turns OFF the compressor relay when the refrigerant pressure is too low or too
relay pressure high to protect the A/C system.
ECM turns OFF the compressor relay for a few seconds if the throttle position is widely
Throttle position
open during acceleration or during vehicle start-up.
Coolant ECM turns OFF the compressor relay at very high engine coolant temperature to avoid
temperature overheating.
13. HVAC Sensors
Sensor name Element Location Feature

Inside air temperature Thermistor Center of instrument It detects temperature of air flowing through the
panel sensor by making use of air flow generated by
aspirator.
Aspirator is located on the Auto A/C unit.
Outside air temperature Thermistor Behind the front Outside of thermistor is formed by resin to slow
bumber down the reaction to drastic change in ambient
temperature.
Sun load Photo diode Center on The sensor changes current flowing through the
dashboard circuit. HVAC control module converts current
into voltage.
Evaporator temperature Thermistor Evaporator outlet It detects temperature of evaporator core fin at
outlet part.
Refrigerant pressure Piezo electric Between condenser It detects pressure linearly. More precise control
and expansion valve compared with ON/OFF switching type sensor. It
contributes to a better fuel economy.
14. HVAC pressure range
[A]: R-134a model

[B]: R-1234yf model
[C]: Pressure on high pressure gauge
[D]: Pressure on low pressure gauge
[E]: Ambient temperature
[F]: Humidity
[G]: Acceptable range
15. Compressor
[A] M16A R134a compressor
Tightening torque
(a) 25 Nm
(c) 11 Nm
(d) 11 Nm
Refrigerant capacity: 400g
Bolt tightening sequence
Model Supplier Oil

M16A HFC-134a MITSUBUSHI Heavy Industries 99000-99095-00A MITSUBISHI S10X
16. Compressor (Cont’d)
[M16AA engine]
1. A/C compressor drive belt
2. A/C compressor pulley
3. Crankshaft pulley
Compressor drive belt tension “a”:

9-10mm/100N for used belt [M16AA engine]
7-8mm/100N for new belt 1. Tension pulley bolt (55Nm)
2. Tension pulley adjusting bolt
3. A/C compressor drive belt
SECTION 8
RESTRAINTS
1. Airbag System Description
Lateral G
Front left Rear left Front Left side Left side Left seatbelt Right seatbelt
sensor in
side sensor side sensor airbag curtain airbag pretensioners pretensioners
SDM
ON ON ON
ON ON OFF
Deployed Deployed Deployed Deployed
ON OFF ON
OFF ON ON
OFF OFF ON
OFF ON OFF
Not deployed Not deployed Not deployed Not deployed
ON OFF OFF
OFF OFF OFF
Lateral G
Front right Rear right Front Right Right side Right seatbelt Left seatbelt
sensor in
side sensor side sensor side airbag curtain airbag pretensioners pretensioners
SDM
ON ON ON
ON ON OFF
Deployed Deployed Deployed Deployed
ON OFF ON
OFF ON ON
OFF OFF ON
OFF ON OFF
Not deployed Not deployed Not deployed Not deployed
ON OFF OFF
OFF OFF OFF
2. SDM (Sensing and Diagnostic Module)
• SDM is mounted on the floor

carpet via steel brackets, close to
the parking brake lever.
• SDM is made by Continental.

3. Knee Airbag
Left
Left
1. Airbag
2. Knee airbag module trim
3. Inflator
4. Generated gas
3. Knee Airbag (Cont’d)
Left
Left
4. Seat Belt Pretensioners
• Only front seat belts are equipped

Left with pretensioners
Left
5. Front Side Sensors
• Front side sensors are pressure

Left sensors, not G- sensors
• Pressure sensor • Mounting location

6. Rear side sensors
• Rear side sensor is

Left fitted near the rear
door
Left switch.
• This sensor detects
lateral deceleration
using an
accelerometer.
6. Forward Sensors
•
Left
Front
sensors are
fitted both
on left and
right sides
7. Passenger Airbag OFF Switch
Passenger airbag deactivation switch - location
Left
Indicator
17. Passenger Airbag OFF Switch (Cont’d)
Knee
Airbag Side airbag Curtain airbag Seat belt pretensioner
airbag
Driver Passenger Driver Driver Passenger Driver Passenger Driver Passenger
Air bag ON (switch closed)
Air bag OFF (switch open) Left
1. Passenger airbag deactivation switch

2. Passenger airbag deactivation indicator
3. SDM
4. Passenger airbag (inflator) module
Left
36691-61M00 : Repair Harness

36620-61M** : Instrument panel harness
36630-61M** : Floor harness
19. Passenger
Airbag Harness
Repair (Cont’d)
SECTION 9
BODY, CAB AND

ACCESSORIES
1-3. Lifting & Towing
: Front side : Rear side
1. Floor jack point

2. Frame contact hoist
/ Safety stand point
3. Gravity center without
load on vehicle
[a] Wheel center “a”: Approx. 957-1021mm
[F] Vehicle front

