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

10

Section 00
Precautions
CONTENTS
Precautions ...............................................00-1
Precautions........................................................... 00-1
General Precautions ........................................... 00-1
Precautions for Electrical Circuit Service ............ 00-3
Fastener Caution ................................................ 00-5
Precautions for Catalytic Converter (Petrol
Engine Model) ................................................... 00-5
Precautions for Catalytic Converter (Diesel
Engine Model) ................................................... 00-5
Suspension Caution ............................................ 00-5
Warning for Wheel (with Tire) Removal .............. 00-5
Table of Contents 00- i
00
Wheel and Brake Caution ................................... 00-5
Air Bag Warning .................................................. 00-5
Precautions for Vehicles Equipped with
Supplemental Restraint (Air Bag) System......... 00-6
Precautions for CAN Communication System .... 00-8
Precautions for Installing Mobile
Communication Equipment ............................... 00-9
Repair Instructions .............................................. 00-9
Electrical Circuit Inspection Procedure ............... 00-9
Intermittent Connection and Poor Contact
Inspection........................................................ 00-11
00-1 Precautions:

Precautions
Precautions

Precautions
General Precautions – Whenever handling any of these service
AENBL80A0000001 materials, wear moisture-proof gloves to
The WARNING and CAUTION describe some general
protect your skin. If it adheres to your
precautions that you should observe when servicing a
skin, it may cause inflammation.
vehicle. These general precautions apply to many of the
service procedures, but they will not necessarily be – Do not swallow any of these service
repeated for every procedure to which they apply. materials. It would cause diarrhea or
nausea.
! WARNING – Keep all these materials out of reach of
children.
• Whenever raising a vehicle for service, be
• Make sure the hood is fully closed and
sure to follow the instructions under
latched before driving. Unlatched hood
“Vehicle Lifting Points” in Section 0A
can fly up unexpectedly during driving,
(Page 0A-7).
obstructing your view and resulting in an
• When it is necessary to do service work accident.
with the engine running, make sure that
the parking brake is set fully and the • Before starting any service work, cover fenders, seats
transaxle is in Neutral. Keep hands, hair, and any other parts that are likely to get scratched or
clothing, tools, etc. away from the fan and stained during servicing. Also, be aware that what you
belts when the engine is running. wear (e.g., buttons) may cause damage to the
• When it is necessary to run the engine vehicle’s finish.
indoors, make sure that the exhaust gas is
forced outdoors.
• Do not perform service work in areas
where combustible materials can come in
contact with a hot exhaust system
component. When working with toxic or
flammable materials (such as gasoline and
refrigerant), make sure that the area you
work in is well-ventilated.
• To avoid getting burned, keep away from
hot metal parts such as the radiator,
exhaust manifold, tail pipe, muffler, etc. I2RH01010025-01

• New and used engine oil can be
hazardous. Children and pets may be
harmed by swallowing new or used oil.
Keep new and used oil and used engine oil
filters away from children and pets.
Continuous contact with used engine oil
has been found to cause skin cancer in
laboratory animals. Brief contact with used
oil may irritate skin. To minimize your
exposure to used engine oil, wear a long-
sleeve shirt and moisture-proof gloves
(such as dish washing gloves) when
changing engine oil. If engine oil contacts
your skin, wash thoroughly with soap and
water. Launder any clothing or rags if wet
with oil. Recycle or properly dispose of
used oil and filters.
– Whenever handling any of these service
materials, wear safety glasses to protect
your eyes. If such a material gets into
your eye, it may cause inflammation.
• When performing service to electrical parts that does
not require use of battery power, disconnect negative
(–) cable at battery.
• Before disconnecting the negative (–) cable at the
battery or after connecting the cable to the battery,
perform the following.
– Check and record DTCs in all control modules if
necessary before disconnecting the cable.
– Record displayed contents of the clock, audio
system, etc. before disconnecting to be able to
restore the original settings after connecting the
cable.
– For petrol engine model, perform electric throttle
body system calibration referring to “Electric
Throttle Control System Calibration”: K14B in
Section 1C (Page 1C-4) after reconnecting the
negative (–) cable at the battery.
 Precautions: 00-2

• When removing the battery, be sure to disconnect the

negative (–) cable first and then the positive (+) cable.
When reconnecting the battery, connect the positive
(+) cable first and then the negative (–) cable.
Reinstall the terminal cover.

I2RH01010030-01

• Be sure to use special tools when instructed.

Special tool
(A): 09917M98221
I2RH01010027-01 (B): 09916M58210
• When removing parts that are to be reused, be sure to
keep them arranged in an orderly manner so that they
can be reinstalled in the proper order and into the
correct positions.

I2RH01010031-01

• After servicing any system that is concerned with fuel,

oil, coolant, vacuum, exhaust gases or brakes, check
I5RW0A000002-01
all related lines for leaks.
• Do not reuse oil seals, gaskets, packing, O-rings, lock
washers, split pins, self-locking nuts, and other
specified parts, but use new ones. Also, before
installing new gaskets, packing, etc., be sure to
remove any residual material from the mating
surfaces.

I2RH01010033-01

• Never disconnect any of the fuel lines between fuel

pump and injectors without first releasing the fuel
pressure, or fuel can be sprayed out under pressure.
• When performing any work that produces a heat
I2RH01010029-01 exceeding 80 °C (176 °F) in the vicinity of the
• Make sure that all parts used for reassembly are electrical parts, remove the heat sensitive electrical
thoroughly clean. part(s) beforehand.
When the use of a certain type of lubricant, adhesive
or sealant is specified, be sure to use only the
specified material.
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No. 1207F)
00-3 Precautions:

• Before disconnecting or connecting connectors, be

• When disconnecting connectors, never pull on the
I2RH01010034-01
• Do not expose connectors and electrical parts to
water, which will cause trouble to electrical systems.
sure to do either of the following depending on the
type of power supply. Otherwise, the electrical parts to
which the power is supplied may be damaged.
– Continuous power supply: Disconnect the negative
(–) cable at the battery.
– Ignition power supply: Set ignition “OFF”.
wiring harness. Unlock the connector lock first and
then pull the male and female connectors apart by
holding them.

I2RH01010040-01

• When connecting male and female connectors, also

I2RH01010035-01 hold connectors and put them together until they lock
• Always be careful not to handle electrical components securely (a click is heard).
(computers, relays, etc.) in a rough manner or drop
them.

I2RH01010041-01

• When installing a wiring harness, secure it with

clamps so that no slack is left.
I2RH01010036-01

Precautions for Electrical Circuit Service

AENBL80A0000002
• When replacing a fuse, make sure to use a fuse of the
specified capacity. Use of a fuse with a larger capacity
will cause a damage to electrical parts and a fire.

I2RH01010042-01

• When installing vehicle parts, make sure so that they

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

I2RH01010038-01
 Precautions: 00-4

I2RH01010046-01
I2RH01010043-01

• Protect the part of harness which may touch any edge
by wrapping it with tape or the like.
• When it is impossible to insert a tester probe from the
harness side of connector, insert a properly sized
male terminal with a lead into the connector and
connect the tester probe to the lead as shown. Do not
insert the probe directly into the connector, or the
female terminal may be deformed.

I2RH01010044-01

• Be careful not to touch the electrical terminals of parts

IAW101000003-01
which use microcomputers (e.g. electronic control unit
• When checking connection of terminals, check male
like as ECM, PCM, P/S control module, etc.). The
terminals for bend, female terminals for excessive
static electricity from your body can damage these
opening, and both for locking (looseness), corrosion,
parts.
dust, etc.
• Before measuring voltage at each terminal, confirm
that battery voltage is 11 V or more. Terminal voltage
check at low battery voltage will lead to erroneous
results.

I3RM0A000004-01

• Never connect any tester (voltmeter, ohmmeter or

whatever) to terminals of an electronic control unit
when its connector is disconnected. Doing so may
cause damage to the electronic control unit.
• Never connect an ohmmeter to an electronic control I2RH01010048-01
unit with its connector connected to it. Doing so may
cause damage to electronic control unit and sensors.
• Be sure to use only the specified voltmeter /
ohmmeter. Otherwise, accurate measurements may
not be obtained or personal injury may result. Where
no voltmeter type is specified, use a voltmeter with
high impedance (M Ω/V minimum) or a digital type
voltmeter.
• When taking measurements at electrical connectors
using a tester probe, be sure to insert the probe (2)
from the wire harness side (backside) of the
connector (1).
00-5 Precautions:
Fastener Caution
AENBL80A0000003
! CAUTION
When fasteners are removed, always reinstall
them at the same location from which they
were removed. All fasteners for suspensions,
wheels and brakes are important attaching
parts in that they could affect the
performance of vital parts and systems, and/
or could result in major repair expanse. If a
fastener needs to be replaced, use the
correct part number fastener for that
application. If the correct part number
fastener is not available, a fastener of equal
size and strength (or stronger) may be used.
Do not use a replacement part of lesser
quality or substitute design. Fasteners that
are not reused, and those requiring thread-
locking compound, will be called out. The
correct torque value must be used when
installing fasteners that require it. If the
conditions are not followed, parts or system
damage could result.
Precautions for Catalytic Converter (Petrol
Engine Model)
AENBL80A0000004
As this vehicle equipped with a catalytic converter, use
only unleaded gasoline and be careful not to let a large
amount of unburned gasoline enter the converter or it
can be damaged.
• Conduct a spark jump test only when necessary to the
shortest possible time without opening the throttle.
• Conduct engine compression checks within the
shortest possible time.
• Avoid any situations which can result in engine misfire
(e.g. starting the engine when the fuel tank is nearly
empty.)
Precautions for Catalytic Converter (Diesel
Engine Model)
AENBL80A0000005
Use only specified fuel and be careful not to let a large
amount of unburned fuel enter the converter and filter or
they can be damaged.
Suspension Caution
AENBL80A0000006
! CAUTION
Never attempt to heat, quench or straighten
any suspension part. Replace it with a new
part or damage to the part may result.
Warning for Wheel (with Tire) Removal
AENBL80A0000007
! WARNING
Do not remove all wheel bolts or nuts, but
leave at least one bolt or nut for each wheel
to prevent the wheel from dropping. When
removing the remaining bolt(s) or nut(s), hold
the wheel so as not to let it fall down.
Wheel and Brake Caution
AENBL80A0000008
! CAUTION
There is to be no welding as it may result in
extensive damage and weakening of the
metal.
Air Bag Warning
AENBL80A0000009
! WARNING
• Service on and around the air bag system
components or wiring must be performed
only by an authorized SUZUKI dealer. Refer
to “Air Bag System Component, Wiring
and Connector Location” in Section 8B
(Page 8B-5) in order to confirm whether
you are performing service on or near the
air bag system components or wiring.
Please observe all information of
“WARNING” and “Precautions for Air Bag
System Service” in Section 8B (Page 8B-1)
before performing service on or around the
air bag system components or wiring.
Failure to follow “WARNING” information
could result in unintentional activation of
the system or could render the system
inoperative. Either of these two conditions
may result in severe injury.
• Technical service operation must be
started at least 90 seconds after set
ignition “OFF” and disconnecting negative
(–) cable at the battery. Otherwise, the
system may be activated by reserve
energy in the Sensing and Diagnostic
Module (SDM).
 Precautions: 00-6

Precautions for Vehicles Equipped with Diagnosis

Supplemental Restraint (Air Bag) System • When troubleshooting the air bag system, be sure to
AENBL80A0000010
follow “Air Bag Diagnostic System Check” in Section
! WARNING 8B (Page 8B-6). Bypassing these procedures may
result in extended diagnostic time, incorrect
• The configuration of air bag system parts diagnosis, and incorrect replacement of parts.
are as shown in figure. When it is
necessary to service (remove, reinstall and • Never use electrical test equipment other than that
inspect) these parts, be sure to follow specified.
procedures described in “Precautions for
! WARNING
Air Bag System Service” in Section 8B
(Page 8B-1). Failure to follow proper Never attempt to measure the resistance of
procedures could result in possible air bag the air bag (inflator) modules (driver and
system activation, personal injury, damage passenger) and seat belt pretensioners
to parts or air bag system being unable to (driver and passenger). Resistance
activate when necessary. measurement of these components is very
• If the air bag system and another vehicle dangerous as the electric current from the
system both need repair, SUZUKI tester may deploy the air bag or activate the
recommends that the air bag system be pretensioner.
repaired first, to help avoid unintended air
bag system activation.
• Do not modify the steering wheel,
instrument panel, or any other air bag
system components.
Any modifications can adversely affect air
bag system performance and lead to
injury.
• If the vehicle is exposed to temperatures
over 93 °C (199.4 °F) (for example, during a
paint baking process), remove the air bag
system components beforehand to avoid
component damage or unintended air bag
system activation. IAP70P821001-01

3
5

7
2
4

IBL80A000002-01

1. SDM 5. Contact coil

2. Driver air bag (inflator) module 6. Forward impact sensor
3. Passenger air bag (inflator) module 7. “A/B” fuse
4. Retractor pretensioner
00-7 Precautions:
Servicing and Handling
! WARNING
Many of service procedures require
disconnection of negative battery cable or
“A/B” fuse to avoid an accidental
deployment.
Driver and Passenger Air Bag (Inflator)
Modules
• For handling and storage of a live air bag
(inflator) modules and seat belt
pretensioners, select a place where the
ambient temperature is below 65 °C (149
°F) and these is no high humidity and
electric noise.
• When carrying a live air bag (inflator)
module, make sure the bag opening is
pointed away from you. In case of an
accidental deployment, doing so will help
minimize the chance of injury in case of an
accidental deployment. Never carry the air
bag (inflator) module by the wires or
connector on the underside of the module.
When leaving or storing live air bag
(inflator) module unattended on
workbench or other surface, always place
it with the bag (trim cover) facing up but
not against the surface. It is also
prohibited to place anything on top of the
trim cover and stack air bag (inflator)
modules. This is necessary to provide air
bag with a free space to expand in the
event of its accidental deployment.
Otherwise, personal injury may result.
• Never dispose of live (undeployed) air bag
(inflator) modules (driver and passenger).
If disposal is necessary, be sure to deploy
them according to deployment procedures
described in “Air Bag (Inflator) Module and
Seat Belt Pretensioner Disposal” in
Section 8B (Page 8B-68) before disposal.
• The air bag (inflator) module immediately
after deployment is very hot. Wait for at
least half an hour to cool it down before
proceeding to the next work.
• After an air bag (inflator) module has been
deployed, the surface of the air bag may
contain a powdery residue. This powder
consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by-
products of the chemical reaction. As with
many service procedures, gloves and
safety glasses should be worn.
[A]
[B]
:[C]
IBP80A000002-01
[A]: Always carry air bag (inflator) module with trim cover (air bag opening)
away from body.
[B]: Always place air bag (inflator) module on workbench with trim cover (air
bag opening) up, away from loose objects.
[C]: Air bag deployment direction
! WARNING
SDM
• For handling and storage of an SDM, select
a place where the ambient temperature is
below 65 °C (149 °F), and there is no high
humidity and electric noise.
• Handle the SDM very carefully during
service procedures. Never strike or jar
SDM.
• Never power up the air bag system when
SDM is not rigidly attached to the vehicle.
All SDM and mounting bracket fasteners
must be carefully torqued and the arrow
must point toward the front of the vehicle
to ensure proper operation of the air bag
system.
When the SDM is powered while not rigidly
attached to the vehicle, the SDM could
activate air bag (inflator) deployment and
result in personal injury.
! WARNING
Driver and Passenger Seat Belt
Pretensioners
• For handling and storage of a live seat belt
pretensioner, select a place where the
ambient temperature is below 65 °C (149
°F) and there is no high humidity and
electric noise.
 Precautions: 00-8

• Never carry seat belt pretensioner by its
wire or connector of pretensioner. When
placing a live seat belt pretensioner on the
workbench or some place like that, never
put something on seat belt pretensioner.
Otherwise, personal injury may result.
• Never dispose of live (inactivated) seat belt
pretensioners (driver and passenger). If
disposal is necessary, be sure to activate
them according to activation procedures
described in “Air Bag (Inflator) Module and
Seat Belt Pretensioner Disposal” in
Section 8B (Page 8B-68) before disposal.
• The seat belt pretensioner immediately
after activation is very hot. Wait for at least
half an hour to cool it down before
proceeding to the next work.
• As with many service procedures, gloves
and safety glasses should be worn to
prevent possible irritation of skin or eyes.
! CAUTION
• When air bag wire harness broken or
damaged wires, connectors or terminals,
replace the whole wire harness assembly.
• Do not apply power to the air bag system
unless all components are connected or
diagnostic flow requires to do so, or DTC
will be set.
• Never use air bag system components
from another vehicle.
• When performing electric welding, be sure
to disconnect all air bag (inflator) module
connectors and pretensioner harness.
• Never expose air bag system components
directly to hot air (for drying or baking the
vehicle after painting) or flames.
• WARNING / CAUTION labels are attached
on every of air bag system component. Be
sure to follow the instructions.
• After vehicle is completely repaired,
perform “Air Bag Diagnostic System
Check” in Section 8B (Page 8B-6).

• Even when the accident was not severe
enough to cause air bags to activate, be
sure to inspect system parts and other
related parts according to the instructions
under “Repair and Inspection Required
after Accident” in Section 8B (Page 8B-59).
• When servicing parts other than air bag
system, if shocks may be applied to air bag
system component parts, remove those
parts beforehand.
Precautions for CAN Communication System
AENBL80A0000011
• The length of a loose twist (1) in a twist pair wire
harnesses of the CAN lines except around the
connector (3) should be within 100 mm (3.9 in.). Refer
to the circuit diagram to identify the CAN lines.
Excessively loosed lines are more susceptible to
interference by electric noise.
3 3

• Carefully handle the following components

not to drop or otherwise give impact to
them: the driver and passenger air bag
(inflator) modules; the driver and
passenger seat belt pretensioners; the
forward and side sensors; and the SDM. If
1
any of these components receives impact,
2 2
never try to disassemble and repair it but I4JA01000002-01
replace it with a new one.
2. Control module
• Grease, cleaning agent, oil, water, etc. on
air bag (inflator) modules (driver and • Do not connect CAN line terminals using a bypass
passenger) or seat belt pretensioners wire (1). Doing so makes, the CAN line receive
(driver and passenger) should be wiped off electric noise interference.
immediately with a dry cloth.
• Air bag wire harness is included in the
1
main, instrument panel and floor harness.
Air bag wire harness can be identified
easily by a yellow protection tube or tape
covering the connector end of the harness.
Handle it very carefully when handling it.

I4JA01000003-01
00-9 Precautions:

Precautions for Installing Mobile
Communication Equipment
AENBL80A0000012
When installing mobile communication equipment such
as CB (Citizens-Band)-radio or cellular-telephone, be
sure to observe the following precautions.
Failure to follow these cautions may adversely affect
electronic control system.
• Keep the antenna as far away as possible from the
vehicle’s electronic control unit.
• Keep the antenna feeder more than 20 cm (7.9 in.)
away from any electronic control unit and its wire
harnesses.
• Do not run the antenna feeder parallel with other wire
harnesses.
• Confirm that the antenna and feeder are correctly
adjusted.

Repair Instructions
Electrical Circuit Inspection Procedure
AENBL80A0006001
While there are various electrical circuit inspection
methods, the following describes the general methods
using an ohmmeter and a voltmeter to check open and
short circuits.

Open Circuit Check

Possible causes for the open circuit are as listed below. I2RH01010050-01
As defects in connectors or terminals are most often the
1. Check contact tension by inserting and removing just for once.
causes, they need to be checked particularly carefully.
• Loose connection of connector 4) Perform continuity test or voltage check using the
• Poor contact of terminal (due to dirt, corrosion or rust following procedures, to check the wire harness for
on it, poor contact tension, entry of foreign object, open circuit and poor connection at its terminals.
etc.)
• Open wire harness
When checking circuits including an electronic control
unit such as ECM, ABS control module, etc., it is
important to carefully perform check, starting with items
which are easiest to check.
1) Disconnect negative (–) cable at battery I2RH01010051-01

2) Check connectors at both ends of the circuit being
checked for loose connection. Also check lock
condition of connectors if equipped with connector
locks.
1. Looseness of crimping 3. Thin wire (single strand of wire)
2. Open
Continuity Test
1) Measure resistance between connector terminals at
both ends of the circuit under test (between “A-1”
and “C-1” in the figure). If no continuity is indicated
(infinity or over limit), that means that the circuit is
open between terminals “A-1” and “C-1”.

I2RH01010049-01

3) Using a male terminal for test use, check terminals

on both ends of the circuit being checked for contact
tension of female terminals. Check each terminal
visually for cause of poor contact (dirt, corrosion,
rust, entry of foreign object, etc.). At the same time,
check that each terminal is held and locked in
connector fully. I2RH01010052-01

2) Disconnect the connector included in the circuit

(connector-B in the figure) and measure resistance
between terminals “A-1” and “B-1”.
 Precautions: 00-10

If no continuity is indicated, that means that the

circuit is open between terminals “A-1” and “B-1”. If
continuity is indicated, there is an open circuit
between terminals “B-1” and “C-1” or connector-B is
defective.

I2RH01010053-01

Voltage Check
If the circuit being checked is under voltage, voltage
check can be used to check the circuit.
1) With all connectors connected and voltage applied to
the circuit being checked, measure voltage between
each terminal and ground.
a) If measurements are taken as shown in the I5RH01000005-01

figure and results are as listed below, it means

that the circuit is open between terminals “B-1”
and “A-1”.
Voltage between
“C-1” and ground: Approx. 5 V
“B-1” and ground: Approx. 5 V
“A-1” and ground: 0 V
b) If measurements are as listed below, it means
that there is an abnormally high resistance
causing the indicated voltage drop in the circuit
between terminals “A-1” and “B-1”.
Voltage between
“C-1” and ground: Approx. 5 V
“B-1” and ground: Approx. 5 V
“A-1” and ground: Approx. 3 V
Short Circuit Check (Wire Harness to Ground)
1) Disconnect negative (–) cable at battery.
2) Disconnect connectors at both ends of the circuit to
be checked.
NOTE
If the circuit to be checked is connected to
other parts (1), disconnect all connections to
these parts.
This is essential to having correct check
results.
3) Measure resistance between the terminal at one end
of the circuit (“A-1” terminal in the figure) and
ground. If continuity is indicated, it means that the
circuit is shorted to ground between terminals “A-1”
and “C-1”.
00-11 Precautions:

• Damaged connector body, terminals exposed to

moisture and dirt, misalignment of terminals on
component or connector and mating connector.

I2RH01010057-01

• Improperly formed or damaged terminals.

Check each connector terminal in circuit with problem
for good contact tension using a corresponding test
terminal.
If contact tension is not enough, correct terminal
shape to increase contact tension or replace harness.

I5RH01000006-01

4) Disconnect the connector included in circuit

(connector-B) and measure resistance between “A-
1” and ground. If continuity is indicated, the circuit is
shorted to ground between terminals “A-1” and “B-
1”.

I2RH01010056-01 I5RH01000007-01

1. To other parts 1. Check contact tension by inserting and removing just once.
2. Check each terminal for bend and proper alignment.

Intermittent Connection and Poor Contact

• Poor connection of terminal and wire.
Inspection
AENBL80A0006002 Check each wire harness in circuit with problem for
Most intermittent connections are caused by faulty poor connection by shaking it by hand lightly. If any
electrical connections or wiring, although a sticking relay abnormal condition is found, repair or replace
or solenoid can occasionally be a cause. When checking harness.
connections, perform check of suspect circuit for:
• Poor mating of connector halves, or terminals not fully
seated in the connector body (backed out).
• Dirt or corrosion on the terminals. The terminals must
be clean and free of any foreign material which could
impede proper terminal contact. However, cleaning
the terminal with a sand paper or the like is prohibited.
 Precautions: 00-12

I2RH01010059-01

• Damaged wire insulation, causing intermittent short

circuit to other wiring or parts.
• Broken wire inside the insulation. If one or two strands
of a multi stranded wire are intact, continuity check will
show good circuit, but resistance could be too high. If
the resistance is too high, repair or replace the
harness.

I2RH01010060-01
00-13 Precautions:

Section 0
General Information
CONTENTS
General Information ................................ 0A-1
General Description .............................................0A-1
Abbreviations ...................................................... 0A-1
ISO-to-SUZUKI Term .......................................... 0A-2
Symbols .............................................................. 0A-4
Wire Color Symbols ............................................ 0A-5
Ignition Modes and Ignition Switch Positions ...... 0A-5
Fasteners Information ......................................... 0A-5
Vehicle Lifting Points........................................... 0A-7
Vehicle Identification Number ............................. 0A-9
Engine Identification Number .............................. 0A-9
Component Location .........................................0A-10
Warning, Caution and Information Labels
Location .......................................................... 0A-10
Maintenance and Lubrication................. 0B-1
Scheduled Maintenance ......................................0B-1
Maintenance Schedule under Normal Driving
Conditions ......................................................... 0B-1
Repair Instructions ..............................................0B-3
Accessory Drive Belt Inspection.......................... 0B-3
Accessory Drive Belt Replacement..................... 0B-3
Valve Lash (Clearance) Inspection (Petrol
Engine Model) ................................................... 0B-3
Engine Oil and Filter Change .............................. 0B-3
Engine Coolant Change ...................................... 0B-3
Exhaust System Inspection................................. 0B-3
PCV Valve Inspection (Petrol Engine Model)...... 0B-4
Special Tools and Equipment ...........................0B-10
Table of Contents 0- i
0
Fuel Evaporative Emission Control System
Inspection (Petrol Engine Model) ......................0B-4
Spark Plug Replacement (Petrol Engine
Model) ...............................................................0B-4
Air Cleaner Filter Inspection................................0B-4
Air Cleaner Filter Replacement ...........................0B-4
Fuel Tank, Cap Gasket and Fuel Lines
Inspection..........................................................0B-4
Fuel Filter Replacement ......................................0B-5
Water Draining of Fuel Filter (Diesel Engine
Model) ...............................................................0B-5
Clutch Pedal Inspection ......................................0B-5
Clutch Fluid Inspection........................................0B-5
Manual Transaxle Oil Inspection.........................0B-5
Manual Transaxle Oil Replacement ....................0B-5
Drive Shaft (Axle) Boots Inspection ....................0B-5
Brake Discs and Pads Inspection .......................0B-5
Brake Drums and Shoes Inspection....................0B-5
Brake Hoses and Pipes Inspection .....................0B-6
Brake Fluid Replacement....................................0B-6
Brake Lever and Cable Inspection ......................0B-6
Tires Inspection...................................................0B-6
Wheel Discs Inspection.......................................0B-7
Wheel Bearing Inspection ...................................0B-7
Suspension System Inspection ...........................0B-7
Steering System Inspection ................................0B-8
All Latches, Hinges and Locks Inspection...........0B-8
Final Inspection for Maintenance Service ...........0B-8
Recommended Fluids and Lubricants...............0B-10
0A-1 General Information:

General Information
General Information

General Description
Abbreviations ELR: Emergency Locking Retractor
AENBL80A0101001 ENG A-Stop: Engine Auto Stop Start
A:
EPS: Electronic Power Steering
A/B: Air Bag
ESP®: Electronic Stability Program
ABDC: After Bottom Dead Center EVAP: Evaporative Emission
ABS: Anti-lock Brake System F:
AC: Alternating Current FET: Field-Effect Transistor
A/C: Air Conditioning G:
A-ELR: Automatic-Emergency Locking Retractor GND: Ground
A/F: Air Fuel Ratio GPS: Global Positioning System
ALR: Automatic Locking Retractor H:
API: American Petroleum Institute HVAC: Heating, Ventilating and Air Conditioning
APP: Accelerator Pedal Position HC: Hydrocarbons
A/T: Automatic Transmission, Automatic Transaxle HFC: Hydro Fluorocarbon
ATDC: After Top Dead Center HI: High
ATF: Automatic Transmission Fluid, Automatic HO2S: Heated Oxygen Sensor
Transaxle Fluid I:
AWD: All Wheel Drive IAC: Idle Air Control
B: IAT: Intake Air Temperature
BARO: Barometric Pressure IMT: Intake Manifold Tuning
BBDC: Before Bottom Dead Center ISC: Idle Speed Control
BCM: Body electrical Control Module ISO: International Organization for Standardization
BTDC: Before Top Dead Center J:
B+: Battery Positive Voltage JIS: Japanese Industrial Standards
BB+: Battery Positive Voltage for Backup J/B: Junction Block
C: J/C: Junction Connector
CAN: Controller Area Network L:
CKP: Crankshaft Position L: Left
CMP: Camshaft Position LCD: Liquid Crystal Display
CO: Carbon Monoxide LED: Light Emitting Diode
CO2: Carbon Dioxide LHD: Left Hand Drive vehicle
CPP: Clutch Pedal Position LIN: Local Interconnect Network
CPU: Central Processing Unit LO: Low
CVT: Continuously Variable Transmission, LSPV: Load Sensing Proportioning Valve
Continuously Variable Transaxle M:
D: MAF: Mass Air Flow
DC: Direct Current MAP: Manifold Absolute Pressure
D/C: Driving Cycle Max: Maximum
DLC: Data Link Connector MFI: Multiport Fuel Injection
DOHC: Double Over Head Camshaft Min: Minimum
DOJ: Double Offset Joint MIL: Malfunction Indicator Lamp (“CHECK ENGINE”
DOT: Department of Transportation Light or “SERVICE ENGINE SOON” Light)
DPF®: Diesel Particulate Filter M/T: Manual Transmission, Manual Transaxle
DRL: Daytime Running Light
N:
DTC: Diagnostic Trouble Code (Diagnostic Code)
NOx: Nitrogen Oxides
D/C: Driving Cycle
O:
E:
OBD: On-Board Diagnostic system
EBD: Electronic Brake Force Distribution
OCM: Occupant Classification Module
ECM: Engine Control Module
OCV: Oil Control Valve
ECT: Engine Coolant Temperature
O/D: Overdrive
ECU: Electronic Control Unit
OHC: Over Head Camshaft
EEPROM: Electrically Erasable Programmable Read
O2S: Oxygen Sensor
Only Memory
P:
EFE Heater: Early Fuel Evaporation Heater
PCM: Powertrain Control Module
EGR: Exhaust Gas Recirculation
PCV: Positive Crankcase Ventilation
EGT: Exhaust Gas Temperature
 General Information: 0A-2

PM: Particulate Mater TPMS: Tire Pressure Monitoring System

PNP: Park / Neutral Position TWC: Three-Way Catalytic converter
P/S: Power Steering U:
PSP: Power Steering Pressure UART: Universal Asynchronous Receiver / Transmitter
R: USB: Universal Serial Bus
R: Right V:
RAM: Random Access Memory VFD: Vacuum Fluorescent Display
RHD: Right Hand Drive Vehicle VIN: Vehicle Identification Number
ROM: Read Only Memory VSS: Vehicle Speed Sensor
RPM: Engine Speed (Revolutions per Minute) VVT: Variable Valve Timing
S: W:
SAE: Society of Automotive Engineers WU-OC: Warm Up Oxidation Catalytic converter
SDM: Sensing and Diagnostic Module (Air Bag WU-TWC: Warm Up Three-Way Catalytic converter
Controller, Air bag Control Module) Other:
SDT: Smart Diagnostic Tester 2WD: 2-Wheel Drive
SFI: Sequential Multiport Fuel Injection 4WD: 4-Wheel Drive
SI: System International
SOHC: Single Over Head Camshaft NOTE
SRS: Supplemental Restraint System • DPF® is a trademark of HJS
T: Fahrzeugtechnik GmbH & Co KG and
TCC: Torque Converter Clutch Suzuki is the trade mark licensee.
TCM: Transmission Control Module
• ESP® is a registered trademark of Daimler
TCSS: Traction Control Support System
AG.
TDC: Top Dead Center
TP: Throttle Position

ISO-to-SUZUKI Term
AENBL80A0101002
This table lists ISO (International Organization for Standardization) TR15031 terms and abbreviations which may be
used in this manual in compliance with ISO recommendations, as well as their SUZUKI terms.
ISO Term
SUZUKI Term
Full Term Abbreviation
A
Accelerator Pedal Position APP Accelerator Pedal Position (APP)
Air Cleaner ACL Air Cleaner
Air Cleaner Element ACL Element Air Cleaner Element
Air Cleaner Housing ACL Housing Air Cleaner Housing
Air Conditioning A/C Air Conditioner (A/C)
Air Conditioning System A/C System Air Conditioning System (A/C system)
Air Fuel Ratio Sensor A/F Sensor Air Fuel Ratio Sensor (A/F sensor)
Automatic Transaxle, Automatic A/T Automatic Transaxle, Automatic Transmission (A/T)
Transmission
B
Barometric Pressure BARO Barometric Pressure (BARO)
Barometric Pressure Sensor BARO Sensor Barometric Pressure Sensor (BARO sensor)
Battery Positive Voltage B+ Battery Positive Voltage (B+)
C
Camshaft Position CMP Camshaft Position
Camshaft Position Sensor CMP Sensor Camshaft Position Sensor (CMP sensor)
Carbon Monoxide CO Carbon Monoxide (CO)
Carbon Dioxide CO2 Carbon Dioxide (CO2)
Clutch Pedal Position Switch CPP Switch Clutch Pedal Position Switch (CPP switch)
Closed Loop CL Closed Loop
Closed Throttle Position CTP Closed Throttle Position
Continuously variable transaxle, CVT Continuously variable transaxle, Continuously
Continuously variable transmission variable transmission (CVT)
Crankshaft Position CKP Crankshaft Position (CKP)
Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKP sensor)
D
Data Link Connector DLC Data Link Connector (DLC)
0A-3 General Information:

ISO Term
SUZUKI Term
Full Term Abbreviation
Diagnostic Trouble Code DTC Diagnostic Trouble Code (DTC)
E
Electrically Erasable Programmable Read EEPROM Electrically Erasable Programmable Read Only
Only Memory Memory (EEPROM)
Engine Control Module ECM Engine Control Module (ECM)
Engine Coolant Temperature Sensor ECT Sensor Engine Coolant Temperature Sensor (ECT sensor)
Engine Speed RPM Engine Speed, RPM, rpm
Evaporative Emission Canister EVAP Canister Evaporative Emission Canister (EVAP canister)
Evaporative Emission Canister Purge EVAP Canister EVAP canister purge valve
Valve Purge Valve
Evaporative Emission System EVAP System Evaporative Emission System
Exhaust Gas Re-circulation EGR Exhaust Gas Recirculation (EGR)
Exhaust Gas Re-circulation Valve EGR Valve Exhaust Gas Recirculation Valve (EGR valve)
F
Fan Control FC Radiator Fan Control
Fan Control Relay FC Relay: Radiator cooling fan relay
Four Wheel Drive 4WD 4WD
Fourth Gear 4GR 4th Gear
Front Wheel Drive FWD Front Wheel Drive
Fuel Pump FP Fuel Pump
Fuel Pump Relay FP Relay Fuel Pump Relay
Full Time Four Wheel Drive F4WD Full-Time 4WD
G
Generator GEN Generator
Ground GND Ground
H
Heated Oxygen Sensor HO2S Heated Oxygen Sensor (HO2S)
Hydrocarbon HC Hydrocarbon (HC)
I
Idle Air Control IAC Idle Air Control (IAC)
Idle Speed Control ISC Idle Speed Control (ISC)
Intake Air IA Intake Air
Intake Air temperature IAT Intake Air temperature (IAT)
Intake Air temperature Sensor IAT Sensor Intake Air temperature Sensor, IAT Sensor
Input Shaft Speed ISS Input Shaft Speed
Inspection and Maintenance I/M Inspection and Maintenance
K
Knock Sensor KS Knock Sensor
L
Calculated Load Value LORD Calculated Load Value (CALC)
M
Mass Airflow MAF Mass Airflow (MAF)
Mass Airflow Sensor MAF Sensor MAF Sensor
Malfunction Indicator Lamp MIL Malfunction Indicator Lamp (MIL)
Manifold Absolute Pressure Sensor MAP Sensor Manifold Absolute Pressure Sensor, MAP Sensor
Manual/Transaxle M/T Manual Transaxle, M/T
Manual/Transmission M/T Manual Transmission, M/T
Multiport Fuel Injection MFI Multiport Fuel Injection
N
Nitrogen Oxides NOX Nitrogen Oxides (NOx)
O
On-Board Diagnostic OBD OBD
Open Loop OL Open Loop
Output Shaft Speed Sensor OSS Sensor Output Shaft Speed Sensor
Oxygen O2 O2
Oxidation catalytic converter OC Oxidation catalytic converter
Oxygen Sensor O2S O2 Sensor, O2S
P
 General Information: 0A-4

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

Symbols
AENBL80A0101003
Symbol Definition Symbol Definition
Tightening torque Apply SUZUKI BOND NO. 1217G
99000-31260
Apply oil (engine, transmission, transfer, Apply SUZUKI BOND NO. 1216B
differential) 99000-31230
Apply fluid (brake, power steering or Apply SUZUKI BOND NO. 1207B
automatic transmission fluid) 99000-31140
Apply SUZUKI SUPER GREASE A Apply SILICONE SEALANT
99000-25011 99000-31120
Apply SUZUKI SUPER GREASE C Apply SEALING COMPOUND 366E
99000-25030 99000-31090
Apply SUZUKI SUPER GREASE E Apply THREAD LOCK 1322
99000-25051 99000-32110
Apply SUZUKI SUPER GREASE H Apply THREAD LOCK 1333B
99000-25121 99000-32020
Apply SUZUKI SUPER GREASE I Apply THREAD LOCK 1342
99000-25210 99000-32050
Apply SUZUKI BOND NO. 1215 Do not reuse
99000-31110
Apply SUZUKI BOND NO. 1207F Note on reassembly
99000-31250
0A-5 General Information:

Wire Color Symbols

AENBL80A0101004
Symbol Wire Color Symbol Wire Color
— BEG Beige Lg LT GRN Light green
B BLK Black O, Or ORN Orange
Bl BLU Blue R RED Red
Br BRN Brown W WHT White
G GRN Green Y YEL Yellow
Gr GRY Gray P PNK Pink
Lbl LT BLU Light blue V PPL Violet

There are two types of colored wire used in this vehicle. One is single-colored type and the other is dual-colored
(striped) type.
The single-colored type of wire uses only one color symbol (i.e. “GRN”).
The dual-colored type of wire uses two color symbols (i.e. “GRN/YEL”). The first symbol represents the base color of
the wire (“GRN” in the figure) and the second symbol represents the color of the stripe (“YEL” in the figure).

I2RH01010010-01

Ignition Modes and Ignition Switch Positions JIS-TO-ISO main fasteners comparison table
AENBL80A0101005 Nominal diameter
In this manual, each ignition switch position (models with
M6 M8 M10 M12 M14
a conventional ignition switch system) and the
Thread pitch 1.0 1.25 1.25 1.25 1.5
corresponding ignition mode (models with a keyless JIS
Width across flats 10 12 14 17 19
push start system) are indicated using the following
Thread pitch 1.0 1.25 1.5 1.5 1.5
unified word / acronym preceded by “ignition”: START, ISO
Width across flats 10 13 16 18 21
ON, ACC or OFF (e.g. “ignition ON”) unless there is
need to express it otherwise.

Fasteners Information
AENBL80A0101006
Metric Fasteners
Most of the fasteners used for this vehicle are JIS-
defined and ISO-defined metric fasteners. When
replacing any fasteners, it is most important that
replacement fasteners are of the correct diameter,
thread pitch and strength.

! CAUTION
The thread pitch (2) or the width across flats I4RH0A010005-01

(3) may vary between ISO-defined and JIS-

defined fasteners even when the nominal
diameter (1) of thread is the same. Refer to
JIS-TO-ISO Main Fasteners Comparison
Table below for the difference.
Installing a mismatched bolt or nut will cause
damage to the threads.
Before installing a fastener, check the thread
pitch for correct matching and then tighten it
by hand temporarily. If it is tight, recheck the
thread pitch.
Fastener Strength Identification
Most commonly used strength classes of metric
fasteners are 4T, 6.8, 7T and 8.8. Strength class is
indicated by a number or radial line(s) embossed on the
head of each bolt. Some metric nuts have a punched
number, 6 or 8 on their end surfaces. Figure shows
different strength markings.
When replacing metric fasteners, be sure to use bolts
and nuts of the same strength class as or higher class
than the original bolts and nuts. It is also important to
 General Information: 0A-6

select replacement fasteners of the correct diameter and

thread pitch. Correct replacement bolts and nuts are
available as SUZUKI spare parts.
Metric bolts and nuts: Strength class numbers or marks
(The larger the number, the greater the strength).

I5RH01010001-01

1. Nut strength identification

Standard Tightening Torque

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

NOTE
• For flanged bolts, flanged nuts and self-locking nuts of the 4T and 7T strength classes, add 10% to
the applicable tightening torque given in the following chart.
• The following chart is applicable only where the fastened parts are made of steel or light alloy.

Tightening torque chart

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

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

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

I2RH01010014-01
0A-7 General Information:

Thread diameter (Nominal diameter) (mm)

Strength Unit
4 5 6 8 10 12 14 16 18
Fastener of strength class equivalent to N⋅m 2.3 4.5 10 23 50 85 135 210 240
7T kgf-m 0.23 0.45 1.0 2.3 5.0 8.5 13.5 21 24
lbf-ft 2.0 3.5 7.5 17.0 36.5 61.5 98.0 152.0 174.0

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

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

I2RH01010017-01

*: Self-locking nut

Vehicle Lifting Points

AENBL80A0101007
! WARNING

• Before applying the hoist arms to the underbody, take in mind the balance of the vehicle on the hoist
that should change depending on the parts going to be removed.
• Before lifting up the vehicle on the hoist, make sure that the hoist arm is not in contact with such
components as the brake pipes, fuel pipes and brackets.
• When using a frame contact hoist, apply the right and left arms to the symmetrically located points
shown in the figure. Hoist the vehicle till 4 tires are a little off the ground and make sure that the
vehicle will not fall off by rocking the vehicle body. Work can be started only after this confirmation.
• Make absolutely sure to lock the hoist after vehicle is hoisted up.
 General Information: 0A-8

When Using Frame Contact Hoist

[A] [B]

2 2

[F]
1
1
3

2 2

[a] “a”
IBL80A010001-01

[A]: Front side [a]: Wheel center 2. Support position for frame contact hoist and safety stand
[B]: Rear side “a”: Approx 940 mm (Approx 37.00 in.) 3. Gravity center position without load in vehicle
[F]: Vehicle front 1. Floor jack position

When Using Floor Jack Length “l”: above 900 mm (above 35.4 in.)

! WARNING

• When the vehicle is jacked up only at the

front or rear end, be sure to block all the
wheels on the ground.
• After the vehicle is jacked up, be sure to
support it on safety stands. It is extremely
dangerous to do any work on the vehicle
supported by a jack alone. “l”

! CAUTION

• Never apply jack against rear suspension

parts (i.e., torsion beam, etc.), vehicle floor “h”
or exhaust pipe or it may get deformed. I4RS0A010002-01

• When jacking up the front end, be sure to In raising front or rear vehicle end off the floor by jacking,
use an air type floor jack with the following be sure to put the jack against front suspension frame
specified height or a manual type floor jack (1) or rear towing hook (2).
of the following size. Otherwise, the jack
may cause the bumper or vehicle body
panel damage.

Jack size
Height “h”: under 145 mm (under 5.71 in.)
0A-9 General Information:

Front Rear

2
1

I9P60A010002-01 I9P60A010005-01

Rear Vehicle Identification Number

AENBL80A0101008
The vehicle identification number is punched on the cowl
side outer member (1).

(2)
1

(2)
I9P60A010006-01

Engine Identification Number

AENBL80A0101009
The engine identification number is punched on cylinder
block.
IBL80A010002-01

To perform service with either front or rear vehicle end [A]

jacked up, be sure to place safety stands (1) under body
mounting stays (2) so that vehicle body is securely
supported. Then check to ensure that vehicle body does
not slide on safety stands (1) and the vehicle is held
stable for safety’s sake.
Front

[B]

I9P60A010004-01

I7V20A010003-02

[A]: Petrol engine model [B]: Diesel engine model

 General Information: 0A-10

Component Location
Warning, Caution and Information Labels Location
AENBL80A0103001
The figure shows main labels among others that are attached to vehicle components.
When servicing and handling components, refer to WARNING / CAUTION instructions printed on labels.
If any WARNING / CAUTION label is found stained or damaged, clean or replace it if necessary.

4 5

[A] 1 [B] 1

2
3 3
IBL80A010003-01

[A]: Petrol engine model 1. Battery label 3. Engine cooling fan label 5. Jack label
[B]: Diesel engine model 2. Radiator cap label 4. Steering shaft joint cover label
0A-11 General Information:

[A]
2
3 1

IBL80A010004-01

[A]: These labels are attached on vehicle equipped with air bag system only. 4. Air bag label on SDM
1. Air bag label on driver air bag (inflator) module 5. Pretensioner label on seat belt retractor
2. Air bag label on contact coil assembly 6. Air bag label on sun visor
3. Air bag label on passenger air bag (inflator) module
 Maintenance and Lubrication: 0B-1

Maintenance and Lubrication

General Information

Scheduled Maintenance
Maintenance Schedule under Normal Driving Conditions
AENBL80A0205001
NOTE
• This interval should be judged by odometer reading or months, whichever comes first.
• This table includes service as scheduled up to 80,000 kms. Beyond 80,000 kms, carry out the same
services at the same intervals respectively.

Km (x 1,000) 1 5 10 20 30 40 50 60 70 80
Interval
Months 1 6 12 24 36 48 60 72 84 96
Engine
Water Pump drive belt (Tension, wear)
(I: )(Page 0B-3), — — — — — I — — — R
R: )(Page 0B-3))
Valve lash (clearance) (Petrol) (I: )(Page 0B-3)) — — — — I — — I — —
Engine oil and oil filter
— — R R R R R R R R
(R: )(Page 0B-3))
Engine coolant (Level, leakage)
I I I R I R I R I R
(R: )(Page 0B-3))
Cooling system hoses and connections (leakage,
I I I I I I I I I I
damage)
Engine bolts (All cylinder head and manifold
— — T — T — T — T —
fixings)
Engine mounting (loose, damage) — — T — T — T — T —
Exhaust system (noise, leakage, otherwise
— I — I — — — — — I
defective) (I: )(Page 0B-3))
PCV valve (Hoses, connections and valve) (I:
— I — I — — — — — I
)(Page 0B-4))
Exhaust Gas Recirculation valve (Diesel) — — — — C — — C — —
Fuel Evaporative Emission Control System
I I I I I I I I I I
Inspection (Petrol Engine Model) )(Page 0B-4)
Ignition system
Ignition wiring (damage, deterioration) — — — I — I — I — I
Spark plugs
— — — — — R — — — R
(R: )(Page 0B-4))
Fuel system
Paved-road Clean after every 5,000 Kms. Replace after every 40,000 kms
Air cleaner filter (Petrol) (R:
Dusty Clean after every 2,500 Kms or as required. Replace after every
)(Page 0B-4), I: )(Page 0B-4))
conditions 40,000 kms
Paved-road Replace after every 20,000 Kms. Cleaning not required.
Air cleaner filter (Diesel) (R:
Dusty Replace after every 20,000 Kms. Cleaning not required. More
)(Page 0B-4), I: )(Page 0B-4))
conditions frequent replacement if dust condition is severe.
Fuel tank cap, fuel lines and connections
— I — — — I — — — I
(leakage, damage) (I: )(Page 0B-4))
Fuel Filter (leakage) (R: )(Page 0B-5), — — — — — R — — — R
Fuel Filter and Water Draining (Diesel) (R:
I I I R I R I R I R
)(Page 0B-5), Drain: )(Page 0B-5))
Clutch and Transmission
Clutch Fluid (Level, Leakage) (I: )(Page 0B-5):) I I I R I R I R I R
Clutch slipping (dragging or excessive damage) I I I I I I I I I I
Transmission oil (level, leakage) (I: )(Page 0B-
5), R:“Manual Transaxle Oil Replacement” (Page I I I R I R I R I R
0B-5))
Drive Shaft
Drive shaft boots (Boot cut or damage) (I: )(Page
— I I I I I I I I I
0B-5))
0B-2 Maintenance and Lubrication:

Km (x 1,000) 1 5 10 20 30 40 50 60 70 80
Interval
Months 1 6 12 24 36 48 60 72 84 96
Drive shaft (Noise) I I I I I I I I I I
Brake
Brake discs and pads (wear) (I: )(Page 0B-5)) — I I I I I I I I I
Brake drums and shoes (wear, damage) (I:
— — I I I I I I I I
)(Page 0B-5))
Brake hoses and pipes (leakage, damage, clamp)
I I I I I I I I I I
(I: )(Page 0B-6))
Brake fluid (level, leakage) (R: )(Page 0B-6)) I I I R I R I R I R
Brake pedal (pedal-to-wall clearance) I I I I I I I I I I
Master cylinder and wheel cylinder (oil leakage,
I I I I I R I I I R
boot cut) (Replace piston and boot kits)
Parking brake lever and cable (damage, play) (I:
I I I I I I I I I I
)(Page 0B-6))
Wheel
Tire (air pressure, abnormal wear, crack) (I:
I I&O I&O I&O I&O I&O I&O I&O I&O I&O
)(Page 0B-6))
Wheels (damage) (I: )(Page 0B-7)) I I I I I I I I I I
Front / Rear wheel bearings (loose,
I I I I I I I I I I
damage))(Page 0B-7)
Suspension
Suspension strut (Oil leakage, damage)
I I I I I I I I I I
(I:“Suspension System Inspection” (Page 0B-7))
Suspension arms and knuckle supports (loose,
— I I I I I I I I I
damage) (I: )(Page 0B-7))
Shock absorber (oil leakage, damage) (I: )(Page
I I I I I I I I I I
0B-7))
All bolts and nuts (loose) (I: )(Page 0B-7)) — T T T T T T T T T
Suspension arms and tension rods (I: )(Page
— I I I I I I I I I
0B-7))
Steering
Steering wheel (play, loose) (I: )(Page 0B-8)) I I I I I I I I I I
All rods and arms (loose, damage, wear) I I I I I I I I I I
Electrical
Battery electrolyte (level, leakage) I I I I I I I I I I
Wiring harness connection (looseness, damage) — I I I I I I I I I
Lighting system (operation, stains, damage) I I I I I I I I I I
Horn (operation) I I I I I I I I I I
System voltage — I I I I I I I I I
Body
All latches, hinges and locks (Function) (I:
I I&L I&L I&L I&L I&L I&L I&L I&L I&L
)(Page 0B-8))
All chassis bolts and nuts (tighten) — I T T T T T T T T
Road Test
Operation of brakes, gear shifting and
I I I I I I I I I I
speedometer
Body and chassis noise I I I I I I I I I I
Air Conditioner
Check belt tension I I I I I I I I I I
Tighten compressor mounting bolts — T T T T T T T T T
Check all hose joints, tighten if necessary I I I I I I I I I I
Check functioning of Recirculating flap I I I I I I I I I I
Clean condenser with low pressure water — C C C C C C C C C
Check belt for frayed edges, change if necessary I I I I I I I I I I
Check all mounting bolts I I I I I I I I I I
 Maintenance and Lubrication: 0B-3

NOTE
• “R”: Replace or change
• “I”: Inspect and correct, or replace if necessary
• “L”: Lubricate
• “T”: Tighten to specified torque wherever applicable
• “C”: Clean
• “O”: Rotate

Repair Instructions
Accessory Drive Belt Inspection
AENBL80A0206001
! WARNING
All inspection and replacement operations
must be performed with ENGINE NOT
RUNNING.

Inspect belt for cracks, cuts, deformation, wear and

contamination. If any defect is found, replace belt.
Check belt for tension.
• Petrol engine model: I2RH0B020003-02

– Water pump / generator drive belt: )(Page 1J-10) 1. Camshaft 2. Feeler gauge

– Compressor drive belt for single A/C model:

)(Page 7B-43) Engine Oil and Filter Change
AENBL80A0206004
– Compressor drive belt for dual A/C model: )(Page Replace engine oil and filter.
7B-92)
• Petrol engine model: )(Page 1E-3)
• Diesel engine model: )(Page 1J-26)
• Diesel engine model: )(Page 1E-16)
Accessory Drive Belt Replacement
AENBL80A0206002 Engine Coolant Change
Replace accessory drive belt with new one. AENBL80A0206005
Change engine coolant with new one.
• Petrol engine model:
• Petrol engine model:
– Water pump / generator drive belt: )(Page 1J-11)
– Draining: “Cooling System Draining”: K14B in
– Compressor drive belt for single A/C model: Section 1F (Page 1F-11)
)(Page 7B-43)
– Refilling: “Cooling System Refilling”: K14B in
– Compressor drive belt for dual A/C model: )(Page Section 1F (Page 1F-11)
7B-92)
• Diesel engine model:
• Diesel engine model: )(Page 1J-26)
– Draining: “Cooling System Draining”: D13A in
Section 1F (Page 1F-25)
Valve Lash (Clearance) Inspection (Petrol
– Refilling: “Cooling System Refill”: D13A in Section
Engine Model)
AENBL80A0206003 1F (Page 1F-26)
Inspect intake and exhaust valve lashes. Adjust them if
necessary. Exhaust System Inspection
Refer to “Valve Clearance Inspection and Adjustment”: AENBL80A0206006
K14B in Section 1D (Page 1D-2) for valve lash ! WARNING
inspection and adjustment procedures.
To avoid danger of being burned, do not
touch exhaust system when it is still hot.
Any service on exhaust system should be
performed when it is cool.
0B-4 Maintenance and Lubrication:

When carrying out periodic maintenance, or the vehicle

is raised for other service, check exhaust system as
follows:
• Check rubber mountings for damage, deterioration,
and dislocation.
• Check exhaust system for leakage, loose
connections, dents and damages.
If bolts or nuts are loose, tighten them to specification.
• Check nearby body areas for damaged, missing or ill-
placed parts, open seams, holes, loose connections
IAW101020005-01
or other defects which could permit exhaust fumes to
3) Install air cleaner filter.
seep into the vehicle.
• Petrol engine model: )(Page 1D-5)
• Make sure that exhaust system components have
enough clearance from the underbody to avoid • Diesel engine model: )(Page 1D-78)
overheating and possible damage to floor carpet.
Air Cleaner Filter Replacement
AENBL80A0206011
Replace air cleaner filter with new one.
• Petrol engine model: )(Page 1D-5)
• Diesel engine model: )(Page 1D-78)

Fuel Tank, Cap Gasket and Fuel Lines

Inspection
AENBL80A0206012
• Check fuel tank, fuel filler cap (1) and fuel lines for
loose connection, deterioration or damage which
could cause leakage. Make sure all clamps are
secure.
• Check fuel filler cap gasket (2) for an even filler neck
I9P60A020001-01 imprint or any damage.
• Any defects should be fixed at once.

PCV Valve Inspection (Petrol Engine Model)

AENBL80A0206007
Check PCV valve and hose. )(Page 1B-4) 2

Fuel Evaporative Emission Control System

Inspection (Petrol Engine Model) 1
AENBL80A0206008
Check EVAP canister and fuel vapor hose. )(Page 1B- I9P60A020002-01
3) • Replace any damaged or deteriorated parts.
There should be no sign of fuel leakage or moisture at
Spark Plug Replacement (Petrol Engine Model) any fuel connection.
AENBL80A0206009
Replace spark plugs with new ones. )(Page 1H-6)

Air Cleaner Filter Inspection

AENBL80A0206010
1) Remove air cleaner filter.
• Petrol engine model: )(Page 1D-5)
• Diesel engine model: )(Page 1D-78)
2) Check that filter is not excessively dirty, damaged or
oily.
• Petrol engine model: Clean filter with compressed
air from air outlet side of filter. I4RS0A020005-01
• Diesel engine model: Replace the filter.
 Maintenance and Lubrication: 0B-5

Fuel Filter Replacement Drive Shaft (Axle) Boots Inspection

AENBL80A0206013
Replace fuel filter with new one.
• Petrol engine model: )(Page 1G-26)
• Diesel engine model: )(Page 1G-56)
AENBL80A0206019
Check drive shaft boots (wheel side and differential side)
for leaks, detachment, tear or other damage.
Replace defective parts if necessary.

Water Draining of Fuel Filter (Diesel Engine

Model)
AENBL80A0206014
Bleed fuel filter of water. )(Page 1G-40)

Clutch Pedal Inspection

AENBL80A0206015
Check clutch pedal travel.
For checking procedure.
• Petrol engine model: “Clutch Pedal Inspection”: K14B
Model in Section 5C (Page 5C-4)
• Diesel engine model: “Clutch Pedal Inspection”: D13A I9P60A020008-01
Model in Section 5C (Page 5C-17)
Brake Discs and Pads Inspection
AENBL80A0206020
Clutch Fluid Inspection
AENBL80A0206016 1) Remove wheel and caliper but do not disconnect
1) Check clutch system for sign of fluid leakage. Repair brake hose from caliper.
leaky point if any. 2) Check disc brake pads and discs for excessive wear,
2) Check reservoir for fluid level. damage and deflection. Replace parts if necessary.
• Petrol engine model: “Clutch Fluid Level Be sure to torque caliper pin bolts to specification.
Inspection”: K14B Model in Section 5C (Page 5C- • Front brake pad: )(Page 4B-3)
5) • Front brake disc: )(Page 4B-7)
• Diesel engine model: “Clutch Fluid Level
Inspection”: D13A Model in Section 5C (Page 5C-
19)
If fluid is lower than minimum level of reservoir, refill
reservoir with specified brake fluid indicated on
reservoir cap.

I3RM0A020006-01
IAP70P020005-01

Manual Transaxle Oil Inspection Brake Drums and Shoes Inspection

AENBL80A0206017
Check transaxle oil for leakage, contamination and level.
• Petrol engine model: )(Page 5B-6)
• Diesel engine model: )(Page 5B-52)
Manual Transaxle Oil Replacement
AENBL80A0206018
Replace transaxle oil.
• Petrol engine model: )(Page 5B-7)
• Diesel engine model: )(Page 5B-52)
AENBL80A0206021
1) Remove wheel and brake drum.
2) Check rear brake drums and brake linings for
excessive wear and damage, while wheels and
drums are removed. At the same time, check wheel
cylinders for leaks. Replace these parts if necessary.
“Rear Brake Drum and Shoe Inspection” in Section
4C (Page 4C-3)
0B-6 Maintenance and Lubrication:

I4RS0B020004-01
I4RS0A020009-01

Brake Hoses and Pipes Inspection 2) Check tooth tip of each brake lever ratchet notch for
AENBL80A0206022
damage or wear. If any damage or wear is found,
Perform this inspection where there is enough light and
replace parking brake lever.
use a mirror if necessary.
3) Check parking brake lever for proper operation and
• Check brake hoses and pipes for improper
stroke, and adjust it if necessary.
connections, leaks, cracks, chafing and other
For checking and adjusting procedures, refer to
damage.
“Parking Brake Inspection” in Section 4D (Page 4D-
• Check that hoses and pipes are clear of sharp edges 2).
and moving parts.
Repair or replace any of these parts if necessary. Parking brake lever stroke
“a”: 4 – 9 notches (with 200 N (20.4 kgf, 45.0 lbf) of
! CAUTION pull pressure)
After replacing any brake pipe or hose, be
sure to carry out air purge operation.

I7V20A440002-01

Tires Inspection
AENBL80A0206025
1) Check tires for uneven or excessive wear, or
damage. If defective, replace tire.
I9P60A020003-01
Refer to “Tire Inspection” in Section 2D (Page 2D-2)
for details.
Brake Fluid Replacement
AENBL80A0206023
Change brake fluid as follows.
Drain existing fluid from brake system completely, fill
system with specified fluid and carry out air purge
operation.
For air purging procedure, refer to “Air Bleeding of Brake
System” in Section 4A (Page 4A-5).

Brake Lever and Cable Inspection

AENBL80A0206024
1) Inspect brake cables for damage and check that they
move smoothly. I2RH01020022-01
Replace deteriorated cable(s).
1. Wear indicator
 Maintenance and Lubrication: 0B-7

2) Check inflation pressure of each tire and adjust Front

pressure to specification if necessary.

NOTE
• Tire inflation pressure should be checked
when tires are cool.
• Specified tire inflation pressure is
indicated on the tire placard.

3) Rotate tires. For details, refer to “Tire Rotation” in

Section 2D (Page 2D-4).

Wheel Discs Inspection

AENBL80A0206026
Inspect each wheel disc for dents, distortion and cracks.
Badly damaged wheel disc must be replaced.

Wheel Bearing Inspection

AENBL80A0206027
1) Check front wheel bearings for wear, damage and
abnormal noise. For details, refer to “Front Wheel I9P60A020005-01
Bearing Check”: Front in Section 3A (Page 3A-13).
2) Check rear wheel bearings for wear, damage and Rear
abnormal noise. For details, refer to “Rear Wheel
Bearing Check”: Rear in Section 3A (Page 3A-19).

I9W10P020026-01

Suspension System Inspection

AENBL80A0206028
• Inspect front strut assemblies and rear shock
absorbers for sign of oil leakage, dents or any other
damage on sleeves. Also inspect anchor ends for I9P60A020006-01

deterioration. • Check dust covers of front suspension arm ball joints

Replace defective parts, if any. for leakage, detachment, tear or any other damage.
• Check front and rear suspension systems for Replace defective dust cover(s).
damaged, loose or missing parts. Also check them for
parts showing signs of wear or lack of lubrication.
Repair or replace defective parts, if any.

IAW101020014-01
0B-8 Maintenance and Lubrication:
Steering System Inspection
AENBL80A0206029
1) Check steering wheel for play and abnormal noise,
holding vehicle straight on ground.
Steering wheel play
“a”: 0 – 30 mm (0 – 1.2 in.)
I2RH01020026-01
2) Check bolts and nuts for tightness and retighten
them if necessary. Repair or replace defective parts.
3) Check steering linkage for looseness and damage.
Repair or replace defective parts.
4) Check boots (1) and (2) of steering linkage and
steering gear case for damage (leak, detachment,
tear, etc.). Replace defective boot(s) with new
one(s).
If any dent is found on steering gear case boots,
correct it to original shape by turning steering wheel
to the right or left as far as it stops and holding it for a
few seconds.
5) Check universal joints (3) of steering shaft for
abnormal noise and damage. If abnormal noise or
damage is detected, replace defective part with new
one.
3 properly and hood locks securely when closed.
1
2 Check that each front seat slides smoothly and locks
1 mechanism of each front seat allows the seatback to be
IBP80A020001-01
6) Check that steering wheel can be turned fully to the
right and left. Repair or replace defective parts, if
any.
7) Check that steering wheel can be turned fully to the
right and left with smaller force when engine is
running at idle speed than when it is stopped. Repair
power steering system if it provides no assistance.
8) Check wheel alignment referring to “Front Wheel
Alignment Inspection and Adjustment” in Section 2B
(Page 2B-1).
All Latches, Hinges and Locks Inspection
AENBL80A0206030
Doors
Check that each door opens and closes smoothly and
locks securely when closed.
If any malfunction is found, lubricate hinges and latch or
repair door lock system.
I2RH01020033-01
Rear End Door
Check that rear end door open and close smoothly and
lock securely when closed.
If any malfunction is found, adjust rear end door latch
striker.
Hood
Check that secondary latch operates properly (check
that secondary latch keeps hood from opening all the
way when hood release handle inside vehicle is pulled.)
Also check that hood opens and closes smoothly and
If any malfunction is found, lubricate hinges and latch, or
repair hood lock system.
Final Inspection for Maintenance Service
AENBL80A0206031
! WARNING
When carrying out road tests, select a safe
place without people and running vehicles to
prevent any accident.
Seats
securely at any position. Also check that reclining
locked at any angle.
Seat Belts
Inspect seat belt systems including webbing, buckles,
latch plates, retractors and anchors for damage or wear.
Check that each seat belt locks securely. If “REPLACE
BELT” label on seat belt is visible, replace belt.
 Maintenance and Lubrication: 0B-9

Battery Electrolyte Level Check Parking brake

Check that the electrolyte level of every battery cell is
between the upper and lower level lines on the case. If
battery is equipped with built-in indicator, check battery
condition by the indicator.
Accelerator Pedal Operation
Check that accelerator pedal operates smoothly without
getting caught by or interfering any other part.
Engine Start
Check the engine starts readily.
! WARNING
Be sure to observe the following precautions
to prevent personal injuries and property
damages in the event of accidental
movements of vehicle.
• Provide enough spaces around the
vehicle.
• Firmly apply both the parking brake and
foot brakes.
• Do not use the accelerator pedal.
• Be ready to set ignition “OFF” when
engine starts.
Place the gearshift lever in “Neutral”, depress clutch
pedal halfway and try to start.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (Manual Transaxle Model)
Check for the following:
• Clutch is completely released when clutch pedal is
depressed.
• No slipping clutch occurs when releasing pedal and
accelerating.
• Clutch itself is free from any abnormal conditions.
Gearshift or Select Lever
Check gearshift or select lever for smooth movement to
all positions and for good and correct response of
transaxle in any position.
Check that lever stroke is proper.
! WARNING
Observe the following precautions when
performing parking brake test on a slope.
• Make sure that no person and obstruction
is in the way ahead.
• Be prepared to apply foot brakes quickly in
case of a vehicle movement.
Check that parking brake is fully effective when the
vehicle is stopped on a slope by pulling parking brake
lever all the way.
Steering
• Check that steering wheel is not instable and has no
abnormally large resistance to turn.
• Check that vehicle does not wander or pull to one
side.
Engine
• Check that speed changes responsively to
accelerator positions.
• Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheels and Power Train Components
Check that body, wheels and power train components
are free from any abnormal conditions such as abnormal
noise and vibration.
Meters and Gauges
Check that speedometer, odometer, fuel gauge,
temperature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan
switch lever to highest position for this check.

Brakes
Foot brakes
Check the following:
• Brake pedal has proper travel.
• Brakes work properly.
• Brakes do not generate abnormal noise.
• Vehicle does not pull to one side when brakes are
applied.
• Brakes do not drag.
0B-10 Maintenance and Lubrication:

Special Tools and Equipment

Recommended Fluids and Lubricants
AENBL80A0208001
Engine oil • Petrol engine model: Refer to “Engine Oil and Filter Change”: K14B in
Section 1E (Page 1E-3) for engine oil viscosity.
/
/

Engine coolant
(Ethylene glycol base coolant)
Brake fluid
Manual transaxle oil
• Diesel engine model: Refer to “Engine Oil and Filter Change”: D13A in
Section 1E (Page 1E-16) for engine oil viscosity.
“Antifreeze/Anticorrosion coolant”
Refer to reservoir cap of brake master cylinder.
• Petrol engine model: Refer to “Manual Transaxle Oil Change”: D13A Model in
Section 5B (Page 5B-52).
/
/

Door hinges
Hood latch assembly
Key lock cylinder
• Diesel engine model: Refer to “Manual Transaxle Oil Change”: D13A Model
in Section 5B (Page 5B-52).
Engine oil or water resistance chassis grease
Engine oil or water resistance chassis grease
Spray lubricant

Section 1
Engine
CONTENTS
Precautions .................................................1-1
Precautions............................................................. 1-1
Precautions for Engine (K14B) ............................. 1-1
Precautions for Engine (D13A) ............................. 1-2
Engine General Information and
Diagnosis ................................................. 1A-1
K14B .........................................................................1A-1
General Description .............................................1A-1
Statement on Cleanliness and Care ................... 1A-1
Engine Diagnosis General Description ............... 1A-1
OBD System Description .................................... 1A-1
DLC Description .................................................. 1A-4
Engine and Emission Control System
Description ........................................................ 1A-4
Air Intake System Description ............................. 1A-4
Description of Electric Throttle Control
System Calibration ............................................ 1A-5
Electric Throttle Control System Description....... 1A-5
Electronic Control System Description................ 1A-6
Engine and Emission Control Input / Output
Table ................................................................. 1A-7
Schematic and Routing Diagram........................1A-9
Engine and Emission Control System
Diagram ............................................................ 1A-9
Engine and Emission Control System Flow
Diagram .......................................................... 1A-11
Electronic Control System Circuit Diagram ....... 1A-12
Component Location .........................................1A-14
Electronic Control System Component
Location .......................................................... 1A-14
Diagnostic Information and Procedures..........1A-15
Engine and Emission Control System Check.... 1A-15
MIL Check ......................................................... 1A-18
DTC Check ....................................................... 1A-18
DTC Clearance ................................................. 1A-19
DTC Table......................................................... 1A-19
Fail-Safe Table.................................................. 1A-24
Scan Tool Data ................................................. 1A-27
Visual Inspection ............................................... 1A-31
Engine Basic Inspection.................................... 1A-31
Engine Symptom Diagnosis .............................. 1A-32
Table of Contents 1- i
MIL Does Not Come ON with Ignition “ON”
and Engine Stopped (but Engine Can Be
Started) ...........................................................1A-37
MIL Remains ON after Engine Starts................1A-37
DTC P0010 / P2088 / P2089.............................1A-37
DTC P0011 .......................................................1A-39
DTC P0030 / P0031 / P0032.............................1A-41
DTC P0036 / P0037 / P0038.............................1A-43
DTC P0107 / P0108 ..........................................1A-45
DTC P0112 / P0113 ..........................................1A-46
DTC P0116 .......................................................1A-48
DTC P0117 / P0118 ..........................................1A-49
DTC P0122 / P0123 ..........................................1A-50
DTC P0130 .......................................................1A-51
DTC P0131 / P0132 ..........................................1A-53
DTC P0133 .......................................................1A-55
DTC P0134 .......................................................1A-57
DTC P0137 / P0138 / P0140.............................1A-59
DTC P0171 / P0172 ..........................................1A-61
DTC P0222 / P0223 ..........................................1A-63
DTC P0300 / P0301 / P0302 / P0303 / P0304 ..1A-64
DTC P0327 .......................................................1A-65
DTC P0335 .......................................................1A-67
DTC P0340 .......................................................1A-69
DTC P0351 / P0352 / P0353 / P0354 / P2300
/ P2301 / P2303 / P2304 / P2306 / P2307 /
P2309 / P2310 ................................................1A-72
DTC P0420 .......................................................1A-74
DTC P0443 / P0458 / P0459.............................1A-76
DTC P0480 / P0692 ..........................................1A-78
DTC P0481 / P0694 ..........................................1A-80
DTC P0500 .......................................................1A-81
DTC P0530 .......................................................1A-83
DTC P0560 / P0562 / P0563.............................1A-85
DTC P0602 .......................................................1A-87
DTC P0607 .......................................................1A-87
DTC P0645 / P0646 / P0647.............................1A-89
DTC P2100 .......................................................1A-90
DTC P2101 / P2119 ..........................................1A-92
DTC P2122 / P2123 ..........................................1A-94
DTC P2127 / P2128 ..........................................1A-96
DTC P2135 .......................................................1A-97
DTC P2138 .......................................................1A-98
DTC P2176 .....................................................1A-100
DTC P2270 / P2271 ........................................1A-102
1-ii Table of Contents
DTC U0073 ..................................................... 1A-103
DTC U0121 ..................................................... 1A-103
DTC U0131 ..................................................... 1A-103
DTC U0140 ..................................................... 1A-103
DTC U0155 ..................................................... 1A-104
Inspection of ECM and Its Circuits .................. 1A-104
ECM Power Supply and Ground Circuit
Check ............................................................ 1A-114
Fuel Cut Operation Inspection ........................ 1A-117
Repair Instructions ..........................................1A-117
Idle Speed and IAC Throttle Valve Opening
Inspection...................................................... 1A-117
Special Tools and Equipment .........................1A-118
Special Tool .................................................... 1A-118
D13A .....................................................................1A-119
General Description .........................................1A-119
Statement on Cleanliness and Care ............... 1A-119
Engine Diagnosis General Description ........... 1A-119
OBD System Description ................................ 1A-119
DLC Description .............................................. 1A-120
Schematic and Routing Diagram....................1A-122
Electronic Control System Diagram ................ 1A-122
Electronic Control System Circuit Diagram ..... 1A-123
Component Location .......................................1A-125
Electronic Control System Component
Location ........................................................ 1A-125
Diagnostic Information and Procedures........1A-126
MIL Check ....................................................... 1A-126
Engine and Emission Control System Check.. 1A-126
DTC Check...................................................... 1A-129
DTC Clearance ............................................... 1A-129
DTC Table....................................................... 1A-130
Fail-Safe Table................................................ 1A-135
Scan Tool Data ............................................... 1A-139
Visual Inspection ............................................. 1A-143
Engine Basic Inspection.................................. 1A-144
Engine Symptom Diagnosis ............................ 1A-144
MIL Does Not Come ON with Ignition in “ON”
and Engine Stopped (but Engine Can Be
Started) ......................................................... 1A-158
MIL Remains ON after Engine Starts.............. 1A-159
DTC P0001 ..................................................... 1A-159
DTC P0069 / P0107 / P0234........................... 1A-160
DTC P0087 / P0089 ........................................ 1A-163
DTC P0088 ..................................................... 1A-164
DTC P0095 ..................................................... 1A-167
DTC P0100 ..................................................... 1A-168
DTC P0101 ..................................................... 1A-169
DTC P0110 ..................................................... 1A-170
DTC P0115 ..................................................... 1A-171
DTC P0120 ..................................................... 1A-172
DTC P0130 / P2244 ........................................ 1A-173
DTC P0135 ..................................................... 1A-176
DTC P0168 / P0180 ........................................ 1A-177
DTC P0190 ..................................................... 1A-178
DTC P0201 / P0202 / P0203 / P0204 / P2146 1A-181
DTC P0217 ..................................................... 1A-182
DTC P0219 ..................................................... 1A-184
DTC P0220 ..................................................... 1A-185
DTC P0230 .....................................................1A-187
DTC P0235 .....................................................1A-188
DTC P0243 .....................................................1A-189
DTC P0335 .....................................................1A-190
DTC P0340 .....................................................1A-192
DTC P0380 / P0683 ........................................1A-193
DTC P0401 / P0402 ........................................1A-195
DTC P0403 .....................................................1A-197
DTC P0480 .....................................................1A-198
DTC P0481 .....................................................1A-199
DTC P0500 .....................................................1A-201
DTC P0520 .....................................................1A-202
DTC P0530 .....................................................1A-203
DTC P0560 .....................................................1A-205
DTC P0571 / P1571 ........................................1A-207
DTC P0600 / P0601 / P0604 / P060B / P2226 1A-209
DTC P0641 .....................................................1A-211
DTC P0645 .....................................................1A-212
DTC P0651 .....................................................1A-214
DTC P0657 / P0685 ........................................1A-215
DTC P0697 .....................................................1A-217
DTC P0704 .....................................................1A-219
DTC P1647 .....................................................1A-221
DTC P2135 .....................................................1A-221
DTC P2237 / P2297 ........................................1A-223
DTC P2264 .....................................................1A-224
DTC P268A .....................................................1A-226
DTC U0073 .....................................................1A-226
DTC U0121 .....................................................1A-227
DTC U0140 .....................................................1A-227
DTC U2101 .....................................................1A-227
Table A-1: Fuel Pump Relay Operation Check 1A-227
Table A-2: Fuel Injector Circuit Check ............1A-229
Table A-3: Fuel Temperature Sensor Check ..1A-230
Table A-4: Fuel Pressure Sensor Circuit
Check ............................................................1A-232
Table A-5: Fuel Flow Actuator Operation
Check ............................................................1A-234
Table B-1: Air Intake / Turbocharger Circuit
Check ............................................................1A-235
Table B-2: MAF Sensor Check .......................1A-236
Table B-3: Boost Pressure Sensor Check ......1A-238
Table B-4: Barometric Pressure Check...........1A-240
Table B-5: EGR Valve Operation Check.........1A-240
Table B-6: A/F Sensor Check .........................1A-241
Table B-7: Boost Pressure Control Solenoid
Valve Operation Check .................................1A-243
Table C-1: Main Relay Operation Check ........1A-245
Table C-2: Engine Speed Check.....................1A-247
Table C-3: ECT Sensor Check........................1A-248
Table C-4: IAT-1 Sensor Check ......................1A-250
Table C-5: IAT-2 Sensor Check ......................1A-251
Table C-6: Accelerator Pedal Check...............1A-252
Table C-7: Speed Signal Check......................1A-254
Table C-8: Glow Plugs Operation Check ........1A-257
Table C-9: Radiator Cooling Fan Operation
Check ............................................................1A-260
Inspection of ECM and Its Circuits ..................1A-263
Repair Instructions ..........................................1A-274
Idle Speed Inspection......................................1A-274

Special Tools and Equipment .........................1A-274
Special Tool .................................................... 1A-274
Aux. Emission Control Devices ............. 1B-1
K14B .........................................................................1B-1
Diagnostic Information and Procedures............1B-1
EVAP Canister Purge System Inspection ........... 1B-1
Repair Instructions ..............................................1B-2
EVAP System Components ................................ 1B-2
EVAP Canister Purge Valve Inspection .............. 1B-2
EVAP Canister Inspection................................... 1B-3
EVAP Connection Hose Inspection .................... 1B-4
PCV Hose Inspection .......................................... 1B-4
PCV Valve Inspection ......................................... 1B-4
Special Tools and Equipment .............................1B-4
Special Tool ........................................................ 1B-4
D13A .........................................................................1B-5
Repair Instructions ..............................................1B-5
EGR Valve and EGR Cooler Components.......... 1B-5
EGR Valve and EGR Cooler Removal and
Installation......................................................... 1B-6
EGR Valve Inspection ......................................... 1B-7
Cleaning Procedure for EGR Valve .................... 1B-7
A/F Sensor On-Vehicle Inspection ...................... 1B-8
A/F Sensor Removal and Installation.................. 1B-9
Specifications.......................................................1B-9
Tightening Torque Specifications........................ 1B-9
Engine Electrical Devices ....................... 1C-1
K14B .........................................................................1C-1
Repair Instructions ..............................................1C-1
ECM Removal and Installation............................1C-1
Procedure after ECM Replacement ....................1C-2
Electric Throttle Body Assembly On-Vehicle
Inspection..........................................................1C-2
Electric Throttle Control System Calibration .......1C-4
APP Sensor On-Vehicle Inspection ....................1C-4
Accelerator Pedal Assembly (Incorporating
APP Sensor) Removal and Installation .............1C-4
APP Sensor Inspection .......................................1C-5
ECT Sensor Removal and Installation ................1C-5
ECT Sensor Inspection .......................................1C-6
HO2S-1 and HO2S-2 On-Vehicle Inspection ......1C-6
HO2S-1 and HO2S-2 Removal and
Installation.........................................................1C-7
CMP Sensor On-Vehicle Inspection....................1C-7
CMP Sensor Removal and Installation ...............1C-7
CMP Sensor Inspection ......................................1C-8
CKP Sensor Removal and Installation ................1C-8
CKP Sensor Inspection .......................................1C-8
Knock Sensor On-Vehicle Inspection .................1C-9
Knock Sensor Removal and Installation .............1C-9
Engine and Emission Control System Relay
Inspection..........................................................1C-9
MAP Sensor Removal and Installation................1C-9
MAP Sensor Inspection ....................................1C-10
IAT Sensor Removal and Installation................1C-10
IAT Sensor Inspection.......................................1C-11
OCV Inspection .................................................1C-11
Table of Contents 1-iii
VSS Removal and Installation...........................1C-11
VSS Inspection..................................................1C-12
Specifications.....................................................1C-12
Tightening Torque Specifications......................1C-12
Special Tools and Equipment ...........................1C-13
Special Tool ......................................................1C-13
D13A .......................................................................1C-14
General Description ...........................................1C-14
Description of ECM Registration .......................1C-14
Repair Instructions ............................................1C-14
ECM Removal and Installation..........................1C-14
Registration for ECM Replacement...................1C-15
Fuel Injector Registration ..................................1C-16
Flywheel Data Initialization................................1C-16
A/F Sensor Data Initialization............................1C-16
MAF Sensor Data Initialization..........................1C-17
Fuel Pressure Sensor Initialization....................1C-17
MAF and IAT-1 Sensor Removal and
Installation .......................................................1C-17
MAF and IAT-1 Sensor Inspection ....................1C-18
Glow Plug Removal and Installation .................1C-19
Glow Plug Inspection ........................................1C-19
APP Sensor Assembly On-Vehicle Inspection ..1C-19
APP Sensor Assembly Removal and
Installation .......................................................1C-20
APP Sensor Assembly Inspection.....................1C-20
ECT Sensor Removal and Installation ..............1C-20
ECT Sensor Inspection .....................................1C-21
CMP Sensor Removal and Installation .............1C-21
CMP Sensor Inspection ....................................1C-22
CKP Sensor Removal and Installation ..............1C-22
CKP Sensor Inspection .....................................1C-22
Boost Pressure and IAT-2 Sensor Removal
and Installation ................................................1C-23
Boost Pressure and IAT-2 Sensor Inspection ...1C-23
Fuel Pump Relay, Starting Motor Control
Relay and Main Relay Inspection....................1C-24
Glow Plug Control Module Removal and
Installation .......................................................1C-24
Boost Pressure Control Solenoid Valve
Removal and Installation.................................1C-25
Boost Pressure Control Solenoid Valve
Inspection........................................................1C-25
VSS Removal and Installation...........................1C-25
VSS Inspection..................................................1C-26
Specifications.....................................................1C-26
Tightening Torque Specifications......................1C-26
Special Tools and Equipment ...........................1C-27
Special Tool ......................................................1C-27
Engine Mechanical .................................. 1D-1
K14B .........................................................................1D-1
General Description .............................................1D-1
Engine Construction Description.........................1D-1
Diagnostic Information and Procedures ............1D-1
Compression Check............................................1D-1
Engine Vacuum Check........................................1D-2
Valve Clearance Inspection and Adjustment ......1D-2
Repair Instructions ..............................................1D-4
1-iv Table of Contents
Air Cleaner Components.....................................1D-4
Air Cleaner Filter Removal and Installation.........1D-5
Air Cleaner Filter Inspection and Cleaning..........1D-5
Air Cleaner Assembly Removal and
Installation .........................................................1D-5
Throttle Body and Intake Manifold
Components......................................................1D-5
Throttle Body On-Vehicle Inspection...................1D-6
Electric Throttle Body Assembly Removal and
Installation .........................................................1D-6
Throttle Body Cleaning........................................1D-7
Intake Manifold Removal and Installation ...........1D-7
Cylinder Head Cover Components .....................1D-8
Cylinder Head Cover Removal and
Installation .......................................................1D-10
Camshaft, Tappet and Shim Components ........1D-11
Camshaft and Tappet Removal and
Installation .......................................................1D-12
Camshaft and Tappet Inspection ......................1D-16
Engine Mounting Components..........................1D-20
Engine Assembly Removal and Installation ......1D-21
Timing Chain Cover Components .....................1D-24
Timing Chain Cover Removal and Installation ..1D-24
Timing Chain Cover Inspection .........................1D-28
OCV Removal and Installation ..........................1D-28
Flywheel Removal and Installation....................1D-28
Flywheel Inspection...........................................1D-29
Timing Chain and Chain Tensioner
Components....................................................1D-29
Timing Chain and Chain Tensioner Removal
and Installation ................................................1D-30
Timing Chain and Chain Tensioner Inspection ..1D-33
Valve and Cylinder Head Components .............1D-34
Valve and Cylinder Head Removal and
Installation .......................................................1D-36
Valve and Cylinder Head Disassembly and
Reassembly ....................................................1D-37
Valve and Valve Guide Inspection ....................1D-41
Cylinder Head Inspection ..................................1D-43
Cylinder Head Bolt Inspection...........................1D-43
Valve Spring Inspection ....................................1D-44
Piston, Piston Ring, Connecting Rod and
Cylinder Components .....................................1D-44
Piston, Piston Ring, Connecting Rod and
Cylinder Removal and Installation ..................1D-45
Piston, Piston Ring, Connecting Rod and
Cylinder Disassembly and Reassembly..........1D-47
Cylinder, Piston and Piston Ring Inspection .....1D-48
Piston Pin and Connecting Rod Inspection.......1D-51
Crankshaft Pin and Connecting Rod Bearing
Inspection........................................................1D-52
Main Bearing, Crankshaft and Cylinder Block
Components....................................................1D-56
Main Bearing, Crankshaft and Cylinder Block
Removal and Installation.................................1D-57
Crankshaft Inspection .......................................1D-60
Main Bearing Inspection....................................1D-61
Sensor Plate Inspection ....................................1D-66
Rear Oil Seal Inspection ...................................1D-66
Timing Chain Jet Inspection..............................1D-66
Cylinder Block Inspection..................................1D-67
Specifications .....................................................1D-67
Tightening Torque Specifications......................1D-67
Special Tools and Equipment ...........................1D-68
Recommended Service Material .......................1D-68
Special Tool ......................................................1D-68
D13A .......................................................................1D-71
Diagnostic Information and Procedures ..........1D-71
Compression Check..........................................1D-71
Timing Check ....................................................1D-71
Repair Instructions ............................................1D-74
Air Cleaner Components...................................1D-74
Air Cleaner Filter Removal and Installation.......1D-76
Air Cleaner Filter Inspection and Cleaning........1D-76
Air Cleaner Assembly Removal and
Installation .......................................................1D-76
Intercooler Components....................................1D-77
Intercooler Removal and Installation.................1D-78
Vacuum Pump Removal and Installation ..........1D-78
Vacuum Pump Inspection .................................1D-79
EGR Valve and EGR Cooler Components........1D-80
EGR Valve and EGR Cooler Removal and
Installation .......................................................1D-80
Crankcase Ventilation System Components.....1D-82
Oil Separator and Crankcase Ventilation
Cover Removal and Installation ......................1D-82
Turbocharger Components ...............................1D-85
Turbocharger Removal and Installation ............1D-85
Turbocharger Inspection ...................................1D-87
Intake Manifold Components ............................1D-88
Intake Manifold Removal and Installation .........1D-88
Engine Mounting Components..........................1D-90
Engine Assembly Removal and Installation ......1D-91
Timing Chain Cover and Timing Chain
Components....................................................1D-97
Timing Chain Cover and Timing Chain
Removal and Installation.................................1D-97
Timing Chain Cover and Timing Chain
Inspection......................................................1D-103
Camshaft Housing Components .....................1D-105
Camshaft Housing Assembly Removal and
Installation .....................................................1D-106
Camshaft Housing Assembly Disassembly
and Reassembly ...........................................1D-107
Camshaft Inspection .......................................1D-109
Valve and Cylinder Head Components ...........1D-112
Valve and Cylinder Head Assembly Removal
and Installation ..............................................1D-113
Valve and Cylinder Head Assembly
Disassembly and Reassembly ......................1D-116
Valve and Guide Inspection ............................1D-117
Cylinder Head Inspection ................................1D-118
Valve Spring Inspection ..................................1D-119
Piston, Piston Ring, Connecting Rod and
Cylinder Components....................................1D-119
Piston, Piston Ring, Connecting Rod and
Cylinder Removal and Installation.................1D-120
Piston, Piston Ring, Connecting Rod and
Cylinder Disassembly and Reassembly........1D-122