Front Left
1-3. Lifting & Towing (cont’d) Front Right
Rear Left
Rear Right
1-3. Lifting & Towing (cont’d) 1. Front lifting point by floor jack
(Front suspension frame)
2. Rear lifting point by floor jack
(Rear hook)
3. Vehicle center of gravity
[a] Wheel center
“a” : 957-1021mm
[F]: Front side

1-3. Lifting & Towing (cont’d)
1. Towing hook cover

2. Jack handle
3. Towing hook
1. Front tie-down hook
2. Shipping hook
3. Rear tie-down hole]

[Tie-down hook, right]
[Tie-down hook, left]

[Rear tie-down hole, left]
[Rear tie-down hole, right]

2. Lighting
1. Discharge Headlamp System

2. Headlight Auto Leveling System
3. Headlamp Beam Switching Solenoid
4. Auto Lighting System
5. DRL
6. LED Positioning Lamp
7. Headlamp Washer System
2-1. Discharge Headlamp System
Light intensity characteristics with low beam ON
Discharge Halogen
[A] Discharge headlamp
Power consumption (W) 35 55
[B] Halogen headlamp
Light flux (lm) 3500 1000/1650
[NOTE] Lifetime (h) 3xT T
d Forward distance
L Left offset
BCM incorporates DRL control module. R Right offset
Keyless push start model employs HID system only. (Low consumption)
Halogen cannot be used for keyless push start system’s BCM. (Beyond BCM’s capacity)
Halogen headlamp is used for ignition switch model only.
2-1. Discharge Headlamp System
1. Ballast
2. Igniter
3. DC 12V
4. Power noise filter
5. DC/AC converter
6. Pulse inverter
7. Output noise filter A. Lighting switch ON
8. Booster transformer
B. Booster starts
9. CPU
C. Bulb is lit
10. Igniter circuit + socket
11. Discharge bulb
2-1. Discharge Headlamp System (cont’d)
Fail safe function of Ballast
1.Discharge bulb
2.Molybdenum film
3.Xenon gas
4.Tangsten electrode
5.Metal iodide
6.Mercury
[Light emission process] 7.Anhydrous quartz glass
1)High voltage is applied to both electrodes.
2)Xenon gas is ionised and emits light.
3)Mercury evaporates and arc-discharges due to high temperature.
4)Metal iodide evaporates and metal atom discharges and emits light
due to higher temperature.
5)Stable light is emitted by ballast control.
2-2. Headlight Auto Leveling System
1. General
2. Component Location
3. Input / Output Chart
4. Circuit Diagram
5. Height Sensor
6. Headlight Leveling Actuator
7. Headlight Leveling Control Module
8. DTC
9. Initial Setting
2-2-1. General
[A]: Optical axis of headlight
in standard position
[B]: Corrected optical axis of headlight
1.Headlight
2.Headlight leveling actuator
3.Headlight leveling and headlamp
washer control module
4.ECM
5. (Blank)
6.Rear height sensor
7.Vehicle displacement (stroke)
8.Wheel speed sensor
9.Vehicle speed signal
10.Control signal
11.Warning
12.Combination meter
13.Pitching angle
14.After loading
15.Before loading
16.Optical axis before loading
17.Optical axis after loading
18.Automatic adjustment
1. Rear vehicle height sensor
2. Headlight leveling actuator
3. Headlight auto leveling and
head lamp washer control
4. Lighting & turn signal switch
6. Auto leveling warning lamp
2-2-2. Component Location

2-2-3. Input / Output Chart
2-2-4. Circuit Diagram
1. J/B
2. “BACK” fuse
3. Headlight leveling actuator (L)
4. Headlight leveling actuator (R)
5. Control circuit
6. To each control module
8. Voltage regulator circuit
9. Output circuit
10. CAN driver
11. Windshield washer pump
12. Headlight washer switch
13. Headlight washer pump
14. Rear vehicle height sensor
15. To lighting switch 23. J/C
16. “WIP” fuse 24. DLC
17. Relay box No.1
18. “H/L CLHR” fuse
20. Headlight auto leveling
warning light
21. Meter driver
22. “MTR” fuse
23. Junction connector
24. DLC
2-2-5. Height Sensor
Do not remove sensor link and brackets

from the sensor !
2-2-5. Height Sensor
2-2-5. Height Sensor (cont’d)
[A]Shaft angle 0o (normal height)

[B]Shaft angle 45o
1.HALL IC
2.Shaft
3.Oil seal
4.Magnetic circuit
5.Terminal
V : Sensor output voltage
Vo : Basic voltage position
W : Shaft angle
L : Low height
H : High height
2-2-5. Height Sensor (cont.)
[A]When electrically adjusted
2-2-6. Headlight Leveling Actuator [B]When adjusted by aiming screw
1.Actuator assembly
2.Actuator bar
3.Actuator bar gear
4.Intermediate gear
5.Light position sensor
6.Motor
7.Aiming screw
8.Reflector
2-2-7. Headlight Leveling Control Module (cont.)
Vehicle Headlight switch Control

Leveling actuator is driven according to the vehicle
OFF-->ON heights detected just before turning headlight
switch on.
Stationary If the vehicle height is changed due to loading or
unloading and specified time passed, leveling
ON
actuator is driven according to the change in
vehicle heights.
If the vehicle speed is kept constant above 30km/h
for specified time after turning on the headlight
OFF-->ON switch, leveling actuator is driven according to the
vehicle heights detected when the headlight switch
is OFF.
Running
If the vehicle speed is kept constant above 30km/h
with headlight switch ON for specified time,
ON leveling actuator is driven to adjust optical axis.
Adjustment is performed only once until the vehicle
is stopped again.
2-2-8. DTC
DTC DTC name Description Warning

Headlight auto leveling and washer control module
B1950 Control Module Programming Error Lit
internal failure
- Headlight auto leveling and washer control module
B1951 Ignition Power Supply Voltage Data Error power supply circuit voltage is higher than 16.4 V for OFF
10 Sec.
- Headlight auto leveling and washer control module
power supply circuit voltage is lower than 9.3 V for 10
Sec.
Windshield Washer Motor Supply Voltage
B1952 See "Headlamp Washer System".
Circuit
B1956 Rear Height Sensor Error Any of the following conditions is met. Lit
- Rear vehicle height sensor signal circuit voltage is
higher than 4.75 V for 10 sec.
- Rear vehicle height sensor signal circuit voltage is
lower than 0.25 V for 10 sec.
- Rear vehicle height sensor power supply voltage is
higher than 6.25 V for 10 sec.
- Rear vehicle height sensor power supply voltage is
lower than 4.45 V for 10 sec.
Rear vehicle height sensor initial setting is not
B1967 Lack of Height Sensor Initial Setting Lit
completed.
Wheel Speed Sensor and/or Its Circuit Vehicle speed signal is not inputted by CAN
B1970 Lit
Malfunction communication.
U0073 Control Module Communication Bus Off CAN bus off error. OFF
U0100 Lost Communication with ECM No communication with ECM. OFF
2-2-9. Initial Setting
Initialization of the auto leveling headlight system is required when any of the following
works has been performed.
- Replacement of headlight auto leveling and headlamp washer control module
- Removal of rear height sensor
- Replacement of rear height sensor
1) Observe the following instructions.

-Park vehicle on level ground.
-Adjust air pressure of all tires to the
specified value respectively.
-Bounce vehicle body up and down by
hand to stabilize suspension.
2) Turn ignition mode to OFF.
3) Connect SUZUKI Scan Tool to DLC.
4) Set ignition mode “ON” and select
“Height Sensor Initial Setting” under
“Utility” mode on scan tool.
5) Follow the instructions on scan tool.
2-2-9. Initial Setting (Cont’d)
2-2-9. Initial Setting (Cont’d)
2-3. Headlight Beam Switching Solenoid
1. General
2. Bulbs
3. Control Circuit
4. Components
5. Operation
6. Inspection
2-3-1. General
High beam
HID bulb +
Low beam SW solenoid High beam
HID bulb +
Low beam SW solenoid
2-3-2. Bulbs
1. Clearance lamp bulb

2. Turn signal lamp bulb
3. Discharge headlamp bulb
4. Igniter
5. Back cover
6. Ballast
7. O-ring
8. Clearance lamp bulb socket
9. Turn signal lamp socket
1. Turn signal lamp bulb

2. Turn signal lamp socket
3. Discharge headlamp bulb
4. Igniter
5. Ballast
6. O-ring
(Clearance lamp is LED and
included in headlamp assembly
2-3-5. Operation
[At Low Beam] [At High Beam]
The shade cuts off high The shade is laid down by
beam distribution solenoid to admit high
beam distribution.
Lamp Unit
Shade Solenoid
2-4. Auto Lighting System
Lighting switch IG switch Ambient condition Headlamp Position/tail lamp

OFF Any - OFF OFF
Clearance Any - OFF ON
Headlight Any - ON ON
AUTO ON Clear OFF OFF
AUTO ON Clear -> Dark for a moment -> Clear ON ON
AUTO ON Dim ON ON
AUTO ON Dark ON ON
AUTO ON Dark -> Clear for a moment -> Dark ON ON
AUTO OFF - OFF OFF
2-4. Auto Lighting System (Cont’d)
Kizashi A6B424 SX4 AKK416/416D