Cylinder, Piston and Piston Ring Inspection ...1D-123
Piston Pin and Connecting Rod Inspection.....1D-124
Crank Pin and Connecting Rod Bearing
Inspection......................................................1D-125
Main Bearing, Crankshaft and Cylinder Block
Components..................................................1D-128
Main Bearing, Crankshaft and Cylinder Block
Removal and Installation...............................1D-129
Main Bearing, Crankshaft and Cylinder Block
Inspection......................................................1D-132
Main Bearing Inspection .................................1D-133
Cylinder Block Inspection................................1D-137
Specifications...................................................1D-137
Tightening Torque Specifications....................1D-137
Special Tools and Equipment .........................1D-138
Recommended Service Material .....................1D-138
Special Tool ....................................................1D-139
Engine Lubrication System .................... 1E-1
K14B ......................................................................... 1E-1
General Description ............................................. 1E-1
Engine Lubrication Description ........................... 1E-1
Diagnostic Information and Procedures............ 1E-2
Oil Pressure Check ............................................. 1E-2
Repair Instructions .............................................. 1E-3
Engine Oil and Filter Change .............................. 1E-3
Oil Pressure Switch On-Vehicle Inspection......... 1E-5
Oil Pan and Oil Pump Strainer Components....... 1E-5
Oil Pan and Oil Pump Strainer Removal and
Installation......................................................... 1E-6
Oil Pump Assembly Components ....................... 1E-8
Oil Pump Assembly Removal and Installation .... 1E-9
Oil Pump Assembly Disassembly and
Reassembly ...................................................... 1E-9
Oil Pump Inspection .......................................... 1E-10
Specifications..................................................... 1E-13
Tightening Torque Specifications...................... 1E-13
Special Tools and Equipment ........................... 1E-14
Recommended Service Material ....................... 1E-14
Special Tool ...................................................... 1E-14
D13A ....................................................................... 1E-15
Diagnostic Information and Procedures.......... 1E-15
Oil Pressure Check ........................................... 1E-15
Repair Instructions ............................................ 1E-16
Engine Oil and Filter Change ............................ 1E-16
Oil Pressure Switch On-Vehicle Inspection....... 1E-17
Oil Pressure Switch Removal and Installation .. 1E-17
Oil Cooler Components..................................... 1E-18
Oil Cooler Removal and Installation.................. 1E-18
Oil Pan Components ......................................... 1E-19
Oil Pan Removal and Installation ...................... 1E-19
Oil Pump / Oil Pump Strainer Components....... 1E-21
Oil Pump / Oil Pump Strainer Removal and
Installation....................................................... 1E-21
Oil Pump Disassembly and Reassembly .......... 1E-21
Oil Pump Strainer Cleaning .............................. 1E-22
Oil Pump Inspection .......................................... 1E-22
Specifications..................................................... 1E-22
Tightening Torque Specifications...................... 1E-22
Table of Contents 1-v
Special Tools and Equipment ...........................1E-23
Recommended Service Material .......................1E-23
Special Tool ......................................................1E-23
Engine Cooling System ...........................1F-1
K14B ......................................................................... 1F-1
Precautions........................................................... 1F-1
Precautions for Cooling System.......................... 1F-1
General Description ............................................. 1F-1
Cooling System Description ................................ 1F-1
Coolant Description............................................. 1F-1
Cooling Fan Operation Description ..................... 1F-1
Schematic and Routing Diagram ........................ 1F-3
Coolant Circulation.............................................. 1F-3
Radiator Cooling Fan Control System Circuit
Diagram............................................................. 1F-3
Diagnostic Information and Procedures ............ 1F-5
Engine Cooling Symptom Diagnosis................... 1F-5
Radiator Cooling Fan System Check .................. 1F-6
Repair Instructions .............................................. 1F-9
Cooling System Components.............................. 1F-9
Coolant Level Check ........................................... 1F-9
Engine Cooling System Inspection ................... 1F-10
Cooling System Draining................................... 1F-10
Cooling System Refilling ................................... 1F-10
Cooling Water Pipe or Hose Removal and
Installation ....................................................... 1F-11
Thermostat Assembly (Incorporating with
ECT Sensor) Removal and Installation ........... 1F-11
Thermostat Assembly (Incorporating with
ECT Sensor) Inspection .................................. 1F-11
Radiator Cooling Fan Assembly On-Vehicle
Inspection........................................................ 1F-12
Radiator Cooling Fan Relay Inspection............. 1F-13
Radiator Cooling Fan Assembly Removal and
Installation ....................................................... 1F-13
Radiator Cooling Fan Disassembly and
Reassembly .................................................... 1F-14
Radiator On-Vehicle Inspection and Cleaning .. 1F-14
Radiator Removal and Installation .................... 1F-15
Water Pump Removal and Installation.............. 1F-15
Water Pump Inspection..................................... 1F-16
Specifications..................................................... 1F-16
Tightening Torque Specifications...................... 1F-16
Special Tools and Equipment ........................... 1F-16
Recommended Service Material ....................... 1F-16
Special Tool ...................................................... 1F-16
D13A ....................................................................... 1F-17
Precautions......................................................... 1F-17
Precautions for Cooling System........................ 1F-17
General Description ........................................... 1F-17
Cooling System Description .............................. 1F-17
Coolant Description........................................... 1F-17
Coolant Degassing Tank Description................ 1F-17
Schematic and Routing Diagram ...................... 1F-18
Coolant Circulation............................................ 1F-18
Diagnostic Information and Procedures .......... 1F-19
Engine Cooling Symptom Diagnosis................. 1F-19
1-vi Table of Contents
Radiator Fan Control System Inspection .......... 1F-19
Repair Instructions ............................................ 1F-21
Cooling System Components............................ 1F-21
Coolant Level Check ......................................... 1F-22
Engine Cooling System Inspection and
Cleaning .......................................................... 1F-22
Cooling System Draining................................... 1F-23
Cooling System Flush and Refill ....................... 1F-23
Cooling System Refill ........................................ 1F-24
Cooling Water Pipe or Hose Removal and
Installation ....................................................... 1F-24
Thermostat Assembly Removal and
Installation ....................................................... 1F-24
Radiator Cooling Fan Assembly On-Vehicle
Inspection........................................................ 1F-24
Radiator Cooling Fan Relay Inspection............. 1F-25
Radiator Cooling Fan Assembly Removal and
Installation ....................................................... 1F-25
Radiator On-Vehicle Inspection and Cleaning .. 1F-27
Radiator Removal and Installation .................... 1F-27
Water Pump Removal and Installation.............. 1F-28
Water Pump Inspection..................................... 1F-28
Specifications..................................................... 1F-28
Tightening Torque Specifications...................... 1F-28
Special Tools and Equipment ........................... 1F-29
Special Tool ...................................................... 1F-29
Fuel System ............................................. 1G-1
K14B ........................................................................ 1G-1
Precautions.......................................................... 1G-1
Precautions for Fuel System Service ................. 1G-1
General Description ............................................ 1G-2
Fuel System Description .................................... 1G-2
Fuel Delivery System Description ...................... 1G-2
Fuel Pump Description....................................... 1G-2
Schematic and Routing Diagram....................... 1G-3
Fuel Delivery System Diagram........................... 1G-3
Fuel Injector Control System Circuit Diagram .... 1G-3
Fuel Pump Control System Circuit Diagram ...... 1G-4
Diagnostic Information and Procedures........... 1G-5
Fuel System Inspection...................................... 1G-5
Power Balance Test ........................................... 1G-6
Fuel Injector Circuit Check ................................. 1G-6
Fuel Pump and Its Circuit Check........................ 1G-8
Fuel Pressure Check........................................ 1G-11
Fuel Pressure Basic Check.............................. 1G-12
Repair Instructions ........................................... 1G-14
Fuel System Components................................ 1G-14
Fuel Hose Disconnection and Reconnection ... 1G-14
Fuel Pressure Relief Procedure ....................... 1G-16
Fuel Leakage Check Procedure....................... 1G-16
Fuel Lines On-Vehicle Inspection .................... 1G-17
Fuel Pipe Removal and Installation.................. 1G-17
Fuel Injector On-Vehicle Inspection ................. 1G-17
Fuel Injector Removal and Installation ............. 1G-18
Fuel Injector Inspection .................................... 1G-19
Fuel Filler Cap Inspection ................................ 1G-20
Fuel Tank Removal and Installation................. 1G-21
Fuel Tank Inspection........................................ 1G-22
Fuel Tank Flushing Procedure ......................... 1G-23
Fuel Pump On-Vehicle Inspection.................... 1G-23
Fuel Pump Assembly Removal and
Installation ...................................................... 1G-24
Fuel Pump Inspection ...................................... 1G-24
Fuel Level Sensor Removal and Installation.... 1G-24
Fuel Level Sensor Inspection........................... 1G-25
Fuel Filter Removal and Installation................. 1G-25
Specifications .................................................... 1G-25
Tightening Torque Specifications..................... 1G-25
Special Tools and Equipment .......................... 1G-27
Special Tool ..................................................... 1G-27
D13A ...................................................................... 1G-28
Precautions........................................................ 1G-28
Precautions for Fuel System Service ............... 1G-28
General Description .......................................... 1G-31
Fuel System Description .................................. 1G-31
Diagnostic Information and Procedures ......... 1G-33
Low-Pressure Fuel Supply Circuit Check......... 1G-33
High-Pressure Fuel Supply Circuit Check ........ 1G-35
Repair Instructions ........................................... 1G-38
Fuel Hose Disconnecting and Reconnecting ... 1G-38
Fuel Pressure Relief Procedure ....................... 1G-39
Fuel Leakage Check Procedure....................... 1G-40
Water Draining of Fuel Filter ............................ 1G-40
Air Bleeding of Fuel System............................. 1G-40
Fuel System Components................................ 1G-41
High Pressure Pipe Removal and Installation .. 1G-43
Fuel Injector On-Vehicle Inspection ................. 1G-45
Fuel Injector Removal and Installation ............. 1G-46
Common Rail Removal and Installation ........... 1G-47
High Pressure Pump Removal and
Installation ...................................................... 1G-48
Fuel Pressure Sensor Removal and
Installation ...................................................... 1G-50
Fuel Flow Actuator On-Vehicle Inspection ....... 1G-50
Fuel Line and Connection Inspection............... 1G-51
Fuel Pipe Removal and Installation.................. 1G-51
Fuel Filler Cap Inspection ................................ 1G-52
Fuel Tank On-Vehicle Inspection ..................... 1G-52
Fuel Tank Removal and Installation................. 1G-53
Fuel Tank Inspection........................................ 1G-54
Fuel Tank Flushing Procedure ......................... 1G-55
Fuel Pump On-Vehicle Inspection.................... 1G-55
Fuel Pump Assembly Removal and
Installation ...................................................... 1G-55
Fuel Pump Inspection ...................................... 1G-56
Fuel Level Sensor Inspection........................... 1G-56
Fuel Filter Element Removal and Installation... 1G-56
Fuel Filter Assembly Removal and Installation . 1G-58
Fuel Temperature Sensor Removal and
Installation ...................................................... 1G-58
Fuel Temperature Sensor Inspection ............... 1G-58
Fuel Filter Water Detection Sensor Inspection . 1G-58
Specifications .................................................... 1G-59
Tightening Torque Specifications..................... 1G-59
Special Tools and Equipment .......................... 1G-59
Special Tool ..................................................... 1G-59

Ignition System........................................ 1H-1
General Description .............................................1H-1
Ignition System Construction ..............................1H-1
Schematic and Routing Diagram........................1H-2
Ignition System Circuit Diagram..........................1H-2
Component Location ...........................................1H-3
Ignition System Component Location .................1H-3
Diagnostic Information and Procedures............1H-4
Ignition System Check ........................................1H-4
Ignition Spark Test ..............................................1H-6
Repair Instructions ..............................................1H-6
Spark Plug Removal and Installation ..................1H-6
Spark Plug Inspection .........................................1H-6
Ignition Coil Assembly Removal and
Installation.........................................................1H-7
Ignition Coil Assembly Inspection .......................1H-7
Ignition Timing Inspection ...................................1H-7
Specifications.......................................................1H-8
Tightening Torque Specifications........................1H-8
Special Tools and Equipment .............................1H-8
Special Tool ........................................................1H-8
Starting System .........................................1I-1
K14B .......................................................................... 1I-1
Schematic and Routing Diagram......................... 1I-1
Cranking System Circuit Diagram ........................ 1I-1
Diagnostic Information and Procedures............. 1I-1
Cranking System Symptom Diagnosis................. 1I-1
Cranking System Test.......................................... 1I-2
Repair Instructions ............................................... 1I-3
Starting Motor Components ................................. 1I-3
Starting Motor Removal and Installation .............. 1I-4
Starting Motor Inspection ..................................... 1I-5
Specifications........................................................ 1I-8
Cranking System Specifications........................... 1I-8
Tightening Torque Specifications......................... 1I-8
Special Tools and Equipment .............................. 1I-8
Recommended Service Material .......................... 1I-8
D13A .......................................................................... 1I-9
General Description .............................................. 1I-9
Cranking System Description............................... 1I-9
Schematic and Routing Diagram......................... 1I-9
Cranking System Circuit Diagram ........................ 1I-9
Diagnostic Information and Procedures............. 1I-9
Cranking System Symptom Diagnosis................. 1I-9
Repair Instructions ............................................. 1I-10
Starting Motor Control Relay Inspection ............ 1I-10
Starting Motor Removal and Installation ............ 1I-11
Starting Motor Components ............................... 1I-13
Starting Motor Disassembly and Reassembly ... 1I-14
Starting Motor Inspection ................................... 1I-17
Specifications...................................................... 1I-20
Cranking System Specifications......................... 1I-20
Tightening Torque Specifications....................... 1I-20
Special Tools and Equipment ............................ 1I-21
Recommended Service Material ........................ 1I-21
Special Tool ....................................................... 1I-21
Table of Contents 1-vii
Charging System ......................................1J-1
K14B ......................................................................... 1J-1
Precautions........................................................... 1J-1
Precautions for Handling Battery ........................ 1J-1
General Description ............................................. 1J-1
Battery Description.............................................. 1J-1
Generator Description ......................................... 1J-4
Diagnostic Information and Procedures ............ 1J-6
Battery Inspection ............................................... 1J-6
Generator Symptom Diagnosis ........................... 1J-6
Generator Test .................................................... 1J-8
Repair Instructions .............................................. 1J-8
Jump-Starting in Case of Emergency ................. 1J-8
Battery Removal and Installation ........................ 1J-9
Water Pump / Generator Drive Belt Tension
Inspection and Adjustment.............................. 1J-10
Water Pump / Generator Drive Belt Removal
and Installation ................................................ 1J-11
Generator Removal and Installation.................. 1J-12
Generator Bracket Removal and Installation .... 1J-12
Generator Components..................................... 1J-13
Generator Disassembly and Reassembly......... 1J-13
Generator Inspection......................................... 1J-16
Specifications..................................................... 1J-19
Charging System Specifications ....................... 1J-19
Tightening Torque Specifications...................... 1J-19
Special Tools and Equipment ........................... 1J-19
Special Tool ...................................................... 1J-19
D13A ....................................................................... 1J-20
Precautions......................................................... 1J-20
Precautions for Handling Battery ...................... 1J-20
General Description ........................................... 1J-20
Battery Description............................................ 1J-20
Generator Description ....................................... 1J-21
Diagnostic Information and Procedures .......... 1J-22
Battery Inspection ............................................. 1J-22
Generator Symptom Diagnosis ......................... 1J-22
Generator Test .................................................. 1J-23
Repair Instructions ............................................ 1J-24
Jump-Starting in Case of Emergency ............... 1J-24
Battery Removal and Installation ...................... 1J-24
Accessory Drive Belt Tension Inspection.......... 1J-25
Accessory Drive Belt Removal and
Installation ....................................................... 1J-25
Accessory Drive Belt Tensioner Removal and
Installation ....................................................... 1J-25
Generator Removal and Installation.................. 1J-26
Generator Components..................................... 1J-27
Generator Disassembly and Reassembly......... 1J-27
Generator Inspection......................................... 1J-32
Specifications..................................................... 1J-34
Charging System Specifications ....................... 1J-34
Tightening Torque Specifications...................... 1J-34
Special Tools and Equipment ........................... 1J-35
Special Tool ...................................................... 1J-35
Exhaust System ....................................... 1K-1
K14B .........................................................................1K-1
1-viii Table of Contents
General Description .............................................1K-1
Exhaust System Description ............................... 1K-1
Diagnostic Information and Procedures............1K-1
Exhaust System Check ....................................... 1K-1
Repair Instructions ..............................................1K-2
Exhaust System Components............................. 1K-2
Exhaust Manifold Removal and Installation ........ 1K-3
Exhaust Pipe and Muffler Removal and
Installation ......................................................... 1K-4
Specifications.......................................................1K-4
Tightening Torque Specifications........................ 1K-4
D13A .........................................................................1K-5
General Description .............................................1K-5
Exhaust System Description ...............................1K-5
Diagnostic Information and Procedures ............1K-5
Exhaust System Check .......................................1K-5
Repair Instructions ..............................................1K-6
Exhaust System Components.............................1K-6
Exhaust Manifold Components ...........................1K-6
Exhaust Manifold Removal and Installation ........1K-7
Exhaust Manifold Inspection ...............................1K-8
Catalytic Converter Removal and Installation .....1K-8
Exhaust Pipe and Muffler Removal and
Installation .........................................................1K-9
Specifications .......................................................1K-9
Tightening Torque Specifications........................1K-9

Precautions
Engine
Precautions
Precautions for Engine (K14B)
AENBL80A1000001
Air Bag Warning
Refer to “Air Bag Warning” in Section 00 (Page 00-5).
Precautions on Fuel System Service
Refer to “Precautions for Fuel System Service”: K14B in
Section 1G (Page 1G-1).
Precautions for CAN Communication System
Refer to “Precautions for CAN Communication System”
in Section 00 (Page 00-8).
Precautions for Catalytic Converter
Refer to “Precautions for Catalytic Converter (Petrol
Engine Model)” in Section 00 (Page 00-5).
Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3).
Reassembling Note for Wiring Harness
Be sure to observe the Wiring Diagram Manual
whenever installing wiring harness.
Otherwise, electrical trouble may occur.
Precautions for Engine Service
! CAUTION
The following information on engine service
should be noted carefully, as it is important in
preventing damage to engine and ensuring
reliable engine performance.
• When supporting or removing engine, do not apply
excessive force to oil pan since that may deform or
damage it. Deformed or damaged oil pan could cause
oil leakage or lubrication failure.
• It should be kept in mind, while working on engine,
that 12-volt electrical system involves danger of
violent and damaging short circuits.
When performing any work where electrical terminals
can be grounded, disconnect negative (–) at battery.
• Any time the air cleaner, throttle body or intake
manifold is removed, the intake opening must be
covered. This prevents entrance of foreign material
which would otherwise reach cylinder through intake
passage and cause extensive damage to engine
when engine is started.
• When disconnecting connectors, do not pull wire
harness but make sure to hold connector itself. With
lock type connector, be sure to unlock before
disconnection.
Precautions: 1-1
Attempt to disconnect connector without unlocking
may result in damage to connector. When connecting
lock type connector, insert it till clicking sound is heard
and connect it securely.
IYSQ01110001-01
Precautions for Diagnosing Trouble
Diagnostic information stored in ECM memory can be
cleared as well as checked using SUZUKI scan tool or
CAN communication OBD generic scan tool. Before
using scan tool, read its operator’s (instruction) manual
carefully to know how to use it.
• MIL is turned on by command from ECM. Therefore,
check ECM for DTC when MIL lights up.
• Priorities for diagnosing troubles:
If two or more DTCs are stored, perform DTC
troubleshooting for these DTCs beginning with the
DTC detected earliest while following the instructions
if given in the troubleshooting procedure.
If no instructions are given, troubleshoot DTCs
according to the following priorities.
a. DTCs other than DTC P0171 / P0172 (Fuel
system too lean / too rich) and DTC P0300 /
P0301 / P0302 / P0303 / P0304 (Misfire detected)
b. DTC P0171 / P0172 (Fuel system too lean / too
rich)
c. DTC P0300 / P0301 / P0302 / P0303 / P0304
(Misfire detected)
• Be sure to read “Precautions for Electrical Circuit
Service” in Section 00 (Page 00-3) before inspection
and observe what is written there.
• Communication of ECM and other control module is
established by CAN. (For more detail of CAN
communication for ECM, refer to “CAN
Communication System Diagnosis General
Description”: K14B Model in Section 10H (Page 10H-
2)). Therefore, handle CAN communication line with
care referring to “Precautions for CAN
Communication System” in Section 00 (Page 00-8).
• Before performing troubleshooting, be sure to read
“Precautions for ECM Circuit Inspection” (Page 1-2).
• Upon completion of inspection and repair work,
perform “DTC Confirmation Procedure” and confirm
that the trouble has been repaired.
1-2 Precautions:
Precautions for Replacing ECM
• ECM must be replace with new one. Before
replacement of the ECM, check for the following
conditions. Neglecting this check may cause damage
to new ECM.
– Resistance values of all relays and actuators are as
specified.
– TP sensor, APP sensor, MAP sensor and A/C
refrigerant pressure sensor are in good condition
and none of their power circuits is shorted to
ground.
• Perform “Procedure after ECM Replacement”: K14B
in Section 1C (Page 1C-2).
Precautions for ECM Circuit Inspection
Do not measure circuit voltage and/or pulse signal of
ECM by inserting tester probe into a sealed terminal of
ECM.
When measuring circuit voltage and/or pulse signal of
ECM, be sure to connect service wires (5) to terminals of
each sensor / actuator (1) and sensor / actuator
connector (2). Otherwise, sealed terminals, ECM and its
circuits may be damaged.
3 Be sure to observe the Wiring Diagram Manual
1 Otherwise, electrical trouble may occur.
2
5 should be noted carefully, as it is important in
4 • When supporting or removing engine, do not apply
I8C50A110001-02
3. Voltmeter 4. Oscilloscope
Precautions for Electric Throttle Control System
Calibration
Completely closed and opened throttle valve positions
data are stored in ECM.
(For details of Electric Throttle Control System
Calibration, refer to “Description of Electric Throttle
Control System Calibration”: K14B in Section 1A (Page
1A-5))
After performing any one of the following services, it is
necessary to calibrate the completely closed and
opened throttle valve positions stored in ECM. )(Page
1C-4)
• Replacement of ECM
• Clearance of DTC related to electric throttle control
system (P0607, P0122, P0123, P0222, P0223,
P2100, P2101, P2119, P2122, P2123, P2127, P2128,
P2135, P2138 or P2176)
• Replacement of electric throttle body assembly or
accelerator pedal assembly with APP sensor
• Disconnecting negative (–) cable at battery
Precautions for Engine (D13A)
AENBL80A1000002
Air Bag Warning
Refer to “Air Bag Warning” in Section 00 (Page 00-5).
Precautions on Fuel System Service
Refer to “Precautions for Fuel System Service”: D13A in
Section 1G (Page 1G-28).
Precautions for CAN Communication System
Refer to “Precautions for CAN Communication System”
in Section 00 (Page 00-8).
Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3).
Precautions for Catalytic Converter
Refer to “Precautions for Catalytic Converter (Diesel
Engine Model)” in Section 00 (Page 00-5).
Reassembling Note for Wiring Harness
whenever installing wiring harness.
Precautions for Engine Service
! CAUTION
The following information on engine service
preventing damage to engine and ensuring
reliable engine performance.
excessive force to oil pan since that may deform or
damage it. Deformed or damaged oil pan could cause
oil leakage or lubrication failure.
• It should be kept in mind, while working on engine,
that 12-volt electrical system involves danger of
violent and damaging short circuits.
When performing any work where electrical terminals
could possibly be grounded, disconnect negative (–)
cable at battery.
• Any time the air cleaner, air cleaner outlet hose,
turbocharger, intercooler, intercooler outlet hose or
intake manifold is removed, the intake opening must
be covered. This prevents entrance of foreign material
which would otherwise reach cylinder through intake
passage and cause extensive damage to engine
when engine is started.
• When disconnecting connectors, do not pull wire
harness but make sure to hold connector itself. With
lock type connector, be sure to unlock before
disconnection.
 Precautions: 1-3

Attempt to disconnect connector without unlocking Precautions for Replacing ECM

may result in damage to connector. When connecting
lock type connector, insert it till clicking sound is heard
and connect it securely.
• ECM must be replaced with new one.
When ECM is replaced with new one, register vehicle
information to new ECM according to “Registration for
ECM Replacement”: D13A in Section 1C (Page 1C-
15).
• If vehicle information is not registered, engine cannot
be stared or original engine performance will be
affected even if engine is started.

Precautions of ECM Circuit Inspection

Do not measure circuit voltage and/or pulse signal of
ECM by inserting tester probe into a sealed terminal of
IYSQ01110001-01 ECM.
When measuring circuit voltage and/or pulse signal of
Precautions for Diagnosing Trouble ECM, be sure to connect service wires (5) to terminals of
• Do not disconnect connectors from ECM, battery each sensor / actuator (1) and sensor / actuator
cable at battery, ECM ground wire harness from connector (2). Otherwise, sealed terminals, ECM and its
engine or fuse before confirming diagnostic circuits may be damaged.
information (DTC) stored in ECM memory.
Such disconnection will erase memorized information
3
in ECM memory.
• Diagnostic information stored in ECM memory can be 1
cleared as well as checked using SUZUKI scan tool.
Before using scan tool, read its operator’s (instruction)
manual carefully to know how to use it.
• Be sure to read “Precautions for Electrical Circuit
Service” in Section 00 (Page 00-3) before inspection 2
and observe what is written there.
5
• ECM communication lines consist of CAN-line and K-
line.
K-line is provided for scan tool to communicate with
ECM via DLC. 4
Either of SUZUKI scan tool (SUZUKI-SDT) or OBD I8C50A110001-02

generic scan tool can be used through K-line. For 3. Voltmeter 4. Oscilloscope
details, refer to “DLC Description”: D13A in Section
1A (Page 1A-125).
Through CAN-line, ECM communicates with each
control module.
For details of CAN communication, refer to
“Communication System Description”: D13A Model in
Section 10H (Page 10H-21). Since CAN-line is
sensitive handle CAN communication line with care,
referring to “Precautions for CAN Communication
System” in Section 00 (Page 00-8).
1A-1 Engine General Information and Diagnosis: K14B

Engine General Information and Diagnosis

Engine

K14B
General Description
Statement on Cleanliness and Care OBD System Description
AENBL80A1111001 AENBL80A1111003
An automobile engine is a combination of many General Description
machined, honed, polished and lapped surfaces with ECM in this model has the following functions.
tolerances that are of the order of thousands of a • When ignition is “ON” with the engine at a stop, MIL
millimeter (ten thousandths of an inch). (1) turns on to check the circuit of the MIL (1).
Accordingly, when any internal engine parts are
• When ECM detects a malfunction which gives an
serviced, care and cleanliness are important.
adverse effect to vehicle emission while the engine is
It should be understood that proper cleaning and
running, ECM makes the MIL (1) in the meter cluster
protection of machined surfaces and friction areas is part
of the instrument panel turn on or blink (blinking only
of the repair procedure. This is considered standard
when detecting a misfire which can cause damage to
shop practice even if not specifically stated.
the catalyst) and stores the malfunction area in its
• A liberal coating of engine oil should be applied to memory.
friction areas during assembly to protect and lubricate (If ECM detects a malfunction only in the first driving
the surfaces on initial operation. cycle (refer to “Driving Cycle”: K14B (Page 1A-2).) but
• Whenever valve train components, pistons, piston does not detect the same malfunction in the next 2
rings, connecting rods, rod bearings, and crankshaft consecutive driving cycles, ECM does not turn on MIL
journal bearings are removed for service, they should (1) although it retains the associated DTC in its
be retained in order. memory.)
At the time of installation, they should be installed in • For some malfunctions, ECM adopts the 3 driving
the original locations and with the same mating cycle detection logic (refer to “3 Driving Cycle
surfaces as when removed. Detection Logic”: K14B (Page 1A-2)) to prevent
• Battery cables should be disconnected before any erroneous detection.
major work is performed on the engine. With this logic, MIL is turned on when the same
Failure to disconnect cables may result in damage to malfunction is detected in 3 consecutive driving
wire harness or other electrical parts. cycles.
• The four cylinders of the engine are identified by • When a malfunction is detected, engine and driving
numbers; No.1, No.2, No.3 and No.4 counted from conditions at the moment the malfunction was
crankshaft pulley side to flywheel side. detected are stored in ECM memory as freeze frame
data. (For the details, refer to description on “Freeze
Engine Diagnosis General Description frame data clearance:”: K14B (Page 1A-3).)
AENBL80A1111002
• It is possible to communicate via DLC (3) using not
The engine and emission control system in this vehicle
only SUZUKI scan tool (2) but also CAN
are controlled by ECM. ECM has an OBD system which
communication OBD generic scan tool. (Diagnostic
detects a malfunction in this system and abnormality of
information can be accessed using a scan tool.)
those parts that influence the engine exhaust emission.
When diagnosing engine troubles, be sure to have full
understanding of the outline of “OBD System
Description”: K14B (Page 1A-1) and each item in
“Precautions for Diagnosing Trouble” under “Precautions
for Engine (K14B)” in Section 1 (Page 1-1) and execute
diagnosis according to “Engine and Emission Control
System Check”: K14B (Page 1A-15).
There is a close relationship between the engine
mechanical, engine cooling system, ignition system,
exhaust system, etc. and the engine and emission
control system in their structure and operation. In case of
an engine trouble, even when the MIL does not turn ON,
it should be diagnosed according to “Engine and
Emission Control System Check”: K14B (Page 1A-15).
 Engine General Information and Diagnosis: K14B 1A-2

Freeze Frame Data

[A] ECM stores the engine and driving conditions at the
moment of the detection of a malfunction in its memory.
This data is called “Freeze frame data”.
Therefore, it is possible to know engine and driving
conditions (e.g., whether the engine was warm or not,
where the vehicle was running or stopped, where air/fuel
mixture was lean or rich) when a malfunction was
[B]
detected by checking the freeze frame data. Also, ECM
has a function to store each freeze frame data for three
1 different malfunctions in the order of their detection.
Utilizing this function, it is possible to know the order of
detection of these malfunctions. This is helpful when
rechecking or diagnosing a problem.
For details of freeze data that can be read from ECM,
refer to the following table.
DTC
Fuel System
Calculated Load
ECT
Short Term Fuel Trim
2
Long Term Fuel Trim
MAP
3
Engine Speed
Vehicle Speed
Ignition Advance
Intake Air Temperature
Absolute TP 1*
Time Since Engine Start
EVAP Canist Prg Duty
IBP80A111002-01
Fuel Tank Level
[A]: Without tachometer [B]: With tachometer Barometric Pres
Battery Voltage
Warm-Up Cycle Relative TP**
A “warm-up cycle” means keeping the engine operating Absolute TP 2*
after the start until the coolant temperature rises by at Absolute APP 1*
least 22 °C (40 °F) or reaches a minimum temperature of Absolute APP 2*
71 °C (160 °F). Target Throt Pos

Driving Cycle NOTE

A “Driving Cycle” is a duration from an engine startup to
the following engine shutoff. • Freeze frame data with asterisk (*)
indicates the ratio of the output voltage to
3 Driving Cycle Detection Logic the power supply voltage of related sensor.
The malfunction detected in the first driving cycle is When power supply voltage is 5.0 V and
stored in ECM memory (in the form of pending DTC) but output voltage is 4.0 V, freeze frame data is
MIL does not light at this time. ECM causes the MIL to displayed as follows.
light up when it detects third time the same malfunction – For systems where the output is
in the next two driving cycles. proportional to the input voltage, it
displays 80% (= the percent of maximum
Pending DTC input reference voltage).
“Pending DTC” is relevant to those DTCs to which the “3 – For systems where the output is
driving cycle detection logic” is applied. If such a DTC is inversely proportional to the input
detected and stored temporarily during the first of three voltage, it displays 20% (=100% minus
consecutive driving cycles, the DTC is called “pending the percent of maximum input reference
DTC”. voltage).
1A-3 Engine General Information and Diagnosis: K14B

• For relative TP with asterisks (**) in above

table, it indicates value calculated by Freeze frame data (for example)
formula ((output voltage – output voltage
Function View System Bar Help
at closed throttle position) / power supply
voltage). Engine / Powertrain / Freeze Frame Data

When power supply voltage is 5.0 V and Engine Coolant Temperature Sensor1
P0118
Circuit High
output voltage at closed throttle position is
Parameter Value Unit
1.0 V, freeze frame data is displayed as
DTC P0118
follows. Fuel System -
– At closed throttle position (output Calculated Load 0.00 %
voltage = 1.0 V), it displays 0%. ECT -40 C
Short Term Fuel Trim 0.00 %
– At wide open throttle position (output
Long Term Fuel Trim 0.00 %
voltage = 4.0 V), it displays 60%. MAP 102 kPa
However, for systems where the output is Engine Speed 0 rpm
inversely proportional to the input voltage, it Vehicle Speed 0 km/h
displays 100% minus above mentioned
Exit
formula.
Data Active
DTC View Utility
List Test
I9R90A111029-01

Details of freeze frame data:

ECM has 4 freeze frames from 0 to 3 where freeze frame data can be stored.
Frame 0 is a special frame limited for freeze frame data that MIL turns on.
Frames 1 to 3 are assigned to store DTCs in detected order whether MIL turn on or not.
ECM stores 3 freeze frame data maximum, that is, DTCs are stored in detected order and a DTC that turns on MIL is
stored in frame 0 as well.
If more than 2 DTCs that turn on MIL are detected, the first DTC is stored in frame 0.
If more than 3 DTCs are detected, frames 0 to 3 are stored fully. Therefore, it is not possible to access to the 4th DTC.
In this situation, when a malfunction stored in frame 0 to 3 is resolved, the next DTC becomes accessible.

Frame 0 Frame 1 Frame 2 Frame 3

Freeze frame 1st freeze frame 2nd freeze frame 3rd freeze frame
data data data data
1 No DTC
2 P0530 P0530 data
DTC 3 P0480 P0530 data P0480 data
detection
order 4 P0443 P0443 data P0530 data P0480 data P0443 data
5 P0171 P0443 data P0530 data P0480 data P0443 data
6 P0112 P0443 data P0530 data P0480 data P0443 data
IBL80A111007-01
—: No freeze frame data

Freeze frame data clearance:

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

System Readiness Test

The system readiness test is performed for the purpose of confirming that each of the exhaust-emission-related
systems fulfills the conditions that allow ECM to detect a malfunction if it occurs and to set the corresponding DTC.
The test is carried out by monitoring the specific items (components) using a scan tool (SUZUKI scan tool or CAN
communication OBD generic scan tool). When the test shows that the conditions pre-established for the tested system
are met, ECM performs an on-board diagnosis of the system, changes the status of the system readiness test from
“Incomplete” to “Complete”, and causes the “Complete” status to be displayed on the scan tool.
The “Complete” status is maintained until DTC clearance operation is performed using the scan tool.
 Engine General Information and Diagnosis: K14B 1A-4

NOTE
• The system readiness test status may change from “Complete” to “Incomplete” if any of the
following service operations is performed.
– Disconnection of battery negative (–) cable
– Disconnection of ECM connectors
– Removal of ECM ground cable
• The items (components) indicated in the following table are monitored in the system readiness test
to confirm the readiness for detecting the DTCs listed beside each monitoring item.
• The “Complete” or “Incomplete” status identified through the system readiness test does NOT
mean the “Normal” or “Abnormal” result of the on-board diagnosis.

Monitoring item of system readiness test table

Monitoring item DTC related to monitoring item
Catalyst P0420 — —
O2 Sensor P0133 P2270 P2271

DLC Description
AENBL80A1111004
DLC (1) is in compliance with SAE J1962 in the shape of
connector and pin assignment.
OBD CAN High line (6) and Low line (3) (CAN line of ISO
15765-4) are used for SUZUKI scan tool (SUZUKI-SDT)
(A) or CAN communication OBD generic scan tool to
communicate with ECM and other control modules.
(A)
2
3

16 15 14 13 12 11 10 9 1

8 7 6 5 4 3 2 1

6 5
4
1
I9P60A111002-03
IBP80A111003-01

2. B + (Continuously battery power)

4. ECM ground (Signal ground)
5. Ground (Chassis ground)

Engine and Emission Control System

Description
AENBL80A1111005
The engine and emission control system is divided into 4
major sub-systems: air intake system, fuel delivery
system, electronic control system and emission control
system.
Air intake system includes air cleaner, electric throttle
body assembly and intake manifold.
Fuel delivery system includes fuel pump, delivery pipe,
etc.
Electronic control system includes ECM, various sensors
and controlled devices.
Emission control system includes, EVAP and PCV
systems.

Air Intake System Description

AENBL80A1111006
The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), electric throttle body
assembly (3) and intake manifold (4).
1A-5 Engine General Information and Diagnosis: K14B

The air (by the amount corresponding to throttle valve (5) opening and engine speed) is filtered by the air cleaner,
distributed by the intake manifold, and finally drawn into each combustion chamber. Electric throttle body assembly is
not equipped with IAC valve for idle speed control. Idle speed control is done by the throttle actuator (6) which opens/
closes the throttle valve. (For the details, refer to “Electric Throttle Control System Description”: K14B (Page 1A-5).)

3
6

IBP80A111004-01

Description of Electric Throttle Control System
Calibration
AENBL80A1111007
ECM calculates controlled opening of the throttle valve
on the basis of the completely closed throttle valve
position of the electric throttle control system. The
completely closed position data is saved in memory of
ECM. However, the completely closed position of the
throttle valve of the electric throttle control system (signal
voltage from throttle position sensor when throttle is
completely closed) differs one from the other depending
on individual differences of the throttle valve and throttle
position sensor. As such individual differences must be
taken into account for controlling the throttle valve, it is
necessary to register the completely closed throttle valve
position data in ECM. When such data is registered in
ECM, it is saved in RAM of ECM and used as the base
data for controlling the throttle valve. This data is
cleared, when any of the works described in
“Precautions for Electric Throttle Control System
Calibration” under “Precautions for Engine (K14B)” in
Section 1 (Page 1-1) is performed.
Also, after replacement of the electric throttle body
assembly and/or APP sensor assembly, the completely
closed position data in memory of ECM must be cleared
once and a new one must be registered, or ECM cannot
judge the complete closure position properly.
For the procedure to register such data, refer to “Electric
Throttle Control System Calibration”: K14B in Section 1C
(Page 1C-4). (After the completely closed position data
is cleared from ECM, for the first time only, the throttle
valve opens and closes for about 60 sec. after ignition is
“ON”, for registration of the completely closed throttle
valve position. If the engine is started during this
registration process, such symptom as “longer cranking
time” or “slow rise of engine speed immediately after
start-up” may occur. However, set ignition “OFF” once
and then restarting the engine will register the position to
ECM correctly.)

Electric Throttle Control System Description

AENBL80A1111008
The electric throttle control system consists of the following:
• Electric throttle body assembly incorporating the throttle valve, throttle actuator and TP sensors (main/sub)
• Accelerator pedal assembly incorporating APP sensors (main/sub)
• ECM

Operation Description
ECM (5) detects depressed extent of the accelerator pedal based on the signal voltage of the APP sensor (1). Using
that data and engine operation condition, ECM calculates the optimum throttle valve opening. On the other hand, it
detects the throttle valve opening based on the signal voltage of the TP sensor (3) in the electric throttle body
assembly (2) and compares this value with the above calculated optimum throttle valve opening. When there is a
difference between them, ECM changes the duty ratio (100% to 0%) of throttle actuator control according to this
 Engine General Information and Diagnosis: K14B 1A-6

difference to drive the throttle actuator (4) in the electric throttle body assembly. When there is no difference, ECM
fixes the duty ratio to about 15% to maintain the throttle valve opening. In this way, the throttle valve (13) is opened
and closed to achieve the optimum throttle valve opening.
In this system, TP sensor and APP sensor have 2 sensors (main and sub) each to assure highly accurate and reliable
control and abnormality detection. When ECM detects an abnormality in the system, it stops controlling the throttle
actuator.
This electric throttle body assembly is not equipped with IAC valve for idle speed control. Idle speed control is
performed by the throttle actuator by adjusting the throttle valve opening.

5
8

2 9 3 6
10
1
7

13
11

12

I7Y50A110003-01

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

Electronic Control System Description

AENBL80A1111009
The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2)
ECM which controls various devices according to the signals from the sensors and 3) various controlled devices.
Functionally, the electronic control system is divided into the following sub systems:
• Fuel injection control system
• Ignition control system
• Electric throttle body assembly control system
• Fuel pump control system
• Radiator cooling fan control system
• Evaporative emission control system
• HO2S heater control system
• A/C control system
• Camshaft position control system
• Immobilizer control system
• Controller (computer) communication system
ECM is using CAN communication system to communicate with other control modules. For more detail of CAN
communication, refer to “Communication System Description”: K14B Model in Section 10H (Page 10H-1).
1A-7 Engine General Information and Diagnosis: K14B

Engine and Emission Control Input / Output Table

AENBL80A1111010
Function Output Input
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
Injection control Fuel injector • APP sensor
• MAP sensor
• IAT sensor
• HO2S-1
• HO2S-2
• Battery voltage
• VSS
Fuel injector • Ignition “ON” signal
Immobilizer control
Ignition coil with igniter • BCM
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
Ignition control Ignition coil with igniter
• APP sensor
• MAP sensor
• IAT sensor
• Knock sensor
• Battery voltage
• VSS
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• TP sensor
Idle speed control Throttle actuator
• APP sensor
• MAP sensor
• IAT sensor
• BCM (electric load signal and A/C ON request signal)
• VSS
• Ignition “ON” signal
• ECT sensor
• CKP sensor
• TP sensor
• APP sensor
Throttle valve control Throttle actuator
• MAP sensor
• IAT sensor
• A/C refrigerant pressure sensor
• BCM (electric load signal and A/C OFF/ON request signal)
• ABS control module (torque up request signal)
 Engine General Information and Diagnosis: K14B 1A-8

Function Output Input

• Ignition “ON” signal
• ECT sensor
• CKP sensor
HO2S heater control HO2S
• TP sensor
• IAT sensor
• Battery voltage
• Ignition “ON” signal
• ECT sensor
• CKP sensor
EVAP canister purge
EVAP purge control • TP sensor
valve
• MAP sensor
• IAT sensor
• VSS
• Ignition “ON” signal
• ECT sensor
• CKP sensor
CMP actuator control
OCV • CMP sensor
(VVT control)
• MAP sensor
• TP sensor
• Brake light switch
• Ignition “ON” signal
• ECT sensor
• CKP sensor
• TP sensor
A/C compressor control A/C compressor relay
• APP sensor
• A/C refrigerant pressure sensor
• BCM (A/C ON request signal)
• VSS
• Ignition “ON” signal
• ECT sensor
Radiator cooling fan Radiator cooling fan
• CKP sensor
control relay
• A/C refrigerant pressure sensor
• VSS
• Ignition “ON” signal
Fuel pump control Fuel pump relay
• CKP sensor
Starting motor control Starting motor control • Ignition “ON” signal
relay control relay • CKP sensor
Main relay control Main relay • Ignition “ON” signal
1A-9 Engine General Information and Diagnosis: K14B

Schematic and Routing Diagram

Engine and Emission Control System Diagram
AENBL80A1112001

17

18

19

20

21

23

27
24
22

25

26
28

29
30

31
33

24
32
16

15
2

13

14
12
1

6
4

7
5

11
10
9

IBL80A111001-01
 Engine General Information and Diagnosis: K14B 1A-10

1. Air cleaner 12. Knock sensor 23. Brake light

2. IAT sensor 13. ECT sensor 24. Brake light switch
3. TP sensor 14. HO2S-1 25. Starting motor control relay
4. Throttle actuator 15. HO2S-2 26. Ignition switch
5. MAP sensor 16. OCV 27. Starting motor
6. Ignition coil assembly 17. Radiator cooling fan relay 28. Main relay
7. Fuel injector 18. A/C compressor relay 29. CKP sensor
8. EVAP canister purge valve 19. Electric load signal 30. CMP sensor
9. EVAP canister 20. A/C refrigerant pressure sensor 31. APP sensor
10. Tank vapor control valve 21. VSS 32. CPP switch
11. Fuel pump (with pressure regulator) 22. Other control modules and DLC connected by CAN 33. ECM
 Air Vapor

Exhaust gas Fuel

* : if equipped

Electric throttle body

Air cleaner Intake manifold Engine Exhaust Three-way Exhaust
assembly
manifold catalyst pipe
Throttle TP MAP sensor CMP CKP Knock Ignition coil
IAT sensor
actuator sensor sensor sensor sensor with igniter OCV HO2S-1 HO2S-2
Fuel
injector

EVAP canister ECT

purge valve sensor Heater Heater
Vapor control control
Check Fuel
control
valve pump
valve
EVAP
canister Fuel tank
1A-11 Engine General Information and Diagnosis: K14B

Engine and Emission Control System Flow Diagram

ECM

*ABS control module CPP switch APP sensor

Vehicle speed Blower speed

sensor selector A/C refrigerant Brake light switch
pressure sensor
Combination meter DLC
· MIL
A/C switch BCM · Information display A/C compressor Radiator cooling
· Immobilizer indicator light relay fan relay
· Coolant Temp.
· Speedometer
· Fuel level
· Odometer *Air bag control module
P/S control module · *Tachometer

IBL80A111002-01
AENBL80A1112002
 Engine General Information and Diagnosis: K14B 1A-12

Electronic Control System Circuit Diagram

AENBL80A1112003

2 +B
LT GRN C01-55 29
3 C01-13 BLU/YEL
YEL/RED C01-56
6 30
RED C01-14 C01-37 BLU/WHT
4 31
GRN C01-42
5 C01-25 BLU/RED
WHT C01-30
32
BLK C01-21 C01-1 LT GRN/BLK
BLK C01-35 33
7 C01-38 BLU/BLK
BRN E01-31
34
8 GRN/RED E01-29 C01-46 RED/WHT
IG1
BLU E01-24 C01-19 YEL
RED E01-43 35
9 YEL E01-32
WHT E01-22 36
+B C01-4 GRN/YEL
10
RED/YEL C01-8
C01-17 GRN/WHT
11
PNK C01-9
37
GRY
12
GRY/RED C01-2
38
RED/BLK C01-29 C01-5 BRN
13
BLK/YEL C01-34
C01-6 LT GRN
14
LT GRN C01-32

GRY/BLU C01-20 39
15 E01-49 YEL/RED 40
6
WHT C01-31 P PNK
BLK 41
BLK C01-43
E01-42 LT GRN
+B GRY C01-36 BLU GRY
16 6
BLU C01-41 42
RED C01-40 L+ GRN BLU
44 H+
GRN/WHT C01-54 BLU/BLK GRY
YEL/GRN H-
6 C01-26 43
17 L-
YEL C01-22 E01-41 GRN GRN BLU
BRN C01-27 BLK
RED/BLU C01-49 BLU/WHT
45
YEL/BLK C01-23
E01-37 GRY
18
GRY/RED E01-30 WHT BLU/YEL
46
RED/GRN E01-35
12V E01-55 BLK/RED
BLU/RED E01-14 5V 47
3.3V
19 +B E01-56 BLK/RED BLK/YEL
E01-54 BRN/WHT BLK/YEL
PPL C01-10
BLK/WHT
GRY IG2
+BB 20 48
IG2 BLK YEL/BLK E01-10 54 IG1
+BB E01-5 BLK/WHT GRN
55 ST
BLK RED/WHT BRN
21 YEL RED
23 49
GRN/WHT E01-8
+BB
22 C01-52 BLU/YEL YEL
53 YEL
24
BLU/WHT E01-48 51
25
26 50 M
27
C01-50 BLK 52
RED E01-1 C01-51 BLK
28
WHT E01-2 C01-53 BLK
: 56 : 57 : 12V : 5V : 3.3V
IBL80A111008-01
1A-13 Engine General Information and Diagnosis: K14B

1. ECM 20. CPP switch 39. Fuel pump relay

2. Electric throttle body assembly 21. Brake light switch 40. Fuel pump
3. Throttle actuator 22. Brake light 41. Radiator cooling fan relay No.1
4. TP sensor (main) 23. Heater relay 42. Radiator cooling fan relay No.2
5. TP sensor (sub) 24. Blower motor 43. Radiator cooling fan relay No.3
6. Shield wire 25. Blower speed selector 44. Radiator cooling fan motor
7. APP sensor 26. A/C switch 45. A/C compressor relay
8. APP sensor (main) 27. To BCM 46. A/C compressor
9. APP sensor (sub) 28. Other control modules and DLC connected by CAN 47. Main relay
10. CMP sensor 29. Fuel injector No.1 48. Ignition switch
11. CKP sensor 30. Fuel injector No.2 49. Starting motor control relay
12. MAP sensor 31. Fuel injector No.3 50. Starting motor
13. IAT sensor 32. Fuel injector No.4 51. Main fuse box
14. ECT sensor 33. EVAP canister purge valve 52. Battery
15. Knock sensor 34. OCV 53. “ST SIG2” fuse
16. HO2S-1 35. Ignition coil No.1 54. “IG COIL” fuse
17. HO2S-2 36. Ignition coil No.2 55. “ST SIG” fuse
18. A/C refrigerant pressure sensor 37. Ignition coil No.3 56. Engine ground
19. VSS 38. Ignition coil No.4 57. Ground

Terminal Arrangement of ECM Connector

NOTE
For circuit names and terminal voltages, refer to “Inspection of ECM and Its Circuits”: K14B (Page 1A-
109).

[A] C01 E01

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

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

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

I9P60A111006-02

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

 Engine General Information and Diagnosis: K14B 1A-14

Component Location
Electronic Control System Component Location
AENBL80A1113001

[b] [a]
8 7

[3]

[2]

[c]

3
5, [n]
1 14

[1] [g]
[f] [e]
[j]
9
[i]

[h]
[d]

[4]

[l]
[k] 13
10

[m] 11 12

IBL80A111004-01

Information sensors Control devices Others

1. CKP sensor [a]: MIL [1]: ECM
2. Knock sensor [b]: Immobilizer indicator light [2]: DLC
3. MAP sensor [c]: EVAP canister purge valve [3]: Combination meter
4. IAT sensor [d]: Fuel pump relay [4]: Individual circuit fuse box No.1
5. TP sensor [e]: Starting motor control relay
6. Accelerator pedal assembly (incorporating APP sensor) [f]: A/C compressor relay
7. Brake light switch [g]: Radiator cooling fan relay No.3
8. CPP switch [h]: Radiator cooling fan relay No.1
9. A/C refrigerant pressure sensor [i]: Main relay
10. HO2S-1 [j]: Radiator cooling fan relay No.2
11. HO2S-2 [k]: OCV
12. ECT sensor [l]: Fuel injector
13. CMP sensor [m]: Ignition coil assembly
14. VSS [n]: Electric throttle body assembly
1A-15 Engine General Information and Diagnosis: K14B

Diagnostic Information and Procedures

Engine and Emission Control System Check
AENBL80A1114001
Refer to the following items for the details of each step.
Step Action Yes No
1 Customer complaint analysis )(Page 1A-16) Go to Step 2. Perform customer
1) Perform customer complaint analysis referring to “Step complaint analysis.
1: Customer Complaint Analysis”: K14B (Page 1A-16).

Was customer complaint analysis performed?

2 DTC / Freeze frame data check, record and clearance Print DTCs and freeze Go to Step 4.
)(Page 1A-17) frame data or write them
1) Check for DTCs (including pending DTCs) referring to down and clear them
“Step 2: DTC / Freeze Frame Data Check, Record and referring to “DTC
Clearance”: K14B (Page 1A-17). Clearance”: K14B
(Page 1A-19), and go to
Is there any DTC(s) / Freeze frame data? Step 3.
3 Visual inspection )(Page 1A-18) Repair or replace Go to Step 5.
1) Perform visual inspection referring to “Visual Inspection”: defective part, and go to
K14B (Page 1A-31). Step 11.

Is there any faulty condition?

4 Visual inspection )(Page 1A-18) Repair or replace Go to Step 8.
1) Perform visual inspection referring to “Visual Inspection”: defective part, and go to
K14B (Page 1A-31). Step 11.

Is there any faulty condition?

5 Trouble symptom confirmation )(Page 1A-18) Go to Step 6. Go to Step 7.
1) Confirm trouble symptom referring to “Step 5: Trouble
Symptom Confirmation”: K14B (Page 1A-18).

Is trouble symptom identified?

6 Rechecking and recording DTC / Freeze frame data Go to Step 9. Go to Step 8.
)(Page 1A-18)
1) Recheck for DTC and freeze frame data referring to
“DTC Check”: K14B (Page 1A-18).

Is there any DTC(s)?

7 Rechecking and recording DTC / Freeze frame data Go to Step 9. Go to Step 10.
)(Page 1A-18)
1) Recheck for DTC and freeze frame data referring to
“DTC Check”: K14B (Page 1A-18).

Is there any DTC(s)?

8 Engine basic inspection and engine symptom diagnosis Go to Step 11. Check and repair
)(Page 1A-18) defective part(s), and go
1) Check and repair according to “Engine Basic to Step 11.
Inspection”: K14B (Page 1A-32) and “Engine Symptom
Diagnosis”: K14B (Page 1A-33).

Are check and repair complete?

9 Troubleshooting for DTC )(Page 1A-18) Go to Step 11. Check and repair
1) Check and repair according to applicable DTC defective part(s), and go
troubleshooting. to Step 11.

Are check and repair complete?

 Engine General Information and Diagnosis: K14B 1A-16

Step Action Yes No

10 Intermittent problems check )(Page 1A-18) Repair or replace Go to Step 11.
1) Check for intermittent problems referring to “Step 10: defective part(s), and go
Intermittent Problems Check”: K14B (Page 1A-18). to Step 11.

Is there any faulty condition?

11 Final confirmation test )(Page 1A-18) Go to Step 6. End.
1) Clear DTC if any.
2) Perform final confirmation test referring to “Step 11: Final
Confirmation Test”: K14B (Page 1A-18).

Is there any problem symptom, DTC or abnormal condition?

Step 1: Customer Complaint Analysis

Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose,
use of an inspection form as shown will facilitate collecting information required for proper analysis and diagnosis.
1A-17 Engine General Information and Diagnosis: K14B

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

Customer problem inspection form (Example)

I9P60A111042-01

Step 2: DTC / Freeze Frame Data Check, Record and If DTC is indicated, print it and freeze frame data or write
Clearance them down and then clear them. )(Page 1A-19)
First, check DTC (including pending DTC). )(Page 1A-
18)
 Engine General Information and Diagnosis: K14B 1A-18

Steps 3 and 4: Visual Inspection
As a preliminary step, be sure to perform visual check of
the items that support proper function of the engine.
)(Page 1A-31)
Step 5: Trouble Symptom Confirmation
If there is no DTC in Step 2:
Based on information obtained in “Step 1: Customer
Complaint Analysis”: K14B (Page 1A-16) and “Step 2:
DTC / Freeze Frame Data Check, Record and
Clearance”: K14B (Page 1A-17), confirm trouble
symptoms.
If MIL does not light up but engine can be started, go
to “MIL Does Not Come ON with Ignition “ON” and
Engine Stopped (but Engine Can Be Started)”: K14B
(Page 1A-41) for troubleshooting.
If MIL does not light with ignition “ON” and engine
does not start though it is cranked, go to “ECM
Power Supply and Ground Circuit Check”: K14B
(Page 1A-119).
2) Start engine and check that MIL turns OFF.
If MIL remains ON and no DTC is stored in ECM, go
to “MIL Remains ON after Engine Starts”: K14B
(Page 1A-41) for troubleshooting.

If there is any DTC in Step 2: [A]

Recheck DTC according to “DTC Confirmation
Procedure” described in each DTC troubleshooting.

Steps 6 and 7: Rechecking and Record in DTC /

Freeze Frame Data
Refer to “DTC Check”: K14B (Page 1A-18) for checking
procedure.
[B]

Step 8: Engine Basic Inspection and Engine

1
Symptom Diagnosis
1) Perform basic engine inspection. )(Page 1A-32)
2) If there is no faulty part found in inspection I9P60A111008-01

procedure of “Engine basic inspection”, perform [A]: Without tachometer [B]: With tachometer
“Engine Symptom Diagnosis”: K14B (Page 1A-33)
based on symptom found in vehicle checking in the DTC Check
following steps. AENBL80A1114003

• Customer complaint analysis 1) Prepare SUZUKI scan tool or CAN communication

OBD generic scan tool.
• Trouble symptom confirmation
Special tool
Step 9: Troubleshooting for DTC (A): SUZUKI scan tool (SUZUKI-SDT)
Perform applicable DTC troubleshooting and repair or
2) With ignition “OFF”, connect scan tool to DLC (1).
replace faulty parts.

Step 10: Intermittent Problems Check

If there is no DTC in Step 2:
Check for intermittent problem. )(Page 00-11)

If there is any DTC in Step 2:

Check parts related to detected DTC (e.g., wire harness,
connector, etc.). (A)

Step 11: Final Confirmation Test

1
Confirm that the problem symptom has gone and engine
is free from any abnormal conditions. If what has been
repaired is related to DTC, clear DTC once, perform
DTC confirmation procedure and confirm that no DTC is
indicated.

IBP80A111003-01
MIL Check
AENBL80A1114002 3) Set ignition “ON” and confirm that MIL lights up.
1) Set ignition “ON” (with engine at stop) and check that 4) Read DTC, pending DTC and freeze frame data
MIL (1) lights. according to instructions displayed on scan tool and
print them or write them down. Refer to scan tool
operator's manual for further details.
1 A -1 9 E n g i n e G e n e r a l In f o r m a t i o n a n d D i a g n o s i s : K 1 4 B

If communication between scan tool and ECM is 3) Clear DTC and pending DTC according to
impossible, go to “Troubleshooting for instructions displayed on scan tool. Refer to scan
Communication Bus Off”: K14B Model in Section tool operator's manual for further details.
10H (Page 10H-14). 4) After completing the clearance, set ignition “OFF”
5) After completing the check, set ignition “OFF” and and disconnect scan tool from DLC.
disconnect scan tool from DLC.
NOTE
DTC Clearance DTC and freeze frame data stored in ECM
AENBL80A1114004 memory are also cleared when the same
1) Connect SUZUKI scan tool or CAN communication malfunction (DTC) is not detected again
OBD generic scan tool to DLC in the same manner during 40 engine warm-up cycles. (See
as when making this connection for DTC check. “Warm-Up Cycle” of “OBD System
2) Set ignition “OFF” and then “ON”. Description”: K14B (Page 1A-1).) Be careful
not to clear them before keeping their record.

DTC Table
AENBL80A1114005
NOTE
• When DTC P0300, P0301, P0302, P0303 or P0304 is detected, MIL blinks or lights up according to
detecting condition. For details, refer to “DTC P0300 / P0301 / P0302 / P0303 / P0304”: K14B (Page
1A-68).
• With the CAN communication generic scan tool, only DTC marked with asterisk (*) in the following
table can be read.

DTC
DTC DTC name DTC detecting condition detection MIL
logic
*P0010 “A” Camshaft Position
OCV control circuit is open. 3 D/C Lights up
)(Page 1A-41) Actuator Circuit / Open
“A” Camshaft Position
*P0011)(Page Measured CMP does not reach target CMP for
Timing Over Advanced or 3 D/C Lights up
1A-43) specified time.
System Performance
*P0030 HO2S Heater Control
HO2S-1 heater control circuit is open. 3 D/C Lights up
)(Page 1A-45) Circuit (Sensor 1)
*P0031 HO2S Heater Control
HO2S-1 heater control circuit is shorted to ground. 3 D/C Lights up
)(Page 1A-45) Circuit Low (Sensor 1)
*P0032 HO2S Heater Control HO2S-1 heater control circuit is shorted to power
3 D/C Lights up
)(Page 1A-45) Circuit High (Sensor 1) supply.
*P0036 HO2S Heater Control
HO2S-2 heater control circuit is open. 3 D/C Lights up
)(Page 1A-47) Circuit (Sensor 2)
*P0037 HO2S Heater Control
HO2S-2 heater control circuit is shorted to ground. 3 D/C Lights up
)(Page 1A-47) Circuit Low (Sensor 2)
*P0038 HO2S Heater Control HO2S-2 heater control circuit is shorted to power
3 D/C Lights up
)(Page 1A-47) Circuit High (Sensor 2) supply.
Manifold Absolute
*P0107 Output voltage of MAP sensor signal circuit is
Pressure / Barometric 3 D/C Lights up
)(Page 1A-49) lower than 0.1 V for 5 sec.
Pressure Circuit Low
Manifold Absolute
*P0108 Output voltage of MAP sensor signal circuit is
Pressure / Barometric 3 D/C Lights up
)(Page 1A-49) higher than 4.9 V for 5 sec.
Pressure Circuit High
*P0112 Intake Air Temperature Output voltage of IAT sensor signal circuit is lower
3 D/C Lights up
)(Page 1A-50) Sensor 1 Circuit Low than 0.09 V for 5 sec.
*P0113 Intake Air Temperature Output voltage of IAT sensor signal circuit is higher
3 D/C Lights up
)(Page 1A-50) Sensor 1 Circuit High than 3.2 V for 5 sec.
Engine Coolant
Difference between measured ECT and estimated
*P0116 Temperature Sensor 1
ECT is more than specified value for specified time 3 D/C Lights up
)(Page 1A-52) Circuit Range /
with engine running.
Performance
 Engine General Information and Diagnosis: K14B 1A-20

DTC
DTC DTC name DTC detecting condition detection MIL
logic
Engine Coolant
*P0117 Output voltage of ECT sensor signal circuit is lower
Temperature Sensor 1 3 D/C Lights up
)(Page 1A-53) than 0.1 V for 5 sec.
Circuit Low
Engine Coolant
*P0118 Output voltage of ECT sensor signal circuit is
Temperature Sensor 1 3 D/C Lights up
)(Page 1A-53) higher than 3.2 V for 5 sec.
Circuit High
Throttle / Pedal Position
*P0122 Output voltage of TP sensor (main) signal circuit is
Sensor / Switch “A” Circuit 1 D/C Lights up
)(Page 1A-54) lower than 0.2 V.
Low
Throttle / Pedal Position
*P0123 Output voltage of TP sensor (main) signal circuit is
Sensor / Switch “A” Circuit 1 D/C Lights up
)(Page 1A-54) higher than 4.8 V.
High
Any of the following conditions is met.
• HO2S-1 signal voltage is between 0.06 V and
0.42 V even if HO2S-2 signal voltage is higher
*P0130 O2 Sensor Circuit (Sensor
than 0.6 V for 30 sec. 3 D/C Lights up
)(Page 1A-56) 1)
• HO2S-1 signal voltage is between 0.5 V and
1.27 V even if HO2S-2 signal voltage is lower
than 0.1 V for 25 sec.
Output voltage of HO2S-1 circuit is lower than 0.06
*P0131 O2 Sensor Circuit Low
V and output voltage of HO2S-2 circuit is higher 3 D/C Lights up
)(Page 1A-57) Voltage (Sensor 1)
than 0.6 V for 30 sec.
*P0132 O2 Sensor Circuit High Output voltage of HO2S-1 circuit is higher than
3 D/C Lights up
)(Page 1A-57) Voltage (Sensor 1) 1.27 V for 25 sec.
*P0133 O2 Sensor Circuit Slow Cycle duration from rich to lean and lean to rich of
3 D/C Lights up
)(Page 1A-59) Response (Sensor 1) HO2S-1 is longer than specified time.
O2 Sensor Circuit No
*P0134 Output voltage of HO2S-1 circuit stays between
Activity Detected (Sensor 3 D/C Lights up
)(Page 1A-61) 0.42 and 0.50 V for 25 sec.
1)
*P0137 O2 Sensor Circuit Low Output voltage of HO2S-2 circuit is lower than 0.06
3 D/C Lights up
)(Page 1A-63) Voltage (Sensor 2) V for 30 sec.
*P0138 O2 Sensor Circuit High Output voltage of HO2S-2 signal circuit is higher
3 D/C Lights up
)(Page 1A-63) Voltage (Sensor 2) than 1.27 V for 25 sec.
O2 Sensor Circuit No
*P0140 Output voltage of HO2S-2 circuit stays between
Activity Detected (Sensor 3 D/C Lights up
)(Page 1A-63) 0.42 to 0.50 V for 500 sec.
2)
*P0171 Fuel trim correction is higher than specified value
System Too Lean 3 D/C Lights up
)(Page 1A-65) for specified time under specified vehicle condition.
*P0172 Fuel trim correction is lower than specified value
System Too Rich 3 D/C Lights up
)(Page 1A-65) for specified time under specified vehicle condition.
Throttle / Pedal Position
*P0222 Output voltage of TP sensor (sub) signal circuit is
Sensor / Switch “B” Circuit 1 D/C Lights up
)(Page 1A-67) lower than 0.2 V.
Low
Throttle / Pedal Position
*P0223 Output voltage of TP sensor (sub) signal circuit is
Sensor / Switch “B” Circuit 1 D/C Lights up
)(Page 1A-67) higher than 4.8 V.
High
Any of the following conditions is met.
• Misfire, which causes catalyst to overheat
during 200 engine revolutions, is detected at 2
*P0300 Random / Multiple or more cylinders. (MIL blinks as long as misfire
3 D/C Lights up
)(Page 1A-68) Cylinder Misfire Detected lasts.)
• Misfire, which affects exhaust emission
adversely during 1000 engine revolutions, is
detected at 2 or more cylinders.
1A-21 Engine General Information and Diagnosis: K14B

DTC
DTC DTC name DTC detecting condition detection MIL
logic
*P0301 Cylinder 1 Misfire Any of the following conditions is met.
3 D/C Lights up
)(Page 1A-68) Detected • Misfire, which causes catalyst to overheat
*P0302 Cylinder 2 Misfire during 200 engine revolutions, is detected at 3 D/C Lights up
)(Page 1A-68) Detected specific cylinder. (MIL blinks as long as misfire
*P0303 Cylinder 3 Misfire lasts.) 3 D/C Lights up
)(Page 1A-68) Detected
• Misfire, which affects exhaust emission
*P0304 Cylinder 4 Misfire adversely during 1000 engine revolutions, is 3 D/C Lights up
)(Page 1A-68) Detected detected at specific cylinder.
*P0327 Knock Sensor 1 Circuit Knock sensor signal is out of specified range for 5
3 D/C Lights up
)(Page 1A-71) Low sec.
• This DTC is detected if any one of the following
error counters related to CKP sensor signal is
more than specified number with engine
running.
*P0335 Crankshaft Position – Displaced gap by one tooth or more 3 D/C Lights up
)(Page 1A-72) Sensor “A” Circuit
– Detection of gap at missing gap range
– Faulty distance between gaps
• CKP sensor signal is not inputted while CMP
sensor signal is being inputted.
Any of the following conditions is met.
• CMP sensor signal is not inputted while CKP
*P0340 Camshaft Position Sensor
sensor signal is being inputted. 3 D/C Lights up
)(Page 1A-74) “A” Circuit
• CMP sensor signal pattern is not equal to the
expected pattern.
*P0351 Ignition Coil “A” Primary / Ignition coil assembly No.1 and/or its circuit is open
3 D/C Lights up
)(Page 1A-77) Secondary Circuit with engine running.
*P0352 Ignition Coil “B” Primary / Ignition coil assembly No.2 and/or its circuit is open
3 D/C Lights up
)(Page 1A-77) Secondary Circuit with engine running.
*P0353 Ignition Coil “C” Primary / Ignition coil assembly No.3 and/or its circuit is open
3 D/C Lights up
)(Page 1A-77) Secondary Circuit with engine running.
*P0354 Ignition Coil “D” Primary / Ignition coil assembly No.4 and/or its circuit is open
3 D/C Lights up
)(Page 1A-77) Secondary Circuit with engine running.
Average amplitude of HO2S-2 signal is more than
*P0420 Catalyst System Efficiency
specified value for 60 sec. under specified vehicle 3 D/C Lights up
)(Page 1A-79) Below Threshold
condition.
Evaporative Emission
*P0443
System Purge Control EVAP canister purge valve control circuit is open. 3 D/C Lights up
)(Page 1A-81)
Valve Circuit
Evaporative Emission
*P0458 EVAP canister purge valve control circuit is shorted
System Purge Control 3 D/C Lights up
)(Page 1A-81) to ground.
Valve Circuit Low
Evaporative Emission
*P0459 EVAP canister purge valve control circuit is shorted
System Purge Control 3 D/C Lights up
)(Page 1A-81) to power supply.
Valve Circuit High
P0480 )(Page Radiator cooling fan relay No.1 drive circuit is
Fan 1 Control Circuit 3 D/C Off
1A-83) shorted to ground or open.
P0481 )(Page Radiator cooling fan relay No.2 and/or No.3 drive
Fan 2 Control Circuit 3 D/C Off
1A-85) circuit is shorted to ground or open.
*P0500 Vehicle speed is slower than 4 km/h (2 mile/h) for
Vehicle Speed Sensor “A” 3 D/C Lights up
)(Page 1A-87) 12 sec. at fuel cut driving condition.
 Engine General Information and Diagnosis: K14B 1A-22

DTC
DTC DTC name DTC detecting condition detection MIL
logic
Any of the following conditions is met.
• Output voltage of A/C refrigerant pressure
P0530 )(Page A/C Refrigerant Pressure
sensor signal circuit is lower than 0.15 V. 3 D/C Off
1A-88) Sensor “A” Circuit
• Output voltage of A/C refrigerant pressure
sensor signal circuit is higher than 4.93 V.
*P0560 Main power supply voltage is lower than 2.54 V for
System Voltage 3 D/C Lights up
)(Page 1A-90) 10 sec.
*P0562 Main power supply circuit voltage is lower than 9.8
System Voltage Low 3 D/C Lights up
)(Page 1A-90) V for 5 sec. with engine speed 2,200 rpm or more.
Main power supply circuit voltage is higher than
*P0563
System Voltage High 16.5 V for 5 sec. with engine speed 2,200 rpm or 3 D/C Lights up
)(Page 1A-90)
more.
P0602 )(Page Control Module
ECM internal failure (data programming error). 1 D/C Off
1A-92) Programming Error
*P0607 Control Module
Internal failure in ECM is detected. 1 D/C Lights up
)(Page 1A-92) Performance
P0645 )(Page A/C Clutch Relay Control
A/C compressor relay drive circuit is open. 3 D/C Off
1A-94) Circuit
P0646 )(Page A/C Clutch Relay Control A/C compressor relay drive circuit is shorted to
3 D/C Off
1A-94) Circuit Low ground.
P0647 )(Page A/C Clutch Relay Control A/C compressor relay drive circuit is shorted to
3 D/C Off
1A-94) Circuit High power supply.
P0692 )(Page Radiator cooling fan relay No.1 drive circuit is
Fan 1 Control Circuit High 3 D/C Off
1A-83) shorted to power supply.
P0694 )(Page Radiator cooling fan relay No.2 and/or No.3 drive
Fan 2 Control Circuit High 3 D/C Off
1A-85) circuit is shorted to power supply.
Immobilizer ID and/or
P1610 1 D/C Off
Password Not Registered
P1611 Password Not Matched 1 D/C Off
EEPROM Reading /
P1622 1 D/C Off
Writing Error
Refer to “DTC Table” in Section 10C (Page 10C-4).
Immobilizer
P1642 1 D/C Off
Communication Line Error
Immobilizer ID
P1644 1 D/C Off
Mismatched
P1646 ID Code Incorrectness 1 D/C Off
“A” Camshaft Position
*P2088
Actuator Control Circuit OCV control circuit is shorted to ground. 3 D/C Lights up
)(Page 1A-41)
Low
“A” Camshaft Position
*P2089
Actuator Control Circuit OCV control circuit is shorted to power supply. 3 D/C Lights up
)(Page 1A-41)
High
Throttle Actuator “A” Throttle actuator and/or its circuit malfunction
*P2100
Control Motor Circuit / (open, short to power supply or short to ground) is 1 D/C Lights up
)(Page 1A-95)
Open detected.
Any of the following conditions is met.
• Difference between measured throttle valve
Throttle Actuator “A”
*P2101 position and targeted throttle valve position is
Control Motor Circuit 1 D/C Lights up
)(Page 1A-97) more than specified value.
Range / Performance
• Duty ratio of throttle actuator signal is out of
specified range for specified time.
1A-23 Engine General Information and Diagnosis: K14B

DTC
DTC DTC name DTC detecting condition detection MIL
logic
Any of the following conditions is met.
• Time taken by throttle valve to return from
partially open position to mechanical default
Throttle Actuator Control
*P2119 position is more than specified time during
Throttle Body Range / 1 D/C Lights up
)(Page 1A-97) return spring check process after setting ignition
Performance
“OFF”.
• Measured default throttle position is out of
specified range.
Throttle / Pedal Position
*P2122 Output voltage of APP sensor (main) signal circuit
Sensor / Switch “D” Circuit 1 D/C Lights up
)(Page 1A-99) is lower than 0.6 V.
Low
Throttle / Pedal Position
*P2123 Output voltage of APP sensor (main) signal circuit
Sensor / Switch “D” Circuit 1 D/C Lights up
)(Page 1A-99) is higher than 4.4 V.
High
*P2127 Throttle / Pedal Position
Output voltage of APP sensor (sub) signal circuit is
)(Page 1A- Sensor / Switch “E” Circuit 1 D/C Lights up
lower than 0.3 V.
101) Low
*P2128 Throttle / Pedal Position
Output voltage of APP sensor (sub) signal circuit is
)(Page 1A- Sensor / Switch “E” Circuit 1 D/C Lights up
higher than 2.5 V.
101) High
*P2135 Throttle / Pedal Position Difference between TP sensor (main) signal
)(Page 1A- Sensor / Switch “A” / “B” voltage and TP sensor (sub) signal voltage is 1 D/C Lights up
102) Voltage Correlation higher than specified value.
*P2138 Throttle / Pedal Position Difference between half of APP (main) sensor
)(Page 1A- Sensor / Switch “D” / “E” signal and APP (sub) sensor signal is more than 1 D/C Lights up
104) Voltage Correlation specified value.
Any of the following conditions is met.
• TP sensor (main) or TP sensor (sub) signal
*P2176 Throttle Actuator Control
voltage at default position is out of specified
)(Page 1A- System-Idle Position Not 1 D/C Lights up
range for specified time.
105) Learned
• Electric throttle control system calibration is not
completed.
*P2270 HO2S-2 signal stays in lean state for specified time
O2 Sensor Signal Biased /
)(Page 1A- with specified driving condition even if A/F is 3 D/C Lights up
Stuck Lean (Sensor 2)
107) enrichment control.
*P2271 Output voltage of HO2S-2 signal circuit is higher
O2 Sensor Signal Biased /
)(Page 1A- than 0.6 V for 10 sec. even if vehicle is fuel cut 3 D/C Lights up
Stuck Rich (Sensor 2)
107) driving condition.
*P2300 Ignition Coil “A” Primary Ignition coil assembly No.1 drive circuit voltage is
3 D/C Lights up
)(Page 1A-77) Control Circuit Low shorted to ground with engine running.
*P2301 Ignition Coil “A” Primary Ignition coil assembly No.1 drive circuit voltage is
3 D/C Lights up
)(Page 1A-77) Control Circuit High shorted to power supply with engine running.
*P2303 Ignition Coil “B” Primary Ignition coil assembly No.2 drive circuit voltage is
3 D/C Lights up
)(Page 1A-77) Control Circuit Low shorted to ground with engine running.
*P2304 Ignition Coil “B” Primary Ignition coil assembly No.2 drive circuit voltage is
3 D/C Lights up
)(Page 1A-77) Control Circuit High shorted to power supply with engine running.
*P2306 Ignition Coil “C” Primary Ignition coil assembly No.3 drive circuit voltage is
3 D/C Lights up
)(Page 1A-77) Control Circuit Low shorted to ground with engine running.
*P2307 Ignition Coil “C” Primary Ignition coil assembly No.3 drive circuit voltage is
3 D/C Lights up
)(Page 1A-77) Control Circuit High shorted to power supply with engine running.
*P2309 Ignition Coil “D” Primary Ignition coil assembly No.4 drive circuit voltage is
3 D/C Lights up
)(Page 1A-77) Control Circuit Low shorted to ground with engine running.
*P2310 Ignition Coil “D” Primary Ignition coil assembly No.4 drive circuit voltage is
3 D/C Lights up
)(Page 1A-77) Control Circuit High shorted to power supply with engine running.
 Engine General Information and Diagnosis: K14B 1A-24

DTC
DTC DTC name DTC detecting condition detection MIL
logic
Control Module
U0073 1 D/C Off
Communication Bus Off
Lost Communication With
U0121 ABS / ESP® Control 1 D/C Off
Module
Lost Communication With Refer to “CAN DTC (Lost Communication and
U0131 Power Steering Control Communication Bus Off) Table”: K14B Model in 1 D/C Off
Module Section 10H (Page 10H-7).
Lost Communication With
U0140 1 D/C Off
Body Control Module
Lost Communication With
U0155 Instrument Panel Cluster 1 D/C Off
(IPC) Control Module

Fail-Safe Table
AENBL80A1114006
When any of the following DTCs is detected, ECM control enters the fail-safe mode as long as the failure condition
associated with the DTC continues. The fail-safe mode is canceled when ECM detects normal condition.
DTC DTC name Fail-safe operation
P0010 )(Page “A” Camshaft Position Actuator Circuit /
1A-41) Open
ECM stops CMP actuator control.
P0011 )(Page “A” Camshaft Position Timing Over
1A-43) Advanced or System Performance
P0030 )(Page
HO2S Heater Control Circuit (Sensor 1)
1A-45)
P0031 )(Page HO2S Heater Control Circuit Low (Sensor
—
1A-45) 1)
P0032 )(Page HO2S Heater Control Circuit High (Sensor
1A-45) 1)
P0036 )(Page
HO2S Heater Control Circuit (Sensor 2)
1A-47)
P0037 )(Page HO2S Heater Control Circuit Low (Sensor
—
1A-47) 2)
P0038 )(Page HO2S Heater Control Circuit High (Sensor
1A-47) 2)
P0107 )(Page Manifold Absolute Pressure / Barometric
1A-49) Pressure Circuit Low
ECM calculates MAP value from TP sensor.
P0108 )(Page Manifold Absolute Pressure / Barometric
1A-49) Pressure Circuit High
P0112 )(Page Intake Air Temperature Sensor 1 Circuit
1A-50) Low ECM controls actuators assuming that intake air
P0113 )(Page Intake Air Temperature Sensor 1 Circuit temperature is 20 °C (68 °F).
1A-50) High
P0116 )(Page Engine Coolant Temperature Sensor 1
1A-52) Circuit Range / Performance
P0117 )(Page Engine Coolant Temperature Sensor 1 • ECM calculates ECT value from engine load.
1A-53) Circuit Low • ECM operates radiator cooling fan. (high speed)
P0118 )(Page Engine Coolant Temperature Sensor 1
1A-53) Circuit High
P0122 )(Page Throttle / Pedal Position Sensor / Switch
1A-54) “A” Circuit Low • ECM performs fuel cut at specified engine speed.
P0123 )(Page Throttle / Pedal Position Sensor / Switch • ECM stops CMP actuator control.
1A-54) “A” Circuit High
1A-25 Engine General Information and Diagnosis: K14B

DTC DTC name Fail-safe operation

P0130 )(Page
O2 Sensor Circuit (Sensor 1)
1A-56)
P0131 )(Page
O2 Sensor Circuit Low Voltage (Sensor 1) ECM stops A/F feedback (closed-loop) control.
1A-57)
P0132 )(Page
O2 Sensor Circuit High Voltage (Sensor 1)
1A-57)
P0133 )(Page O2 Sensor Circuit Slow Response (Sensor
—
1A-59) 1)
P0134 )(Page O2 Sensor Circuit No Activity Detected
ECM stops A/F feedback (closed-loop) control.
1A-61) (Sensor 1)
P0137 )(Page
O2 Sensor Circuit Low Voltage (Sensor 2)
1A-63)
P0138 )(Page
O2 Sensor Circuit High Voltage (Sensor 2) —
1A-63)
P0140 )(Page O2 Sensor Circuit No Activity Detected
1A-63) (Sensor 2)
P0171 )(Page
System Too Lean
1A-65)
—
P0172 )(Page
System Too Rich
1A-65)
P0222 )(Page Throttle / Pedal Position Sensor / Switch
1A-67) “B” Circuit Low • ECM performs fuel cut at specified engine speed.
P0223 )(Page Throttle / Pedal Position Sensor / Switch • ECM stops CMP actuator control.
1A-67) “B” Circuit High
P0300 )(Page Random / Multiple Cylinder Misfire
—
1A-68) Detected
P0301 )(Page • ECM stops fuel injector No.1 control.
Cylinder 1 Misfire Detected
1A-68) • ECM stops A/F feedback (closed-loop) control.
P0302 )(Page • ECM stops fuel injector No.2 control.
Cylinder 2 Misfire Detected
1A-68) • ECM stops A/F feedback (closed-loop) control.
P0303 )(Page • ECM stops fuel injector No.3 control.
Cylinder 3 Misfire Detected
1A-68) • ECM stops A/F feedback (closed-loop) control.
P0304 )(Page • ECM stops fuel injector No.4 control.
Cylinder 4 Misfire Detected
1A-68) • ECM stops A/F feedback (closed-loop) control.
P0327 )(Page
Knock Sensor 1 Circuit Low ECM retards ignition timing.
1A-71)
P0335 )(Page • ECM limits engine speed to 2,000 rpm.
Crankshaft Position Sensor “A” Circuit
1A-72) • ECM stops CMP actuator control.
P0340 )(Page • ECM stops CMP actuator control.
Camshaft Position Sensor “A” Circuit
1A-74) • ECM retards ignition timing.
P0351 )(Page Ignition Coil “A” Primary / Secondary
1A-77) Circuit
P0352 )(Page Ignition Coil “B” Primary / Secondary
1A-77) Circuit
—
P0353 )(Page Ignition Coil “C” Primary / Secondary
1A-77) Circuit
P0354 )(Page Ignition Coil “D” Primary / Secondary
1A-77) Circuit
P0420 )(Page Catalyst System Efficiency Below
—
1A-79) Threshold
P0443 )(Page Evaporative Emission System Purge
1A-81) Control Valve Circuit
P0458 )(Page Evaporative Emission System Purge
ECM stops EVAP canister purge valve control.
1A-81) Control Valve Circuit Low
P0459 )(Page Evaporative Emission System Purge
1A-81) Control Valve Circuit High
 Engine General Information and Diagnosis: K14B 1A-26

DTC DTC name Fail-safe operation

P0480 )(Page
Fan 1 Control Circuit
1A-83)
—
P0481 )(Page
Fan 2 Control Circuit
1A-85)
P0500 )(Page ECM controls actuators assuming that vehicle speed is 0
Vehicle Speed Sensor “A”
1A-87) km/h (0 mph).
• ECM operates radiator cooling fan. (high speed)
P0530 )(Page A/C Refrigerant Pressure Sensor “A”
1A-88) Circuit • ECM controls actuators assuming that A/C refrigerant
pressure is 94.1 kPa.
P0560 )(Page ECM controls actuators assuming that system voltage is
System Voltage
1A-90) 13.5 V.
P0562 )(Page
System Voltage Low
1A-90)
—
P0563 )(Page
System Voltage High
1A-90)
P0602 )(Page
Control Module Programming Error —
1A-92)
Any one of the following operations will be taken:
• ECM performs fuel cut at specified engine speed.
P0607 )(Page
Control Module Performance • ECM stops throttle valve control and all injector
1A-92)
control.
• ECM resets internal memory.
P0645 )(Page
A/C Clutch Relay Control Circuit
1A-94)
P0646 )(Page
A/C Clutch Relay Control Circuit Low —
1A-94)
P0647 )(Page
A/C Clutch Relay Control Circuit High
1A-94)
P0692 )(Page
Fan 1 Control Circuit High
1A-83)
—
P0694 )(Page
Fan 2 Control Circuit High
1A-85)
P2088 )(Page “A” Camshaft Position Actuator Control
1A-41) Circuit Low
ECM stops CMP actuator control.
P2089 )(Page “A” Camshaft Position Actuator Control
1A-41) Circuit High
P2100 )(Page Throttle Actuator Control Motor Circuit /
ECM performs fuel cut at specified engine speed.
1A-95) Open
P2101 )(Page Throttle Actuator Control Motor Circuit
1A-97) Range / Performance
ECM performs fuel cut at specified engine speed.
P2119 )(Page Throttle Actuator Control Throttle Body
1A-97) Range / Performance
P2122 )(Page Throttle / Pedal Position Sensor / Switch
ECM limits APP signal within specified range.
1A-99) “D” Circuit Low
If DTC P2127 or P2128 is detected at the same time,
P2123 )(Page Throttle / Pedal Position Sensor / Switch
ECM controls engine speed at specified value.
1A-99) “D” Circuit High
P2127 )(Page Throttle / Pedal Position Sensor / Switch
ECM limits APP within specified range.
1A-101) “E” Circuit Low
If DTC P2122 or P2123 is detected at the same time,
P2128 )(Page Throttle / Pedal Position Sensor / Switch
ECM controls engine speed at specified value.
1A-101) “E” Circuit High
P2135 )(Page Throttle / Pedal Position Sensor / Switch • ECM performs fuel cut at specified engine speed.
1A-102) “A” / “B” Voltage Correlation • ECM stops CMP actuator control.
P2138 )(Page Throttle / Pedal Position Sensor / Switch
ECM limits APP within specified range.
1A-104) “D” / “E” Voltage Correlation
1A-27 Engine General Information and Diagnosis: K14B

DTC DTC name Fail-safe operation

Any one of the following operations will be taken:
P2176 )(Page Throttle Actuator Control System-Idle • ECM performs fuel cut at specified engine speed.
1A-105) Position Not Learned • ECM fixes minimum throttle valve position to specified
throttle valve position.
P2270 )(Page O2 Sensor Signal Biased / Stuck Lean
1A-107) (Sensor 2)
—
P2271 )(Page O2 Sensor Signal Biased / Stuck Rich
1A-107) (Sensor 2)
P2300 )(Page Ignition Coil “A” Primary Control Circuit
1A-77) Low
—
P2301 )(Page Ignition Coil “A” Primary Control Circuit
1A-77) High
P2303 )(Page Ignition Coil “B” Primary Control Circuit
1A-77) Low
—
P2304 )(Page Ignition Coil “B” Primary Control Circuit
1A-77) High
P2306 )(Page Ignition Coil “C” Primary Control Circuit
1A-77) Low
—
P2307 )(Page Ignition Coil “C” Primary Control Circuit
1A-77) High
P2309 )(Page Ignition Coil “D” Primary Control Circuit
1A-77) Low
—
P2310 )(Page Ignition Coil “D” Primary Control Circuit
1A-77) High

Scan Tool Data

AENBL80A1114007
As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles
using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases
where the checked value does not fall within each specified data range. Therefore, judgment as abnormal should not
be made depending on these data alone.
Also, conditions that can be checked by the scan tool are those detected by ECM and output from ECM as commands
and there may be cases where the engine or actuator is not operating (in the condition) as indicated by the scan tool.
Be sure to use the timing light to check the ignition timing. )(Page 1H-7)

NOTE
• With the CAN communication generic scan tool, only data marked with asterisk (*) in the following
table can be read.
• When checking data with engine running at idle or racing, be sure to place gear shift lever in
“Neutral” and apply parking brake fully. Also, if nothing or “no load” is indicated, turn off A/C, all
electric loads.