Customized 37320-57L00 37320-61M00
sensitivity ON-timing OFF-timing ON-timing OFF-timing
Sensor
threshold threshold threshold threshold
Early ON 3000 lx 4000 lx 7000 lx 10000 lx
Upside Normal 2500 lx 3500 lx 5500 lx 8500 lx
Late ON 2000 lx 3200 lx 4000 lx 6500 lx
Front Normal 500 lx 850 lx 500 lx 850 lx
2-4. Auto Lighting System (cont’d)
[Auto Lighting Customize]
- Early ON / Late OFF See “Auto Windshield Wiper”

- Normal ON / Normal OFF  Default
- Late ON / Early OFF to customize
[Auto-Wiper Synchronization Customize]
- Heavy rain synchronization  Default

With wiper switch in “AUTO” and auto wiper setting in “Full Auto”, each lamp is automatically
turned ON when the rain/light sensor detects heavy rain condition.
- Light rain synchronization
With wiper switch in “AUTO” and auto wiper setting in “Full Auto”, each lamp is automatically
turned ON when the rain/light sensor detects heavy rain condition.
- No synchronization
Each lamp is automatically controlled depending on the ambient light intensity only.
2-5. Daytime Running Light (DRL) (Cont’d)
Position Lamp without DRL

Position Lamp with DRL
2-5. Daytime Running Light (DRL) (Cont’d)
Position Lamp without DRL Position Lamp with DRL

2-5. Daytime Running Light (DRL) (cont’d)
Ambient light condition

Summary !
Ignition mode
Lighting
LOCK(OFF)/ACC "ON"
switch Main lights to operate
Engine stop Engine stop Engine running
position
LIGHT DARK LIGHT DIM DARK LIGHT DIM DARK
DRL - - - - - ON ON ON
OFF Pos./Tail lamps - - - - - - - -
Headlamps - - - - - - - -
DRL - - - - - ON ON -
AUTO Pos./Tail lamps - - - ON ON - - ON
Headlamps - - - - ON - - ON
DRL - - - - - - - -
Pos./Tail lamps ON ON ON ON ON ON ON ON
Headlamps - - - - - - - -
DRL - - - - - - - -
Pos./Tail lamps ON ON ON ON ON ON ON ON
Headlamps ON ON ON ON ON ON ON ON
Note:
DRL ON = Position/Tail Lamps ON and Headlamps ON
2-5. Daytime Running Light (DRL) (cont’d)
Disabling/enabling DRL on BCM

Note:
DRL ON = Position/Tail Lamps ON and Headlamps ON
[A]: Pump side
[B]: Nozzle side
1. Windshield washer nozzle
2. Check valve
3. Washer hose
4. Rear washer nozzle
5. Connector
6. Washer tank
7. Headlight washer hose
8. Headlight washer nozzle
9. Windshield washer pump
10. Rear washer pump
11. Headlight washer pump
13. Headlight washer switch
2-7. Headlamp
Washer System
2-7. Headlamp Washer System (Cont’d)
2-7. Headlamp Washer System
Headlamp washer switch
on instrument panel
(momentary type)
Once in
1 DC only
Any time
when pushed
3. Instrument / Driver Information
1. Combination Meter
2. Parking Sensor System
3-1. Combination Meter
3-1. Combination Meter (cont’d)
1. TRIP mode select knob

2. Info display mode select knob
Setting mode Selectable modes
km
Distance unit
mile
km/liter
Fuel economy liter/100km
MPG
English
German
French
Language
Spanish
Italian
Russian
Refueling
Avg. fuel economy reset Manual reset
Trip meter A
o
C
Temperature unit o
F
Normal mode
Set sensors
Trailer mode
Time adjustment
Clock setting 12-hour indication
24-hour indication
1-action unlock
Door lock setting 2-action unlock
Outside buzzer ON/OFF
OFF
Footwell lamps Door-synchro
Door & Light synchro
+0
+1
Turn signal lamps
+2
+3
Comfort Mode
TPMS pressure setting Eco Mode
Load Mode
Warning and Master Warning and Master
Sound Description Sound Description
indicator warning indicator warning
"Ping" Any door (including trunk lid) "ACC" mode is selected as
(once is open with vehicle power supply mode.
Blinks
from stationary. Close all doors
(only
interior completely.
while OFF OFF
buzzer
vehicle is
while
in motion)
vehicle is
in motion)
Brake pedal is depressed Engine switch is pushed
(CVT) or clutch pedal is with shift lever in a position
depressed (M/T). Push the other than "P".
engine switch to start the
OFF OFF OFF OFF
engine.
CVT fluid temperature is too Engine switch is pushed

high. Park the vehicle in a with shift lever in a position
"Ping"
safe place and let the CVT other than "P" and "N",
(once
fuild cool down. and/or without depressing
Blinks from OFF OFF
the brake pedal.
interior
buzzer)
Remote controller battery is The engine switch is

almost flat. Replace the pushed without depressing
battery of remote controller. the clutch pedal.
OFF OFF OFF OFF
"ON" mode is selected as
power supply mode.
(Keyless push start model)
OFF OFF
Repeated Remote controller is outside
beeps (2 the vehicle or its battery is
sec. from flat. Locate the remote
Blinks
exterior/int controller or touch the Fuel level is low. Refill
erior engine switch with the immediately.
"Ping"
buzzers) remote controller.
(once
OFF from
interior
buzzer)
Steering lock is not

disengaged. While lightly
"Ping" "Ping"
There is a problem in turning the steering wheel in
(once (once
steering lock system. Have both directions, push the
Blinks from Blinks from
your vehicle inspected by an engine switch again.
interior interior
authorized SUZUKI dealer.
buzzer) buzzer)
Remote controller battery is

low. Replace the battery.
"Ping" There is a problem in
(once keyless push start system.
Blinks from Have your vehicle inspected OFF OFF
interior by an authorized SUZUKI
buzzer) dealer.
Headlamps and position Tires of different sizes may
lamps are left ON. Turn be fitted or tires may be
Continuou "Ping"
them OFF. insufficiently inflated.
s beep (once
Blinks (from Blinks from
interior interior
buzzer) buzzer)
Outside temperature is low. One of the tires is

Drive with care. insufficiently inflated.
"Ping"
(once
OFF OFF Blinks from
interior
buzzer)
There may be problem with There may be a problem in

the AWD system. the TPMS system.
"Ping" "Ping"
(one time (once
interior interior
buzzer) buzzer)
Driver train components Wheel ID codes are not

may be overheated. Stop in registered in the TPMS
"Ping" "Ping"
a safe place and allow the system.
(one time (once
engine to idle.
interior interior
buzzer) buzzer)
One of the parking sensors There may be a problem
does not work due to dirt. with the fuel filter. Have the
"Ping" "Ping"
vehicle inspected by an
(one time (one time
authorized SUZUKI dealer.
interior interior
buzzer) buzzer)
Parking sensor system is There may be a problem

faulty. with the fuel filter. Have the
"Ping" "Ping"
(one time vehicle inspected by an
(one time
Blinks from authorized SUZUKI dealer.
Blinks from
interior interior
buzzer) buzzer)
System related to BCM is

faulty.
"Ping"
(one time
Blinks from
interior
buzzer)
Change the engine oil and

oil filter immediately.
The oil life monitoring
system must be reset after
Off Off
changing the engine oil and
oil filter.
indicator warning 3-1. Combination Meter (cont’d) indicator warning
There may be a problem There may be a problem
with the diesel particulate with the 4WD system.
"Ping" "Ping"
filter. Have the vehicle inspected
(one time (one time
Have the vehicle inspected by an authorized SUZUKI
by an authorized SUZUKI dealer.
interior interior
dealer.
buzzer) buzzer)
Regenerate the DPF®. Tires of different sizes may

be fitted or tires may be
"Ping" "Ping"
insufficiently inflated.
(one time (one time
interior interior
buzzer) buzzer)
There may be a problem There may be a problem

with the ESP® system. with the ESP® system.
"Ping" "Ping"
Have the vehicle inspected Have the vehicle inspected
(one time (one time
by an authorized SUZUKI by an authorized SUZUKI
dealer. dealer.
interior interior
buzzer) buzzer)
There may be a problem The “LOCK” part of the

with the hill hold control driving mode switch is
"Ping" "Ping"
system. Have the vehicle pushed when the vehicle
(one time (one time
inspected by an authorized speed is more than 60 km/h
SUZUKI dealer. (37 mph).
interior interior
buzzer) buzzer)
Warning and Master
Sound Description
indicator warning
If this message is displayed,
have the vehicle inspected
"Ping"
by an authorized SUZUKI
(one time
dealer.
Blinks from
interior
buzzer)
The “LOCK” part of the

driving mode switch is
"Ping"
pushed without selecting the
(one time
SNOW mode.
Blinks from
interior
buzzer)
There may be a problem

with the driving
mode switch.
3-2. Parking Sensor System
: LIN
3-2. Parking Sensor System (cont’d)
[A]: 5 M/T model

[B]: 6 M/T model
[C]: Without ESP® OFF switch
[D]: With ESP® OFF switch
1. Parking sensor system control module
2. Parking sensor rear buzzer
3. Rear parking sensor
4. Front parking sensor
5. Back up light switch
6. Transmission range sensor
7. Parking sensor OFF switch
8. Parking sensor front buzzer
Parking sensor used D range R range

1. Front/right YES YES
2. Front/left YES YES
3. Front/center/right YES -
4. Front/center/left YES -
5. Rear/right - YES
6. Rear/left - YES
7. Rear/center/right - YES
8. Rear/center/left - YES
Sensor to Sensor to
Information Information
barrier Buzzer barrier Buzzer
display display
distance distance
600-1500mm 375-600mm
450-600mm 250-375mm
350-450mm
below 250mm
below 350mm
Information
Faulty condition Buzzer
display
Parking sensor temporal fault
Flash
Parking sensor continuous fault
Flash
CAN bus error between parking

sensor and combination meter
Flash
Parking sensor system control module Rear buzzer
Right rear pillar inner lower reinforcement