Normal condition /
Scan tool data Vehicle condition
reference value
Open-loop control before satisfaction of closed-loop
control conditions (ECT >10 °C, IAT, TP, HO2S-1/system = OL (open loop)
OK)
Open-loop control due to driving conditions (Power
OL-Drive (open loop)
Fuel System )(Page 1A- enrichment, etc.)
*
29) Open-loop control due to system fault detected OL-Fault (open loop)
Closed-loop control using HO2S-1 as feedback sensors
CL (closed-loop)
for fuel control
Closed-loop control due to system fault detected CL-Fault (closed-loop)
When engine stops with ignition “ON” —
Short Term Fuel Trim
* Engine: Idle speed after warming up Approx. –20 to 20%
)(Page 1A-30)
Long Term Fuel Trim
* Engine: Idle speed after warming up Approx. –20 to 20%
)(Page 1A-30)
 Engine General Information and Diagnosis: K14B 1A-28

Normal condition /
Scan tool data Vehicle condition
reference value
Total Fuel Trim )(Page
Engine: Idle speed after warming up Approx. –30 to 30%
1A-30)
Inj Pulse Width )(Page
Engine: Idle speed with no load after warming up Approx. 1.6 to 4.0 msec
1A-30)
Ignition Advance )(Page
* Engine: Idle speed with no load after warming up –5 to 15° BTDC
1A-30)
Calculated Load )(Page
* Engine: Idle speed with no load after warming up Approx. 10 to 30%
1A-30)
Engine: Idle speed after warming up
Engine Speed )(Page Radiator cooling fan: Stopped
* 600 to 700 rpm
1A-30) All electrical equipment: OFF
Shift lever: “Neutral”
Engine: Idle speed after warming up
Desired Idle )(Page 1A- Radiator cooling fan: Stopped
Approx. 650 rpm
30) All electrical equipment: OFF
Shift lever: “Neutral”
Vehicle Speed )(Page
* Vehicle running Vehicle speed is displayed.
1A-30)
* MAP )(Page 1A-30) Engine: Idle speed after warming up Approx. 20 to 55 kPa
Approx. 80 to 105 °C (176
* ECT )(Page 1A-30) Engine: Idle speed after warming up
– 221 °F)
–5 °C (23 °F) +
Intake Air Temperature environmental temperature
* Engine: Idle speed after warming up
)(Page 1A-30) to 40 °C (104 °F) +
environmental temperature
Barometric Pres )(Page Barometric pressure is
* —
1A-30) displayed.
EVAP Canist Prg Duty
* Engine: Idle speed after warming up 0%
)(Page 1A-30)
VVT Gap )(Page 1A-30) Engine: Idle speed after warming up –1.0 to 1.0° CA
Engine: Idle speed with no load after warming up Approx. 10 to 45%
IAC Throttle Opening Engine: Idle speed after warming up
)(Page 1A-30) A/C switch: ON Approx. 10 to 55%
Blower speed selector: Max
Ignition: “ON”
0.6 to 1.0 V
TP Sensor 1 Volt )(Page Accelerator pedal: Released
1A-30) Ignition: “ON”
4.2 to 4.7 V
Accelerator pedal: Depressed fully
Ignition: “ON”
3.9 to 4.4 V
TP Sensor 2 Volt )(Page Accelerator pedal: Released
1A-30) Ignition: “ON”
0.3 to 0.8 V
Accelerator pedal: Depressed fully
Ignition: “ON”
0.6 to 0.9 V
APP Sensor 1 Volt Accelerator pedal: Released
)(Page 1A-30) Ignition: “ON”
3.7 to 4.4 V
Accelerator pedal: Depressed fully
Ignition: “ON”
0.3 to 0.5 V
APP Sensor 2 Volt Accelerator pedal: Released
)(Page 1A-30) Ignition: “ON”
1.8 to 2.2 V
Accelerator pedal: Depressed fully
Ignition: “ON”
0 to 2%
Accel Position )(Page Accelerator pedal: Released
*
1A-30) Ignition: “ON”
90 to 100%
Accelerator pedal: Depressed fully
Ignition: “ON”
0 to 10%
Throttle Position )(Page Accelerator pedal: Released
*
1A-30) Ignition: “ON”
90 to 100%
Accelerator pedal: Depressed fully
1A-29 Engine General Information and Diagnosis: K14B

Normal condition /
Scan tool data Vehicle condition
reference value
Ignition: “ON”
0 to 10%
Target Throttle Posi Accelerator pedal: Released
*
)(Page 1A-30) Ignition: “ON”
90 to 100%
Accelerator pedal: Depressed fully
O2S B1 S1 )(Page 1A-
* Engine: Idle speed after warming up 0 to 1.0 V
30)
O2S B1 S2 )(Page 1A-
* Engine: 2,000 rpm for 3 min. or more after warming up 0 to 1.0 V
31)
Battery Voltage )(Page
* Engine: Idle speed Approx. 13 to 15 V
1A-31)
Fuel Tank Level )(Page
Ignition: “ON” 0 to 100%
1A-31)
Engine: Idle speed
A/C Pressure )(Page
A/C switch: ON 600 to 1,300 kPa
1A-31)
Blower speed selector: MAX
Radiator cooling fan: Off Off
Radiator Fan )(Page 1A-
Radiator cooling fan: Low speed Low
31)
Radiator cooling fan: High speed High
A/C switch: ON
A/C Comp Relay )(Page ON
Blower speed selector: ON
1A-31)
Other than above condition OFF
Fuel Pump )(Page 1A- Engine running ON
31) Other than above condition OFF
Starter SW )(Page 1A- Ignition: “ST” (engine cranking) ON
31) Other than above condition OFF
A/C switch: ON
A/C Switch )(Page 1A- ON
Blower speed selector: ON
31)
Other than above condition OFF
Manual A/C: 2nd or higher speed position
ON
Blower Fan )(Page 1A- Auto A/C: 4th or higher speed position
31) Manual A/C: Other than above condition
OFF
Auto A/C: Other than above condition
Brake Switch )(Page Brake pedal: Depressed ON
1A-31) Brake pedal: Released OFF
Electric Load )(Page 1A- Headlight switch: ON ON
31) Headlight switch: OFF OFF
Clutch SW )(Page 1A- Clutch pedal: Depressed fully Declutch
31) Clutch pedal: Released Clutched
Engine: Idle speed after warming up OFF
Fuel Cut )(Page 1A-31) Accelerator pedal: Released
ON
Engine condition: 2,000 rpm or more after warming up
Ignition: “ON”
ON
Closed Throttle Pos Accelerator pedal: Released
)(Page 1A-31) Ignition: “ON”
OFF
Accelerator pedal: Depressed fully
O2S B1 S1 Act )(Page
Engine: Idle speed after warming up Active
1A-31)
O2S B1 S2 Act )(Page
Engine: Idle speed after warming up Active
1A-31)

Scan Tool Data Definitions
Fuel System (Fuel system status):
A/F ratio feedback loop status is displayed as follows.
OL: Open-loop control before satisfaction of closed loop
control conditions (ECT > 10 °C, IAT, TP, HO2S-1/
system = OK).
CL: Closed-loop control using oxygen sensor(s) as
feedback sensor(s).
OL-DRIVE: Open-loop control due to driving requirement
(power-up enrichment etc.).
OL-FAULT: Open-loop control due to system fault
detected.
CL-FAULT: Closed-loop control due to system fault
detected.
 Engine General Information and Diagnosis: K14B 1A-30
Short Term Fuel Trim (%):
Short term fuel trim value represents short term
corrections to air/fuel mixture. 0 (zero) indicates no
correction, a value greater than 0 indicates enrichment
correction, and a value less than 0 indicates enleanment
correction.
Long Term Fuel Trim (%):
Long term fuel trim value represents long term
corrections to air/fuel mixture. 0 (zero) indicates no
correction, a value greater than 0 indicates enrichment
correction, and a value less than 0 indicates enleanment
correction.
Total Fuel Trim (%):
Total Fuel Trim is calculated from Short Term Fuel Trim
and Long Term Fuel Trim. This value indicates how
much correction is necessary to keep the air/fuel mixture
stoichiometrical.
Inj Pulse Width (Fuel injection pulse width, msec.):
This parameter indicates the injector drive pulse width
(time) during which the injector valve stays open as
commanded by ECM. (For multipoint fuel injection, the
injector drive time means that of the No. 1 cylinder.)
Ignition Advance (Ignition timing advance for No.1
cylinder, ° BTDC):
This parameter indicates the ignition timing of No.1
cylinder commanded by ECM. The actual ignition timing
should be checked using the timing light.
Calculated Load (Calculated load value, %):
This parameter indicates calculated engine load in
percent. The load is calculated based on input signals to
ECM from various engine sensors.
Engine Speed (rpm):
The engine speed is calculated from reference pulses
from the camshaft position sensor.
Desired Idle (Desired idle speed, rpm):
The Desired Idle Speed is an ECM internal parameter
which indicates the ECM requested idle speed. If the
engine is not running, this number is not valid.
Vehicle Speed (km/h, mph):
The vehicle speed is calculated based on pulse signals
from VSS.
MAP (Manifold absolute pressure, kPa, mmHg, inHg,
psi, inH2O):
This parameter indicates the calculated manifold
pressure based on MAP sensor signal.
ECT (Engine coolant temperature, °C, °F):
It is detected by engine coolant temperature sensor.
Intake Air Temperature. (°C, °F):
It is detected by intake air temperature sensor.
Barometric Pres (Barometric pressure, kPa, mmHg,
inHg, psi, inH2O):
This parameter represents barometric air pressure
measurement and is used for altitude correction of the
fuel injection rate.
Evap Canist Prg Duty (Evap canister purge flow
duty, %):
This parameter indicates valve ON (valve open) time
rate within a certain set cycle of EVAP canister purge
valve which controls the amount of EVAP purge.
VVT Gap (Variable valve timing difference between
target and actual position, °CA):
This parameter indicates difference between target
camshaft position and actual camshaft position.
IAC Throttle Opening (Idle air throttle valve opening,
%):
This parameter indicates throttle valve opening of idle air
control in % (100% indicates the maximum idle air flow).
TP Sensor 1 Volt (TP sensor (main) output voltage,
V):
TP Sensor (Main) data provides throttle valve opening
information in the form of voltage.
TP Sensor 2 Volt (TP sensor (sub) output voltage, V):
TP Sensor (Sub) data provides throttle valve opening
information in the form of voltage.
APP Sensor 1 Volt (APP sensor (main) output
voltage, V):
APP Sensor (Main) data provides accelerator pedal
position information in the form of voltage.
APP Sensor 2 Volt (APP sensor (sub) output voltage,
V):
APP Sensor (Sub) data provides accelerator pedal
position information in the form of voltage.
Accel Position (Absolute accelerator pedal position,
%):
This parameter indicates calculated accelerator pedal
position in percent based on input from accelerator pedal
position sensor.
Throttle Position (Absolute throttle position, %):
This parameter indicates calculated throttle opening in
percent based on input from throttle position sensor.
Target Throttle Posi (Target throttle valve position,
%):
Target Throttle Valve Position is an ECM internal
parameter which indicates the ECM requested throttle
valve position.
O2S B1 S1 (HO2S-1, V):
It indicates output voltage of HO2S-1 installed on
exhaust manifold (Pre-TWC).
1A-31 Engine General Information and Diagnosis: K14B

O2S B1 S2 (HO2S-2, V): OFF: Command for A/C operation is not being output.
It indicates output voltage of HO2S-2 installed on
exhaust manifold (post-TWC). It is used to detect Blower Fan (ON/OFF):
catalyst deterioration. This parameter indicates the state of the blower speed
selector.
Battery Voltage (V):
This parameter indicates battery voltage inputted from Brake Switch (ON/OFF):
main relay to ECM. This parameter indicates the state of the brake switch.

Fuel Tank Level (%): Electric Load (ON/OFF):

This parameter indicates approximate fuel level in the ON: ON signal of headlight, clearance lights or rear end
fuel tank. The fuel level data is provided in percentage door window defogger is input.
from 0 to 100%. OFF: Above electric loads all turned off.

A/C Pressure (A/C refrigerant absolute pressure,
kPa, mmHg, inHg, psi, inH2O):
This parameter indicates A/C refrigerant absolute
pressure detected by A/C refrigerant pressure sensor.
Radiator Fan (Radiator cooling fan control relay,
Low/High/Off):
Low: ON command is being output to the radiator
cooling fan relay No.1.
High: ON command is being output to radiator cooling
fan relays No.2 and No.3.
Off: No command is being output.
A/C Comp Relay (A/C compressor relay, ON/OFF):
This parameter indicates the state of the A/C
compressor relay.
Fuel Pump (ON/OFF):
ON is displayed when ECM activates the fuel pump via
the fuel pump relay switch.
Clutch SW (Clutch switch, Declutch / Clutch):
Declutch: Clutch pedal depressed fully
Clutched: Clutch pedal released
Fuel Cut (ON/OFF):
ON: Fuel injection is cut (output signal to injector is
stopped).
OFF: Fuel injection is not cut.
Closed Throttle Pos (Closed throttle position, ON/
OFF):
This parameter is ON when throttle valve is at idle
position and OFF when the valve is not at idle position.
O2S B1 S1 ACT (HO2S-1, Active / Inactive):
This parameter indicates the activation condition of
HO2S-1.
ACTIVE: The sensor is activated.
INACTIVE: The sensor is being warmed up or not
activated.

Starter SW (Starter switch, ON/OFF): O2S B1 S2 ACT (HO2S-2, Active / Inactive):

This parameter indicates state of starting motor relay
output.
ON: Starting motor relay is ON.
OFF: Starting motor relay is OFF.
A/C Switch (ON/OFF):
ON: Command for A/C operation is being output from
ECM to HVAC.
This parameter indicates the activation condition of
HO2S-2.
ACTIVE: The sensor is activated.
INACTIVE: The sensor is being warmed up or not
activated.

Visual Inspection
AENBL80A1114008
• Visually check the following parts and systems.
Inspection Item Referring section
“Engine Oil and Filter Change” in Section 0B
Level
Engine oil (Page 0B-3)
Leakage —
“Coolant Level Check”: K14B in Section 1F
Level
(Page 1F-10)
Engine coolant
“Engine Cooling System Inspection”: K14B
Leakage
in Section 1F (Page 1F-11)
Level —
Fuel “Fuel Leakage Check Procedure”: K14B in
Leakage
Section 1G (Page 1G-16)
 Engine General Information and Diagnosis: K14B 1A-32

Inspection Item Referring section

Dirt “Air Cleaner Filter Inspection and Cleaning”:
Air cleaner filter
Clogging K14B in Section 1D (Page 1D-5)
Fluid level “Battery Inspection”: K14B in Section 1J
Battery
Corrosion of terminal (Page 1J-6)
Tension “Water Pump / Generator Drive Belt Tension
Accessory drive belt Inspection and Adjustment”: K14B in Section
Damage
1J (Page 1J-10)
Throttle valve Operating sound —
Disconnection —
Looseness —
Vacuum hoses of air intake system
Deterioration —
Bend —
Disconnection —
Connectors of electric wire harness
Friction / pinch —
Fuses Blown —
Installation —
Parts
Deformation —
Bolt Looseness —

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

Inspection Item Referring section
MIL Operation “MIL Check”: K14B (Page 1A-18)
“Generator Symptom Diagnosis”: K14B in
Charging light Operation
Section 1J (Page 1J-6)
“Oil Pressure Switch On-Vehicle Inspection”:
Engine oil pressure light Operation
K14B in Section 1E (Page 1E-5)
“ECT Sensor Inspection”: K14B in Section
Engine coolant temperature meter Operation
1C (Page 1C-6)
“Fuel Level Sensor Inspection”: K14B in
Fuel level sensor Operation
Section 1G (Page 1G-25)
Tachometer Operation Section 9C.
“Exhaust System Check”: K14B in Section
Exhaust system Leakage of exhaust gas, noise
1K (Page 1K-1)
Abnormal air being inhaled at air intake system —
Other parts that can be checked visually —

Engine Basic Inspection

AENBL80A1114009
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found
in “Visual Inspection”: K14B (Page 1A-31).
Follow the flow carefully.
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 Check battery voltage Go to Step 3. Charge or replace
battery.
Is it 12 V or more?
3 Is engine cranked? Go to Step 4. Go to “Cranking System
Symptom Diagnosis”:
K14B in Section 1I
(Page 1I-1).
4 Does engine start? Go to Step 5. Go to Step 7.
5 Check idle speed Go to Step 6. Go to “Engine Symptom
1) Check engine idle speed. )(Page 1A-122) Diagnosis”: K14B (Page
1A-33).
Is check result OK?
1A-33 Engine General Information and Diagnosis: K14B
Step Action
6 Check ignition system
1) Check ignition system. )(Page 1H-4)
Is check result OK?
7 Check immobilizer system for operation
1) Check immobilizer control system. )(Page 10C-3)
Is check result OK?
Engine Symptom Diagnosis
Perform troubleshooting referring to the following points when ECM has detected no DTC and no abnormality has
been found in “Visual Inspection”: K14B (Page 1A-31) and “Engine Basic Inspection”: K14B (Page 1A-32).
Condition Possible cause
Hard starting (Engine can Faulty spark plug
be cranked)
Faulty ignition coil
Dirty or clogged fuel hoses or pipes
Malfunctioning fuel pump
Air drawn in through intake manifold
gasket or throttle body gasket
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Faulty APP sensor assembly
Faulty ECT sensor or MAP sensor
Faulty ECM
Low compression
Poor spark plug tightening or faulty
gasket
Compression leak from valve seat
Sticky valve stem
Weak or damaged valve springs
Compression leak at cylinder head
gasket
Sticking or damaged piston ring
Worn piston, piston ring or cylinder
Malfunctioning PCV valve
Camshaft position control (VVT) system “OCV Inspection”: K14B in Section 1C (Page
out of order
Yes No
Go to “Engine Symptom Repair or replace
Diagnosis”: K14B (Page defective parts.
1A-33).
Go to “Engine Symptom Immobilizer control
Diagnosis”: K14B (Page system malfunction.
1A-33).
AENBL80A1114010
Correction / Reference Item
“Spark Plug Inspection” in Section 1H (Page
1H-6)
“Ignition Coil Assembly Inspection” in Section
1H (Page 1H-7)
“Fuel Pressure Check”: K14B in Section 1G
(Page 1G-11)
“Fuel Pressure Check”: K14B in Section 1G
(Page 1G-11)
Check air intake system.
Inspection”: K14B in Section 1C (Page 1C-2)
“APP Sensor Inspection”: K14B in Section 1C
(Page 1C-5)
“ECT Sensor Inspection”: K14B in Section 1C
(Page 1C-6) or “IAT Sensor Inspection”: K14B
in Section 1C (Page 1C-11)
“Inspection of ECM and Its Circuits”: K14B
(Page 1A-109)
“Compression Check”: K14B in Section 1D
(Page 1D-1)
“Spark Plug Removal and Installation” in
Section 1H (Page 1H-6)
“Valve and Valve Guide Inspection”: K14B in
Section 1D (Page 1D-43)
“Valve and Valve Guide Inspection”: K14B in
Section 1D (Page 1D-43)
“Valve Spring Inspection”: K14B in Section 1D
(Page 1D-46)
“Cylinder Head Inspection”: K14B in Section
1D (Page 1D-45)
“Cylinder, Piston and Piston Ring Inspection”:
K14B in Section 1D (Page 1D-50)
“Cylinder, Piston and Piston Ring Inspection”:
K14B in Section 1D (Page 1D-50)
“PCV Valve Inspection”: K14B in Section 1B
(Page 1B-4)
1C-11)
 Engine General Information and Diagnosis: K14B 1A-34

Condition Possible cause Correction / Reference Item

Low oil pressure Improper oil viscosity “Engine Oil and Filter Change” in Section 0B
(Page 0B-3)
Malfunctioning oil pressure switch “Oil Pressure Switch On-Vehicle Inspection”:
K14B in Section 1E (Page 1E-5)
Clogged oil strainer Check oil strainer for clog.
Functional deterioration of oil pump “Oil Pump Inspection”: K14B in Section 1E
(Page 1E-10)
Worn oil pump relief valve “Oil Pump Inspection”: K14B in Section 1E
(Page 1E-10)
Excessive clearance in various sliding —
parts
Engine noise – Valve Improper valve lash “Camshaft and Tappet Inspection”: K14B in
noise Section 1D (Page 1D-16)
Worn valve stem and guide “Valve and Valve Guide Inspection”: K14B in
NOTE Section 1D (Page 1D-43)
Before checking Weak or broken valve spring “Valve Spring Inspection”: K14B in Section 1D
mechanical noise, make (Page 1D-46)
sure that: Warped or bent valve “Valve and Valve Guide Inspection”: K14B in
• Specified spark plug is Section 1D (Page 1D-43)
used.
• Specified fuel is used.

Engine noise – Piston, Worn piston, piston ring and cylinder “Cylinder, Piston and Piston Ring Inspection”:
piston ring and cylinder bore K14B in Section 1D (Page 1D-50)
noise

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

Engine noise – Worn piston, piston ring and cylinder “Cylinder, Piston and Piston Ring Inspection”:
Connecting rod noise bore K14B in Section 1D (Page 1D-50)
Worn connecting rod bearing “Crankshaft Pin and Connecting Rod Bearing
NOTE Inspection”: K14B in Section 1D (Page 1D-54)
Before checking Worn crankshaft pin “Crankshaft Pin and Connecting Rod Bearing
mechanical noise, make Inspection”: K14B in Section 1D (Page 1D-54)
sure that: Loose connecting rod bolts “Piston, Piston Ring, Connecting Rod and
• Specified spark plug is Cylinder Removal and Installation”: K14B in
used. Section 1D (Page 1D-47)
Low oil pressure Condition “Low oil pressure”
• Specified fuel is used.

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

Crankshaft noise Worn main bearing “Main Bearing Inspection”: K14B in Section 1D
(Page 1D-63)
NOTE Worn crankshaft journal “Crankshaft Inspection”: K14B in Section 1D
Before checking (Page 1D-62)
mechanical noise, make Loose bearing cap bolts “Main Bearing Inspection”: K14B in Section 1D
sure that: (Page 1D-63)
• Specified spark plug is Excessive crankshaft thrust play “Crankshaft Inspection”: K14B in Section 1D
used. (Page 1D-62)
• Specified fuel is used.
1A-35 Engine General Information and Diagnosis: K14B
Condition Possible cause
Engine overheating Inoperative thermostat
Poor water pump performance
Clogged or leaky radiator
Improper engine oil grade
Clogged oil filter or oil strainer
Poor oil pump performance
Faulty radiator cooling fan control
system
Dragging brakes
Slipping clutch
Blown cylinder head gasket
Air mixed in cooling system
Poor fuel mileage Faulty spark plug (improper gap, heavy “Spark Plug Inspection” in Section 1H (Page
deposits and burned electrodes, etc.) 1H-6)
High idle speed
Poor performance of ECT sensor or
MAP sensor
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Faulty APP sensor assembly
Faulty fuel injector(s)
Faulty ECM
Low compression
Poor valve seating
Dragging brakes
Slipping clutch
Thermostat out of order
Improper tire pressure
Camshaft position control (VVT) system “OCV Inspection”: K14B in Section 1C (Page
out of order
Correction / Reference Item
“Thermostat Assembly (Incorporating with ECT
Sensor) Inspection”: K14B in Section 1F (Page
1F-12)
“Water Pump Inspection”: K14B in Section 1F
(Page 1F-17)
“Radiator On-Vehicle Inspection and
Cleaning”: K14B in Section 1F (Page 1F-15)
“Engine Oil and Filter Change” in Section 0B
(Page 0B-3)
“Oil Pressure Check”: K14B in Section 1E
(Page 1E-2)
“Oil Pressure Check”: K14B in Section 1E
(Page 1E-2)
“Radiator Cooling Fan System Check”: K14B
in Section 1F (Page 1F-6)
Condition “Dragging brakes” in “Brake System
Description” in Section 4A (Page 4A-1)
Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis”: K14B Model in Section
5C (Page 5C-2)
“Cylinder Head Inspection”: K14B in Section
1D (Page 1D-45)
“Cooling System Refilling”: K14B in Section 1F
(Page 1F-11)
Condition “Improper engine idling or engine
fails to idle”
“ECT Sensor Inspection”: K14B in Section 1C
(Page 1C-6) or “MAP Sensor Inspection”:
K14B in Section 1C (Page 1C-10)
Inspection”: K14B in Section 1C (Page 1C-2)
“APP Sensor Inspection”: K14B in Section 1C
(Page 1C-5)
“Fuel Injector Circuit Check”: K14B in Section
1G (Page 1G-6)
“Inspection of ECM and Its Circuits”: K14B
(Page 1A-109)
“Compression Check”: K14B in Section 1D
(Page 1D-1)
“Valve and Valve Guide Inspection”: K14B in
Section 1D (Page 1D-43)
Condition “Dragging brakes” in “Brakes
Symptom Diagnosis” in Section 4A (Page 4A-
2)
Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis”: K14B Model in Section
5C (Page 5C-2)
“Thermostat Assembly (Incorporating with ECT
Sensor) Inspection”: K14B in Section 1F (Page
1F-12)
“Tire Description” in Section 2D (Page 2D-1)
1C-11)
 Engine General Information and Diagnosis: K14B 1A-36

Condition Possible cause Correction / Reference Item

Excessive engine oil Broken cylinder head gasket
consumption – Oil
leakage Leaky crankshaft pulley oil seal
Leaky crankshaft rear oil seal
Leaky cylinder head cover gasket
Excessive engine oil Sticky piston ring
consumption – Oil
entering combustion Worn piston and cylinder
chamber
Worn piston ring groove and ring
Improper location of piston ring gap
Worn or damaged valve stem seal
Worn valve stem
Engine hesitates – Spark plug faulty or plug gap out of
Momentary lack of adjustment
response as accelerator Fuel pressure out of specification
is depressed. Can occur
at all vehicle speeds. Poor performance of ECT sensor or
Usually most severe when MAP sensor
moving out from a stop at
stop signal etc. Faulty electric throttle body assembly
Faulty APP sensor assembly
Faulty fuel injector
Faulty ECM
Engine overheating
Low compression
“Cylinder Head Inspection”: K14B in Section
1D (Page 1D-45)
“Camshaft and Tappet Inspection”: K14B in
Section 1D (Page 1D-16)
“Rear Oil Seal Inspection”: K14B in Section 1D
(Page 1D-68)
“Cylinder Head Cover Components”: K14B in
Section 1D (Page 1D-8)
“Cylinder, Piston and Piston Ring Inspection”:
K14B in Section 1D (Page 1D-50)
“Cylinder, Piston and Piston Ring Inspection”:
K14B in Section 1D (Page 1D-50)
“Cylinder, Piston and Piston Ring Inspection”:
K14B in Section 1D (Page 1D-50)
“Piston, Piston Ring, Connecting Rod and
Cylinder Disassembly and Reassembly”: K14B
in Section 1D (Page 1D-49)
“Valve and Valve Guide Inspection”: K14B in
Section 1D (Page 1D-43)
“Valve and Valve Guide Inspection”: K14B in
Section 1D (Page 1D-43)
“Spark Plug Inspection” in Section 1H (Page
1H-6)
“Fuel Pressure Check”: K14B in Section 1G
(Page 1G-11)
“ECT Sensor Inspection”: K14B in Section 1C
(Page 1C-6) or “MAP Sensor Inspection”:
K14B in Section 1C (Page 1C-10)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K14B in Section 1C (Page 1C-2)
“APP Sensor Inspection”: K14B in Section 1C
(Page 1C-5)
“Fuel Injector Circuit Check”: K14B in Section
1G (Page 1G-6)
“Inspection of ECM and Its Circuits”: K14B
(Page 1A-109)
Condition “Engine overheating”
“Compression Check”: K14B in Section 1D
(Page 1D-1)
1A-37 Engine General Information and Diagnosis: K14B

Condition Possible cause Correction / Reference Item

Surge – Engine power Faulty spark plug (excessive carbon “Spark Plug Inspection” in Section 1H (Page
variation under steady deposits, improper gap, burned 1H-6)
throttle or cruise. Vehicle electrodes, etc.)
speed changes up and Variable fuel pressure “Fuel Pressure Check”: K14B in Section 1G
down with no change in (Page 1G-11)
accelerator pedal Kinky or damaged fuel lines “Fuel Pressure Check”: K14B in Section 1G
position. (Page 1G-11)
Faulty fuel pump (clogged fuel filter) “Fuel Pump and Its Circuit Check”: K14B in
Section 1G (Page 1G-8)
Poor performance of MAP sensor “MAP Sensor Inspection”: K14B in Section 1C
(Page 1C-10)
Faulty fuel injector “Fuel Injector Circuit Check”: K14B in Section
1G (Page 1G-6)
Faulty ECM “Inspection of ECM and Its Circuits”: K14B
(Page 1A-109)
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection”: K14B in Section 1C (Page 1C-2)
Faulty APP sensor assembly “APP Sensor Inspection”: K14B in Section 1C
(Page 1C-5)
Camshaft position control (VVT) system “OCV Inspection”: K14B in Section 1C (Page
out of order 1C-11)
Excessive detonation – Faulty spark plug “Spark Plug Inspection” in Section 1H (Page
Engine continuously 1H-6)
generates sharp, metallic Engine overheating Condition “Engine overheating”
knocking sound that Clogged fuel filter (faulty fuel pump) or “Fuel Pressure Check”: K14B in Section 1G
changes with throttle fuel lines (Page 1G-11) or “Fuel Pump and Its Circuit
opening. Check”: K14B in Section 1G (Page 1G-8)
Air drawn in through intake manifold or Check air intake system.
throttle body gasket
Poor performance of knock sensor, ECT “Knock Sensor On-Vehicle Inspection”: K14B
sensor or MAP sensor in Section 1C (Page 1C-9), “ECT Sensor
Inspection”: K14B in Section 1C (Page 1C-6)
or “MAP Sensor Inspection”: K14B in Section
1C (Page 1C-10)
Faulty fuel injector(s) “Fuel Injector Circuit Check”: K14B in Section
1G (Page 1G-6) or “Fuel Injector Inspection”:
K14B in Section 1G (Page 1G-19)
Faulty ECM “Inspection of ECM and Its Circuits”: K14B
(Page 1A-109)
Excessive combustion chamber “Cylinder, Piston and Piston Ring Inspection”:
deposits K14B in Section 1D (Page 1D-50) and/or
“Piston Pin and Connecting Rod Inspection”:
K14B in Section 1D (Page 1D-53)
Camshaft position control (VVT) system “OCV Inspection”: K14B in Section 1C (Page
out of order 1C-11)
 Engine General Information and Diagnosis: K14B 1A-38

Condition Possible cause Correction / Reference Item

Poor engine power Faulty spark plug “Spark Plug Inspection” in Section 1H (Page
1H-6)
Faulty ignition coil with ignitor “Ignition Coil Assembly Inspection” in Section
1H (Page 1H-7)
Faulty knock sensor “Knock Sensor On-Vehicle Inspection”: K14B
in Section 1C (Page 1C-9)
Clogged fuel hoses or pipes “Fuel Pressure Check”: K14B in Section 1G
(Page 1G-11)
Malfunctioning fuel pump “Fuel Pump and Its Circuit Check”: K14B in
Section 1G (Page 1G-8)
Air drawn in through intake manifold Check air intake system.
gasket or throttle body gasket
Engine overheating Condition “Engine overheating”
Poor performance of ECT sensor or “ECT Sensor Inspection”: K14B in Section 1C
MAP sensor (Page 1C-6) or “MAP Sensor Inspection”:
K14B in Section 1C (Page 1C-10)
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection”: K14B in Section 1C (Page 1C-2)
Faulty APP sensor assembly “APP Sensor Inspection”: K14B in Section 1C
(Page 1C-5)
Faulty fuel injector(s) “Fuel Injector Circuit Check”: K14B in Section
1G (Page 1G-6) or “Fuel Injector Inspection”:
K14B in Section 1G (Page 1G-19)
Faulty ECM “Inspection of ECM and Its Circuits”: K14B
(Page 1A-109)
Dragging brakes Condition “Dragging brakes” in “Brake System
Description” in Section 4A (Page 4A-1)
Slipping clutch Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis”: K14B Model in Section
5C (Page 5C-2)
Low compression “Compression Check”: K14B in Section 1D
(Page 1D-1)
Camshaft position control (VVT) system “OCV Inspection”: K14B in Section 1C (Page
out of order 1C-11)
1A-39 Engine General Information and Diagnosis: K14B
Condition Possible cause
Improper engine idling or Faulty spark plug
engine fails to idle
Faulty ignition coil with ignitor
Fuel pressure out of specification
Leaky manifold, electric throttle body
assembly, or cylinder head gasket
Faulty evaporative emission control
system
Faulty fuel injector(s)
Poor performance of ECT sensor or
MAP sensor
Faulty electric throttle body assembly
Faulty APP sensor assembly
Faulty ECM
Loose connection or disconnection of
vacuum hoses
Malfunctioning PCV valve
Engine overheating
Low compression
Faulty generator and/or its circuit
Camshaft position control (VVT) system “OCV Inspection”: K14B in Section 1C (Page
out of order
Correction / Reference Item
“Spark Plug Inspection” in Section 1H (Page
1H-6)
“Ignition Coil Assembly Inspection” in Section
1H (Page 1H-7)
“Fuel Pressure Check”: K14B in Section 1G
(Page 1G-11)
Check air intake system.
“EVAP Canister Purge Valve Inspection”: K14B
in Section 1B (Page 1B-2)
“Fuel Injector Circuit Check”: K14B in Section
1G (Page 1G-6) or “Fuel Injector Inspection”:
K14B in Section 1G (Page 1G-19)
“ECT Sensor Inspection”: K14B in Section 1C
(Page 1C-6) or “IAT Sensor Inspection”: K14B
in Section 1C (Page 1C-11)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K14B in Section 1C (Page 1C-2)
“APP Sensor Inspection”: K14B in Section 1C
(Page 1C-5)
“Inspection of ECM and Its Circuits”: K14B
(Page 1A-109)
Check connection of vacuum hoses.
“PCV Valve Inspection”: K14B in Section 1B
(Page 1B-4)
Condition “Engine overheating”
“Compression Check”: K14B in Section 1D
(Page 1D-1)
“Generator Test”: K14B in Section 1J (Page
1J-8)
1C-11)
 Engine General Information and Diagnosis: K14B 1A-40
Condition Possible cause
Excessive hydrocarbon Faulty spark plug
(HC) emission or carbon
monoxide (CO) emission Faulty ignition coil with ignitor
Low compression
Lead contamination of three-way
catalytic converter
Faulty evaporative emission control
system
Fuel pressure out of specification
Faulty closed-loop system (A/F
feedback compensation) (Poor
performance of ECT sensor or MAP
sensor)
Faulty electric throttle body assembly
Faulty APP sensor assembly
Faulty injector(s)
Faulty ECM
Engine not at normal operating
temperature
Clogged air cleaner
Vacuum leaks
Camshaft position control (VVT) system “OCV Inspection”: K14B in Section 1C (Page
out of order
Excessive nitrogen Improper ignition timing
oxides (NOx) emission
Lead contamination of catalytic
converter
Fuel pressure out of specification
Faulty closed-loop system (A/F
feedback compensation) (Poor
performance of ECT sensor or MAP
sensor)
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Faulty APP sensor assembly
Faulty injector(s)
Faulty ECM
Camshaft position control (VVT) system “OCV Inspection”: K14B in Section 1C (Page
out of order
Correction / Reference Item
“Spark Plug Inspection” in Section 1H (Page
1H-6)
“Ignition Coil Assembly Inspection” in Section
1H (Page 1H-7)
“Compression Check”: K14B in Section 1D
(Page 1D-1)
Check for absence of filler neck restructure.
“EVAP Canister Purge System Inspection”:
K14B in Section 1B (Page 1B-1)
“Fuel Pressure Check”: K14B in Section 1G
(Page 1G-11)
“ECT Sensor Inspection”: K14B in Section 1C
(Page 1C-6) or “MAP Sensor Inspection”:
K14B in Section 1C (Page 1C-10)
“Electric Throttle Body Assembly On-Vehicle
Inspection”: K14B in Section 1C (Page 1C-2)
“APP Sensor Inspection”: K14B in Section 1C
(Page 1C-5)
“Fuel Injector Circuit Check”: K14B in Section
1G (Page 1G-6)
“Inspection of ECM and Its Circuits”: K14B
(Page 1A-109)
—
“Air Cleaner Filter Inspection and Cleaning”:
K14B in Section 1D (Page 1D-5)
“Engine Vacuum Check”: K14B in Section 1D
(Page 1D-2)
1C-11)
“Ignition Timing Inspection” in Section 1H
(Page 1H-7)
Check for absence of filler neck restructure.
“Fuel Pressure Check”: K14B in Section 1G
(Page 1G-11)
“ECT Sensor Inspection”: K14B in Section 1C
(Page 1C-6) or “MAP Sensor Inspection”:
K14B in Section 1C (Page 1C-10)
Inspection”: K14B in Section 1C (Page 1C-2)
“APP Sensor Inspection”: K14B in Section 1C
(Page 1C-5)
“Fuel Injector Circuit Check”: K14B in Section
1G (Page 1G-6) or “Fuel Injector Inspection”:
K14B in Section 1G (Page 1G-19)
“Inspection of ECM and Its Circuits”: K14B
(Page 1A-109)
1C-11)
1A-41 Engine General Information and Diagnosis: K14B

MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)
AENBL80A1114011
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Go to Step 2.
1) Check combination meter for DTC. for applicable DTC.

Is there any DTC(s) detected?

2 Combination meter operation check Replace ECM and Replace combination
1) Set ignition “ON”. recheck MIL operation. meter and recheck MIL
)(Page 1C-1) operation. )(Page 9C-
2) Check warning / indicator lights other than MIL in
10)
combination meter light up.

Is check result OK?

MIL Remains ON after Engine Starts

AENBL80A1114012
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Replace combination
1) Start engine and recheck DTC of ECM while engine for applicable MIL meter and recheck
running. operation. DTC. )(Page 9C-10)
If MIL still remains ON,
Is there any DTC(s)?
replace ECM and
recheck MIL operation.
)(Page 1C-1)

DTC P0010 / P2088 / P2089

AENBL80A1114013
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0010: “A” Camshaft Position Actuator Circuit / Open • OCV and/or its circuit
OCV control circuit is open. • ECM
(3 D/C detection logic)
P2088: “A” Camshaft Position Actuator Control Circuit Low
OCV control circuit is shorted to ground.
(3 D/C detection logic)
P2089: “A” Camshaft Position Actuator Control Circuit High
OCV control circuit is shorted to power supply.
(3 D/C detection logic)
 Engine General Information and Diagnosis: K14B 1A-42

Circuit Diagram

2
12V

A1 1
C01-46 RED/WHT

C01-19 YEL
A2

[A] C01 E01

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

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

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

IAP70B110005-02

[A]: ECM connector (View: [a]) A2: OCV drive circuit 2. ECM
A1: OCV power supply circuit 1. OCV

DTC Confirmation Procedure

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

1) Run engine at idle speed for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 OCV power supply circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect OCV connector. defective wire harness.
2) Check for proper terminal connection to OCV connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

1A-43 Engine General Information and Diagnosis: K14B

Step Action Yes No

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

Is check result OK?

4 OCV check Go to Step 5. Replace OCV.
1) Check OCV. )(Page 1C-11)

Is check result OK?

5 Troubleshooting of other DTC(s) detected at the same Go to troubleshooting Replace ECM and
time for applicable DTC. recheck DTC. )(Page
1C-1)
Is other DTC(s) detected together?

DTC P0011
AENBL80A1114014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0011: “A” Camshaft Position Timing Over Advanced or System • OCV and/or its circuit
Performance • CKP sensor and sensor plate
Measured CMP does not reach target CMP for specified time.
• CMP sensor and signal rotor
(3 D/C detection logic)
• OCV oil passage
• CMP actuator
• Valve timing
• ECM
 Engine General Information and Diagnosis: K14B 1A-44

Circuit Diagram

2
12V

A1 1
C01-46 RED/WHT

C01-19 YEL
A2

[A] C01 E01

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

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

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

IAP70B110005-02

[A]: ECM connector (View: [a]) A2: OCV drive circuit 2. ECM
A1: OCV power supply circuit 1. OCV

DTC Confirmation Procedure

! WARNING

• Perform road test in a place where there is no traffic to prevent an accident.

• Road test should be performed by two persons, a driver and a tester, on a level road.

1) Warm up engine and repeat acceleration and deceleration between 30 and 80 km/h (18 to 50 mile/h) for more than
10 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 DTC check Go to applicable Go to Step 3.
1) Check DTC. DTC(s).

Is there DTC(s) other than P0011?

3 OCV power supply circuit and OCV drive circuit check Go to Step 4. Repair or replace
1) Check “A1” and “A2” circuits according to Steps 2 and 3 defective wire harness.
under “DTC P0010 / P2088 / P2089”: K14B (Page 1A-
41).

Is check result OK?

4 Oil pressure check Go to Step 5. Repair or replace
1) Check oil pressure. )(Page 1E-2) defective parts.

Is check result OK?

1A-45 Engine General Information and Diagnosis: K14B

Step Action Yes No

5 OCV oil circuit visual check Go to Step 6. Repair or replace
1) Remove cylinder head cover. )(Page 1D-10) defective parts.
2) Check oil pressure leakage from OCV oil circuit.

Is check result OK?

6 CKP sensor and sensor plate check Go to Step 7. Repair or replace
1) Check CKP sensor and sensor plate. defective parts.
• CKP sensor: )(Page 1C-8)
• Sensor plate: )(Page 1D-68)

Is check result OK?

7 CMP sensor and signal rotor check Go to Step 8. Repair or replace
1) Check CMP sensor and signal rotor. defective parts.
• CMP sensor: )(Page 1C-8)
• Signal rotor: )(Page 1D-16)

Is check result OK?

8 OCV check Go to Step 9. Replace OCV. )(Page
1) Check OCV. )(Page 1C-11) 1D-29)

Is check result OK?

9 CMP actuator check Go to Step 10. Replace CMP actuator.
1) Check CMP actuator. )(Page 1D-16) )(Page 1D-12)

Is check result OK?

10 Valve timing check Replace ECM and Reinstall parts related to
1) Check parts related to timing chain and their installing recheck DTC. )(Page timing chain correctly, or
condition. )(Page 1D-31) 1C-1) replace defective parts.

Is check result OK?

DTC P0030 / P0031 / P0032

AENBL80A1114015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0030: HO2S Heater Control Circuit (Sensor 1) • HO2S-1 heater and/or its circuit
HO2S-1 heater control circuit is open. • ECM
(3 D/C detection logic)
P0031: HO2S Heater Control Circuit Low (Sensor 1)
HO2S-1 heater control circuit is shorted to ground.
(3 D/C detection logic)
P0032: HO2S Heater Control Circuit High (Sensor 1)
HO2S-1 heater control circuit is shorted to power supply.
(3 D/C detection logic)
 Engine General Information and Diagnosis: K14B 1A-46

Circuit Diagram

3.3V
+B
1 3
A2
RED C01-40
A3
BLU C01-41
GRN/WHT C01-54
A4
A1 YEL/GRN C01-26
3.3V
2 3
B2
BRN C01-27
B3
YEL C01-22
RED/BLU C01-49
B4
B1 YEL/BLK C01-23

[A] C01 E01

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

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

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

IBP80A111011-10

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

DTC Confirmation Procedure

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

1) Warm up engine to normal operating temperature and run engine at idle speed for 60 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 HO2S-1 heater power supply circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect HO2S-1 connector. defective wiring
harness.
2) Check for proper terminal connection to HO2S-1
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

1A-47 Engine General Information and Diagnosis: K14B

Step Action Yes No

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

Is check result OK?

4 HO2S-1 heater check Replace ECM and Replace HO2S-1.
1) Check HO2S-1 heater. )(Page 1C-6) recheck DTC. )(Page )(Page 1C-7)
1C-1)
Is check result OK?

DTC P0036 / P0037 / P0038

AENBL80A1114016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0036: HO2S Heater Control Circuit (Sensor 2) • HO2S-2 heater and/or its circuit
HO2S-2 heater control circuit is open. • ECM
(3 D/C detection logic)
P0037: HO2S Heater Control Circuit Low (Sensor 2)
HO2S-2 heater control circuit is shorted to ground.
(3 D/C detection logic)
P0038: HO2S Heater Control Circuit High (Sensor 2)
HO2S-2 heater control circuit is shorted to power supply.
(3 D/C detection logic)
 Engine General Information and Diagnosis: K14B 1A-48

Circuit Diagram

3.3V
+B
1 3
A2
RED C01-40
A3
BLU C01-41
GRN/WHT C01-54
A4
A1 YEL/GRN C01-26
3.3V
2 3
B2
BRN C01-27
B3
YEL C01-22
RED/BLU C01-49
B4
B1 YEL/BLK C01-23

[A] C01 E01

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

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

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

IBP80A111011-10

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

DTC Confirmation Procedure

NOTE
Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
• Battery voltage > 8.5 V

1) Warm up engine to normal operating temperature and run engine at idle speed for 60 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 HO2S-2 heater power supply circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect HO2S-2 sensor defective wiring
connector. harness.
2) Check for proper terminal connection to HO2S-2 sensor
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1” circuit and ground is
battery voltage.

Is check result OK?

1A-49 Engine General Information and Diagnosis: K14B

Step Action Yes No

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

Is check result OK?

4 HO2S-2 check Replace ECM and Replace HO2S-2.
1) Check HO2S-2 heater. )(Page 1C-6) recheck DTC. )(Page )(Page 1C-7)
1C-1)
Is check result OK?

DTC P0107 / P0108

AENBL80A1114017
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0107: Manifold Absolute Pressure / Barometric Pressure Circuit Low • MAP sensor and/or its circuit
Output voltage of MAP sensor signal circuit is lower than 0.1 V for 5 sec. • ECM
(3 D/C detection logic)
P0108: Manifold Absolute Pressure / Barometric Pressure Circuit High
Output voltage of MAP sensor signal circuit is higher than 4.9 V for 5 sec.
(3 D/C detection logic)

Circuit Diagram

1 5V
A1
GRY/RED C01-2

A2
RED/BLK C01-29
A3
GRY/BLU C01-20

[A] C01 E01

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

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

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

IBP80A111012-01

[A]: ECM connector (View: [a]) A2: MAP sensor signal circuit 1. MAP sensor
A1: MAP sensor power supply circuit A3: MAP sensor ground circuit 2. ECM
 Engine General Information and Diagnosis: K14B 1A-50

DTC Confirmation Procedure

1) Run engine at idle speed for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 MAP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) When ignition is “OFF”, disconnect MAP sensor
connector.
2) Check for proper terminal connection to MAP sensor
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is approx. 5 V.

Is check result OK?

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

Is check result OK?

5 MAP sensor check Replace ECM and Replace MAP sensor.
1) Check MAP sensor. )(Page 1C-10) recheck DTC. )(Page )(Page 1C-10)
1C-1)
Is check result OK?

DTC P0112 / P0113

AENBL80A1114018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0112: Intake Air Temperature Sensor 1 Circuit Low • IAT sensor and/or its circuit
Output voltage of IAT sensor signal circuit is lower than 0.09 V for 5 sec. • ECM
(3 D/C detection logic)
P0113: Intake Air Temperature Sensor 1 Circuit High
Output voltage of IAT sensor signal circuit is higher than 3.2 V for 5 sec.
(3 D/C detection logic)
1A-51 Engine General Information and Diagnosis: K14B

Circuit Diagram

3.3V
1
A1
BLK/YEL C01-34

A2
GRY/BLU C01-20

[A] C01 E01

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

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

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

IBP80A111013-01

[A]: ECM connector (View: [a]) 1. IAT sensor

A1: IAT sensor signal circuit 2. ECM
A2: IAT sensor ground circuit

DTC Confirmation Procedure

1) Run engine at idle speed for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 IAT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM and connector from IAT sensor.
2) Check for proper terminal connection to connectors of
“C01”, “E01” and IAT sensor.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at IAT sensor connector: infinity
• Resistance between “A2” circuit terminal and other
terminal at IAT sensor connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 IAT sensor check Replace ECM and Replace IAT sensor.
1) Check IAT sensor. )(Page 1C-11) recheck DTC. )(Page )(Page 1C-10)
1C-1)
Is check result OK?
 Engine General Information and Diagnosis: K14B 1A-52

DTC P0116
AENBL80A1114019
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0116: Engine Coolant Temperature Sensor 1 Circuit Range / • ECT sensor and/or its circuit
Performance • Thermostat
Difference between measured ECT and estimated ECT is more than
• Cooling system
specified value for specified time with engine running.
(3 D/C detection logic) • ECM

Circuit Diagram

3.3V
1
A1
LT GRN C01-32

A2
GRY/BLU C01-20

[A] C01 E01

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

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

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

IBP80A111014-02

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

DTC Confirmation Procedure

! WARNING

• Perform road test in a place where there is no traffic to prevent an accident.

• Road test should be performed by two persons, a driver and a tester, on a level road.

1) Start engine and drive vehicle at 60 to 80 km/h (37 to 50 mile/h) constantly for 20 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 Coolant level check Go to Step 3. Check coolant leakage
1) Check coolant level. )(Page 1F-10) and add coolant, then
recheck DTC.
Is check result OK?
3 ECT sensor circuit check Go to Step 4. Repair or replace
1) Check ECT sensor circuits according to Step 2 under defective wire harness.
“DTC P0117 / P0118”: K14B (Page 1A-53).

Is check result OK?

1A-53 Engine General Information and Diagnosis: K14B

Step Action Yes No

4 Thermostat check Go to Step 5. Replace thermostat.
1) Check thermostat. )(Page 1F-12) )(Page 1F-12)

Is check result OK?

5 ECT sensor check Replace ECM and Replace ECT sensor.
1) Check ECT sensor. )(Page 1C-6) recheck DTC. )(Page )(Page 1C-5)
1C-1)
Is check result OK?

DTC P0117 / P0118

AENBL80A1114020
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0117: Engine Coolant Temperature Sensor 1 Circuit Low • ECT sensor and/or its circuit
Output voltage of ECT sensor signal circuit is lower than 0.1 V for 5 sec. • ECM
(3 D/C detection logic)
P0118: Engine Coolant Temperature Sensor 1 Circuit High
Output voltage of ECT sensor signal circuit is higher than 3.2 V for 5 sec.
(3 D/C detection logic)

Circuit Diagram

3.3V
1
A1
LT GRN C01-32

A2
GRY/BLU C01-20

[A] C01 E01

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

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

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

IBP80A111014-02

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

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
 Engine General Information and Diagnosis: K14B 1A-54

Step Action Yes No

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

Is check result OK?

3 ECT sensor check Replace ECM and Replace ECT sensor.
1) Check ECT sensor. )(Page 1C-6) recheck DTC. )(Page )(Page 1C-5)
1C-1)
Is check result OK?

DTC P0122 / P0123

AENBL80A1114021
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0122: Throttle / Pedal Position Sensor / Switch “A” Circuit Low • TP sensor (main) and/or its circuit
Output voltage of TP sensor (main) signal circuit is lower than 0.2 V. • ECM
(1 D/C detection logic)
P0123: Throttle / Pedal Position Sensor / Switch “A” Circuit High
Output voltage of TP sensor (main) signal circuit is higher than 4.8 V.
(1 D/C detection logic)

Circuit Diagram

12V
1
A1
C01-55 LT GRN
A2
C01-56 YEL/RED 4
5V B1
C01-14 RED B2 2
C01-42 GRN
B3 3
C01-30 WHT
C01-21 BLK B4
C01-35 BLK 6

[A] C01 E01

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

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

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

IAP70B110018-04
1A-55 Engine General Information and Diagnosis: K14B

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

DTC Confirmation Procedure

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 TP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) When ignition is “OFF”, disconnect TP sensor connector.
2) Check for proper terminal connection to TP sensor
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1” and “B4” is approx. 5 V.

Is check result OK?

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

Is check result OK?

5 TP sensor check Replace ECM and Replace electric throttle
1) Check TP sensor referring to “Throttle Position Sensor recheck DTC. )(Page body assembly. )(Page
Performance Check” under “Electric Throttle Body 1C-1) 1D-6)
Assembly On-Vehicle Inspection”: K14B in Section 1C
(Page 1C-2).

Is check result OK?

 Engine General Information and Diagnosis: K14B 1A-56

DTC P0130
AENBL80A1114022
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0130: O2 Sensor Circuit (Sensor 1) • HO2S-1 and/or its circuit
Any of the following conditions is met. • HO2S-2 and/or its circuit
• HO2S-1 signal voltage is between 0.06 V and 0.42 V even if HO2S-2 signal • HO2S-1 heater and/or its circuit
voltage is higher than 0.6 V for 30 sec.
• HO2S-2 heater and/or its circuit
• HO2S-1 signal voltage is between 0.5 V and 1.27 V even if HO2S-2 signal
• ECM
voltage is lower than 0.1 V for 25 sec.
(3 D/C detection logic)

Circuit Diagram

3.3V
+B
1 3
A2
RED C01-40
A3
BLU C01-41
GRN/WHT C01-54
A4
A1 YEL/GRN C01-26
3.3V
2 3
B2
BRN C01-27
B3
YEL C01-22
RED/BLU C01-49
B4
B1 YEL/BLK C01-23

[A] C01 E01

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

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

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

IBP80A111011-10

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

DTC Confirmation Procedure

! WARNING

• Perform road test in a place where there is no traffic to prevent an accident.

• Road test should be performed by two persons, a driver and a tester, on a level road.

NOTE
• Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
– Battery voltage > 11 V
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.

1) Warm up engine to normal operating temperature.

2) Drive vehicle at 60 to 80 km/h (37 to 50 mile/h) constantly for 10 min. or more.
1A-57 Engine General Information and Diagnosis: K14B

3) Release accelerator pedal, and keep vehicle coasting for 15 sec. with engine braking applied (fuel cut condition).

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15)
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. for applicable DTC.

Is there DTC(s) detected other than P0130?

3 HO2S-1 heater, HO2S-1 circuit and HO2S-1 heater circuit Go to Step 4. Repair or replace
check defective parts.
1) Check the following points.
• HO2S-1 heater: )(Page 1C-6)
• HO2S-1 circuit: Step 3 under “DTC P0131 / P0132”:
K14B (Page 1A-57)
• HO2S-1 heater circuit: Step 2 through 3 under “DTC
P0030 / P0031 / P0032”: K14B (Page 1A-45)

Is check result OK?

4 HO2S-2 heater, HO2S-2 circuit and HO2S-2 heater circuit Go to Step 5. Repair or replace
check defective parts.
1) Check the following points.
• HO2S-2 heater: )(Page 1C-6)
• HO2S-2 circuit: Step 3 under “DTC P0137 / P0138 /
P0140”: K14B (Page 1A-63)
• HO2S-2 heater circuit: Step 2 through 3 under “DTC
P0036 / P0037 / P0038”: K14B (Page 1A-47)

Is check result OK?

5 DTC recheck Go to Step 6. END.
1) Replace HO2S-1. )(Page 1C-7)
2) Perform DTC confirmation procedure, and check DTC.

Is DTC P0130 still detected?

6 DTC recheck Replace ECM and END.
1) Replace HO2S-2. )(Page 1C-7) recheck DTC. )(Page
1C-1)
2) Perform DTC confirmation procedure, and check DTC.

Is DTC P0130 still detected?

DTC P0131 / P0132

AENBL80A1114023
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0131: O2 Sensor Circuit Low Voltage (sensor 1) • HO2S-1 and/or its circuit
Output voltage of HO2S-1 circuit is lower than 0.06 V and output voltage of • ECM
HO2S-2 circuit is higher than 0.6 V for 30 sec.
(3 D/C detection logic)
P0132: O2 Sensor Circuit High Voltage (sensor 1)
Output voltage of HO2S-1 circuit is higher than 1.27 V for 25 sec.
(3 D/C detection logic)
 Engine General Information and Diagnosis: K14B 1A-58

Circuit Diagram

3.3V
+B
1 3
A2
RED C01-40
A3
BLU C01-41
GRN/WHT C01-54
A4
A1 YEL/GRN C01-26
3.3V
2 3
B2
BRN C01-27
B3
YEL C01-22
RED/BLU C01-49
B4
B1 YEL/BLK C01-23

[A] C01 E01

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

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

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

IBP80A111011-10

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

DTC Confirmation Procedure

! WARNING

• Perform road test in a place where there is no traffic to prevent an accident.

• Road test should be performed by two persons, a driver and a tester, on a level road.

NOTE
• Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
– Battery voltage > 11 V
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.

1) Warm up engine to normal operating temperature.

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0131 and P0132?
1A-59 Engine General Information and Diagnosis: K14B

Step Action Yes No

3 HO2S-1 signal circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM and connector from HO2S-1.
2) Check for proper terminal connection to connectors of
“C01”, “E01” and HO2S-1.
3) If connections are OK, check the following points.
• Resistance of “A2” and “A3” circuits: less than 1 Ω
• Resistance between each of “A2” and “A3” circuits
and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at HO2S-1 connector: infinity
• Voltage of “A2” and “A3” circuits: approx. 0 V (when
ignition is “ON”)

Is check result OK?

4 DTC recheck Replace ECM and End.
1) Replace HO2S-1. )(Page 1C-7) recheck DTC. )(Page
1C-1)
2) Perform DTC confirmation procedure to check for DTCs.

Is DTC P0131 or P0132 still detected?

DTC P0133
AENBL80A1114024
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0133: O2 Sensor Circuit Slow Response (sensor 1) • HO2S-1 and/or its circuit
Cycle duration from rich to lean and lean to rich of HO2S-1 is longer • HO2S-1 heater
than specified time.
• Air intake system
(3 D/C detection logic)
• Exhaust system
• Fuel system
• ECM
 Engine General Information and Diagnosis: K14B 1A-60

Circuit Diagram

3.3V
+B
1 3
A2
RED C01-40
A3
BLU C01-41
GRN/WHT C01-54
A4
A1 YEL/GRN C01-26
3.3V
2 3
B2
BRN C01-27
B3
YEL C01-22
RED/BLU C01-49
B4
B1 YEL/BLK C01-23

[A] C01 E01

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

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

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

IBP80A111011-10

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

DTC Confirmation Procedure

! WARNING

• Perform road test in a place where there is no traffic to prevent an accident.

• Road test should be performed by two persons, a driver and a tester, on a level road.

NOTE
• Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
– A/F feedback (closed-loop) control is activated.
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.

1) Warm up engine to normal operating temperature.

2) With engine speed at 2,200 to 3,200 rpm, drive vehicle at 60 to 90 km/h (37 to 56 mile/h) for 5 min or more at 5th
gear.
3) Check whether O2 sensor readiness / monitoring test has completed or not by using scan tool.
If O2 sensor readiness / monitoring test has not completed, check vehicle conditions (environmental) and repeat
Steps 2) through 3).

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
1A-61 Engine General Information and Diagnosis: K14B

Step Action Yes No

2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0133?
3 Exhaust system and air intake system check Go to Step 4. Repair or replace
1) Check exhaust system and air intake system for defective part.
clogging or leakage.

Is check result OK?

4 Fuel system inspection Go to Step 5. Repair or replace
1) Check fuel system according to “Fuel System defective part.
Inspection”: K14B in Section 1G (Page 1G-5).

Is check result OK?

5 HO2S-1 signal circuit check Go to Step 6. Repair or replace
1) Check “A2” circuit according to Step 3 under “DTC defective wire harness.
P0131 / P0132”: K14B (Page 1A-57).

Is check result OK?

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

Is check result OK?

7 DTC recheck Replace ECM and End.
1) Replace HO2S-1. )(Page 1C-7) recheck DTC. )(Page
1C-1)
2) Perform DTC confirmation procedure and check DTC.

Is DTC P0133 still detected?

DTC P0134
AENBL80A1114025
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0134: O2 Sensor Circuit No Activity Detected (Sensor 1) • HO2S-1 heater and/or its circuit
Output voltage of HO2S-1 circuit stays between 0.42 and 0.50 V for 25 sec. • HO2S-1 and/or its circuit
(3 D/C detection logic)
• ECM
 Engine General Information and Diagnosis: K14B 1A-62

Circuit Diagram

3.3V
+B
1 3
A2
RED C01-40
A3
BLU C01-41
GRN/WHT C01-54
A4
A1 YEL/GRN C01-26
3.3V
2 3
B2
BRN C01-27
B3
YEL C01-22
RED/BLU C01-49
B4
B1 YEL/BLK C01-23

[A] C01 E01

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

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

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

IBP80A111011-10

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

DTC Confirmation Procedure

! WARNING

• Perform road test in a place where there is no traffic to prevent an accident.

• Road test should be performed by two persons, a driver and a tester, on a level road.

NOTE
• Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
– Battery voltage > 11 V
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.

1) Warm up engine to normal operating temperature.

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 HO2S-1 heater check Go to Step 3. Replace HO2S-1.
1) Check HO2S-1 heater. )(Page 1C-6) )(Page 1C-7)

Is check result OK?

1A-63 Engine General Information and Diagnosis: K14B

Step Action Yes No

3 HO2S-1 heater circuit check Go to Step 4. Repair or replace
1) Check HO2S-1 heater circuits according to Steps 2 and defective wire harness.
3 under “DTC P0030 / P0031 / P0032”: K14B (Page 1A-
45).

Is check result OK?

4 HO2S-1 signal circuit check Replace ECM and Repair or replace
1) Check HO2S-1 circuits according to Step 3 under “DTC recheck DTC. )(Page defective wire harness,
P0131 / P0132”: K14B (Page 1A-57). 1C-1) and recheck DTC. If
DTC P0134 still
Is check result OK? detected, replace
HO2S-1. )(Page 1C-7)

DTC P0137 / P0138 / P0140

AENBL80A1114026
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0137: O2 Sensor Circuit Low Voltage (sensor 2) • HO2S-2 and/or its circuit
Output voltage of HO2S-2 circuit is lower than 0.06 V for 30 sec. • HO2S-2 heater and/or its circuit
(3 D/C detection logic)
• Exhaust system
P0138: O2 Sensor Circuit High Voltage (sensor 2)
Output voltage of HO2S-2 signal circuit is higher than 1.27 V for 25 sec. • Air intake system
(3 D/C detection logic) • Fuel system
P0140: O2 Sensor Circuit No Activity Detected (sensor 2) • ECM
Output voltage of HO2S-2 circuit stays between 0.42 to 0.50 V for 500 sec.
(3 D/C detection logic)

Circuit Diagram

3.3V
+B
1 3
A2
RED C01-40
A3
BLU C01-41
GRN/WHT C01-54
A4
A1 YEL/GRN C01-26
3.3V
2 3
B2
BRN C01-27
B3
YEL C01-22
RED/BLU C01-49
B4
B1 YEL/BLK C01-23

[A] C01 E01

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

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

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

IBP80A111011-10

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. Shield wire
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. ECM
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
 Engine General Information and Diagnosis: K14B 1A-64

DTC Confirmation Procedure

! WARNING

• Perform road test in a place where there is no traffic to prevent an accident.

• Road test should be performed by two persons, a driver and a tester, on a level road.

NOTE
• Confirm that the following condition is met in this “DTC Confirmation Procedure”.
– Battery voltage > 11 V
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.

1) Warm up engine to normal operating temperature.

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC(s).
Is there any DTC(s) other than P0137, P0138 and P0140?
3 HO2S-2 signal circuit and ground circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wiring
connectors from ECM and connector from HO2S-2. harness.
2) Check for proper terminal connection to connectors of
“C01”, “E01” and HO2S-2.
3) If connections are OK, check the following points.
• Resistance of “B2” and “B3” circuits: less than 1 Ω
• Resistance between each of “B2” and “B3” circuits
and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at HO2S-2 connector: infinity
• Resistance between “B3” circuit terminal and other
terminal at HO2S-2 connector: infinity
• Voltage of “B2” and “B3” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

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

Is check result OK?

5 HO2S-2 heater circuit check Go to Step 6. Repair or replace
1) Check HO2S-2 heater circuits according to Steps 2 defective part.
through 3 under “DTC P0036 / P0037 / P0038”: K14B
(Page 1A-47).

Is check result OK?

1A-65 Engine General Information and Diagnosis: K14B

Step Action Yes No

6 Fuel injectors and its circuit check Go to Step 7. Repair or replace
1) Check fuel injector circuit. )(Page 1G-6) defective part.
2) Check fuel injectors. )(Page 1G-19)

Is check result OK?

7 DTC recheck Replace ECM and End.
1) Replace HO2S-2. )(Page 1C-7) recheck DTC. )(Page
1C-1)
2) Perform DTC confirmation procedure to check for DTCs.

Is DTC P0137, P0138 or P0140 still detected?

DTC P0171 / P0172

AENBL80A1114027
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0171: System Too Lean • Fuel system
Fuel trim correction is higher than specified value for specified time under • Air intake system
specified vehicle condition.
• Exhaust system
(3 D/C detection logic)
P0172: System Too Rich • HO2S-1 and/or its circuit
Fuel trim correction is lower than specified value for specified time under • Emission control system
specified vehicle condition. • ECM
(3 D/C detection logic)

Circuit Diagram

3.3V
+B
1 3
A2
RED C01-40
A3
BLU C01-41
GRN/WHT C01-54
A4
A1 YEL/GRN C01-26
3.3V
2 3
B2
BRN C01-27
B3
YEL C01-22
RED/BLU C01-49
B4
B1 YEL/BLK C01-23

[A] C01 E01

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

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

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

IBP80A111011-10

[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. Shield wire
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. ECM
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
 Engine General Information and Diagnosis: K14B 1A-66

DTC Confirmation Procedure

! WARNING

• Perform road test in a place where there is no traffic to prevent an accident.

• Road test should be performed by two persons, a driver and a tester, on a level road.

NOTE
• Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
– A/F feedback (closed-loop) control is activated.
– IAT < 60 °C (140 °F)
– ECT ≥ 70 °C (158 °C)
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.

1) Start engine and warm up to normal operating temperature.

2) Drive vehicle at 50 to 80 km/h (31 to 50 mile/h) constantly for 5 min. or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P0171 and P0172?
3 Fuel system and emission system check Go to Step 4. Repair or replace
1) Check the following points related to fuel and emission defective parts.
control systems.
• Fuel pressure: )(Page 1G-11)
• Fuel injector circuit: )(Page 1G-6)
• Fuel injector: )(Page 1G-19)
• MAP sensor: )(Page 1C-10)
• EVAP canister purge valve: )(Page 1B-2)
• PCV valve: )(Page 1B-4)

Is check result OK?

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

Is check result OK?

5 HO2S-1 signal circuit check Go to Step 6. Repair or replace
1) Check HO2S-1 signal circuits according to Step 3 under defective wire harness.
“DTC P0131 / P0132”: K14B (Page 1A-57).

Is check result OK?

6 DTC recheck Replace ECM and End.
1) Replace HO2S-1. )(Page 1C-7) recheck DTC. )(Page
1C-1)
2) Perform DTC confirmation procedure and check DTCs.

Is DTC P0171 or P0172 still detected?

1A-67 Engine General Information and Diagnosis: K14B

DTC P0222 / P0223

AENBL80A1114029
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0222: Throttle / Pedal Position Sensor / Switch “B” Circuit Low • TP sensor (sub) and/or its circuit
Output voltage of TP sensor (sub) signal circuit is lower than 0.2 V. • ECM
(1 D/C detection logic)
P0223: Throttle / Pedal Position Sensor / Switch “B” Circuit High
Output voltage of TP sensor (sub) signal circuit is higher than 4.8 V.
(1 D/C detection logic)

Circuit Diagram

12V
1
A1
C01-55 LT GRN
A2
C01-56 YEL/RED 4
5V B1
C01-14 RED B2 2
C01-42 GRN
B3 3
C01-30 WHT
C01-21 BLK B4
C01-35 BLK 6

[A] C01 E01

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

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

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

IAP70B110018-04

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

DTC Confirmation Procedure

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
 Engine General Information and Diagnosis: K14B 1A-68

Step Action Yes No

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

Is check result OK?

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

Is check result OK?

5 TP sensor check Replace ECM and Replace electric throttle
1) Check TP sensor for performance. )(Page 1C-2) recheck DTC. )(Page body assembly. )(Page
1C-1) 1D-6)
Is check result OK?

DTC P0300 / P0301 / P0302 / P0303 / P0304

AENBL80A1114030
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0300: Random / Multiple Cylinder Misfire Detected • Exhaust system
Any of the following conditions is met. • Air intake system
• Misfire, which causes catalyst to overheat during 200 engine revolutions, is • Ignition system
detected at 2 or more cylinders.
• Fuel system
(MIL blinks as long as misfire lasts.)
• Engine compression
• Misfire, which affects exhaust emission adversely during 1000 engine revolutions,
is detected at 2 or more cylinders. • Valve clearance
(3 D/C detection logic) • Valve timing
• ECM
1A-69 Engine General Information and Diagnosis: K14B

DTC detecting condition Trouble area

P0301: Cylinder 1 Misfire Detected • Ignition system
P0302: Cylinder 2 Misfire Detected • Engine compression
P0303: Cylinder 3 Misfire Detected
• Valve clearance
P0304: Cylinder 4 Misfire Detected
Any of the following conditions is met. • Fuel injector and/or its
circuit
• Misfire, which causes catalyst to overheat during 200 engine revolutions, is
detected at specific cylinder. • ECM
(MIL blinks as long as misfire lasts.)
• Misfire, which affects exhaust emission adversely during 1000 engine revolutions,
is detected at specific cylinder.
(3 D/C detection logic)
 Engine General Information and Diagnosis: K14B 1A-70

DTC Confirmation Procedure

! WARNING

• Perform road test in a place where there is no traffic to prevent an accident.

• Road test should be performed by two persons, a driver and a tester, on a level road.

NOTE
Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
• ECT > –10 °C (14 °F)
• IAT > –10 °C (14 °F)
• Engine speed < 4,500 rpm

1) Warm up engine to normal operating temperature.

2) With engine speed at less than 4,500 rpm, drive vehicle at 50 to 80 km/h (31 to 50 mile/h) constantly for 5 min. or
more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 Ignition system check Go to Step 3. Repair or replace
1) Check ignition system. )(Page 1H-4) defective parts.

Is check result OK?

3 Fuel level check Add fuel and recheck Go to Step 4.
1) Check fuel level by fuel level meter. DTC.

Does it indicate “E” level (empty)?

4 Fuel quality check Go to Step 5. Replace correct type
1) Is correct type fuel used? fuel and recheck DTC.

Is check result OK?

5 Air intake system and exhaust system inspection Go to Step 6. Repair or replace
1) Check exhaust system and air intake system for defective parts.
clogging or leakage.

Is check result OK?

6 Fuel system inspection Go to Step 7. Repair or replace
1) Check the following points related to fuel system. defective parts.
• Fuel pressure: )(Page 1G-11)
• Fuel injector circuit: )(Page 1G-6)
• Fuel injector: )(Page 1G-19)

Is check result OK?

7 Engine mechanical systems check Check ECM power Repair or replace
1) Check following points which can be cause of rough supply and ground defective parts.
idling or poor performance. circuit. )(Page 1A-119)
• Engine compression: )(Page 1D-1) If circuit is OK, replace
• Valve clearance: )(Page 1D-2) ECM and recheck DTC.
)(Page 1C-1)
• Valve timing: )(Page 1D-31)

Is check result OK?

1A-71 Engine General Information and Diagnosis: K14B

DTC P0327
AENBL80A1114031
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0327: Knock Sensor 1 Circuit Low • Knock sensor and/or its circuit
Output voltage of knock sensor signal circuit is out of specified range for 5 sec. • ECM
(3 D/C detection logic)

Circuit Diagram

1
2 A1
WHT C01-31
B1
BLK C01-43

GRY C01-36

[A] C01 E01

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

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

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

IBP80A111016-01

[A]: ECM connector (View: [a]) B1: Knock sensor signal circuit 2 2. Shield wire
A1: Knock sensor signal circuit 1 1. Knock sensor 3. ECM

DTC Confirmation Procedure

! WARNING

• Perform road test in a place where there is no traffic to prevent an accident.

• Road test should be performed by two persons, a driver and a tester, on a level road.

NOTE
Confirm that the following condition is met in this “DTC Confirmation Procedure”.
• ECT > 40 °C (104 °F)

1) Start engine and warm up to normal operating temperature.

2) Drive vehicle at engine speed 2,400 rpm and 5th gear.
3) Increase engine speed gradually until vehicle speed reaches 80 to 100 km/h (50 to 62 mile/h).
4) Decrease engine speed to 2,400 rpm and keep engine at the speed.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
 Engine General Information and Diagnosis: K14B 1A-72

Step Action Yes No

2 Knock sensor signal circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM and connector from knock sensor.
2) Check for proper terminal connection to connectors of
“C01”, “E01” and knock sensor.
3) If connections are OK, check the following points.
• Resistance of “A1” and “B1” circuits: less than 1 Ω
• Resistance between each of “A1” and “B1” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at knock sensor connector: infinity
• Voltage of “A1” and “B1” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 Knock sensor check Go to Step 4. Replace knock sensor.
1) Check knock sensor. )(Page 1C-9) )(Page 1C-9)

Is check result OK?

4 Troubleshooting of other DTC(s) at the same time Go to troubleshooting Replace ECM and
for applicable DTC. recheck DTC. )(Page
Is other DTC(s) detected together? 1C-1)

DTC P0335
AENBL80A1114032
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0335: Crankshaft Position Sensor “A” Circuit • CKP sensor and/or its circuit
• This DTC is detected if any one of the following error counters related to • Sensor plate
CKP sensor signal is more than specified number with engine running. • ECM
– Displaced gap by one tooth or more
– Detection of gap at missing gap range
– Faulty distance between gaps
• CKP sensor signal is not inputted while CMP sensor signal is being
inputted.
(3 D/C detection logic)
1A-73 Engine General Information and Diagnosis: K14B

Circuit Diagram

+B

BLK/RED 3

A1 5V
1 A2
RED/YEL C01-8
A3

B1 5V
2 B2
PNK C01-9
B3
GRY

[A] C01 E01

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

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

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

IAP70B110010-04

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

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Run engine at idle speed for 5 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 CKP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) When ignition is “OFF”, disconnect CKP sensor
connector.
2) Check for proper terminal connection to CKP sensor
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1” and “B3” is battery
voltage.

Is check result OK?

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

Is check result OK?

 Engine General Information and Diagnosis: K14B 1A-74

Step Action Yes No

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

Is check result OK?

5 CKP sensor and sensor plate check Replace ECM and Repair or replace
1) Check CKP sensor and sensor plate. recheck DTC. )(Page defective parts.
1C-1)
• CKP sensor )(Page 1C-8)
• Sensor plate )(Page 1D-68)

Is check result OK?

DTC P0340
AENBL80A1114033
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0340: Camshaft Position Sensor “A” Circuit • CMP sensor and/or its circuit
Any of the following conditions is met. • Signal rotor
• CMP sensor signal is not inputted while CKP sensor signal is being • ECM
inputted.
• CMP sensor signal pattern is not equal to the expected pattern.
(3 D/C detection logic)
1A-75 Engine General Information and Diagnosis: K14B

Circuit Diagram

+B

BLK/RED 3

A1 5V
1 A2
RED/YEL C01-8
A3

B1 5V
2 B2
PNK C01-9
B3
GRY

[A] C01 E01

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

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

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

IAP70B110010-04

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

DTC Confirmation Procedure

1) Run engine at idle speed for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 CMP sensor power supply circuit check Go to Step 4. Go to Step 3.
1) When ignition is “OFF”, disconnect CMP sensor
connector.
2) Check for proper terminal connection to CMP sensor
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is battery
voltage.

Is check result OK?

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

Is check result OK?

 Engine General Information and Diagnosis: K14B 1A-76

Step Action Yes No

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

Is check result OK?

5 CMP sensor and signal rotor check Replace ECM and Repair or replace
1) Check the following points: recheck DTC. )(Page defective parts.
1C-1)
• CMP sensor )(Page 1C-8)
• Signal rotor )(Page 1D-16)

Is check result OK?

1A-77 Engine General Information and Diagnosis: K14B

DTC P0351 / P0352 / P0353 / P0354 / P2300 / P2301 / P2303 / P2304 / P2306 / P2307 / P2309 / P2310
AENBL80A1114034
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0351: Ignition Coil “A” Primary / Secondary Circuit • Ignition coil and/or its circuit
Ignition coil assembly No.1 and/or its circuit is open with engine running. • ECM
(3 D/C detection logic)
P0352: Ignition Coil “B” Primary / Secondary Circuit
Ignition coil assembly No.2 and/or its circuit is open with engine running.
(3 D/C detection logic)
P0353: Ignition Coil “C” Primary / Secondary Circuit
Ignition coil assembly No.3 and/or its circuit is open with engine running.
(3 D/C detection logic)
P0354: Ignition Coil “D” Primary / Secondary Circuit
Ignition coil assembly No.4 and/or its circuit is open with engine running.
(3 D/C detection logic)
P2300: Ignition Coil “A” Primary Control Circuit Low
Ignition coil assembly No.1 drive circuit voltage is shorted to ground with
engine running.
(3 D/C detection logic)
P2301: Ignition Coil “A” Primary Control Circuit High
Ignition coil assembly No.1 drive circuit voltage is shorted to power supply with
engine running.
(3 D/C detection logic)
P2303: Ignition Coil “B” Primary Control Circuit Low
Ignition coil assembly No.2 drive circuit voltage is shorted to ground with
engine running.
(3 D/C detection logic)
P2304: Ignition Coil “B” Primary Control Circuit High
Ignition coil assembly No.2 drive circuit voltage is shorted to power supply with
engine running.
(3 D/C detection logic)
P2306: Ignition Coil “C” Primary Control Circuit Low
Ignition coil assembly No.3 drive circuit voltage is shorted to ground with
engine running.
(3 D/C detection logic)
P2307: Ignition Coil “C” Primary Control Circuit High
Ignition coil assembly No.3 drive circuit voltage is shorted to power supply with
engine running.
(3 D/C detection logic)
P2309: Ignition Coil “D” Primary Control Circuit Low
Ignition coil assembly No.4 drive circuit voltage is shorted to ground with
engine running.
(3 D/C detection logic)
P2310: Ignition Coil “D” Primary Control Circuit High
Ignition coil assembly No.4 drive circuit voltage is shorted to power supply with
engine running.
(3 D/C detection logic)
 Engine General Information and Diagnosis: K14B 1A-78

Circuit Diagram

IG1
BLK/WHT A1 1

2
A2 5V
B1 GRN/YEL C01-4

C1 3
B2 5V
D1 C01-17
GRN/WHT

4 A3
C2 5V
B3
BRN C01-5

5
C3 D2 5V

LT GRN C01-6

D3

[A] C01 E01

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

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

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

IBP80A111017-01

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

DTC Confirmation Procedure

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

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
1A-79 Engine General Information and Diagnosis: K14B

Step Action Yes No

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

Is check result OK?

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

Is check result OK?

4 Ignition coil assembly drive circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors from ECM.
2) Check for proper terminal connections to “C01” and
“E01” connectors.
3) If connections are OK, check the following points.
• Resistance of “A2”, “B2”, “C2” or “D2” circuit: less than
1Ω
• Resistance between each of “A2”, “B2”, “C2” or “D2”
circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “B2” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “C2” circuit terminal and other
terminal at ignition coil connector: infinity
• Resistance between “D2” circuit terminal and other
terminal at ignition coil connector: infinity
• Voltage of “A2”, “B2”, “C2” or “D2” circuit: approx. 0 V
(When ignition is “ON”)

Is check result OK?

5 Ignition coil assembly check Replace ECM and Replace ignition coil
1) Replace ignition coil assembly related to DTC with recheck DTC. )(Page assembly related to
normal ignition coil assembly. 1C-1) DTC. )(Page 1H-7)
2) Clear DTC and recheck DTC.

Is same DTC still detected?

DTC P0420
AENBL80A1114035
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0420: Catalyst System Efficiency Below Threshold • Exhaust system
Average amplitude of HO2S-2 signal is more than specified value for 60 sec. • HO2S-1 and/or its circuit
under specified vehicle condition.
• HO2S-2 and/or its circuit
(3 D/C detection logic)
• TWC
• ECM
 Engine General Information and Diagnosis: K14B 1A-80

Circuit Diagram

3.3V
BLU C01-41
1
RED C01-40
2
3.3V
3 YEL C01-22
BRN C01-27

[A] C01 E01

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

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

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

IBP80A111018-01

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

1. HO2S-1 3. HO2S-2

DTC Confirmation Procedure

! WARNING

• Perform road test in a place where there is no traffic to prevent an accident.

• Road test should be performed by two persons, a driver and a tester, on a level road.

NOTE
• ECT at engine start ≥ –9 °C (16 °F)
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.

1) Start engine and warm up to normal operating temperature.

2) With engine speed at 2,000 to 2,800 rpm, drive vehicle at 60 to 80 km/h (37 to 50 mile/h) constantly for 5 min. or
more at 5th gear. (Keep throttle valve opening constant in this step.)
3) Check whether catalyst readiness / monitoring test has completed or not by using scan tool. If catalyst readiness /
monitoring test has not completed, check vehicle conditions (environmental) and repeat Steps 2) through 4).

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 DTC check Go to troubleshooting Go to Step 3.
1) Check DTC. for applicable DTC.

Is there DTC(s) detected other than P0420?

1A-81 Engine General Information and Diagnosis: K14B

Step Action Yes No

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

Is check result OK?

4 HO2S-2 circuit check Go to Step 5. Repair or replace
1) Check signal and ground circuits according to Step 3 defective wire harness.
under “DTC P0137 / P0138 / P0140”: K14B (Page 1A-
63).

Is check result OK?

5 HO2S-1 signal circuit check Go to Step 6. Repair or replace
1) Check HO2S-1 signal circuit according to Step 3 under defective wire.
“DTC P0131 / P0132”: K14B (Page 1A-57).

Is check result OK?

6 DTC recheck Go to Step 7. End.
1) Replace exhaust manifold (built in TWC). )(Page 1K-3)
2) Perform DTC confirmation procedure.

Is DTC P0420 still detected?

7 DTC recheck Go to Step 8. End.
1) Replace HO2S-2. )(Page 1C-7)
2) Check DTC.

Is DTC P0420 still detected?

8 DTC recheck Replace ECM and End.
1) Replace HO2S-1. )(Page 1C-7) recheck DTC. )(Page
1C-1)
2) Check DTC.

Is DTC P0420 still detected?

DTC P0443 / P0458 / P0459

AENBL80A1114036
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0443: Evaporative Emission System Purge Control Valve Circuit • EVAP canister purge valve and/or
EVAP canister purge valve control circuit is open. its circuit
(3 D/C detection logic) • ECM
P0458: Evaporative Emission System Purge Control Valve Circuit Low
EVAP canister purge valve control circuit is shorted to ground.
(3 D/C detection logic)
P0459: Evaporative Emission System Purge Control Valve Circuit High
EVAP canister purge valve control circuit is shorted to power supply.
(3 D/C detection logic)
 Engine General Information and Diagnosis: K14B 1A-82

Circuit Diagram

3
B1 A1

1
C01-38 BLU/BLK BLK/RED 2

[A] C01 E01

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

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

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

I9P60A111020-02

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

DTC Confirmation Procedure

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

1) Run engine at idle speed for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 EVAP canister purge valve power supply circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect EVAP canister purge defective wire harness.
valve connector.
2) Check for proper terminal connection to EVAP canister
purge valve connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

1A-83 Engine General Information and Diagnosis: K14B

Step Action Yes No

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

Is check result OK?

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

Is check result OK?

DTC P0480 / P0692

AENBL80A1114037
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0480: Fan 1 Control Circuit • Radiator cooling fan relay No.1
Radiator cooling fan relay No.1 drive circuit is shorted to ground or open. and/or its circuit
(3 D/C detection logic but MIL does not light up) • ECM
P0692: Fan 1 Control Circuit High
Radiator cooling fan relay No.1 drive circuit is shorted to power supply.
(3 D/C detection logic but MIL does not light up)

Circuit Diagram

6
A1 1 B1
BLK/RED LT GRN E01-42
5
GRY BLU
C1
A2 2
BLU GRN H+ L+
GRY BLU/BLK 4
C2 3 L- H-
A3 B2
BLU GRN GRN E01-41
BLK C3
BLU/WHT

[A] C01 E01

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

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

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

IBP80A111019-01
 Engine General Information and Diagnosis: K14B 1A-84

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

DTC Confirmation Procedure

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

1) Run engine at idle speed for 1 min.

2) Keep engine at idle speed until engine coolant temperature reaches 97 °C (206.6 °F) or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 Radiator cooling fan relay No.1 power supply circuit Go to Step 3. Repair or replace
(coil side) check defective wire harness.
1) When ignition is “OFF”, remove radiator cooling fan
relay.
2) Check for proper terminal connection to radiator cooling
fan relay No.1 connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

3 Radiator cooling fan relay No.1 check Go to Step 4. Replace radiator cooling
1) Check radiator cooling fan relay No.1. )(Page 1F-14) fan relay No.1.

Is check result OK?

4 Radiator cooling fan relay drive circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” recheck DTC. )(Page defective wire harness.
connectors from ECM. 1C-1)
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at radiator cooling fan relay No.1 connector:
infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

1A-85 Engine General Information and Diagnosis: K14B

DTC P0481 / P0694

AENBL80A1114038
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0481: Fan 2 Control Circuit • Radiator cooling fan relay No.1 (switch
Radiator cooling fan relay No.2 and/or No.3 drive circuit is shorted to side) and/or its circuit
ground or open. • Radiator cooling fan relay No.2 (coil
(3 D/C detection logic but MIL does not light up) side) and/or its circuit
P0694: Fan 2 Control Circuit High
• Radiator cooling fan relay No.3 (coil
Radiator cooling fan relay No.2 and/or No.3 drive circuit is shorted to
side) and/or its circuit
power supply.
(3 D/C detection logic but MIL does not light up) • ECM

Circuit Diagram

6
A1 1 B1
BLK/RED LT GRN E01-42
5
GRY BLU
C1
A2 2
BLU GRN H+ L+
GRY BLU/BLK 4
C2 3 L- H-
A3 B2
BLU GRN GRN E01-41
BLK C3
BLU/WHT

[A] C01 E01

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

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

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

IBP80A111019-01

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

DTC Confirmation Procedure

NOTE
• Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
– Battery voltage > 8.5 V
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.

1) Warm up engine to normal operating temperature.

2) Keep engine at idle speed until engine coolant temperature reaches 97 °C (206.6 °F) or more.
 Engine General Information and Diagnosis: K14B 1A-86

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 Radiator cooling fan relay No.1 power supply circuit Go to Step 3. Check “RDTR” fuse for
(switch side) check blowout. If fuse is not
1) When ignition is “OFF”, remove radiator cooling fan blown, repair or replace
relays No.1, No.2 and No.3. “C1” circuit.
2) Check for proper terminal connection to radiator cooling
fan relay No.1, No.2 and No.3 connectors.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “C1” and ground is battery
voltage.

Is check result OK?

3 Radiator cooling fan relay check Go to Step 4. Replace radiator cooling
1) Check radiator cooling fan relays No.1, No.2 and No.3. fan relays No.1, No.2
)(Page 1F-14) and/or No.3.

Is check result OK?

4 Radiator cooling fan relay No.2 and No.3 power supply Go to Step 5. Repair or replace
circuit (coil side) check defective wire harness.
1) When ignition is “OFF”, disconnect “C01” and “E01”
connectors from ECM.
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “A2” and “A3” circuits: less than 1 Ω
• Resistance between each of “A2” and “A3” circuits
and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at radiator cooling fan relay No.2 connector:
infinity
• Resistance between “A3” circuit terminal and other
terminal at radiator cooling fan relay No.3 connector:
infinity
• Voltage of “A2” and “A3” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

5 Radiator cooling fan relay No.2 and No.3 drive circuit Replace ECM and Repair or replace
check recheck DTC. )(Page defective wire harness.
1) When ignition is “OFF”, check the following points. 1C-1)
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at drive circuit connector of radiator cooling
fan relay No.2 and No.3: infinity
• Voltage of “B2” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

1A-87 Engine General Information and Diagnosis: K14B

DTC P0500
AENBL80A1114039
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0500: Vehicle Speed Sensor “A” • VSS and/or its circuit
Vehicle speed is slower than 4 km/h (2 mile/h) for 12 sec. at fuel cut driving • ECM
condition.
(3 D/C detection logic)

Circuit Diagram

+B 2

BLK/RED 5V
1
A1
A2
PPL C01-10
A3

GRY

[A] C01 E01

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

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

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

IBL80A111005-01

[A]: ECM connector (View: [a]) A2: VSS signal circuit 1. VSS
A1: VSS power supply circuit A3: VSS ground circuit 2. ECM

DTC Confirmation Procedure

! WARNING

• Perform road test in a place where there is no traffic to prevent an accident.

• Road test should be performed by two persons, a driver and a tester, on a level road.

NOTE
• Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
– ECT > 40 °C (104 °F)
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.

1) Warm up engine to normal operating temperature.

2) With engine speed at 1,600 to 4,500 rpm, drive vehicle at 60 to 80 km/h (37 to 50 mile/h) constantly for 1 min. or
more
3) Release accelerator pedal, and keep vehicle coasting for 10 sec. with engine braking applied, i.e. keep vehicle
running under fuel cut condition.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
 Engine General Information and Diagnosis: K14B 1A-88

Step Action Yes No

2 VSS power supply circuit check Go to Step 4. Go to Step 3.
1) When ignition is “OFF”, disconnect VSS connector.
2) Check for proper terminal connection to VSS connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is battery
voltage.

Is check result OK?

3 VSS ground circuit check Repair “A3” circuit. Repair “A1” circuit.
1) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

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

Is check result OK?

5 VSS check Replace ECM and Replace VSS. )(Page
1) Check VSS. )(Page 1C-12) recheck DTC. )(Page 1C-12)
1C-1)
Is check result OK?

DTC P0530
AENBL80A1114040
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0530: A/C Refrigerant Pressure Sensor “A” Circuit • A/C refrigerant pressure
Any of the following conditions is met. sensor and/or its circuit
• Output voltage of A/C refrigerant pressure sensor signal circuit is lower than 0.15 V. • ECM
• Output voltage of A/C refrigerant pressure sensor signal circuit is higher than 4.93 V.
(3 D/C detection logic but MIL does not light up)
1A-89 Engine General Information and Diagnosis: K14B

Circuit Diagram

1 5V
A1 5V
GRY/RED C01-30

A2
RED/GRN C01-35
A3
BLU/RED C01-14

[A] C01 E01

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

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

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

IBP80A111021-01

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

DTC Confirmation Procedure

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 A/C refrigerant pressure sensor power supply circuit Go to Step 4. Go to Step 3.
check
1) When ignition is “OFF”, disconnect A/C refrigerant
pressure sensor connector.
2) Check for proper terminal connection to A/C refrigerant
pressure sensor connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is approx. 5 V.

Is check result OK?

3 A/C refrigerant pressure sensor ground circuit check Repair “A3” circuit. Check “A1” circuit.
1) Check that voltage between “A1” and ground is approx. If defective circuit is
5 V. found, repair “A1”
circuit.
Is check result OK?
If circuit is OK, replace
ECM and recheck DTC.
)(Page 1C-1)
 Engine General Information and Diagnosis: K14B 1A-90

Step Action Yes No

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

Is check result OK?

5 A/C refrigerant pressure sensor check Replace ECM and Replace A/C refrigerant
1) Check A/C refrigerant pressure sensor. recheck DTC. )(Page pressure sensor.
1C-1) • Single A/C type:
• Single A/C type: )(Page 7B-38)
• Dual A/C type: )(Page 7B-85) )(Page 7B-39)
• Dual A/C type:
Is check result OK? )(Page 7B-85)

DTC P0560 / P0562 / P0563

AENBL80A1114041
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0560: System Voltage • ECM power supply circuit and/or
Main power supply voltage is lower than 2.54 V for 10 sec. ground circuit
(3 D/C detection logic) • Charging system
P0562: System Voltage Low
• ECM
Main power supply circuit voltage is lower than 9.8 V for 5 sec. with engine
speed 2,200 rpm or more.
(3 D/C detection logic)
P0563: System Voltage High
Main power supply circuit voltage is higher than 16.5 V for 5 sec. with engine
speed 2,200 rpm or more.
(3 D/C detection logic)
1A-91 Engine General Information and Diagnosis: K14B

Circuit Diagram

1
6
LT GRN C01-55
7
YEL/RED C01-56
5V
C1
RED C01-14
8
GRN C01-42
9
WHT C01-30

BLK C01-21
2 BLK C01-35 5V
A1
BRN E01-31
3 GRN/RED E01-29
E3
12V E01-55 BLK/RED
BLU E01-24 5V
5V 11
A2 3.3V F2
RED E01-43 E01-56 BLK/RED BLK/YEL
E01-54 BRN/WHT E2 BLK/YEL
4 YEL E01-32 E1 F1
WHT E01-22
5V 14
5 B1 15
GRY/RED C01-2 E01-5 BLK/WHT GRN
G1
RED/BLK C01-29 13 12
GRY/BLU C01-20 16
10 5V
D1 5V H1
GRY/RED E01-30 C01-50 BLK
H2 17
RED/GRN E01-35 C01-51 BLK
H3
BLU/RED E01-14 C01-53 BLK

[A] C01 E01

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

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

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

IBP80A111022-01

[A]: ECM connector (View: [a]) G1: Ignition “ON” signal circuit 8. TP sensor (main)
A1: APP sensor (main) power supply circuit H1: ECM ground circuit 1 9. TP sensor (sub)
A2: APP sensor (sub) power supply circuit H2: ECM ground circuit 2 10. A/C refrigerant pressure sensor
B1: MAP sensor power supply circuit H3: ECM ground circuit 3 11. Main relay
C1: TP sensor power supply circuit 1. ECM 12. “FI” fuse
D1: A/C refrigerant pressure sensor power supply circuit 2. APP sensor 13. “IG1 ACC” fuse
E1: Main relay drive circuit 3. APP sensor (main) 14. Ignition switch
E2: Main power supply circuit 1 4. APP sensor (sub) 15. “IG COIL” fuse
E3: Main power supply circuit 2 5. MAP sensor 16. Main fuse box
F1: Main relay power supply circuit (coil side) 6. Electric throttle body assembly 17. Battery
F2: Main relay power supply circuit (switch side) 7. Throttle actuator

DTC Confirmation Procedure

P0560:
1) Set ignition “ON” for 1 min.

P0562 / P0563:
1) Run engine at 2,500 rpm or more for 1 min.
 Engine General Information and Diagnosis: K14B 1A-92

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 ECM power supply and ground circuit check Replace ECM and Repair ECM power
1) Check ECM power supply and ground circuits. )(Page recheck DTC. )(Page supply and/or ground
1A-119) 1C-1) circuit.

Is check result OK?

DTC P0602
AENBL80A1114042
DTC Detecting Condition and Trouble Area

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

DTC detecting condition Trouble area

P0602: Control Module Programming Error • Reprogramming of ECM failure
ECM internal failure (data programming error). • ECM power supply circuit and/or ground circuit
(1 D/C detection logic but MIL does not light up)
• ECM

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. )(Page 1A-19) trouble. )(Page 00-11)
2) Set ignition “OFF”.
3) Perform DTC confirmation procedure and check DTC.

Is DTC P0602 still detected?

2 ECM reprogramming check Execute reprogramming Go to Step 3.
1) Was reprogramming of ECM executed? of ECM correctly once
again.
Is check result OK?
3 ECM reprogramming check Replace ECM and Repair ECM power and/
1) Check ECM power and ground circuit. )(Page 1A-119) recheck DTC. )(Page or ground circuit.
1C-1)
Is it in good condition?

DTC P0607
AENBL80A1114043
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0607: Control Module Performance • ECM power supply circuit and/or ground circuit
Internal failure in ECM is detected. • APP sensor and/or its circuit
(1 D/C detection logic)
• TP sensor and/or its circuit
• MAP sensor and/or its circuit
• A/C refrigerant pressure sensor and/or its circuit
• ECM
1A-93 Engine General Information and Diagnosis: K14B

Circuit Diagram

1
6
LT GRN C01-55
7
YEL/RED C01-56
5V
C1
RED C01-14
8
GRN C01-42
9
WHT C01-30

BLK C01-21
2 BLK C01-35 5V
A1
BRN E01-31
3 GRN/RED E01-29
E3
12V E01-55 BLK/RED
BLU E01-24 5V
5V 11
A2 3.3V F2
RED E01-43 E01-56 BLK/RED BLK/YEL
E01-54 BRN/WHT E2 BLK/YEL
4 YEL E01-32 E1 F1
WHT E01-22
5V 14
5 B1 15
GRY/RED C01-2 E01-5 BLK/WHT GRN
G1
RED/BLK C01-29 13 12
GRY/BLU C01-20 16
10 5V
D1 5V H1
GRY/RED E01-30 C01-50 BLK
H2 17
RED/GRN E01-35 C01-51 BLK
H3
BLU/RED E01-14 C01-53 BLK

[A] C01 E01

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

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

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

IBP80A111022-01

[A]: ECM connector (View: [a]) G1: Ignition “ON” signal circuit 8. TP sensor (main)
A1: APP sensor (main) power supply circuit H1: ECM ground circuit 1 9. TP sensor (sub)
A2: APP sensor (sub) power supply circuit H2: ECM ground circuit 2 10. A/C refrigerant pressure sensor
B1: MAP sensor power supply circuit H3: ECM ground circuit 3 11. Main relay
C1: TP sensor power supply circuit 1. ECM 12. “FI” fuse
D1: A/C refrigerant pressure sensor power supply circuit 2. APP sensor 13. “IG1 ACC” fuse
E1: Main relay drive circuit 3. APP sensor (main) 14. Ignition switch
E2: Main power supply circuit 1 4. APP sensor (sub) 15. “IG COIL” fuse
E3: Main power supply circuit 2 5. MAP sensor 16. Main fuse box
F1: Main relay power supply circuit (coil side) 6. Electric throttle body assembly 17. Battery
F2: Main relay power supply circuit (switch side) 7. Throttle actuator

DTC Confirmation Procedure

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

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

2) If possible, run engine at 1,200 rpm or more for 30 sec. and at 3,000 rpm for 10 sec.
 Engine General Information and Diagnosis: K14B 1A-94

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. )(Page 1A-19) trouble. )(Page 00-11)
2) Set ignition “OFF”.
3) Perform DTC confirmation procedure and check DTC.

Is DTC P0607 still detected?

2 ECM power supply and ground circuit check Replace ECM and Repair ECM power and/
1) Check ECM power supply circuit and ECM ground recheck DTC. )(Page or ground circuit.
circuit. )(Page 1A-119) 1C-1)

Is check result OK?

DTC P0645 / P0646 / P0647

AENBL80A1114045
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0645: A/C Clutch Relay Control Circuit • A/C compressor relay and/or its
A/C compressor relay drive circuit is open. circuit
(3 D/C detection logic but MIL does not light up) • ECM
P0646: A/C Clutch Relay Control Circuit Low
A/C compressor relay drive circuit is shorted to ground.
(3 D/C detection logic but MIL does not light up)
P0647: A/C Clutch Relay Control Circuit High
A/C compressor relay drive circuit is shorted to power supply.
(3 D/C detection logic but MIL does not light up)

Circuit Diagram

5
B1 A1
12V
1
E01-37 GRY BLK/RED 3
WHT BLU/YEL 4
2

[A] C01 E01

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

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

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

IAP70B110021-01

[A]: ECM connector (View: [a]) 1. A/C compressor relay 4. To “A/C” fuse
A1: A/C compressor relay power supply circuit (coil side) 2. A/C compressor 5. ECM
B1: A/C compressor relay drive circuit 3. To main relay
1A-95 Engine General Information and Diagnosis: K14B

DTC Confirmation Procedure

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

1) Run engine at idle speed for 10 sec.

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 A/C compressor relay power supply circuit (coil side) Go to Step 3. Repair or replace
check defective wire harness.
1) When ignition is “OFF”, remove A/C compressor relay.
2) Check for proper terminal connection to A/C compressor
relay connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

3 A/C compressor relay check Go to Step 4. Replace A/C
1) Check A/C compressor relay. compressor relay.
• Single A/C type: )(Page 7B-43)
• Dual A/C type: )(Page 7B-92)

Is check result OK?

4 A/C compressor relay drive circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “C01” and “E01” recheck DTC. )(Page defective wire harness.
connectors from ECM. 1C-1)
2) Check for proper terminal connection to “C01” and “E01”
connectors.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at A/C compressor relay connector: infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

DTC P2100
AENBL80A1114046
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2100: Throttle Actuator “A” Control Motor Circuit / Open • Throttle actuator and/or its circuit
Throttle actuator and/or its circuit malfunction (open, short to power supply or • ECM
short to ground) is detected.
(1 D/C detection logic)
 Engine General Information and Diagnosis: K14B 1A-96

Circuit Diagram

12V
1
A1
C01-55 LT GRN
A2
C01-56 YEL/RED 4
5V B1
C01-14 RED B2 2
C01-42 GRN
B3 3
C01-30 WHT
C01-21 BLK B4
C01-35 BLK 6

[A] C01 E01

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

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

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

IAP70B110018-04

[A]: ECM connector (View: [a]) B3: TP sensor (sub) signal circuit 4. Throttle actuator
A1: Throttle actuator control circuit (close) B4: TP sensor ground circuit 5. ECM
A2: Throttle actuator control circuit (open) 1. Electric throttle body assembly 6. Shield wire
B1: TP sensor power supply circuit 2. TP sensor (main)
B2: TP sensor (main) signal circuit 3. TP sensor (sub)
1A-97 Engine General Information and Diagnosis: K14B

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Keep the accelerator pedal at fully depressed position for 2 sec.
3) Keep the accelerator pedal at idle position for 2 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 Throttle actuator drive circuit check Go to Step 3. Repair throttle actuator
1) When ignition is “OFF”, disconnect “C01” and “E01” drive circuit.
connectors from ECM and connector from electric
throttle body assembly.
2) Check for proper terminal connection to connectors of
“C01”, “E01” and electric throttle body assembly.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at electric throttle body assembly connector:
infinity
• Resistance between “A2” circuit terminal and other
terminal at electric throttle body assembly connector:
infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (When
ignition is “ON”)

Is check result OK?

3 Electric throttle body assembly check Replace ECM and Replace electric throttle
1) Check electric throttle body assembly for performance. recheck DTC. )(Page body assembly. )(Page
)(Page 1C-2) 1C-1) 1D-6)

Is check result OK?

DTC P2101 / P2119

AENBL80A1114047
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2101: Throttle Actuator “A” Control Motor Circuit Range / Performance • Throttle actuator and/or its
Any of the following conditions is met. circuit
• Difference between measured throttle valve position and targeted throttle valve • TP sensor and/or its circuit
position is more than specified value. • Electric throttle body assembly
• Duty ratio of throttle actuator signal is out of specified range for specified time. • ECM
(1 D/C detection logic)
P2119: Throttle Actuator Control Throttle Body Range / Performance
Any of the following conditions is met.
• Time taken by throttle valve to return from partially open position to mechanical
default position is more than specified time during return spring check process
after setting ignition “OFF”.
• Measured default throttle position is out of specified range.
(1 D/C detection logic)
 Engine General Information and Diagnosis: K14B 1A-98

Circuit Diagram

12V
1
A1
C01-55 LT GRN
A2
C01-56 YEL/RED 4
5V B1
C01-14 RED B2 2
C01-42 GRN
B3 3
C01-30 WHT
C01-21 BLK B4
C01-35 BLK 6

[A] C01 E01

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

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

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

IAP70B110018-04

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

DTC Confirmation Procedure

NOTE
Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
• Battery voltage > 8.5 V
• ECT > 5 °C (41 °F)
• IAT > 5 °C (41 °F)

1) Set ignition “ON”.

2) Keep the accelerator pedal at fully depressed position for 10 sec.
3) Keep the accelerator pedal at idle position for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 DTC recheck Go to Step 3. End.
1) Clear DTC.
2) Perform electric throttle control system calibration.
)(Page 1C-4)
3) Recheck DTC.

Is DTC P2101 / P2119 still detected?

1A-99 Engine General Information and Diagnosis: K14B

Step Action Yes No

3 Throttle actuator drive circuit check Go to Step 4. Repair throttle actuator
1) Check throttle actuator drive circuits according to Step 2 drive circuit.
under “DTC P2100”: K14B (Page 1A-95).

Is check result OK?

4 Electric throttle body assembly check Replace ECM and Replace electric throttle
1) Check electric throttle body assembly for performance. recheck DTC. )(Page body assembly. )(Page
)(Page 1C-2) 1C-1) 1D-6)

Is check result OK?

DTC P2122 / P2123

AENBL80A1114048
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2122: Throttle / Pedal Position Sensor / Switch “D” Circuit Low • APP sensor (main) and/or its circuit
Output voltage of APP sensor (main) signal circuit is lower than 0.6 V. • ECM
(1 D/C detection logic)
P2123: Throttle / Pedal Position Sensor / Switch “D” Circuit High
Output voltage of APP sensor (main) signal circuit is higher than 4.4 V.
(1 D/C detection logic)

Circuit Diagram

3
5V
A1
BRN E01-31
A2
1 GRN/RED E01-29
A3
BLU E01-24 5V
B1
RED E01-43
B2
2 YEL E01-32
B3
WHT E01-22

[A] C01 E01

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

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

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

IAP70B110022-02

[A]: ECM connector (View: [a]) B1: APP sensor (sub) power supply circuit 2. APP sensor (sub)
A1: APP sensor (main) power supply circuit B2: APP sensor (sub) signal circuit 3. ECM
A2: APP sensor (main) signal circuit B3: APP sensor (sub) ground circuit
A3: APP sensor (main) ground circuit 1. APP sensor (main)
 Engine General Information and Diagnosis: K14B 1A-100

DTC Confirmation Procedure

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

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 APP sensor (main) power supply circuit check Go to Step 4. Go to Step 3.
1) When ignition is “OFF”, disconnect APP sensor
connector.
2) Check for proper terminal connection to APP sensor
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” is approx. 5 V.

Is check result OK?

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

Is check result OK?

5 APP sensor check Replace ECM and Replace accelerator
1) Check APP sensor. )(Page 1C-5) recheck DTC. )(Page pedal assembly
1C-1) (incorporated with APP
Is check result OK? sensor). )(Page 1C-4)
1A-101 Engine General Information and Diagnosis: K14B

DTC P2127 / P2128

AENBL80A1114049
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2127: Throttle / Pedal Position Sensor / Switch “E” Circuit Low • APP sensor (sub) and/or its circuit
Output voltage of APP sensor (sub) signal circuit is lower than 0.3 V. • ECM
(1 D/C detection logic)
P2128: Throttle / Pedal Position Sensor / Switch “E” Circuit High
Output voltage of APP sensor (sub) signal circuit is higher than 2.5 V.
(1 D/C detection logic)

Circuit Diagram

3
5V
A1
BRN E01-31
A2
1 GRN/RED E01-29
A3
BLU E01-24 5V
B1
RED E01-43
B2
2 YEL E01-32
B3
WHT E01-22

[A] C01 E01

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

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

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

IAP70B110022-02

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

DTC Confirmation Procedure

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

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
 Engine General Information and Diagnosis: K14B 1A-102

Step Action Yes No

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

Is check result OK?

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

Is check result OK?

5 APP sensor check Replace ECM and Replace accelerator
1) Check APP sensor. )(Page 1C-5) recheck DTC. )(Page pedal assembly
1C-1) (incorporated with APP
Is check result OK? sensor). )(Page 1C-4)

DTC P2135
AENBL80A1114050
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2135: Throttle / Pedal Position Sensor / Switch “A”/“B” Voltage • TP sensor and/or its circuit
Correlation • Electric throttle body assembly
Difference between TP sensor (main) signal voltage and TP sensor (sub)
• ECM
signal voltage is higher than specified value.
(1 D/C detection logic)
1A-103 Engine General Information and Diagnosis: K14B

Circuit Diagram

12V
1
A1
C01-55 LT GRN
A2
C01-56 YEL/RED 4
5V B1
C01-14 RED B2 2
C01-42 GRN
B3 3
C01-30 WHT
C01-21 BLK B4
C01-35 BLK 6

[A] C01 E01

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

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

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

IAP70B110018-04

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

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Start engine.
2) Depress accelerator pedal fully, and release it.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 Wire harness check Go to Step 3. Repair or replace
1) Check the following points. defective wire harness.
• “B2” circuit: Refer to Step 2 through 4 under “DTC
P0122 / P0123”: K14B (Page 1A-54).
• “B3” circuit: Refer to Step 2 through 4 under “DTC
P0222 / P0223”: K14B (Page 1A-67).

Is check result OK?

3 TP sensor check Replace ECM and Replace electric throttle
1) Check TP sensor for performance referring to “Throttle recheck DTC. )(Page body assembly. )(Page
Position (TP) Sensor Performance Check” under 1C-1) 1D-6)
“Electric Throttle Body Assembly On-Vehicle Inspection”:
K14B in Section 1C (Page 1C-2).

Is check result OK?

 Engine General Information and Diagnosis: K14B 1A-104

DTC P2138
AENBL80A1114051
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2138: Throttle / Pedal Position Sensor / Switch “D”/“E” Voltage Correlation • APP sensor and/or its circuit
Difference between half of APP (main) sensor signal and APP (sub) sensor signal is • ECM
more than specified value.
(1 D/C detection logic)

Circuit Diagram

3
5V
A1
BRN E01-31
A2
1 GRN/RED E01-29
A3
BLU E01-24 5V
B1
RED E01-43
B2
2 YEL E01-32
B3
WHT E01-22

[A] C01 E01

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

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

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

IAP70B110022-02

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

DTC Confirmation Procedure

NOTE
• Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
– System voltage > 8 V
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.

1) Set ignition “ON”.

2) Keep the accelerator pedal at fully depressed position for 2 sec.
3) Keep the accelerator pedal at idle position for 2 sec.
4) Repeat Step 2) through 3) for 3 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
1A-105 Engine General Information and Diagnosis: K14B

Step Action Yes No

2 Wire harness check Go to Step 3. Repair or replace
1) Check the following points. defective wire harness.
• “A1”, “A2” and “A3” circuits: Refer to Step 3 through 5
under “DTC P2122 / P2123”: K14B (Page 1A-99).
• “B1”, “B2” and “B3” circuits: Refer to Step 3 through 5
under “DTC P2127 / P2128”: K14B (Page 1A-101).

Is check result OK?

3 APP sensor check Replace ECM and Replace APP sensor
1) Check APP sensor for performance. )(Page 1C-4) recheck DTC. )(Page assembly (incorporated
1C-1) with APP sensor).
Is check result OK? )(Page 1C-4)

DTC P2176
AENBL80A1114052
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2176: Throttle Actuator Control System - Idle Position Not Learned • TP sensor and/or its circuit
Any of the following conditions is met. • Electric throttle body assembly
• TP sensor (main) or TP sensor (sub) signal voltage at default position is out • ECM
of specified range for specified time.
• Electric throttle control system calibration is not completed.
(1 D/C detection logic)

Circuit Diagram

12V
1
A1
C01-55 LT GRN
A2
C01-56 YEL/RED 4
5V B1
C01-14 RED B2 2
C01-42 GRN
B3 3
C01-30 WHT
C01-21 BLK B4
C01-35 BLK 6

[A] C01 E01

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

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

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

IAP70B110018-04

[A]: ECM connector (View: [a]) B3: TP sensor (sub) signal circuit 4. Throttle actuator
A1: Throttle actuator control circuit (close) B4: TP sensor ground circuit 5. ECM
A2: Throttle actuator control circuit (open) 1. Electric throttle body assembly 6. Shield wire
B1: TP sensor power supply circuit 2. TP sensor (main)
B2: TP sensor (main) signal circuit 3. TP sensor (sub)
 Engine General Information and Diagnosis: K14B 1A-106

DTC Confirmation Procedure

NOTE
Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
• Battery voltage > 10 V
• ECT > 5 °C
• IAT > 5 °C

1) Set ignition “ON” for 10 sec.

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

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 Electric throttle control system calibration Go to Step 3. End.
1) Perform electric throttle control system calibration.
)(Page 1C-4)
2) Recheck DTC.

Is DTC P2176 still detected?

3 Wire harness check Go to Step 4. Repair or replace
1) Check the following points. defective wire harness.
• TP sensor circuit (main): Refer to Step 2 through 4
under “DTC P0122 / P0123”: K14B (Page 1A-54).
• TP sensor circuit (sub): Refer to Step 2 through 4
under “DTC P0222 / P0223”: K14B (Page 1A-67).

Is check result OK?

4 TP sensor check Go to Step 5. Replace electric throttle
1) Check TP sensor referring to “Throttle Position (TP) body assembly. )(Page
Sensor Performance Check” under “Electric Throttle 1D-6)
Body Assembly On-Vehicle Inspection”: K14B in Section
1C (Page 1C-2).

Is check result OK?

5 Electric throttle body check Replace ECM and Replace electric throttle
1) Check electric throttle body referring to “Electric Throttle recheck DTC. )(Page body assembly. )(Page
Body Assembly On-Vehicle Inspection”: K14B in Section 1C-1) 1D-6)
1C (Page 1C-2).

Is check this result OK?

1A-107 Engine General Information and Diagnosis: K14B

DTC P2270 / P2271

AENBL80A1114053
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2270: O2 Sensor Signal Biased / Stuck Lean • HO2S-2 and/or its circuit
HO2S-2 signal stays in lean state for specified time with specified driving • Exhaust system
condition even if A/F is enrichment control.
• Air intake system
(3 D/C detection logic)
P2271: O2 Sensor Signal Biased / Stuck Rich • Fuel system
Output voltage of HO2S-2 signal circuit is higher than 0.6 V for 10 sec. even if • Emission control system
vehicle is fuel cut driving condition. • ECM
(3 D/C detection logic)

Circuit Diagram

3.3V
+B
1 3
A2
RED C01-40
A3
BLU C01-41
GRN/WHT C01-54
A4
A1 YEL/GRN C01-26
3.3V
2 3
B2
BRN C01-27
B3
YEL C01-22
RED/BLU C01-49
B4
B1 YEL/BLK C01-23

[A] C01 E01

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

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

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

IBP80A111023-02

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

DTC Confirmation Procedure

! WARNING

• Perform road test in a place where there is no traffic to prevent an accident.

• Road test should be performed by two persons, a driver and a tester, on a level road.

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Start engine and warm up to normal operating temperature.

2) Drive vehicle at 60 to 80 km/h (37 to 50 mile/h) for 20 min. or more at 5th gear.
3) Release accelerator pedal at vehicle speed of 60 km/h (37 miles/h) and let vehicle coast under effect of engine
braking to produce fuel cut condition.
 Engine General Information and Diagnosis: K14B 1A-108

4) Repeat Step 2) though 3) for 5 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B
(Page 1A-15).
2 DTC check Go to troubleshooting Go to Step 3.
for applicable DTC.
Is there any DTC(s) other than P2270 and P2271?
3 Exhaust system and air intake system check Go to Step 4. Repair or replace
1) Check exhaust system and air intake system for defective part.
clogging or leakage.

Is check result OK?

4 HO2S-2 signal and ground circuit check Go to Step 5. Repair or replace
1) Check the following point. defective wire harness.
• “B2” and “B3” circuits: Refer to Step 3 under “DTC
P0137 / P0138 / P0140”: K14B (Page 1A-63)

Is check result OK?

5 Recheck DTC Go to Step 6. End.
1) Replace HO2S-2. )(Page 1C-7)
2) Perform DTC confirmation procedure and check DTCs.

Is DTC P2270 or P2271 still detected?

6 Engine mechanical system check Go to Step 7. Repair or replace
1) Check the following points related to engine mechanical defective parts.
system.
• Engine compression: )(Page 1D-1)
• Fuel pressure: )(Page 1G-11)
• Spark plug: )(Page 1H-6)

Is check result OK?

7 Fuel system and emission control system check Replace ECM and Repair or replace
1) Check the following points related to fuel system and recheck DTC. )(Page defective parts.
emission control system. 1C-1)
• EVAP canister purge valve: )(Page 1B-2)
• MAP sensor:
• PCV valve: )(Page 1B-4)
• Fuel injector: )(Page 1G-19)
• Fuel injector circuit: )(Page 1G-6)

Is check result OK?

DTC U0073
AENBL80A1114054
Refer to “Troubleshooting for Communication Bus Off”: K14B Model in Section 10H (Page 10H-14).

DTC U0121
AENBL80A1114055
Refer to “Troubleshooting for Lost Communication”: K14B Model in Section 10H (Page 10H-9).

DTC U0131
AENBL80A1114056
Refer to “Troubleshooting for Lost Communication”: K14B Model in Section 10H (Page 10H-9).
1A-109 Engine General Information and Diagnosis: K14B

DTC U0140
AENBL80A1114057
Refer to “Troubleshooting for Lost Communication”: K14B Model in Section 10H (Page 10H-9).

DTC U0155
AENBL80A1114058
Refer to “Troubleshooting for Lost Communication”: K14B Model in Section 10H (Page 10H-9).

Inspection of ECM and Its Circuits

AENBL80A1114059
Voltage Check

NOTE
• As each terminal voltage is affected by battery voltage, confirm that it is 11 V or more when ignition
is “ON”.
• Voltage with asterisk (*) cannot be measured with voltmeter because it is pulse signal. Use
oscilloscope for its check.
• Before performing this inspection, be sure to read “Precautions for ECM Circuit Inspection” under
“Precautions for Engine (K14B)” in Section 1 (Page 1-1).

[A] C01 E01

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

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

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

I9P60A111032-02

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

Terminal No. Wire color Circuit Normal voltage Condition

10 to 14 V Ignition: “ON”
Refer to reference waveform.
LT GRN/
C01-1* Fuel injector No.4 drive circuit • “Fuel injector signal”: K14B (Page 1A-114)
BLK
• “Fuel injector No.4 signal and ignition coil No.4 signal”:
K14B (Page 1A-115)
MAP sensor power supply
C01-2 GRY/RED 4.5 to 5.5 V Ignition: “ON”
circuit
C01-3 — — — —
0 to 1 V Ignition: “ON”
Refer to reference waveform.
C01-4* GRN/YEL Ignition coil No.1 drive circuit • “Ignition coil signal”: K14B (Page 1A-116)
• “Fuel injector No.1 signal and ignition coil No.1 signal”:
K14B (Page 1A-114)
0 to 1 V Ignition: “ON”
Refer to reference waveform.
C01-5* BRN Ignition coil No.3 drive circuit • “Ignition coil signal”: K14B (Page 1A-116)
• “Fuel injector No.3 signal and ignition coil No.3 signal”:
K14B (Page 1A-115)
0 to 1 V Ignition: “ON”
Refer to reference waveform.
C01-6* LT GRN Ignition coil No.4 drive circuit • “Ignition coil signal”: K14B (Page 1A-116)
• “Fuel injector No.4 signal and ignition coil No.4 signal”:
K14B (Page 1A-115)
C01-7 — — — —
 Engine General Information and Diagnosis: K14B 1A-110

Terminal No. Wire color Circuit Normal voltage Condition

0 to 1 V
or Ignition: “ON”
4 to 5 V
C01-8* RED/YEL CMP sensor signal circuit
Refer to reference waveform.
“CKP sensor signal and CMP sensor signal”: K14B (Page
1A-118)
0 to 1 V
or Ignition: “ON”
4 to 5 V
C01-9* PNK CKP sensor signal circuit
Refer to reference waveform.
“CKP sensor signal and CMP sensor signal”: K14B (Page
1A-118)
0 to 1 V
or Ignition: “ON”
C01-10* PPL VSS signal circuit 4 to 5 V
Refer to reference waveform. “VSS signal”: K14B (Page
1A-115)
C01-11 — — — —
C01-12 — — — —
10 to 14 V Ignition: “ON”
Refer to reference waveform.
C01-13* BLU/YEL Fuel injector No.1 drive circuit • “Fuel injector signal”: K14B (Page 1A-114)
• “Fuel injector No.1 signal and ignition coil No.1 signal”:
K14B (Page 1A-114)
TP sensor power supply
C01-14 RED 4.5 to 5.5 V Ignition: “ON”
circuit
C01-15 — — — —
C01-16 — — — —
0 to 1 V Ignition: “ON”
Refer to reference waveform.
C01-17* GRN/WHT Ignition coil No.2 drive circuit • “Ignition coil signal”: K14B (Page 1A-116)
• “Fuel injector No.2 signal and ignition coil No.2 signal”:
K14B (Page 1A-114)
C01-18 — — — —
10 to 14 V Ignition: “ON”
C01-19* YEL OCV drive circuit Refer to reference waveform.
“OCV signal”: K14B (Page 1A-118)
MAP sensor, IAT sensor and
C01-20 GRY/BLU Below 0.3 V Ignition: “ON”
ECT sensor ground circuit
C01-21 BLK TP sensor ground circuit Below 0.3 V Ignition: “ON”
C01-22 YEL HO2S-2 ground circuit Below 0.3 V Ignition: “ON”
C01-23 YEL/BLK HO2S-2 shield ground circuit Below 0.3 V Ignition: “ON”
C01-24 — — — —
10 to 14 V Ignition: “ON”
Refer to reference waveform.
C01-25* BLU/RED Fuel injector No.3 drive circuit • “Fuel injector signal”: K14B (Page 1A-114)
• “Fuel injector No.3 signal and ignition coil No.3 signal”:
K14B (Page 1A-115)
C01-26 YEL/GRN HO2S-1 shield ground circuit Below 0.3 V Ignition: “ON”
Refer to reference waveform.
C01-27 BRN HO2S-2 signal circuit
“HO2S signal”: K14B (Page 1A-116)
C01-28 — — — —
3.85 to 4.35 V Ignition: “ON”
C01-29 RED/BLK MAP sensor signal circuit Refer to reference waveform. “MAP sensor signal”: K14B
(Page 1A-117)
1A-111 Engine General Information and Diagnosis: K14B

Terminal No. Wire color Circuit Normal voltage Condition

Ignition: “ON”
3.9 to 4.4 V Accelerator pedal: Not
depressed
C01-30 WHT TP sensor (sub) signal circuit
Ignition: “ON”
0.3 to 0.8 V Accelerator pedal: Fully
depressed
1 to 2 V Ignition: “ON”
C01-31* WHT Knock sensor signal circuit 1 Refer to reference waveform.
“Knock sensor signal”: K14B (Page 1A-118)
Ignition: “ON”
2.2 to 2.6 V
ECT: 20 °C (68 °F)
Ignition: “ON”
C01-32 LT GRN ECT sensor signal circuit 1.0 to 1.3 V
ECT: 50 °C (122 °F)
Ignition: “ON”
0.4 to 0.6 V
ECT: 80 °C (176 °F)
C01-33 — — — —
Ignition: “ON”
2.2 to 2.6 V
IAT: 20 °C (68 °F)
Ignition: “ON”
C01-34 BLK/YEL IAT sensor signal circuit 1.3 to 1.7 V
IAT: 40 °C (104 °F)
Ignition: “ON”
0.8 to 1.5 V
IAT: 60 °C (140 °F)
TP sensor shield ground
C01-35 BLK Below 0.3 V Ignition: “ON”
circuit
Knock sensor shield ground
C01-36 GRY Below 0.3 V Ignition: “ON”
circuit
10 to 14 V Ignition: “ON”
Refer to reference waveform.
C01-37* BLU/WHT Fuel injector No.2 drive circuit • “Fuel injector signal”: K14B (Page 1A-114)
• “Fuel injector No.2 signal and ignition coil No.2 signal”:
K14B (Page 1A-114)
10 to 14 V Ignition: “ON”
EVAP canister purge valve
C01-38* BLU/BLK Refer to reference waveform.
drive circuit
“EVAP canister purge valve signal”: K14B (Page 1A-117)
C01-39 — — — —
Refer to reference waveform.
C01-40 RED HO2S-1 signal circuit
“HO2S signal”: K14B (Page 1A-116)
C01-41 BLU HO2S-1 ground circuit Below 0.3 V Ignition: “ON”
Ignition: “ON”
0.6 to 1.0 V Accelerator pedal: Not
depressed
C01-42 GRN TP sensor (main) signal circuit
Ignition: “ON”
4.2 to 4.7 V Accelerator pedal: Fully
depressed
1 to 2 V Ignition: “ON”
C01-43* BLK Knock sensor signal circuit 2 Refer to reference waveform.
“Knock sensor signal”: K14B (Page 1A-118)
C01-44 — — — —
C01-45 — — — —
C01-46 RED/WHT OCV power supply circuit 10 to 14 V Ignition: “ON”
C01-47 — — — —
C01-48 — — — —
10 to 14 V Ignition: “ON”
C01-49* RED/BLU HO2S-2 heater drive circuit Refer to reference waveform.
“HO2S heater signal”: K14B (Page 1A-116)
C01-50 BLK ECM ground circuit 1 Below 0.3 V Ignition: “ON”
C01-51 BLK ECM ground circuit 2 Below 0.3 V Ignition: “ON”
 Engine General Information and Diagnosis: K14B 1A-112

Terminal No. Wire color Circuit Normal voltage Condition

Starting motor relay signal 0 to 1 V Ignition: “ON”
C01-52 BLU/YEL
circuit 6 to 12 V Ignition: “START”
C01-53 BLK ECM ground circuit 3 Below 0.3 V Ignition: “ON”
10 to 14 V Ignition: “ON”
C01-54* GRN/WHT HO2S-1 heater drive circuit Refer to reference waveform.
“HO2S heater signal”: K14B (Page 1A-116)
Throttle actuator drive circuit Refer to reference waveform.
C01-55* LT GRN
(close) “Throttle actuator signal”: K14B (Page 1A-117)
Throttle actuator drive circuit Refer to reference waveform.
C01-56* YEL/RED
(open) “Throttle actuator signal”: K14B (Page 1A-117)

Terminal No. Wire color Circuit Normal voltage Condition

CAN (high) communication Refer to reference waveform.
E01-1* RED
circuit “CAN communication signal”: K14B (Page 1A-119)
CAN (low) communication Refer to reference waveform.
E01-2* WHT
circuit “CAN communication signal”: K14B (Page 1A-119)
E01-3 — — — —
E01-4 — — — —
0 to 1 V Ignition: “OFF”, “ACC”
E01-5 BLK/WHT Ignition signal circuit
10 to 14 V Ignition: “ON”
E01-6 — — — —
E01-7 — — — —
Ignition: “ON”
0 to 1 V
Brake light switch signal Brake pedal: Not depressed
E01-8 GRN/WHT
circuit Ignition: “ON”
10 to 14 V
Brake pedal: Fully depressed
E01-9 — — — —
Ignition: “ON”
10 to 14 V
Clutch pedal: Not depressed
E01-10 YEL/BLK CPP switch signal circuit
Ignition: “ON”
0 to 1 V
Brake pedal: Fully depressed
E01-11 — — — —
E01-12 — — — —
E01-13 — — — —
A/C refrigerant pressure
E01-14 BLU/RED Below 0.3 V Ignition: “ON”
sensor ground circuit
E01-15 — — — —
E01-16 — — — —
E01-17 — — — —
E01-18 — — — —
E01-19 — — — —
E01-20 — — — —
E01-21 — — — —
APP sensor (sub) ground
E01-22 WHT Below 0.3 V Ignition: “ON”
circuit
E01-23 — — — —
APP sensor (main) ground
E01-24 BLU Below 0.3 V Ignition: “ON”
circuit
E01-25 — — — —
E01-26 — — — —
E01-27 — — — —
E01-28 — — — —
Ignition: “ON”
0.6 to 0.9 V Accelerator pedal: Not
APP sensor (main) signal depressed
E01-29 GRN/RED
circuit Ignition: “ON”
3.7 to 4.4 V Accelerator pedal: Fully
depressed
1A-113 Engine General Information and Diagnosis: K14B

Terminal No. Wire color Circuit Normal voltage Condition

A/C refrigerant pressure
E01-30 GRY/RED 4.5 to 5.5 V Ignition: “ON”
sensor power supply circuit
APP sensor (main) power
E01-31 BRN 4.5 to 5.5 V Ignition: “ON”
supply circuit
Ignition: “ON”
0.2 to 0.5 V Accelerator pedal: Not
APP sensor (sub) signal depressed
E01-32 YEL
circuit Ignition: “ON”
1.8 to 2.2 V Accelerator pedal: Fully
depressed
E01-33 — — — —
E01-34 — — — —
Engine: Idling after warming
up
0.9 to 1.3 V
A/C compressor: Not
A/C refrigerant pressure
E01-35 RED/GRN operated
sensor signal circuit
Engine: Idling after warming
1.3 to 2.2 V up
A/C compressor: Operated
E01-36 — — — —
A/C compressor: Not
A/C compressor relay drive 10 to 14 V
E01-37 GRY operated
circuit
0 to 1 V A/C compressor: Operated
E01-38 — — — —
E01-39 — — — —
E01-40 — — — —
Ignition: “ON”
95 °C (203 °F) < ECT <102
10 to 14 V
°C (215.6 °F)
Radiator cooling fan relay
E01-41 GRN A/C switch: OFF
No.2 and No.3 drive circuit
Ignition: “ON”
0 to 1 V ECT > 102 °C (215.6 °F)
A/C switch: OFF
Ignition: “ON”
10 to 14 V ECT < 95 °C (203 °F)
Radiator cooling fan relay A/C switch: OFF
E01-42 LT GRN
No.1 drive circuit Ignition: “ON”
0 to 1 V ECT > 97 °C (206.6 °F)
A/C switch: OFF
APP sensor (sub) power
E01-43 RED 4.5 to 5.5 V Ignition: “ON”
supply circuit
E01-44 — — — —
E01-45 — — — —
E01-46 — — — —
E01-47 — — — —
Ignition: “ON”
0 to 1 V Blower speed switch: 2nd or
more
Ignition: “ON”
E01-48 BLU/WHT Blower motor signal circuit
5 to 7 V Blower speed switch: 1st
position
Ignition: “ON”
10 to 14 V
Blower speed switch: “OFF”
Refer to reference waveform.
E01-49 YEL/RED Fuel pump relay drive circuit
“Fuel pump relay signal”: K14B (Page 1A-118)
E01-50 — — — —
E01-51 — — — —
E01-52 — — — —
E01-53 — — — —
 Engine General Information and Diagnosis: K14B 1A-114

Terminal No. Wire color Circuit Normal voltage Condition

0 to 1 V Ignition: “ON”
E01-54 BRN/WHT Main relay drive circuit Ignition: 10 sec. after ignition
10 to 14 V
“OFF”
E01-55 BLK/RED Main power supply circuit 1 10 to 14 V Ignition: “ON”
E01-56 BLK/RED Main power supply circuit 2 10 to 14 V Ignition: “ON”

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

NOTE Fuel injector No.1 signal (1):

• How to read waveforms is shown below. Channel Probe Terminal No.
+ C01-13
1
– C01-51

Ignition coil No.1 signal (2):

Channel Probe Terminal No.
+ C01-4
2
– C01-51

CMP sensor signal (3):

Channel Probe Terminal No.
+ C01-8
3
– C01-51

CKP sensor signal (4):

Channel Probe Terminal No.
+ C01-9
4
IBP80A111034-01 – C01-51
[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel
[B]: Ground level of each channel [D]: TIME/DIV Measurement condition
Engine: Idle speed after warming up
• Waveform may vary with measurement
condition and vehicle specifications.

Fuel injector signal

Channel Probe Terminal No.
C01-13, C01-
+ 37, C01-25 or
1
C01-1
– C01-51

Measurement condition
Engine: Idle speed after warming up
I8RW0A110013-01

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

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

Fuel injector No.2 signal (1):

Channel Probe Terminal No.
+ C01-37
1
– C01-51

Ignition coil No.2 signal (2):

I7V20A111014-02 Channel Probe Terminal No.
+ C01-17
2
– C01-51
1A-115 Engine General Information and Diagnosis: K14B

CMP sensor signal (3):

Channel Probe Terminal No.
+ C01-8
3
– C01-51

CKP sensor signal (4):

Channel Probe Terminal No.
+ C01-9
4
– C01-51

Measurement condition
Engine: Idle speed after warming up
I8RW0A110016-01

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

Fuel injector No.4 signal and ignition coil No.4 signal

Fuel injector No.4 signal (1):

Channel Probe Terminal No.
+ C01-1
1
– C01-51

Ignition coil No.4 signal (2):

Channel Probe Terminal No.
I8RW0A110014-01 + C01-6
2
5. Camshaft 360° angle 6. Crankshaft 720° angle – C01-51

Fuel injector No.3 signal and ignition coil No.3 signal CMP sensor signal (3):
Channel Probe Terminal No.
Fuel injector No.3 signal (1): + C01-8
3
Channel Probe Terminal No. – C01-51
+ C01-25
1
– C01-51 CKP sensor signal (4):
Channel Probe Terminal No.
Ignition coil No.3 signal (2): + C01-9
4
Channel Probe Terminal No. – C01-51
+ C01-5
2
– C01-51 Measurement condition
Engine: Idle speed after warming up
CMP sensor signal (3):
Channel Probe Terminal No.
+ C01-8
3
– C01-51

CKP sensor signal (4):

Channel Probe Terminal No.
+ C01-9
4
– C01-51

Measurement condition
Engine: Idle speed after warming up
I8RW0A110017-01

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

VSS signal
Channel Probe Terminal No.
+ C01-10
1
– C01-51

Measurement condition Ignition: “ON”

 Engine General Information and Diagnosis: K14B 1A-116

Lift up vehicle until all 4 tires rotate smoothly and rotate Measurement condition
tire by hand. Engine: Idle speed after warming up

I9P60A111033-02

HO2S signal

IBP80A111024-02 HO2S-1 signal (1):

Channel Probe Terminal No.
HO2S heater signal + C01-40
1
Channel Probe Terminal No. – C01-51
+ C01-54 or C01-49
1
– C01-51 HO2S-2 signal (2):
Channel Probe Terminal No.
+ C01-27
2
– C01-51

Measurement condition
Engine: Racing after warming up

IBP80A111026-01

3. Engine: Idle speed 4. Engine: Racing

Ignition coil signal

Channel Probe Terminal No.
C01-4, C01-17,
1 +
C01-5 or C01-6
– C01-51

Measurement condition
Engine: Idle speed after warming up
1A-117 Engine General Information and Diagnosis: K14B

I7V20A111065-02

IBP80A111035-02
Throttle actuator signal
MAP sensor signal
Throttle actuator signal (Open) (1):
MAP sensor signal (1): Channel Probe Terminal No.
Channel Probe Terminal No. + C01-56
1
+ C01-29 – C01-51
1
– C01-51
Throttle actuator signal (Close) (2):
TP sensor (main) signal circuit (2): Channel Probe Terminal No.
Channel Probe Terminal No. + C01-55
2
+ C01-42 – C01-51
2
– C01-51
Measurement condition
Measurement condition Engine: Racing after warming up (Momentarily at
Engine: Racing after warming up accelerator pedal depressed)

IAV10A112026-01

Measurement condition
IBP80A111033-01 Engine: Idle speed after warming up
3. Engine: Idle speed 4. Engine: Racing

EVAP canister purge valve signal

Channel Probe Terminal No.
+ C01-38
1
– C01-51

Measurement condition
EVAP canister purge valve: 10% open
(using “Active Test” of SUZUKI scan tool)

IAV10A112025-01
 Engine General Information and Diagnosis: K14B 1A-118

CKP sensor signal and CMP sensor signal OCV signal (–) (2):
Channel Probe Terminal No.
CMP sensor signal (1): + C01-19
2
Channel Probe Terminal No. – C01-51
+ C01-8
1
– C01-51 Measurement condition
Engine: Racing after warming up (Momentarily at
CKP sensor signal (2): accelerator pedal depressed)
Channel Probe Terminal No.
+ C01-9
2
– C01-51

Measurement condition
Engine: Idle speed after warming up

I8RW0A110018-02

Fuel pump relay signal

Fuel pump relay signal (1):

Channel Probe Terminal No.
+ E01-49
1
– C01-51
IAP70B110017-01
Ignition signal (2):
Knock sensor signal Channel Probe Terminal No.
+ E01-5
Channel Probe Terminal No. 2
– C01-51
+ C01-31 or C01-43
1
– C01-51
Starting motor relay signal (3):
Measurement condition Channel Probe Terminal No.
Engine: Running at 4,000 rpm after warming up + C01-52
3
– C01-51

Measurement condition
Ignition: “OFF” → “ON” → “START”

I9P60A111041-01

OCV signal

OCV signal (+) (1):

Channel Probe Terminal No.
+ C01-46
1
– C01-51
IBP80A111036-02

4. Ignition: “OFF” 6. Ignition: “START”

5. Ignition: “ON”
1A-119 Engine General Information and Diagnosis: K14B

CAN communication signal

CAN communication signal (High) (1):

Channel Probe Terminal No.
+ E01-1
1
– C01-51

CAN communication signal (Low) (2):

Channel Probe Terminal No.
+ E01-2
2
– C01-51

Measurement condition
• Engine: Stop
• Ignition: “ON” IBP80A111027-02

ECM Power Supply and Ground Circuit Check

AENBL80A1114060
Circuit Diagram

1
6
LT GRN C01-55
7
YEL/RED C01-56
5V
C1
RED C01-14
8
GRN C01-42
9
WHT C01-30

BLK C01-21
2 BLK C01-35 5V
A1
BRN E01-31
3 GRN/RED E01-29
E3
12V E01-55 BLK/RED
BLU E01-24 5V
5V 11
A2 3.3V F2
RED E01-43 E01-56 BLK/RED BLK/YEL
E01-54 BRN/WHT E2 BLK/YEL
4 YEL E01-32 E1 F1
WHT E01-22
5V 14
5 B1 15
GRY/RED C01-2 E01-5 BLK/WHT GRN
G1
RED/BLK C01-29 13 12
GRY/BLU C01-20 16
10 5V
D1 5V H1
GRY/RED E01-30 C01-50 BLK
H2 17
RED/GRN E01-35 C01-51 BLK
H3
BLU/RED E01-14 C01-53 BLK

[A] C01 E01

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

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

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

IBL80A111009-01
 Engine General Information and Diagnosis: K14B 1A-120

[A]: ECM connector (View: [a]) G1: Ignition “ON” signal circuit 8. TP sensor (main)
A1: APP sensor (main) power supply circuit H1: ECM ground circuit 1 9. TP sensor (sub)
A2: APP sensor (sub) power supply circuit H2: ECM ground circuit 2 10. A/C refrigerant pressure sensor
B1: MAP sensor power supply circuit H3: ECM ground circuit 3 11. Main relay
C1: TP sensor power supply circuit 1. ECM 12. “FI” fuse
D1: A/C refrigerant pressure sensor power supply circuit 2. APP sensor 13. “IG1 ACC” fuse
E1: Main relay drive circuit 3. APP sensor (main) 14. Ignition switch
E2: Main power supply circuit 1 4. APP sensor (sub) 15. “IG COIL” fuse
E3: Main power supply circuit 2 5. MAP sensor 16. Main fuse box
F1: Main relay power supply circuit (coil side) 6. Electric throttle body assembly 17. Battery
F2: Main relay power supply circuit (switch side) 7. Throttle actuator

Circuit Description
When ignition is “ON”, the main relay turns ON, i.e. contact in relay closes and the main power is supplied to ECM.
ECM then supplies 5 V power to the following sensors: A/C refrigerant pressure sensor, APP sensor, TP sensor and
MAP sensor.

Troubleshooting

NOTE
• Before troubleshooting, be sure to read “Precautions for ECM Circuit Inspection” under
“Precautions for Engine (K14B)” in Section 1 (Page 1-1).
• Before performing, be sure to confirm that related fuses of ECM power circuit have not blown out.
If any fuse has blown out, replace the fuse and check circuits connected to the blown fuse for short
circuit to ground.

Step Action Yes No

1 Battery check Go to Step 2. Check battery and
1) Check that battery voltage is 12 V or more. generator referring to
“Battery Inspection”:
Is check result OK? K14B in Section 1J
(Page 1J-6) and
“Generator Test”: K14B
in Section 1J (Page 1J-
8).
2 Main relay power supply check Go to Step 3. Check that “FI” fuse has
1) With ignition “OFF”, remove main relay (1) from not blown. If check
individual circuit fuse box No.1. result is OK, repair or
replace defective wire
1 harness.

IBP80A111029-01

2) Check for proper terminal connection to main relay

connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “F1” and “F2” circuit
and ground is battery voltage.

Is check result OK?

3 Main relay check Go to Step 4. Replace main relay.
1) Check main relay. )(Page 1C-10)

Is check result OK?

1A-121 Engine General Information and Diagnosis: K14B

Step Action Yes No

4 Ignition switch circuit check Go to Step 5. Check that “IG COIL”
1) When ignition is “OFF”, install main relay to individual fuse has not blown. If
circuit fuse box No.1. check result is OK,
repair or replace
2) Disconnect “C01” and “E01” connectors from ECM.
defective wire harness.
3) Check for proper terminal connection to “C01” and “E01”
connectors.
4) If connections are OK, set ignition “ON”.
5) Check that voltage between “G1” and ground is battery
voltage.

Is check result OK?

5 Main relay drive circuit check Go to Step 6. Repair or replace
1) Set ignition “OFF”. defective wire harness.
2) Check that voltage between “E1” and ground is battery
voltage.

Is check result OK?

6 Main power supply circuit check Go to Step 7. Repair or replace
1) Using service wire, ground “E1”. defective wire harness.
2) Set ignition “ON”.
3) Check that voltage between each of “E2” and “E3” circuit
and ground is battery voltage.

Is check result OK?

7 ECM ground circuit check Go to Step 8. Repair or replace
1) Set ignition “OFF”. defective wire harness.
2) Check that resistance between each of “H1”, “H2” and
“H3” circuit and ground is less than 1 Ω.

Is check result OK?

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

Is check result OK?

 Engine General Information and Diagnosis: K14B 1A-122

Fuel Cut Operation Inspection

AENBL80A1114061
1) Place gear shift lever in “Neutral” and apply parking 1
brake.
2) Warm up engine to normal operating temperature. 2

3) While listening to sound of injector (2) using sound

scope (1) or the like, increase engine speed to
higher than 3,000 rpm.

IBP80A111030-01

4) Check that injector operation sound stops when

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

Repair Instructions
Idle Speed and IAC Throttle Valve Opening 1) With ignition “OFF”, connect SUZUKI scan tool to
Inspection DLC (1).
AENBL80A1116001
Before idle speed check, make sure of the following. Special tool
• Lead wires and hoses of electronic fuel injection and (A): SUZUKI scan tool (SUZUKI-SDT)
engine and emission control systems are connected
securely.
• Valve clearance is checked according to maintenance
schedule.
• Ignition timing is within specification.
• All electrical systems (wipers, heater, lights, A/C, etc.)
are out of service. (A)
• Air cleaner has been properly installed and is in good
condition.
1
• There are no air abnormally drawn in from air intake
system.
• There are no obstruction in PCV valve or its hoses.
• There are no DTCs in ECM.
• The following items are turned OFF as checked using
“Data List” mode on SUZUKI scan tool. IBP80A111031-01

– A/C Comp Relay 2) Warm up engine to normal operating temperature.

– A/C Switch 3) Check engine idle speed and “IAC throttle opening”
– Brake Switch using “Data List” mode on SUZUKI scan tool.
– Electric Load 4) If check result is out of specification, check engine
idle speed referring to “Improper engine idling or
– Blower Fan
engine fails to idle” under “Engine Symptom
After confirming all items, check idle speed and IAC
Diagnosis”: K14B (Page 1A-33).
throttle opening as follows.
Engine idle speed
NOTE A/C OFF: 600 to 700 rpm (IAC throttle opening: 1
Before starting engine, place gearshift lever to 45%)
in “Neutral”, apply parking brake and block A/C ON: 700 to 900 rpm (IAC throttle opening: 1
drive wheels. to 55%)
1A-123 Engine General Information and Diagnosis: K14B

Special Tools and Equipment

Special Tool
AENBL80A1118001
SUZUKI scan tool (SUZUKI- 6
SDT)
— 1 2
This kit includes following
4
items. 1. SUZUKI-SDT 2. 3
DLC cable 3. USB cable 4. 5
AC/DC power supply 5.
Voltage meter probe 6.
Storage case) / )
 Engine General Information and Diagnosis: D13A 1A-124

D13A
General Description
Statement on Cleanliness and Care
AENBL80A1121001 1
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousands of a
millimeter (ten thousands of an inch).
Accordingly, when any internal engine parts are
serviced, care and cleanliness are important.
It should be understood that proper cleaning and
protection of machined surfaces and friction areas is part
of the repair procedure. This is considered standard
I9P60A112053-01
shop practice even if not specifically stated.
• When ECM detects a malfunction which gives an
• A liberal coating of engine oil should be applied to
adverse effect to vehicle emission while the engine is
friction areas during assembly to protect and lubricate
running, it makes the MIL in the meter cluster of the
the surfaces on initial operation.
instrument panel turn on and stores the malfunction
• Whenever valve train components, pistons, piston area in its memory.
rings, connecting rods, connecting rod bearings, and
• As a condition for detecting a malfunction in some
crankshaft main bearings are removed for service,
areas in the system being monitored by ECM and
they should be retained in order.
turning on MIL due to that malfunction, 1 driving cycle
At the time of installation, they should be installed in
or 3 driving cycle detection logic is adopted to prevent
the original locations and with the same mating
erroneous detection.
surfaces as when removed.
• Battery cables should be disconnected before any Warm-Up Cycle
major work is performed on the engine. A “warm-up cycle” is defined in the OBD regulations to
Failure to disconnect cables may result in damage to be sufficient vehicle operation such that coolant
wire harness or other electrical parts. temperature rises by at least 22 °C (40 °F) from engine
• The four cylinders of the engine are identified by starting and reaches a minimum temperature of 70 °C
numbers; No.1, No.2, No.3 and No.4 as counted from (158 °F).
crankshaft pulley side to flywheel side.
Driving Cycle
Engine Diagnosis General Description A “driving cycle” consists of two parts, engine startup
AENBL80A1121002 and engine shutoff.
The engine and emission control system in this vehicle
are controlled by ECM. ECM has an OBD system which 1 Driving Cycle Detection Logic
detects a malfunction in this system and abnormality of The malfunction detected in the first driving cycle is
those parts that influence the engine exhaust emission. stored in ECM memory and MIL light up at the same
When diagnosing engine troubles, be sure to have full time.
understanding of the outline of “OBD System
Description”: D13A (Page 1A-124) and each item in 3 Driving Cycle Detection Logic
“Precautions for Diagnosing Trouble” under “Precautions The malfunction detected in the first driving cycle is
for Engine (D13A)” in Section 1 (Page 1-2) and execute stored in ECM memory (in the form of pending DTC) but
diagnosis according to “Engine and Emission Control the MIL does not light at this time.
System Check”: D13A (Page 1A-131). The MIL does not light up at the second detection of the
There is a close relationship between the emission same malfunction also in the second driving cycle. The
system, engine mechanical, engine cooling system, MIL lights up at the third detection of the same
exhaust system, etc. in their structure and operation. In malfunction also in the third driving cycle.
case of an engine trouble, even when the MIL does not
turn on, it should be diagnosed according to “Engine and Pending DTC
Emission Control System Check”: D13A (Page 1A-131). Pending DTC means a DTC detected and stored
temporarily at first or second driving cycle of the DTC
OBD System Description which is detected in the 2 or 3 driving cycle detection
AENBL80A1121003
logic.
ECM in this vehicle has the following functions.
• When ignition is “ON” with the engine at a stop, MIL
(1) turns on to check the circuit of the MIL.
1A-125 Engine General Information and Diagnosis: D13A

Freeze Frame Data Freeze frame data clearance

ECM stores the engine and driving conditions at the The freeze frame data is cleared at the same time as
moment of the detection of a malfunction in its memory. clearance of DTC.
This data is called “Freeze frame data”.
Therefore, it is possible to know engine and driving System Readiness Test
conditions (e.g., whether the engine was warm or not, The system readiness test is to check if the on-board
where the vehicle was running or stopped, where air/fuel diagnosis of each system related to exhaust emission
mixture was lean or rich) when a malfunction was has been completed or not using a scan tool (“GST
detected by checking the freeze frame data using a scan mode” of SUZUKI scan tool or OBD generic scan tool).
tool (“GST mode” of SUZUKI scan tool or OBD generic When the conditions established for each system are
scan tool). met, ECM performs an on-board diagnosis of
Utilizing this function, it is possible to know the order of corresponding system and changes the status of system
detection of these malfunctions. readiness test from “Incomplete” to “Complete”. When
This is helpful when rechecking or diagnosing a trouble. “Complete” status is displayed, it is maintained until the
For details of freeze frame data that can be read from “DTC clearance” is performed using scan tool.
ECM, refer to table below.
NOTE
DTC
Calculated Load • The status of system readiness test may
ECT be changed as “incomplete” when
MAP performing the following services.
Engine Speed – Disconnection of battery negative (–)
Vehicle Speed cable
Intake Air Temperature
– Disconnection of ECM connectors
MAF
Fuel Rail Pressure – Removal of ground cables for ECM
– Disconnection of “ECM” fuse
Freeze flame data (for example) • By utilizing this system readiness test, it is
possible to confirm that all DTC
Function View System Bar Help
confirmation procedure for each system
Engine (GST Mode) / Freeze Frame Data
has been completed or incompleted. For
P0100 Mass or Volume Air Flow “A” Circuit all DTCs related to each system, refer to
the table below.
Parameter Value Unit
DTC P0100 • The system readiness test is NOT the
Calc Load 7.8 % result (“Normal” or “Abnormal”) of the
Coolant Temp 71 C onboard diagnosis but the result
MAP 99 kPa (“Complete” or “Incomplete”) of the on-
Engine Speed 898.0 rpm board diagnosis.
Vehicle Speed 0 km/h
Intake Air Temp -40 C
MAF 655.35 g/sec
Fuel Rail Pressure 57400 kPa

Exit

Data Active
DTC View Utility
List Test
IAY40A110002-01

Monitor item of system readiness test table

Monitoring item DTC related to monitoring item
Fuel system P0190 P0201 P0202 P0203 P0204 — —
Comprehensive component P0095 P0115 P0500 — — — —
P0069 P0100 P0101 P0234 P0235 P0401 P0402
EGR system
P0403 P2226 — — — — —

DLC Description
AENBL80A1121004
DLC (1) is in compliance with SAE J1962 in the shape of
connector and pin assignment.
K line (3) of ISO 9141 is used for SUZUKI scan tool
(SUZUKI-SDT) (A) or OBD generic scan tool to
communicate with ECM.
 Engine General Information and Diagnosis: D13A 1A-126

16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1

5
4
3
1

(A)

IBP80A112002-01

2. B + (Continuous battery power)

4. ECM ground (Signal ground)
5. Ground (Chassis ground)
1A-127 Engine General Information and Diagnosis: D13A

Schematic and Routing Diagram

Electronic Control System Diagram
AENBL80A1122001

3 24
26 1
22
26 2

25

15
26 26

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

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

16

26

14
:A
20
19
:B
26
21 :C
28

IAY40A110024-01

A: Fuel feed line 10. Glow plug 22. A/F sensor

B: Fuel return line 11. ECT sensor 23. Oil separator
C: Fuel high pressure line 12. CKP sensor 24. Boost pressure control valve actuator
1. Air cleaner 13. Fuel injector 25. Catalytic converter
2. MAF and IAT-1 sensor 14. Fuel temperature sensor 26. To ECM
3. Turbocharger 15. Fuel pressure sensor 27. Common rail
4. Intercooler 16. EGR valve 28. Fuel filter water detection sensor
5. APP sensor 17. High pressure pump 29. Boost pressure control solenoid valve
6. Brake light switch / Brake switch 18. Fuel flow actuator 30. To glow plug control module
7. CPP switch 19. Fuel filter 31. Vacuum pump
8. Boost pressure and IAT-2 sensor 20. Fuel pump 32. Vacuum tank
9. CMP sensor 21. Fuel tank
 Engine General Information and Diagnosis: D13A 1A-128

Electronic Control System Circuit Diagram

AENBL80A1122002

IG1 64

BLU/RED E01-56 C01-47 ORN

BLK/WHT 1 BLU/ORN E01-62 24
C01-16 ORN/WHT
BLU/YEL E01-34
C01-49 YEL
RED/BLK C01-23 25
C01-17 YEL/BLK
ORN C01-41
2
BLK C01-24 C01-48 GRN
26
WHT/GRN C01-37 C01-31 WHT/GRN
IG1 +BB +B
PNK C01-25 C01-46 BLU
27
3 PNK/BLK C01-56 C01-1 WHT/BLU
PPL C01-21
C01-30 YEL/GRN
65
GRY/BLK C01-43 C01-15 GRY/RED 28 BLU
4
YEL/RED C01-59

GRN/YEL C01-8
5 ORN/BLK C01-38 C01-5 BLU/RED BLU
YEL/RED C01-6 BLK/WHT
6 E01-90 YEL/RED 29
PPL/WHT C01-54 GRY
7 GRN C01-29
8 BRN E01-83 E01-70 BLU BLK/WHT
30
GRN/RED E01-65 E01-74 GRY/BLU RED
BLU E01-35 BLU RED YEL GRN GRY
9 RED E01-15
YEL E01-41 31 32 33 34
WHT E01-32
BLK E01-47 35
10 E01-7 LT GRN/RED
RED/WHT E01-44
BLU
GRN/WHT E01-46 38
+B 36
YEL E01-45 BLU/BLK 39
LT GRN E01-12 GRY
BLU BLK 37
E01-8 GRN
BLU/WHT BLK
+BB 11 40 42
GRY/YEL C01-9 E01-75 PPL/WHT BLK/RED
41
BLK PNK BLK/RED
IG1
12
43
LT GRN/BLK YEL/GRN E01-22 RED/BLU
E01-13
13 E01-61 BLK/YEL
14
GRN/YEL E01-68
15
PNK GRN/WHT E01-81 44
16 E01-79 GRY BLU
17 45
BLU/YEL

WHT WHT
GRY/RED E01-37 E01-1 BRN 46
BLK BLK
18 RED/GRN E01-87 E01-2 BRN
BLU/RED E01-10 E01-3 BRN +B

BLU
E01-89 PPL 47
YEL/BLK C01-4 GRY
19
ORN/BLK C01-20
50 48 49
YEL RED
E01-23 BLK/WHT IG1 BLK
RED E01-64 IG2 51
20 21 53
WHT E01-40 IG1 52

54 ST

23 E01-50 YEL/GRN
22 57 YEL/GRN 55
E01-80 BRN/WHT
58 BLK/YEL 56
E01-4 BLK/RED BLK/RED
E01-6 BLK/RED
59
E01-5 BLK/RED 60
GRY/BLK E01-66

: 12V 61
: 62 : 63 : 5V

IBL80A112001-02
1A-129 Engine General Information and Diagnosis: D13A

1. MAF and IAT-1 sensor 23. Barometric pressure sensor 45. “A/C” fuse
2. Boost pressure and IAT-2 sensor 24. Fuel injector No.1 46. A/C compressor
3. CMP sensor 25. Fuel injector No.2 47. VSS
4. CKP sensor 26. Fuel injector No.3 48. Starting motor control relay
5. Fuel pressure sensor 27. Fuel injector No.4 49. “ST MOT” fuse
6. ECT sensor 28. EGR valve 50. Starting motor
7. APP sensor 29. Fuel filter water detection sensor 51. Ignition switch
8. APP sensor (main) 30. Glow plug control module 52. “IG1 SIG” fuse
9. APP sensor (sub) 31. Glow plug No.1 53. “IG COIL” fuse
10. A/F sensor 32. Glow plug No.2 54. “ST SIG” fuse
11. Oil pressure switch 33. Glow plug No.3 55. “ECM” fuse
12. CPP switch 34. Glow plug No.4 56. “FI” fuse
13. Brake light switch / Brake switch 35. Radiator cooling fan relay No.1 57. Main relay
14. Brake switch 36. Radiator cooling fan relay No.2 58. “INJ DRV” fuse
15. Brake light switch 37. Radiator cooling fan relay No.3 59. “FL1” fuse
16. “STOP” fuse 38. Radiator cooling fan motor 60. Battery
17. Brake light 39. “RDTR” fuse 61. “FI2” fuse
18. A/C refrigerant pressure sensor 40. Fuel pump relay 62. Engine ground
19. Fuel flow actuator 41. Fuel pump 63. Ground
20. To other control module 42. “F/P” fuse 64. ECM
21. CAN driver 43. Fuel temperature sensor 65. Boost pressure control solenoid valve
22. DLC 44. A/C compressor relay

Terminal Arrangement of ECM Connector

NOTE
For circuit name and terminal voltage, refer to “Inspection of ECM and Its Circuits”: D13A (Page 1A-
272).

[A]
E01 C01

[a]

IBL80A112002-01

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

 Engine General Information and Diagnosis: D13A 1A-130

Component Location
Electronic Control System Component Location
AENBL80A1123001

[3]

[g] [f]

[4]
11 10 9

13 14
[1]

15

[m] [h] [i] [j] [k]

[q]
[l]

[n]

12

[2]

1
[a]
[b]
[c]
[d]
8

2 7

[o] [e]

[p]

5 6
3

IBL80A112003-03
1A-131 Engine General Information and Diagnosis: D13A

Information sensors Control devices Others

1. MAF and IAT-1 sensor
2. CMP sensor
3. A/F sensor
4. CKP sensor
5. Oil pressure switch
6. ECT sensor
7. Boost pressure and IAT-2 sensor
8. Fuel pressure sensor
9. APP sensor
10. Brake light switch / Brake switch
11. CPP switch
12. A/C refrigerant pressure sensor
13. VSS
14. Fuel temperature sensor
15. Fuel filter water detection sensor
[a]: Fuel injector No.1 [1]: ECM
[b]: Fuel injector No.2 [2]: Glow plug control module
[c]: Fuel injector No.3 [3]: Combination meter
[d]: Fuel injector No.4 [4]: DLC
[e]: EGR valve
[f]: MIL
[g]: Glow indicator light
[h]: Radiator cooling fan relay No.3
[i]: Main relay
[j]: A/C compressor relay
[k]: Starting motor relay
[l]: Fuel pump relay
[m]: Radiator cooling fan relay No.2
[n]: Radiator cooling fan relay No.1
[o]: Glow plug
[p]: Fuel flow actuator
[q]: Boost pressure control solenoid valve

Diagnostic Information and Procedures

MIL Check 2) Start engine and check that MIL turns off. If MIL
AENBL80A1124001 remains on and no DTC is stored in ECM, go to “MIL
1) Set ignition “ON” and check that MIL (1) comes on. Remains ON after Engine Starts”: D13A (Page 1A-
If MIL does not light up (or MIL dims) but engine can 167) for troubleshooting.
be started, go to “MIL Does Not Come ON with
Ignition in “ON” and Engine Stopped (but Engine 1
Can Be Started)”: D13A (Page 1A-166) for
troubleshooting.
If MIL does not light with ignition in “ON” and engine
does not start though it is cranked up, go to
“Inspection of ECM and Its Circuits”: D13A (Page
1A-272).

I9P60A112053-01

Engine and Emission Control System Check

AENBL80A1124002
Refer to the following items for the details of each step.
Step Action Yes No
1 Customer complaint analysis )(Page 1A-132) Go to Step 2. Perform customer
1) Perform customer complaint analysis referring to “Step complaint analysis.
1: Customer Complaint Analysis”: D13A (Page 1A-132).

Was customer complaint analysis performed?

2 DTC record and clearance )(Page 1A-133) Print DTC or write them Go to Step 4.
1) Check for DTCs. )(Page 1A-133) down, clear them and
go to Step 3. )(Page
Is there any DTC(s)? 1A-134)
3 Visual inspection )(Page 1A-134) Repair or replace Go to Step 5.
1) Perform visual inspection referring to “Visual Inspection”: defective part(s), and go
D13A (Page 1A-149). to Step 11.

Is there any faulty condition?

4 Visual inspection )(Page 1A-134) Repair or replace Go to Step 8.
1) Perform visual inspection referring to “Visual Inspection”: defective part(s), and go
D13A (Page 1A-149). to Step 11.

Is there any faulty condition?

 Engine General Information and Diagnosis: D13A 1A-132

Step Action Yes No

5 Trouble symptom confirmation )(Page 1A-134) Go to Step 6. Go to Step 7.
1) Confirm trouble symptom referring to “Step 5: Trouble
Symptom Confirmation”: D13A (Page 1A-134).

Is trouble symptom identified?

6 Rechecking and recording DTCs )(Page 1A-134) Go to Step 9. Go to Step 8.
1) Recheck for DTCs. )(Page 1A-134)

Is there any DTC(s)?

7 Rechecking and recording DTCs )(Page 1A-134) Go to Step 9. Go to Step 10.
1) Recheck for DTCs. )(Page 1A-134)

Is there any DTC(s)?

8 Engine basic inspection and engine symptom diagnosis Go to Step 11. Check and repair
)(Page 1A-134) defective part(s), and go
1) Check and repair according to “Engine Basic to Step 11.
Inspection”: D13A (Page 1A-150) and “Engine Symptom
Diagnosis”: D13A (Page 1A-150).

Are check and repair complete?

9 Troubleshooting for DTC )(Page 1A-134) Go to Step 11. Check and repair
1) Check and repair according to applicable DTC defective part(s), and go
troubleshooting. to Step 11.

Are check and repair complete?

10 Intermittent problems check )(Page 1A-134) Repair or replace Go to Step 11.
1) Check for intermittent problems. )(Page 1A-134) defective part(s), and go
to Step 11.
Is there any faulty condition?
11 Final confirmation test )(Page 1A-134) Go to Step 6. End.
1) Clear DTC if any.
2) Perform final confirmation test referring to “Step 11: Final
Confirmation Test”: D13A (Page 1A-134).

Is there any problem symptom, DTC or abnormal condition?

Step 1: Customer Complaint Analysis

Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose,
use of such an inspection form will facilitate collecting information to the point required for proper analysis and
diagnosis.
1A-133 Engine General Information and Diagnosis: D13A
Customer problem inspection form (Example)
Step 2: DTC Record and Clearance
First, check DTC. )(Page 1A-134) If DTC is indicated,
print it or write DTC down and then clear DTC. )(Page
1A-134) DTC indicates malfunction that occurred in the
system but does not indicate whether it exists now or it
occurred in the past and the normal condition has been
I9P60A111042-01
restored now. To check which case applies, check the
symptom in question according to Step 5 and recheck
DTC according to Steps 6 and 7.
Attempt to diagnose a trouble based on DTC in this step
alone or failure to clear the DTC in this step will lead to
incorrect diagnosis, trouble diagnosis of a normal circuit
or difficulty in troubleshooting.
 Engine General Information and Diagnosis: D13A 1A-134

Steps 3 and 4: Visual Inspection DTC Check

As a preliminary step, be sure to perform visual check of AENBL80A1124003

the items that support proper function of the engine. 1) Set ignition “OFF”.
)(Page 1A-149) 2) Connect SUZUKI scan tool to DLC (1) located on
underside of instrument panel on driver’s seat side.
Step 5: Trouble Symptom Confirmation
Special tool
Based on information obtained in “Step 1: Customer
(A): SUZUKI scan tool (SUZUKI-SDT)
Complaint Analysis”: D13A (Page 1A-132) and “Step 2:
DTC Record and Clearance”: D13A (Page 1A-133),
confirm trouble symptoms. Also, reconfirm DTC
according to “DTC Confirmation Procedure” under
applicable DTC.

Steps 6 and 7: Rechecking and Recording of DTC

Refer to “DTC Check”: D13A (Page 1A-134) for checking
procedure. (A)

Step 8: Engine Basic Inspection and Engine

1
Symptom Diagnosis
Perform basic engine check according to “Engine Basic
Inspection”: D13A (Page 1A-150) first. When the end of
the flow has been reached, check the parts of the
system suspected as a possible cause referring to
“Engine Symptom Diagnosis”: D13A (Page 1A-150) and
based on symptoms appearing on the vehicle IBP80A112006-01

(symptoms obtained through steps of customer 3) Set ignition “ON”.

complaint analysis, trouble symptom confirmation and/or
basic engine check) and repair or replace faulty parts, if
any.
Step 9: Troubleshooting for DTC (See each DTC
Troubleshooting)
Based on the DTC indicated in Step 6 or 7 and referring
to the applicable DTC troubleshooting procedure, locate
the cause of the trouble, namely in a sensor, switch, wire
harness, connector, actuator, ECM or other part and
repair or replace faulty parts.
Step 10: Intermittent Problems Check
Check parts where an intermittent trouble is easy to
occur (e.g., wire harness, connector, etc.) and related
circuit of DTC recorded in Step 2.
Step 11: Final Confirmation Test
Confirm that the problem symptom has gone and the
engine is free from any abnormal conditions. If what has
been repaired is related to a DTC, clear the DTC once,
perform DTC confirmation procedure and confirm that no
DTC is indicated.
4) Read DTC according to instructions displayed on
scan tool and print them or write them down. Refer to
scan tool operator's manual for details. If
communication between scan tool and ECM is not
possible, check if scan tool is communicable by
connecting it to ECM in another vehicle.
If communication is possible in this case, scan tool is
good condition. Then DLC and serial data line
(circuit) in the vehicle with which communication was
not possible.
5) After completing the check, set ignition “OFF” and
disconnect scan tool from DLC.
DTC Clearance
AENBL80A1124004
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC in the same manner as when making this
connection for DTC check.
2) Set ignition “ON”.
3) Clear DTC according to instructions displayed on
scan tool. Refer to scan tool operator's manual for
further details.
4) After completing the clearance, set ignition “OFF”
and disconnect scan tool from DLC.
1A-135 Engine General Information and Diagnosis: D13A

DTC Table
AENBL80A1124005
NOTE
With the generic scan tool, only asterisk (*) marked DTC in the following table can be read.

DTC
DTC DTC name DTC detecting condition detection MIL
logic
Any of the following conditions is met.
*P0001 • Measured voltage of fuel flow actuator drive circuit is
Fuel Volume Regulator
)(Page higher than specified value. 1 D/C Lights up
Control Circuit / Open
1A-167) • Measured voltage of fuel flow actuator drive circuit is
lower than specified value.
Any of the following conditions is met.
• Measured boost pressure is higher than barometric
*P0069 Manifold Absolute pressure by 22.5 kPa (0.225 kgf/cm2, 3.26 psi, 225
)(Page Pressure-Barometric mbar) for 2 sec. 1 D/C Lights up
1A-168) Pressure Correlation • Measured boost pressure is lower than barometric
pressure by 22.5 kPa (0.225 kgf/cm2, 3.26 psi, 225
mbar) for 2 sec.
*P0087
Fuel Rail / System Measured fuel pressure in common rail is lower than
)(Page 1 D/C Lights up
Pressure-Too Low specified value.
1A-171)
*P0088
Fuel Rail / System Measured fuel pressure in common rail is higher than
)(Page 1 D/C Lights up
Pressure-Too High specified value.
1A-172)
*P0089
Fuel Pressure Regulator Measured fuel pressure in common rail is lower than
)(Page 1 D/C Lights up
1 Performance targeted fuel pressure by specified value.
1A-171)
Any of the following conditions is met.
*P0095 • Measured voltage of IAT-2 sensor signal circuit is
Intake Air Temperature
)(Page higher than 4.6 V for 1.6 sec. 3 D/C Lights up
Sensor 2 Circuit
1A-175) • Measured voltage of IAT-2 sensor signal circuit is lower
than 0.1 V for 1.6 sec.
Any of the following conditions is met.
*P0100 • Duty ratio of MAF sensor signal is higher than
Mass or Volume Air Flow
)(Page specified value for 2 sec. 3 D/C Lights up
“A” Circuit
1A-176) • Duty ratio of MAF sensor signal is lower than specified
value for 2 sec.
Any of the following conditions is met.
*P0101 Mass or Volume Air Flow • Measured MAF is higher than estimated MAF by
)(Page “A” Circuit Range / specified value. 3 D/C Lights up
1A-177) Performance • Measured MAF is lower than estimated MAF by
specified value.
*P0107 Manifold Absolute
Difference between boost pressure and barometric
)(Page Pressure / Barometric 1 D/C Lights up
pressure is lower than specified value.
1A-168) Pressure Circuit Low
Any of the following conditions is met.
P0110 • Duty ratio of IAT-1 sensor signal is higher than
Intake Air Temperature
)(Page specified value for 3.25 sec. 1 D/C Off
Sensor 1 Circuit
1A-178) • Duty ratio of IAT-1 sensor signal is lower than specified
value for 3.25 sec.
Any of the following conditions is met.
*P0115 Engine Coolant • Measured voltage of ECT sensor signal circuit is
)(Page Temperature Sensor 1 higher than 4.85 V for 1.6 sec. 1 D/C Lights up
1A-179) Circuit • Measured voltage of ECT sensor signal circuit is lower
than 0.10 V for 1.6 sec.
 Engine General Information and Diagnosis: D13A 1A-136

DTC
DTC DTC name DTC detecting condition detection MIL
logic
Any of the following conditions is met.
• Measured voltage of APP sensor (main) signal circuit
is lower than 0.30 V and output voltage of APP sensor
*P0120 Throttle / Pedal Position (sub) signal circuit is higher than 1.17 V for 1 sec.
)(Page Sensor / Switch “A” • Measured voltage of APP sensor (main) signal circuit 1 D/C Lights up
1A-180) Circuit is higher than 4.80 V for 1 sec.
• Both measured voltages of APP sensor (main) and
APP sensor (sub) signal circuits are lower than 0.05 V
for 1 sec.
P0130
Measured voltage of A/F sensor signal circuit are out of
)(Page O2 Sensor Circuit 1 D/C Off
specified range.
1A-181)
Any of the following conditions is met.
• Measured voltage of A/F sensor heater drive circuit is
P0135 higher than specified value for 3.25 sec. even when
)(Page O2 Sensor Heater Circuit command signal of A/F sensor heater is ON. 1 D/C Off
1A-184) • Measured voltage of A/F sensor heater drive circuit is
lower than specified value for 3.25 sec. even when
command signal of A/F sensor heater is OFF.
P0168
Fuel Temperature Too
)(Page Fuel temperature is higher than specified value. 1 D/C Off
High
1A-185)
Any of the following conditions is met.
*P0180 • Measured voltage of fuel temperature sensor signal
Fuel Temperature Sensor
)(Page circuit is higher than 4.85 V for 2.5 sec. 1 D/C Lights up
“A” Circuit
1A-185) • Measured voltage of fuel temperature sensor signal
circuit is lower than 0.10 V for 2.5 sec.
Any of the following conditions is met.
• Measured voltage of fuel pressure sensor signal circuit
is higher than 4.85 V.
*P0190
Fuel Rail Pressure • Measured voltage of fuel pressure sensor signal circuit
)(Page 1 D/C Lights up
Sensor “A” Circuit is lower than 0.15 V.
1A-186)
• Difference between current fuel pressure and previous
fuel pressure at specified vehicle condition is more
than specified value.
*P0201
Injector Circuit / Open-
)(Page 1 D/C Lights up
Cylinder 1
1A-189) Any of the following conditions is met.
*P0202
Injector Circuit / Open- • Measured voltage of relevant fuel injector drive circuit
)(Page 1 D/C Lights up
Cylinder 2 (high side) does not match with command signal for 5
1A-189)
sec. when engine is idling.
*P0203
Injector Circuit / Open- • Measured voltage of relevant fuel injector drive circuit
)(Page 1 D/C Lights up
Cylinder 3 (low side) does not match with command signal for 5
1A-189)
*P0204 sec. when engine is idling.
Injector Circuit / Open-
)(Page 1 D/C Lights up
Cylinder 4
1A-189)
P0217
Engine Coolant Over
)(Page ECT is higher than specified value. 1 D/C Off
Temperature Condition
1A-190)
*P0219
Engine Overspeed
)(Page Engine speed exceeds 6,000 rpm for 1.95 sec. 1 D/C Lights up
Condition
1A-192)
1A-137 Engine General Information and Diagnosis: D13A
DTC DTC name
*P0220 Throttle / Pedal Position
)(Page Sensor / Switch “B”
1A-193) Circuit
*P0230
Fuel Pump Primary
)(Page
Circuit
1A-195)
*P0234 Turbocharger /
)(Page Supercharger “A”
1A-168) Overboost Condition
*P0235 Turbocharger /
)(Page Supercharger Boost
1A-196) Sensor “A” Circuit
*P0243 Turbocharger /
)(Page Supercharger Wastegate
1A-197) Solenoid “A”
*P0335
Crankshaft Position
)(Page
Sensor “A” Circuit
1A-198)
*P0340
Camshaft Position
)(Page
Sensor “A” Circuit
1A-200)
P0380
Glow Plug / Heater Circuit Measured voltage of glow plug control module drive
)(Page
“A”
1A-201)
*P0401 Exhaust Gas
)(Page Recirculation “A” Flow
1A-203) Insufficient Detected
*P0402 Exhaust Gas
)(Page Recirculation “A” Flow
1A-203) Excessive Detected
DTC
DTC detecting condition detection MIL
logic
Any of the following conditions is met.
• Measured voltage of APP sensor (sub) signal circuit is
lower than 0.30 V and output voltage of APP sensor
(main) signal circuit is higher than 0.86 V for 1 sec.
• Measured voltage of APP sensor (sub) signal circuit is 1 D/C Lights up
higher than 4.90 V for 1 sec.
• Both measured voltages of APP sensor (main) and
APP sensor (sub) signal circuits are lower than 0.05 V
for 1 sec.
Any of the following conditions is met.
• Measured voltage of fuel pump relay drive circuit is
higher than specified value even when command
signal of fuel pump relay is ON. 1 D/C Lights up
• Measured voltage of fuel pump relay drive circuit is
lower than specified value even when command signal
of fuel pump relay is OFF.
Boost pressure is higher than barometric pressure by 200
1 D/C Lights up
kPa (2.0 kgf/cm2, 29.0 psi, 2,000 mbar) for 1 sec.
Any of the following conditions is met.
• Measured voltage of boost pressure sensor signal
circuit is higher than 4.9 V for 2 sec. 1 D/C Lights up
• Measured voltage of boost pressure sensor signal
circuit is lower than 0.2 V for 2 sec.
Any of the following conditions is met.
• Measured voltage of boost pressure control solenoid
valve drive circuit does not match with command
signal of boost pressure control solenoid valve. 1 D/C Lights up
• Difference between actual boost pressure and
estimated boost pressure is more than specified value
when turbocharger is operated.
CKP sensor signal is not input even if CMP sensor signal
1 D/C Lights up
is input.
Any of the following conditions is met.
• Measured voltage of CMP sensor signal circuit is
higher or lower than specified value for 1 sec.
• Measured voltage of CMP sensor signal circuit is lower
than specified value when cylinder No.1 is at 1 D/C Lights up
compression TDC for 1 sec.
• Measured voltage of CMP sensor signal circuit is
higher than specified value when cylinder No.4 is at
compression TDC for 1 sec.
1 D/C Off
circuit does not match with command signal for 1.6 sec.
Measured MAF is higher than estimated MAF for 10 sec. 3 D/C Lights up
Difference between measured MAF and estimated MAF
3 D/C Lights up
is out of specified range.
 Engine General Information and Diagnosis: D13A 1A-138

DTC
DTC DTC name DTC detecting condition detection MIL
logic
*P0403 Exhaust Gas
Measured voltage of EGR valve drive circuit does not
)(Page Recirculation “A” Control 3 D/C Lights up
match with command signal for 1.6 sec.
1A-205) Circuit
Any of the following conditions is met.
• Measured voltage at drive circuit of radiator cooling fan
relay No.1 is higher than specified value for 0.26 sec.
P0480 even though command signal of radiator cooling fan
)(Page Fan 1 Control Circuit relay No.1 is ON. 1 D/C Off
1A-206) • Measured voltage at drive circuit of radiator cooling fan
relay No.1 is lower than specified value for 0.26 sec.
even though command signal of radiator cooling fan
relay No.1 is OFF.
Any of the following conditions is met.
• Measured voltage at drive circuit of radiator cooling fan
relays No.2 and No.3 is higher than specified value for
P0481 0.26 sec. even though command signal of radiator
)(Page Fan 2 Control Circuit cooling fan relays No.2 and No.3 is ON. 1 D/C Off
1A-207) • Measured voltage at drive circuit of radiator cooling fan
relays No.2 and No.3 is lower than specified value for
0.26 sec. even though command signal of radiator
cooling fan relays No.2 and No.3 is OFF.
*P0500
Vehicle speed is lower than specified for 3 sec. even
)(Page Vehicle Speed Sensor “A” 3 D/C Lights up
though engine speed is higher than specified value.
1A-209)
P0520
Engine Oil Pressure Measured voltage of oil pressure switch signal circuit is
)(Page 1 D/C Off
Sensor / Switch Circuit higher than specified value when engine is not running.
1A-210)
Any of the following conditions is met.
P0530 • Measured voltage of A/C refrigerant pressure sensor
A/C Refrigerant Pressure
)(Page signal circuit is lower than 0.1 V for 1.6 sec. 1 D/C Off
Sensor “A” Circuit
1A-211) • Measured voltage of A/C refrigerant pressure sensor
signal circuit is higher than 4.9 V for 1.6 sec.
Any of the following conditions is met.
P0560 • Measured voltage of backup power supply circuit is
)(Page System Voltage higher than 16 V for 1 sec. 1 D/C Off
1A-213) • Measured voltage of backup power supply circuit is
lower than 6 V for 1 sec.
Any of the following conditions is met.
• Measured voltage of brake light switch circuit is higher
P0571 than specified value.
)(Page Brake Switch “A” Circuit • Measured voltage of brake light switch circuit is lower 1 D/C Off
1A-215) than specified value.
• Brake pedal positions detected by brake light switch
and brake switch disagree.
P0600
Serial Communication
)(Page ECM internal failure is detected. 1 D/C Off
Link
1A-217)
*P0601 Internal Control Module
)(Page Memory Check Sum ECM internal failure is detected. 1 D/C Lights up
1A-217) Error
*P0604 Internal Control Module
)(Page Random Access Memory ECM internal failure is detected. 1 D/C Lights up
1A-217) (RAM) Error
1A-139 Engine General Information and Diagnosis: D13A

DTC
DTC DTC name DTC detecting condition detection MIL
logic
*P060B Internal Control Module
)(Page A/D Processing ECM internal failure is detected. 1 D/C Lights up
1A-217) Performance
*P0641
Sensor Reference Sensor power supply voltage “A” is out of specified
)(Page 1 D/C Lights up
Voltage “A” Circuit / Open range.
1A-219)
Any of the following conditions is met.
• Measured voltage of A/C compressor relay drive circuit
P0645 is higher than specified value for 1.6 sec. even when
A/C Clutch Relay Control
)(Page command signal of A/C compressor relay is ON. 1 D/C Off
Circuit
1A-220) • Measured voltage of A/C compressor relay drive circuit
is lower than specified value for 1.6 sec. even when
command signal of A/C compressor relay is OFF.
*P0651
Sensor Reference Sensor power supply voltage “B” is out of specified
)(Page 1 D/C Lights up
Voltage “B” Circuit / Open range.
1A-222)
P0657
Actuator Supply Voltage Measured voltage of main relay drive circuit is lower or
)(Page 1 D/C Off
“A” Circuit / Open higher than specified value for 0.4 sec.
1A-224)
P0683 Glow Plug Control
Measured voltage of glow plug drive circuit does not
)(Page Module to PCM 1 D/C Off
match with command signal for 2.6 sec.
1A-201) Communication Circuit
Any of the following conditions is met.
• Measured voltage of main relay drive circuit is higher
*P0685 than specified value even when command signal of
ECM/PCM Power Relay
)(Page main relay is ON. 1 D/C Lights up
Control Circuit / Open
1A-224) • Measured voltage of main relay drive circuit is lower
than specified value even when command signal of
main relay is OFF.
*P0697
Sensor Reference Sensor power supply voltage “C” is out of specified
)(Page 1 D/C Lights up
Voltage “C” Circuit / Open range.
1A-226)
P0704
Clutch Switch Input CPP switch signal does not change though gear is shifted
)(Page 1 D/C Off
Circuit 60 times.
1A-228)
Any of the following conditions is met.
• Measured voltage of brake switch circuit is higher than
P1571 specified value.
)(Page Brake Switch Circuit • Measured voltage of brake switch circuit is lower than 1 D/C Off
1A-215) specified value.
• Brake pedal positions detected by brake light switch
and brake switch disagree.
Immobilizer ID and/or
P1610 1 D/C Off
Password Not Registered
P1611 Password Not Matched 1 D/C Off
EEPROM Reading /
P1622 1 D/C Off
Writing Error
Immobilizer Refer to “DTC Table” in Section 10C (Page 10C-4).
P1642 Communication Line 1 D/C Off
Error
Immobilizer ID
P1644 1 D/C Off
Mismatched
P1646 ID Code Incorrectness 1 D/C Off
 Engine General Information and Diagnosis: D13A 1A-140

DTC
DTC DTC name DTC detecting condition detection MIL
logic
P1647
Vehicle Valiant Not
)(Page Vehicle variant data is not registered in ECM. 1 D/C Off
Programmed
1A-230)
Any of the following conditions is met.
• Measured voltage of APP sensor (main) signal circuit
is higher than output voltage of APP sensor (sub) by
*P2135 Throttle / Pedal Position 0.22 V for 1 sec. though output voltage of APP sensor
)(Page Sensor / Switch “A” / “B” (main) is lower than 1.27 V. 1 D/C Lights up
1A-230) Voltage Correlation • Measured voltage of APP sensor (main) signal circuit
is higher than output voltage of APP sensor (sub) by
0.32 V for 1 sec. though output voltage of APP sensor
(main) is higher than 1.27 V.
Any of the following conditions is met.
P2146 Fuel Injector Group “A” • Measured voltage of fuel injector drive circuit (high
)(Page Supply Voltage Circuit / side) is higher than 50 V for 1 sec. 1 D/C Off
1A-189) Open • Measured voltage of fuel injector drive circuit (high
side) is lower than 30 V for 1 sec.
Any of the following conditions is met.
*P2226 • Measured voltage of barometric pressure sensor
Barometric Pressure
)(Page signal circuit is higher than 4.80 V for 1.6 sec. 1 D/C Lights up
Sensor “A” Circuit
1A-217) • Measured voltage of barometric pressure sensor
signal circuit is lower than 0.20 V for 1.6 sec.
P2237 O2 Sensor Positive
Any one of A/F sensor signal voltage is in abnormal
)(Page Current Control Circuit / 1 D/C Off
condition.
1A-232) Open
P2244
O2 Sensor Reference
)(Page A/F power supply voltage is out of specified range. 1 D/C Off
Voltage Performance
1A-181)
P2264
Water in Fuel Sensor Measured voltage of fuel filter water detection sensor is
)(Page 1 D/C Off
Circuit higher than specified value for at least 0.37 sec.
1A-233)
P2297
O2 Sensor Out of Range
)(Page A/F value at fuel cut is out of specified value. 1 D/C Off
During Deceleration
1A-232)
P268A Fuel Injector Calibration
)(Page Not Learned / Injector calibration code is not registered in ECM. 1 D/C Off
1A-235) Programmed
Control Module
U0073 1 D/C Off
Communication Bus Off
Lost Communication With
U0121 ABS / ESP® Control Refer to “CAN DTC (Lost Communication and 1 D/C Off
Module Communication Bus Off) Table”: D13A Model in Section
Lost Communication With 10H (Page 10H-27).
U0140 1 D/C Off
Body Control Module
Control Module Program
U2101 1 D/C Off
Error

Fail-Safe Table
AENBL80A1124006
When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to exist but
that mode is canceled when ECM detects normal condition.
1A-141 Engine General Information and Diagnosis: D13A

DTC DTC name Fail-safe operation

• ECM controls actuators assuming that rail pressure is
P0001 )(Page Fuel Volume Regulator Control Circuit / specified range.
1A-167) Open • ECM limits driving performance slightly.
• ECM stops engine.
P0069 )(Page Manifold Absolute Pressure-Barometric • ECM stops EGR valve control.
1A-168) Pressure Correlation • ECM limits driving performance slightly.
P0087 )(Page
Fuel Rail / System Pressure-Too Low ECM stops engine.
1A-171)
P0088 )(Page
Fuel Rail / System Pressure-Too High ECM stops engine.
1A-172)
• ECM controls actuators assuming that rail pressure is
P0089 )(Page specified range.
Fuel Pressure Regulator1 Performance
1A-171)
• ECM limits driving performance slightly.
P0095 )(Page ECM controls actuators assuming that IAT-2 is 40 °C
Intake Air Temperature Sensor 2 Circuit
1A-175) (104 °F).
• ECM controls actuators assuming that air flow value is
P0100 )(Page specified value.
Mass or Volume Air Flow “A” Circuit
1A-176) • ECM stops A/F feedback (closed-loop) control.
• ECM stops EGR valve control.
• ECM controls actuators assuming that air flow value is
P0101 )(Page Mass or Volume Air Flow “A” Circuit Range specified value.
1A-177) / Performance • ECM stops A/F feedback (closed-loop) control.
• ECM stops EGR valve control.
P0107 )(Page Manifold Absolute Pressure / Barometric • ECM stops EGR valve control.
1A-168) Pressure Circuit Low • ECM limits driving performance slightly.
• ECM controls actuators assuming that IAT-1 is 40 °C
P0110 )(Page (104 °F).
Intake Air Temperature Sensor1 Circuit
1A-178) • ECM stops idle speed control related to A/C.
• ECM stops A/F feedback (closed-loop) control.
• ECM controls actuators assuming that ECT is fuel
temperature at cranking.
P0115 )(Page Engine Coolant Temperature Sensor1 • ECM stops A/C control.
1A-179) Circuit
• ECM operates radiator cooling fan at high speed.
• ECM stops idle speed control related to A/C.
Error of APP main sensor:
• ECM controls actuators assuming that value of APP is
value of APP (sub) or 0%.
• ECM limits driving performance slightly.
• If DTC P0220, P0571, P1571 or P2135 is concurrently
present, ECM executes the following fail-safe control:
– When brake pedal is depressed, ECM fixes engine
speed at 800 rpm.
P0120 )(Page Throttle / Pedal Position Sensor / Switch – When brake pedal is released, ECM fixes engine
1A-180) “A” Circuit speed at 1000 rpm.
Error of both APP main and sub sensors:
• ECM controls actuators assuming that value of APP is
0%.
• If DTC P0220 is concurrently present, ECM executes
the following fail-safe control:
– When brake pedal is depressed, ECM fixes engine
speed at 800 rpm.
– When brake pedal is released, ECM fixes engine
speed at 1000 rpm.
 Engine General Information and Diagnosis: D13A 1A-142

DTC DTC name Fail-safe operation

P0130 )(Page
O2 Sensor Circuit ECM stops A/F feedback (closed-loop) control.
1A-181)
P0135 )(Page
O2 Sensor Heater Circuit ECM stops A/F feedback (closed-loop) control.
1A-184)
P0168 )(Page
Fuel Temperature Too High —
1A-185)
• ECM controls actuators assuming that fuel
temperature is specified value.
P0180 )(Page • ECM controls fuel heater according to value of ECT
Fuel Temperature Sensor “A” Circuit
1A-185) sensor.
• ECM controls actuators assuming that fuel
temperature is ECT at cranking.
P0190 )(Page
Fuel Rail Pressure Sensor “A” Circuit ECM stops engine.
1A-186)
P0201 )(Page
Injector Circuit / Open-Cylinder1
1A-189)
P0202 )(Page
Injector Circuit / Open-Cylinder2
1A-189)
ECM stops control of applicable fuel injector.
P0203 )(Page
Injector Circuit / Open-Cylinder3
1A-189)
P0204 )(Page
Injector Circuit / Open-Cylinder4
1A-189)
P0217 )(Page Engine Coolant Over Temperature
—
1A-190) Condition
P0219 )(Page
Engine Overspeed Condition —
1A-192)
Error of APP sub sensor:
• ECM controls actuators assuming that value of APP is
value of APP (sub) or 0%.
• ECM limits driving performance slightly.
• If DTC P0120, P0571, P1571 or P2135 is concurrently
present, ECM executes the following fail-safe control:
– When brake pedal is depressed, ECM fixes engine
speed at 800 rpm.
P0220 )(Page Throttle / Pedal Position Sensor / Switch – When brake pedal is released, ECM fixes engine
1A-193) “B” Circuit speed at 1000 rpm.
Error of both APP main and sub sensors:
• ECM controls actuators assuming that value of APP is
0%.
• If DTC P0120 is concurrently present, ECM executes
the following fail-safe control:
– When brake pedal is depressed, ECM fixes engine
speed at 800 rpm.
– When brake pedal is released, ECM fixes engine
speed at 1000 rpm.
P0230 )(Page
Fuel Pump Primary Circuit —
1A-195)
P0234 )(Page Turbocharger / Supercharger “A” • ECM stops EGR valve control.
1A-168) Overboost Condition • ECM limits driving performance slightly.
• ECM controls actuators assuming that boost pressure
P0235 )(Page Turbocharger / Supercharger Boost is barometric pressure
1A-196) Sensor “A” Circuit • ECM stops EGR valve control.
• ECM limits driving performance slightly.
P0243 )(Page Turbocharger / Supercharger Wastegate
ECM limits driving performance slightly.
1A-197) Solenoid “A”
1A-143 Engine General Information and Diagnosis: D13A

DTC DTC name Fail-safe operation

P0335 )(Page
Crankshaft Position Sensor “A” Circuit —
1A-198)
P0340 )(Page
Camshaft Position Sensor “A” Circuit —
1A-200)
P0380 )(Page
Glow Plug / Heater Circuit “A” —
1A-201)
P0401 )(Page Exhaust Gas Recirculation “A” Flow
ECM stops EGR valve control.
1A-203) Insufficient Detected
P0402 )(Page Exhaust Gas Recirculation “A” Flow
ECM stops EGR valve control.
1A-203) Excessive Detected
P0403 )(Page Exhaust Gas Recirculation “A” Control
ECM stops EGR valve control.
1A-205) Circuit
P0480 )(Page
Fan1 Control Circuit ECM operates radiator cooling fan at high speed.
1A-206)
P0481 )(Page
Fan2 Control Circuit ECM operates radiator cooling fan at high speed.
1A-207)
P0500 )(Page ECM controls actuators assuming that vehicle speed is
Vehicle Speed Sensor “A”
1A-209) specified value.
P0520 )(Page Engine Oil Pressure Sensor / Switch
—
1A-210) Circuit
• ECM controls actuators assuming that A/C refrigerant
pressure is 1,600 kPa (16.3 kgf/cm2, 232 psi, 16 bar).
P0530 )(Page A/C Refrigerant Pressure Sensor “A”
• ECM stops A/C control.
1A-211) Circuit
• If DTC P0645 is concurrently present, ECM operates
radiator cooling fan at high speed.
P0560 )(Page ECM controls actuators assuming that battery voltage is
System Voltage
1A-213) 13.5 V.
If DTC P0120, P0220, P1571 or P2135 is concurrently
present, ECM executes the following fail-safe control:
P0571 )(Page • When brake pedal is depressed, ECM fixes engine
Brake Switch “A” Circuit
1A-215) speed at 800 rpm.
• When brake pedal is released, ECM fixes engine
speed at 1000 rpm.
P0600 )(Page
Serial Communication Link —
1A-217)
P0601 )(Page Internal Control Module Memory Check
ECM stops engine.
1A-217) Sum Error
P0604 )(Page Internal Control Module Random Access
ECM stops engine.
1A-217) Memory (RAM) Error
P060B )(Page Internal Control Module A/D Processing
ECM stops engine.
1A-217) Performance
P0641 )(Page Sensor Reference Voltage “A” Circuit /
ECM stops engine.
1A-219) Open
P0645 )(Page • ECM stops idle speed control related to A/C.
A/C Clutch Relay Control Circuit
1A-220) • ECM operates radiator cooling fan at high speed.
• ECM controls actuators assuming that sensor supply
P0651 )(Page Sensor Reference Voltage “B” Circuit / voltage is 5 V.
1A-222) Open
• ECM limits driving performance slightly.
P0657 )(Page
Actuator Supply Voltage “A” Circuit / Open —
1A-224)
P0683 )(Page Glow Plug Control Module to PCM
—
1A-201) Communication Circuit
P0685 )(Page ECM/PCM Power Relay Control Circuit /
—
1A-224) Open
• ECM controls actuators assuming that sensor supply
P0697 )(Page Sensor Reference Voltage “C” Circuit / voltage is 5 V.
1A-226) Open
• ECM limits driving performance slightly.
 Engine General Information and Diagnosis: D13A 1A-144

DTC DTC name Fail-safe operation

P0704 )(Page ECM controls actuators assuming that clutch pedal is
Clutch Switch Input Circuit
1A-228) depressed.
If DTC P0120, P0220, P0571 or P2135 is concurrently
present, ECM executes the following fail-safe control:
P1571 )(Page • When brake pedal is depressed, ECM fixes engine
Brake Switch Circuit
1A-215) speed at 800 rpm.
• When brake pedal is released, ECM fixes engine
speed at 1000 rpm.
Immobilizer ID and/or Password Not
P1610
Registered
P1611 Password Not Matched
P1622 EEPROM Reading / Writing Error —
P1642 Immobilizer Communication Line Error
P1644 Immobilizer ID Mismatched
P1646 ID Code Incorrectness
P1647 )(Page
Vehicle Valiant not Programmed —
1A-230)
• ECM controls actuators assuming minimum value of
APP sensor (main) and APP sensor (sub) as APP.
• ECM limits driving performance slightly.
• If DTC P0120, P0220, P0571 or P1571 is concurrently
P2135 )(Page Throttle / Pedal Position Sensor / Switch
present, ECM executes the following fail-safe control:
1A-230) “A” / “B” Voltage Correlation
– When brake pedal is depressed, ECM fixes engine
speed at 800 rpm.
– When brake pedal is released, ECM fixes engine
speed at 1000 rpm.
P2146 )(Page Fuel Injector Group “A” Supply Voltage
ECM stops injector electric diagnosis.
1A-189) Circuit / Open
• ECM controls actuators assuming that boost pressure
P2226 )(Page is barometric pressure.
Barometric Pressure Sensor “A” Circuit
1A-217)
• ECM limits driving performance slightly.
P2237 )(Page O2 Sensor Positive Current Control Circuit
ECM stops A/F feedback (closed-loop) control.
1A-232) / Open
P2244 )(Page O2 Sensor Reference Voltage
ECM stops A/F feedback (closed-loop) control.
1A-181) Performance
P2264 )(Page
Water in Fuel Sensor Circuit —
1A-233)
P2297 )(Page O2 Sensor Out of Range During
ECM stops A/F feedback (closed-loop) control.
1A-232) Deceleration
P268A )(Page Fuel Injector Calibration Not Learned /
—
1A-235) Programmed
U0073 Control Module Communication Bus Off
Lost Communication With ABS / ESP®
U0121
Control Module
—
Lost Communication With Body Control
U0140
Module
U2101 Control Module Program Error

Scan Tool Data

AENBL80A1124007
As the data values below are standard values estimated on the basis of values obtained from the normally operating
vehicles using a SUZUKI scan tool, use them as reference values. Even when the vehicle is in good condition, there
may be cases where the checked value does not fall within each specified data range. Therefore, judgment as
abnormal should not be made by checking against these data alone. Also, conditions that can be checked by the
SUZUKI scan tool are those detected by ECM and output from ECM as commands and there may be cases where the
engine or actuator is not operating (in the condition) as indicated by the SUZUKI scan tool.
1A-145 Engine General Information and Diagnosis: D13A

! CAUTION
If ECM detects DTC and enters fail-safe mode, scan tool data is changed from its normal operating
value. This may lead to misdiagnosis.
Therefore, be sure to check DTCs and repair malfunctions associated with stored DTCs before
checking scan tool data.