Right rear door striker reinforcement
Front buzzer
LED
Parking sensor system active:

- Engine switch ON
- Shift lever D/R
- VSS below 10km/h
 LED lit
Parking sensor
system
deactivated:
 LED OFF
4. Auto Windshield Wipers
AUTO mode not equipped AUTO mode equipped

4. Auto Windshield Wipers (cont’d)
1. Rain / light sensor

2. Windshield wiper motor
3. Windshield wiper HI/LO relay
4. Windshield wiper relay
5. BCM
6. Wiper and washer switch
1. LED
2. Light emission
3. Detecting surface
4. Photodiode
5. Light reception
6. Lens
7. Windshield glass
8. Rain drop
9. Permeating light
a : Rain drop on the windshield
[NOTE]
• Under the following conditions, the rain sensor may not be able to sense the rain
or snow correctly, and thus the auto windshield wiper function may not work or
may work incorrectly:
– Rain or snow does not hit the rain sensor area of the windshield, or the type of snow is
not suited for detection
by the sensor.
– The rain sensor area is covered with mud, ice or other similar substance.
– There were raindrops on the windshield already before starting the auto windshield
wiper operation.
Remove the raindrops by operating the wipers under manual control.
– The rain sensor is hotter than 80oC in the sun or lower than –10oC in freezing weather.
– The windshield is coated with a water repellent substance, which causes raindrops to
run down quickly; the system then assumes it is heavy rain and increases the wiping
rate.
– The sensor area is covered with a sticker.
– The wiper blades are damaged.
• The following conditions may indicate problems with the auto windshield wiper
system.
– Rainfall/snowfall rate varies but the wiping interval remains constant.
– Rain/snow is falling but the wipers do not operate.
[REFERENCE]
•If the wiper switch is turned from OFF to AUTO with engine switch in ON mode or
while engine cranking, wiper operates once regardless of weather condition.
[WARNING]
• Observe the following instructions when the ring control on the wiper lever is set
to the “AUTO” position with the engine switch in the “ON” mode. Otherwise, the
wipers could unexpectedly operate and cause an injury, and could also be
damaged.
– Do not touch or wipe the rain sensor area of the windshield with a cloth.
– Do not give impact to the windshield or rain sensor.
• Be sure to set the wiper control lever to the “OFF” position before washing the
vehicle in an automatic car wash or cleaning the windshield.
[Function Customization]
Semi-automatic wiping
- intermittent wiping
- low-speed wiping
- high-speed wiping. (The wipers do not stop automatically.)
Intermittent wiping
- Intermittent wiping mode only. The interval can be changed with the ring control.
Full-automatic wiping (factory setting)

- stopping
- intermittent wiping
- low speed wiping
- high-speed wiping.
[Service which requires Rain/Light sensor initial setting]
- Rain/Light sensor replacement
- Windshield replacement
[Initial setting procedure]

1) Meet the following conditions:
- There is no dirt on the rain/light sensor
mating surface with windshield
- Engine switch in OFF mode
- Wiper switch in OFF position
- Lighting switch in OFF position
- Wiper motor is in “auto stop” position
- Rain/Light sensor surrounding ambient temperature between 5 and 40oC (41 and 103 oF)
- Auto wiper volume (1) is in the position shown in the figure
[A] –
2) Turn engine switch in ON mode. [B] +
3) Within 4 seconds after position lamps start flashing,
turn the auto wiper volume as shown below:
a) Set the volume 1.
b) Set the volume 5 again.
4) Confirm if position lamps are flashing with an
interval of 0.5 second and that the flashing ends
within 10 seconds.
[Auto windshield wipers customization]
1) Meet the following conditions:
- There is no dirt on the rain/light sensor
mating surface with windshield
- Engine switch in OFF mode
- Wiper switch in OFF position
- Lighting switch in OFF position
- Wiper motor is in “auto stop” position
- Rain/Light sensor surrounding ambient temperature between 5 and 40oC (41 and 103 oF)
- Auto wiper volume (1) is in the position shown in the figure
[A] –
2) Perform the following steps within 10 seconds. [B] +
a) Set engine switch in ON mode and wait for 3 seconds.
b) Within 1 second from step a), turn volume: 545
c) Within 1 second from step b), turn volume: 515
d) Within 1 second from step c), turn volume: 545
3) Confirm if position lamps are flashing with an interval of
1.0 second.
If position lamps repeats flashing (3-second ON and 1-
second OFF), troubleshoot the rain/light sensor.
Continued to the next page :