NOTE
When checking the data with the engine running at idle or racing, be sure to shift M/T gear to the
neutral position and apply the parking brake fully.

Normal condition
Scan tool data Vehicle condition Reference item
/ reference value
“Table C-2:
Engine Speed )(Page Engine: Idle speed after warming up Engine Speed
Approx. 800 rpm
1A-148) A/C: Not operating Check”: D13A
(Page 1A-256)
Desired Idle )(Page Engine: Idle speed after warming up
Approx. 800 rpm —
1A-148) Radiator cooling fan: Not operating
“Table C-7:
Vehicle Speed )(Page Value as the same Speed Signal
Vehicle: Running
1A-148) as speedometer Check”: D13A
(Page 1A-263)
“Table C-3: ECT
Coolant Temp )(Page 80 to 110 °C (176 Sensor Check”:
Engine: Idle speed after warming up
1A-148) to 230 °F) D13A (Page 1A-
257)
–5 °C (–9 °F) +
environmental “Table C-4: IAT-1
temp. to 40 °C (72 Sensor Check”:
IAT 1 )(Page 1A-148) Engine: Idle speed after warming up
°F) + D13A (Page 1A-
environmental 259)
temp.
Environmetal “Table C-5: IAT-2
temp. to 60 °C Sensor Check”:
IAT 2 )(Page 1A-148) Engine: Idle speed after warming up
(108 °F) + D13A (Page 1A-
environmetal temp. 260)
Engine: Idle speed after warming up “Table B-2: MAF
5.5 g/sec. or more
EGR: Not operating Sensor Check”:
MAF )(Page 1A-148)
Engine: Idle speed after warming up D13A (Page 1A-
3.0 g/sec. or more
EGR: Operating 245)
Barometric “Table B-3: Boost
Boost pressure )(Page Ignition: “ON” pressure is Pressure Sensor
1A-148) displayed Check”: D13A
Engine: Accelerated to 3,500 rpm 120 kPa or more (Page 1A-247)
Engine: Idle speed after warming up 70 to 90% “Table B-7: Boost
Pressure Control
BP Valve Duty Cycle Solenoid Valve
)(Page 1A-148) Engine: Accelerated to 3,500 rpm 40 to 60% Operation
Check”: D13A
(Page 1A-252)
Ignition: “ON” “Table C-6:
0.60 to 1.10 V
Accelerator pedal: Not depressed Accelerator
APP Sensor 1 Volt
Pedal Check”:
)(Page 1A-148) Ignition: “ON”
3.60 to 4.30 V D13A (Page 1A-
Accelerator pedal: Fully depressed position
261)
 Engine General Information and Diagnosis: D13A 1A-146

Normal condition
Scan tool data Vehicle condition Reference item
/ reference value
Ignition: “ON” “Table C-6:
0.30 to 0.50 V
Accelerator pedal: Not depressed Accelerator
APP Sensor 2 Volt
Pedal Check”:
)(Page 1A-148) Ignition: “ON”
1.80 to 2.20 V D13A (Page 1A-
Accelerator pedal: Fully depressed position
261)
Ignition: “ON” “Table C-6:
0 to 5%
Accelerator pedal: Not depressed Accelerator
Accel Position )(Page
Pedal Check”:
1A-148) Ignition: “ON”
95 to 100% D13A (Page 1A-
Accelerator pedal: Fully depressed position
261)
“A/C System
Performance
Inspection”:
Single A/C Type
Engine: Running in Section 7B
A/C Pressure )(Page AC: Operating (Page 7B-9) or
1,600 – 2,040 kPa
1A-148) Ambient temperature: 30 °C “A/C System
Humidity: 50% Performance
Inspection”: Dual
A/C Type in
Section 7B
(Page 7B-58)
“Table A-3: Fuel
Temperature
Fuel temperature –25 to 95 °C (–13
Ignition: “ON” Sensor Check”:
)(Page 1A-148) to 194 °F)
D13A (Page 1A-
239)
Fuel Injection Quantity
Engine: Idle speed after warming up 3.0 – 6.0 mm3/str —
)(Page 1A-148)
25.00 – 45.00 MPa “Table A-4: Fuel
Engine: Idle speed after warming up
(250 – 450 bar) Pressure Sensor
Fuel Rail Pressure
Circuit Check”:
)(Page 1A-148) 60.00 MPa (600
Engine: Accelerated to 3,500 rpm D13A (Page 1A-
bar) or more
241)
Desired Rail Press 25.00 – 45.00 MPa
Engine: Idle speed after warming up —
)(Page 1A-148) (250 – 450 bar)
Engine: Idle speed after warming up 15 – 20% “Table A-5: Fuel
Flow Actuator
Rail Press Regulator
Operation
)(Page 1A-148) Engine: Accelerated to 3,500 rpm 25 – 35%
Check”: D13A
(Page 1A-243)
Ignition: “ON”
ON
Closed Throttle Pos Accelerator pedal: Not depressed
—
)(Page 1A-148) Ignition: “ON”
OFF
Accelerator pedal: Fully depressed position
Engine: Idle speed after warming up ON “Table B-5: EGR
EGR Valve )(Page 1A- Valve Operation
148) Engine: Accelerated to 4,000 rpm OFF Check”: D13A
(Page 1A-249)
Engine: Idle speed after warming up 20 – 70% “Table B-5: EGR
EGR Sol duty cycle Valve Operation
)(Page 1A-148) Engine: Accelerated to 4,000 rpm 0 – 10% Check”: D13A
(Page 1A-249)
“Table B-4:
Barometric Barometric
Barometric Pres
Ignition: “ON” pressure is Pressure Check”:
)(Page 1A-148)
displayed D13A (Page 1A-
249)
1A-147 Engine General Information and Diagnosis: D13A

Normal condition
Scan tool data Vehicle condition Reference item
/ reference value
“Battery
Battery Voltage )(Page Inspection”:
Ignition: “ON” 10 to 14 V
1A-148) D13A in Section
1J (Page 1J-23)
Glow indicator light Ignition: Within a few seconds after set ignition “ON” ON
—
)(Page 1A-148) Engine: Idle speed after warming up OFF
Ignition: Within a few seconds after set ignition “ON” ON “Table C-8: Glow
Glow Plug )(Page 1A- Plugs Operation
148) Engine: Idle speed after warming up OFF Check”: D13A
(Page 1A-266)
Ignition: “ON” ON “Table C-1: Main
Main Relay )(Page 1A- Relay Operation
148) Ignition: “OFF” OFF Check”: D13A
(Page 1A-254)
Ignition: “ON” “MIL Check”:
ON
MIL )(Page 1A-148) Engine: Running with faulty condition D13A (Page 1A-
Engine: Running without faulty condition OFF 131)
Engine: Idle speed after warming up
ON
A/C Comp Relay A/C: Operating
—
)(Page 1A-149) Engine: Idle speed after warming up
OFF
A/C: Not operating
Engine: Idle speed after warming up
ON
A/C Switch )(Page 1A- A/C: Operating
—
149) Engine: Idle speed after warming up
OFF
A/C: Not operating
At rising ECT: ECT < 98 °C (208 °F)
OFF “Table C-9:
At falling ECT: ECT < 95 °C (203 °F)
Radiator Cooling
Radiator cooling fan At rising ECT: 98 °C (208 °F) < ECT < 103 °C (217 °F)
Low Fan Operation
)(Page 1A-149) At falling ECT: 95 °C (203 °F) < ECT < 98 °C (208 °F)
Check”: D13A
At rising ECT: ECT > 103 °C (217 °F)
High (Page 1A-269)
At falling ECT: ECT > 98 °C (208 °F)
Ignition: Within 20 seconds after set ignition “ON” “Table A-1: Fuel
ACTIVE
Engine: Running Pump Relay
Fuel Pump )(Page 1A-
Operation
149)
Except above-mentioned condition INACTIVE Check”: D13A
(Page 1A-236)
Ignition: “ON”
OFF
Brake light switch Brake pedal: Released
—
)(Page 1A-149) Ignition: “ON”
ON
Brake pedal: Depressed fully
Ignition: “ON”
ON
Brake Switch )(Page Brake pedal: Released
—
1A-149) Ignition: “ON”
OFF
Brake pedal: Depressed fully
Ignition Switch )(Page Ignition: “ON” ON
—
1A-149) Ignition: “OFF” OFF
Ignition: “ON”
OFF
CPP switch )(Page 1A- Clutch pedal: Released
—
149) Ignition: “ON”
ON
Clutch pedal: Depressed fully
Ignition: “ON”
ON
Fuel filter warning light Water in fuel filter: More than specified value
—
)(Page 1A-149) Ignition: “ON”
OFF
Water in fuel filter: Less than specified value
A/F Sen Ht duty Cycl Ignition: “ON” 0% “Table B-6: A/F
)(Page 1A-149) Engine: Idle speed after warming up 40 – 60% Sensor Check”:
A/F heater Temp 730 – 830 °C D13A (Page 1A-
Engine: Idle speed after warming up
)(Page 1A-149) (1346 – 1526 °F) 250)
 Engine General Information and Diagnosis: D13A 1A-148
Scan Tool Data Definitions
Engine Speed (rpm):
This parameter indicates revolutions per minute of
engine.
Desired Idle (Desired idle speed) (rpm):
The desired Idle speed is an ECM internal parameter
which indicates the ECM requested idle speed. If the
engine is not running this number is not valid.
Vehicle Speed (km/h, mph):
This parameter indicates vehicle speed.
Coolant Temp (Engine coolant temperature) (°C, °F):
This parameter indicates engine coolant temperature
measured by ECT sensor
IAT 1 (Intake air temperature-1) (°C, °F):
This parameter indicates intake air temperature-1
measured by IAT-1 sensor.
IAT 2 (Intake air temperature-2) (°C, °F)
This parameter indicates intake air temperature-2
measured by IAT-2 sensor.
MAF (Mass air flow rate) (g/sec.):
This parameter indicates mass air flow rate measured by
MAF sensor.
Boost pressure (kPa, mmHg, inHg, psi, inH2O):
This parameter indicates boost pressure measured by
boost pressure sensor.
BP Valve Duty Cycle (Boost pressure control
solenoid valve duty cycle, %)
This parameter indicates the valve ON (valve open) time
ratio of signal for controlling boost pressure control
solenoid valve which controls the boost pressure.
APP Sensor 1 Volt (APP sensor (main) output
voltage) (V):
The APP sensor (Main) reading provides accelerator
pedal opening information in the form of voltage.
APP Sensor 2 Volt (APP sensor (sub) output voltage)
(V):
The APP sensor (Sub) reading provides accelerator
pedal opening information in the form of voltage.
Accel Position (Accelerator pedal position) (%):
When accelerator pedal is at fully released position,
accelerator pedal is indicated as 0 – 3% and 90 – 100%
fully depressed position.
A/C Pressure (A/C refrigerant pressure) (kPa):
This parameter indicates A/C refrigerant absolute
pressure calculated by ECM.
Fuel temperature (°C, °F):
This parameter indicates fuel temperature measured by
fuel temperature sensor.
Fuel Injection Quantity (mm3/str):
This parameter indicates the injection volume.
Fuel Rail Pressure (Fuel pressure in rail) (MPa, bar):
This parameter indicates fuel pressure in common rail
measured by fuel pressure sensor.
Desired Rail Press (Fuel pressure in rail (target))
(MPa, bar):
The Desired Rail Press is an ECM internal parameter.
This parameter indicates fuel pressure in common rail
targeted by ECM.
Rail Press Regulator (Fuel pressure regulator valve
opening) (%):
This parameter indicates opening rate of fuel pressure
regulator.
Closed Throttle Pos (Closed throttle position) (ON/
OFF):
This parameter indicates operating state of accelerator
pedal.
ON: Accelerator pedal is depressed.
OFF: Accelerator pedal is released.
EGR Valve (ON/OFF):
This parameter indicates operating state of EGR valve.
EGR sol duty cycle (EGR solenoid valve duty cycle)
(%):
This parameter indicated valve ON (valve open) time
rate within a certain set cycle of EGR valve which control
the amount of EGR.
Barometric Pres (Barometric pressure) (kPa):
This parameter represents a measurement of barometric
air pressure and is used for altitude correction of the fuel
injection quantity.
Battery Voltage (V):
This parameter indicates battery positive voltage
inputted from main relay to ECM.
Glow Indicator light (ON/OFF):
This parameter indicates operating state of glow
indicator light.
Glow Plug (ON/OFF):
This parameter indicates operating signal of glow plug
from ECM to glow control module.
Main relay (ON/OFF):
This parameter indicates operating state of main relay.
MIL (ON/OFF):
This parameter indicates operating state of MIL.
1A-149 Engine General Information and Diagnosis: D13A

A/C Comp Relay (A/C compressor relay) (ON/OFF):
This parameter indicates operating state of A/C
compressor relay.
A/C Switch (ON/OFF):
ON: Command for A/C operation being output from ECM
to HVAC control unit.
OFF: Command for A/C operation not being output.
Radiator cooling fan (OFF/LOW/HIGH):
LOW: ON command being output to radiator cooling fan
relay No.1.
HIGH: ON command being output to radiator cooling fan
relay No.1, No.2 and No.3.
OFF: No command being output.
Brake Switch (ON/OFF):
This parameter indicates operating state of brake switch.
Ignition Switch (ON/OFF):
This parameter indicates operating state of ignition
switch.
CPP Switch (Clutch pedal position switch) (ON/
OFF):
This parameter indicates operating state of CPP switch.
Fuel filter warning light (Fuel filter warning light)
(ON/ OFF):
The parameter indicates operating state of fuel filter
warning light.

Fuel Pump (ON/OFF): A/F Sen Ht duty Cycl (A/F sensor heater duty cycle)
ON is displayed when ECM activates fuel pump via fuel (%):
pump relay. This parameter indicates heater ON time rate within a
certain set cycle of A/F sensor heater.
Brake light switch (ON/OFF):
This parameter indicates operating state of brake light A/F heater Temp (A/F sensor heater temperature)
switch. (°C, °F):
This parameter indicates A/F sensor heater temperature
measured by A/F sensor.

Visual Inspection
AENBL80A1124008
Visually check the following parts and systems.
Inspection item Referring section
• Engine oil-level, leakage “Engine Oil and Filter Change”: D13A in Section 1E
(Page 1E-16)
• Engine coolant-level, leakage “Coolant Level Check”: D13A in Section 1F (Page 1F-
24)
• Fuel-level, leakage “Fuel Leakage Check Procedure”: D13A in Section 1G
(Page 1G-40)
• Air cleaner filter-dirt, clogging “Air Cleaner Filter Inspection and Cleaning”: D13A in
Section 1D (Page 1D-78)
• Battery-corrosion of terminal “Battery Description”: D13A in Section 1J (Page 1J-
21)
• Accessory drive belt-tension, damage “Accessory Drive Belt Tension Inspection”: D13A in
Section 1J (Page 1J-26)
• Vacuum hoses of air intake system-disconnection,
—
looseness, deterioration, bend
• Connectors of electric wire harness-disconnection, friction —
• Fuses-blown —
• Parts-installation, bolts-looseness —
• Parts-deformation —
• Other parts that can be checked visually —
Also check the following items at engine start, if possible
• MIL-Operation “MIL Check”: D13A (Page 1A-131)
• Charging light-Operation “Generator Symptom Diagnosis”: D13A in Section 1J
(Page 1J-23)
• Oil pressure light-Operation “Oil Pressure Switch On-Vehicle Inspection”: D13A in
Section 1E (Page 1E-17)
• Engine coolant temperature meter-Operation —
• Fuel level meter-Operation “Fuel Level Sensor Inspection”: D13A in Section 1G
(Page 1G-56)
• Tachometer-Operation —
• Abnormal air being inhaled from air intake system —
 Engine General Information and Diagnosis: D13A 1A-150

Inspection item Referring section

• Exhaust system-leakage of exhaust gas, noise —
• Other parts that can be checked visually —

Engine Basic Inspection

AENBL80A1124009
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found
in “Visual Inspection”: D13A (Page 1A-149).
Follow the flow carefully.
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Check battery voltage Go to Step 3. Charge or replace
battery.
Is it 11 V or more?
3 Can engine be cranked? Go to Step 4. Go to “Cranking System
Symptom Diagnosis”:
D13A in Section 1I
(Page 1I-9).
4 Does engine start? Go to “Engine Symptom Go to Step 5.
Diagnosis”: D13A (Page
1A-150).
5 Immobilizer system check Go to Step 6. Repair or replace
1) Check immobilizer control system. )(Page 10C-3) defective part(s).

Is check result OK?

6 Low fuel pressure circuit check Go to Step 7. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s).

Is check result OK?

7 High fuel pressure circuit check Go to “Hard Starting Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) (Engine Can Be defective part(s).
Cranked)” under
Is check result OK? “Engine Symptom
Diagnosis”: D13A (Page
1A-150).

Engine Symptom Diagnosis

AENBL80A1124010
Perform troubleshooting referring to the following table when ECM has detected no DTC and no abnormality has been
found in “Visual Inspection”: D13A (Page 1A-149) and “Engine Basic Inspection”: D13A (Page 1A-150).
Condition Correction / Reference Item
Hard starting (Engine can be cranked) Refer to “Hard Starting (Engine Can Be Cranked)”: D13A
(Page 1A-151).
Engine not running smoothly Refer to “Engine Not Running Smoothly”: D13A (Page 1A-
152).
Engine does not produce best performance Refer to “Engine Does Not Produce Best Performance”:
D13A (Page 1A-154).
Engine hesitates-momentary lack of response as Refer to “Engine Hesitates – Momentary Lack of
accelerator is depressed Response as Accelerator is Depressed.”: D13A (Page 1A-
155).
Improper engine idle or engine stops at idle Refer to “Improper Engine Idling or Engine Stops at Idle”:
D13A (Page 1A-156).
Engine cuts out whilst driving Refer to “Engine Cuts Out Whilst Driving”: D13A (Page
1A-158).
Engine knocking Refer to “Engine Knocking”: D13A (Page 1A-158).
White exhaust fumes Refer to “White Exhaust Fumes”: D13A (Page 1A-159).
Black exhaust fumes Refer to “Black Exhaust Fumes”: D13A (Page 1A-161).
1A-151 Engine General Information and Diagnosis: D13A

Condition Correction / Reference Item

Excessive exhaust fumes Refer to “Excessive Exhaust Fumes”: D13A (Page 1A-
162).
Excessive engine oil level Refer to “Engine Oil Excessive Level”: D13A (Page 1A-
163).
Poor fuel mileage Refer to “Poor Fuel Mileage”: D13A (Page 1A-164).
Excessive engine oil consumption Refer to “Engine Oil Excessive Consumption”: D13A
(Page 1A-165).

Hard Starting (Engine Can Be Cranked)

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. )(Page 1E-16)
• Check that intake air / turbocharger circuit is working
properly. )(Page 1A-244)
• Check that main and circuit fuses have not blown.
• Wiring on engine correctly connected to ground.
• Battery correctly connected to ground.
• Battery positive (+) cable and all leads are firmly
connected.

Is check result OK?

2 Parameters check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check the values of the following parameters. )(Page
1A-144)
• Battery Voltage
• Accel Position
• APP Sensor 1 Volt
• APP Sensor 2 Volt
• Barometric Pressure
• Fuel Temperature
• Fuel Rail Pressure
• EGR Valve

Is check result OK?

3 Glow plug control module and its circuit check Go to Step 4. Repair or replace
1) Check that glow plugs are working properly. )(Page 1A- defective part(s).
266)

Is check result OK?

4 Low fuel pressure circuit check Go to Step 5. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s).

Is check result OK?

5 High fuel pressure circuit check Go to Step 6. Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) defective part(s).

Is check result OK?

6 Lubrication system check Go to Step 7. Repair or replace
1) Check lubrication system is working properly. )(Page defective part(s).
1E-15)

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-152

Step Action Yes No

7 Cylinder compression check Go to Step 8. Cylinder compression is
1) Carry out cylinder compression check. )(Page 1D-73) insufficient. Repair or
replace defective
Is check result OK? part(s).
8 Timing check Go to Step 9. Valve timing is not
1) Check that valve timing is correct. )(Page 1D-74) correct. Adjust valve
timing referring to
Is check result OK? “Installation” under
“Timing Chain Cover
and Timing Chain
Removal and
Installation”: D13A in
Section 1D (Page 1D-
99).
9 Combustion chamber check Go to Step 10. Repair or replace
1) Check combustion chamber for excessive deposits. defective part(s).
• Valve: )(Page 1D-119)
• Cylinder head: )(Page 1D-120)
• Piston: )(Page 1D-125)

Is check result OK?

10 Valve spring and hydraulic valve adjuster check End. Repair or replace
1) Check valve spring and hydraulic valve adjuster. defective part(s).
)(Page 1D-46)

Is check result OK?

Engine Not Running Smoothly

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. )(Page 1E-16)
• Check that intake air / turbocharger circuit is working
properly. )(Page 1A-244)
• Check that main and circuit fuses have not blown.

Is check result OK?

2 Parameters check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal of faulty
DLC. parameter.
2) Check the values of the following parameters. )(Page
1A-144)
• Battery Voltage
• Accel Position
• APP Sensor 1 Volt
• APP Sensor 2 Volt
• Barometric Pressure
• Fuel Temperature
• Fuel Rail Pressure
• EGR Valve

Is check result OK?

1A-153 Engine General Information and Diagnosis: D13A

Step Action Yes No

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s).

Is check result OK?

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) defective part(s).

Is check result OK?

5 Vehicle speed signal check Go to Step 6. Repair or replace
1) Check that vehicle speed signal is correct. )(Page 1A- defective part(s).
263)

Is check result OK?

6 A/C system check Go to Step 7. Repair or replace
1) Check that A/C system is working properly. defective part(s).
• Single A/C model: )(Page 7B-9)
• Dual A/C model: )(Page 7B-58)

Is check result OK?

7 Glow plug control module and its circuit check Go to Step 8. Repair or replace
1) Check that glow plugs are working properly. )(Page 1A- defective part(s).
266)

Is check result OK?

8 EGR valve check Go to Step 9. Repair or replace
1) Check EGR valve operation. )(Page 1A-249) defective part(s).

Is check result OK?

9 Turbocharger system check Go to Step 10. Repair or replace
1) Check turbocharger system is working properly. )(Page defective part(s).
1A-244)

Is check result OK?

10 Timing check Go to Step 11. Valve timing is not
1) Check that valve timing is correct. )(Page 1D-74) correct. Adjust valve
timing referring to
Is check result OK? “Installation” under
“Timing Chain Cover
and Timing Chain
Removal and
Installation”: D13A in
Section 1D (Page 1D-
99).
11 Cylinder compression check Go to Step 12. Cylinder compression is
1) Carry out cylinder compression check. )(Page 1D-73) insufficient. Repair or
replace defective
Is check result OK? part(s).
12 Lubrication system check End. Repair or replace
1) Check lubrication system is working properly. )(Page defective part(s).
1E-15)

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-154

Engine Does Not Produce Best Performance

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. )(Page 1E-16)
• Check that intake air/turbocharger circuit is working
properly. )(Page 1A-244)
• Check that main and circuit fuses have not blown.

Is check result OK?

2 Parameters check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check the values of the following parameters. )(Page
1A-144)
• Battery Voltage
• Accel Position
• APP Sensor 1 Volt
• APP Sensor 2 Volt
• Barometric Pressure
• IAT 1
• IAT 2
• Fuel Temperature
• Fuel Rail Pressure
• EGR Valve

Is check result OK?

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s).

Is check result OK?

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) defective part(s).

Is check result OK?

5 Glow plug control module and its circuit check Go to Step 6. Repair or replace
1) Check that glow plugs are working properly. )(Page 1A- defective part(s).
266)

Is check result OK?

6 EGR valve check Go to Step 7. Repair or replace
1) Check EGR valve operation. )(Page 1A-249) defective part(s).

Is check result OK?

7 Brake light switch check Go to Step 8. Brake pedal does not
1) Check that brake light switch is working properly. return. Eliminate cause
)(Page 4A-11) of sticking.
Switch stuck closed or
Is check result OK? wiring short circuit.
Repair circuit or replace
brake light switch.
8 Turbocharger system check Go to Step 9. Repair or replace
1) Check turbocharger system is working properly. )(Page defective part(s).
1A-244)

Is check result OK?

1A-155 Engine General Information and Diagnosis: D13A

Step Action Yes No

9 Timing check Go to Step 10. Valve timing is not
1) Check that valve timing is correct referring to correct. Adjust valve
“Installation” under “Timing Chain Cover and Timing timing referring to
Chain Removal and Installation”: D13A in Section 1D “Installation” under
(Page 1D-99). “Timing Chain Cover
and Timing Chain
Is check result OK? Removal and
Installation”: D13A in
Section 1D (Page 1D-
99).
10 Cylinder compression check Go to Step 11. Cylinder compression is
1) Carry out cylinder compression check. )(Page 1D-73) insufficient. Repair or
replace defective
Is check result OK? part(s).
11 Brake system check Go to Step 12. Repair or replace
1) Check brake system for dragging. )(Page 4A-2) defective part(s).

Is check result OK?

12 Clutch system check End. Repair or replace
1) Check clutch system for slipping. “Clutch System defective part(s).
Symptom Diagnosis”: D13A Model in Section 5C (Page
5C-16)

Is check result OK?

Engine Hesitates – Momentary Lack of Response as Accelerator is Depressed.

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. )(Page 1E-16)
• Check that intake air / vacuum circuit is working
properly. )(Page 1A-244)
• Check that main and circuit fuses have not blown.

Is check result OK?

2 Parameters check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check values of the following parameters. )(Page 1A-
144)
• Battery Voltage
• Accel Position
• APP Sensor 1 Volt
• APP Sensor 2 Volt
• Barometric Pressure
• IAT 1
• IAT 2
• Fuel Temperature
• EGR Valve
• Fuel Rail Pressure

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-156

Step Action Yes No

3 Low fuel Pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s).

Is check result OK?

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) defective part(s).

Is check result OK?

5 Glow plug control module and its circuit check Go to Step 6. Repair or replace
1) Check that glow plugs are working properly. )(Page 1A- defective part(s).
266)

Is check result OK?

6 Cylinder compression check End. Cylinder compression is
1) Carry out cylinder compression check. )(Page 1D-73) insufficient. Repair or
replace defective
Is check result OK? part(s).

Improper Engine Idling or Engine Stops at Idle

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. )(Page 1E-16)
• Check that intake air / turbocharger circuit is working
properly. )(Page 1A-244)
• Check main and circuit fuses have blown.

Is check result OK?

2 Configuration tests Go to Step 3. Carry out register data
1) If symptom is occurs after replacing any of the following of replacing
component(s), it is necessary to register data into ECM. component(s) in ECM
)(Page 1C-14) described in
“Description of ECM
• Injector calibration code
Registration”: D13A in
• Vehicle variant data (ABS, A/C) Section 1C (Page 1C-
• A/F sensor data 14).
• MAF sensor data
• Fuel pressure sensor data
• Fly wheel data

Is check result OK?

1A-157 Engine General Information and Diagnosis: D13A

Step Action Yes No

3 Parameters check Go to Step 4. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check values of the following parameters. )(Page 1A-
144)
• Battery Voltage
• Accel Position
• APP Sensor 1 Volt
• APP Sensor 2 Volt
• Barometric Pressure
• IAT 1
• IAT 2
• A/C Pressure
• Fuel Temperature
• EGR Valve
• Fuel Rail Pressure

Is check result OK?

4 Low fuel pressure circuit check Go to Step 5. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s).

Is check result OK?

5 High fuel pressure circuit check Go to Step 6. Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) defective part(s).

Is check result OK?

6 Glow plug control module and its circuit check Go to Step 7. Repair or replace
1) Check that glow plugs are working properly. )(Page 1A- defective part(s).
266)

Is check result OK?

7 EGR valve check Go to Step 8. Repair or replace
1) Check EGR valve operation. )(Page 1A-249) defective part(s).

Is check result OK?

8 A/C compressor magnet clutch check Go to Step 9. Repair or replace
1) Check magnet clutch operation for being stuck on and defective part(s).
chattering.

Is check result OK?

9 Cylinder compression check Go to Step 10. Cylinder compression is
1) Carry out cylinder compression check. )(Page 1D-73) insufficient. Repair or
replace defective
Is check result OK? part(s).
10 Lubrication system check End. Repair or replace
1) Check lubrication system is working properly. )(Page defective part(s).
1E-15)

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-158

Engine Cuts Out Whilst Driving

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. )(Page 1E-16)
• Check that intake air / turbocharger circuit is working
properly. )(Page 1A-244)
• Check that main and circuit fuses have not blown.
• Wiring on engine correctly connected to ground.
• Battery correctly connected to ground.
• Battery positive (+) cable and all leads are firmly
connected.

Is check result OK?

2 Parameters check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check value of the following parameter. )(Page 1A-
144)
• Battery Voltage

Is check result OK?

3 Glow plug control module and its circuit check Go to Step 4. Repair or replace
1) Check that glow plugs are working properly. )(Page 1A- defective part(s).
266)

Is check result OK?

4 Low fuel pressure circuit check Go to Step 5. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s).

Is check result OK?

5 High fuel pressure circuit check End. Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) defective part(s).

Is check result OK?

Engine Knocking
Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. )(Page 1E-16)
• Check that intake air / turbocharger circuit is working
properly. )(Page 1A-244)

Is check result OK?

1A-159 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 Parameters check Go to Step 3. Check that systems
1) When ignition is “OFF”, connect SUZUKI scan tool to showing abnormal
DLC. parameter.
2) Check values of the following parameters. )(Page 1A-
144)
• Battery Voltage
• Barometric Pressure
• IAT 1
• IAT 2
• Fuel Temperature

Is check result OK?

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s).

Is check result OK?

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) defective part(s).

Is check result OK?

5 Glow plug control module and its circuit check Go to Step 6. Repair or replace
1) Check that glow plugs are working properly. )(Page 1A- defective part(s).
266)

Is check result OK?

6 Combustion chamber check End. Repair or replace
1) Check combustion chamber for excessive deposits. defective part(s).
• Valve: )(Page 1D-119)
• Cylinder head: )(Page 1D-120)
• Piston: )(Page 1D-125)

Is check result OK?

White Exhaust Fumes

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. )(Page 1E-16)
• Check that intake air / turbocharger circuit is working
properly. )(Page 1A-244)
• Check that main and circuit fuses have not blown.

Is check result OK?

2 Parameters check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check values of the following parameters. )(Page 1A-
144)
• Battery Voltage
• Barometric Pressure
• Fuel Temperature
• IAT 1
• IAT 2

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-160

Step Action Yes No

3 Glow plug control module and its circuit check Go to Step 4. Repair or replace
1) Check that glow plugs are working properly. )(Page 1A- defective part(s).
266)

Is check result OK?

4 Cylinder compression check Go to Step 5. Cylinder compressions
1) Carry out cylinder compression check. )(Page 1D-73) is insufficient. Repair or
replace defective
Is check result OK? part(s).
5 Cylinder head gasket and valve oil seals check Go to Step 6. • Cylinder head
1) Check the following points. tightening incorrect:
• Check that cylinder head is correctly tightened – Proceed with
• Check seal of cylinder head gasket removing-refitting
of cylinder head to
• Check seal of valve oil seals correctly retighten
Is check result OK? cylinder head.
“Valve and
Cylinder Head
Assembly
Removal and
Installation”: D13A
in Section 1D
(Page 1D-115)
• Cylinder head gasket
damaged:
– Replace cylinder
head gasket.
“Valve and
Cylinder Head
Assembly
Removal and
Installation”: D13A
in Section 1D
(Page 1D-115)
• Valve oil seal
missing:
– Replace valve oil
seals. “Valve and
Cylinder Head
Assembly
Disassembly and
Reassembly”:
D13A in Section
1D (Page 1D-118)
1A-161 Engine General Information and Diagnosis: D13A

Step Action Yes No

6 Blow-by gas intake circuit check Go to Step 7. • Fault in hose
1) Check condition of blow-by gas intake circuit, especially between oil separator
for obstructions in separator or hoses. and intake manifold:
– Restore circuit to
Is check result OK?
working order.
– Replace pipe if
necessary.
• Fault in oil separator:
– Restore circuit to
working order.
– If necessary,
replace oil
separator. )(Page
1D-84)
7 Turbocharger seal check End. Gasket seal insufficient:
1) Check that there are no engine oil leaks from • Replace turbocharger.
turbocharger impeller shaft. )(Page 1D-87)
Is check result OK?

Black Exhaust Fumes

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. )(Page 1E-16)
• Check that intake air / vacuum circuit is working
properly. )(Page 1A-244)
• Check that main and circuit fuses have not blown.

Is check result OK?

2 Parameters check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check values of the following parameters. )(Page 1A-
144)
• Battery Voltage
• Barometric Pressure
• Fuel Temperature
• EGR Valve

Is check result OK?

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s).

Is check result OK?

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) defective part(s).

Is check result OK?

5 EGR valve check Go to Step 6. Repair or replace
1) Check EGR valve operation. )(Page 1A-249) defective part(s).

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-162

Step Action Yes No

6 Glow plug control module and its circuit check Go to Step 7. Repair or replace
1) Check that glow plugs are working properly. )(Page 1A- defective part(s).
266)

Is check result OK?

7 A/F sensor check Go to Step 8. Repair or replace
1) Check A/F sensor operation. )(Page 1A-250) defective part(s).

Is check result OK?

8 Timing check Go to Step 9. Valve timing is not
1) Check that valve timing is correct. )(Page 1D-74) correct. Adjust valve
timing referring to
Is check result OK? “Installation” under
“Timing Chain Cover
and Timing Chain
Removal and
Installation”: D13A in
Section 1D (Page 1D-
99).
9 Turbocharger system check End. Repair or replace
1) Check turbocharger system is working properly. )(Page defective part(s).
1A-247)

Is check result OK?

Excessive Exhaust Fumes

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. )(Page 1E-16)
• Check that intake air / turbocharger circuit is working
properly. )(Page 1A-244)
• Check that main and circuit fuses have not blown.

Is check result OK?

2 Parameters check Go to Step 3. Check systems showing
1) When ignition is “OFF”, connect SUZUKI scan tool to abnormal parameter.
DLC.
2) Check values of the following parameters. )(Page 1A-
144)
• Battery Voltage
• Barometric Pressure
• Coolant Temp

Is check result OK?

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s).

Is check result OK?

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) defective part(s).

Is check result OK?

1A-163 Engine General Information and Diagnosis: D13A

Step Action Yes No

5 Glow plug control module and its circuit check Go to Step 6. Repair or replace
1) Check that glow plugs are working properly. )(Page 1A- defective part(s).
266)

Is check result OK?

6 Cylinder compression check Go to Step 7. Cylinder compression is
1) Carry out cylinder compression check. )(Page 1D-73) insufficient. Repair or
replace defective
Is check result OK? part(s).
7 A/F sensor check Go to Step 8. Repair or replace
1) Check A/F sensor operation. )(Page 1A-250) defective part(s).

Is check result OK?

8 Timing check Go to Step 9. Valve timing is not
1) Check that valve timing is correct. )(Page 1D-74) correct. Adjust valve
timing referring to
Is check result OK? “Installation” under
“Timing Chain Cover
and Timing Chain
Removal and
Installation”: D13A in
Section 1D (Page 1D-
99).
9 Turbocharger system check End. Repair or replace
1) Check turbocharger system is working properly. )(Page defective part(s).
1A-247)

Is check result OK?

Engine Oil Excessive Level

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. )(Page 1E-16)
• Check condition of fuel circuit and make sure that it is
working properly. )(Page 1A-236)

Is check result OK?

2 Cylinder compression check Go to Step 3. Cylinder compression is
1) Carry out cylinder compression check. )(Page 1D-73) insufficient. Repair or
replace defective
Is check result OK? part(s).
3 Timing check Go to Step 4. Valve timing not correct.
1) Check that valve timing is correct. )(Page 1D-74) Adjust valve timing
referring to “Installation”
Is check result OK? under “Timing Chain
Cover and Timing Chain
Removal and
Installation”: D13A in
Section 1D (Page 1D-
99).
4 Low fuel pressure circuit check Go to Step 5. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s).

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-164

Step Action Yes No

5 High fuel pressure circuit check End. Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) defective part(s).

Is check result OK?

Poor Fuel Mileage

Step Action Yes No
1 Preliminary check Go to Step 2. Repair or replace
1) Check the following points. defective part(s).
• Check that engine oil level is correct. )(Page 1E-16)
• Check that intake air / turbocharger circuit is working
properly. )(Page 1A-244)
• Check tire pressure. )(Page 2D-1)

Is check result OK?

2 Parameters check Go to Step 3. Check that system
1) When ignition is “OFF”, connect SUZUKI scan tool to faulty parameter.
DLC.
2) Check the values of the following parameters. )(Page
1A-144)
• Battery Voltage
• Accel Position
• APP Sensor 1 Volt
• APP Sensor 2 Volt
• Barometric Pressure
• Fuel Rail Pressure
• EGR Valve

Is check result OK?

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s).

Is check result OK?

4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) defective part(s).

Is check result OK?

5 Cylinder compression check Go to Step 6. Cylinder compression is
1) Carry out cylinder compression check. )(Page 1D-73) insufficient. Repair or
replace defective
Is check result OK? part(s).
6 Turbocharger system check Go to Step 7. Repair or replace
1) Check turbocharger system is working properly. )(Page defective part(s).
1A-247)

Is check result OK?

7 Timing check Go to Step 8. Valve timing is not
1) Check that valve timing is correct. )(Page 1D-74) correct. Adjust valve
timing referring to
Is check result OK? “Installation” under
“Timing Chain Cover
and Timing Chain
Removal and
Installation”: D13A in
Section 1D (Page 1D-
99).
1A-165 Engine General Information and Diagnosis: D13A

Step Action Yes No

8 A/F sensor check Go to Step 9. Repair or replace
1) Check A/F sensor operation. )(Page 1A-250) defective part(s).

Is check result OK?

9 Lubrication system check Go to Step 10. Repair or replace
1) Check lubrication system is working properly. )(Page defective part(s).
1E-15)

Is check result OK?

10 A/C compressor magnet clutch check Go to Step 11. Repair or replace
1) Check magnet clutch operation for stuck on and defective part(s).
chattering.

Is check result OK?

11 Brake system check Go to Step 12. Repair or replace
1) Check brake system for dragging. )(Page 4A-2) defective part(s).

Is check result OK?

12 Clutch system check Go to Step 13. Repair or replace
1) Check clutch system for slipping. )(Page 5C-16) defective part(s).

Is check result OK?

13 Combustion chamber check End. Repair or replace
1) Check combustion chamber for excessive deposits. defective part(s).
• Valve: )(Page 1D-119)
• Cylinder head: )(Page 1D-120)
• Piston: )(Page 1D-125)

Is check result OK?

Engine Oil Excessive Consumption

Step Action Yes No
1 Preliminary check Go to Step 2. Refill or replace
1) Check that engine oil level is correct. )(Page 1E-16) defective part(s).

Is check result OK?

2 Cylinder compression check Go to Step 3. Cylinder compression is
1) Carry out cylinder compression check. )(Page 1D-73) insufficient. Repair or
replace defective
Is check result OK? part(s).
 Engine General Information and Diagnosis: D13A 1A-166

Step Action Yes No

3 Cylinder head gasket and valve oil seals check Go to Step 4. • Cylinder head
1) Check the following points. tightening incorrect:
• Check that cylinder head is correctly tightened – Proceed with
• Check seal of cylinder head gasket removing-refitting
of cylinder head to
• Check seal of stem seals correctly retighten
Is check result OK? cylinder head
correctly. )(Page
1D-115)
• Cylinder head gasket
damaged:
– Replace cylinder
head gasket.
)(Page 1D-115)
• Valve oil seal
missing:
– Replace stem
seals. )(Page 1D-
115)
4 Blow-by gas intake circuit check Go to Step 5. • Fault in hose
1) Check condition of blow-by gas intake circuit, especially between oil separator
for obstructions in separator or hoses. and intake manifold:
– Restore circuit to
Is check result OK? working order.
– Replace pipe if
necessary.
• Fault in oil separator:
– Restore circuit to
working order.
– If necessary,
replace cylinder
head cover.
5 Turbocharger seal check End. Gasket seal insufficient.
1) Check that there are no engine oil leaks from Replace turbocharger.
turbocharger impeller shaft. )(Page 1D-87)
Is check result OK?

MIL Does Not Come ON with Ignition in “ON” and Engine Stopped (but Engine Can Be Started)
AENBL80A1124011
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Go to Step 2.
1) Check combination meter for DTC. for applicable DTC.

Is there any DTC(s) detected?

2 Combination meter operation check Replace ECM and Replace combination
1) Set ignition “ON”. recheck MIL operation. meter and recheck MIL
)(Page 1C-14) operation. )(Page 9C-
2) Check warning / indicator lights other than MIL in
10)
combination meter light up.

Is check result OK?

1A-167 Engine General Information and Diagnosis: D13A

MIL Remains ON after Engine Starts

AENBL80A1124012
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Substitute a known-
1) Start engine and recheck DTC of ECM while engine for applicable DTC. good combination meter
running. and recheck MIL
operation. )(Page 9C-
Is there any DTC(s)? 10)
If MIL still remains on,
replace ECM and
recheck MIL operation.
)(Page 1C-14)

DTC P0001
AENBL80A1124086
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0001: Fuel Volume Regulator Control / Open Circuit • Fuel flow actuator and/or its circuit
Any of the following conditions is met. • ECM
• Measured voltage of fuel flow actuator drive circuit is higher than
specified value.
• Measured voltage of fuel flow actuator drive circuit is lower than
specified value.
(1 D/C detection logic)

Circuit Diagram

A1
YEL/BLK C01-4
2 A2
ORN/BLK C01-20

[A]
E01 C01

[a]

IBL80A112005-01

[A]: ECM connector (View: [a]) A2: Fuel flow actuator drive circuit 2. Fuel flow actuator
A1: Fuel flow actuator power supply 1. ECM
circuit

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

 Engine General Information and Diagnosis: D13A 1A-168

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Fuel flow actuator circuit check Go to Step 3. Repair or replace
1) Check “A1” and “A2” circuits according to Step 1 of defective wire harness.
“Table A-5: Fuel Flow Actuator Operation Check”: D13A
(Page 1A-243).

Is check result OK?

3 Fuel flow actuator check Replace ECM and Replace fuel flow
1) Check fuel flow actuator. recheck DTC. )(Page actuator.
1C-14)
Is check result OK?

DTC P0069 / P0107 / P0234

AENBL80A1124013
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0069: Manifold Absolute Pressure-Barometric Pressure • Boost pressure sensor and/or its circuit
Correlation • Air intake circuit
Any of the following conditions is met.
• Turbocharger
• Measured boost pressure is higher than barometric pressure by 22.5
• Vacuum system
kPa (0.225 kgf/cm2, 3.26 psi, 225 mbar) for 2 sec.
• Barometric pressure sensor (in ECM)
• Measured boost pressure is lower than barometric pressure by 22.5
kPa (0.225 kgf/cm2, 3.26 psi, 225 mbar) for 2 sec. • ECM
(1 D/C detection logic)
P0107: Manifold Absolute Pressure / Barometric Pressure Circuit
Low
Difference between boost pressure and barometric pressure is lower
than specified value.
(1 D/C detection logic)
P0234: Turbocharger / Supercharger “A” Overboost Condition
Boost pressure is higher than barometric pressure by 200 kPa (2.0 kgf/
cm2, 29.0 psi, 2,000 mbar) for 1 sec.
(1 D/C detection logic)
1A-169 Engine General Information and Diagnosis: D13A

Circuit Diagram

A1
RED/BLK C01-23
A2
2 ORN C01-41
A3
BLK C01-24

3 B1
WHT/GRN C01-37

[A]
E01 C01

[a]

IBL80A112006-01

[A]: ECM connector (View: [a]) A3: Boost pressure sensor ground circuit 1. ECM
A1: Boost pressure sensor power supply circuit B1: IAT-2 sensor signal circuit 2. Boost pressure sensor
A2: Boost pressure sensor signal circuit 1. ECM 3. IAT-2 sensor

DTC Confirmation Procedure

For DTC P0069, P0234:

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Run engine at idle speed for 1 min.
For DTC P0107:

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Run engine at 2,000 rpm and keep the speed for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Boost pressure sensor power supply circuit, signal Go to Step 3. Repair or replace
circuit and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Steps 5
through 8 of “Table B-3: Boost Pressure Sensor Check”:
D13A (Page 1A-247).

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-170

Step Action Yes No

3 Boost pressure sensor check Go to Step 4. Replace boost pressure
1) Check boost pressure sensor. )(Page 1C-23) and IAT-2 sensor.
)(Page 1C-23)
Is check result OK?
4 Air intake / turbocharger circuit check Go to Step 5. Repair or replace
1) Check that air intake / turbocharger circuit is working defective part(s).
properly. )(Page 1A-244)

Is check result OK?

5 Vacuum system check Replace ECM and Repair or replace
1) Check the following parts: recheck DTC. )(Page defective part(s).
1C-14)
• Check vacuum hoses and pipes.
• Check vacuum pump. )(Page 1D-81)

Is check result OK?

1A-171 Engine General Information and Diagnosis: D13A

DTC P0087 / P0089

AENBL80A1124014
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0087: Fuel Rail / System Pressure-Too Low • Lack of fuel
Measured fuel pressure in common rail is lower than specified • Fuel pressure sensor and/or its circuit
value.
• Low fuel pressure circuit (fuel pressure regulator in
(1 D/C detection logic)
fuel pump, fuel pump and/or its circuit, fuel hose,
P0089: Fuel Pressure Regulator 1 Performance
fuel pipe)
Measured fuel pressure in common rail is lower than targeted
fuel pressure by specified value. • High fuel pressure circuit (high pressure pump,
(1 D/C detection logic) common rail, high pressure pipe, fuel injector)
• ECM

Circuit Diagram

A1
GRN/YEL C01-8
A2
2 ORN/BLK C01-38
A3
YEL/RED C01-6

[A]
E01 C01

[a]

IBL80A112007-01

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

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Fuel level check Add fuel and recheck Go to Step 3.
1) Check fuel level by fuel gauge. DTC.

Does fuel gauge indicate “E” level (empty)?

 Engine General Information and Diagnosis: D13A 1A-172

Step Action Yes No

3 Fuel pressure sensor power supply circuit, signal Go to Step 4. Repair or replace
circuit and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Steps 3
through 6 of “Table A-4: Fuel Pressure Sensor Circuit
Check”: D13A (Page 1A-241).

Is check result OK?

4 Low fuel pressure circuit check Go to Step 5. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s).

Is check result OK?

5 High fuel pressure circuit check Go to Step 6. Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) defective part(s).

Is check result OK?

6 Fuel pressure sensor replacement Replace ECM and End.
1) Replace fuel pressure sensor. )(Page 1G-50) recheck DTC. )(Page
1C-14)
2) Clear DTC. )(Page 1A-134)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure, and check DTC.
)(Page 1A-134)

Is DTC P0087 or P0089 still detected?

DTC P0088
AENBL80A1124015
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0088: Fuel Rail / System Pressure-Too High • Fuel pressure sensor and/or its circuit
Measured fuel pressure in common rail is higher than • Low fuel pressure circuit (fuel pressure regulator in fuel
specified value. pump, fuel pump and/or its circuit, fuel hose, fuel pipe)
(1 D/C detection logic)
• High fuel pressure circuit (high pressure pump,
common rail, high pressure pipe, fuel injector)
• ECM
1A-173 Engine General Information and Diagnosis: D13A

Circuit Diagram

A1
GRN/YEL C01-8
A2
2 ORN/BLK C01-38
A3
YEL/RED C01-6

[A]
E01 C01

[a]

IBL80A112008-01

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

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Fuel pressure sensor power supply circuit, signal Go to Step 3. Repair or replace
circuit and ground circuit check defective wire harness
1) Check “A1”, “A2” and “A3” circuits according to Steps 3 and go to Step 3.
through 6 of “Table A-4: Fuel Pressure Sensor Circuit
Check”: D13A (Page 1A-241).

Is check result OK?

3 Low fuel pressure circuit check Go to Step 4. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s) and go
to Step 5.
Is check result OK?
4 High fuel pressure circuit check Go to Step 5. Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) defective part and go to
Step 5.
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-174

Step Action Yes No

5 Fuel pressure sensor replacement Replace ECM and End.
1) Replace fuel pressure sensor. )(Page 1G-50) recheck DTC. )(Page
1C-14)
2) Clear DTC. )(Page 1A-134)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
)(Page 1A-134)

Is DTC P0088 still detected?

1A-175 Engine General Information and Diagnosis: D13A

DTC P0095
AENBL80A1124087
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0095: Intake Air Temperature Sensor 2 Circuit • IAT-2 sensor and/or its circuit
Any of the following conditions is met. • ECM
• Measured voltage of IAT-2 sensor signal circuit is
higher than 4.6 V for 1.6 sec.
• Measured voltage of IAT-2 sensor signal circuit is lower
than 0.1 V for 1.6 sec.
(3 D/C detection logic)

Circuit Diagram

A1
RED/BLK C01-23
A2
2 ORN C01-41
A3
BLK C01-24

3 B1
WHT/GRN C01-37

[A]
E01 C01

[a]

IBL80A112009-01

[A]: ECM connector (View: [a]) A3: Boost pressure sensor ground circuit 2. Boost pressure sensor
A1: Boost pressure sensor power supply circuit B1: IAT-2 sensor signal circuit 3. IAT-2 sensor
A2: Boost pressure sensor signal circuit 1. ECM

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 IAT-2 sensor signal circuit and boost pressure sensor Go to Step 3. Repair or replace
ground circuit check defective wire harness.
1) Check “B1” and “A3” circuits according to Step 2 of
“Table C-5: IAT-2 Sensor Check”: D13A (Page 1A-260).

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-176

Step Action Yes No

3 IAT-2 sensor check Replace ECM and Replace boost pressure
1) Check IAT-2 sensor. )(Page 1C-23) recheck DTC. )(Page and IAT-2 sensor.
1C-14) )(Page 1C-23)
Is check result OK?

DTC P0100
AENBL80A1124018
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0100: Mass or Volume Air Flow “A” Circuit • MAF sensor and/or its circuit
Any of the following conditions is met. • ECM
• Duty ratio of MAF sensor signal is higher than specified value for 2 sec.
• Duty ratio of MAF sensor signal is lower than specified value for 2 sec.
(3 D/C detection logic)

Circuit Diagram

IG1 1

A1
BLK/WHT
A2
2 BLU/RED E01-56
A3
BLU/YEL E01-34

3 B1
BLU/ORN E01-62

[A]
E01 C01

[a]

IBL80A112010-01

[A]: ECM connector (View: [a]) A3: MAF sensor ground circuit 2. MAF sensor
A1: MAF sensor power supply circuit B1: IAT-1 sensor signal circuit 3. IAT-1 sensor
A2: MAF sensor signal circuit 1. ECM

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
1A-177 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 MAF sensor power supply circuit, signal circuit and Go to Step 3. Repair or replace
ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Steps 5
through 7 of “Table B-2: MAF Sensor Check”: D13A
(Page 1A-245).

Is check result OK?

3 MAF sensor check Replace ECM and Replace MAF and IAT-1
1) Check MAF sensor. )(Page 1C-18) recheck DTC. )(Page sensor. )(Page 1C-17)
1C-14)
Is check result OK?

DTC P0101
AENBL80A1124019
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0101: Mass or Volume Air Flow “A” Circuit Range / Performance • MAF sensor and/or its circuit
Any of the following conditions is met. • EGR valve and/or its circuit
• Measured MAF is higher than estimated MAF by specified value. • Air intake circuit
• Measured MAF is lower than estimated MAF by specified value. • ECM
(3 D/C detection logic)

Circuit Diagram

IG1 1

A1
BLK/WHT
A2
2 BLU/RED E01-56
A3
BLU/YEL E01-34

3 B1
BLU/ORN E01-62

[A]
E01 C01

[a]

IBL80A112010-01

[A]: ECM connector (View: [a]) A3: MAF sensor ground circuit 2. MAF sensor
A1: MAF sensor power supply circuit B1: IAT-1 sensor signal circuit 3. IAT-1 sensor
A2: MAF sensor signal circuit 1. ECM
 Engine General Information and Diagnosis: D13A 1A-178

DTC Confirmation Procedure

! WARNING

• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

NOTE
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.
• Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
– Fuel cut < 50 times

1) Warm up engine to normal operating temperature.

2) Drive vehicle (with engine speed at 2,500 rpm or more) and gear at 4th for 10 sec.
3) Release accelerator pedal, and let vehicle coast to 1,500 rpm with engine braking applied.
4) Repeat Steps 2) and 3) 20 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 MAF sensor power supply circuit, signal circuit and Go to Step 3. Repair or replace
ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Steps 5
through 7 of “Table B-2: MAF Sensor Check”: D13A
(Page 1A-245).

Is check result OK?

3 MAF sensor check Go to Step 4. Replace MAF and IAT-1
1) Check MAF sensor. )(Page 1C-18) sensor. )(Page 1C-17)

Is check result OK?

4 EGR valve operation check Go to Step 5. Repair or replace
1) Check EGR valve operation. )(Page 1A-249) defective part(s).

Is check result OK?

5 Air intake / turbocharger circuit check Replace ECM and Repair or replace
1) Check that air intake / turbocharger circuit is working recheck DTC. )(Page defective part(s).
properly. )(Page 1A-244) 1C-14)

Is check result OK?

DTC P0110
AENBL80A1124020
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0110: Intake Air Temperature Sensor 1 Circuit • IAT-1 sensor and/or its circuit
Any of the following conditions is met. • ECM
• Duty ratio of IAT-1 sensor signal is higher than specified value for 3.25 sec.
• Duty ratio of IAT-1 sensor signal is lower than specified value for 3.25 sec.
(1 D/C detection logic but MIL does not light up)
1A-179 Engine General Information and Diagnosis: D13A

Circuit Diagram

IG1 1

A1
BLK/WHT
A2
2 BLU/RED E01-56
A3
BLU/YEL E01-34

3 B1
BLU/ORN E01-62

[A]
E01 C01

[a]

IBL80A112010-01

[A]: ECM connector (View: [a]) A3: MAF sensor ground circuit 2. MAF sensor
A1: MAF sensor power supply circuit B1: IAT-1 sensor signal circuit 3. IAT-1 sensor
A2: MAF sensor signal circuit 1. ECM

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 IAT-1 sensor signal circuit and MAF sensor ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) Check “B1” and “A3” circuits according to Step 2 of
“Table C-4: IAT-1 Sensor Check”: D13A (Page 1A-259).

Is check result OK?

3 IAT-1 sensor check Replace ECM and Replace MAF and IAT-1
1) Check IAT-1 sensor. )(Page 1C-18) recheck DTC. )(Page sensor. )(Page 1C-17)
1C-14)
Is check result OK?

DTC P0115
AENBL80A1124021
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0115: Engine Coolant Temperature Sensor 1 Circuit • ECT sensor and/or its circuit
Any of the following conditions is met. • ECM
• Measured voltage of ECT sensor signal circuit is higher than 4.85 V for 1.6 sec.
• Measured voltage of ECT sensor signal circuit is lower than 0.10 V for 1.6 sec.
(1 D/C detection logic)
 Engine General Information and Diagnosis: D13A 1A-180

Circuit Diagram

1
A1
2
PPL/WHT C01-54
A2
GRN C01-29

[A]
E01 C01

[a]

IBL80A112011-01

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

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 ECT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
1) Check “A1” and “A2” circuits according to Step 2 of defective wire harness.
“Table C-3: ECT Sensor Check”: D13A (Page 1A-257).

Is check result OK?

3 ECT sensor check Replace ECM and Replace ECT sensor.
1) Check ECT sensor. )(Page 1C-21) recheck DTC. )(Page )(Page 1C-20)
1C-14)
Is check result OK?

DTC P0120
AENBL80A1124022
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0120: Throttle / Pedal Position Sensor / Switch “A” Circuit • APP sensor and/or its circuit
Any of the following conditions is met. • ECM
• Measured voltage of APP sensor (main) signal circuit is lower than 0.30 V
and output voltage of APP sensor (sub) signal circuit is higher than 1.17 V
for 1 sec.
• Measured voltage of APP sensor (main) signal circuit is higher than 4.80 V
for 1 sec.
• Both measured voltages of APP sensor (main) and APP sensor (sub)
signal circuits are lower than 0.05 V for 1 sec.
(1 D/C detection logic)
1A-181 Engine General Information and Diagnosis: D13A

Circuit Diagram

1
A1
2 BRN E01-83
A2
GRN/RED E01-65
A3
BLU E01-35
B1
3 RED E01-15
B2
YEL E01-41
B3
WHT E01-32

[A]
E01 C01

[a]

IBL80A112012-01

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

DTC Confirmation Procedure

1) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 APP sensor (main) power supply circuit, signal circuit Go to Step 3. Repair or replace
and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Steps 3
through 6 of “Table C-6: Accelerator Pedal Check”:
D13A (Page 1A-261).

Is check result OK?

3 APP sensor (main) check Replace ECM and Replace APP sensor.
1) Check APP sensor (main). )(Page 1C-20) recheck DTC. )(Page )(Page 1C-20)
1C-14)
Is check result OK?

DTC P0130 / P2244

AENBL80A1124023
 Engine General Information and Diagnosis: D13A 1A-182

DTC Detecting Condition and Trouble Area

DTC detection condition Trouble area
P0130: O2 Sensor Circuit • A/F sensor and/or its circuit
Measured voltage of A/F sensor signal circuit are out of specified range. • ECM
(1 D/C detection logic but MIL does not light up)
P2244: O2 Sensor Reference Voltage Performance
A/F power supply voltage is out of specified range.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

2 1
A1
BLK E01-47
A2
RED/WHT E01-44
A3
GRN/WHT E01-46
A4
+B
YEL E01-45
B1 B2
LT GRN E01-12
BLU

[A]
E01 C01

[a]

IBL80A112013-01

[A]: ECM connector (View: [a]) A3: A/F sensor signal circuit (VSIP) B2: A/F sensor heater drive circuit
A1: A/F sensor signal circuit (RC) A4: A/F sensor signal circuit (IP) 1. ECM
A2: A/F sensor signal circuit (VS) B1: A/F sensor heater power supply circuit 2. A/F sensor

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 A/F sensor signal circuit check Go to Step 3. Repair or replace
1) Check “A1”, “A2”, “A3” and “A4” circuits according to defective wire harness.
Step 3 of “Table B-6: A/F Sensor Check”: D13A (Page
1A-250).

Is check result OK?

1A-183 Engine General Information and Diagnosis: D13A

Step Action Yes No

3 A/F sensor replacement Replace ECM and End.
1) Replace A/F sensor. )(Page 1B-9) recheck DTC. )(Page
1C-14)
2) Clear DTC. )(Page 1A-134)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTCs.
)(Page 1A-134)

Is DTC P0130 or P2244 still detected?

 Engine General Information and Diagnosis: D13A 1A-184

DTC P0135
AENBL80A1124024
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0135: O2 Sensor Heater Circuit • A/F sensor heater and/or its
Any of the following conditions is met. circuit
• Measured voltage of A/F sensor heater drive circuit is higher than specified value • ECM
for 3.25 sec. even when command signal of A/F sensor heater is ON.
• Measured voltage of A/F sensor heater drive circuit is lower than specified value
for 3.25 sec. even when command signal of A/F sensor heater is OFF.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

2 1
A1
BLK E01-47
A2
RED/WHT E01-44
A3
GRN/WHT E01-46
A4
+B
YEL E01-45
B1 B2
LT GRN E01-12
BLU

[A]
E01 C01

[a]

IBL80A112013-01

[A]: ECM connector (View: [a]) A3: A/F sensor signal circuit (VSIP) B2: A/F sensor heater drive circuit
A1: A/F sensor signal circuit (RC) A4: A/F sensor signal circuit (IP) 1. ECM
A2: A/F sensor signal circuit (VS) B1: A/F sensor heater power supply circuit 2. A/F sensor

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
1A-185 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 A/F sensor heater power supply circuit and drive circuit Go to Step 3 Repair or replace
check defective wire harness.
1) Check “B1” and “B2” circuits according to Steps 1 and 2
of “Table B-6: A/F Sensor Check”: D13A (Page 1A-250).

Is check result OK?

3 A/F sensor heater check Replace ECM and Replace A/F sensor.
1) Check A/F sensor heater for resistance. )(Page 1B-9) recheck DTC. )(Page )(Page 1B-9)
1C-14)
Is check result OK?

DTC P0168 / P0180

AENBL80A1124025
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0168: Fuel Temperature Too High • Fuel temperature sensor and/or its circuit
Fuel temperature is higher than specified value. • ECM
(1 D/C detection logic but MIL does not light up)
P0180: Fuel Temperature Sensor “A” Circuit
Any of the following conditions is met.
• Measured voltage of fuel temperature sensor signal
circuit is higher than 4.85 V for 2.5 sec.
• Measured voltage of fuel temperature sensor signal
circuit is lower than 0.10 V for 2.5 sec.
(1 D/C detection logic)

Circuit Diagram

2 A1
BLK/YEL E01-61
A2
RED/BLU E01-13

[A]
E01 C01

[a]

IBL80A112014-01

[A]: ECM connector (View: [a]) A2: Fuel temperature sensor ground circuit 2. Fuel temperature sensor
A1: Fuel temperature sensor signal circuit 1. ECM
 Engine General Information and Diagnosis: D13A 1A-186

DTC Confirmation Procedure

For DTC P1068

! WARNING

• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

1) Warm up engine to normal operating temperature.

2) Drive vehicle for 1 min.

For DTC P0180

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Fuel temperature sensor signal circuit and ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) Check “A1” and “A2” circuits according to Step 2 of
“Table A-3: Fuel Temperature Sensor Check”: D13A
(Page 1A-239)

Is check result OK?

3 Fuel temperature sensor check Replace ECM and Replace fuel filter
1) Check fuel temperature sensor. )(Page 1G-58) recheck DTC. )(Page assembly. )(Page 1G-
1C-14) 58)
Is check result OK?

DTC P0190
AENBL80A1124026
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0190: Fuel Rail Pressure Sensor “A” Circuit • Lack of fuel
Any of the following conditions is met. • Fuel pressure sensor and/or its circuit
• Measured voltage of fuel pressure sensor signal circuit is higher than • Low fuel pressure circuit (fuel pressure
4.85 V. regulator in fuel pump, fuel pump and/
• Measured voltage of fuel pressure sensor signal circuit is lower than or its circuit, fuel hose, fuel pipe)
0.15 V. • High fuel pressure circuit (high
• Difference between current fuel pressure and previous fuel pressure at pressure pump, common rail, high
specified vehicle condition is more than specified value. pressure pipe, fuel injector)
(1 D/C detection logic) • ECM
1A-187 Engine General Information and Diagnosis: D13A

Circuit Diagram

A1
GRN/YEL C01-8
A2
2 ORN/BLK C01-38
A3
YEL/RED C01-6

[A]
E01 C01

[a]

IBL80A112015-01

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

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Fuel level check Add fuel and recheck Go to Step 3.
1) Check fuel level by fuel gauge. DTC.

Does fuel gauge indicate “E” level (empty)?

3 Fuel pressure sensor power supply circuit, signal Go to Step 4. Repair or replace
circuit and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Steps 3
through 6 of “Table A-4: Fuel Pressure Sensor Circuit
Check”: D13A (Page 1A-241).

Is check result OK?

4 Low fuel pressure circuit check Go to Step 5. Repair or replace
1) Check low fuel pressure circuit. )(Page 1G-33) defective part(s).

Is check result OK?

5 High fuel pressure circuit check Go to Step 6. Repair or replace
1) Check high fuel pressure circuit. )(Page 1G-35) defective part(s).

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-188

Step Action Yes No

6 Fuel pressure sensor replacement Replace ECM and End.
1) Replace fuel pressure sensor. )(Page 1G-50) recheck DTC. )(Page
1C-14)
2) Clear DTC. )(Page 1A-134)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
)(Page 1A-134)

Is DTC P0190 still detected?

1A-189 Engine General Information and Diagnosis: D13A

DTC P0201 / P0202 / P0203 / P0204 / P2146

AENBL80A1124028
NOTE
For identification of each cylinder, refer to “Statement on Cleanliness and Care”: D13A (Page 1A-124).

DTC Detecting Condition and Trouble Area

DTC detection condition Trouble area
P0201: Injector Circuit / Open-Cylinder 1 • Fuel injector and/or its
P0202: Injector Circuit / Open-Cylinder 2 circuit
P0203: Injector Circuit / Open-Cylinder 3 • ECM
P0204: Injector Circuit / Open-Cylinder 4
Any of the following conditions is met.
• Measured voltage of relevant fuel injector drive circuit (high side) does not match with
command signal for 5 sec. when engine is idling.
• Measured voltage of relevant fuel injector drive circuit (low side) does not match with
command signal for 5 sec. when engine is idling.
(1 D/C detection logic)
P2146: Fuel Injector Group “A” Supply Voltage Circuit / Open
Any of the following conditions is met.
• Measured voltage of fuel injector drive circuit (high side) is higher than 50 V for 1 sec.
• Measured voltage of fuel injector drive circuit (high side) is lower than 30 V for 1 sec.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

A1
ORN C01-47
2 A2
ORN/WHT C01-16

B1
YEL C01-49
3 B2
YEL/BLK C01-17

C1
GRN C01-48
4 C2
WHT/GRN C01-31

D1
BLU C01-46
5 D2
WHT/BLU C01-1

[A]
E01 C01

[a]

IBL80A112016-01
 Engine General Information and Diagnosis: D13A 1A-190

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

DTC Confirmation Procedure

For DTC P0201, P0202, P0203 and P0204:

NOTE
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.
• Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
– Battery voltage > 10 V

1) Warm up engine to normal operating temperature.

2) Run engine at 3,000 rpm and keep the speed for 10 sec.
For DTC P2146:

NOTE
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.
• Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
– Battery voltage > 7 V

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Fuel injector drive circuit (high side) and (low side) Go to Step 3. Repair or replace
check defective wire harness.
1) Check of “A1”, “A2”, “B1”, “B2”, “C1”, “C2”, “D1” and “D2”
circuits according to Step 1 of “Table A-2: Fuel Injector
Circuit Check”: D13A (Page 1A-238).

Is check result OK?

3 Fuel injector check Replace ECM and Replace fuel injector.
1) Check fuel injector. )(Page 1G-45) recheck DTC. )(Page )(Page 1G-46)
1C-14)
Is check result OK?

DTC P0217
AENBL80A1124029
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0217: Engine Coolant Over Temperature Condition • ECT sensor and/or its circuit
ECT is higher than specified value. • Engine cooling system
(1 D/C detection logic but MIL does not light up)
• Engine oil insufficient
• ECM
1A-191 Engine General Information and Diagnosis: D13A

Circuit Diagram

1
A1
2
PPL/WHT C01-54
A2
GRN C01-29

[A]
E01 C01

[a]

IBL80A112017-01

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

DTC Confirmation Procedure

! WARNING

• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

1) Warm up engine to normal operating temperature.

2) Drive vehicle for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 ECT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
1) Check “A1” and “A2” circuits according to Step 2 of defective wire harness.
“Table C-3: ECT Sensor Check”: D13A (Page 1A-257).

Is check result OK?

3 ECT sensor check Go to Step 4. Replace ECT sensor.
1) Check ECT sensor. )(Page 1C-21) )(Page 1C-20)

Is check result OK?

4 Cooling system check Go to Step 5. Repair or replace
1) Check cooling system. defective part(s).
• Radiator cooling fan operation: )(Page 1A-269)
• Coolant level: )(Page 1F-24)
• Engine cooling system: )(Page 1F-24)

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-192

Step Action Yes No

5 Engine lubrication system check Go to Step 6. Repair or replace
1) Check that there are no engine oil leaks and engine oil defective part(s).
level is correct. )(Page 1E-16)

Is check result OK?

6 Thermostat replacement Replace ECM and End.
1) Replace thermostat. )(Page 1F-26) recheck DTC. )(Page
1C-14)
2) Check DTC. )(Page 1A-134)

Is DTC P0217 still detected?

DTC P0219
AENBL80A1124030
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0219: Engine Overspeed Condition • CKP sensor and/or its circuit
Engine speed exceeds 6,000 rpm for 1.95 sec. • ECM
(1 D/C detection logic)

Circuit Diagram

3 1
A1
GRY/BLK C01-43
2 A2
YEL/RED C01-59

B1
5 PNK C01-25
B2
4 PNK/BLK C01-56
B3
PPL C01-21

[A]
E01 C01

[a]

IBL80A112018-01

[A]: ECM connector (View: [a]) B2: CMP sensor signal circuit 3. CKP sensor teeth
A1: CKP sensor signal circuit (+) B3: CMP sensor ground circuit 4. CMP sensor
A2: CKP sensor signal circuit (–) 1. ECM 5. CMP sensor teeth
B1: CMP sensor power supply circuit 2. CKP sensor
1A-193 Engine General Information and Diagnosis: D13A

DTC Confirmation Procedure

1) Warm up engine to normal operating temperature.
2) Run engine at 6,000 rpm and keep the speed for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Customer’s driving condition check Go to Step 3. Inform customer that
1) Check engine speed is higher than 6,000 rpm for 2 this high engine speed
seconds in customer’s driving condition. may cause mechanical
damage.
Is check result OK?
3 CKP sensor signal circuit check Go to Step 4. Repair or replace
1) Check “A1” and “A2” circuits according to Step 3 of defective wire harness.
“Table C-2: Engine Speed Check”: D13A (Page 1A-256).

Is check result OK?

4 CKP sensor check Go to Step 5. Replace CKP sensor.
1) Check CKP sensor. )(Page 1C-22) )(Page 1C-22)

Is check result OK?

5 CKP sensor teeth check Replace ECM and Replace flywheel.
1) Check CKP sensor teeth. )(Page 1D-105) recheck DTC. )(Page )(Page 1D-99)
1C-14)
Is check result OK?

DTC P0220
AENBL80A1124031
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0220: Throttle / Pedal Position Sensor / Switch “B” Circuit • APP sensor and/or its circuit
Any of the following conditions is met. • ECM
• Measured voltage of APP sensor (sub) signal circuit is lower than 0.3 V and output
voltage of APP sensor (main) signal circuit is higher than 0.86 V for 1 sec.
• Measured voltage of APP sensor (sub) signal circuit is higher than 4.9 V for 1 sec.
• Both measured voltages of APP sensor (main) and APP sensor (sub) signal circuits
are lower than 0.05 V for 1 sec.
(1 D/C detection logic)
 Engine General Information and Diagnosis: D13A 1A-194

Circuit Diagram

1
A1
2 BRN E01-83
A2
GRN/RED E01-65
A3
BLU E01-35
B1
3 RED E01-15
B2
YEL E01-41
B3
WHT E01-32

[A]
E01 C01

[a]

IBL80A112019-01

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

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Keep accelerator pedal at released position for 2 sec.
4) Repeat Steps 2) and 3) 3 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 APP sensor (sub) power supply circuit, signal circuit Go to Step 3. Repair or replace
and ground circuit check defective wire harness.
1) Check “B1”, “B2” and “B3” circuits according to Steps 3
through 6 of “Table C-6: Accelerator Pedal Check”:
D13A (Page 1A-261).

Is check result OK?

3 APP sensor (sub) check Replace ECM and Replace APP sensor.
1) Check APP sensor (sub). )(Page 1C-20) recheck DTC. )(Page )(Page 1C-20)
1C-14)
Is check result OK?
1A-195 Engine General Information and Diagnosis: D13A

DTC P0230
AENBL80A1124032
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0230: Fuel Pump Primary Circuit • Fuel pump relay (coil side) and/or its
Any of the following conditions is met. circuit
• Measured voltage of fuel pump relay drive circuit is higher than specified • ECM
value even when command signal of fuel pump relay is ON.
• Measured voltage of fuel pump relay drive circuit is lower than specified
value even when command signal of fuel pump relay is OFF.
(1 D/C detection logic)

Circuit Diagram

+B 1

A1 2 A3
4
BLK/RED PPL/WHT E01-75
BLK/RED PNK B1
B3
A2 3
BLK

[A]
E01 C01

[a]

IBL80A112020-01

[A]: ECM connector (View: [a]) B1: Fuel pump power supply circuit 3. Fuel pump
A1: Fuel pump relay power supply circuit (coil side) B2: Fuel pump ground circuit 4. “F/P” fuse
A2: Fuel pump relay power supply circuit (switch side) 1. ECM
A3: Fuel pump relay drive circuit 2. Fuel pump relay

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
 Engine General Information and Diagnosis: D13A 1A-196

Step Action Yes No

2 Fuel pump relay (coil side) power supply circuit and Go to Step 3. Repair or replace
drive circuit check defective wire harness.
1) Check “A1” and “A3” circuits according to Steps 2 and 3
of “Table A-1: Fuel Pump Relay Operation Check”: D13A
(Page 1A-236).

Is check result OK?

3 Fuel pump relay check Replace ECM and Replace fuel pump
1) Check fuel pump relay for resistance. )(Page 1C-24) recheck DTC. )(Page relay. )(Page 10B-7)
1C-14)
Is check result OK?

DTC P0235
AENBL80A1124033
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0235: Turbocharger / Supercharger Boost Sensor “A” Circuit • Boost pressure sensor and/or its circuit
Any of the following conditions is met. • ECM
• Measured voltage of boost pressure sensor signal circuit is higher
than 4,9 V for 2 sec.
• Measured voltage of boost pressure sensor signal circuit is lower
than 0.2 V for 2 sec.
(1 D/C detection logic)

Circuit Diagram

A1
RED/BLK C01-23
A2
2 ORN C01-41
A3
BLK C01-24

3 B1
WHT/GRN C01-37

[A]
E01 C01

[a]

IBL80A112021-01

[A]: ECM connector (View: [a]) A3: Boost pressure sensor ground circuit 2. Boost pressure sensor
A1: Boost pressure sensor power supply circuit B1: IAT-2 sensor signal circuit 3. IAT-2 sensor
A2: Boost pressure sensor signal circuit 1. ECM

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.
1A-197 Engine General Information and Diagnosis: D13A

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Boost pressure sensor power supply circuit, signal Go to Step 3. Repair or replace
circuit and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Steps 5
through 8 of “Table B-3: Boost Pressure Sensor Check”:
D13A (Page 1A-247).

Is check result OK?

3 Boost pressure sensor check Replace ECM and Replace boost pressure
1) Check boost pressure sensor. )(Page 1C-23) recheck DTC. )(Page and IAT-2 sensor.
1C-14) )(Page 1C-23)
Is check result OK?

DTC P0243
AENBL80A1124088
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0243: Turbocharger / Supercharger Wastegate Solenoid “A” • Boost pressure control solenoid valve
Any of the following conditions is met. and/or its circuit
• Measured voltage of boost pressure control solenoid valve drive • Boost pressure and IAT-2 sensor and/or
circuit does not match with command signal of boost pressure its circuit
control solenoid valve. • Air intake system
• Difference between actual boost pressure and estimated boost • Turbocharger
pressure is more than specified value when turbocharger is
• Vacuum system
operated.
(1 D/C detection logic) • ECM

Circuit Diagram

1
B2

YEL/GRN C01-30
3 B1 A1 A2
+B
BLU 2 GRY/RED C01-15

BLU BLU/RED C01-5

[A]
E01 C01

[a]

IBL80A112023-01
 Engine General Information and Diagnosis: D13A 1A-198

[A]: ECM connector (View: [a]) B1: Boost pressure control solenoid valve 2. EGR valve
power supply circuit
A1: EGR valve power supply circuit B2: Boost pressure control solenoid valve drive 3. Boost pressure control solenoid valve
circuit
A2: EGR valve drive circuit 1. ECM

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Run engine at 2,500 rpm or more for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Boost pressure control solenoid valve operation check Go to Step 3. Repair or replace
1) Check that boost pressure control solenoid valve is defective part(s).
working properly. )(Page 1A-252).

Is check result OK?

3 Boost pressure sensor check Go to Step 4. Repair or replace
1) Check boost pressure sensor. )(Page 1A-247) defective part(s).

Is check result OK?

4 Air intake / turbocharger circuit check Go to Step 5. Repair or replace
1) Check that air intake / turbocharger circuit is working defective part(s).
properly. )(Page 1A-244)

Is check result OK?

5 Vacuum system check Replace ECM and Repair or replace
1) Check the following parts: recheck DTC. )(Page defective part(s).
1C-14)
• Vacuum hose and pipe
• Vacuum pump )(Page 1D-81)

Is check result OK?

DTC P0335
AENBL80A1124034
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0335: Crankshaft Position Sensor “A” Circuit • CKP sensor and/or its circuit
CKP sensor signal is not input even if CMP sensor signal • CKP sensor rotor
is input.
• ECM
(1 D/C detection logic)
1A-199 Engine General Information and Diagnosis: D13A

Circuit Diagram

3 1
A1
GRY/BLK C01-43
2 A2
YEL/RED C01-59

B1
5 PNK C01-25
B2
4 PNK/BLK C01-56
B3
PPL C01-21

[A]
E01 C01

[a]

IBL80A112024-01

[A]: ECM connector (View: [a]) B2: CMP sensor signal circuit 3. CKP sensor teeth
A1: CKP sensor signal circuit (+) B3: CMP sensor ground circuit 4. CMP sensor
A2: CKP sensor signal circuit (–) 1. ECM 5. CMP sensor teeth
B1: CMP sensor power supply circuit 2. CKP sensor

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Crank engine for 5 sec.

2) Run engine at 2,000 rpm or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 CKP sensor signal circuit check Go to Step 3. Repair or replace
1) Check “A1” and “A2” circuits according to Step 3 of defective wire harness.
“Table C-2: Engine Speed Check”: D13A (Page 1A-256).

Is check result OK?

3 CKP sensor check Go to Step 4. Replace CKP sensor.
1) Check CKP sensor. )(Page 1C-22) )(Page 1C-22)

Is check result OK?

4 CKP sensor teeth check Replace ECM and Replace flywheel.
1) Check CKP sensor teeth. )(Page 1D-105) recheck DTC. )(Page )(Page 1D-99)
1C-14)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-200

DTC P0340
AENBL80A1124035
NOTE
For identification of each cylinder, refer to “Statement on Cleanliness and Care”: D13A (Page 1A-124).

DTC Detecting Condition and Trouble Area

DTC detection condition Trouble area
P0340: Camshaft Position Sensor “A” Circuit • CMP sensor and/or its circuit
Any of the following conditions is met. • CMP sensor rotor
• Measured voltage of CMP sensor signal circuit is higher or lower than • ECM
specified value for 1 sec.
• Measured voltage of CMP sensor signal circuit is lower than specified value
when cylinder No.1 is at compression TDC for 1 sec.
• Measured voltage of CMP sensor signal circuit is higher than specified
value when cylinder No.4 is at compression TDC for 1 sec.
(1 D/C detection logic)

Circuit Diagram

3 1
A1
GRY/BLK C01-43
2 A2
YEL/RED C01-59

B1
5 PNK C01-25
B2
4 PNK/BLK C01-56
B3
PPL C01-21

[A]
E01 C01

[a]

IBL80A112025-01

[A]: ECM connector (View: [a]) B2: CMP sensor signal circuit 3. CKP sensor teeth
A1: CKP sensor signal circuit (+) B3: CMP sensor ground circuit 4. CMP sensor
A2: CKP sensor signal circuit (–) 1. ECM 5. CMP sensor teeth
B1: CMP sensor power supply circuit 2. CKP sensor

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
1A-201 Engine General Information and Diagnosis: D13A

Step Action Yes No

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

Is check result OK?

3 CMP sensor ground circuit check Repair “B3” circuit. Go to Step 4.
1) Check that voltage between “B1” circuit and ground is If DTC is detected
approx. 5 V. again, replace ECM and
recheck DTC. )(Page
Is check result OK? 1C-14)
4 CMP sensor power supply circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “C01” connector from recheck DTC. )(Page defective wire harness.
ECM. 1C-14)
2) Check for proper terminal connection to “C01”
connector.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at CMP sensor connector: infinity
• Voltage of “B1” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

5 CMP sensor signal circuit check Go to Step 6. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and other
terminal at CMP sensor connector: infinity
• Voltage of “B2” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

6 CMP sensor check Go to Step 7. Replace CMP sensor.
1) Check CMP sensor. )(Page 1C-22) )(Page 1C-21)

Is check result OK?

7 CMP sensor teeth check Replace ECM and Replace exhaust
1) Check CMP sensor teeth. )(Page 1D-111) recheck DTC. )(Page manifold side camshaft.
1C-14) )(Page 1D-109)
Is check result OK?

DTC P0380 / P0683

AENBL80A1124036
 Engine General Information and Diagnosis: D13A 1A-202

NOTE
For identification of each cylinder, refer to “Statement on Cleanliness and Care”: D13A (Page 1A-124).

DTC Detecting Condition and Trouble Area

DTC detection condition Trouble area
P0380: Glow Plug / Heater Circuit “A” • Glow plug and/or its circuit
Measured voltage of glow plug control module drive circuit does not • Glow plug control module and/or its circuit
match with command signal for 1.6 sec.
• ECM
(1 D/C detection logic but MIL does not light up)
P0683: Glow Plug Control Module to PCM Communication
Circuit
Measured voltage of glow plug drive circuit does not match with
command signal for 2.6 sec.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

+BB IG1 1
A2 A1
B1
BLK/WHT BLU E01-70
B2
RED 2
GRY/BLU E01-74
A3
GRY
C1 C2 C3 C4
BLU RED YEL GRN
3 4 5 6

[A]
E01 C01

[a]

IBL80A112026-01

[A]: ECM connector (View: [a]) C1: Glow plug No.1 drive circuit 3. Glow Plug No.1
A1: Glow plug control module power supply circuit C2: Glow plug No.2 drive circuit 4. Glow Plug No.2
A2: Glow plug control module power supply circuit C3: Glow plug No.3 drive circuit 5. Glow Plug No.3
A3: Glow plug control module ground circuit C4: Glow plug No.4 drive circuit 6. Glow Plug No.4
B1: Glow plug control module drive circuit 1. ECM
B2: Glow plug control module communication circuit 2. Glow plug control module

DTC Confirmation Procedure

For DTC P0380:

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

For DTC P0683:
1A-203 Engine General Information and Diagnosis: D13A

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 30 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Glow plug control module power supply circuit, ground Go to Step 3. Repair or replace
circuit and drive circuit check defective wire harness.
1) Check “A1”, “A2”, “A3” and “B1” circuits according to
Steps 2 through 5 of “Table C-8: Glow Plugs Operation
Check”: D13A (Page 1A-266).

Is check result OK?

3 Glow plug check Go to Step 4. Replace faulty glow
1) Check glow plugs. )(Page 1C-19) plug. )(Page 1C-19)

Is check result OK?

4 Glow plug circuit check Go to Step 5. Repair or replace
1) Check “C1”, “C2”, “C3” and “C4” circuits according to defective wire harness.
Step 7 of “Table C-8: Glow Plugs Operation Check”:
D13A (Page 1A-266).

Is check result OK?

5 Glow plug control module replacement Replace ECM and End.
1) Replace glow plug control module. )(Page 1C-24) recheck DTC. )(Page
1C-14)
2) Clear DTC. )(Page 1A-134)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTCs.
)(Page 1A-134)

Is DTC P0380 or P0683 still detected?

DTC P0401 / P0402

AENBL80A1124037
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0401: Exhaust Gas Recirculation “A” Flow • MAF sensor and/or its circuit
Insufficient Detected • EGR valve and/or its circuit
Measured MAF is higher than estimated MAF for 10 sec.
• Air intake circuit leakage or clog
(3 D/C detection logic)
P0402: Exhaust Gas Recirculation “A” Flow • Turbocharger
Excessive Detected • ECM
Difference between measured MAF and estimated MAF is
out of specified range.
(3 D/C detection logic)
 Engine General Information and Diagnosis: D13A 1A-204

Circuit Diagram

IG1 1

A1
BLK/WHT
A2
2 BLU/RED E01-56
A3
BLU/YEL E01-34

3 B1
BLU/ORN E01-62

[A]
E01 C01

[a]

IBL80A112027-01

[A]: ECM connector (View: [a]) A3: MAF sensor ground circuit 2. MAF sensor
A1: MAF sensor power supply circuit B1: IAT-1 sensor signal circuit 3. IAT-1 sensor
A2: MAF sensor signal circuit 1. ECM

DTC Confirmation Procedure

NOTE
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.
• Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
– Barometric pressure > 90 kPa (675 mmHg, 26.6 in.Hg, 0.90 bar)
– IAT > 15 °C (59 °F)

1) Warm up engine to normal operating temperature.

2) Run engine at 1,400 to 3,000 rpm for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 MAF sensor power supply circuit, signal circuit and Go to Step 3. Repair or replace
ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuit according to Steps 5
through 7 of “Table B-2: MAF Sensor Check”: D13A
(Page 1A-245).

Is check result OK?

3 MAF sensor check Go to Step 4. Replace MAF and IAT-1
1) Check MAF sensor. )(Page 1C-18) sensor. )(Page 1C-17)

Is check result OK?

1A-205 Engine General Information and Diagnosis: D13A

Step Action Yes No

4 EGR valve operation check Go to Step 5. Repair or replace
1) Check EGR valve operation. )(Page 1A-249) defective part(s).

Is check result OK?

5 Air intake / turbocharger circuit check Replace ECM and Repair or replace
1) Check that air intake / turbocharger circuit is working recheck DTC. )(Page defective part(s).
properly. )(Page 1A-244) 1C-14)

Is check result OK?

DTC P0403
AENBL80A1124038
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0403: Exhaust Gas Recirculation “A” Control Circuit • EGR valve and/or its circuit
Measured voltage of EGR valve drive circuit does not match with command signal for • ECM
1.6 sec.
(3 D/C detection logic)

Circuit Diagram

1
B2

YEL/GRN C01-30
3 B1 A1 A2
+B
BLU 2 GRY/RED C01-15

BLU BLU/RED C01-5

[A]
E01 C01

[a]

IBL80A112028-01

[A]: ECM connector (View: [a]) B1: Boost pressure control solenoid valve power supply circuit 2. EGR valve
A1: EGR valve power supply circuit B2: Boost pressure control solenoid valve drive circuit 3. Boost pressure control solenoid valve
A2: EGR valve drive circuit 1. ECM

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

2) Run engine at idle speed for 1 min.
 Engine General Information and Diagnosis: D13A 1A-206

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 EGR valve power supply circuit and drive circuit check Go to Step 3. Repair or replace
1) Check “A1” and “A2” circuits according to Step 2 and 3 of defective wire harness.
“Table B-5: EGR Valve Operation Check”: D13A (Page
1A-249).

Is check result OK?

3 EGR valve check Replace ECM and Replace EGR valve.
1) Check EGR valve. )(Page 1B-7) recheck DTC. )(Page )(Page 1B-6)
1C-14)
Is check result OK?

DTC P0480
AENBL80A1124039
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0480: Fan1 Control Circuit • Radiator cooling fan relay No.1 (coil side)
Any of the following conditions is met. and/or its circuit
• Measured voltage at drive circuit of radiator cooling fan relay No.1 • ECM
is higher than specified value for 0.26 sec. even though command
signal of radiator cooling fan relay No.1 is ON.
• Measured voltage at drive circuit of radiator cooling fan relay No.1
is lower than specified value for 0.26 sec. even though command
signal of radiator cooling fan relay No.1 is OFF.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

1
+BB +B
A3
A1 3 LT GRN/RED E01-7
D1
6
BLU
B1 4 B3 2
A2

GRY BLU/BLK
B2 D3 BLK
C1 5 C3
D2
GRN E01-8
BLK BLU/WHT
C2 D4
[A]
E01 C01

[a]

IBL80A112029-01
1A-207 Engine General Information and Diagnosis: D13A

[A]: ECM connector (View: [a]) D1: Radiator cooling fan power supply circuit (low speed side)
A1: Radiator cooling fan relay No.1 power supply circuit (coil side) D2: Radiator cooling fan ground circuit (low speed side)
A2: Radiator cooling fan relay No.1 power supply circuit (switch side) D3: Radiator cooling fan power supply circuit (high speed side)
A3: Radiator cooling fan relay No.1 drive circuit D4: Radiator cooling fan ground circuit (high speed side)
B1: Radiator cooling fan relay No.2 power supply circuit (coil side) 1. ECM
B2: Radiator cooling fan relay No.2 power supply circuit (switch side) 2. Radiator cooling fan motor
B3: Radiator cooling fan relay No.2 drive circuit 3. Radiator cooling fan relay No.1
C1: Radiator cooling fan relay No.3 power supply circuit (coil side) 4. Radiator cooling fan relay No.2
C2: Radiator cooling fan relay No.3 ground circuit 5. Radiator cooling fan relay No.3
C3: Radiator cooling fan relay No.3 drive circuit 6. “RDTR” fuse

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Keep engine at idle speed until engine coolant temperature reaches 98 °C (208 °F) or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Radiator cooling fan relay No.1 power supply circuit Go to Step 3. Repair or replace
(coil side) and radiator cooling fan relay No.1 drive defective wire harness.
circuit check
1) Check “A1” and “A3” circuits according to Steps 3
through 4 of “Table C-9: Radiator Cooling Fan Operation
Check”: D13A (Page 1A-269).

Is check result OK?

3 Radiator cooling fan relay No.1 check Replace ECM and Replace radiator cooling
1) Check radiator cooling fan relay No.1. )(Page 1F-27) recheck DTC. )(Page fan relay No.1. )(Page
1C-14) 10B-7)
Is check result OK?

DTC P0481
AENBL80A1124040
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0481: Fan2 Control Circuit • Radiator cooling fan relays No.2 (coil side)
Any of the following conditions is met. and No.3 (coil side) and/or their circuit
• Measured voltage at drive circuit of radiator cooling fan relays No.2 • ECM
and No.3 is higher than specified value for 0.26 sec. even though
command signal of radiator cooling fan relays No.2 and No.3 is ON.
• Measured voltage at drive circuit of radiator cooling fan relays No.2
and No.3 is lower than specified value for 0.26 sec. even though
command signal of radiator cooling fan relays No.2 and No.3 is OFF.
(1 D/C detection logic but MIL does not light up)
 Engine General Information and Diagnosis: D13A 1A-208

Circuit Diagram

1
+BB +B
A3
A1 3 LT GRN/RED E01-7
D1
6
BLU
B1 4 B3 2
A2

GRY BLU/BLK
B2 D3 BLK
C1 5 C3
D2
GRN E01-8
BLK BLU/WHT
C2 D4
[A]
E01 C01

[a]

IBL80A112030-01

[A]: ECM connector (View: [a]) D1: Radiator cooling fan power supply circuit (low speed side)
A1: Radiator cooling fan relay No.1 power supply circuit (coil side) D2: Radiator cooling fan ground circuit (low speed side)
A2: Radiator cooling fan relay No.1 power supply circuit (switch side) D3: Radiator cooling fan power supply circuit (high speed side)
A3: Radiator cooling fan relay No.1 drive circuit D4: Radiator cooling fan ground circuit (high speed side)
B1: Radiator cooling fan relay No.2 power supply circuit (coil side) 1. ECM
B2: Radiator cooling fan relay No.2 power supply circuit (switch side) 2. Radiator cooling fan motor
B3: Radiator cooling fan relay No.2 drive circuit 3. Radiator cooling fan relay No.1
C1: Radiator cooling fan relay No.3 power supply circuit (coil side) 4. Radiator cooling fan relay No.2
C2: Radiator cooling fan relay No.3 ground circuit 5. Radiator cooling fan relay No.3
C3: Radiator cooling fan relay No.3 drive circuit 6. “RDTR” fuse

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Keep engine at idle speed until engine coolant temperature reaches 103 °C (217 °F) or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
1A-209 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 Radiator cooling fan relay No.2 power supply circuit Go to Step 3. Repair or replace
(coil side), radiator cooling fan relay No.3 power supply defective wire harness.
circuit (coil side) radiator cooling fan relay No.2 drive
circuit radiator cooling fan relay No.3 drive circuit check
1) Check “B1”, “B3”, “C1” and “C3” circuits according to
Steps 8 through 10 of “Table C-9: Radiator Cooling Fan
Operation Check”: D13A (Page 1A-269).

Is check result OK?

3 Radiator cooling fan relay No.2 and No.3 check Replace ECM and Replace radiator cooling
1) Check radiator cooling fan relays No.2 and No.3. recheck DTC. )(Page fan relays No.2 and/or
)(Page 1F-27) 1C-14) No.3. )(Page 10B-7)

Is check result OK?

DTC P0500
AENBL80A1124041
DTC Detecting Condition and Trouble Area
DTC detection condition Trouble area
P0500: Vehicle Speed Sensor “A” • VSS and/or its circuit
Vehicle speed is lower than specified for 3 sec. even • ECM
though engine speed is higher than specified value.
(3 D/C detection logic)

Circuit Diagram

+B 1

BLU A1
A2
2 PPL E01-89
GRY A3

[A]
E01 C01

[a]

IBL80A112031-02

[A]: ECM connector (View: [a]) A3: VSS ground circuit

A1: VSS power supply circuit 1 ECM
A2: VSS signal circuit 2 VSS

DTC Confirmation Procedure

! WARNING

• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.
 Engine General Information and Diagnosis: D13A 1A-210

1) Warm up engine to normal operating temperature.

2) Drive vehicle at engine speed of 2,000 to 3,000 rpm for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 VSS check Replace ECM and Repair or replace
1) Check that VSS is working properly. )(Page 1A-263) recheck DTC. )(Page defective part(s).
1C-14)
Is check result OK?

DTC P0520
AENBL80A1124042
DTC detecting condition Trouble area
P0520: Engine Oil Pressure Sensor / Switch Circuit • Oil pressure switch and/or its circuit
Measured voltage of oil pressure switch signal circuit is • ECM
higher than specified value when engine is not running.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

1
A1
2
GRY/YEL C01-9

[A]
E01 C01

[a]

IBL80A112032-01

[A]: ECM connector (View: [a]) 1. ECM

A1: Oil pressure switch signal circuit 2. Oil pressure switch

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Set ignition “OFF” and wait for more than 30 sec.
3) Set ignition “ON” for 10 sec.
1A-211 Engine General Information and Diagnosis: D13A

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Oil pressure switch signal circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect “C01” connector from defective wire harness.
ECM and oil pressure switch connector.
2) Check for proper terminal connection to “C01” connector
and oil pressure switch connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Voltage of “A1” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

3 Oil pressure switch check Replace ECM and Replace oil pressure
1) Check oil pressure switch. )(Page 1E-17) recheck DTC. )(Page switch. )(Page 1E-17)
1C-14)
Is check result OK?

DTC P0530
AENBL80A1124043
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0530: A/C Refrigerant Pressure Sensor “A” Circuit • A/C refrigerant pressure sensor and/or
Any of the following conditions is met. its circuit
• Measured voltage of A/C refrigerant pressure sensor signal circuit is • ECM
lower than 0.1 V for 1.6 sec.
• Measured voltage of A/C refrigerant pressure sensor signal circuit is
higher than 4.9 V for 1.6 sec.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

1
A1
GRY/RED E01-37
A2
2 RED/GRN E01-87
A3
BLU/RED E01-10

[A]
E01 C01

[a]

IBL80A112033-01
 Engine General Information and Diagnosis: D13A 1A-212

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

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 A/C refrigerant pressure sensor power supply circuit Go to Step 5. Go to Step 3.
check
1) When ignition is “OFF”, disconnect A/C refrigerant
pressure sensor connector.
2) Check for proper terminal connection to A/C refrigerant
pressure sensor connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A1” and “A3”
circuits and ground is approx. 5 V.

Is check result OK?

3 A/C refrigerant pressure sensor ground circuit check Repair “A3” circuit. Go to Step 4.
1) Check that voltage between “A1” circuit and ground is If DTC P0530 is
approx. 5 V. detected again, replace
ECM and recheck DTC.
Is check result OK?
)(Page 1C-14)
4 A/C refrigerant pressure sensor power supply circuit Replace ECM and Repair or replace
check recheck DTC. )(Page defective wire harness.
1) When ignition is “OFF”, disconnect “E01” connector from 1C-14)
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at A/C refrigerant pressure sensor connector:
infinity
• Voltage of “A1” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

5 A/C refrigerant pressure sensor signal circuit check Go to Step 6. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at A/C refrigerant pressure sensor connector:
infinity
• Voltage of “A2” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

1A-213 Engine General Information and Diagnosis: D13A

Step Action Yes No

6 A/C refrigerant pressure sensor check Replace ECM and Replace A/C refrigerant
1) Check A/C refrigerant pressure sensor. recheck DTC. )(Page pressure sensor.
1C-14)
• Single A/C model: )(Page 7B-38) • Single A/C model:
• Dual A/C model: )(Page 7B-85) )(Page 7B-39)
• Dual A/C model:
Is check result OK? )(Page 7B-85)

DTC P0560
AENBL80A1124044
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0560: System Voltage • ECM backup power supply
Any of the following conditions is met. circuit
• Measured voltage of backup power supply circuit is higher than 16 V for 1 sec. • ECM ground circuit
• Measured voltage of backup power supply circuit is lower than 6 V for 1 sec. • Charging system
(1 D/C detection logic but MIL does not light up) • ECM

Circuit Diagram

1
D1
YEL/GRN E01-50

A1 2 A3
YEL/GRN BRN/WHT E01-80
BLK/YEL BLK/RED B1
A2 BLK/RED E01-4
B2
BLK/RED E01-5
B3
BLK/RED E01-6
C1
BRN E01-1
C2
BRN E01-2
C3
BRN E01-3

[A]
E01 C01

[a]

IBL80A112034-01

[A]: ECM connector (View: [a]) B2: ECM power supply circuit D1: ECM backup power supply circuit
A1: Main relay power supply circuit (coil side) B3: ECM power supply circuit 1. ECM
A2: Main relay power supply circuit (switch side) C1: ECM ground circuit 2. Main relay
A3: Main relay drive circuit C2: ECM ground circuit
B1: ECM power supply circuit C3: ECM ground circuit
 Engine General Information and Diagnosis: D13A 1A-214

DTC Confirmation Procedure

1) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 ECM backup power supply circuit and ground circuit Go to Step 3. Repair or replace
check defective wire harness.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM and “ECM” fuse.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check that ECM backup power
supply circuit and ground circuit (“D1”, “C1”, “C2” and
“C3”) is as follows.
• Resistance of “D1”, “C1”, “C2” and “C3” circuits: less
than 1 Ω
• Resistance between each of “D1”, “C1”, “C2” and “C3”
circuits and ground: infinity
• Resistance between “D1” circuit terminal and other
terminal at ECM connector: infinity
• Resistance between “C1” circuit terminal and other
terminal at ECM connector: infinity
• Resistance between “C2” circuit terminal and other
terminal at ECM connector: infinity
• Resistance between “C3” circuit terminal and other
terminal at ECM connector: infinity
• Voltage of “D1”, “C1”, “C2” and “C3” circuits: approx. 0
V (when ignition is “ON”)

Is check result OK?

3 Charging system check Go to Step 4. Repair or replace
1) Check that charging system is working properly. )(Page defective part(s).
1J-24)

Is check result OK?

4 DTC check Replace ECM and End.
1) Clear DTC. )(Page 1A-134) recheck DTC. )(Page
1C-14)
2) Set ignition “OFF”.
3) Perform DTC confirmation procedure to check for DTC.
)(Page 1A-134)

Is DTC P0560 still detected?

1A-215 Engine General Information and Diagnosis: D13A

DTC P0571 / P1571

AENBL80A1124045
DTC Detecting Condition and Table Area
DTC detection condition Trouble area
P0571: Brake Switch “A” Circuit • Brake light switch and/or its circuit
Any of the following conditions is met. • Brake switch and/or its circuit
• Measured voltage of brake light switch circuit is higher • ECM
than specified value.
• Measured voltage of brake light switch circuit is lower
than specified value.
• Brake pedal positions detected by brake light switch
and brake switch disagree.
(1 D/C detection logic but MIL does not light up)
P1571: Brake Switch Circuit
Any of the following conditions is met.
• Measured voltage of brake switch circuit is higher than
specified value.
• Measured voltage of brake switch circuit is lower than
specified value.
• Brake pedal positions detected by brake light switch
and brake switch disagree.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

+BB IG1

B1 A1 1
A2
2
GRN/YEL E01-68
5 3
GRN/WHT E01-81
4
B2

[A]
E01 C01

[a]

IBL80A112036-01

[A]: ECM connector (View: [a]) B2: Brake light switch signal circuit 4. Brake light
A1: Brake switch power supply circuit 1. ECM 5. “STOP” fuse
A2: Brake switch signal circuit 2. Brake switch
B1: Brake light switch power supply circuit 3. Brake light switch
 Engine General Information and Diagnosis: D13A 1A-216

DTC Confirmation Procedure

! WARNING

• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

1) Drive vehicle at 90 km/h or less.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Brake switch power supply circuit and brake light Go to Step 3. Check “STOP” fuse for
switch power supply circuit check blowout. If fuse is not
1) When ignition is “OFF”, disconnect brake light switch / blown, repair or replace
brake switch connector. defective wire harness.
2) Check for proper terminal connection to brake light
switch / brake switch connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A1” and “B1”
circuits and ground are battery voltage.

Is check result OK?

3 Brake switch signal circuit and brake light switch signal Go to Step 4. Repair or replace
circuit check defective wire harness.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A2” and “B2” circuits: less than 1 Ω
• Resistance between each of “A2” and “B2” circuits
and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at brake light switch / brake switch connector:
infinity
• Resistance between “B2” circuit terminal and other
terminal at brake light switch / brake switch connector:
infinity
• Voltage of “A2” and “B2” circuits: approx. 0 V (when
ignition is “ON”)

Is check result OK?

4 Brake light switch and brake switch check Replace ECM and Replace brake light
1) Check brake light switch / brake switch. )(Page 4A-11) recheck DTC. )(Page switch / brake switch.
1C-14) )(Page 4A-10)
Is check result OK?
1A-217 Engine General Information and Diagnosis: D13A

DTC P0600 / P0601 / P0604 / P060B / P2226

AENBL80A1124046
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0600: Serial Communication Link • ECM power supply circuit and/or
ECM internal failure is detected. ground circuit
(1 D/C detection logic but MIL does not light up) • ECM
P0601: Internal Control Module Memory Check Sun Error
ECM internal failure is detected.
(1 D/C detection logic)
P0604: Internal Control Module Random Access Memory (RAM) Error
ECM internal failure is detected.
(1 D/C detection logic)
P060B: Internal Control Module A/D Processing Performance
ECM internal failure is detected.
(1 D/C detection logic)
P2226: Barometric Pressure Sensor “A” Circuit • Barometric pressure sensor (in ECM)
Any of the following conditions is met. • ECM
• Measured voltage of barometric pressure sensor signal circuit is higher
than 4.80 V for 1.6 sec.
• Measured voltage of barometric pressure sensor signal circuit is lower
than 0.20 V for 1.6 sec.
(1 D/C detection logic)

Circuit Diagram

1
D1
YEL/GRN E01-50

A1 2 A3
YEL/GRN BRN/WHT E01-80
BLK/YEL BLK/RED B1
A2 BLK/RED E01-4
B2
BLK/RED E01-5
B3
BLK/RED E01-6
C1
BRN E01-1
C2
BRN E01-2
C3
BRN E01-3

[A]
E01 C01

[a]

IBL80A112037-01
 Engine General Information and Diagnosis: D13A 1A-218

[A]: ECM connector (View: [a]) B2: ECM power supply circuit D1: ECM backup power supply circuit
A1: Main relay power supply circuit (coil side) B3: ECM power supply circuit 1. ECM
A2: Main relay power supply circuit (switch side) C1: ECM ground circuit 2. Main relay
A3: Main relay drive circuit C2: ECM ground circuit
B1: ECM power supply circuit C3: ECM ground circuit

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131)
2 DTC recheck Go to Step 3. Check for intermittent
1) Clear DTC. )(Page 1A-134) trouble. )(Page 00-11)
2) Set ignition “OFF”.
3) Perform DTC confirmation procedure to check for DTCs.
)(Page 1A-134)

Is DTC P0600, P0601, P0604, P060B or P2226 still

detected?
3 ECM power supply circuit and ground circuit check Replace ECM and Repair or replace
1) Check “B1”, “B2”, “B3”, “C1”, “C2” and “C3” circuits recheck DTC. )(Page defective wire harness.
according to Step 3 through 4 of “Table C-1: Main Relay 1C-14)
Operation Check”: D13A (Page 1A-254).

Is check result OK?

1A-219 Engine General Information and Diagnosis: D13A

DTC P0641
AENBL80A1124047
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0641: Sensor Reference Voltage “A” Circuit / Open • Fuel pressure sensor and/or its circuit
Sensor power supply voltage “A” is out of specified range. • Boost pressure sensor and/or its circuit
(1 D/C detection logic)
• ECM

Circuit Diagram

GRN/YEL C01-8

2 ORN/BLK C01-38

YEL/RED C01-6

RED/BLK C01-23

3 ORN C01-41

BLK C01-24

[A]
E01 C01

[a]

IBL80A112038-01

[A]: ECM connector (View: [a]) 2. Fuel pressure sensor

1. ECM 3. Boost pressure sensor

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
 Engine General Information and Diagnosis: D13A 1A-220

Step Action Yes No

2 Sensor power supply circuit, signal circuit and ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) Check power supply circuit, signal circuit and ground
circuit of the following sensors.
• Fuel pressure sensor: According to Steps 3 through 6
of “Table A-4: Fuel Pressure Sensor Circuit Check”:
D13A (Page 1A-241)
• Boost pressure sensor: According to Steps 5 through
8 of “Table B-3: Boost Pressure Sensor Check”: D13A
(Page 1A-247).

Is check result OK?

3 DTC check Go to Step 4. Replace fuel pressure
1) When ignition is “OFF”, disconnect connector from fuel sensor. )(Page 1G-50)
pressure sensor.
2) Clear DTC. )(Page 1A-134)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
)(Page 1A-134)

Is DTC P0641 still detected?

4 DTC check Replace ECM and Replace boost pressure
1) When ignition is “OFF”, disconnect connector from boost recheck DTC. )(Page and IAT-2 sensor.
pressure and IAT-2 sensor. 1C-14) )(Page 1C-23)
2) Clear DTC. )(Page 1A-134)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
)(Page 1A-134)

Is DTC P0641 still detected?

DTC P0645
AENBL80A1124048
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0645: A/C Clutch Relay Control Circuit • A/C compressor relay (coil side) and/or its
Any of the following conditions is met. circuit
• Measured voltage of A/C compressor relay drive circuit is higher • ECM
than specified value for 1.6 sec. even when command signal of A/
C compressor relay is ON.
• Measured voltage of A/C compressor relay drive circuit is lower
than specified value for 1.6 sec. even when command signal of A/
C compressor relay is OFF.
(1 D/C detection logic but MIL does not light up)
1A-221 Engine General Information and Diagnosis: D13A

Circuit Diagram

+BB +B 1

A1 2 A2

BLU GRY E01-79

BLU/YEL
WHT WHT
3
BLK BLK

[A]
E01 C01

[a]

IBL80A112039-02

[A]: ECM connector (View: [a]) A2: A/C compressor relay drive circuit 2. A/C compressor relay
A1: A/C compressor relay power supply circuit (coil side) 1. ECM 3. A/C compressor

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Warm up engine to normal operating temperature.

2) Check that the following conditions are met.
• Blower speed selector: Maximum position
• A/C switch: ON
3) Run engine at idle speed for 1 min. and check that the following conditions are met.
• Blower speed selector: OFF
• A/C switch: OFF
4) Run engine at idle speed for 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
 Engine General Information and Diagnosis: D13A 1A-222

Step Action Yes No

2 A/C compressor relay power supply circuit (coil side) Go to Step 3. Repair or replace
check defective wire harness.
1) When ignition is “OFF”, remove A/C compressor relay.
)(Page 10B-7)
2) Check for proper terminal connection to A/C compressor
relay connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

3 A/C compressor relay drive circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and each
terminal at A/C compressor relay connector: infinity
• Voltage of “A2” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

4 A/C compressor relay check Replace ECM and Replace A/C
1) Check A/C compressor relay for resistance. recheck DTC. )(Page compressor relay.
1C-14) )(Page 10B-7)
• Single A/C model: )(Page 7B-43)
• Dual A/C model: )(Page 7B-92)

Is check result OK?

DTC P0651
AENBL80A1124049
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0651: Sensor Reference Voltage “B” Circuit / Open • APP sensor (main) and/or its circuit
Sensor power supply voltage “B” is out of specified range. • CMP sensor and/or its circuit
(1 D/C detection logic)
• ECM
1A-223 Engine General Information and Diagnosis: D13A

Circuit Diagram

2 BRN E01-83
GRN/RED E01-65
BLU E01-35

PNK C01-25
3 PNK/BLK C01-56
PPL C01-21

[A]
E01 C01

[a]

IBL80A112040-01

[A]: ECM connector (View: [a]) 2. APP sensor (main)

1. ECM 3. CMP sensor

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Sensor power supply circuit, signal circuit and ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) Check power supply circuit, signal circuit and ground
circuit of the following sensors.
• APP sensor (main) according to Steps 3 through 6 of
“Table C-6: Accelerator Pedal Check”: D13A (Page
1A-261).
• CMP sensor according to Steps 2 through 5 of “DTC
P0340”: D13A (Page 1A-200).

Are they in good condition?

3 DTC check Go to Step 4. Replace APP sensor.
1) When ignition is “OFF”, disconnect connector from APP )(Page 1C-20)
sensor.
2) Clear DTC. )(Page 1A-134)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
)(Page 1A-134)

Is DTC P0651 still detected?

 Engine General Information and Diagnosis: D13A 1A-224

Step Action Yes No

4 DTC check Replace ECM and Replace CMP sensor.
1) When ignition is “OFF”, disconnect connector CMP recheck DTC. )(Page )(Page 1C-21)
sensor. 1C-14)
2) Clear DTC. )(Page 1A-134)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
)(Page 1A-134)

Is DTC P0651 still detected?

DTC P0657 / P0685

AENBL80A1124050
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0657: Actuator Supply Voltage “A” Circuit / Open • Main relay (coil side) and/or its circuit
Measured voltage of main relay drive circuit is lower or • ECM
higher than specified value for 0.4 sec.
(1 D/C detection logic but MIL does not light up)
P0685: ECM/PCM Power Relay Control Circuit / Open
Any of the following conditions is met.
• Measured voltage of main relay drive circuit is higher
than specified value even when command signal of
main relay is ON.
• Measured voltage of main relay drive circuit is lower
than specified value even when command signal of
main relay is OFF.
(1 D/C detection logic)
1A-225 Engine General Information and Diagnosis: D13A

Circuit Diagram

1
D1
YEL/GRN E01-50

A1 2 A3
YEL/GRN BRN/WHT E01-80
BLK/YEL BLK/RED B1
A2 BLK/RED E01-4
B2
BLK/RED E01-5
B3
BLK/RED E01-6
C1
BRN E01-1
C2
BRN E01-2
C3
BRN E01-3

[A]
E01 C01

[a]

IBL80A112041-01

[A]: ECM connector (View: [a]) B2: ECM power supply circuit D1: ECM backup power supply circuit
A1: Main relay power supply circuit (coil side) B3: ECM power supply circuit 1. ECM
A2: Main relay power supply circuit (switch side) C1: ECM ground circuit 2. Main relay
A3: Main relay drive circuit C2: ECM ground circuit
B1: ECM power supply circuit C3: ECM ground circuit

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Main relay power supply circuit (coil side) and main Go to Step 3. Repair or replace
relay drive circuit check defective wire harness.
1) Check “A1” and “A3” circuits according to Steps 1 and 2
of “Table C-1: Main Relay Operation Check”: D13A
(Page 1A-254).

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-226

Step Action Yes No

3 Main relay check Replace ECM and Replace main relay.
1) Check main relay. )(Page 1C-24) recheck DTC. )(Page )(Page 10B-7)
1C-14)
Is check result OK?

DTC P0697
AENBL80A1124051
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0697: Sensor Reference Voltage “C” Circuit / Open • A/C refrigerant pressure sensor and/or its circuit
Sensor power supply voltage “C” is out of specified range. • APP sensor (sub) and/or its circuit
(1 D/C detection logic)
• ECM

Circuit Diagram

GRY/RED E01-37
2 RED/GRN E01-87
BLU/RED E01-10

3
RED E01-15
YEL E01-41
WHT E01-32

[A]
E01 C01

[a]

IBL80A112042-01

[A]: ECM connector (View: [a]) 2. A/C refrigerant pressure sensor

1. ECM 3. APP sensor (sub)

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
1A-227 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 Sensor power supply circuit, signal circuit and ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) Check power supply circuit, signal circuit and ground
circuit of the following sensors.
• A/C refrigerant pressure sensor according to Steps 2
through 5 of “DTC P0530”: D13A (Page 1A-211).
• APP sensor (sub) according to Steps 3 through 6 of
“Table C-6: Accelerator Pedal Check”: D13A (Page
1A-261).

Is check result OK?

3 DTC check Go to Step 4. Replace A/C refrigerant
1) When ignition is “OFF”, disconnect connector from A/C pressure sensor.
refrigerant pressure sensor. • Single A/C model:
2) Clear DTC. )(Page 1A-134) )(Page 7B-39)
3) Set ignition “OFF”. • Dual A/C model:
4) Perform DTC confirmation procedure to check for DTC. )(Page 7B-85)
)(Page 1A-134)

Is DTC P0697 still detected?

4 DTC check Replace ECM and Replace APP sensor.
1) When ignition is “OFF”, disconnect connector from APP recheck DTC. )(Page )(Page 1C-20)
sensor. 1C-14)
2) Clear DTC. )(Page 1A-134)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
)(Page 1A-134)

Is DTC P0697 still detected?

 Engine General Information and Diagnosis: D13A 1A-228

DTC P0704
AENBL80A1124052
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0704: Clutch Switch Input Circuit • CPP switch and/or its circuit
CPP switch signal does not change though gear is shifted 60 times. • ECM
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

1
IG1
A2 A1
2
LT GRN/BLK YEL/GRN E01-22

[A]
E01 C01

[a]

IBL80A112043-01

[A]: ECM connector (View: [a]) A2: CPP switch power supply circuit 2. CPP switch
A1: CPP switch signal circuit 1. ECM

DTC Confirmation Procedure

! WARNING

• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

1) Drive vehicle at 10 km/h or higher while engine keeps running at 1,000 rpm or higher.
2) In state of step 1), repeat gear shift 60 times or more.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
1A-229 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 CPP switch power supply circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect CPP switch defective wire harness.
connector.
2) Check for proper terminal connection to CPP switch
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A2” circuit and ground is
battery voltage.

Is check result OK?

3 CPP switch signal circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and each
terminal at CPP switch connector: infinity
• Voltage of “A1” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

4 CPP switch check Replace ECM and Replace CPP switch.
Check CPP switch. )(Page 5C-17) recheck DTC. )(Page )(Page 5C-17)
5C-17)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-230

DTC P1647
AENBL80A1124055
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1647: Vehicle Valiant not Programmed • No vehicle variant data
Vehicle variant data is not registered in ECM. • ECM
(1 D/C detection logic but MIL does not light up)

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Registration data check Go to Step 3. Resister correct vehicle
1) When ignition is “OFF”, connect SUZUKI scan tool to variant data to ECM,
DLC. referring to “Procedure
for Vehicle Information
2) Set ignition “ON”.
Manual Input” under
3) Check registered vehicle variant data. )(Page 1A-144) “Registration for ECM
Is registered vehicle variant data correct? Replacement”: D13A in
Section 1C (Page 1C-
15).
3 DTC recheck Replace ECM and End.
1) Clear DTC. )(Page 1A-134) recheck DTC. )(Page
1C-14)
2) Set ignition “ON”.
3) Perform DTC confirmation procedure to check for DTC.
)(Page 1A-134)

Is DTC P1647 still detected?

DTC P2135
AENBL80A1124056
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2135: Throttle / Pedal Position Sensor / Switch “A” / “B” Voltage Correlation • APP sensor and/or its circuit
Any of the following conditions is met. • ECM
• Measured voltage of APP sensor (main) signal circuit is higher than output voltage
of APP sensor (sub) by 0.22 V for 1 sec. though output voltage of APP sensor
(main) is lower than 1.27 V.
• Measured voltage of APP sensor (main) signal circuit is higher than output voltage
of APP sensor (sub) by 0.32 V for 1 sec. though output voltage of APP sensor
(main) is higher than 1.27 V.
(1 D/C detection logic)
1A-231 Engine General Information and Diagnosis: D13A

Circuit Diagram

1
A1
2 BRN E01-83
A2
GRN/RED E01-65
A3
BLU E01-35
B1
3 RED E01-15
B2
YEL E01-41
B3
WHT E01-32

[A]
E01 C01

[a]

IBL80A112044-01

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

DTC Confirmation Procedure

NOTE
Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.

1) Set ignition “ON”.

2) Keep accelerator pedal at fully depressed position for 2 sec.
3) Keep accelerator pedal at released position for 2 sec.
4) Repeat Steps 2) and 3) 3 times.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 APP sensor (main) power supply circuit, signal circuit Go to Step 3. Repair or replace
and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Steps 3
through 6 of “Table C-6: Accelerator Pedal Check”:
D13A (Page 1A-261).

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-232

Step Action Yes No

3 APP sensor (sub) power supply circuit, signal circuit Go to Step 4. Repair or replace
and ground circuit check defective wire harness.
1) Check “B1”, “B2” and “B3” circuits according to Steps 3
through 6 of “Table C-6: Accelerator Pedal Check”:
D13A (Page 1A-261).

Is check result OK?

4 APP sensor check Replace ECM and Replace APP sensor.
1) Check APP sensor. )(Page 1C-20) recheck DTC. )(Page )(Page 1C-20)
1C-14)
Is check result OK?

DTC P2237 / P2297

AENBL80A1124057
DTC Detecting Condition and Table Area
DTC detection condition Trouble area
P2237: O2 Sensor Positive Current Control Circuit / • A/F sensor and/or its circuit
Open • ECM
Any one of A/F sensor signal voltage is in abnormal
condition.
(1 D/C detection logic but MIL does not light up)
P2297: O2 Sensor Out of Range During Deceleration
A/F value at fuel cut is out of specified value.
(1 D/C detection logic but MIL does not light up)

Circuit Diagram

2 1
A1
BLK E01-47
A2
RED/WHT E01-44
A3
GRN/WHT E01-46
A4
+B
YEL E01-45
B1 B2
LT GRN E01-12
BLU

[A]
E01 C01

[a]

IBL80A112045-01

[A]: ECM connector (View: [a]) A3: A/F sensor signal circuit (VSIP) B2: A/F heater drive circuit
A1: A/F sensor signal circuit (RC) A4: A/F sensor signal circuit (IP) 1. ECM
A2: A/F sensor signal circuit (VS) B1: A/F heater power supply circuit 2. A/F sensor
1A-233 Engine General Information and Diagnosis: D13A

DTC Confirmation Procedure

For DTC P2237:
1) Run engine at idle speed for 3 min.

For DTC P2297:

! WARNING

• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

NOTE
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.
• Confirm that the following condition is met in this “DTC Confirmation Procedure”.
– 50 °C (122 °F) < ECT < 100 °C (212 °F)
– –44 °C (–47 °F) < IAT < 100 °C (212 °F)
– Barometric pressure >= 50 kPa (375 mmHg, 14.8 in.Hg, 0.5 bar)

1) Drive vehicle at 40 km/h (25 mile/h) or more for 5 min.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 A/F sensor signal circuit check Go to Step 3. Repair or replace
1) Check “A1”, “A2”, “A3” and “A4” circuits according to defective wire harness.
Step 3 of “Table B-6: A/F Sensor Check”: D13A (Page
1A-250).

Is check result OK?

3 A/F sensor replacement Replace ECM and Repair or replace
1) Replace A/F sensor. )(Page 1B-9) recheck DTC. )(Page defective wire harness.
1C-14)
2) Clear DTC. )(Page 1A-134)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
)(Page 1A-134)

Is DTC P2237 or P2297 still detected?

DTC P2264
AENBL80A1124058
DTC Detecting Condition and Table Area
DTC detection condition Trouble area
P2264: Water in Fuel Sensor Circuit • Fuel filter water detection sensor and/or its circuit
Measured voltage of fuel filter water detection sensor is • ECM
higher than specified value for at least 0.37 sec.
(1 D/C detection logic but MIL does not light up)
 Engine General Information and Diagnosis: D13A 1A-234

Circuit Diagram

IG1 1
A1
A2
BLK/WHT
2 YEL/RED E01-90
GRY
A3

[A]
E01 C01

[a]

IBL80A112046-01

[A]: ECM connector (View: [a]) A2: Fuel filter water detection sensor signal circuit 1. ECM
A1: Fuel filter water detection sensor power supply circuit A3: Fuel filter water detection sensor ground circuit 2. Fuel filter water detection sensor

DTC Confirmation Procedure

1) Warm up engine to normal operating temperature.
2) Set ignition “OFF” and wait for more than 30 sec.
3) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131)
2 Drain water from fuel filter End. Go to Step 3.
1) Drain water. )(Page 1G-40)
2) Clear DTC. )(Page 1A-134)
3) Set ignition “OFF”.
4) Perform DTC confirmation procedure to check for DTC.
)(Page 1A-134)

Is check result OK?

3 Fuel filter water detection sensor power supply circuit Go to Step 5. Go to Step 4.
and ground circuit check
1) When ignition is “OFF”, disconnect fuel filter water
detection sensor connector.
2) Check for proper terminal connection to fuel filter water
detection sensor connector.
3) If connections are OK, set ignition “ON”.
4) Check voltage between “A1” and “A3” circuit is battery
voltage.

Is check result OK?

1A-235 Engine General Information and Diagnosis: D13A

Step Action Yes No

4 Fuel filter water detection sensor ground circuit check Repair “A3” circuit. Repair “A1” circuit.
1) Check voltage between “A1” circuit and ground is battery
voltage.

Is check result OK?

5 Fuel filter water detection sensor signal circuit check Go to Step 6. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Voltage of “A2” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

6 Fuel filter water detection sensor check Replace ECM and Fuel filter water
1) Check fuel filter water detection sensor. )(Page 1G-58) recheck DTC. )(Page detection sensor.
1C-14) )(Page 1G-58)
Is check result OK?

DTC P268A
AENBL80A1124061
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P268A: Fuel Injector Calibration Not Learned / Programmed • NO injector calibration code
Injector calibration code is not registered in ECM. • ECM
(1 D/C detection logic but MIL does not light up)

DTC Confirmation Procedure

1) Set ignition “ON” for 10 sec.

DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: D13A
(Page 1A-131).
2 Injector calibration code check Go to Step 3. Resister correct injector
1) When ignition is “OFF”, connect SUZUKI scan tool to calibration code to
DLC. ECM. )(Page 1C-16)
2) Set ignition “ON”.
3) Check registered injector calibration code with that of the
code mentioned on the injector with the help of SDT.
)(Page 1C-16)

Is registered injector calibration code correct?

3 DTC recheck Replace ECM and End.
1) Clear DTC. )(Page 1A-134) recheck DTC. )(Page
1C-14)
2) Set ignition “ON”.
3) Perform DTC confirmation procedure to check for DTC.
)(Page 1A-134)

Is DTC P268A still detected?

 Engine General Information and Diagnosis: D13A 1A-236

DTC U0073
AENBL80A1124062
Refer to “CAN DTC (Lost Communication and Communication Bus Off) Table”: D13A Model in Section 10H (Page
10H-27).

DTC U0121
AENBL80A1124063
Refer to “CAN DTC (Lost Communication and Communication Bus Off) Table”: D13A Model in Section 10H (Page
10H-27).

DTC U0140
AENBL80A1124064
Refer to “CAN DTC (Lost Communication and Communication Bus Off) Table”: D13A Model in Section 10H (Page
10H-27).

DTC U2101
AENBL80A1124065
Refer to “CAN DTC (Lost Communication and Communication Bus Off) Table”: D13A Model in Section 10H (Page
10H-27).

Table A-1: Fuel Pump Relay Operation Check

AENBL80A1124066
Circuit Diagram

+B 1

A1 2 A3
4
BLK/RED PPL/WHT E01-75
BLK/RED PNK B1
B3
A2 3
BLK

[A]
E01 C01

[a]

IBL80A112047-01

[A]: ECM connector (View: [a]) B1: Fuel pump power supply circuit 3. Fuel pump
A1: Fuel pump relay power supply circuit (coil side) B2: Fuel pump ground circuit 4. “F/P” fuse
A2: Fuel pump relay power supply circuit (switch side) 1. ECM
A3: Fuel pump relay drive circuit 2. Fuel pump relay
1A-237 Engine General Information and Diagnosis: D13A

Troubleshooting
Step Action Yes No
1 Fuel pump operation check End. Go to Step 2.
1) Check fuel pump operation. )(Page 1G-55)

Is check result OK?

2 Fuel pump relay power supply circuit check Go to Step 3. Repair “A1” and/or “A2”
1) When ignition is “OFF”, remove fuel pump relay. )(Page circuit.
10B-7)
2) Check for proper terminal connection to fuel pump relay.
3) If connections are OK, check that voltage between each
of “A1” and “A2” circuits and ground is battery voltage.

Is check result OK?

3 Fuel pump relay drive circuit check Go to Step 4. Repair “A3” circuit.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A3” circuit: less than 1 Ω
• Resistance between “A3” circuit and ground: infinity
• Resistance between “A3” circuit terminal and each
terminal at fuel pump relay connector: infinity
• Voltage of “A3” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

4 Fuel pump relay check Go to Step 5. Replace fuel pump
1) Check fuel pump relay. )(Page 1C-24) relay. )(Page 10B-7)

Is check result OK?

5 Fuel pump relay drive signal check Go to Step 6. Replace ECM and
1) When ignition is “OFF”, connect “E01” connector to recheck fuel pump
ECM. operation. )(Page 1C-
14)
2) Check that voltage between “A3” circuit and ground is
approx. 0 V for about 20 sec. after set ignition “ON”.

Is check result OK?

6 Fuel pump power supply circuit and ground circuit Replace fuel pump. Go to Step 7.
check )(Page 1G-55)
1) When ignition is “OFF”, install fuel pump relay.
2) Disconnect connector from fuel pump.
3) Check for proper connection to fuel pump.
4) If connections are OK, check that voltage between “B1”
and “B2” circuits is battery voltage for about 20 sec. after
set ignition “ON”.

Is check result OK?

7 Fuel pump ground circuit check Repair “B2” circuit. Repair “B1” circuit.
1) Check that voltage between “B1” circuit and ground is
battery voltage for about 20 sec. after set ignition “ON”.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-238

Table A-2: Fuel Injector Circuit Check

AENBL80A1124067
NOTE
• This procedure is to troubleshoot only open, short to ground circuit and short to power supply
circuit of fuel injector circuit. If it is necessary to troubleshoot for injector operation, be sure to
perform “High-Pressure Fuel Supply Circuit Check”: D13A in Section 1G (Page 1G-35).
• For identification of each cylinder, refer to “Statement on Cleanliness and Care”: D13A (Page 1A-
124).

Circuit Diagram

A1
ORN C01-47
2 A2
ORN/WHT C01-16

B1
YEL C01-49
3 B2
YEL/BLK C01-17

C1
GRN C01-48
4 C2
WHT/GRN C01-31

D1
BLU C01-46
5 D2
WHT/BLU C01-1

[A]
E01 C01

[a]

IBL80A112048-01

[A]: ECM connector (View: [a]) C1: Fuel injector No.3 drive circuit (high side) 2. Fuel injector No.1
A1: Fuel injector No.1 drive circuit (high side) C2: Fuel injector No.3 drive circuit (low side) 3. Fuel injector No.2
A2: Fuel injector No.1 drive circuit (low side) D1: Fuel injector No.4 drive circuit (high side) 4. Fuel injector No.3
B1: Fuel injector No.2 drive circuit (high side) D2: Fuel injector No.4 drive circuit (low side) 5. Fuel injector No.4
B2: Fuel injector No.2 drive circuit (low side) 1. ECM
1A-239 Engine General Information and Diagnosis: D13A

Troubleshooting
Step Action Yes No
1 Fuel injector drive circuit (high side) and (low side) Go to Step 2. Repair defective circuit.
check
1) When ignition is “OFF”, disconnect “C01” connector from
ECM and all fuel injector connectors.
2) Check for proper terminal connection to “C01” connector
and all fuel injector connectors.
3) If connections are OK, check the following points.
• Resistance of “A1”, “A2”, “B1”, “B2”, “C1”, “C2”, “D1”
and “D2” circuits: less than 1 Ω
• Resistance between each of “A1”, “A2”, “B1”, “B2”,
“C1”, “C2”, “D1” and “D2” circuits and ground: infinity
• Resistance between “A1” circuit terminal and each
terminal at fuel injector connector: infinity
• Resistance between “B1” circuit terminal and each
terminal at fuel injector connector: infinity
• Resistance between “C1” circuit terminal and each
terminal at fuel injector connector: infinity
• Resistance between “D1” circuit terminal and each
terminal at fuel injector connector: infinity
• Voltage of “A1”, “A2”, “B1”, “B2”, “C1”, “C2”, “D1” and
“D2” circuits: approx. 0 V (when ignition is “ON”.)

Is check result OK?

2 Fuel injector check End. Replace fuel injector.
1) Check fuel injector. )(Page 1G-45) )(Page 1G-46)

Is check result OK?

Table A-3: Fuel Temperature Sensor Check

AENBL80A1124068
Circuit Diagram

2 A1
BLK/YEL E01-61
A2
RED/BLU E01-13

[A]
E01 C01

[a]

IBL80A112049-01
 Engine General Information and Diagnosis: D13A 1A-240

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

Troubleshooting
Step Action Yes No
1 Parameter check End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Start engine and warm it up to normal operating
temperature, then check that “Fuel Temperature”
displayed on SUZUKI scan tool is within environmental
temp. to 95 °C (203 °F).

Is check result OK?

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

Is check result OK?

3 Fuel temperature sensor check Replace ECM and Replace fuel filter
1) Check fuel temperature sensor. )(Page 1G-58) recheck parameter. assembly. )(Page 1G-
)(Page 1C-14) 58)
Is check result OK?
1A-241 Engine General Information and Diagnosis: D13A

Table A-4: Fuel Pressure Sensor Circuit Check

AENBL80A1124069
Circuit Diagram

A1
GRN/YEL C01-8
A2
2 ORN/BLK C01-38
A3
YEL/RED C01-6

[A]
E01 C01

[a]

IBL80A112050-01

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

Troubleshooting
Step Action Yes No
1 Parameter check End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Start engine and warm it up to normal operating
temperature.
3) With engine running at specified idle speed and
accelerator pedal not depressed, check that “Fuel Rail
Pressure” displayed on SUZUKI scan tool is 25,000 to
45,000 kPa.

Is check result OK?

2 Parameter check End. Go to Step 3.
1) With accelerator pedal depressed and engine speed at
3,500 rpm, check that “Fuel Rail Pressure” displayed on
SUZUKI scan tool is more than 60,000 kPa.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-242

Step Action Yes No

3 Fuel pressure sensor power supply circuit and ground Go to Step 6. Go to Step 4.
circuit check
1) When ignition is “OFF”, disconnect fuel presser sensor
connector.
2) Check for proper terminal connection to fuel presser
sensor connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” circuits is
approx. 5 V.

Is check result OK?

4 Fuel pressure sensor ground circuit check Repair “A3” circuit. Go to Step 5.
1) Check that voltage between “A1” circuit and ground is
approx. 5 V.

Is check result OK?

5 Fuel pressure sensor power supply circuit check Replace ECM and Repair “A1” circuit.
1) When ignition is “OFF”, disconnect “C01” connector from recheck parameter.
ECM. )(Page 1C-14)
2) Check for proper terminal connection to “C01”
connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at fuel pressure sensor connector: infinity
• Voltage of “A1” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

6 Fuel pressure sensor signal circuit check Replace fuel pressure Repair “A2” circuit.
1) When ignition is “OFF”, disconnect “C01” connector from sensor and recheck
ECM. parameter. )(Page 1G-
50)
2) Check for proper terminal connection to “C01”
connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at fuel pressure sensor connector: infinity
• Voltage of “A2” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

1A-243 Engine General Information and Diagnosis: D13A

Table A-5: Fuel Flow Actuator Operation Check

AENBL80A1124070
Circuit Diagram

A1
YEL/BLK C01-4
2 A2
ORN/BLK C01-20

[A]
E01 C01

[a]

IBL80A112051-01

[A]: ECM connector (View: [a]) A2: Fuel flow actuator drive circuit 2. Fuel flow actuator
A1: Fuel flow actuator power supply circuit 1. ECM

Troubleshooting
Step Action Yes No
1 Fuel flow actuator power supply circuit and drive circuit Go to Step 2. Repair defective wire
check harness.
1) When ignition is “OFF”, disconnect “C01” connector from
ECM and fuel flow actuator connector.
2) Check for proper terminal connection to “C01” connector
and fuel flow actuator connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A1” circuit terminal and each
terminal at fuel flow actuator connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (when
ignition is “ON”.)

Is check result OK?

2 Fuel flow actuator check Replace ECM and Replace fuel flow
1) Check fuel flow actuator. recheck parameter. actuator.
)(Page 1C-14)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-244

Table B-1: Air Intake / Turbocharger Circuit Check

AENBL80A1124071
Troubleshooting
Step Action Yes No
1 Preliminary check Go to Step 2. Repair replace defective
1) Check the following points. part(s).
• Check seal of turbocharger system hoses.
• Check intercooler for leaks.
• Check that hose clamp in air intake system are
correctly fitted and tightened.
• Check air intake hoses and pipes for obstructions,
damage, etc.
• Check that MAF and IAT-1 sensor is not
contaminated.
• Visually check turbocharger for oil leakage and
damage.

Is check result OK?

2 Air cleaner filter condition check Go to Step 3. Replace air cleaner
1) Check that air cleaner filter is not contaminated. filter. )(Page 1D-78)

Is check result OK?

3 Air cleaner filter condition check Go to Step 4. Refit correctly.
1) Check that air cleaner filter is correctly fitted.

Is check result OK?

4 Turbocharger check Go to Step 5. Repair or replace
1) Check turbocharger. )(Page 1D-89) defective part(s).

Is check result OK?

5 MAF sensor operation check End. Repair or replace
1) Check that MAF sensor is working properly. )(Page 1A- defective part(s).
245)

Is check result OK?

1A-245 Engine General Information and Diagnosis: D13A

Table B-2: MAF Sensor Check

AENBL80A1124072
Circuit Diagram

IG1 1

A1
BLK/WHT
A2
2 BLU/RED E01-56
A3
BLU/YEL E01-34

3 B1
BLU/ORN E01-62

[A]
E01 C01

[a]

IBL80A112052-01

[A]: ECM connector (View: [a]) A3: MAF sensor ground circuit 2. MAF sensor
A1: MAF sensor power supply circuit B1: IAT-1 sensor signal circuit 3. IAT-1 sensor
A2: MAF sensor signal circuit 1. ECM

Troubleshooting
Step Action Yes No
1 Parameter check Go to Step 2. Go to Step 5.
1) When ignition “OFF”, connect SUZUKI scan tool to DLC.
2) Set ignition “ON”.
3) Confirm that engine stops and all electrical loads are
turned off.
4) Check that “MAF” parameter displayed on SUZUKI scan
tool is 0.0 to 1.0 g/sec. (0.0 to 0.13 Lb/min).

Is check result OK?

2 Parameter check Go to Step 3. Go to Step 5.
1) Start engine and warm it up to normal operating
temperature.
2) Check that “MAF” parameter displayed on SUZUKI scan
tool is approx. 5 g/sec. (0.66 Lb/min).

Is check result OK?

3 Parameter check Go to Step 4. Go to Step 5.
1) With all electrical loads turned off, depress accelerator
pedal several times are check that “MAF” parameter
displayed on SUZUKI scan tool is changed in a short
time.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-246

Step Action Yes No

4 Parameter check End. Go to Step 5.
1) Check that “MAF” parameter displayed on SUZUKI scan
tool is 50.0 g/sec. (6.60 Lb/min) or more with engine
speed at 3,500 rpm.

Is check result OK?

5 MAF sensor power supply circuit and ground circuit Go to Step 7. Go to Step 6.
check
1) When ignition is “OFF”, disconnect MAF and IAT-1
sensor connector.
2) Check for proper terminal connection to MAF and IAT-1
sensor connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” circuits is
battery voltage.

Is check result OK?

6 MAF sensor ground circuit check Repair “A3” circuit. Repair “A1” circuit.
1) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

7 MAF sensor signal circuit check Go to Step 8. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01.”
connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at MAF and IAT-1 sensor connector: infinity
• Voltage of “A2” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

8 MAF sensor check Replace ECM and Replace MAF and IAT-1
1) Check MAF sensor. )(Page 1C-18) recheck parameter. sensor. )(Page 1C-17)
)(Page 1C-14)
Is check result OK?
1A-247 Engine General Information and Diagnosis: D13A

Table B-3: Boost Pressure Sensor Check

AENBL80A1124073
Circuit Diagram

A1
RED/BLK C01-23
A2
2 ORN C01-41
A3
BLK C01-24

3 B1
WHT/GRN C01-37

[A]
E01 C01

[a]

IBL80A112053-01

[A]: ECM connector (View: [a]) A3: Boost pressure sensor ground circuit 2. Boost pressure sensor
A1: Boost pressure sensor power supply circuit B1: IAT-2 sensor signal circuit 3. IAT-2 sensor
A2: Boost pressure sensor signal circuit 1. ECM

Troubleshooting
Step Action Yes No
1 Air intake system check Go to Step 2. Repair or replace
1) Check that air intake system is working properly. defective part(s).
)(Page 1A-244)

Is check result OK?

2 Parameter check Go to Step 3. Go to Step 5.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Set ignition “ON”.
3) Confirm that engine stops and all electrical loads are
turned off.
4) Check that “Boost Pressure” displayed on SUZUKI scan
tool is approximately equal to “Barometric Pressure”.

Is check result OK?

3 Parameter check Go to Step 4. Go to Step 5.
1) With engine running at specified idle speed and
accelerator pedal not depressed, check that “Boost
Pressure” is 75 to 105 kPa (0.8 to 1.1 kgf/cm2, 10.8 to
15.2 psi).

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-248

Step Action Yes No

4 Parameter check End. Go to Step 5.
1) With accelerator pedal depressed and engine speed at
3,500 rpm, check that “Boost pressure” is 120 kPa (1.2
kgf/cm2, 17.4 psi) or more

Is check result OK?

5 Boost pressure sensor power supply circuit and ground Go to Step 8. Go to Step 6.
circuit check
1) When ignition is “OFF”, disconnect connector of boost
pressure and IAT-2 sensor.
2) Check for proper terminal connection to connector of
boost pressure and IAT-2 sensor.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” circuits is
approx. 5 V.

Is check result OK?

6 Boost pressure sensor ground circuit check Repair “A3” circuit. Go to Step 7.
1) Check that voltage between “A1” circuit and ground is
approx. 5 V.

Is check result OK?

7 Boost pressure sensor power supply circuit check Go to Step 8. Repair or replace
1) When ignition is “OFF”, disconnect “C01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “C01”
connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at boost pressure and IAT-2 sensor
connector: infinity
• Voltage of “A1” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

8 Boost pressure sensor signal circuit check Go to Step 9. Repair or replace
1) When ignition is “OFF”, disconnect “C01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “C01”
connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at boost pressure and IAT-2 sensor
connector: infinity
• Voltage of “A2” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

9 Boost pressure sensor check Replace ECM and Replace boost pressure
1) Check boost pressure sensor. )(Page 1C-23) recheck parameter. and IAT-2 sensor.
)(Page 1C-14) )(Page 1C-23)
Is check result OK?
1A-249 Engine General Information and Diagnosis: D13A

Table B-4: Barometric Pressure Check

AENBL80A1124074
Troubleshooting
Step Action Yes No
1 Parameter check End. Replace ECM and
1) When ignition is “OFF”, connect SUZUKI scan tool to recheck parameter.
DLC. )(Page 1C-14)
2) Set ignition “ON”.
3) Confirm that engine stops and all electrical loads are
turned off.
4) Check that “Barometric Pressure” displayed on SUZUKI
scan tool is approximately equal to barometric pressure.

Is check result OK?

Table B-5: EGR Valve Operation Check

AENBL80A1124075
Circuit Diagram

1
B2

YEL/GRN C01-30
3 B1 A1 A2
+B
BLU 2 GRY/RED C01-15

BLU BLU/RED C01-5

[A]
E01 C01

[a]

IBL80A112054-01

[A]: ECM connector (View: [a]) B1: Boost pressure control solenoid valve power supply 2. EGR valve
circuit
A1: EGR valve power supply circuit B2: Boost pressure control solenoid valve drive circuit 3. Boost pressure control solenoid valve
A2: EGR valve drive circuit 1. ECM
 Engine General Information and Diagnosis: D13A 1A-250

Troubleshooting
Step Action Yes No
1 Output test End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Check condition of main and circuit fuses. If not, replace
fuse and check for short circuit to ground.
3) Set ignition “ON”.
4) Select “EGR Valve” function in “Output Tests” mode on
SUZUKI scan tool.
5) Check EGR valve operation sound.

Is check result OK?

2 EGR valve power supply circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect EGR valve defective wire harness.
connector.
2) Check for proper terminal connection to EGR valve
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” circuit and ground is
battery voltage.

Is check result OK?

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

Is check result OK?

4 EGR valve check Replace ECM and Replace EGR valve.
1) Check EGR valve. )(Page 1B-7) recheck EGR valve )(Page 1B-6)
operation. )(Page 1C-
Is check result OK? 14)

Table B-6: A/F Sensor Check

AENBL80A1124076
1A-251 Engine General Information and Diagnosis: D13A

Circuit Diagram

2 1
A1
BLK E01-47
A2
RED/WHT E01-44
A3
GRN/WHT E01-46
A4
+B
YEL E01-45
B1 B2
LT GRN E01-12
BLU

[A]
E01 C01

[a]

IBL80A112055-01

[A]: ECM connector (View: [a]) A3: A/F sensor signal circuit (VSIP) B2: A/F sensor heater drive circuit
A1: A/F sensor signal circuit (RC) A4: A/F sensor signal circuit (IP) 1. ECM
A2: A/F sensor signal circuit (VS) B1: A/F sensor heater power supply circuit 2. A/F sensor

Troubleshooting
Step Action Yes No
1 A/F sensor heater power supply circuit check Go to Step 2. Repair or replace
1) When ignition is “OFF”, disconnect A/F sensor defective wire harness.
connector.
2) Check for proper terminal connection to A/F sensor
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1” circuit and ground is
battery voltage.

Is check result OK?

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

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-252

Step Action Yes No

3 A/F sensor signal circuit check Go to Step 4. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “A1, “A2”, “A3” and “A4” circuits: less
than 1 Ω
• Resistance between each of “A1, “A2”, “A3” and “A4”
circuits and ground: infinity
• Resistance between “A1” circuit terminal and each
terminal at A/F sensor connector: infinity
• Resistance between “A2” circuit terminal and each
terminal at A/F sensor connector: infinity
• Resistance between “A3” circuit terminal and each
terminal at A/F sensor connector: infinity
• Resistance between “A4” circuit terminal and each
terminal at A/F sensor connector: infinity
• Voltage of “A1, “A2”, “A3” and “A4” circuits: approx. 0
V (when ignition is “ON”)

Is check result OK?

4 A/F sensor check Replace ECM and Replace A/F sensor.
1) Check A/F sensor. )(Page 1B-9) recheck parameter. )(Page 1B-9)
)(Page 1C-14)
Is check result OK?

Table B-7: Boost Pressure Control Solenoid Valve Operation Check

AENBL80A1124091
Circuit Diagram

1
B2

YEL/GRN C01-30
3 B1 A1 A2
+B
BLU 2 GRY/RED C01-15

BLU BLU/RED C01-5

[A]
E01 C01

[a]

IBL80A112056-01

[A]: ECM connector (View: [a]) B1: Boost pressure control solenoid valve power 2. EGR valve
supply circuit
A1: EGR valve power supply circuit B2: Boost pressure control solenoid valve drive circuit 3. Boost pressure control solenoid valve
A2: EGR valve drive circuit 1. ECM

DTC Troubleshooting
1A-253 Engine General Information and Diagnosis: D13A

Step Action Yes No

1 Preliminary check Go to Step 2. Repair or replace
1) Check the following parts. defective part(s).
• Check vacuum hoses and pipes.
• Check vacuum pump. )(Page 1D-81)

Is check result OK?

2 Output check End. Go to Step 3.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Set ignition “ON”.
3) Select “BP Control Solenoid Valve” function in “Output
Test” mode on SUZUKI scan tool.
4) Check boost pressure control valve for operation sound.

Is check result OK?

3 Boost pressure control solenoid valve power supply Go to Step 4. Repair or replace
circuit check defective wire harness.
1) When ignition is “OFF”, disconnect boost pressure
control solenoid valve connector.
2) Check for proper terminal connection to boost pressure
control solenoid valve connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “B1” circuit and ground is
battery voltage.

Is check result OK?

4 Boost pressure control solenoid valve drive circuit Go to Step 5. Repair or replace
check defective wire harness.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and each
terminal at boost pressure control solenoid valve
connector: infinity
• Voltage of “B2” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

5 Boost pressure control solenoid valve check Replace ECM and Replace boost pressure
1) Check boost pressure control solenoid valve. )(Page recheck boost pressure control solenoid valve.
1C-25) control solenoid valve. )(Page 1C-25)
)(Page 1C-14)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-254

Table C-1: Main Relay Operation Check

AENBL80A1124077
Circuit Diagram

1
D1
YEL/GRN E01-50

A1 2 A3
YEL/GRN BRN/WHT E01-80
BLK/YEL BLK/RED B1
A2 BLK/RED E01-4
B2
BLK/RED E01-5
B3
BLK/RED E01-6
C1
BRN E01-1
C2
BRN E01-2
C3
BRN E01-3

[A]
E01 C01

[a]

IBL80A112057-01

[A]: ECM connector (View: [a]) B2: ECM power supply circuit D1: ECM backup power supply circuit
A1: Main relay power supply circuit (coil side) B3: ECM power supply circuit 1. ECM
A2: Main relay power supply circuit (switch side) C1: ECM ground circuit 2. Main relay
A3: Main relay drive circuit C2: ECM ground circuit
B1: ECM power supply circuit C3: ECM ground circuit

Troubleshooting
Step Action Yes No
1 Main relay power supply circuit check Go to Step 2. Repair or replace
1) When ignition is “OFF”, remove main relay. defective wire harness.
2) Check for proper terminal connection to main relay
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A1” and “A2”
circuits and ground is battery voltage.

Is check result OK?

1A-255 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 Main relay drive circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A3” circuit: less than 1 Ω
• Resistance between “A3” circuit and ground: infinity
• Resistance between “A3” circuit terminal and each
terminal at main relay connector: infinity
• Voltage of “A3” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

3 ECM power supply circuit Go to Step 4. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “B1”, “B2” and “B3” circuits: less than 1
Ω
• Resistance between each of “B1”, “B2” and “B3”
circuits and ground: infinity
• Resistance between “B1” circuit terminal and each
terminal at “E01” connector: infinity
• Resistance between “B2” circuit terminal and each
terminal at “E01” connector: infinity
• Resistance between “B3” circuit terminal and each
terminal at “E01” connector: infinity
• Voltage of “B1”, “B2” and “B3” circuits: approx. 0 V
(when ignition is “ON”)

Is check result OK?

4 ECM ground circuit check Go to Step 5. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “C1”, “C2” and “C3” circuits: less than 1
Ω
• Resistance between each of “C1”, “C2” and “C3”
circuits and ground: infinity
• Resistance between “C1” circuit terminal and each
terminal at “E01” connector: infinity
• Resistance between “C2” circuit terminal and each
terminal at “E01” connector: infinity
• Resistance between “C3” circuit terminal and each
terminal at “E01” connector: infinity
• Voltage of “C1”, “C2” and “C3” circuits: approx. 0 V
(when ignition is “ON”)

Is check result OK?

5 Main relay check End. Replace main relay.
1) Check main relay. )(Page 1C-24) )(Page 10B-30)

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-256

Table C-2: Engine Speed Check

AENBL80A1124078
Circuit Diagram

3 1
A1
GRY/BLK C01-43
2 A2
YEL/RED C01-59

B1
5 PNK C01-25
B2
4 PNK/BLK C01-56
B3
PPL C01-21

[A]
E01 C01

[a]

IBL80A112058-01

[A]: ECM connector (View: [a]) B2: CMP sensor signal circuit 3. CKP sensor teeth
A1: CKP sensor signal circuit (+) B3: CMP sensor ground circuit 4. CMP sensor
A2: CKP sensor signal circuit (–) 1. ECM 5. CMP sensor teeth
B1: CMP sensor power supply circuit 2. CKP sensor

Troubleshooting
Step Action Yes No
1 Parameter check Go to Step 2. Go to Step 3.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Set ignition “ON”.
3) Check that “Engine Speed” exceeds 60 rpm without
engine running.

Is check result OK?

2 Idle speed check End. Go to Step 3.
1) Start engine and warm it up to normal operating
temperature.
2) With engine running at specified idle speed, all electrical
loads turned off and accelerator pedal released, check
that “Engine Speed” is approx. 800 rpm.

Is check result OK?

1A-257 Engine General Information and Diagnosis: D13A

Step Action Yes No

3 CKP sensor signal circuit check Go to Step 4. Repair or replace
1) When ignition is “OFF”, disconnect “C01” connector from defective wire harness.
ECM and CKP sensor connector.
2) Check for proper terminal connection to “C01” connector
and CKP sensor connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and each
terminal at CKP sensor connector: infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (when
ignition is “ON”)

Is check result OK?

4 CKP sensor check Go to Step 5. Replace CKP sensor.
1) Check CKP sensor. )(Page 1C-22) )(Page 1C-22)

Is check result OK?

5 CKP sensor teeth check Replace ECM and Replace flywheel.
1) Check CKP sensor teeth. )(Page 1D-105) recheck parameter. )(Page 1D-105)
)(Page 1C-14)
Is check result OK?

Table C-3: ECT Sensor Check

AENBL80A1124079
Circuit Diagram

1
A1
2
PPL/WHT C01-54
A2
GRN C01-29

[A]
E01 C01

[a]

IBL80A112059-01

[A]: ECM connector (View: [a]) A2: ECT sensor ground circuit 2. ECT sensor
A1: ECT sensor signal circuit 1. ECM
 Engine General Information and Diagnosis: D13A 1A-258

Troubleshooting
Step Action Yes No
1 Parameter check End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Start engine and warm it up normal operating
temperature.
3) Turn off all electrical loads.
4) Check that “Coolant Temp” displayed on SUZUKI scan
tool is 80 to 110 °C (176 to 230 °F).

Is check result OK?

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

Is check result OK?

3 ECT sensor check Replace ECM and Replace ECT sensor.
1) Check ECT sensor. )(Page 1C-21) recheck parameter. )(Page 1C-20)
)(Page 1C-14)
Is check result OK?
1A-259 Engine General Information and Diagnosis: D13A

Table C-4: IAT-1 Sensor Check

AENBL80A1124080
Circuit Diagram

IG1 1

A1
BLK/WHT
A2
2 BLU/RED E01-56
A3
BLU/YEL E01-34

3 B1
BLU/ORN E01-62

[A]
E01 C01

[a]

IBL80A112060-01

[A]: ECM connector (View: [a]) A3: MAF sensor ground circuit 2. MAF sensor
A1: MAF sensor power supply circuit B1: IAT-1 sensor signal circuit 3. IAT-1 sensor
A2: MAF sensor signal circuit 1. ECM

Troubleshooting
Step Action Yes No
1 Parameter check End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Start engine and warm it up to normal operating
temperature.
3) With engine running at specified idle speed, all electrical
loads turned off and accelerator pedal not depressed,
check that “IAT1” is under –5 °C (–9 °F) + environmental
temp. and over 40 °C (72 °F) + environmental temp.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-260

Step Action Yes No

2 IAT-1 sensor signal circuit and MAF sensor ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM and MAF and IAT-1 sensor connector.
2) Check for proper terminal connection to “E01” connector
and MAF and IAT-1 sensor connector.
3) If connections are OK, check the following points.
• Resistance of “B1” and “A3” circuits: less than 1 Ω
• Resistance between each of “B1” and “A3” circuits
and ground: infinity
• Resistance between “B1” circuit terminal and each
terminal at MAF and IAT-1 sensor connector: infinity
• Resistance between “A3” circuit terminal and each
terminal at MAF and IAT-1 sensor connector: infinity
• Voltage of “B1” and “A3” circuits: approx. 0 V (when
ignition is “ON”)

Is check result OK?

3 IAT-1 sensor check Replace ECM and Replace MAF and IAT-1
1) Check IAT-1 sensor. )(Page 1C-18) recheck parameter. sensor. )(Page 1C-17)
)(Page 1C-14)
Is check result OK?

Table C-5: IAT-2 Sensor Check

AENBL80A1124090
Circuit Diagram

A1
RED/BLK C01-23
A2
2 ORN C01-41
A3
BLK C01-24

3 B1
WHT/GRN C01-37

[A]
E01 C01

[a]

IBL80A112061-01

[A]: ECM connector (View: [a]) A3: Boost pressure sensor ground circuit 2. Boost pressure sensor
A1: Boost pressure sensor power supply circuit B1: IAT-2 sensor signal circuit 3. IAT-2 sensor
A2: Boost pressure sensor signal circuit 1. ECM
1A-261 Engine General Information and Diagnosis: D13A

DTC Troubleshooting
Step Action Yes No
1 Parameter check End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Start engine and warm it up to normal operating
temperature.
3) With engine running at specified idle speed, all electrical
loads turned off and accelerator pedal not depressed,
check that “IAT2” is under –5 °C (–9 °F) + environmental
temp. and over 40 °C (72 °F) + environmental temp.

Is check result OK?

2 IAT-2 sensor signal circuit and boost pressure sensor Go to Step 3. Repair or replace
ground circuit check defective wire harness.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM and boost pressure and IAT-2 sensor connector.
2) Check for proper terminal connection to “E01” connector
and boost pressure and IAT-2 sensor connector.
3) If connections are OK, check the following points.
• Resistance of “B1” and “A3” circuits: less than 1 Ω
• Resistance between each of “B1” and “A3” circuits
ground: infinity
• Resistance between “B1” circuit terminal and each
terminal at boost pressure and IAT-2 sensor
connector: infinity
• Resistance between “A3” circuit terminal and each
terminal at boost pressure and IAT-2 sensor
connector: infinity
• Voltage of “B1” and “A3” circuits: approx. 0 V (when
ignition is “ON”)

Is check result OK?

3 IAT-2 sensor check Replace ECM and Replace boost pressure
1) Check IAT-2 sensor. )(Page 1C-23) recheck parameter. and IAT-2 sensor.
)(Page 1C-14) )(Page 1C-23)
Is check result OK?

Table C-6: Accelerator Pedal Check

AENBL80A1124081
 Engine General Information and Diagnosis: D13A 1A-262

Circuit Diagram

1
A1
2 BRN E01-83
A2
GRN/RED E01-65
A3
BLU E01-35
B1
3 RED E01-15
B2
YEL E01-41
B3
WHT E01-32

[A]
E01 C01

[a]

IBL80A112062-01

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

Troubleshooting
Step Action Yes No
1 Parameter check Go to Step 2. Go to Step 3.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Set ignition “ON”.
3) With all electrical loads turned off and accelerator pedal
not depressed, check that the following parameters
displayed on SUZUKI scan tool are within reference
value.
• “Accel Position”: 0 to 5%
• “APP Sensor 1 Volt”: 0.60 to 1.10 V
• “APP Sensor 2 Volt”: 0.30 to 0.50 V

Is check result OK?

2 Parameter check End. Go to Step 3.
1) With accelerator pedal depressed fully, check that the
following parameters displayed on SUZUKI scan tool are
within reference value.
• “Accel Position”: 95 to 100%.
• “APP sensor 1 volt”: 3.60 to 4.30 V
• “APP sensor 2 volt”: 1.80 to 2.20 V

Is check result OK?

1A-263 Engine General Information and Diagnosis: D13A

Step Action Yes No

3 APP sensor power supply circuit and ground circuit Go to Step 6. Go to Step 4.
check
1) When ignition is “OFF”, disconnect APP sensor
connector.
2) Check for proper terminal connection to APP sensor
connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A1” to “A3” circuits
and “B1” to “B3” circuits is approx. 5 V.

Is check result OK?

4 APP sensor ground circuit check Repair “A3” and/or “B3” Go to Step 5.
1) Check that voltage between each of “A1” and “B1” circuits.
circuits and ground is approx. 5 V.

Is check result OK?

5 APP sensor power supply circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from recheck parameter. defective wire harness.
ECM. )(Page 1C-14)
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “B1” circuits: less than 1 Ω
• Resistance between each of “A1” and “B1” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at APP sensor connector: infinity
• Resistance between “B1” circuit terminal and other
terminal at APP sensor connector: infinity
• Voltage of “A1” and “B1” circuits: approx. 0 V (when
ignition is “ON”)

Is check result OK?

6 APP sensor signal circuit check Go to Step 7. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A2” and “B2” circuits: less than 1 Ω
• Resistance between each of “A2” and “B2” circuits
and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal at APP sensor connector: infinity
• Resistance between “B2” circuit terminal and other
terminal at APP sensor connector: infinity
• Voltage of “A2” and “B2” circuits: approx. 0 V (when
ignition is “ON”)

Is check result OK?

7 APP sensor check Replace ECM and Replace APP sensor.
1) Check APP sensor. )(Page 1C-20) recheck parameter. )(Page 1C-20)
)(Page 1C-14)
Is check result OK?

Table C-7: Speed Signal Check

AENBL80A1124082
 Engine General Information and Diagnosis: D13A 1A-264

Circuit Diagram

+B 1

BLU A1
A2
2 PPL E01-89
GRY A3

[A]
E01 C01

[a]

IBL80A112063-01

[A]: ECM connector (View: [a]) A2: VSS signal circuit 1. ECM
A1: VSS power supply circuit A3: VSS ground circuit 2. VSS

Troubleshooting

! WARNING

• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester.

Step Action Yes No

1 Parameter check End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Carry out a road test and drive vehicle at constant speed
of 30 km/h (19 MPH).
3) Check that “Vehicle Speed” displayed on SUZUKI scan
tool is approx. 30 km/h (19 MPH).

Is check result OK?

2 VSS power supply circuit and ground circuit check Go to Step 5. Go to Step 3.
1) When ignition is “OFF”, disconnect VSS connector.
2) Check for proper terminal connection to VSS connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between “A1” and “A3” circuits is
battery voltage.

Is check result OK?

3 VSS ground circuit check Repair “A3” circuit. Go to Step 4.
1) Check that voltage between “A1” and ground is battery
voltage.

Is check result OK?

1A-265 Engine General Information and Diagnosis: D13A

Step Action Yes No

4 VSS power supply circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from recheck DTC. )(Page defective wire harness.
ECM. 1C-14)
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A1” circuit: less than 1 Ω
• Resistance between “A1” circuit and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal VSS connector: infinity
• Voltage of “A1” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

5 VSS signal circuit check Go to Step 6. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A2” circuit: less than 1 Ω
• Resistance between “A2” circuit and ground: infinity
• Resistance between “A2” circuit terminal and other
terminal VSS connector: infinity
• Voltage of “A2” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

6 VSS check Replace ECM and Replace VSS. )(Page
1) Check VSS. )(Page 1C-26) recheck DTC. )(Page 1C-25)
1C-14)
Is check result OK?
 Engine General Information and Diagnosis: D13A 1A-266

Table C-8: Glow Plugs Operation Check

AENBL80A1124083
NOTE
For identification of each cylinder, refer to “Statement on Cleanliness and Care”: D13A (Page 1A-124).

Circuit Diagram

+BB IG1 1
A2 A1
B1
BLK/WHT BLU E01-70
B2
RED 2
GRY/BLU E01-74
A3
GRY
C1 C2 C3 C4
BLU RED YEL GRN
3 4 5 6

[A]
E01 C01

[a]

IBL80A112064-01

[A]: ECM connector (View: [a]) C1: Glow plug No.1 drive circuit 3. Glow plug No.1
A1: Glow plug control module power supply circuit C2: Glow plug No.2 drive circuit 4. Glow plug No.2
A2: Glow plug control module power supply circuit C3: Glow plug No.3 drive circuit 5. Glow plug No.3
A3: Glow plug control module ground circuit C4: Glow plug No.4 drive circuit 6. Glow plug No.4
B1: Glow plug control module drive circuit 1. ECM
B2: Glow plug control module communication circuit 2. Glow plug control module

Troubleshooting
Step Action Yes No
1 Output test End. Go to Step 2.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Disconnect glow plug connector from glow plugs.
3) Set ignition “ON”.
4) Select “Glow Plug” function in “Output Tests” mode on
SUZUKI scan tool.
5) Check that voltage between each of glow plug connector
terminal and vehicle ground is higher than 11 V.

Is check result OK?

1A-267 Engine General Information and Diagnosis: D13A

Step Action Yes No

2 Glow plug control module power supply circuit and Go to Step 5. Go to Step 3.
ground circuit check
1) When ignition is “OFF”, disconnect “E07” connector from
glow plug control module.
2) Check for proper terminal connection to “E07” connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A1” and “A2”
circuits and “A3” circuit are battery voltage.

Is check result OK?

3 Glow plug control module ground circuit check Repair “A3” circuit. Go to Step 4.
1) Check that voltage between each of “A1” and “A2”
circuits and ground is battery voltage.

Is check result OK?

4 Glow plug control module power supply circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “C01” connector from recheck glow plugs defective wire harness.
ECM. operation. )(Page 1C-
14)
2) Check for proper terminal connection to “C01”
connector.
3) If connections are OK, check the following points.
• Resistance of “A1” and “A2” circuits: less than 1 Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at glow plug control module connector:
infinity
• Resistance between “A2” circuit terminal and other
terminal at glow plug control module connector:
infinity
• Voltage of “A1” and “A2” circuits: approx. 0 V (when
ignition is “ON”)

Is check result OK?

5 Glow plug control module drive circuit check Go to Step 6. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Resistance between “B1” circuit terminal and each
terminal at glow plug control module connector:
infinity
• Voltage of “B1” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-268

Step Action Yes No

6 Glow plug control module communication circuit check Go to Step 7. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “B2” circuit: less than 1 Ω
• Resistance between “B2” circuit and ground: infinity
• Resistance between “B2” circuit terminal and each
terminal at glow plug control module connector:
infinity
• Voltage of “B2” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

7 Glow plug drive circuit check Go to Step 8. Repair or replace
1) When ignition is “OFF”, disconnect “D02” connector from defective wire harness.
glow plug control module and all glow plug connectors.
2) Check for proper terminal connection to “D02” connector
and all glow plug connectors.
3) If connections are OK, check that glow plug drive circuit
(“C1”, “C2”, “C3” and “C4”) is as follows.
• Resistance of “C1”, “C2”, “C3” and “C4” circuits: less
than 1 Ω
• Resistance between each of “C1”, “C2”, “C3” and “C4”
circuits and ground: infinity
• Resistance between “C1” circuit terminal and other
terminal at glow plug control module connector:
infinity
• Resistance between “C2” circuit terminal and other
terminal at glow plug control module connector:
infinity
• Resistance between “C3” circuit terminal and other
terminal at glow plug control module connector:
infinity
• Resistance between “C4” circuit terminal and other
terminal at glow plug control module connector:
infinity
• Voltage of “C1”, “C2”, “C3” and “C4” circuits: approx. 0
V (when ignition is “ON”)

Is check result OK?

8 Glow plug check Replace glow plug Replace glow plugs.
1) Check all glow plugs. )(Page 1C-19) control module and go )(Page 1C-19)
to Step 1. )(Page 1C-
Is check result OK? 24)
1A-269 Engine General Information and Diagnosis: D13A

Table C-9: Radiator Cooling Fan Operation Check

AENBL80A1124084
! WARNING
Keep hands, tools, and clothing away from radiator cooling fan to prevent personal injury. This fan is
driven by electric motor that can turn on whether or not the engine is running. The fan motor can start
automatically in response to ECT sensor signal if ignition is “ON”.

Circuit Diagram

1
+BB +B
A3
A1 3 LT GRN/RED E01-7
D1
6
BLU
B1 4 B3 2
A2

GRY BLU/BLK
B2 D3 BLK
C1 5 C3
D2
GRN E01-8
BLK BLU/WHT
C2 D4
[A]
E01 C01

[a]

IBL80A112065-01

[A]: ECM connector (View: [a]) D1: Radiator cooling fan power supply circuit (low speed side)
A1: Radiator cooling fan relay No.1 power supply circuit (coil side) D2: Radiator cooling fan ground circuit (low speed side)
A2: Radiator cooling fan relay No.1 power supply circuit (switch side) D3: Radiator cooling fan power supply circuit (high speed side)
A3: Radiator cooling fan relay No.1 drive circuit D4: Radiator cooling fan ground circuit (high speed side)
B1: Radiator cooling fan relay No.2 power supply circuit (coil side) 1. ECM
B2: Radiator cooling fan relay No.2 power supply circuit (switch side) 2. Radiator cooling fan motor
B3: Radiator cooling fan relay No.2 drive circuit 3. Radiator cooling fan relay No.1
C1: Radiator cooling fan relay No.3 power supply circuit (coil side) 4. Radiator cooling fan relay No.2
C2: Radiator cooling fan relay No.3 ground circuit 5. Radiator cooling fan relay No.3
C3: Radiator cooling fan relay No.3 drive circuit 6. “RDTR” fuse

Troubleshooting
Step Action Yes No
1 Output test Go to Step 2. Go to Step 3.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
2) Set ignition “ON”.
3) Select “Radiator Fan Low” function in “Output Tests”
mode on SUZUKI scan tool.
4) Check that radiator cooling fan operates at low mode.