Continued from the previous page :
4) Three kinds of settings are available after step 3) is

completed. Follow the steps a) and b) shown below.
Auto light ON timing setting Auto wiper setting Auto-lighting synchro-setting

a) Turn auto wiper volume to "4" a) Turn auto wiper volume to "2"
a) Turn lighting switch : AUTO-
position and turn wiper switch position and turn wiper switch
OFF-AUTO within 1 second
OFF-AUTO OFF-AUTO
b) Turn AUTO wiper volume to a corresponding position shown below to obtain the desired mode.
Auto wiper 5 Early ON mode Semi-auto mode Heavy rain synchronization mode
volume 4 or 3 Standard ON mode Full-auto mode Rain synchronization mode
position 2 or 1 Late ON mode Manual intermittent mode No rain-synchronization mode
Selected mode confirmation: Available since 5 seconds elapsed after mode setting
Headlamp/position lamp
Setting item Mode
flashing pattern
Early ON 0.5 sec flashing
Auto-lighting setting Standard ON 0.5 sec ON / 1.5 sec OFF
Late ON 0.5 sec ON / 3.5 sec OFF
Semi-auto 0.5 sec flashing
Auto wiper setting Full-auto 0.5 sec ON / 1.5 sec OFF
Manual intermittent 0.5 sec ON / 3.5 sec OFF
Heavy rain synchronization 0.5 sec flashing
Auto-lighting synchro setting Rain synchronization 0.5 sec ON / 1.5 sec OFF
No rain-synchronization 0.5 sec ON / 3.5 sec OFF
SECTION 10
CONTROL SYSTEM
Contents
• Rear seatbelt warning
• Keyless Start System – similar to
Kizashi and AZH Swift
• Imobilizer for ignition switch model
• Communication system
1. Warning Buzzer Control (cont’d)
[Driver seat belt reminder]

1) Reminder lamp ON
2) VSS>15km/h, then lamp blinks and buzzer
sounds for 95 sec.
3) Buzzer stops and lamp remains ON.
These steps are repeated until belt is buckled.
[Front passenger seat belt reminder]

1) Reminder lamp ON
2) VSS>15km/h, then lamp blinks and buzzer
sounds for 95 sec.
3) Buzzer stops and lamp remains ON.
These steps are repeated until belt is buckled.
1. Driver seat belt reminder lamp

2. Front passenger seat belt reminder lamp
3. Rear left passenger seat belt reminder lamp
4. Rear center passenger seat belt reminder lamp
5. Rear right passenger seat belt reminder lamp
2. Warning Buzzer Control (cont’d)
Rear passenger’s seat belt reminder
If a rear seat belt is not fastened when the engine is started, all the rear passenger’s
seat belt reminder lights will come on for about 35 seconds and then go out. Within this
35 seconds, the corresponding reminder is highlighted. The reminder fades when the
seat belt is fastened.
The rear passenger’s seat belt reminder lights will also come on for about 35 seconds in
the following conditions.
• If a seat belt is unfastened when the vehicle speed is less than 15 km/h, the
corresponding light will be highlighted.
• If a seat belt is unfastened when the vehicle speed is more than 15 km/h, the
corresponding light will be highlighted and a buzzer will sound one time.
The reminder will be automatically canceled when the rear seat belt is buckled or the
ignition mode is turned to “OFF”.
3. Immobilizer system (Keyless start) model
- Immobilizer control system is included in keyless push start control
: Unique to each hard ware

Remote controller Keyless start Impossible to clear
Immobilizer
Control module : Registered by SDT
Transponder Possible to clear
Code Immobilizer : Registered by SDT only once
Transponder Impossible to clear
Code : Verification at engine start
Keyless
Remote Keyless
Controller Remote
ID Code Controller ECM
ID Code
ECM ID
Keyless start
Control module ID
Keyless start
Control module ID
ECM ID
- Engine start operation is the same between immobilizer control system

and keyless start system.
4. Immobilizer system (Ignition switch model)
- Immobilizer control system is included in Keyless Entry Control Module

: Unique to each hard ware
Impossible to clear
: Registered by SDT
Remote controller Keyless entry Possible to clear
Immobilizer
control module : Registered by SDT only once
Transponder Possible to update only once
Code Immobilizer by a NEW control module ID.
Transponder Impossible to update by
Code a used control module ID.
: Verification at engine start
ECM
ECM ID
KECM ID
KECM ID
ECM ID
1. KECM
5. Operation 2. ECM
3. Ignition key
4. Immobilizer coil antenna
A. Transponder code 5. Fuel injector
B. TP code verification 6. Ignition coil with igniter
C. Engine start permission 7. Combination meter
D. Engine start prohibition 8. Immobilizer warning indicator
E. Immobilizer indicator request
9. CAN communication
10. Serial communnication
a. Turn ignition sw itch to ST position.

b. KECM reads TP code via coil antenna.
c. If TP code maches the registered one,
engine starting permission is sent to ECM.
d. If TP code verification fails, immobilizer
indicator flashes (or off depending on DTC)
ECM-Keyless matching
: Unique combination !
6. Key registration
Up to 4 transponders can be registered in Keyless Entry

Control Module.
When transponder registration is performed, the registered

transponder codes are once cleared.
--->Existing transponder has to be also registered again when

new transponder has to be registered.
6. Key registration (cont’d)
When ECM is replaced, “ECM registration” must be performed.
ECM – KECM matching is required to start engine.
Matching data is unique to each ECM – KECM.
This unique matching data can be written in KECM only ONCE with new
ECM.
ECM cannot be replaced with a used one from another vehicle.
Use a NEW ECM for replacement.