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-270

Step Action Yes No

2 Output test End. Go to Step 8.
1) Select “Radiator Fan High” function in “Output Tests”
mode on SUZUKI scan tool.
2) Check that radiator cooling fan operates at high mode.

Is check result OK?

3 Radiator cooling fan relay No.1 power supply circuit Go to Step 4. Repair or replace
check defective wire harness.
1) When ignition is “OFF”, remove radiator cooling fan relay
No.1. )(Page 10B-7)
2) Check for proper terminal connection to radiator cooling
fan relay No.1 connector.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “A1” and “A2”
circuits and ground is battery voltage.

Is check result OK?

4 Radiator cooling fan relay No.1 drive circuit check Go to Step 5. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “A3” circuit: less than 1 Ω
• Resistance between “A3” circuit and ground: infinity
• Resistance between “A3” circuit terminal and each
terminal at radiator cooling fan relay No.1 connector:
infinity
• Voltage of “A3” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

5 Radiator cooling fan relay No.1 check Go to Step 6. Replace radiator cooling
1) Check radiator cooling fan relay No.1. )(Page 1F-27) fan relay No.1. )(Page
10B-7)
Is check result OK?
6 Radiator cooling fan power supply circuit (low speed Go to Step 7. Repair or replace
side) defective wire harness.
1) When ignition is “OFF”, disconnect radiator cooling fan
connector.
2) Check for proper terminal connection to radiator cooling
fan connector.
3) If connections are OK, check the following points.
• Resistance of “D1” circuit: less than 1 Ω
• Resistance between “D1” circuit and ground: infinity
• Resistance between “D1” circuit terminal and each
terminal at radiator cooling fan connector: infinity
• Voltage of “D1” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

1A-271 Engine General Information and Diagnosis: D13A

Step Action Yes No

7 Radiator cooling fan ground circuit (low speed side) Go to Step 14. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “D2” circuit: less than 1 Ω
• Resistance between “D2” circuit and ground: infinity
• Resistance between “D2” circuit terminal and each
terminal at radiator cooling fan connector: infinity
• Voltage of “D2” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

8 Radiator cooling fan relay No.2 and No.3 power supply Go to Step 9. Repair or replace
circuit check defective wire harness.
1) When ignition is “OFF”, remove radiator cooling fan relay
No.2 and No.3. )(Page 10B-7)
2) Check for proper terminal connection to radiator cooling
fan relay No.2 and No.3 connectors.
3) If connections are OK, set ignition “ON”.
4) Check that voltage between each of “B1”, “B2” and “C1”
circuits and ground is battery voltage.

Is check result OK?

9 Radiator cooling fan relay No.3 ground circuit check Go to Step 10. Repair or replace
1) Check that resistance “C2” circuit and ground is less defective wire harness.
than 1 Ω.

Is check result OK?

10 Radiator cooling fan relay No.2 and No.3 drive circuit Go to Step 11. Repair or replace
check defective wire harness.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM.
2) Check for proper terminal connection to “E01” connector.
3) If connections are OK, check the following points.
• Resistance of “B3” and “C3” circuits: less than 1 Ω
• Resistance between each of “B3” and “C3” circuits
and ground: infinity
• Resistance between “B3” circuit terminal and each
terminal at radiator cooling fan relay No.2 connector:
infinity
• Resistance between “C3” circuit terminal and each
terminal at radiator cooling fan relay No.3 connector:
infinity
• Voltage of “B3” and “C3” circuits: approx. 0 V (when
ignition is “ON”)

Is check result OK?

 Engine General Information and Diagnosis: D13A 1A-272

Step Action Yes No

11 Radiator cooling fan power supply circuit (high speed Go to Step 12. Repair or replace
side) defective wire harness.
1) When ignition is “OFF”, disconnect radiator cooling fan
connector.
2) Check for proper terminal connection to radiator cooling
fan connector.
3) If connections are OK, check the following points.
• Resistance of “D3” circuit: less than 1 Ω
• Resistance between “D3” circuit and ground: infinity
• Resistance between “D3” circuit terminal and each
terminal at radiator cooling fan connector: infinity
• Voltage of “D3” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

12 Radiator cooling fan ground circuit (high speed side) Go to Step 13. Repair or replace
1) Check the following points. defective wire harness.
• Resistance of “D4” circuit: less than 1 Ω
• Resistance between “D4” circuit and ground: infinity
• Resistance between “D4” circuit terminal and each
terminal at radiator cooling fan connector: infinity
• Voltage of “D4” circuit: approx. 0 V (when ignition is
“ON”)

Is check result OK?

13 Radiator cooling fan relay No.2 and No.3 check Go to Step 14. Replace radiator cooling
1) Check radiator cooling fan relay No.2 and No.3. )(Page fan relay No.2 and No.3.
1F-27) )(Page 10B-7)

Is check result OK?

14 Radiator cooling fan motor check Replace ECM and Replace radiator cooling
1) Check radiator cooling fan. )(Page 1F-26) recheck radiator cooling fan motor. )(Page 1F-
fan motor operation. 27)
Is check result OK? )(Page 1C-14)

Inspection of ECM and Its Circuits

AENBL80A1124085
! CAUTION
ECM can be checked only through its connect. It is strictly prohibited to connect voltmeter to ECM
with ECM connectors disconnected from it.
1A-273 Engine General Information and Diagnosis: D13A

NOTE
As each terminal voltage is affected by battery voltage, confirm that it is 11 V or more when ignition is
“ON”.

Terminal Arrangement of ECM Connector

[A]
E01 C01

[a]

IBL80A112066-01

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

Terminal No. Wire color Circuit Normal voltage Condition

Fuel injector No.4 drive circuit Refer to reference waveform.
C01-1 WHT/BLU
(low side) “Fuel injector signal”: D13A (Page 1A-279)
C01-2 — — — —
C01-3 — — — —
Fuel flow actuator power
C01-4 YEL/BLK 10 to 14 V Ignition: “ON”
supply circuit
EGR valve power supply Engine: Idle speed after
C01-5 BLU/RED 10 to 14 V
circuit warming up
Fuel pressure sensor ground
C01-6 YEL/RED Below 0.3 V Ignition: “ON”
circuit
C01-7 — — — —
Fuel pressure sensor power
C01-8 GRN/YEL 4 to 6 V Ignition: “ON”
supply circuit
0 to 1 V Ignition: “ON”
Oil pressure switch signal
C01-9 GRY/YEL Engine: Idle speed after
circuit 10 to 14 V
warming up
C01-10 — — — —
C01-11 — — — —
C01-12 — — — —
C01-13 — — — —
C01-14 — — — —
Refer to reference waveform.
C01-15 GRY/RED EGR valve drive circuit
“EGR valve signal”: D13A (Page 1A-280)
Fuel injector No.1 drive circuit Refer to reference waveform.
C01-16 ORN/WHT
(low side) “Fuel injector signal”: D13A (Page 1A-279)
Fuel injector No.2 drive circuit Refer to reference waveform.
C01-17 YEL/BLK
(low side) “Fuel injector signal”: D13A (Page 1A-279)
C01-18 — — — —
C01-19 — — — —
Refer to reference waveform.
C01-20 ORN/BLK Fuel flow actuator drive circuit
“Fuel flow actuator signal”: D13A (Page 1A-279)
C01-21 PPL CMP sensor ground circuit Below 0.3 V Ignition: “ON”
C01-22 — — — —
Boost pressure sensor power Engine: Idle speed after
C01-23 RED/BLK 4 to 6 V
supply circuit warming up
 Engine General Information and Diagnosis: D13A 1A-274

Terminal No. Wire color Circuit Normal voltage Condition

Boost pressure sensor ground
C01-24 BLK Below 0.3 V Ignition: “ON”
circuit
CMP sensor power supply Engine: Idle speed after
C01-25 PNK 4 to 6 V
circuit warming up
C01-26 — — — —
C01-27 — — — —
C01-28 — — — —
C01-29 GRN ECT sensor ground circuit Below 0.3 V Ignition: “ON”
Refer to reference waveform.
Boost pressure control
C01-30 YEL/GRN “Boost pressure control solenoid valve signal”: D13A
solenoid valve drive circuit
(Page 1A-280)
Fuel injector No.3 drive circuit Refer to reference waveform.
C01-31 WHT/GRN
(low side) “Fuel injector signal”: D13A (Page 1A-279)
C01-32 — — — —
C01-33 — — — —
C01-34 — — — —
C01-35 — — — —
C01-36 — — — —
Ignition: “ON”
Approx. 1.7 V Intake air temperature: 20 °C
(68 °F)
Ignition: “ON”
C01-37 WHT/GRN IAT-2 sensor signal circuit Approx. 1.0 V Intake air temperature: 40 °C
(105 °F)
Ignition: “ON”
Approx. 0.5 V Intake air temperature: 60 °C
(140 °F)
Engine: Idle speed after
warming up
Approx. 1.1 V Reference rail pressure: 30
Mpa (305.9 kgf/cm2, 4350 psi,
Fuel pressure sensor signal 300 bar)
C01-38 ORN/BLK
circuit Engine: Running at 3500 rpm
after warmed up
Approx. 2.2 V Reference rail pressure: 75
Mpa (764.8 kgf/cm2, 10,900
psi, 750 bar)
C01-39 — — — —
C01-40 — — — —
Engine: Idle speed after
warming up
Approx. 2.0 V Reference boost pressure:
102 kPa (1.04 kgf/cm2, 14.8
Boost pressure sensor signal psi, 1.02 bar)
C01-41 ORN
circuit Engine: Running at 3500 rpm
after warmed up
Approx. 3.0 V Reference boost pressure:
169 kPa (1.72 kgf/cm2, 24.5
psi, 1.69 bar)
C01-42 — — — —
Refer to reference waveform.
C01-43 GRY/BLK CKP sensor signal circuit (+) “CMP sensor signal and CKP sensor signal”: D13A
(Page 1A-281)
C01-44 — — — —
C01-45 — — — —
Fuel injector No.4 drive circuit Refer to reference waveform.
C01-46 BLU
(high side) “Fuel injector signal”: D13A (Page 1A-279)
Fuel injector No.1 drive circuit Refer to reference waveform.
C01-47 ORN
(high side) “Fuel injector signal”: D13A (Page 1A-279)
1A-275 Engine General Information and Diagnosis: D13A

Terminal No. Wire color Circuit Normal voltage Condition

Fuel injector No.3 drive circuit Refer to reference waveform.
C01-48 GRN
(high side) “Fuel injector signal”: D13A (Page 1A-279)
Fuel injector No.2 drive circuit Refer to reference waveform.
C01-49 YEL
(high side) “Fuel injector signal”: D13A (Page 1A-279)
C01-50 — — — —
C01-51 — — — —
C01-52 — — — —
C01-53 — — — —
Ignition: “ON”
Approx. 2.8 V
ECT: Approx. 20 °C (68 °F)
Ignition: “ON”
C01-54 PPL/WHT ECT sensor signal circuit Approx. 1.8 V
ECT: Approx. 40 °C (104 °F)
Ignition: “ON”
Approx. 0.7 V
ECT: Approx. 80 °C (176 °F)
C01-55 — — — —
Refer to reference waveform.
C01-56 PNK/BLK CMP sensor signal circuit “CMP sensor signal and CKP sensor signal”: D13A
(Page 1A-281)
C01-57 — — — —
C01-58 — — — —
Refer to reference waveform.
C01-59 YEL/RED CKP sensor signal circuit (–) “CMP sensor signal and CKP sensor signal”: D13A
(Page 1A-281)
C01-60 — — — —

Terminal No. Wire color Circuit Normal voltage Condition

E01-1 BRN ECM ground circuit Below 0.3 V Ignition: “ON”
E01-2 BRN ECM ground circuit Below 0.3 V Ignition: “ON”
E01-3 BRN ECM ground circuit Below 0.3 V Ignition: “ON”
E01-4 BLK/RED ECM power supply circuit 10 to 14 V Ignition: “ON”
E01-5 BLK/RED ECM power supply circuit 10 to 14 V Ignition: “ON”
E01-6 BLK/RED ECM power supply circuit 10 to 14 V Ignition: “ON”
Radiator cooling fan motor:
0 to 1 V
Radiator cooling fan relay Low speed
E01-7 LT GRN/RED
No.1 drive circuit Radiator cooling fan motor:
10 to 14 V
Not operate
Radiator cooling fan motor:
0 to 1 V
Radiator cooling fan relay High speed
E01-8 GRN
No.2 and No.3 drive circuit Radiator cooling fan motor:
10 to 14 V
Not operate
E01-9 — — — —
A/C refrigerant pressure
E01-10 BLU/RED Below 0.3 V Ignition: “ON”
sensor ground circuit
E01-11 — — — —
Refer to reference waveform.
E01-12 LT GRN A/F sensor heater drive circuit “A/F sensor heater relay drive signal”: D13A (Page
1A-281)
Fuel temperature sensor
E01-13 RED/BLU Below 0.3 V Ignition: “ON”
ground circuit
E01-14 — — — —
APP sensor (sub) power
E01-15 RED 4 to 6 V Ignition: “ON”
supply circuit
E01-16 — — — —
E01-17 — — — —
E01-18 — — — —
E01-19 — — — —
E01-20 — — — —
E01-21 — — — —
 Engine General Information and Diagnosis: D13A 1A-276

Terminal No. Wire color Circuit Normal voltage Condition

Ignition: “ON”
10 to 14 V
Clutch pedal: Not depressed
E01-22 YEL/GRN CPP switch signal circuit
Ignition: “ON”
0 to 1 V
Clutch pedal: Fully depressed
E01-23 BLK/WHT Ignition signal circuit 10 to 14 V Ignition: “ON”
E01-24 — — — —
E01-25 — — — —
E01-26 — — — —
E01-27 — — — —
E01-28 — — — —
E01-29 — — — —
E01-30 — — — —
E01-31 — — — —
APP sensor (sub) ground
E01-32 WHT Below 0.3 V Ignition: “ON”
circuit
E01-33 — — — —
E01-34 BLU/YEL MAF sensor ground circuit Below 0.3 V Ignition: “ON”
APP sensor (main) ground
E01-35 BLU Below 0.3 V Ignition: “ON”
circuit
E01-36 — — — —
A/C refrigerant pressure Engine: Idle speed after
E01-37 GRY/RED 4 to 6 V
sensor power supply circuit warming up
E01-38 — — — —
E01-39 — — — —
CAN (low) communication Refer to reference waveform.
E01-40 WHT
circuit “CAN communication signal”: D13A (Page 1A-282)
Ignition: “ON”
1.74 to 2.17 V Accelerator pedal: Fully
APP sensor (sub) signal depressed
E01-41 YEL
circuit Ignition: “ON”
0.30 to 0.44 V Accelerator pedal: Not
depressed
E01-42 — — — —
E01-43 — — — —
Engine: Idle speed after
E01-44 RED/WHT A/F sensor signal circuit (VS) 2 to 6 V
warming up
Engine: Idle speed after
E01-45 YEL A/F sensor signal circuit (IP) 2 to 6 V
warming up
A/F sensor signal circuit Engine: Idle speed after
E01-46 GRN/WHT 2 to 6 V
(VSIP) warming up
Engine: Idle speed after
E01-47 BLK A/F sensor signal circuit (RC) 2 to 6 V
warming up
E01-48 — — — —
E01-49 — — — —
ECM backup power supply
E01-50 YEL/GRN 10 to 14 V —
circuit
E01-51 — — — —
E01-52 — — — —
E01-53 — — — —
E01-54 — — — —
E01-55 — — — —
Refer to reference waveform.
E01-56 BLU/RED MAF sensor signal circuit
“MAF sensor signal”: D13A (Page 1A-282)
E01-57 — — — —
E01-58 — — — —
E01-59 — — — —
E01-60 — — — —
1A-277 Engine General Information and Diagnosis: D13A

Terminal No. Wire color Circuit Normal voltage Condition

Engine: Idle speed after
warming up
Approx. 2.54 V
Fuel temperature: 25 °C (77
°F)
Engine: Idle speed after
Fuel temperature sensor warming up
E01-61 BLK/YEL Approx. 1.14 V
signal circuit Fuel temperature: 60 °C (140
°F)
Engine: Idle speed after
warming up
Approx. 0.43 V
Fuel temperature: 100 °C (212
°F)
Refer to reference waveform.
E01-62 BLU/ORN IAT-1 sensor signal circuit
“IAT-1 sensor signal”: D13A (Page 1A-282)
E01-63 — — — —
CAN (high) communication Refer to reference waveform.
E01-64 RED
circuit “CAN communication signal”: D13A (Page 1A-282)
Ignition: “ON”
3.50 to 4.27 V Accelerator pedal: Fully
APP sensor (main) signal depressed
E01-65 GRN/RED
circuit Ignition: “ON”
0.65 to 0.82 V Accelerator pedal: Not
depressed
Refer to reference waveform.
E01-66 PPL/WHT Serial communication circuit
“Serial communication signal”: D13A (Page 1A-282)
E01-67 — — — —
Ignition: “ON”
10 to 14 V
Brake pedal: Not depressed
E01-68 GRN/YEL Brake switch signal circuit
Ignition: “ON”
0 to 1 V
Brake pedal: Fully depressed
E01-69 — — — —
Ignition: Within 20 sec. after
0 to 1 V
BLU Glow plug control module set ignition “ON”
E01-70
drive circuit Ignition: After 20 sec. from
10 to 14 V
ignition “ON”
E01-71 — — — —
E01-72 — — — —
E01-73 — — — —
Ignition: Within 20 sec. after
10 to 14 V
Glow plug control module set ignition “ON”
E01-74 GRY/BLU
communication circuit Ignition: After 20 sec. from
0 to 1 V
ignition “ON”
Ignition: Within 20 sec. after
0 to 1 V set ignition “ON”
Engine: Idle speed after
E01-75 PPL/WHT Fuel pump relay drive circuit
warming up
Ignition: After 20 sec. from
10 to 14 V
ignition “ON”
E01-76 — — — —
E01-77 — — — —
E01-78 — — — —
Engine: Idle speed after
0 to 1 V warming up
A/C compressor relay drive A/C compressor: ON
E01-79 GRY
circuit Engine: Idle speed after
10 to 14 V warming up
A/C compressor: OFF
0 to 1 V Ignition: “ON”
E01-80 BRN/WHT Main relay drive circuit
10 to 14 V Ignition: “OFF”
 Engine General Information and Diagnosis: D13A 1A-278

Terminal No. Wire color Circuit Normal voltage Condition

Ignition: “ON”
0 to 1 V
Brake light switch signal Brake pedal: Not depressed
E01-81 GRN/WHT
circuit Ignition: “ON”
10 to 14 V
Brake pedal: Fully depressed
E01-82 — — — —
APP sensor (main) power
E01-83 BRN 4 to 6 V Ignition: “ON”
supply circuit
E01-84 — — — —
E01-85 — — — —
E01-86 — — — —
Engine: Idle speed after
warming up
A/C switch: OFF
Approx. 1.315 V
A/C refrigerant pressure: 850
kPa (8.7 kgf/cm2, 123 psi, 8.5
bar)
Engine: Idle speed after
warming up
A/C refrigerant pressure A/C switch: ON
E01-87 RED/GRN Approx. 1.940 V
sensor signal circuit A/C refrigerant pressure: 1300
kPa (13.3 kgf/cm2, 188 psi, 13
bar)
Engine: Idle speed after
warming up
A/C switch: ON
Approx. 2.35 V
A/C refrigerant pressure: 1600
kPa (16.3 kgf/cm2, 232 psi, 16
bar)
E01-88 — — — —
Refer to reference waveform.
E01-89 PPL VSS signal circuit
“VSS signal”: D13A (Page 1A-283)
Ignition: After 5 sec. from
10 to 14 V
Fuel filter water detection ignition “ON”
E01-90 YEL/RED
sensor signal circuit Ignition: After 2 sec. from
0 to 1 V
ignition “OFF”
E01-91 — — — —
E01-92 — — — —
E01-93 — — — —
E01-94 — — — —

Reference Waveform

NOTE
• Display includes the following types of
data:

I8T401111066-01

[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel

[B]: Ground level of each channel [D]: TIME/DIV
1A-279 Engine General Information and Diagnosis: D13A

• Waveforms may vary with measurement

conditions and vehicle specifications.

Fuel injector signal

Fuel injector No.1 signal (high side) (1):

Channel Probe Terminal No.
+ C01-47
1
– E01-1

Fuel injector No.1 signal (low side) (2):

Channel Probe Terminal No.
+ C01-16
2
– E01-1
IAY40A110011-02
Fuel injector No.4 signal (high side) (3):
Channel Probe Terminal No. 5. Signal is outputted, but fuel is not injected. 7. Crankshaft angle at 360°
6. Fuel is injected.
+ C01-46
3
– E01-1

Fuel injector No.4 signal (low side) (4):

Channel Probe Terminal No.
+ C01-1
4
– E01-1

Fuel injector No.2 signal (high side) (1):

Channel Probe Terminal No.
+ C01-49
1
– E01-1

Fuel injector No.2 signal (low side) (2):

Channel Probe Terminal No.
+ C01-17
2
– E01-1
IAY40A110019-01

5. Signal is outputted, but fuel is not injected. 6. Fuel is injected.

Fuel injector No.3 signal (high side) (3):
Channel Probe Terminal No.
+ C01-48 Fuel flow actuator signal
3
– E01-1
Fuel flow actuator signal (1):
Fuel injector No.3 signal (low side) (4): Channel Probe Terminal No.
Channel Probe Terminal No. + C01-20
1
+ C01-31 – E01-1
4
– E01-1
Measurement condition
Measurement condition Ignition: “ON”
Engine: Idle speed after warming up
 Engine General Information and Diagnosis: D13A 1A-280

I7N20A112003-02

Measurement condition
• Engine: Running after warming up
• EGR valve duty: 2.0%

IAY40A110034-01

Measurement condition
Engine: Idle speed after warming up

I7N20A112004-02

Boost pressure control solenoid valve signal

Boost pressure control solenoid valve signal (1):

Channel Probe Terminal No.
+ C01-30
1
– E01-1

Measurement condition
Ignition: “ON”

IAY40A110035-01

EGR valve signal

EGR valve signal (1):

Channel Probe Terminal No.
+ C01-15
1
– E01-1

Measurement condition
• Engine: Running after warming up
EGR valve duty: 50%
1A-281 Engine General Information and Diagnosis: D13A

CKP sensor signal (–) (3):

Channel Probe Terminal No.
+ C01-59
3
– E01-1

Measurement condition
• Engine: Idle speed after warming up

IAY40A110036-01

I9P60A112043-01
Measurement condition
Engine: Idle speed after warming up

I9P60A112044-01

4. Camshaft 360° angle 5. Crankshaft 360° angle

A/F sensor heater relay drive signal

A/F sensor heater relay drive signal:

Channel Probe Terminal No.
IAY40A110037-01 + E01-12
1
– E01-1
CMP sensor signal and CKP sensor signal
Measurement condition
CMP sensor signal (1): Engine: Idle speed after warming up
Channel Probe Terminal No.
+ C01-56
1
– E01-1

CKP sensor signal (+) (2):

Channel Probe Terminal No.
+ C01-43
2
– E01-1
 Engine General Information and Diagnosis: D13A 1A-282

I7N20A112012-02
I7V10A112001-01

IAT-1 sensor signal

CAN communication signal
IAT-1 sensor signal:
CAN (high) communication (1):
Channel Probe Terminal No.
Channel Probe Terminal No.
+ E01-62
+ E01-40 1
1 – E01-1
– E01-1
Measurement condition
CAN (low) communication (2):
Engine: Idle speed after warming up
Channel Probe Terminal No.
+ E01-64
2
– E01-1

Measurement condition
Engine: Idle speed after warming up

I7N20A112013-02

Serial communication signal

Serial communication signal:

Channel Probe Terminal No.
I7N20A112011-03
+ E01-66
1
– E01-1
MAF sensor signal
Measurement condition
MAF sensor signal:
Ignition: “ON”
Channel Probe Terminal No.
+ E01-56
1
– E01-1

Measurement condition
Engine: Idle speed after warming up
1A-283 Engine General Information and Diagnosis: D13A

Measurement condition
Vehicle: Running at 40 km/h (25 mile/h)

I7N20A112014-02

VSS signal
IBP80A112067-01
VSS signal:
Channel Probe Terminal No.
+ E01-89
1
– E01-1

Repair Instructions
Idle Speed Inspection Special tool
AENBL80A1126001 : SUZUKI scan tool (SUZUKI-SDT)
1) Shift transaxle into neutral.
Engine idle speed
2) Start engine and warm it up to normal operating
: Approx. 800 rpm
temperature.
3) Turn all electrical loads off. 5) If engine idle speeds are not as specified, go to
“Improper Engine Idling or Engine Stops at Idle”
4) Using SUZUKI scan tool, verify that idle speed is
under “Engine Symptom Diagnosis”: D13A (Page
within specification.
1A-150).

Special Tools and Equipment

Special Tool
AENBL80A1128001
SUZUKI scan tool (SUZUKI- 6
SDT)
— 1 2
This kit includes following
4
items. 1. SUZUKI-SDT 2. 3
DLC cable 3. USB cable 4. 5
AC/DC power supply 5.
Voltage meter probe 6.
Storage case) / )
 Aux. Emission Control Devices: K14B 1B-1

Aux. Emission Control Devices

Engine

K14B
Diagnostic Information and Procedures
EVAP Canister Purge System Inspection a. Connect service wire (2) between EVAP
AENBL80A1214001 canister purge valve and EVAP canister purge
! WARNING valve connector with ignition “OFF”.
Do not use your mouth to apply vacuum to b. Set ignition “ON”.
EVAP canister purge valve. Fuel vapor is NOTE
harmful.
EVAP canister purge valve (1) is operated
using service wire as follows.
! CAUTION
• EVAP canister purge valve is off:
Do not apply vacuum more than –66 kPa Disconnect “BLU/BLK” harness side of
(–0.67 kgf/cm2, –9.57 psi, –0.66 bar); EVAP canister purge valve and ground [a]
otherwise EVAP canister purge valve could
• EVAP canister purge valve is on:
be damaged.
Connect “BLU/BLK” harness side of EVAP
canister purge valve and ground [b]
1) Prepare to operate EVAP canister purge valve as
follows.
• Using SUZUKI scan tool:
[a]
a. Connect SUZUKI scan tool to DLC (1) with
ignition “OFF”.
[b]
b. Set ignition “ON”, clear DTC and select
“Engine / Active Test” mode on SUZUKI scan
tool.
Special tool 2

(A): SUZUKI scan tool (SUZUKI-SDT) 1

NOTE
IBP80A121004-01
EVAP canister purge valve is operated using
2) Disconnect vacuum hose (2) from intake manifold
scan tool as follows.
and purge hose from EVAP canister purge valve (1).
• EVAP canister purge valve is off: 0%
3) Install special tool to vacuum hose.
• EVAP canister purge valve is on: 100%
Special tool
(A): 09917M47011
4) Check EVAP canister purge valve operation as
follows.
a) Check that vacuum of –60 kPa (–0.6 kgf/cm2,
–8.7 psi, –0.6 bar) can be applied when EVAP
canister purge valve is turned off [A].
b) Check that no vacuum can be applied when
(A)
EVAP canister purge valve is turned on [B].
5) If faulty condition is found, check the following
1 points.
• Wire harness and connections
• EVAP canister purge valve: )(Page 1B-2)
• Vacuum hoses: )(Page 1B-4)

IBP80A121001-01

• Using service wire:

1B-2 Aux. Emission Control Devices: K14B

[A] [B]
1 1

(A) (A)

2 2

I9P60A121004-01

Repair Instructions
EVAP System Components
AENBL80A1216001

7
6

IBL80A121002-01

1. EVAP canister purge valve 4. To intake manifold 7. Vacuum hose

2. EVAP canister 5. To fuel tank 8. Purge hose
3. EVAP canister bracket 6. EVAP canister purge valve chamber

EVAP Canister Purge Valve Inspection
AENBL80A1216002
! WARNING
Do not use your mouth to apply vacuum to
EVAP canister purge valve. Fuel vapor is
harmful.
! CAUTION
Do not apply vacuum more than –66 kPa
(–0.67 kgf/cm2, –9.57 psi, –0.66 bar);
otherwise EVAP canister purge valve could
be damaged.
1) With ignition “OFF”, disconnect connector and hoses
from EVAP canister purge valve (1).
2) Remove purge valve from air cleaner assembly.
3) Check resistance between two terminals of purge
valve.
If faulty condition is found, replace EVAP canister
purge valve.
EVAP canister purge valve resistance
30 to 34 Ω at 20 °C (68 °F)
 Aux. Emission Control Devices: K14B 1B-3

3) Check that there is no restriction of flow through

purge pipe (1) and air pipe (2) when air is blown (4)
into tank pipe (3).
If faulty condition is found, replace EVAP canister.

4
3
1 1 2
IBP80A121005-01

4) Check EVAP canister purge valve operation as

follows.
If faulty condition is found, replace EVAP canister
purge valve.
a) Install special tool and vacuum hose (2) to purge
valve (1).
Special tool
(A): 09917M47011
b) With 12 V battery connected to purge valve
I9P60A121003-01
terminals, check that vacuum (–60 kPa, –0.6 kgf/
cm2, –8.7 psi, –0.6 bar) cannot be applied to 4) Check EVAP canister for air leaks according to the
purge valve. following procedure.
c) With no 12 V battery connected to purge valve a) Plug purge port (1) and air port (2) using rubber
terminals, check that vacuum (–60 kPa, –0.6 kgf/ plug (3).
cm2, –8.7 psi, –0.6 bar) can be applied to purge b) Install hose (4) and special tool to tank port (5).
valve.
Special tool
[A]
(A): 09917M47011
c) Using special tool, apply specified vacuum
pressure to EVAP canister for one minute.
If faulty condition is found, replace EVAP
canister.
2

(A)
EVAP canister holding vacuum pressure
1 19.6 kPa (0.2 kgf/cm2, 2.84 psi, 0.2 bar)

(A)
[B]
4

5
3

3 2
2

(A) 1
1

IBP80A121006-01

[A]: Purge valve ON [B]: Purge valve OFF

EVAP Canister Inspection

AENBL80A1216003
I9P60A121005-01
! WARNING
Do not suck nozzles on EVAP canister. Fuel
vapor inside EVAP canister is harmful.

1) Check outside of EVAP canister visually.

2) Disconnect hoses from EVAP canister.
1B-4 Aux. Emission Control Devices: K14B

EVAP Connection Hose Inspection 4) Stop engine and remove PCV valve (1).
AENBL80A1216004 Install clean hose to valve and check that there is air
Check hoses for connection, leakage, clogging and
flow when blowing air into hose from [a] to [b] and
deterioration.
that there is no air flow when blowing air into hose
Replace hose if defective.
from [b] to [a] as shown in figure.
If faulty condition is found, replace PCV valve.
PCV Hose Inspection
AENBL80A1216005
Check PCV hose for connection, leakage, clogging and
deterioration.
[b]
Replace hose if defective.

1 [a]
PCV Valve Inspection
AENBL80A1216006
1) Remove PCV valve from cylinder head cover and
close PCV valve hole with plug.
2) Run engine at idle.
3) Place your finger over end of PCV valve (1) to check
for vacuum. IBP80A121003-01

If no vacuum is felt, check valve for clogging. 5) Remove plug from PCV valve hole of cylinder head
Replace PCV valve if defective. cover.
6) Install PCV valve to cylinder head cover.
1

I7V20A121009-01

Special Tools and Equipment

Special Tool
AENBL80A1218001
09917M47011 SUZUKI scan tool (SUZUKI- 6
SDT)
Vacuum pump gauge — 1 2
)/)/) This kit includes following
4
items. 1. SUZUKI-SDT 2. 3
DLC cable 3. USB cable 4. 5
AC/DC power supply 5.
Voltage meter probe 6.
Storage case)
 Aux. Emission Control Devices: D13A 1B-5

D13A
Repair Instructions
EGR Valve and EGR Cooler Components
AENBL80A1226001

IBL80A122003-01

1. EGR valve 5. Clamp 9. To intake manifold : 1.2 N⋅m (0.1 kgf-m, 1.0 lbf-ft)
2. EGR cooler 6. Gasket 10. To thermostat : Do not reuse.
3. EGR cooler hose 7. EGR pipe clamp : 22 N⋅m (2.2 kgf-m, 16.5 lbf-ft)
4. EGR cooler pipe 8. To heater hose : 25 N⋅m (2.5 kgf-m, 18.5 lbf-ft)
1B-6 Aux. Emission Control Devices: D13A

EGR Valve and EGR Cooler Removal and

Installation 2
AENBL80A1226002

Removal
1) Remove battery from vehicle. )(Page 1J-25)
2) Drain cooling system. )(Page 1F-25)
3) Remove degassing tank (1).

IBL80A122004-01

1 Tightening torque
IBL80A122001-01
4) Remove battery tray from vehicle. )(Page 1J-25)
5) Remove heater outlet pipe. )(Page 1F-23)
6) Disconnect water hose (1) and heater hose (2).
7) Remove EGR pipe clamp (3).
8) Disconnect connector from EGR valve.
9) Remove EGR valve (4) and EGR cooler together
from cylinder head.
Installation
Reverse removal procedure noting the following points.
• Clean mating surface of EGR valve and cylinder
head.
• Use new gaskets.
• Tighten EGR cooler bolts to specified torque, if
removed.
EGR cooler bolt (b): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)
• Tighten EGR valve bolts and EGR pipe clamp bolt to
specified torque.
Tightening torque
EGR valve bolt (a): 22 N·m (2.2 kgf-m, 16.5 lbf-ft)
EGR pipe clamp bolt (c): 1.2 N·m (0.1 kgf-m, 1.0
lbf-ft)

(c)

(a)

(b)
1
2 IBL80A122005-01
IBL80A122002-01
• Refill cooling system with coolant. )(Page 1F-26)
10) Remove EGR cooler (1) from EGR valve (2), if • Check cooling system for leakage. )(Page 1F-24)
necessary.
 Aux. Emission Control Devices: D13A 1B-7

EGR Valve Inspection Cleaning Procedure for EGR Valve

AENBL80A1226003 AENBL80A1226006
! WARNING
EGR Valve Visual Check
Check EGR valve for damage on valve and valve seat. If When performing the following procedure,
faulty condition is found, replace EGR valve. gloves and safety glasses should be worn in
order to prevent any possible irritation of
EGR Valve Operation Check skin or eyes.
1) Connect battery positive terminal to “Power supply”
terminal (2) and negative terminal to “Ground” 1) Remove EGR valve assembly referring to “EGR
terminal (3) of EGR valve (4). Valve and EGR Cooler Removal and Installation”:
D13A in Section 1D (Page 1D-82)
2) Check valve (1) operation as shown in figure. If it is
not operated, replace EGR valve. 2) Remove EGR valve assembly referring to“EGR
Valve and EGR Cooler Components”: D13A in
Section 1D (Page 1D-82)
3 2
3) Remove EGR solenoid(1) from EGR valve
housing(2).

4
! CAUTION
Be sure to keep EGR solenoid (1) away from
cleaning area so as to prevent it from
corrosion caused by diesel fuel and any
damage.
1

I7V20A122002-01

EGR Valve Motor Resistance Check

Check resistance between terminals of EGR valve.
If resistance is not as specified, replace EGR valve.
EGR valve resistance
7.5 to 8.5 Ω at 20 °C (68 °F)
IAY40A120001-01
4) Clean EGR valve housing (EGR cooler side) as
follows.
a) Place EGR valve housing on a tray (1) so that
EGR cooler side (2) is facing up.
b) Fill up diesel fuel (3) into EGR valve housing
(EGR cooler side). and leave it for 30 min.

3
2

IAY40A120002-01

IBL80A122006-01
1B-8 Aux. Emission Control Devices: D13A

c) Clean deposited soot from side wall and valve

plate of EGR valve housing (shaded area in 2
figure below) by using fine grain water proof
abrasive paper (1) which is wet with diesel fuel.

! CAUTION 3

Use care not to damage edges of valve plate

(2) and valve stem (3)

IAY40A120005-01

6) Drain diesel fuel from EGR valve housing and dry it

as follows.

! CAUTION

• Use care not to drop EGR valve housing

IAY40A120003-01 when shaking.
• Use care not to damage edges of valve
d) Pour fresh diesel fuel into EGR valve housing plate and stem when cleaning.
(EGR cooler side) and rinse to clean lose
deposited soot remaining in it. a) Shake EGR valve housing while pushing valve
5) Clean EGR valve housing (inside) as follows. stem from EGR solenoid side by hand so as to
drain diesel fuel remaining.
a) While pouring diesel fuel (3) from EGR cooler
side (2), move valve plate up and down 50 times b) Using a clean cloth, wipe off any diesel fuel from
by pushing valve stem (1) by hand from EGR EGR valve housing.
solenoid side so as to flush internal carbon. c) Dry EGR valve housing completely.
7) Install EGR solenoid (1) with new gasket to EGR
valve housing (2).
8) Tighten EGR solenoid valve bolts to specified
3 torque.
2 Tightening torque
EGR valve solenoid bolt (a): 6.5 N·m (0.65 kgf-
m, 4.5 lbf-ft)

IAY40A120004-01

b) While pouring diesel fuel EGR cooler side, rotate

valve stem (1) 3 revolutions by hand from EGR
solenoid side so as to clean EGR valve plate (2)
and valve seat (3) IAY40A120006-01

9) Install EGR cooler to EGR valve referring to“EGR

Valve and EGR Cooler Removal and Installation”:
D13A in Section 1D (Page 1D-82)
 Aux. Emission Control Devices: D13A 1B-9

10) Install EGR valve assembly referring to“EGR Valve
and EGR Cooler Components”: D13A in Section 1D
(Page 1D-82)
A/F Sensor On-Vehicle Inspection
AENBL80A1226004
A/F Sensor Heater
1) Disconnect negative (–) cable at battery.
2) Disconnect A/F sensor connector.
3) Using ohmmeter, measure resistance between
terminals “Heater +” and “Heater –” at sensor
connector (1).
If resistance is not as specified, replace A/F sensor.
)(Page 1B-9)
2) Remove intercooler inlet No.1 hose (6).
3) Detach connector (1) of A/F sensor from its bracket
(2).
4) Disconnect connector from A/F sensor as follows.
a) Move connector lock pin (3) in arrow direction as
shown in figure.
b) Push connector lock lever (4) and disconnect
connector from A/F sensor (5).
5) Remove A/F sensor.
2 1

NOTE 6
Ambient temperature of sensor affects
resistance largely. Check that sensor heater
is at reference temperature. 5

A/F sensor heater resistance 3

4
2.0 to 4.5 Ω at 25 °C (77 °F)

IBL80A122007-01

Installation
Reverse removal procedure noting the following points.
• Visually check gasket (1) and thread. If faulty
condition is found, replace A/F sensor.
I9P60A122014-01

A/F Sensor Removal and Installation

AENBL80A1226005

! WARNING
Touching a hot exhaust system component
will cause a burn.
Do not perform any service work on the
exhaust system until the exhaust system is
cool. I7V20A122014-01

• Tighten A/F sensor to specified torque.

NOTE
If A/F sensor is replaced, be sure to initialize
A/F sensor data in ECM.
For details, refer to “Description of ECM
Registration”: D13A in Section 1C (Page 1C-
14).
Tightening torque
A/F sensor: 45 N·m (4.6 kgf-m, 33.5 lbf-ft)
• When replacing A/F sensor, initialize A/F sensor data
in ECM. “A/F Sensor Data Initialization”: D13A in
Section 1C (Page 1C-17)

Removal
1) Disconnect negative (–) cable at battery.

Specifications
Tightening Torque Specifications
AENBL80A1227001
1B-10 Aux. Emission Control Devices: D13A

Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
EGR cooler bolt 25 2.5 18.5 )
EGR valve bolt 22 2.2 16.5 )
EGR pipe clamp bolt 1.2 0.1 1.0 )
EGR valve solenoid bolt 6.5 0.65 4.5 )
A/F sensor 45 4.6 33.5 )

NOTE
The tightening torque(s) also specified in:
“EGR Valve and EGR Cooler Components”: D13A

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
 Engine Electrical Devices: K14B 1C-1

Engine Electrical Devices

Engine

K14B
Repair Instructions
ECM Removal and Installation Installation
AENBL80A1316001 Reverse removal procedure noting the following points.
! CAUTION • Tighten ECM mounting nuts to specified torque.
• As ECM consists of precision parts, be Tightening torque
careful not to expose it to excessive ECM mounting nut (a): 5.5 N·m (0.56 kgf-m, 4.0
shock. lbf-ft)
• Before replacing ECM, check the following
conditions. Neglecting this check may (a)

cause damage to ECM.

– Resistance values of all relays and
actuators are as specified respectively.
– APP sensor, TP sensor, A/C refrigerant
pressure sensor and MAP sensor are in
good condition and none of power
circuits of these sensors are shorted to
ground. (a)
IBP80A131002-01

NOTE • Connect connectors to ECM as follows:

After ECM is replaced with new one, perform a. Check that lock lever of ECM connectors is in
“Procedure after ECM Replacement”: K14B unlock position.
(Page 1C-2).

Removal
1) Disconnect negative (–) cable at battery.
2) Turn lock lever (1) in direction of arrow until it stops.
Then, disconnect connectors from ECM.

1 I7Y50A130004-01
1
b. Insert ECM connectors to ECM until they stop with
lock lever in unlocked position.

I7Y50A130001-01

3) Remove ECM (1) from its bracket by removing

mounting nuts (2).

2
I7Y50A130005-01

c. Pull lock lever down to lock ECM connectors

securely.

2
IBP80A131001-01

I7Y50A130006-01
1C-2 Engine Electrical Devices: K14B

Procedure after ECM Replacement
AENBL80A1316002
NOTE
When ECM and BCM are replaced with new
ones at the same time, perform “Immobilizer
Key Registration” instead of “ECM
Registration” using SUZUKI scan tool and
immobilizer cable. Refer to “SUZUKI SDT
Immobilizer Control System Operator's
Manual” for the immobilizer registration.
After ECM is replaced with new one, perform the
following procedure:
1) Perform “ECM Registration”. )(Page 10C-14)
2) Perform electric throttle control system calibration.
)(Page 1C-4)
3) Check that there is no foreign materials caught
between throttle valve and throttle body housing. If
foreign materials are present, remove throttle body
and clean its inside thoroughly. )(Page 1D-6)
Throttle Valve Operation Check
1) Set ignition “OFF”.
2) Remove air cleaner assembly and air cleaner outlet
hose. )(Page 1D-5)
3) Check throttle valve operation as follows.
If faulty condition is found, replace throttle body.
)(Page 1D-6)
a) Check that throttle valve (1) moves smoothly to
both fully closed position and fully open position
when pressed manually.

Electric Throttle Body Assembly On-Vehicle

Inspection
AENBL80A1316003
! WARNING
Never touch throttle valve with finger while
ignition is “ON” and accelerator pedal is
depressed. Otherwise, the finger may be
pinched between throttle valve and throttle
body housing. 1
I7N301132006-01

! CAUTION b) Check throttle valve returns to default position

when finger pressure on throttle valve is
• Do not disassemble electric throttle body released at both fully closed position and fully
assembly. open position.
• Do not drop or expose electric throttle
Throttle valve default position “a”:
body assembly to excessive shock.
7° from fully closed position (1)
Electric throttle body assembly exposed to
excessive shock should be replaced.
• Keep the throttle body housing and/or
throttle valve free of dust, metallic particles 1
or other foreign materials. Contamination
by these materials may cause throttle body
assembly to break down.
• Do not apply excessive forces to throttle “a”
valve when checking operation of throttle
valve or performance of TP sensor;
I7V20A131002-04
otherwise plastic gears in throttle valve
actuator will be damaged.
Electric Throttle Body System Operation Check
NOTE 1) Remove air cleaner assembly and air cleaner outlet
hose. )(Page 1D-5)
After replacing electric throttle body
2) Set ignition “ON”.
assembly, calibration of throttle valve
position is required. )(Page 1C-4) 3) Check electric throttle body system as follows.
If faulty condition is found, go to Step 4).
Throttle Valve Visual Check a) Depress accelerator pedal gradually and check
1) Set ignition “OFF”. that throttle valve moves smoothly until it opens
2) Remove air cleaner assembly and air cleaner outlet fully.
hose. )(Page 1D-5) b) Release accelerator pedal and check that
throttle valve moves back to applicable position.
 Engine Electrical Devices: K14B 1C-3

Throttle valve opening angle “a”:

3 to 15° from completely closed position (1) [A]

1 2 3 45 6

1
2

“a” 1

I7V20A131002-04 [B]
4) Check the following points. 1 2 3 45 6
If check results are satisfactory, replace electric
throttle body assembly.
• Wire harness and connections 2
• APP sensor:
Refer to “APP Sensor On-Vehicle Inspection”:
K14B (Page 1C-4)
1
• TP sensor:
I9P60A131020-01
Refer to “Throttle Position (TP) Sensor
[A]: TP sensor (main) [B]: TP sensor (sub)
Performance Check”: K14B (Page 1C-3).
• Throttle motor:
c) Check that voltage varies depending on throttle
Refer to “Throttle Motor Check”: K14B (Page 1C-
opening angle as following graph while throttle
3).
valve is opened and closed manually.
Throttle Motor Check
[c]
1) Set ignition “OFF”. 4.4 - 4.6 V 4.4 - 4.7 V
4.3 - 4.7 V
4.0 - 4.3 V [a]
2) Disconnect connector from electric throttle body
assembly.
3) Measure resistance between terminal “1” and [b]
terminal “2” of electric throttle body assembly. 0.7 - 1.0 V 0.3 - 0.7 V
If faulty condition is found, replace electric throttle 0.4 - 0.6 V 0.3 - 0.6 V
[d]
body assembly. )(Page 1D-6) [e]
[f]
Throttle motor resistance
[g]
0.3 to 100 Ω at 20 °C (68 °F) IBP80A131003-01

[a]: TP sensor (main) voltage

1 2 3 45 6 [b]: TP sensor (sub) voltage
[c]: TP sensor output voltage
[d]: Throttle valve opening
[e]: Position where throttle valve is open by 7° from fully closed position
(default position)
I7N301132008-02 [f]: Angle obtained when accelerator pedal is depressed fully (84°)
[g]: Angle obtained when throttle valve is fully opened manually (96°)
Throttle Position (TP) Sensor Performance Check
1) Set ignition “OFF”.
2) Disconnect connector from electric throttle body
assembly.
3) Check output voltage of TP sensor main and sub
signals as follows.
If faulty condition is found, replace electric throttle
body. )(Page 1D-6)
a) Arrange 3 new 1.5 V batteries (1) in series, and
check that total voltage is 4.5 to 5.0 V.
b) Connect voltmeter (2) and batteries to TP sensor
as shown in figure.
1C-4 Engine Electrical Devices: K14B
Electric Throttle Control System Calibration
AENBL80A1316004
NOTE
• If the service described under “Description
of Electric Throttle Control System
Calibration”: K14B in Section 1A (Page 1A-
5) is performed, calibrate electric throttle
control system as follows.
• Check that the following conditions are
satisfied when performing this procedure.
– Ambient temperature > 5 °C (41 °F)
– DTC is not detected.
– Accelerator pedal position: Idle position
– 5 °C (41 °F) < ECT < 100 °C (212 °F)
– Battery voltage > 10 V
1) Set ignition “ON” for 60 sec.
2) Set ignition “OFF”.
3) After completing this calibration, check that DTC is
not detected in ECM.
If DTC is detected, go to troubleshooting for
applicable DTC.
APP Sensor On-Vehicle Inspection
AENBL80A1316005
! CAUTION
• Do not drop or otherwise expose
accelerator pedal assembly (incorporating
APP sensor) to large shock. Any
accelerator pedal assembly that has
received large shock must be replaced.
• Keep APP sensor section of accelerator
pedal assembly free from water and oil.
• Do not disassemble accelerator pedal
assembly (incorporating APP sensor).
NOTE
After replacing accelerator pedal assembly
(incorporating APP sensor), calibrate throttle
valve position. )(Page 1C-4)
1) Check that accelerator pedal assembly
(incorporating APP sensor) has been mounted to
vehicle body properly (no pinched floor carpet, etc.).
If mounting is improper, reinstall accelerator pedal
assembly. )(Page 1C-4)
2) Connect scan tool to DLC with ignition “OFF”.
3) Set ignition “ON” and select “Data List” mode.
4) Check that voltage varies depending on accelerator
pedal position as shown in the following graph.
If faulty condition is found, check the following
points.
• Wire harness and connections
• APP sensor )(Page 1C-5)
[c]
3.7-4.4 V
[a]
1.8-2.2 V
[b]
0.6-0.9 V
0.2-0.5 V
[d] [e]
I9P60A131002-01
[a]: APP sensor (main) voltage
[b]: APP sensor (sub) voltage
[c]: Voltage
[d]: Idle position of accelerator pedal
[e]: Fully depressed position of accelerator pedal
Accelerator Pedal Assembly (Incorporating
APP Sensor) Removal and Installation
AENBL80A1316006
! CAUTION
• Do not drop or otherwise expose
accelerator pedal assembly (incorporating
APP sensor) to large shock. Any
accelerator pedal assembly that has
received large shock must be replaced.
• Keep APP sensor section of accelerator
pedal assembly free from water and oil.
• Do not disassemble accelerator pedal
assembly (incorporating APP sensor).
NOTE
After replacing accelerator pedal assembly
(incorporating APP sensor), calibrate throttle
valve position. )(Page 1C-4)
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect connector from accelerator pedal
assembly (incorporating APP sensor).
3) Remove accelerator pedal assembly from its
bracket.
Installation
Reverse removal procedure noting the following points.
• Tighten accelerator pedal assembly nut (1) and
accelerator pedal assembly bracket nut (2) to
specified torque.
Tightening torque
Accelerator pedal assembly nut (a): 5.5 N·m (0.56
kgf-m, 4.0 lbf-ft)
Accelerator pedal assembly bracket nut (b): 13
N·m (1.3 kgf-m, 9.5 lbf-ft)
 Engine Electrical Devices: K14B 1C-5

[c]

3.7-4.4 V

[a]

1.8-2.2 V

0.6-0.9 V [b]
0.2-0.5 V
[d] [e]
IBP80A131004-01 I9P60A131002-01

• Connect connector to APP sensor assembly securely. [a]: APP sensor (main) voltage
[b]: APP sensor (sub) voltage

APP Sensor Inspection [c]: Voltage

AENBL80A1316007 [d]: Accelerator pedal: Idle position
1) Remove APP sensor assembly. )(Page 1C-4) [e]: Accelerator pedal: Fully depressed position

2) Check APP sensor output voltage as follows.

If faulty condition is found, replace APP sensor ECT Sensor Removal and Installation
AENBL80A1316008
assembly. )(Page 1C-4) Removal
a) Arrange 3 new 1.5 V batteries (1) in series, and 1) Set ignition “OFF”.
check that total voltage is 4.5 to 5.0 V.
2) Drain coolant. )(Page 1F-11)
b) Connect voltmeter (2) and batteries to APP
3) Disconnect connector from ECT sensor.
sensor as shown in figure.
4) Remove ECT sensor (1) from thermostat case.
[A]
6 5 4 3 21

1
I7V20A131006-01

[B]
6 5 4 3 21
1
I8C50A130010-01

2 Installation
Reverse removal procedure noting the following points.
• Check O-ring for abnormality like damage,
deterioration, etc.
1
If any abnormality is found, replace ECT sensor.
I7V20A131007-01 • Tighten ECT sensor (1) to specified torque.
[A]: APP sensor (main) [B]: APP sensor (sub)
Tightening torque
ECT sensor (a): 12 N·m (1.2 kgf-m, 9.0 lbf-ft)
c) Check that voltage varies depending on
accelerator pedal position as the following graph.
1C-6 Engine Electrical Devices: K14B

[a]

(5.74)

2.29 - 2.62

(1.16)
(0.59)
0.31 - 0.33
20 40 60 80 [b]
1, (a)
I9P60A131005-04
I8C50A130011-01

• Connect connector to ECT sensor securely. [a]: Resistance [b]: Temperature

• Refill cooling system. )(Page 1F-11)

HO2S-1 and HO2S-2 On-Vehicle Inspection
• Check for coolant leakage. )(Page 1F-11) AENBL80A1316010
HO2S Heater
ECT Sensor Inspection 1) Disconnect connectors, black for HO2S-1 and gray
AENBL80A1316009
for HO2S-2, from HO2S-1 and HO2S-2 respectively
! CAUTION with ignition “OFF”.
2) Using ohmmeter, measure resistance of HO2S
There is a possibility of causing short circuit,
connector (sensor side) of sensor heater between
corrosion and loose connection of terminal
terminals “3” and “4” at sensor connector.
when wet terminal is connected.
If faulty condition is found, replace oxygen sensor.
)(Page 1C-6)
NOTE
Do not measure resistance with terminal of NOTE
the ECT sensor soaked in water. As for the Temperature of sensor affects resistance
measurement in the soaked state, an value largely. Make sure that sensor heater is
accurate measurement cannot be done. at correct temperature.

Check resistance between terminal “1” and terminal “2” HO2S heater resistance
varies depending on engine coolant temperature as 6.0 to 12.0 Ω at 20 °C (68 °F)
shown in the following graph.
If faulty condition is found, replace ECT sensor (1). 1
)(Page 1C-5)

3 2

I7V20A131012-01

1. HO2S connector (viewed from terminal side)

HO2S-1 and HO2S-2 Removal and Installation

AENBL80A1316011

1 1 2 Removal

4 ! WARNING

IBP80A131005-01 To avoid danger of being burned, do not

2. Ohmmeter 3. Temperature gauge 4. Heater touch exhaust system when system is hot.
HO2S-1 and/or HO2S-2 removal should be
performed when system is cool.

1) Set ignition “OFF”.

2) Disconnect connector of HO2S-1 and/or HO2S-2.
3) Remove HO2S-1 (1) and/or HO2S-2 (2) from
exhaust manifold.
 Engine Electrical Devices: K14B 1C-7

Installation
Reverse removal procedure noting the following points.
• Tighten HO2S-1 (1) to specified torque.
Tightening torque
HO2S-1 (a): 45 N·m (4.5 kgf-m, 33.5 lbf-ft)
• Tighten HO2S-2 (2) to specified torque.
Tightening torque
HO2S-2 (b): 45 N·m (4.5 kgf-m, 33.5 lbf-ft)
1

1, (a)

IAP70B130001-02

Installation
Reverse removal procedure noting the following points.
• Apply engine oil to O-ring of sensor.
• Tighten CMP sensor bolt to specified torque.
2, (b)
NOTE
Be sure to use new bolt with pre-coated
adhesive. Otherwise, bolt may loosen.

IBL80A131002-01 Tightening torque

• After installation, check for exhaust gas leakage from CMP sensor bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
sensor with engine running.

CMP Sensor On-Vehicle Inspection

AENBL80A1316012
1) With ignition “OFF”, disconnect CMP sensor
connector.
2) Connect service wires (1) between CMP sensor and
CMP sensor connector as shown in figure.
3) Set ignition “ON” and check that output voltage
alternates between approx. 0 V and 5 V while turning (a)
crankshaft.

1 2 3 IAP70B130002-02

CMP Sensor Inspection

AENBL80A1316014
1) Remove CMP sensor. )(Page 1C-7)
2) Check the following points.
1
IBL80A131003-01 If faulty condition is found, replace CMP sensor.
)(Page 1C-7)
CMP Sensor Removal and Installation • Check that O-ring (1) is free from damage.
AENBL80A1316013
• Check that end face of sensor and signal rotor
Removal tooth are free from any metal particles and
damage.
1) Set ignition “OFF”.
2) Disconnect connector from CMP sensor (1).
3) Remove CMP sensor (1) from cylinder head.

1
I7N301132017-01
1C-8 Engine Electrical Devices: K14B

• Check CMP sensor as follows. Tightening torque

a) Connect battery (1) and ohmmeter (3) to CMP CKP sensor bolt: 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
sensor as shown in figure.
b) Check that CMP sensor resistance varies as
specified below by passing ferromagnetic
material (iron) (2) in front of CMP sensor.

NOTE (a)

Be sure to keep approximately 1 mm (0.03 in)

gap “a” between ferromagnetic material
(iron) and end face of CMP sensor.

CMP sensor resistance

Resistance alternates between 220 Ω or smaller
(ON) and infinity (OFF)
I9P60A131008-01

• Connect connector and fix wire harness with clamp

“a”
1 2 3 securely.

3 CKP Sensor Inspection

AENBL80A1316016
1) Remove CKP sensor. )(Page 1C-8)
2) Check the following points.
2 If faulty condition is found, replace CKP sensor.
1 )(Page 1C-8)
I7V20A131028-02 • Check that O-ring (1) is free from damage.
• Check that end face of sensor and sensor plate
CKP Sensor Removal and Installation tooth are free from any metal particles and
AENBL80A1316015
damage.
Removal
1) Set ignition “OFF”. 1
2) Remove generator. )(Page 1J-12)
3) Disconnect connector from CKP sensor.
4) Remove CKP sensor (1) from cylinder block.
I7N301132020-01

• Check CKP sensor as follows.

a) Connect battery (1) and ohmmeter (3) to CKP
sensor as shown in figure.
1
b) Check that CKP sensor resistance varies as
specified below by passing ferromagnetic
material (iron) (2).

NOTE
Be sure to keep approximately 1 mm (0.03 in)
gap “a” between ferromagnetic material
(iron) and respect to end face of CKP sensor.
I9P60A131017-01

CKP sensor resistance

Installation Resistance alternates between 220 Ω or smaller
Reverse removal procedure noting the following points. (ON) and infinity (OFF)
• Apply engine oil to O-ring of sensor.
• Tighten CKP sensor bolt to specified torque.

! CAUTION
Be sure to use new bolt with pre-coated
adhesive. Otherwise, bolt may loosen.
 Engine Electrical Devices: K14B 1C-9

“a”
1 2 3

2
1

I7V20A131027-04

Knock Sensor On-Vehicle Inspection

AENBL80A1316017 IAP70B130003-02
1) Hoist vehicle.
2) Disconnect connector (2) from knock sensor. Installation
Reverse removal procedure noting the following point.
3) Connect oscilloscope (1) as shown in figure.
• Tighten knock sensor bolt (1) to specified torque.
4) Check that oscilloscope displays waveform like a
one shown below when cylinder block is given a Tightening torque
shock by plastic hammer. Knock sensor bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)
If faulty condition is found, replace knock sensor.
)(Page 1C-9)
1,(a)

1 2

“a”

1
I7V20A131018-01

IAP70B130004-02

“a”: 0 – 45°

Engine and Emission Control System Relay

Inspection
AENBL80A1316019
Refer to “Control Relay Inspection” in Section 10B (Page
10B-30).

MAP Sensor Removal and Installation

AENBL80A1316020
Removal
1) Set ignition “OFF”.
I9P60A131019-02
2) Disconnect connector from MAP sensor.
Knock Sensor Removal and Installation 3) Remove MAP sensor (1) from intake manifold (2).
AENBL80A1316018

Removal
1) Set ignition “OFF”.
2) Remove intake manifold. )(Page 1D-7)
3) Disconnect knock sensor connector.
4) Remove knock sensor (1) from cylinder block.
1C-10 Engine Electrical Devices: K14B

NOTE
Environmental condition affects output
voltage largely.
The sensor voltage below is reference value
when measuring under the following
conditions.
2
• Power supply voltage: 5 V
1
• Ambient temperature: 20 °C (68 °F)
• Atmospheric pressure: 101.3 kPa (1.01 kgf/
cm2, 14.7 psi, 1.01 bar)

MAP sensor reference voltage

IBP80A131006-01 Atmospheric pressure: Approx. 4.10 V
Negative pressure –30 kPa (–0.3 kgf/cm2, –4.35 psi,
Installation –0.3 bar): Approx. 2.86 V
Reverse removal procedure noting the following points. Negative pressure –60 kPa (–0.6 kgf/cm2, –8.70 psi,
• Check that O-ring is free from damage. –0.6 bar): Approx. 1.67 V
• Connect MAP sensor connector securely.
IAT Sensor Removal and Installation
AENBL80A1316022
MAP Sensor Inspection
AENBL80A1316021
! CAUTION
! CAUTION
Do not drop or expose IAT sensor to any
Do not apply vacuum more than –60 kPa shock. Any sensor that has been dropped
(–0.6 kgf/cm2, –8.7 psi, –0.6 bar), otherwise must be replaced.
MAP sensor could be damaged.
Removal
1) Remove MAP sensor. )(Page 1C-9)
1) Set ignition “OFF”.
2) Check MAP sensor output voltage as follows. If
faulty condition is found, replace MAP sensor. 2) Disconnect IAT sensor connector.
)(Page 1C-9) 3) Remove IAT sensor (1) from air cleaner outlet hose
a) Arrange 3 new 1.5 V batteries (1) in series, and (2).
check that total voltage is 4.5 – 5.0 V.
b) Connect voltmeter (2), special tool and batteries
to MAP sensor as shown in figure.
Special tool
(A): 09917M47011 1 2

(A)

1 2 3

IBP80A131007-01
2

1
I7N301132015-01
c) Check that voltage drops gradually when
vacuum is gradually applied with special tool.
Installation
Reverse removal procedure noting the following points.
• Clean matching surface of IAT sensor and air cleaner
outlet hose.
• Connect IAT sensor connector securely.
 Engine Electrical Devices: K14B 1C-11

IAT Sensor Inspection

AENBL80A1316023

! CAUTION
When servicing IAT sensor, be sure to
observe the following precautions.
• Do not drop or expose IAT sensor to any
shock. The sensor that has been dropped
must be replaced.
• Do not heat IAT sensor to temperature
higher than 100 °C (212 °F). IAT sensor will
be damaged if heated to higher 1

temperatures.
I9T401132006-02
1) Remove IAT sensor. )(Page 1C-10) – Connect battery to OCV connector (1) as shown in
2) Check that resistance between sensor terminals figure, and check that operating sound caused by
varies depending on temperature while blowing hot moment of spool valve (2).
air to IAT sensor (1) using hair drier (2).
If faulty condition is found, replace IAT sensor.
)(Page 1C-10)

3
2

1
1

2
[a] I9T401132007-02

VSS Removal and Installation

AENBL80A1316025
Removal
1) Set ignition “OFF”.
2) Remove air cleaner outlet hose.
3) Disconnect VSS connector (1).
4) Remove VSS.

[b]

IBP80A131008-01

[a]: Resistance 3. Temperature gauge

[b]: Temperature 1

OCV Inspection
AENBL80A1316024
• Remove OCV. )(Page 1D-29)
• Check OCV as follows.
– Check resistance between terminals of OCV
connector (1).
If check result is not satisfactory, replace OCV.
IBL80A131004-01
OCV resistance
6.7 to 7.7 Ω at 20 ° C (68 °F) Installation
Reverse removal procedure noting the following points.
1C-12 Engine Electrical Devices: K14B

• Apply transaxle oil to VSS O-ring.

• Tighten VSS bolt to specified torque.
Tightening torque
VSS bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

I4RS0B130018-02

• Check VSS as follows.

a) Connect battery (1) and ohmmeter to VSS as
shown in figure.
b) Check that VSS resistance varies as specified
I8C50A130018-01
below by passing ferromagnetic material (iron)
• Connect VSS connector securely. (2) in front of VSS.

VSS Inspection NOTE

AENBL80A1316026
Be sure to keep approximately 1 mm (0.03 in)
1) Remove VSS. )(Page 1C-11) gap “a” between ferromagnetic material
2) Check the following points. (iron) and end face of VSS.
If faulty condition is found, replace VSS. )(Page 1C-
11) VSS resistance
• Check that O-ring is free from damage. Resistance alternates between less than 100 Ω (ON)
and infinity (OFF)
• Check that end face of sensor and signal rotor
tooth are free from any metal particles and
damage.
1 2 3

2 1

IBP80A131010-01

Specifications
Tightening Torque Specifications
AENBL80A1317001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
ECM mounting nut 5.5 0.56 4.0 )
Accelerator pedal assembly nut 5.5 0.56 4.0 )
Accelerator pedal assembly bracket nut 13 1.3 9.5 )
ECT sensor 12 1.2 9.0 )
HO2S-1 45 4.5 33.5 )
HO2S-2 45 4.5 33.5 )
CMP sensor bolt 11 1.1 8.5 )
CKP sensor bolt 11 1.1 8.5 )
Knock sensor bolt 25 2.5 18.5 )
VSS bolt 10 1.0 7.5 )

Reference:
 Engine Electrical Devices: K14B 1C-13

For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Special Tool
AENBL80A1318001
09917M47011
Vacuum pump gauge
)
1C-14 Engine Electrical Devices: D13A

D13A
General Description
Description of ECM Registration
AENBL80A1321001
The following vehicle information are registered in ECM.
• Injector calibration code
• Vehicle variant data (A/C, ABS)
• Flywheel data
• A/F sensor data
• MAF sensor data
• Fuel pressure sensor data
• Immobilizer ID code
If any one of the following parts is replaced, register / initialize the necessary information in ECM as table below.
Part Registered / initialized data Reference
• Injector calibration code
• Vehicle variant data
• Flywheel data
Go to “Registration for ECM
ECM • A/F sensor data
Replacement”: D13A (Page 1C-15).
• MAF sensor data
• Fuel pressure sensor data
• Immobilizer ID code
Go to “Fuel Injector Registration”:
Fuel injector(s) Injector calibration code
D13A (Page 1C-16).
Go to “Flywheel Data Initialization”:
Flywheel Flywheel data
D13A (Page 1C-16).
Go to “A/F Sensor Data Initialization”:
A/F sensor A/F sensor data
D13A (Page 1C-17).
Go to “MAF Sensor Data
MAF sensor MAF sensor data
Initialization”: D13A (Page 1C-17).
• Common rail Go to “Fuel Pressure Sensor
Fuel pressure sensor data
• Rail pressure sensor Initialization”: D13A (Page 1C-17).
Go to “ECM Registration” in Section
BCM Immobilizer ID code
10C (Page 10C-14).

Repair Instructions
ECM Removal and Installation a) Pull out lock slider (1) to release locking of lock
AENBL80A1326001 lever.
! CAUTION b) Pull up the lock lever (2).
The ECM is a precision unit and can be easily
damaged. 2
Handle the ECM carefully and do not expose
it to a large shock.

Removal
1) In case of replacement with new ECM, perform
“Procedure for Vehicle Information Upload and
Download” under “Registration for ECM
Replacement”: D13A (Page 1C-15). 1
I9P60A132001-02
2) Disconnect negative (–) cable at battery.
4) Remove cowl top garnish. )(Page 9H-3)
3) Disconnect connectors from ECM as follows.
 Engine Electrical Devices: D13A 1C-15

5) Turn over dash outer silencer after removing clips • Tighten ECM box bolts and nuts to specified torque in
(1). numerical order (“1” – “6”).
6) Detach harness clamps (2) from cowl top upper Tightening torque
panel. ECM box bolt* (a): 5.1 N·m (0.52 kgf-m, 4.0 lbf-ft)
7) Remove ECM with ECM box. ECM box nut* (b): 5.7 N·m (0.58 kgf-m, 4.5 lbf-ft)

(a), “1”
(a), “2”

(b), “5” (b), “6”

(a), “3”
(a), “4”
IBL80A132002-02

• In case of replacement with new ECM, register

2 vehicle information in ECM. )(Page 1C-15)
IBL80A132001-01

8) Remove ECM (1) with ECM brackets (2) from ECM Registration for ECM Replacement
box (3). AENBL80A1326002
NOTE
9) Remove ECM brackets from ECM.
• For details of SUZUKI scan tool, refer to its
operator’s manual.
3
• If the injector codes cannot be uploaded
from ECM to be replaced by using SUZUKI
scan tool, input the injector codes to
replaced new ECM manually. Refer to
“Procedure for Vehicle Information Manual
Input”.
• When ECM and BCM are replaced with new
1 ones at the same time, perform
“Immobilizer Key Registration” instead of
“ECM Registration” using SUZUKI scan
2
IBP80A132007-01 tool and immobilizer cable. Refer to
“SUZUKI SDT Immobilizer Control System
Installation Operator’s Manual” for the immobilizer
Reverse removal procedure noting the following points. registration.
• Tighten each bolt and nut to specified torque.
Procedure for Vehicle Information Upload and
Tightening torque Download
ECM nut (a): 5.7 N·m (0.58 kgf-m, 4.5 lbf-ft) 1) When ignition is “OFF”, connect SUZUKI scan tool to
ECM bracket bolt (b): 8.8 N·m (0.90 kgf-m, 6.5 lbf- DLC.
ft)
Special tool
: SUZUKI scan tool (SUZUKI-SDT)
(b) 2) Set ignition “ON”.
(a)
3) Select “Engine / Powertrain” menu.
4) Select the following items.
Area: Other than North America
(b) Model: ERTIGA
5) Select “ECM Replacement” under “Misc Test” menu.

IBP80A132006-01
1C-16 Engine Electrical Devices: D13A
6) Select “Upload Inj Code from ECU” under “Vehicle
Information Copy” and according to instructions
displayed on SUZUKI scan tool. If injector codes
cannot be uploaded from ECM, input the injector
codes to ECM manually. )(Page 1C-16)
7) Set ignition “OFF”, and then replace ECM with new
one, referring to Steps 2 to 9 in “Removal” and
“Installation” under “ECM Removal and Installation”:
D13A (Page 1C-14).
8) Set ignition “ON”.
9) Select “Engine / Powertrain” menu.
10) Select the following items.
Area: Other than North America
Model: ERTIGA
11) Select “ECM Replacement” under “Misc Test” menu.
12) Select “Download Inj Code to ECU” under “Vehicle
Information Copy” and according to instructions
displayed on SUZUKI scan tool.
13) Register vehicle variant information by selecting
“Vehicle variant registration” under “Misc Test” menu.
14) Register immobilizer ID code to ECM. )(Page 10C-
14)
15) Set ignition “OFF”, disconnect SUZUKI scan tool
from DLC.
Procedure for Vehicle Information Manual Input
NOTE
• Use the “Procedure for Vehicle Information
Manual Input” only when the “Upload Inj
Code from ECM” cannot be completed
normally.
• For details of SUZUKI scan tool, refer to its
operator’s manual.
• For identification of each cylinder, refer to
“Statement on Cleanliness and Care”:
D13A in Section 1A (Page 1A-124).
After replacing ECM with new one, perform the following
procedure.
1) Set ignition “OFF”, connect SUZUKI scan tool to
DLC.
Special tool
: SUZUKI scan tool (SUZUKI-SDT)
2) Record injector codes stamped on top of fuel
injector. )(Page 1G-46)
3) Set ignition “ON”.
4) Select “Engine / Powertrain” menu.
5) Select the following items.
Area: Other than North America
Model: ERTIGA
6) Select “ECM Replacement” under “Misc Test” menu.
7) Select “Vehicle Information Manual Input”.
8) Input the injector codes manually according to
instructions displayed on SUZUKI scan tool.
9) Check that injector codes have correctly inputted in
ECM by displayed on SUZUKI scan tool.
10) Register vehicle variant information by selecting
“Vehicle variant registration” under “Misc Test” menu.
11) Register immobilizer ID code to ECM. )(Page 10C-
14)
12) Set ignition “OFF”, disconnect SUZUKI scan tool
from DLC.
Fuel Injector Registration
AENBL80A1326003
NOTE
• For details of SUZUKI scan tool, refer to its
operator’s manual.
• For identification of each cylinder, refer to
“Statement on Cleanliness and Care”:
D13A in Section 1A (Page 1A-124).
After replacing one or more fuel injector(s) with new
one(s), perform the following procedure.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
Special tool
: SUZUKI scan tool (SUZUKI-SDT)
2) Record injector codes stamped on top of fuel
injector. )(Page 1G-46)
3) Set ignition “ON”.
4) Select “Engine / Powertrain” menu.
5) Select the following items.
Area: Other than North America
Model: ERTIGA
6) Select “Injector calibration code” under “Misc Test”
menu.
7) Input the injector codes manually according to
instructions displayed on SUZUKI scan tool.
8) Check injector codes have been correctly inputted in
ECM.
9) Set ignition “OFF”, disconnect SUZUKI scan tool
from DLC.
Flywheel Data Initialization
AENBL80A1326004
NOTE
For details of SUZUKI scan tool, refer to its
operator’s manual.
After replacing flywheel, perform the following
procedure.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
Special tool
: SUZUKI scan tool (SUZUKI-SDT)
2) Set ignition “ON”.
3) Select “Engine / Powertrain” menu.

4) Select the following items.
Area: Other than North America
Model: ERTIGA
5) Select “Initialize Flywheel Data” under “Misc Test”
menu and according to instructions displayed on
SUZUKI scan tool.
6) Set ignition “OFF”, disconnect SUZUKI scan tool
from DLC.
A/F Sensor Data Initialization
AENBL80A1326005
NOTE
For details of SUZUKI scan tool, refer to its
operator’s manual.
After replacing A/F sensor with new one, perform the
following procedure.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
Special tool
: SUZUKI scan tool (SUZUKI-SDT)
2) Set ignition “ON”.
3) Select “Engine / Powertrain” menu.
4) Select the following items.
Area: Other than North America
Model: ERTIGA
5) Select “Initialize A/F Sensor Data” under “Misc Test”
menu and according to instructions displayed on
SUZUKI scan tool.
6) Set ignition “OFF”, disconnect SUZUKI scan tool
from DLC.
MAF Sensor Data Initialization
AENBL80A1326006
NOTE
For details of SUZUKI scan tool, refer to its
operator’s manual.
After replacing MAF and IAT-1 sensor with new one,
perform the following procedure.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
Special tool
: SUZUKI scan tool (SUZUKI-SDT)
2) Set ignition “ON”.
3) Select “Engine / Powertrain” menu.
4) Select the following items.
Area: Other than North America
Model: ERTIGA
5) Select “Initialize MAF Sensor Data” under “Misc
Test” menu and according to instructions displayed
on SUZUKI scan tool.
6) Set ignition “OFF”, disconnect SUZUKI scan tool
from DLC.
Engine Electrical Devices: D13A 1C-17
Fuel Pressure Sensor Initialization
AENBL80A1326007
NOTE
For details of SUZUKI scan tool, refer to its
operator’s manual.
After replacing fuel pressure sensor with new one,
perform the following procedure.
1) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
Special tool
: SUZUKI scan tool (SUZUKI-SDT)
2) Set ignition “ON”.
3) Select “Engine / Powertrain” menu.
4) Select the following items.
Area: Other than North America
Model: ERTIGA
5) Select “Initialize Fuel Pressure Sensor Data” under
“Misc Test” menu and according to instructions
displayed on SUZUKI scan tool.
6) Set ignition “OFF”, disconnect SUZUKI scan tool
from DLC.
MAF and IAT-1 Sensor Removal and Installation
AENBL80A1326008
! CAUTION
When servicing MAF and IAT-1 sensor, be
sure to observe the following precautions.
• Do not disassemble MAF and IAT-1 sensor.
• Do not drop or expose MAF and IAT-1
sensor to any shock. Any sensor that has
been dropped must be replaced.
• Do not clean MAF and IAT-1 sensor.
• Do not blow compressed air to MAF and
IAT-1 sensor using air blow gun or the like.
• Do not put a finger or any other object into
MAF and IAT-1 sensor.
NOTE
If MAF and IAT-1 sensor is replaced, be sure
to initialize MAF sensor data in ECM.
For details, refer to “Description of ECM
Registration”: D13A (Page 1C-14).
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect connector from MAF and IAT-1 sensor.
3) Disconnect air cleaner outlet hose (1) from MAF and
IAT-1 sensor.
4) Remove MAF and IAT-1 sensor (2) from air cleaner
case.
1C-18 Engine Electrical Devices: D13A

Blowing air: Small

IBP80A132005-01

Installation I9P60A132010-02

Reverse removal procedure noting the following points.

• Check O-ring for damage. Replace O-ring if defective. Blowing air: Large
• Tighten air cleaner outlet hose clamp to specified
torque. )(Page 1D-76)
• When replacing MAF and IAT-1 sensor, be sure to
initialize MAF sensor data in ECM. )(Page 1C-17)

MAF and IAT-1 Sensor Inspection

AENBL80A1326009

! CAUTION
The MAF and IAT-1 sensor will be damaged if
exposed to a temperature higher than 100 °C
(212 °F).
Do not heat the MAF and IAT-1 sensor to a
I9P60A132011-01
temperature higher than 100 °C (212 °F).

MAF Sensor IAT-1 Sensor

1) Arrange 3 new 1.5 V batteries (2) in series, and
check that total voltage is 4.5 to 5.0 V.
2) Connect 12 V battery (1), batteries (2), 1.2 kΩ
resistance (3) and oscilloscope (4) to MAF and IAT-1
sensor (5) as shown in figure.
3
Measure resistance between sensor terminals (1) and
(2) while blowing hot air against temperature sensing
part of MAF and IAT-1 sensor (3) using a hair drier (4). If
faulty condition is found, replace MAF and IAT-1 sensor.
IAT-1 sensor resistance
20 °C (68 °F): 2 to 3 kΩ
60 °C (140 °F): 0.5 to 0.7 kΩ

2
4
5
4
1 2

5 1

3
IBP80A132009-01

3) Check that signal waveform changes depending on

amount of blowing air as shown in figures. If faulty IBP80A132031-01
condition is found, replace MAF and IAT-1 sensor. 5. Thermometer
)(Page 1C-17)
 Engine Electrical Devices: D13A 1C-19

Glow Plug Removal and Installation

AENBL80A1326010
Removal
1) Disconnect negative (–) cable at battery.
2) Pull off glow plug wires.
3) Loosen glow plugs using special tool.
4) Remove glow plugs from cylinder head by hand.
Special tool
(A): 09911M78610 I5RW0D130003-01

APP Sensor Assembly On-Vehicle Inspection

AENBL80A1326012
1) Check that APP sensor assembly has been mounted
to vehicle body properly (no pinched floor carpet,
etc.).
(A) If mounting is not proper, reinstall APP sensor
assembly. )(Page 1C-20)
2) When ignition is “OFF”, connect SUZUKI scan tool to
DLC.
3) Set ignition “ON” and select “Data List” mode.
4) Check that APP sensor voltage varies depending on
accelerator pedal position as shown in the following
graph.
IBL80A132003-01
If faulty condition is found, check the following
points:
Installation
Reverse removal procedure noting the following points. • Wire harness and connections
• Tighten glow plug to specified torque. • APP sensor. )(Page 1C-20)

Special tool
[c]
(A): 09911M78610
Tightening torque
Glow plug (a): 9.0 N·m (0.92 kgf-m, 7.0 lbf-ft) 3.7-4.4 V

[a]

1.8-2.2 V

0.6-0.9 V [b]
(a) 0.2-0.5 V
[d] [e]
I9P60A131002-01

[a]: APP sensor (main) voltage

[b]: APP sensor (sub) voltage
[c]: Voltage
[d]: Accelerator pedal: Idle position
(A) [e]: Accelerator pedal: Fully depressed position

IBL80A132004-01

• Connect glow plug wires securely.

Glow Plug Inspection

AENBL80A1326011
Check glow plug for resistance as shown in figure.
If resistance is not as specified, replace glow plug.
Glow plug resistance
Approx. 0.4 Ω at 20 °C (68 °F)
1C-20 Engine Electrical Devices: D13A

APP Sensor Assembly Removal and Installation

AENBL80A1326013 [A]
6 5 4 3 21
! CAUTION
When servicing APP sensor assembly, be
sure to observe the following precautions. 2

• Do not drop or expose APP sensor

assembly to large shock. Any APP sensor
assembly that has been received large
shock must be replaced. 1
I7V20A131006-01
• Keep the sensor section of the APP sensor
assembly away from water.
[B]

Removal 6 5 4 3 21

1) Disconnect negative (–) cable at battery.

2) Disconnect connector from APP sensor assembly. 2
3) Remove APP sensor assembly from its bracket.

Installation
Reverse removal procedure noting the following points.
1
• Tighten APP sensor assembly nuts (1) and APP I7V20A131007-01

sensor bracket nuts (2) to specified torque. [A]: APP sensor (main) [B]: APP sensor (sub)

Tightening torque
APP sensor assembly nut (a): 5.5 N·m (0.56 kgf- c) Set ignition “ON” and check APP sensor voltage
m, 4.0 lbf-ft) varies depending on accelerator opening angle
APP sensor bracket nut (b): 13 N·m (1.3 kgf-m, as shown in the following graph while accelerator
9.0 lbf-ft) pedal is released and fully depressed.

[c]

3.7-4.4 V

[a]

1.8-2.2 V

0.6-0.9 V [b]
0.2-0.5 V
[d] [e]
I9P60A131002-01

[a]: APP sensor (main) voltage

IBP80A132014-01
• Connect connector to APP sensor assembly securely.
APP Sensor Assembly Inspection
AENBL80A1326014
1) Check APP sensor output voltage as follows.
If check result is not as specified, replace APP
sensor assembly. )(Page 1C-20)
a) Arrange 3 new 1.5 V batteries (1) in series, and
check that total voltage is 4.5 to 5.0 V.
b) Connect voltmeter (2) and batteries to APP
sensor as shown in figure.
[b]: APP sensor (sub) voltage
[c]: Voltage
[d]: Accelerator pedal: Idle position
[e]: Accelerator pedal: Fully depressed position
ECT Sensor Removal and Installation
AENBL80A1326015
Removal
1) Remove battery and battery tray from vehicle.
2) Drain cooling system. )(Page 1F-25)
3) Remove degassing tank. )(Page 1F-23)
4) Disconnect connector from ECT sensor as follows.
a) Move connector lock pin (1) in arrow direction as
shown in figure.
b) Raise connector lock lever (2) and disconnect
connector from ECT sensor (3).
5) Remove heater outlet pipe (4). )(Page 1F-23).
 Engine Electrical Devices: D13A 1C-21

6) Remove ECT sensor from thermostat housing.

2 I6RS0E130003-01

Reference resistance of ECT sensor

1
Temperature Resistance
4 10 °C (50 °F) Approx. 3.8 kΩ
20 °C (68 °F) Approx. 2.5 kΩ
IBL80A132005-01
30 °C (86 °F) Approx. 1.7 kΩ
40 °C (104 °F) Approx. 1.1 kΩ
Installation
60 °C (140 °F) Approx. 0.6 kΩ
Reverse removal procedure noting the following points.
80 °C (176 °F) Approx. 0.3 kΩ
• Check O-ring for deterioration and damage. If faulty
condition is found, replace ECT sensor.
CMP Sensor Removal and Installation
• Tighten ECT sensor to specified torque. AENBL80A1326017
Removal
Tightening torque
1) Disconnect negative (–) cable at battery.
ECT sensor (a): 22 N·m (2.2 kgf-m, 16.5 lbf-ft)
2) Remove engine cover. )(Page 1D-76)
3) Disconnect connector from CMP sensor as follows:
a) Move connector lock pin (1) in arrow direction as
shown in figure.
b) Push connector lock lever (2) and disconnect
connector from CMP sensor (3).
4) Remove CMP sensor from camshaft housing (4).

(a)

3 4

IBL80A132006-01

• Refill cooling system with coolant. )(Page 1F-26)

• Check cooling system for leakage. )(Page 1F-24) 1
2

ECT Sensor Inspection

AENBL80A1326016
Immerse temperature sensing part of ECT sensor in
water and measure resistance between sensor terminals
while heating water gradually.
If measured resistance is not as specified, replace ECT
sensor.
IBP80A132018-01
Installation
Reverse removal procedure noting the following points.
• Check O-ring for deterioration and damage. If faulty
condition is found, replace CMP sensor.
• Tighten CMP sensor bolt to specified torque.
Tightening torque
CMP sensor bolt (a): 8.0 N·m (0.82 kgf-m, 6.0 lbf-
ft)
1C-22 Engine Electrical Devices: D13A

CKP Sensor Removal and Installation

AENBL80A1326019
Removal
1) Disconnect negative (–) cable at battery.
(a)
2) Disconnect connector from CKP sensor as follows.
a) Move connector lock pin (1) in arrow direction as
shown in figure.
b) Push connector lock lever (2) and disconnect
connector from CKP sensor (3).
3) Remove CKP sensor from cylinder block.

IBP80A132035-02

• Install engine cover. )(Page 1D-76)

CMP Sensor Inspection

AENBL80A1326018
1) Check CMP sensor power supply circuit, signal
circuit and ground circuit according to Steps 2 3
1
through 5 of “DTC P0340”: D13A in Section 1A 2
(Page 1A-200).
2) Set ignition “OFF”, connect ECM connector to ECM.
3) Connect service wires (1) between CMP sensor (2)
and CMP sensor connector (3). IBL80A132007-01

4) Set ignition “ON”.

Installation
5) Check that CMP sensor output voltage alternates Reverse removal procedure noting the following points.
between approx. 0 V and 5 V when iron (4) is
• Clean CKP sensor and sensor rotor teeth before
brought in front of CMP sensor and away from CMP
installation.
sensor.
If check result is not satisfactory, replace CMP • Tighten CKP sensor bolt to specified torque.
sensor. Tightening torque
CKP sensor bolt (a): 8.0 N·m (0.82 kgf-m, 6.0 lbf-
NOTE
ft)
Be sure to keep approximately 1 mm (0.03 in)
gap “a” between magnetic substance (iron)
and end face of CMP sensor.

3
2

(a)

4 IBL80A132008-01
1
“a”
CKP Sensor Inspection
IBP80A132021-01 AENBL80A1326020
1) Check CKP sensor and sensor rotor teeth are free
from any metal particles and damage.
2) Check resistance between terminals of CKP sensor
is within specified range.
If resistance is not as specified, replace CKP sensor.
 Engine Electrical Devices: D13A 1C-23

CKP sensor resistance

600 to 1,000 Ω at 20 °C (68 °F)

(a)

I5RW0D130011-01

Boost Pressure and IAT-2 Sensor Removal and IBL80A132010-01

Installation
AENBL80A1326021 Boost Pressure and IAT-2 Sensor Inspection
Removal AENBL80A1326022

1) Disconnect negative (–) cable at battery.

Boost Pressure Sensor
2) Remove engine cover.
3) Disconnect connector from boost pressure and IAT-2 ! CAUTION
sensor as follows. Failure to take proper precautions when
a) Move connector lock pin (1) in arrow direction as inspecting the boost pressure and IAT-2
shown in figure. sensor will damage the sensor.
b) Push connector lock lever (2) and disconnect Be sure to take the following precautions to
connector from boost pressure and IAT-2 sensor. reduce the risk of the damage to the sensor.
4) Remove boost pressure and IAT-2 sensor (3) from • Do not heat boost pressure and IAT-2
intake manifold. sensor to temperature higher than 100 °C
(212 °F).
• Do not apply vacuum more than –60 kPa
1
(–0.6 kgf/cm2, –8.7 psi, –0.6 bar) to boost
pressure and IAT-2 sensor.
• Do not apply more than 100 kPa (1.0 kgf/
cm2, 14.5 psi, 1.0 bar) to boost pressure
2
and IAT-2 sensor.

1) Check that boost pressure sensor output voltage as

3 follows. If check result is not as specified, replace
boost pressure and IAT-2 sensor.

NOTE
IBL80A132009-01
Environmental condition affects output
voltage largely.
Installation
The sensor voltage below is reference value
Reverse removal procedure noting the following points.
when measuring under the following
• Check O-ring of boost pressure and IAT-2 sensor for condition.
deformation or damage.
• Atmospheric pressure: 101.3 kPa (1.01 kgf/
If faulty condition is found, replace boost pressure and
cm2, 14.7 psi, 1.01 bar)
IAT-2 sensor.
• Tighten boost pressure and IAT-2 sensor bolt to a) Arrange 3 new 1.5 V batteries (1) in series, and
specified torque. check that total voltage is 4.5 – 5.0 V.
Tightening torque b) Connect voltmeter (2), special tool, hose and
Boost pressure and IAT-2 sensor bolt (a): 1.0 N·m batteries to boost pressure and IAT-2 sensor as
(0.10 kgf-m, 1.0 lbf-ft) shown in figure.
Special tool
(A): 09917M47011
c) Check that voltage drops gradually when
vacuum is gradually applied with special tool.
1C-24 Engine Electrical Devices: D13A

d) Disconnect special tool. Fuel Pump Relay, Starting Motor Control Relay
e) Connect special tool and hose to boost pressure and Main Relay Inspection
AENBL80A1326023
and IAT-2 sensor as shown in figure.
Refer to “Control Relay Inspection” in Section 10B (Page
Special tool 10B-30).
(B): 09918M18111
f) Check that voltage drops gradually when Glow Plug Control Module Removal and
pressure is gradually applied with special tool. Installation
AENBL80A1326024
Boost pressure sensor output voltage Removal
Atmospheric pressure: Approx. 1.5 V 1) Disconnect negative (–) cable at battery.
Vacuum –30 kPa (–0.3 kgf/cm2, –4.35 psi, –0.3 2) Remove left side front fender lining. )(Page 9J-2)
bar): Approx. 1 V
3) Disconnect connectors from glow plug control
Positive pressure 30 kPa (0.3 kgf/cm2, 4.35
module.
psi, 0.3 bar): Approx. 2 V
4) Remove glow plug control module (1).
2 5) Remove glow plug control module bracket, if
necessary.