When KECM is replaced, use a NEW one.
ECM-KECM matching data can be written in ECM only ONCE with new
KECM.
Perform “ECM registration” and “Key registration” after replacement.

If all remote controllers were lost---:
Purchase new keys and register TP codes to KECM.
KECM replacement is not required.

7. Communication System
1. Serial Communication Network

2. LIN Communication
[A] 4WD model
[B] 2WD model
[C] M/T model without ENG A-STOP
9-1. Serial Communication Network
[D] ENG A-STOP model
[E] CVT model
[a] CAN bus
[b] LIN bus
[c] UART serial bus
Scan CAN- Bus
Module
tool DTC Check
1. Combination meter CAN OK OK
2. P/S control module CAN OK OK
3. DLC - - -
4. Keyless entry / start
CAN OK OK
control module
5. HVAC control module CAN - OK
6. Steering angle sensor
- - OK
module
7. Headlight auto leveling
CAN OK OK
/washer control module
8. Rain / light sensor - - OK
9. 4WD control module CAN OK OK
10. SDM CAN OK OK
11. TPMS control module CAN OK OK
12. BCM CAN OK OK
13. ENG A-STOP control
CAN OK OK
module
14. TCM CAN OK OK
15. ABS/ESP control
CAN OK OK
module
16. ECM CAN OK OK
17. Parking sensor control
LIN*1 - -
module
18. Auto A/C panel LIN*2 - -
UART
19. Auto steering lock unit - -
*3
9-1. Serial Communication Network (Cont’d)
CAN Junction Connector

9-2. LIN Communication
Application layer
Software Control
- Single wire
Presentation layer
- Low cost
Session layer - 9.6 kbps
Transport layer
Network layer
-Network configuration
-Time trigger scheduling
Data link layer
-Master/Slave communication method
Hardware Control
-Synchronization method
-Recovery administration LIN Protocol
-Message confirmation
-Error detection/report method
Physical layer
- Gateway between CAN and LIN
-Bit timing
-Bit synchronization
-Driver (ISO9141)
Diagnosis by SDT is available
9-2. LIN Communication

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New SX4 (AKK416)

New Car Features

Manual transmission oil:

Fuse location during shipment

For transportation the following fuses are

• Piston newly designed

- Bee hive type

Intake camshaft Exhaust camshaft

RS416 45,504 8,504 57K00

Steel strainer Plastic strainer

Double relief port

[A] Relief port 1 starts opening AKK416

[Revised liquid seal mounting]

[A]: Ignition switch model 12. Fuel pump

12. A/C refrigerant pressure sensor

1. Engine cover + air cleaner 5. IAT sensor

1. Fuel tank 6. Fuel feed line 11. Intake manifold

1. Generator 6. Charge warning light

Starting control Voltage generation is suspended during starting

RW420 – 1 Aux belt AZH416 & AKK416

Paint Coil spring Specification Destination

F : Forward [A]: Camber (Front view)

Diameter increased by 10%

Diameter increased by 10%

1. Match mark ( before removing)

1-3. System Components (cont’d)

- Mode switching OK/NG signal - Mode signal

Mode signal Mode signal

LOCK OK/NG signal Indicator blink request

- Mode switching request

1. Vehicle Take-Off Control

⊿ω:Front wheel slip speed

When TP is increasing at high VSS

Wheel speed i-AWD coupling Ignition coil

Vehicle Dynamics Electronic Stability

Grip zone Slip zone

Mild Severe Tire

- Feel back control available to all modes to avoid wheel spin.

- Feed-forward control : Torque is transmitted to rear wheels in

- Feed-forward control by steering angle: Applicable to SNOW

M16A : Throttle position

Pulley ratio shifted to lower gear side

S-mode switch ON:

Active brake is applied especially when the vehicle starts up to

ESP and ABS operations have priority.

In “mild” oversteering is detected by

In 4WD “LOCK” mode, this request is

• Coupling air temperature is too high

“4WD MODE UNSELECTABLE, AUTO MODE ON”

“LOCK MODE CANNOT BE SET”

- LOCK button is pressed over 60 km/h

“NOT LOCKABLE, SET TO SNOW MODE FIRST”

- LOCK button is pressed with traction mode at AUTO and SPORT.

[A] Standard value

Do not remove from the

Steel Aluminium alloy

Special Tool (A) : 09945-16060

[Brake pad installation : SWIFT AZG/AZH, SX4 AKK]