(A)

1
1

(B)

3
IBL80A132011-01

Installation
I9P60A132028-03
Reverse removal procedure noting the following point.
3. Compressed air
• Tighten glow plug control module bolt and glow plug
control module bracket bolts to specified torque.
IAT-2 Sensor
Measure resistance between sensor terminals while Tightening torque
blowing hot air against temperature sensing part of boost Glow plug control module bracket bolt (a): 8.8
pressure and IAT-2 sensor (1) using a hair drier (2). If N·m (0.90 kgf-m, 7.0 lbf-ft)
faulty condition is found, replace boost pressure and IAT- Glow plug control module bolt (b): 7.0 N·m (0.71
2 sensor. kgf-m, 5.5 lbf-ft)
IAT-2 sensor resistance
20 °C (68 °F): 2 to 3 kΩ (b)
60 °C (140 °F): 0.5 to 0.7 kΩ

(a)

3 2

I9P60A132029-02
IBL80A132012-01
3. Temperature gauge
 Engine Electrical Devices: D13A 1C-25

Boost Pressure Control Solenoid Valve

Removal and Installation
AENBL80A1326027
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect vacuum hoses (1) from boost pressure
control solenoid valve (2).
3) Disconnect connector (3) from boost pressure
control solenoid valve.
4) Remove boost pressure control solenoid valve from
I7V20A132016-01
bracket (4).
5) Remove boost control solenoid valve bracket, if
VSS Removal and Installation
necessary. AENBL80A1326025
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect degassing tank from bracket.
3 3) Remove battery and battery tray.
4) Disconnect gear shift and select control cables (1)
4 from transaxle. )(Page 5B-54)
5) Remove cable bracket (2) from transaxle.
2
6) Disconnect VSS connector (3).
1

IBL80A132013-01

3
Installation
Reverse removal procedure noting the following point.
• Tighten boost pressure control solenoid valve bolts to
specified torque.
Tightening torque 2

Boost pressure control solenoid valve bolt (a): 8.5

N·m (0.87 kgf-m, 6.5 lbf-ft)

(a) IBP80A132029-01

7) Remove VSS.

Installation
Reverse removal procedure noting the following points.
• Apply oil to VSS O-ring.
• Tighten VSS bolt to specified torque.
Tightening torque
VSS bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
IBL80A132014-01

Boost Pressure Control Solenoid Valve

Inspection
AENBL80A1326028
Check resistance between two terminals of boost
pressure control solenoid valve. If resistance is not as
specified, replace boost pressure control solenoid valve.
Boost pressure control solenoid valve resistance
14.8 – 16.2 Ω at 20 °C (68 °F)
1C-26 Engine Electrical Devices: D13A

VSS Inspection
AENBL80A1326026
(a)
Refer to “VSS Inspection”: K14B (Page 1C-12).

IBP80A132030-01

• Connect VSS connector securely.

• Install cable bracket to transaxle. )(Page 5B-54)

Specifications
Tightening Torque Specifications
AENBL80A1327001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
ECM nut 5.7 0.58 4.5 )
ECM bracket bolt 8.8 0.90 6.5 )
ECM box bolt* 5.1 0.52 4.0 )
ECM box nut* 5.7 0.58 4.5 )
Glow plug 9.0 0.92 7.0 )
APP sensor assembly nut 5.5 0.56 4.0 )
APP sensor bracket nut 13 1.3 9.0 )
ECT sensor 22 2.2 16.5 )
CMP sensor bolt 8.0 0.82 6.0 )
CKP sensor bolt 8.0 0.82 6.0 )
Boost pressure and IAT-2 sensor bolt 1.0 0.10 1.0 )
Glow plug control module bracket bolt 8.8 0.90 7.0 )
Glow plug control module bolt 7.0 0.71 5.5 )
Boost pressure control solenoid valve bolt 8.5 0.87 6.5 )
VSS bolt 10 1.0 7.5 )

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
 Engine Electrical Devices: D13A 1C-27

Special Tools and Equipment

Special Tool
AENBL80A1328001
09911M78610 09917M47011
Glow plug wrench Vacuum pump gauge
)/) )

09918M18111 SUZUKI scan tool (SUZUKI- 6

SDT)
Air pressure regulator — 1 2
) This kit includes following
4
items. 1. SUZUKI-SDT 2. 3
DLC cable 3. USB cable 4. 5
AC/DC power supply 5.
Voltage meter probe 6.
Storage case) / ) / ) / ) /
)/)/)
1D-1 Engine Mechanical: K14B

Engine Mechanical
Engine

K14B
General Description
Engine Construction Description
AENBL80A1411001
The engine is a water-cooled, in-line 4 cylinders, 4-stroke-cycle gasoline unit with a DOHC valve mechanism arranged
in a “V” type valve configuration and has 16 valves (4 valves / one cylinder). The intake camshaft equipped with a VVT
actuator and the exhaust camshaft are mounted over the cylinder head and are driven by a crankshaft with a timing
chain.

Diagnostic Information and Procedures

Compression Check
AENBL80A1414001
1) Warm up engine to normal operating temperature.
2) Stop engine after warming up.
3) Place gear shift lever in “Neutral” and apply parking
brake.
4) Remove air cleaner assembly with air suction pipe.
)(Page 1D-5)
5) Remove all ignition coil assemblies and all spark
plugs. )(Page 1H-6)
I2RH0B140005-01
6) Disconnect all fuel injector connectors.
9) Crank engine with fully charged battery, and read the
7) Install special tools into spark plug hole. highest pressure on special tool.
Special tool
NOTE
(A): 09915M64512
(B): 09915M64530 • For measuring compression pressure,
(C): 09915M64550 crank engine at least 200 rpm with fully
charged battery.
(A) • Check installation condition of special tool
if measured compression pressure is
(B) lower than the limit.
• If the measured compression pressure of
particular cylinder is lower than the limit,
add a bit of engine oil into the cylinder
through the spark plug hole, and then
repeat the compression check.
(C)
– If the compression pressure increases
after adding engine oil, the following
I7V20A141002-01 may be the cause:
8) Disengage clutch (1) (to lighten starting load on – Pressure leakage due to worn piston
engine), and depress accelerator pedal (2) all the rings or worn cylinder
way to make throttle fully open.
– If the compression pressure does not
increase, one of the following may be
the cause:
– Incorrect valve timing
– Pressure leakage from the valve or
valve seats
– Pressure leakage from the cylinder
head gasket

Compression pressure
Standard: 1250 kPa (12.7 kgf/cm2, 181 psi)
Limit: 1000 kPa (10.2 kgf/cm2, 145 psi)
Max. difference between any two cylinders: 100
kPa (1.0 kgf/cm2, 14.5 psi)
10) Carry out Steps 6) through 8) on each cylinder to
obtain 4 readings.
11) Install spark plugs and ignition coil assemblies.
)(Page 1H-6)
12) Connect fuel injector connectors.
13) Install air cleaner assembly with air suction pipe.
)(Page 1D-5)
Engine Vacuum Check
AENBL80A1414002
1) Warm up engine to normal operating temperature.
2) Place gear shift lever in “Neutral” and apply parking
brake.
3) Stop engine and turn off all electric switches.
4) Remove PCV hose (1) from PCV valve (2).
5) Connect special tool to PCV hose (1).
Special tool
(A): 09915M67311
6) Close PCV valve (2) using tape (3) or the like.
(A)
1
I7V20A141003-01
7) Run engine at specified idle speed. )(Page 1A-122)
8) Read vacuum gauge. Vacuum should be within
specification.
Vacuum specification (at sea level)
–50 kPa (–0.50 kgf/cm2, –7.25 psi, –0.5 bar) or
less at specified idle speed
9) Disconnect special tool from PCV hose.
10) Pull off tape from PCV valve.
Valve Clearance Inspection and Adjustment
AENBL80A1414003
Inspection
1) Remove negative (–) cable at battery.
2) Remove cylinder head cover. )(Page 1D-8)
3) Remove right side engine undercover, if necessary.
Engine Mechanical: K14B 1D-2
4) Using wrench, turn crankshaft pulley (1) clockwise
until cam lobes (2) become perpendicular to tappet
faces (3) at valves “1” and “7” as shown in figure.
5) Check valve clearance with feeler gauge (4) as
follows.
a) Check valve clearance at valves “1” and “7”.
b) Turn camshafts by 90° (by turning crankshaft
with wrench).
c) Make sure that cam lobes are perpendicular to
shim faces at valves to be checked (in this case,
“3” and “8”), if not, adjust it by turning crankshaft.
Check valve clearances.
d) In the same manner as b) – c), check valve
clearances at valves “4” and “6”.
e) In the same manner as b) – c) again, check
valve clearances at valves “2” and “5”.
If valve clearance is not as specified, record valve
clearance and adjust it to specification. )(Page 1D-3)
Valve clearance specification
When cold (ECT: 15 – 25 °C (59 – 77 °F)):
• Intake: 0.14 – 0.23 mm (0.0055 – 0.0091 in.)
• Exhaust: 0.30 – 0.40 mm (0.0118 – 0.0157 in.)
1
2
“a”
4
3
I8C50A140005-01
“a”: 90°
1D-3 Engine Mechanical: K14B

c) Select new tappet closest to calculated value

“1” “2” “3” “4” from available size of spare part.

NOTE
If the number in the second decimal place is
odd, use (A-0.01) tappet.

Intake:
A = B + C – 0.19 mm (0.0075 in.)
Exhaust:
A = B + C – 0.35 mm (0.0138 in.)
“5” “6” “7” “8” A: Thickness “a” of new tappet
IAP70B140001-01
B: Thickness “a” of removed tappet
Adjustment C: Measured valve clearance
1) Remove tappet to be replaced. )(Page 1D-10)
"a"
2) Select proper size of tappet as follows to adjust valve 1

clearance to specified valve.

a) Using a micrometer, measure the thickness of
the removed tappet (1).
b) Calculate the thickness of new tappet by formula 1
below.

I7V20A141015-01

3) Install camshafts and tappets. )(Page 1D-10)

4) Recheck valve clearance.

Air Cleaner Components
11
8
9
6 13
1. Air cleaner assembly
2. Air cleaner suction pipe
3. Air cleaner suction hose
4. Air cleaner suction pipe joint
5. Suction pipe grommet
Engine Mechanical: K14B 1D-4
Repair Instructions
AENBL80A1416001
5
5
10
7
12
14
IBP80A141045-01
6. Air cleaner outlet hose 11. To cylinder head cover
7. Air cleaner bracket 12. To cooling water pipe
8. Breather pipe 13. To throttle body assembly
9. MAF and IAT sensor 14. To intake manifold
10. EVAP canister purge valve : 1.0 N⋅m (0.10 kgf-m, 1.0 lbf-ft)
1D-5 Engine Mechanical: K14B

Air Cleaner Filter Removal and Installation Air Cleaner Assembly Removal and Installation
AENBL80A1416002 AENBL80A1416004

Removal Removal
1) Open air cleaner case (1) by unhooking its clamps 1) Disconnect negative (–) cable at battery.
(2). 2) Remove EVAP canister purge valve (1).
3) Disconnect engine harness clamps.
2 1
2
4) Loosen air cleaner outlet hose clamp bolt and
remove air cleaner assembly (3) with air suction pipe
(4).
5) Remove air cleaner outlet hose (2) according to the
following procedure if necessary.
a) Disconnect breather pipe (5) from air cleaner
outlet hose.
b) Remove air cleaner outlet hose.

IBP80A141009-01 1
2) Remove air cleaner filter from case. 6

Installation 3
Reverse removal procedure.
4
Air Cleaner Filter Inspection and Cleaning
AENBL80A1416003
5
Inspection
Check air cleaner filter for dirt. Replace excessively dirty
filter.

Cleaning
I9P60A141019-01
Blow off dust by compressed air from air outlet side of
filter.
Installation
Reverse removal procedure.

I2RH0B140150-01

Throttle Body and Intake Manifold Components

AENBL80A1416005
 Engine Mechanical: K14B 1D-6

7
9

5
8

10
1

I9P60A141020-01

1. Intake manifold 5. Electric throttle body assembly 9. Air cleaner bracket

: Do not disassemble.
2. Intake manifold gasket 6. Electric throttle body gasket 10 To breather pipe
3. Spacer 7. MAP Sensor 11 To cooling water pipe
4. Gasket 8. O-ring : Do not reuse.

Throttle Body On-Vehicle Inspection

AENBL80A1416006
Check electric throttle body assembly. )(Page 1C-2)

Electric Throttle Body Assembly Removal and

Installation
AENBL80A1416007

! CAUTION
Never disassemble electric throttle body. If it
is found faulty, replace it with new one. 2

Removal
1) Disconnect negative (–) cable at battery. 3

2) Drain coolant. )(Page 1F-11)

3) Remove air cleaner assembly. )(Page 1D-5)
4
4) Disconnect engine coolant hoses (1) and connector
(2) from electric throttle body assembly (3). 1
5) Remove electric throttle body assembly and air IBP80A141011-01

cleaner bracket (4) from intake manifold.

Installation
1) Clean mating surfaces and install new throttle body
gasket (1) to intake manifold.
1D-7 Engine Mechanical: K14B

• Brake booster hose (1) from brake booster

• PCV hose (2) from PCV valve

1
I7V20A141038-01
2

2) Install electric throttle body assembly (3) and air

IAP70B140003-01
cleaner bracket (4) to intake manifold.
5) Remove heater inlet pipe bolt (1).
3) Connect connector (2) and coolant hoses (1) to
electric throttle body assembly (3).

2
I9P60A141022-01

6) Remove intake manifold (1) and its gasket.

3

1
IBP80A141011-01

4) Install air cleaner assembly. )(Page 1D-5)

5) Connect negative (–) cable at battery.
6) Refill coolant. )(Page 1F-11)
7) Check for coolant leakage. )(Page 1F-11) 1

IAP70B140004-01
Throttle Body Cleaning 7) Remove cooling water pipe (1). )(Page 1F-12)
AENBL80A1416008
Clean electric throttle body assembly referring to 8) Remove spacer (2) and gasket from cylinder head.
“Throttle Valve Visual Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection”: K14B in Section
1C (Page 1C-2).

Intake Manifold Removal and Installation

AENBL80A1416009

Removal
1) Disconnect negative (–) cable at battery.
2) Remove air cleaner assembly. )(Page 1D-5)
3) With engine coolant hoses connected, remove
electric throttle body assembly from intake manifold.
4) Disconnect the following hoses:
 Engine Mechanical: K14B 1D-8

• Use new gasket.

2 • Check to ensure that all removed parts are back in
place.

I9P60A141023-01

Installation
Reverse removal procedure noting the following points.

Cylinder Head Cover Components

AENBL80A1416010

3 (a)

5 1

2 1217G

IBP80A141014-01

1. Cylinder head cover 5. Oil filler cap

2. Cylinder head cover gasket : 5.0 N⋅m → 8.0 N⋅m → 11 N⋅m (0.51 kgf-m → 0.82 kgf-
: Apply sealant 99000-31260 referring to “Cylinder Head Cover Removal and m → 1.1 kgf-m, 4lbf-ft → 6.0 lbf-ft → 8.5 lbf-ft)
Installation”: K14B (Page 1D-8).
3. Cylinder head cover bolt : Do not reuse.
: For tightening order, refer to “Cylinder Head Cover Removal and Installation”: K14B
(Page 1D-8).
4. PCV valve

Cylinder Head Cover Removal and Installation 2) Remove air cleaner assembly. )(Page 1D-5)
AENBL80A1416011
3) Remove ignition coil assemblies. )(Page 1H-7)
Removal 4) Disconnect engine harness clamps.
1) Disconnect negative (–) cable at battery. 5) Remove oil level gauge.
1D-9 Engine Mechanical: K14B

6) Disconnect PCV hose from PCV valve and breather

hose from cylinder head cover. 1

7) Remove PCV valve from cylinder head cover, if

necessary.
8) Loosen cylinder head cover mounting bolts in
numerical order (“1” – “7”) evenly and gradually.

“4” “1” “6”

“2”

“1”

“5”
“3” “7”
IBP80A141021-01 IBP80A141042-01
9) Remove cylinder head cover (1) with gasket (2). 3) Apply sealant “A” to mating surface of timing chain
cover (1) and cylinder head (2).
1
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)

“A”
2

2
“A”
I9P60A141027-01

4) Install cylinder head cover to cylinder head.

IBP80A141042-01 NOTE

Installation When installing cylinder head cover, use care

1) Remove oil, old sealant and dust from sealing
surfaces on cylinder head and cover.
2) Install new gasket (2) to cylinder head cover (1).
so that cylinder head cover gasket will not
get out of place or fall off.
5) Tighten cylinder head cover bolts according to the
following procedure:
a) Tighten cylinder head cover bolts to 5.0 N⋅m
(0.51 kgf-m, 4.0 lbf-ft) in numerical order (“1” –
“7”) evenly and gradually.
b) Retighten them to 8.0 N⋅m (0.82 kgf-m, 6.0 lbf-ft)
in the same manner as in Step a).
c) Retighten them to 11 N⋅m (1.1 kgf-m, 8.5 lbf-ft) in
the same manner as in Step a).
Tightening torque
Cylinder head cover bolt* (a): 5.0 N⋅m → 8.0
N⋅m → 11.0 N⋅m (0.51 kgf-m → 0.82 kgf-m→
1.1 kgf-m, 4.0 lbf-ft → 6.0 lbf-ft → 8.5 lbf-ft)
 Engine Mechanical: K14B 1D-10

6) Install PCV valve to cylinder head cover and tighten

PCV valve to specified torque, if removed. “4” “1” “2”
“6”

Tightening torque
PCV valve (b): 2.5 N·m (0.25 kgf-m, 2.0 lbf-ft)
7) Connect PCV hose to PCV valve.
“7”
8) Connect breather hose to cylinder head cover.
9) Install oil level gauge.

“3”
“5” “1”
IBP80A141022-01

10) Install ignition coil assemblies. )(Page 1H-7)

11) Connect engine harness clamps.
12) Install air cleaner assembly. )(Page 1D-5)
13) Connect negative (–) cable at battery.

Camshaft, Tappet and Shim Components

AENBL80A1416012

4 (a)
4 (a)
3

OIL
1
3

OIL
2
OIL

6 7
OIL

9
(b)
OIL

8
(b)
IAP70B140005-02

1. Intake camshaft 7. Exhaust camshaft timing sprocket

: Apply engine oil to sliding surface.
2. Exhaust camshaft 8. Tappet
: Apply engine oil to sliding surface. : Apply engine oil to sliding surface.
3. Camshaft housing 9. Dowel pin
4. Camshaft housing bolt : 11 N⋅m (1.1 kgf-m, 8.5 lbf-ft)
: For tightening order, refer to “Camshaft and Tappet Removal and Installation”.
5. Camshaft bearing : 60 N⋅m (6.1 kgf-m, 44.5 lbf-ft)
: For applying engine oil, refer to “Camshaft and Tappet Removal and Installation”.
6. VVT actuator
: Do not disassemble.

Camshaft and Tappet Removal and Installation

AENBL80A1416013 1
1

Removal
1) Remove right engine undercover.
2) Remove cylinder head cover. )(Page 1D-8)
3) Turn crankshaft clockwise and adjust No.1 cylinder
to TDC as follows.
a) Align both VVT actuator and exhaust camshaft
timing sprocket marks (1) with surface of cylinder 2 2
head (2) respectively. I7V20A141006-01

b) Align notch (1) on crankshaft pulley with “0” (2) indication on timing chain cover.
1D-11 Engine Mechanical: K14B

2
1
1

I7V20A141007-01

4) Remove timing chain cover plug (1) and gasket (2).

IAP70B140008-01

“a”

1 2
IAP70B140007-01

5) Fix timing chain tensioner (1) as follows.

! CAUTION
Use bolt as specified below for fixing timing
chain tensioner. I8C50A140028-02

“a”: 20°

6) Apply a dab of paint to two timing chain links (2)

which meet timing marks (1) on VVT actuator and
exhaust camshaft timing sprocket.
“a”
2 2
I8T401142029-01
1 1
Timing chain tensioner fixing bolt
Bolt size M8
Pitch 1.25 mm (0.049 in.)
Length “a” 35 mm (1.378 in.)

a) Tighten timing chain tensioner fixing bolt (2) by

I7V20A141012-04
hand to fix timing chain tensioner (1).
7) Remove exhaust camshaft timing sprocket as
b) While turning crankshaft 20° counterclockwise, follows.
tighten timing chain tensioner fixing bolt (2) by
a) Hold the hexagonal section of exhaust camshaft
hand again.
using a wrench.
c) While turning crankshaft 20° clockwise this time,
b) Remove exhaust camshaft timing sprocket bolt,
tighten timing chain tensioner fixing bolt (2) by
then remove sprocket (1).
hand again.
! CAUTION
Do not turn camshaft after removing exhaust
camshaft timing sprocket.
 Engine Mechanical: K14B 1D-12

a) Hold hexagonal section of intake camshaft using

vice.
1
b) Install VVT actuator and tighten VVT actuator
bolt to specified torque.
Tightening torque
VVT actuator bolt (a): 60 N·m (6.1 kgf-m, 44.5
lbf-ft)

(a)

IAP70B140009-01

8) Loosen camshaft housing bolts in numerical order

(“1” – “21”) evenly and gradually.
1
“2” “13” “12” “21” “20” “17” “16” “9” “8”

“5”

“3”

I9P60A141076-01

“4” 2) Apply engine oil to contact surfaces of each tappet

“1” “10” “11” “18” “19” “14” “15” “6” “7”
(hatched area), and install tappets (1) to cylinder
IAP70B140006-01 head, if removed.
9) Remove intake camshaft and exhaust camshaft.
10) Remove camshaft bearings and tappets, if
necessary. 1
11) Remove VVT actuator from intake camshaft as
follows, if necessary.
a) Hold hexagonal section of intake camshaft using
vice.
b) Remove VVT actuator bolt and remove VVT
actuator (1).
I7V20A141016-01

! CAUTION 3) Install camshaft bearings as follows, if removed.

Do not disassemble VVT actuator. a) Fit tab (1) of camshaft bearing to groove (2) of
cylinder head or camshaft housing.
b) Press camshaft bearing end (3) until the bearing
is firmly seated on the cylinder head or camshaft
housing.
c) Apply engine oil to sliding surface (4) of camshaft
bearings.

! CAUTION
1
Do not apply engine oil to mating surface (5)
between bearing and camshaft housing or
cylinder head.

I9P60A141035-01

Installation
1) Install VVT actuator (1) to intake camshaft as
follows, if removed.
1D-13 Engine Mechanical: K14B

1 “20” “9” “10” “2” “1”,(a) “6” “5” “14” “13”

1 3
4
“17”

2 “19”

5
I8T401142036-01
“18”
4) Apply engine oil to sliding surfaces of camshafts. “21” “12” “11” “4” “3” “8” “7” “16” “15”
IAP70B140040-01
5) Install camshafts to cylinder head as follows.
8) Install exhaust camshaft timing sprocket (3) to
a) Align the painted timing chain link (2) with timing
exhaust camshaft as follows.
mark (1) on VVT actuator and then install intake
camshaft. a) Install special tool to exhaust camshaft.
b) Install the exhaust camshaft so that the dowel Special tool
pin (3) is positioned upwards. (A): 09914M06310

2 b) Align the painted timing chain link (1) with timing

1 mark (2) on exhaust camshaft timing sprocket
3 (3).
c) Install exhaust camshaft timing sprocket (3) with
timing chain to the exhaust camshaft.

1
2

(A)

IAP70B140010-01

6) Install camshaft housings (1) to proper places

distinguished by letter (2), number (3) and arrow 3

direction (4) on each camshaft housing.

1 IAP70B140011-01
2 3
9) Tighten exhaust camshaft timing sprocket bolt (1)
using special tool.
4 Special tool
(A): 09911M05120
I8T401142038-01 Tightening torque
2. I: For intake camshaft Exhaust camshaft timing sprocket bolt (a): 60
E: For exhaust camshaft N·m (6.1 kgf-m, 44.5 lbf-ft)
3. Position from timing chain side
4. Point arrowhead to timing chain side ! CAUTION
When using an extension special tool with a
7) Tighten camshaft housing bolts as follows.
torque wrench, the reading value of the
a) Install camshaft housing No.1 (1). torque wrench is smaller than specified
b) Install camshaft housing bolts and tighten them torque. When using extension special tool,
by hand. reading value should be calculated using the
c) Tighten camshaft housing bolts in numerical formula below.
order (“1” – “21”) evenly and gradually.
Formula for reading value of torque wrench.
Tightening torque
M = T X L / (L + “a”)
Camshaft housing bolt* (a): 11 N·m (1.1 kgf-
m, 8.5 lbf-ft) • M: Reading value using extension special tool
• T: Specified torque
• L: Torque wrench length
• “a”: Dimension of special tool
 Engine Mechanical: K14B 1D-14

1 1

(A)
“a”

2 2
I7V20A141006-01

b) Check that crankshaft pulley mark (1) is aligned

1,(a) with “0” (2) of timing chain cover.
IAP70B140012-01

“a”: 20 mm (0.78 in.)

2
10) Confirm that painted timing chain links (2) are
aligned with timing marks (1) on VVT actuator and
exhaust camshaft timing sprocket.

2 2 1

1 1

I7V20A141007-01

c) Turn crankshaft clockwise fully twice and check

again that match marks are aligned.

IAP70B140013-01
11) Remove timing chain tensioner fixing bolt from
timing chain cover.
12) Install timing chain cover plug (1) with new gasket
(2), and tighten it to specified torque.
NOTE
• Be sure to turn crankshaft 720°. If it is
turned only 360°, the timing marks (1) on
VVT actuator and exhaust camshaft timing
sprocket will not meet top face of cylinder
head (2) as shown in figure.

Tightening torque 1 1
Timing chain cover plug (a): 25 N·m (2.5 kgf-m,
18.5 lbf-ft)

2 2
I7V20A141006-01

• After turning crankshaft 720°, the painted

links of the timing chain will not be aligned
with the timing marks on the VVT actuator
1,(a) 2
and exhaust camshaft timing sprocket, but
IAP70B140014-01 this is normal.
13) Check that camshaft and timing chain are installed
properly as follows. 14) Check valve clearance. )(Page 1D-2)
a) Check that VVT actuator and exhaust camshaft 15) Install cylinder head cover. )(Page 1D-8)
timing sprocket marks (1) are aligned with top 16) Run the engine and check for engine oil leaks.
face of cylinder head (2). 17) Install right engine undercover.
1D-15 Engine Mechanical: K14B

Camshaft and Tappet Inspection Camshaft Journal Wear

AENBL80A1416014
• Check camshaft journals and camshaft housings for
Cam Wear pitting, scratches, wear or damage.
Using a micrometer, measure cam height “a”. If If any defect is found, replace camshaft or cylinder
measured height is not as specified, replace camshaft. head with housing. Be sure to replace cylinder head
and housings as a set.
Cam height “a” of camshaft
Camshaft Standard Limit
45.421 – 45.581 mm 45.321 mm
Intake
(1.7883 – 1.7945 in.) (1.7449 in.)
44.659 – 44.819 mm 44.559 mm
Exhaust
(1.7583 – 1.7645 in.) (1.7543 in.)

“a” I2RH0B140082-01

• Check clearance using gauging plastic as follows.

1) Clean housings and camshaft journals.
2) Remove all tappets.
3) Install lower bearing half and camshafts to cylinder
head.
4) Place a piece of gauging plastic to full width of
I9T401142011-01 journal of camshaft (parallel to camshaft).
5) Install camshaft housing referring to Steps 6) to 7) of
Camshaft Runout
“Installation” under “Camshaft and Tappet Removal
Set camshaft on two “V” blocks, and measure its runout
and Installation”: K14B (Page 1D-10).
using a dial gauge.
If measured runout exceeds limit, replace camshaft. 6) Remove housing, and using scale (2) on gauging
plastic envelop, measure gauging plastic (1) width at
Camshaft runout limit its widest point.
0.015 mm (0.0006 in.)
Camshaft journal clearance
Item Standard Limit
Intake camshaft 0.031 – 0.087 mm 0.10 mm
housing No.1 (0.0013 – 0.0034 in.) (0.00394 in.)
0.045 – 0.087 mm 0.10 mm
Others
(0.0018 – 0.0034 in.) (0.00394 in.)

I9T401142012-01

I2RH0B140083-01

If measured camshaft journal clearance exceeds

limit, recheck camshaft journal clearance according
to the following procedure.
a) Install camshaft upper bearing haves and
camshaft housings without camshafts to cylinder
head.
b) Tighten camshaft housing bolts referring to Step
7) in “Installation” under “Camshaft and Tappet
Removal and Installation”: K14B (Page 1D-10).
 Engine Mechanical: K14B 1D-16

c) For intake and exhaust camshaft journal No.1,

measure journal outside diameter at positions "a"
shown in figure.
If measured diameter is not as specified, replace
camshaft and recheck camshaft journal
clearance. I9T401142049-01
If measured diameter is within standard values, 7) Install intake and exhaust camshaft without tappet,
replace camshaft bearings and recheck measure intake and exhaust camshaft housing
camshaft journal clearance. thrust clearance using a dial gauge.
d) For all other camshaft journals, measure If measured clearance exceeds limit, replace
camshaft journal outside diameters and camshaft or cylinder head.
camshaft housing inside diameters.
If measured diameters are not as specified, Camshaft housing thrust clearance
replace corresponding camshaft or cylinder head Standard: 0.10 – 0.35 mm (0.0039 – 0.0138 in.)
and camshaft housings.
Camshaft journal outside diameter
Item Standard
Intake camshaft No.1 29.440 – 29.455 mm
journal “a” (1.1591 – 1.1596 in.)
Exhaust camshaft No.1 26.934 – 26.955 mm
journal “a” (1.0604 – 1.0612 in.)
22.934 – 22.955 mm
Others
(0.9029 – 0.9037 in.)

Camshaft journal housing inside diameter I7V20A141074-01

Item Standard
Intake camshaft No.1 Wear of Tappet
— Check tappet for pitting, scratches, or damage.
housing
Exhaust camshaft No.1 27.000 – 27.021 mm If any defect is found, replace tappet.
housing (1.0630 – 1.0681 in.)
23.000 – 23.021 mm
Others
(0.9055 – 0.9063 in.)

I7V20A141075-01

I8T401142043-02

I9T401142015-01
1D-17 Engine Mechanical: K14B
Measure cylinder head tappet bore and tappet outside
diameter to determine cylinder head-to-tappet
clearance. If clearance exceeds limit, replace tappet or
cylinder head.
Cylinder head to tappet clearance
Standard: 0.025 – 0.062 mm (0.0010 – 0.0024 in.)
Limit: 0.10 mm (0.0039 in.)
Tappet outside diameter [A]
Standard: 27.959 – 27.975 mm (1.1007 – 1.1014 in.)
Cylinder head tappet bore [B]
Standard: 28.000 – 28.021 mm (1.1024 – 1.1032 in.)
I2RH0B140086-01
VVT Actuator
• Check VVT actuator for wear or damage.
Replace VVT actuator if any defective conditions are
found.
• Install VVT actuator to camshaft. Hold hexagonal
section of camshaft stationary using wrench.
Check that VVT actuator (1) cannot be turned by
hand.
Replace VVT actuator if it can be turned by hand.
1
IAP70B140015-01
Signal Rotor
Check signal rotor (1) for crack and damage. If any
defect is found, replace camshaft.
IAP70P140037-01
 Engine Mechanical: K14B 1D-18

Engine Mounting Components

AENBL80A1416015

(a)
(a) (a)

(a)

2
(a)
1
(b)
(a)

4
3
7

(a)
(a) (a)

(a)
6

(a)
IBL80A141001-01

1. Engine right mounting
2. Engine right mounting stiffener
3. Engine left mounting
4. Engine left mounting bracket
5. Engine rear mounting : 93 N⋅m (9.5 kgf-m, 68.5 lbf-ft)
6. Engine rear mounting No.1 bracket : Do not reuse.
7. Engine rear mounting No.2 bracket
55 N⋅m (5.6 kgf-m, 40.5 lbf-ft)
:

Engine Assembly Removal and Installation 10) Disconnect the following electric wires/connectors
AENBL80A1416016 and each clamps.
Removal
• Battery ground cable (1)
1) Relieve fuel pressure. )(Page 1G-16)
• Connectors (2) in main fuse box
2) Remove battery. )(Page 1J-9)
• Electric load current sensor connector (3)
3) Disconnect ECM connectors. )(Page 1C-1)
• Connector (4) in individual circuit fuse box No.1
4) Remove battery bracket with ECM.
5) Remove right and left side engine undercovers.
6) Drain the following oils and fluid if necessary.
1
• Engine oil: )(Page 1E-3)
• Transaxle oil: )(Page 5B-7) 3
4
7) Drain coolant. )(Page 1F-11)
8) Remove air cleaner assembly. )(Page 1D-5)
2
9) With hose connected, detach A/C compressor from
its bracket.
• Single A/C model: )(Page 7B-44)
• Dual A/C model: )(Page 7B-92)

! CAUTION I9P60A141043-01

Suspend removed A/C compressor at a place 11) Disconnect the following cables.
where no damage will be caused during • Gear select control cable (1)
removal and installation of engine assembly. • Gear shift control cable (2)

12) For M/T model, remove clutch operating cylinder assembly (4) from transaxle. )(Page 5C-8)
1D-19 Engine Mechanical: K14B

]
2
3
2

4 4

1
I9P60A141047-01

21) Remove engine left mounting bracket bolt (1) and

IBP80A141037-01
nuts (2).
13) Disconnect the following hoses.
• Brake booster hose (1)
• Radiator inlet and outlet hoses (2)
• Heater inlet and outlet hoses (3)
• Fuel feed hose (4)

2
1
3

IBP80A141039-01

22) Remove engine right mounting bracket bolt (1) and

nuts (2).
IBP80A141038-01

14) Disconnect steering lower shaft from pinion shaft.

)(Page 6B-13)
1
15) Remove stabilizer bar joints from stabilizer bar.
)(Page 2B-11)
16) Disconnect tie-rod end from steering knuckle.
2
)(Page 6C-24)
17) Disconnect right and left drive shaft joints from
steering knuckle. )(Page 3A-3)
18) Remove exhaust No.1 pipe and exhaust center pipe.
)(Page 1K-2)
19) Support front suspension frame (1), transaxle case
IAP70A140006-01
(2) and cylinder block (3) using jack.
23) Before removing engine make sure that all hoses,
20) Remove front suspension frame bolts (4). electric wires and cables are disconnected from
engine.
24) Lower engine with transaxle, front suspension frame,
drive shafts, P/S gear case assembly all together.

! CAUTION
Before lowering engine, in order to avoid
damage to A/C compressor, make clearance
between A/C compressor and engine by
suspending A/C compressor.
 Engine Mechanical: K14B 1D-20

25) Disconnect engine harness from engine and ! CAUTION

transaxle, if necessary.
Before lifting engine, in order to avoid
26) Remove front drive shaft assembly, if necessary.
damage to A/C compressor, make clearance
)(Page 3A-3)
between A/C compressor and engine by
27) Remove drive intermediate shaft assembly, if suspending A/C compressor.
necessary. )(Page 3A-8)
28) Remove front suspension frame, if necessary. 9) Tighten engine right mounting bracket bolt (1) and
29) Disconnect transaxle from engine, if nuts (2) to specified torque.
necessary.)(Page 5B-17) Tightening torque
30) Remove clutch cover and clutch disc, if necessary. Engine right mounting bracket bolt and nut (a):
)(Page 5C-11) 55 N·m (5.6 kgf-m, 40.5 lbf-ft)
31) For M/T model, remove flywheel, if necessary.
)(Page 1D-25)
For A/T model, remove drive plate, if necessary.
)(Page 1D-25) 1, (a)

Installation
1) For M/T model, install flywheel, if removed. )(Page 2, (a)
1D-25)
For A/T model, install drive plate, if removed.
)(Page 1D-25)
2) For M/T model, install clutch cover and clutch disc, if
removed. )(Page 5C-11)
3) Install transaxle to engine, if removed.)(Page 5B- IAP70A140008-01
17)
10) Tighten engine left mounting bracket bolt (1) and
4) Install front suspension frame, if removed. )(Page nuts (2) to specified torque.
1D-18)
Tightening torque
5) Install drive intermediate shaft assembly, if removed.
Engine left mounting bracket bolt and nut (a): 55
)(Page 3A-8)
N·m (5.6 kgf-m, 40.5 lbf-ft)
6) Install front drive shaft assembly, if removed.
)(Page 3A-3)
7) Install engine harness to engine and transaxle and
then tighten engine harness ground bolt (1) to
specified torque, if removed.
Tightening torque
Engine harness ground bolt (a): 11 N·m (1.1 kgf- 2, (a)
m, 8.5 lbf-ft)

IBP80A141040-01

1, (a) 11) Tighten suspension frame bolts to specified torque.

)(Page 2B-11)
12) Install exhaust No.1 pipe and exhaust center pipe.
)(Page 1K-2)
13) Connect right and left drive shaft joints to steering
I9P60A141049-01
knuckle. )(Page 3A-3)
8) Lift up engine with transaxle, front suspension frame, 14) Connect tie-rod end from steering knuckle. )(Page
drive shafts, P/S gear case assembly all together. 6C-24)
15) Install stabilizer bar joints to stabilizer bar. )(Page
2B-11)
1D-21 Engine Mechanical: K14B

16) Connect steering lower shaft from pinion shaft. 22) Install A/C compressor drive belt.
)(Page 6B-13) • Single A/C model: )(Page 7B-43)
17) Install all other removed electric wires, connectors • Dual A/C model: )(Page 7B-92)
and hoses to original locations.
23) Install air cleaner assembly. )(Page 1D-5)
18) Tighten battery ground terminal bolt (1).
24) Check to ensure that all removed parts are back in
place. Reinstall any necessary parts which have not
been reinstalled.
25) Refill the following oils and fluid if necessary.
1 • Engine oil: )(Page 1E-3)
• Transaxle oil (M/T model): )(Page 5B-7)
26) Install battery and battery tray with ECM. )(Page
1J-9)
27) Connect ECM wire harness. )(Page 1C-1)
28) Connect positive (+) and negative (–) cables at
battery.
29) Refill cooling system with coolant. )(Page 1F-11)
I9P60A141052-02
30) Check any leakage of fuel, coolant, oil and exhaust
19) Install clutch operating cylinder assembly. )(Page gas.
5C-8) • Fuel leak: )(Page 1G-16)
20) Connect gear shift control cable. )(Page 5B-8) • Coolant leak: )(Page 1F-11)
21) Install A/C compressor to its bracket. 31) Install right and left side engine undercovers.
• Single A/C model: )(Page 7B-44)
• Dual A/C model: )(Page 7B-92)

Timing Chain Cover Components

AENBL80A1416017
OIL

(a)
9

(b) 7

11 (c)
10

6
8 (c)
OIL

1 1207B 1217G 4

2
OIL

(d) 3

8 (c)

IAP70B140021-01
 Engine Mechanical: K14B 1D-22

1. Timing chain cover 7. OCV : 40 N⋅m (4.1 kgf-m, 29.5 lbf-ft)

: Apply sealant 99000-31140 and 99000-31260.
For details, refer to “Timing Chain Cover
Removal and Installation”: K14B (Page 1D-22).
2. Crankshaft pulley 8. Timing chain cover bolt : 25 N⋅m (2.5 kgf-m, 18.5 lbf-ft)
: For tightening order, refer to
“Timing Chain Cover Removal
and Installation”: K14B (Page
1D-22).
3. Oil seal 9. Engine hook : 150 N⋅m (15.3 kgf-m, 111.0 lbf-ft)
: Apply engine oil to oil seal lip.
4. O-ring 10. Timing chain cover plug gasket : Do not reuse.
: Apply engine oil.
5. Gasket 11. Timing chain cover plug
: Apply engine oil.
6. Dowel pin : 11 N⋅m (1.1 kgf-m, 8.5 lbf-ft)

Timing Chain Cover Removal and Installation NOTE

AENBL80A1416018
Use special tool with its pins removed if
! CAUTION necessary.

• Keep working table, tools and hands clean Special tool

while overhauling. (A): 09917M68221
• Use special care to handle aluminum parts
so as not to damage them.
• Do not expose removed parts to dust.
Keep them always clean.

Removal
1) Remove engine assembly from vehicle. )(Page 1D-
18)
2) Remove water pump / generator drive belt. )(Page
1J-11) (A) 1
3) Remove crankshaft pulley bolt. I7V20A141049-01

To lock crankshaft pulley (1), use special tool with it 4) Remove crankshaft pulley (1).
as shown in figure. If it is hard to remove, use special tools as shown in
figure.
! CAUTION
Special tool
• Use special tool to prevent unnecessary (A): 09926M37610M001
load on timing chain, sprockets and any (B): 09926M58010
other related parts.
• Use bolts as specified below for installing
special tool to crankshaft pulley.

“a”

I8T401142029-01

I2RH0B140052-01
Special tool fixing bolt
5) Remove cylinder head cover. )(Page 1D-8)
Bolt size M8
Pitch 1.25 mm (0.05 in.) 6) Remove oil pan. )(Page 1E-6)
Length “a” 25 mm (0.98 in.) 7) Remove water pump pulley.
Strength 7T 8) Remove timing chain cover bolts, and then remove
timing chain cover.
9) Remove crankshaft oil seal from timing chain cover
using a flat-bladed screwdriver or the like, if
necessary.
1D-23 Engine Mechanical: K14B

10) Remove OCV from timing chain cover, if necessary.

)(Page 1D-24)
11) Disassemble timing chain cover and oil pump, if
necessary. )(Page 1E-9)

Installation
1) Clean sealing surface on timing chain cover, cylinder
block and cylinder head.
Remove oil, old sealant and dust from sealing
surface.
2) Reassemble timing chain cover and oil pump if
removed. )(Page 1E-9)
1
3) Install OCV, if removed. )(Page 1D-24) I9P60A141056-01
4) Check oil seal (1) lip for fault or other damage. 8) Apply sealant “A” to mating surface of cylinder and
Replace oil seal, if necessary. cylinder head and “B” to mating surface of timing
chain cover as shown in figure.
NOTE
When installing new oil seal, press fit to “A”: Water tight sealant 99000–31140 (SUZUKI
timing chain cover (2) using special tool (A) Bond No.1207B)
as shown in figure. “B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Depth Sealant amount for timing chain cover
“a”: 1.5 mm (0.06 in.) Width “a”: 3 mm (0.12 in.)
Special tool Height “b”: 2 mm (0.08 in.)
(A): 09913M75810

“a” “B”
(A)

“A”
“B” “A”
1

“a”
“B” “b”

2 9) Apply engine oil to oil seal lip, then install timing
I7V20A141050-01
5) Install new O-ring (1) to oil pump (2).
6) Install new gasket (3) to timing chain cover (4).
3
4
IAP70B140023-01
chain cover (1). Tighten bolts by gradually in
numerical order “1” through “15” to specified torque.
NOTE
Before installing timing chain cover, check
that pin is securely fitted.
Tightening torque
Timing chain cover bolt* (a): 25 N·m (2.5 kgf-m,
18.5 lbf-ft)

IAP70B140022-01

7) Install dowel pins (1) to cylinder block, if removed.

 Engine Mechanical: K14B 1D-24

“1”, (a)
1

“10” “8”

“6”
“4” “3”
“5”
“2”
(a)
“9”
“7”
“11” (A) 1
I9P60A141040-02
“12”

“13”
14) Install engine assembly to vehicle. )(Page 1D-18)

Timing Chain Cover Inspection

“15” “14” AENBL80A1416019

IAP70B140024-01 Oil Seal

10) Install water pump pulley. Check oil seal lip for fault or other damage.
11) Install cylinder head cover. )(Page 1D-8) Replace oil seal if any abnormalities are found.
12) Install oil pan. )(Page 1E-6)
Timing Chain Cover
13) Install crankshaft pulley (1). Tighten crankshaft Inspect oil passage (1) for VVT actuators and strainers
pulley bolt to specified torque. To lock crankshaft (2).
pulley, use special tool as shown in figure. Clean oil passage and strainers if clogging or foreign
matter exists.
! CAUTION
1
• Use special tool to prevent unnecessary
load on timing chain, sprockets and any
other related parts.
• Use bolts as specified below for installing
special tool to crankshaft pulley.

IAP70B140025-01
“a”

I8T401142029-01 OCV Removal and Installation

AENBL80A1416020
Special tool fixing bolt
Bolt size M8 Removal
Pitch 1.25 mm (0.05 in.) 1) Disconnect negative (–) cable at battery.
Length “a” 25 mm (0.98 in.) 2) Disconnect OCV connector.
Strength 7T
3) Remove OCV (1) from timing chain cover.

NOTE
Use special tool with its pins removed if
necessary.
1
Special tool
(A): 09917M68221
Tightening torque
Crankshaft pulley bolt (a): 150 N·m (15.3 kgf-m,
111.0 lbf-ft)
IAP70B140026-01
1D-25 Engine Mechanical: K14B

Installation • Tighten flywheel bolts to specified torque.

Reverse removal procedure noting the following point:
Tightening torque
• Tighten OCV bolt to specified torque.
Flywheel or Drive plate bolt (a): 70 N·m (7.1 kgf-
Tightening torque m, 52.0 lbf-ft)
OCV bolt: 11 N·m (1.1 kgf-m, 8.5 lbf-ft)

Flywheel Removal and Installation

AENBL80A1416021
Removal
1) Remove clutch cover and clutch disc. )(Page 5C-
11)
2) Install special tool to ring gear teeth to lock flywheel
or drive plate as shown in figure.
Special tool
(A): 09924M17811
I8C50A140046-01

Flywheel Inspection
AENBL80A1416022

Visual Inspection
• If ring gear is damaged, cracked or worn, replace
flywheel.
• If the surface contacting clutch disc is damaged or
excessively worn, replace flywheel.

Flywheel Face Runout

I8C50A140045-01
Check flywheel face runout with a dial gauge.
3) Remove flywheel from crankshaft. If runout exceeds its limit, replace flywheel or drive plate.

Installation Flywheel face runout

Reverse removal procedure noting the following points. Limit: 0.2 mm (0.0079 in.)
• Install new flywheel bolts.
• Install special tool in ring gear teeth to lock flywheel
(M/T model) as shown in figure.
Special tool
(A): 09924M17811

I2RH01140198-01
 Engine Mechanical: K14B 1D-26

Timing Chain and Chain Tensioner Components

AENBL80A1416023

OIL
2

OIL
4

(a)

5 (b)

OIL
3
(b)

(b)
I7V20A141056-01

1. Crankshaft timing sprocket 4. Timing chain tensioner : 11 N⋅m (1.1 kgf-m, 8.5 lbf-ft)
: Apply engine oil to sliding surface.
2. Timing chain 5. Timing chain tensioner adjuster
: Apply engine oil.
3. Timing chain guide : 25 N⋅m (2.5 kgf-m, 18.5 lbf-ft)
: Apply engine oil to sliding surface.

Timing Chain and Chain Tensioner Removal

and Installation
AENBL80A1416024

Removal

! CAUTION
After timing chain is removed, never turn
crankshaft and camshafts independently
more than specified range (“a” and “b”) as
shown in figure.
If either of those shafts is turned over the
specified range, interference may occur
between piston and valves and valves
themselves, and parts related to piston and
valves may be damaged.
1D-27 Engine Mechanical: K14B

4) Remove timing chain tensioner (8).

1
5) Remove timing chain guide (9).
6) Remove timing chain (10) and crankshaft timing
“b” sprocket (11).
“b”
2
1 10

“b” “b” 3
2

5
8
4

4
“a” “a”
9

IAP70B140027-01 7 5

1. Timing mark on VVT actuator 5. Notch on cylinder block

2. Timing mark on exhaust “a”: 90°
camshaft timing sprocket
3. Notch on cylinder head “b”: 15°
4. Key

11
NOTE IAP70B140028-01

If it is necessary to rotate the camshaft after

removing timing chain, turn crankshaft
counterclockwise and position the key (1)
within an angle of 30° to 90° from TDC as
shown in the figure below before rotating the
camshaft in order to prevent the valves from
coming in contact with the pistons.
Installation
1) Align timing mark (1) on VVT actuator with surface of
cylinder head (2).
2) Align timing mark (3) on exhaust camshaft timing
sprocket with notch (4) on cylinder head.
3) Set key (5) and turn crankshaft to match key with
notch (6) on cylinder block.

1 2

“a”

“b”

1
I7V20A141058-01 3
“a”: 30° “b”: 90°
4

1) Remove timing chain cover. )(Page 1D-22)

2) By turning crankshaft, align camshafts and
crankshaft at specific position as follows. 6
a) Align timing marks (1) on VVT actuator with
surface of cylinder head (2). 5
b) Align timing marks (3) on exhaust camshaft
timing sprocket with notch (4) on cylinder head.
c) Position crankshaft sprocket key (5) with notch
(6) on cylinder block.
3) Remove timing chain tensioner adjuster (7).
IAP70B140029-01
 Engine Mechanical: K14B 1D-28

4) Install crankshaft timing sprocket to crankshaft.
5) Install timing chain while aligning painted plates (1)
with timing marks (2) on VVT actuators and exhaust
camshaft timing sprocket.
6) Install timing chain while aligning painted plate (3)
with timing mark (4) on crankshaft timing sprocket.
9) Check that timing mark (2) on VVT actuators and
exhaust camshaft timing sprocket are in match with
painted plates (1) of timing chain and timing mark (4)
on crankshaft timing sprocket is in match with
painted plate (3) of timing chain.
1 1

1 1

2 2

2 2

3
IAP70B140030-02
3
IAP70B140030-02
10) Screw in plunger (1) by turning body (2) in arrow
direction and install a retainer (3) (1.4 mm (0.055 in.)
7) Apply engine oil to sliding surface of timing chain
diameter wire or the like) to hold plunger in place.
guide (1) and install it as shown in figure.
Tighten guide bolts to specified torque.
Tightening torque
Timing chain guide bolt (a): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)
8) Apply engine oil to sliding surface of chain tensioner
(2) and install chain tensioner and spacer.
Tighten tensioner bolt to specified torque.
Tightening torque
Timing chain tensioner bolt (b): 25 N·m (2.5 kgf- I2RH0B140065-01

m, 18.5 lbf-ft) 11) Install timing chain tensioner adjuster (1) with a
retainer (2).
Tighten timing chain tensioner adjuster bolts to
specified torque, and then remove a retainer from
chain tensioner adjuster.
(b) (a)
Tightening torque
Timing chain tensioner adjuster bolt (a): 11 N·m
1 (1.1 kgf-m, 8.5 lbf-ft)

2 (a)

IAP70B140031-01
1D-29 Engine Mechanical: K14B

(a)

1 2
I7V20A141064-01

12) Apply engine oil to timing chain, and then turn I7V20A141066-01
crankshaft clockwise 720°, and confirm that the
following conditions are satisfied: Timing Chain Tensioner
• Timing mark (1) on VVT actuator is aligned with Check sliding surface of timing chain tensioner (1) for
surface of cylinder head (2). wear or damage.
If abnormality is found, replace timing chain tensioner.
• Timing mark (3) on exhaust camshaft timing
sprocket is aligned with notch (4) of cylinder head.
• Crankshaft sprocket key (5) is aligned with notch
(6) of cylinder block.

2
1

I7V20A141067-01

Crankshaft Timing Sprocket

Check teeth of sprocket for wear or damage.
6
If abnormality is found, replace crankshaft timing
sprocket.
5

IAP70B140032-01

13) Install timing chain cover and crankshaft pulley.

)(Page 1D-22)
14) Install water pump pulley. )(Page 1F-16)
15) Install cylinder head cover. )(Page 1D-8)
16) Install oil pan. )(Page 1E-6) I2RH0B140070-01

17) Install engine assembly. )(Page 1D-18)

Timing Chain
Check timing chain for wear or damage.
Timing Chain and Chain Tensioner Inspection If abnormality is found, replace timing chain.
AENBL80A1416025

Timing Chain Guide

Check sliding surface of timing chain guide (1) for wear
or damage.
If abnormality is found, replace timing chain guide.
I2RH01140077-01
 Engine Mechanical: K14B 1D-30

Timing Chain Tensioner Adjuster

Check that tooth surface (1) are free from damage.
If abnormality is found, replace timing chain tensioner
adjuster.

I2RH0B140071-01

Valve and Cylinder Head Components

AENBL80A1416026

OIL
9 (a)

10

1 8

3 1
5
2
OIL

4
3 11
OIL

4
OIL

6
13 (b)
OIL

12

IAP70B140033-01

1. Valve cotters 9. Cylinder head bolt

: Check cylinder head bolt for deformation to reusing. )(Page 1D-37)
: Apply engine oil to bolt thread.
: For tightening order, refer to “Valve and Cylinder Head Removal and Installation”: K14B
(Page 1D-31).
2. Valve spring retainer 10. Cylinder head
3. Valve spring 11. Cylinder head gasket
4. Valve stem seal 12. Dowel pin
: Apply engine oil to valve stem seal lip.
5. Valve spring seat 13. Venturi plug
6. Intake valve : 20 N⋅m → 40 N⋅m → +60° → +60° (2.0 kgf-m → 4.0 kgf-m → +60° → +60°, 14.5 lbf-ft →
: Apply engine oil to sliding surface. 29.0 lbf-ft → +60° → +60°)
7. Exhaust valve : 3.5 N⋅m (0.36 kgf-m, 2.5 lbf-ft)
: Apply engine oil to sliding surface.
8. Valve guide : Do not reuse.
1D-31 Engine Mechanical: K14B

Valve and Cylinder Head Removal and

2
Installation
AENBL80A1416027 1

Removal
1) Remove engine assembly from vehicle. )(Page 1D-
18)
2) Remove Intake manifold. )(Page 1D-7)
3) Remove cooling water pipe. )(Page 1F-12)
4) Remove oil pan. )(Page 1E-6) I9P60A141004-01

5) Remove cylinder head cover. )(Page 1D-8) 4) Install cylinder head to cylinder block as follows.
6) Remove timing chain cover. )(Page 1D-22)
NOTE
7) Remove timing chain. )(Page 1D-26)
• Before placing cylinder head, position
8) Remove intake and exhaust camshafts. )(Page 1D-
crankshaft within “a” range indicated in
10).
figure.
9) Remove camshaft bearings.
• Before tightening cylinder head bolts,
10) Loosen cylinder head bolts in such order as turning crankshaft counterclockwise 30° –
indicated in figure using a 12-point socket wrenches 90° as shown in figure.
and remove them.
• If cylinder head bolt is reused, make sure
“5” “10” “8” “2” to check bolt for deformation. )(Page 1D-
37)

“3”

“a”

“1” “b”

“7” “9” “6” “4” 1

I9P60A141002-01
11) Check all around cylinder head for any other parts
required to be removed or disconnected and remove
or disconnect whatever necessary.
12) Remove cylinder head with exhaust manifold. Use
lifting device, if necessary.
13) Remove following components of cylinder head if
necessary.
• Exhaust manifold: )(Page 1K-3)
• Fuel injector: )(Page 1G-18)
• Oil venturi plug: )(Page 1D-32)
• Thermostat assembly: )(Page 1F-12)
Installation
1) Clean mating surface of cylinder head and cylinder
block. Remove oil, old gasket and dust from mating
surface.
2) Install knock pins (1) to cylinder block.
3) Install new cylinder head gasket (2) to cylinder block.
I7V20A141058-01
“a”: 30° “b”: 90° 1. Key
a) Apply engine oil to new cylinder head bolts.
b) Tighten cylinder head bolts (“1” – “10”) to 20 N⋅m
(2.0 kgf-m, 15.0 lbf-ft) according to numerical
order as shown using a 12-point socket
wrenches.
c) In the same manner as in Step b), tighten them
to 40 N⋅m (4.1 kgf-m, 29.5 lbf-ft).
d) Turn all bolts 60° according to numerical order in
figure.
e) Repeat Step d).
Tightening torque
Cylinder head bolt* (a): 20 N⋅m → 40 N⋅m →
+60° → +60° (2.0 kgf-m → 4.0 kgf-m → +60° →
+60°, 14.5 lbf-ft → 29.0 lbf-ft → +60° →+60°)
 Engine Mechanical: K14B 1D-32

“8”,(a) “6”,(a) “1”,(a) “3”,(a) “9”,(a)

“10”,(a) “4”,(a) “2”,(a) “5”,(a) “7”,(a)

I9P60A141005-02

5) Install camshafts and tappet referring to Step 2)

through 8) of “Installation” under “Camshaft and
Tappet Removal and Installation”: K14B (Page 1D-
10).
6) Install timing chain. )(Page 1D-26)
7) Install timing chain cover. )(Page 1D-22)
8) Install cylinder head cover. )(Page 1D-8)
9) Install oil pan. )(Page 1E-6)

Valve and Cylinder Head Disassembly and

Reassembly I2RH0B140093-01
AENBL80A1416028
5) Release special tools (Valve lifter), and remove
Disassembly spring retainer and valve spring.
1) Remove venturi plug (1). 6) Remove valve from combustion chamber side.
7) Remove valve stem seal (1) and valve spring seat
(2).

1 I2RH0B140094-01

IAP70B140034-01 8) Using special tool, remove valve guide from

2) Place disassembled parts except valve stem seal combustion chamber side to valve spring side.
and valve guide in order so that they can be installed Special tool
in their original position. (A): 09916M44310
3) To facilitate servicing cylinder head, remove injectors
and exhaust manifold from cylinder head.
4) Using special tools (A) and (B) compress valve
spring and then remove valve cotters (1) also using
special tool (C).
Special tool
(A): 09916M14510
(B): 09916M14522
(C): 09916M84511

I2RH0B140095-01
1D-33 Engine Mechanical: K14B

Reassembly
1) Before installing valve guide into cylinder head, ream
guide hole with special tool (10.5 mm reamer) so as
to remove burrs and make it truly round.
Special tool
(A): 09916M34542
(B): 09916M37320

I2RH0B140097-01

3) Ream valve guide bore with special tool.

NOTE
Clean away shavings from reamed hole.
I2RH0B140096-01

2) Using special tools, install new valve guide to Special tool

cylinder head as follows. (A): 09916M34542
Special tool (B): 09916M34570
(A): 09916M57330
(B): 09916M56011

NOTE
• Do not reuse valve guide. Install new
oversized valve guide.
• Intake and exhaust valve guides are
identical.

a) Uniformly heat cylinder head uniformly to a

temperature of 80 to 100 °C (176 to 212 °F) so
that it will not be distorted, and drive new valve
guide into its hole with special tools.
b) Install new valve guide until special tool contacts
cylinder head.
After installation, make sure that valve guide
protrudes from cylinder head by specified
dimension “a”.
Valve guide protrusion (In and Ex)
“a”: 11.0 – 11.5 mm (0.4331 – 0.4528 in.)
I2RH0B140096-01
4) Install valve spring seat to cylinder head.
5) Install new valve stem seal (1) to valve guide.
After applying engine oil to valve stem seal and
spindle of special tool (B), fit valve stem seal to
spindle, and then install valve stem seal to valve
guide by pushing special tool by hand.
After installation, check that valve stem seal is
properly fixed to valve guide.

! CAUTION
When installing, never tap or hit special tool
with a hammer or the like. Install valve stem
seal to guide only by pushing special tool by
hand. Tapping or hitting special tool may
cause damage to valve stem seal.

Special tool
(A): 09917M98221
(B): 09916M57330
 Engine Mechanical: K14B 1D-34

9) Use special tools to compress valve spring and fit

two valve cotters (1) into groove in valve stem.

NOTE
When compressing the valve spring, be
careful not to damage inside surface of
tappet installing hole.

Special tool
(A): 09916M14510
(B): 09916M14522
(C): 09916M84511

I2RH0B140098-01

6) Apply engine oil to valve stem seal, valve guide bore

and valve stem.
7) Install valve to valve guide.

I2RH0B140101-01

10) Install venturi plug (1) and tighten venturi plug to

specified torque.
Tightening torque
Venturi plug (a): 3.5 N·m (0.36 kgf-m, 2.5 lbf-ft)

I2RH0B140099-01

8) Install valve spring and spring retainer.

Each valve spring has top end (large-pitch end (1))
and bottom end (small-pitch end (2)). Be sure to
position spring in place with its bottom end (small-
pitch end) facing the bottom (valve spring seat side).

3
[a]
1
1, (a)

IAP70B140035-01

11) Install fuel injectors. )(Page 1G-18)

2
[b]
12) Install exhaust manifold. )(Page 1K-3)
I9P60A141006-01

[a]: Valve spring retainer side 3. Paint mark

[b]: Valve spring seat side

Valve and Valve Guide Inspection

AENBL80A1416029

Valve Guide
Valve stem-to-guide clearance
Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide
clearance.
Be sure to take reading at more than one place along the length of each stem and guide.
1D-35 Engine Mechanical: K14B

If clearance exceeds limit, replace valve and valve guide.

Valve stem and valve guide specification
Item Standard Limit
In 4.965 – 4.980 mm (0.1955 – 0.1960 in.) —
Valve stem outside diameter [A]
Ex 4.940 – 4.955 mm (0.1945 – 0.1950 in.) —
Valve guide inside diameter [B] In & Ex 5.000 – 5.012 mm (0.1969 – 0.1973 in.) —
In 0.020 – 0.047 mm (0.0008 – 0.0018 in.) 0.070 mm (0.0028 in.)
Stem-to-guide clearance
Ex 0.045 – 0.072 mm (0.0018 – 0.0283 in.) 0.090 mm (0.0035 in.)

I4RS0B140016-01

Valve stem end deflection

If bore gauge is not available, check end deflection of
valve stem with a dial gauge instead.
Move stem end in directions (1) and (2) to measure end 1
deflection. “a”
If deflection exceeds its limit, replace valve stem and
valve guide.
2
Valve stem end deflection limit
In: 0.14 mm (0.0055 in.)
Ex: 0.18 mm (0.0071 in.)

I9T401142024-01

2. Valve guide 3. Valve seat

Venturi plug inspection

IYSQ01141096-01 Check that venturi plug passage is not clogged.
If venturi plug passage is clogged, clean or replace
Valve venturi plug.
Visual inspection
• Remove all carbon deposits from valve.
• Check each valve for wear, burn or distortion at its
face and stem and, if necessary, replace it.
• Measure valve protrusion length “a”.
If measured length is out of standard value, replace I7V20A141083-03

valve.
Valve protrusion length “a” Standard
In: 34.7 – 35.3 mm (1.366 – 1.389 in.)
Ex: 34.6 – 35.2 mm (1.362 – 1.385 in.)
Valve head radial runout
Check each valve for radial runout with a dial gauge and
“V” block. To check runout, rotate valve slowly. If runout
exceeds its limit, replace valve.
 Engine Mechanical: K14B 1D-36

Valve head radial runout Seat width for intake valve seat
Item Standard Limit “a”: 1.0 – 1.1 mm (0.0394 – 0.0433 in.)
In 0 – 0.05 mm 2) Exhaust valve seat:
0.08 mm (0.0031 in.)
(0 – 0.0019 in.) Use valve seat cutters (1) to make two cuts as
Ex 0 – 0.03 mm illustrated in figure. Two cutters must be used: the
0.08 mm (0.0031 in.)
(0 – 0.0012 in.) first for making 15° angle, and the second for making
45° angle. The second cut must be made to produce
desired seat width.
Seat width for exhaust valve seat
“b”: 1.0 – 1.3 mm (0.0394 – 0.0512 in.)
3) Valve lapping:
Lap valve on seat in two steps, first with coarse size
lapping compound applied to face and the second
with fine-size compound, each time using valve
lapper according to usual lapping method.

I2RH01140136-01

Seating contact width

Create contact pattern on each valve in the usual
manner, i.e., by giving uniform coat of marking
compound to valve seat and by rotating and tapping seat 1
with valve head. Valve lapper (tool used in valve lapping)
must be used.
Pattern produced on seating face of valve must be a
continuous ring without any break, and the width of
pattern must be within specified range. [A] [B]
Standard seating width “a” revealed by contact
pattern on valve face “a” “b”
In: 1.0 – 1.1 mm (0.0394 – 0.0433 in.) “f”
Ex: 1.0 – 1.3 mm (0.0394 – 0.0512 in.) “e” “e”
“d”
“c”
I9P60A141078-01

[A]: Intake “c”: 15° “e”: 45°

[B]: Exhaust “d”: 30° “f”: 70°

Cylinder Head Inspection

AENBL80A1416030
• Remove all carbon deposits from combustion
chambers.

I2RH0B140103-01

Valve seat repair

A valve seat not producing a uniform contact with its
valve or showing width of seating contact that is out of
specified range must be repaired by regrinding or by
cutting and regrinding and finished by lapping.
1) Intake valve seat:
Use valve seat cutters (1) to make three cuts as
illustrated in figure. Three cutters must be used: the
1st for making 30° angle, the 2nd for making 70°
angle, and 3rd for making 45° angle. The 3rd cut
(45°) must be made to produce desired seat width.
1D-37 Engine Mechanical: K14B

NOTE
Do not use any sharp-edged tool to scrape
off carbon deposits. Be careful not to scuff or
nick metal surfaces when removing carbon
deposits. The same applies to valves and
valve seats, too.

I2RH0B140105-01

• Check cylinder head for cracks on intake and exhaust

ports, combustion chambers, and head surface.
I2RH0B140106-01

Cylinder Head Flatness Distortion of seating faces intake manifold and

Use a straightedge and feeler gauge to check flatness of exhaust manifold on cylinder head
gasket surface at a total of 6 locations. Limit: 0.05 mm (0.0020 in.)
If any measured value exceeds its limit, correct gasket
[A]
surface with a surface plate and abrasive paper #400
(Waterproof silicon carbide abrasive paper) by placing
abrasive paper on surface plate and rubbing gasket
surface against paper to grind off high spots.
If it is impossible to correct cylinder head distortion,
replace cylinder head.
[B]
NOTE
Distorted mating surface of cylinder head
and cylinder head gasket causes combustion
gas and/or coolant leakage, overheating and
reduced power output. I9P60A141007-01

[A]: Intake side [B]: Exhaust side

Distortion of mating surface of cylinder head and
cylinder head gasket
Limit: 0.03 mm (0.0012 in.) Cylinder Head Bolt Inspection
AENBL80A1416031
NOTE
If they are reused, check thread diameter of
cylinder head bolt (1) for deformation as
follows and replace it with new one if thread
diameter difference exceeds limit.

Measured each thread diameter of cylinder head bolt “c”

at “a” and “d” at “b” using micrometer (3).
Then calculate difference in diameters (“c” – “d”).
If it exceeds limit, replace with new one.
Cylinder head bolt diameter measurement points
“a”: 70.0 mm (2.76 in.)
“b”: 105 mm (4.13 in.)
Cylinder head bolt diameter difference (deformation)
Limit (“c” – “d”): 0.2 mm (0.0079 in.)
 Engine Mechanical: K14B 1D-38

1
“c” “d”

“a”

“b”
I9P60A141079-01

3
I9T401142035-01

2
Spring Squareness
Use a square and surface plate to check each spring for
squareness in terms of clearance between end of valve
spring and square. Valve springs found to exhibit a
larger clearance than limit must be replaced.
I9T401142032-01 Valve spring squareness “a”
2. Thread Limit: 1.9 mm (0.0748 in.)

“a”
Valve Spring Inspection
AENBL80A1416032

Valve Spring Free Length and Preload

• Check each valve spring for breakage or weakening.
• Measure valve spring free length and preload.
If measured value is less than limit, replace valve
spring.
I9P60A141009-01
NOTE
Weakened valve spring can cause chatter,
not to mention possibility of reducing power
output due to gas leakage caused by
decreased seating pressure.

Valve spring free length “a”

Standard: 42.87 mm (1.6878 in.)
Valve spring preload when compressed to 28.9 mm
(1.1378 in.)
Standard: 104 – 120 N (10.7 – 12.2 kgf, 23.4 – 26.9 lbf)
Limit: 94 N (9.6 kgf, 21.1 lbf)

“a”
I9T401142034-01
1D-39 Engine Mechanical: K14B

Piston, Piston Ring, Connecting Rod and Cylinder Components

AENBL80A1416033

OIL
1

OIL
3

OIL
2

OIL
4
9

OIL
8

OIL
5

OIL
10 (a)

6
OIL

7
I7V20A141087-02

1. 1st ring 7. Connecting rod bearing

: For assembly, refer to “Piston, Piston Ring, Connecting Rod and : For applying engine oil, refer to “Piston, Piston Ring,
Cylinder Disassembly and Reassembly”: K14B (Page 1D-41). Connecting Rod and Cylinder Removal and Installation”:
: Apply engine oil to sliding surface. K14B (Page 1D-39).
2. 2nd ring 8. Piston pin
: For assembly, refer to “Piston, Piston Ring, Connecting Rod and : Apply engine oil to sliding surface.
Cylinder Disassembly and Reassembly”: K14B (Page 1D-41).
: Apply engine oil to sliding surface.
3. Oil ring 9. Piston pin circlip
: For assembly, refer to “Piston, Piston Ring, Connecting Rod and
Cylinder Disassembly and Reassembly”: K14B (Page 1D-41).
: Apply engine oil to sliding surface.
4. Piston 10. Connecting rod bolt
: For assembly, refer to “Piston, Piston Ring, Connecting Rod and : Check connecting rod bolt for deformation to reuse. )(Page
Cylinder Removal and Installation”: K14B (Page 1D-39). 1D-43)
: Apply engine oil to sliding surface. : Apply engine oil to bolt thread and seat.
: For tightening order, refer to “Piston, Piston Ring, Connecting
Rod and Cylinder Removal and Installation”: K14B (Page 1D-
39).
5. Connecting rod : 15 N⋅m → +65° (1.5 kgf-m → +65°, 11.0 lbf-ft)
: Do not apply engine oil to mating surface between connecting rod
bearing and connecting rod.
: Apply engine oil to sliding surface.
6. Connecting rod bearing cap : Do not reuse.
: To install connecting rod cap, direct arrow on it to crank pulley.
: Do not apply engine oil to mating surface between connecting rod
bearing and connecting rod cap.

Piston, Piston Ring, Connecting Rod and 7) Remove connecting rod bearings from connecting
Cylinder Removal and Installation rod and connecting rod bearing cap, if necessary.
AENBL80A1416034

Removal
1) Remove engine assembly from vehicle. )(Page 1D-
18)
2) Remove cylinder head. )(Page 1D-31)
3) Mark cylinder number on all pistons, connecting rods
and connecting rod caps using silver pencil or quick
drying paint.
4) Remove connecting rod bearing caps.
5) Remove carbon deposits from top of cylinder bore
before removing piston from cylinder.
6) Push piston and connecting rod assembly out from
the top of cylinder bore.
 Engine Mechanical: K14B 1D-40

Installation Tap piston head to install piston into bore. Hold ring
compressor firmly against cylinder block until all
! CAUTION piston rings have entered cylinder bore.
• Apply engine oil to the following parts: Special tool
– Crankshaft pin (A): 09916M77310
– Connecting rod bearing
– Piston 1
– Piston ring
– Cylinder wall (A)
• Install the following parts in the position
where they were:
– Connecting rod
– Connecting rod bearing
– Connecting rod bearing cap
– Piston I7V20A141090-01

5) Install bearing cap (1) as follows.

1) Apply engine oil to pistons, piston rings, cylinder
walls, connecting rod bearings and crankshaft pins. NOTE

NOTE • Before installing connecting rod bearing

Do not apply engine oil to mating surface
between connecting rod and bearing or
between connecting rod bearing cap and
bearing.
2) Install connecting rod bearing to connecting rod
bearing cap and connecting rod as follows.
a) Fit tab (1) of connecting rod bearing to groove (2)
of connecting rod and bearing cap.
b) Press bearing end (3) until it becomes flush with
connecting rod or connecting rod bearing cap
mating surface.
1 3
2
cap, check connecting rod bolt for
deformation. Refer to “Connecting rod bolt
deformation” under “Piston Pin and
Connecting Rod Inspection”: K14B (Page
1D-43).
• Tighten connecting rod bolt (3) gradually
to the specified torque.
a) Point front mark (2) on cap to crankshaft pulley
side.
b) Apply engine oil to bolt thread and seat of
connecting rod bolt.
c) Tighten all connecting rod bolts to 15 N⋅m (1.5
kgf-m, 11.0 lbf-ft).
d) Retighten them to 65°.
Tightening torque
Connecting rod bolt* (a): 15 N⋅m → +65° (1.5
kgf-m → +65°, 11.0 lbf-ft → +65°)

1
I7V20A141088-01

3) When installing piston and connecting rod assembly

into cylinder bore, point front mark (1) on piston head
to crankshaft pulley side (2). 2

1 3, (a)

I9P60A141072-02

6) Install cylinder head. )(Page 1D-31)

I7V20A141089-01 7) Install engine assembly. )(Page 1D-18)
4) Install piston and connecting rod assembly into
cylinder bore. Use special tool to compress rings.
Guide connecting rod into place on crankshaft.
1D-41 Engine Mechanical: K14B

Piston, Piston Ring, Connecting Rod and Reassembly

Cylinder Disassembly and Reassembly 1) Remove carbon deposits from piston head and ring
AENBL80A1416035
grooves using a suitable tool.
! CAUTION 2) Install piston pin to piston (1) and connecting rod (2)
Parts must be reassembled in the position as follows.
where they were. Keep the following as a a) After applying engine oil to piston pin and piston
group for each cylinder: pin holes in piston and connecting rod.
• Piston b) Fit connecting rod as shown in figure.
• Piston pin NOTE
• Piston ring Be sure to position front mark (4) on piston
• Connecting rod and oil hole (5) of connecting rod at specified
• Connecting rod bearing position as shown in figure.
• Connecting rod bearing cap
c) Insert piston pin to piston and connecting rod.
Disassembly d) Install new piston pin circlips (3).
1) Using a piston ring expander, remove two NOTE
compression rings (1st and 2nd) and oil ring from
Circlip should be installed with its end gap
piston.
facing as shown in figure. Install so that
2) Remove piston pin from connecting rod as follows. circlip end gap comes within such range as
a) Remove piston pin circlips (1), as shown. indicated by arrow (6).

1
6
“a”

2 3
5

I9P60A141073-01
I2RH0B140113-01
“a”: 45°
b) Remove piston pin.

3) Install piston rings to piston noting the following.

• As indicated in figure, 1st and 2nd rings have top
mark (1) respectively. When installing these piston
rings to piston, top mark side of each ring upward.
• 1st ring (2) differs from 2nd ring (3) in thickness,
shape and color of surface contacting cylinder
wall.
Refer to the figure to distinguish 1st ring from 2nd
ring.
• When installing oil ring (4), install spacer first and
I2RH0B140114-01 then two rails.
 Engine Mechanical: K14B 1D-42

3 I7V20A141095-01

4
“e” “f”

I8T401142098-02
“c”
4) After installing three rings (1st, 2nd and oil rings),
distribute their end gaps as shown in figure.
“d”
“b”
“a”
I9P60A141081-01

“e”: 50 mm (1.96 in.) “f”: 100 mm (3.94 in.)

Piston
Visual inspection
I9P60A141080-02
Inspect piston for faults, cracks or other damages.
1. Front mark 4. 2nd ring end gap and oil ring spacer gap Damaged or faulty piston should be replaced.
2. Oil ring upper rail gap 5. Oil ring lower rail gap
3. 1st ring end gap “a”: 45°
Piston diameter
As indicated in figure, piston diameter should be
Cylinder, Piston and Piston Ring Inspection measured at specified position “a” 9.0 mm (0.3543) from
AENBL80A1416036
piston skirt end in the direction perpendicular to piston
Cylinder pin.
Visual inspection Piston diameter specification
Inspect cylinder walls for scratches, roughness or ridges Standard size (used piston): 72.978 – 72.990 mm
which indicate excessive wear. If cylinder bore is very (2.8732 – 2.8736 in.)
rough, deeply scratched, ridged, replace cylinder block, Standard size (new piston with coating): 72.984 –
piston rings and/or pistons. 73.016 mm (2.8734 – 2.8746 in.)

Cylinder bore diameter, taper and out-of-round

Using a cylinder gauge (1), measure cylinder bore in
thrust and axial directions at two positions (“a” and “b”)
and cylinder taper (“c” and “d”) as shown in figure.
If any of the following conditions is noted, replace
cylinder block. “a”

I9T401142038-01
• Cylinder bore dia. exceeds limit.
“a”: 9.0 mm (0.3543 in.)
• Difference of measurements at two positions exceeds
taper limit.
Piston clearance
• Difference between thrust and axial measurements
Measure cylinder bore diameter and piston diameter to
exceeds out-of-round limit.
find their difference which is piston clearance. Piston
Cylinder bore diameter clearance should be within specification. If it is not as
Standard: 73.000 – 73.014 mm (2.8740 – 2.8746 in.) specified, replace cylinder block, piston rings and/or
Limit: 73.056 mm (2.876 in.) pistons.
Cylinder taper and out-of-round
Limit: 0.010 mm (0.0004 in.)
1D-43 Engine Mechanical: K14B

NOTE Piston Ring

Cylinder bore diameters used here are Piston ring end gap
measured in thrust direction at two positions. To measure end gap, insert piston ring (1) into cylinder
bore and then measure the gap using feeler gauge (2).
Piston clearance If measured gap exceeds limit, replace ring.
Limit: 0.139 mm (0.0055 in.)
NOTE
Remove carbon deposit from top of cylinder
bore before inserting piston ring.

Piston ring end gap

Item Standard Limit
0.15 – 0.28 mm
Top ring 0.7 mm (0.0276 in.)
(0.0059 – 0.0110 in.)
0.28 – 0.41 mm
2nd ring 1.0 mm (0.0394 in.)
(0.0110 – 0.0161 in.)
0.20 – 0.50 mm
Oil ring 1.2 mm (0.0472 in.)
(0.0079 – 0.0197 in.)
I7V20A141095-01

“a”

I9T401142038-01

“a”: 9.0 mm (0.3543 in.)

"a"
Ring groove clearance
1
1) Before checking, piston grooves must be clean, dry I7V20A141096-02
and free from carbon deposits. “a”. 50 mm (1.97 in.)
2) Fit new piston ring (1) into piston groove, and
measure clearance between ring and ring land using Piston Pin and Connecting Rod Inspection
feeler gauge (2). If clearance is out of limit, replace AENBL80A1416037
piston.
Piston Pin
Ring groove clearance
Visual inspection
Standard Limit Check piston pin, connecting rod small-end bore and
0.03 – 0.07 mm piston pin hole in piston for wear or damage, paying
1st ring 0.12 mm (0.0047 in.)
(0.0012 – 0.0028 in.) particular attention to condition of small-end bore
0.02 – 0.06 mm bushing. If piston pin, connecting rod small end bore or
2nd ring 0.10 mm (0.0039 in.)
(0.0008 – 0.0023 in.) piston pin hole in piston is badly worn or damaged,
0.04 – 0.12 mm replace pin, connecting rod and/or piston.
Oil ring —
(0.0016 – 0.0047 in.)
Piston pin clearance
Check piston pin clearance in small-end and piston.
Replace connecting rod and/or piston if its small end is
badly worn or damaged or if measured clearance
1 exceeds limit.

I9T401142039-01
 Engine Mechanical: K14B 1D-44

NOTE
For identification of piston pin hole (1) inside
diameter and piston pin (2) outside diameter,
they are indicated by stamped alphabet (3) (A
or B) at the location as shown in figure.

2
1
IAP70B140039-01

Piston pin clearance in connecting rod small-end

Standard: 0.003 – 0.017 mm (0.00012 – 0.00067 in.)
Limit: 0.017 mm (0.00067 in.)
Piston pin clearance in piston
Standard: 0.004 – 0.008 mm (0.00016 – 0.00031 in.) I4RS0A140023-01
Limit: 0.008 mm (0.00031 in.)
Small-end bore Connecting Rod
18.003 – 18.013 mm (0.7088 – 0.7091 in.) Big-end side clearance
Check big-end of connecting rod for side clearance, with
Piston pin outside diameter rod fitted and connected to its crankshaft pin in the
17.9981 – 18.0000 mm normal manner. If measured clearance to exceeds its
A
Stamped alphabet (0.70859 – 0.70866 in.) limit, replace connecting rod.
on piston pin 17.9960 – 17.9980 mm
B Big-end side clearance
(0.70851 – 0.70858 in.)
Standard: 0.1 – 0.3 mm (0.0039 – 0.0118 in.)
Diameter of piston pin hole in piston Limit: 0.55 mm (0.0217 in.)
18.0041 – 18.0060 mm
A
Stamped alphabet (0.70883 – 0.70889 in.)
on piston 18.0020 – 18.0040 mm
B
(0.70875 – 0.70881 in.)

I7V20A141097-01

Connecting rod alignment

Mount connecting rod on aligner to check it for bow and
twist. If measured value exceeds the limit, replace.
Connecting rod alignment
Limit on bow: 0.05 mm (0.0020 in.)
Limit on twist: 0.10 mm (0.0039 in.)
1D-45 Engine Mechanical: K14B

NOTE
When regrind crank pin to under size, use
with under size connecting rod bearing.

Crankshaft pin diameter

Connecting rod bearing
Crankshaft pin diameter
size
37.982 – 38.000 mm
Standard
(1.4954 – 1.4961 in.)
I4RH01140053-01
0.25 mm (0.0098 in.) 37.732 – 37.750 mm
undersize (1.4855 – 1.4862 in.)
Connecting rod bolt deformation
Measure each thread diameter of connecting rod bolt (1) Crankshaft pin taper ([a] – [b]) and out-of-roundness
at “c” on 12 mm (0.47 in.) from bolt mounting surface ([1] – [2])
and “d” on 32 mm (1.26 in.) from bolt mounting surface Limit: 0.01 mm (0.0004 in.)
using a micrometer (3).
Calculate difference in diameters (“c” – “d”). If it is
exceeds limit, replace connected rod bolt (1).
Connecting rod bolt measurement points
“a”: 12 mm (0.47 in.)
“b”: 32 mm (1.26 in.)
Connecting rod bolt diameter difference
Limit (“c” – “d”): 0.05 mm (0.002 in.)

1 “c” “d”

[1] [a] [b]

[2]
“a”

“b”
I8T401142103-01

3 Connecting Rod Bearing General Information

• Service connecting rod bearings are available in
2
standard size and 0.25 mm undersize bearing, and
standard size bearing has 5 kinds of bearings differing
in tolerance.
• For identification of undersize bearing, it is painted red
at the position as indicated in figure, undersize
I9P60A141082-01 bearing thickness is 1.605 – 1.615 mm (0.0632 –
0.0636 in.) at its center.
Crankshaft Pin and Connecting Rod Bearing
Inspection
AENBL80A1416038

Crankshaft Pin Diameter

Check crankshaft pin for uneven wear or damage.
Measure crankshaft pin for out-of-round or its taper with
a micrometer. If crankshaft pin is damaged or out-of
round or taper is out of limit, replace crankshaft or
regrind crankshaft pin to undersize and use undersize
I2RH01140164-01
bearing.
1. Painting
 Engine Mechanical: K14B 1D-46

Connecting Rod Bearing Visual Inspection Selection of Connecting Rod Bearings

Check bearing shells for signs of fusion, pitting, burn or If engine is under the following conditions select a new
flaking and observe contact pattern. Bearing shells standard bearing as follows, and install it.
found in defective condition must be replaced. • Bearing is defective.
• Bearing clearance is out of specification.
Connecting Rod Bearing Clearance
• Crankshaft or connecting rod is replaced.
NOTE 1) Check stamped numbers on connecting rod and its
After checking connecting rod bearing cap as shown.
clearance, check connecting rod bolt for Three kinds of numbers (“1”, “2” and “3”) represent
deformation referring to “Connecting rod the following connecting rod big-end inside
deformation” under “Piston Pin and diameters.
Connecting Rod Inspection”: K14B (Page 1D- For example, stamped number “1” indicates that
43). corresponding connecting rod big-end inside
diameter is 41.0000 – 41.0060 mm (1.61417 –
1) Clean connecting rod bearings and crankshaft pin. 1.61440 in.).
2) Place a piece of gauging plastic (1) to full width of Connecting rod big-end inside diameter
crankshaft pin as contacted by bearing (parallel to
Stamped
crankshaft), avoiding oil hole. Connecting rod big-end inside diameter
number
41.0000 – 41.0060 mm
1
1 (1.61417 – 1.61440 in.)
41.0061 – 41.0120 mm
2
(1.61441 – 1.61464 in.)
41.0121 – 41.0180 mm
3
(1.61465 – 1.61488 in.)

I7V20A141100-01

3) Install connecting rod bearing and its cap. )(Page

1D-39) 2
4) After three minutes has elapsed, remove cap and
measure gauging plastic (1) width at the widest point
using a scale (2) on gauging plastic envelope 1

(clearance).
If clearance exceeds its limit, select a new standard I8T401142106-02
size connecting rod bearing. )(Page 1D-46) 1. Connecting rod big-end inside diameter number
After selecting new connecting rod bearing, recheck 2. Weight indication mark
clearance.
Connecting rod bearing clearance 2) Check crankshaft pin diameter. On crank web No.5,
Standard: 0.031 – 0.049 mm (0.0012 – 0.0019 in.) four alphabets are stamped as shown in figure.
Limit: 0.065 mm (0.0026 in.) Three kinds of alphabet (“A”, “B” and “C”) represent
the following crankshaft pin diameter respectively.
For example, stamped “A” indicates that
2 corresponding crankshaft pin diameter is 37.9940 –
1
38.0000 mm (1.49582 – 1.49606 in.).
Crankshaft pin outer diameter
Stamped
Crankshaft pin diameter
alphabet
37.9940 – 38.0000 mm
A
(1.49582 – 1.49606 in.)
37.9880 – 37.9939 mm
B
I7V20A141101-01 (1.49559 – 1.49581 in.)
5) If clearance cannot be brought to its limit even by a 37.9820 – 37.9879 mm
C
new standard size bearing, use next thicker bearing (1.49535 – 1.49558 in.)
and recheck clearance or regrind crankshaft pin to
undersize and use 0.25 mm undersize bearing.
1D-47 Engine Mechanical: K14B

4) From number stamped on connecting rod and its cap

and alphabets stamped on crank web No.5,
determine new standard bearing to be installed to
connecting rod big-end inside, by referring to the
table.
For example, if number stamped on connecting rod
and its cap is “1” and alphabet stamped on crank
web No.5 is “B”, install a new standard bearing
painted in “Black” to its connecting rod big-end
inside.
Connecting rod bearing cross-reference
1 2 3 4
I9P60A141010-01
selection table (standard size)
1. Crankshaft pin No.1 3. Crankshaft pin No.3
Stamped number for
2. Crankshaft pin No.2 4. Crankshaft pin No.4 connecting rod big end
inside diameter
3) There are five kinds of standard bearings differing in 1 2 3
thickness. To distinguish them, they are painted in Stamped alphabet A Green Black Nothing
the following colors at the position as indicated in for Crankshaft pin B Black Nothing Yellow
figure. diameter C Nothing Yellow Blue
Each color indicates the following thickness at the
center of bearing. 5) Check bearing clearance with newly selected
standard bearing referring to “Connecting Rod
Standard size connecting rod bearing thickness Bearing Clearance”: K14B (Page 1D-46).
Color If clearance still exceeds its limit, use next thicker
Bearing thickness
painted bearing and recheck clearance.
Blue 1.498 – 1.501 mm (0.05898 – 0.05909 in.)
Yellow 1.495 – 1.498 mm (0.05886 – 0.05897 in.)
Nothing 1.492 – 1.495 mm (0.05875 – 0.05885 in.)
Black 1.489 – 1.492 mm (0.05863 – 0.05874 in.)
Green 1.486 – 1.489 mm (0.05850 – 0.05862 in.)

I3RH0A140019-01

1. Paint
 Engine Mechanical: K14B 1D-48

Main Bearing, Crankshaft and Cylinder Block Components

AENBL80A1416039

OIL
3

(b)

4
14

7
OIL

6 (a) 14

5 1217G

OIL
(b) 13
12

OIL
9
OIL

8
OIL

10
15

11

(b)
IAP70B140037-01

1. CKP sensor 10. Main bearing

: For removal and installation, refer to “Knock Sensor Removal and : For applying engine oil, refer to “Main Bearing,
Installation”: K14B in Section 1C (Page 1C-9). Crankshaft and Cylinder Block Removal and
Installation”: K14B (Page 1D-49).
2. Knock sensor 11. Sensor plate
: For removal and installation, refer to “Knock Sensor Removal and
Installation”: K14B in Section 1C (Page 1C-9).
3. Cylinder block 12. Crankshaft timing sprocket key
: Do not apply engine oil to main bearing seating face.
: Apply engine oil to sliding surface
4. Timing chain oil jet 13. Rear oil seal
: Apply engine oil to oil seal lip.
5. Engine rear crankshaft oil seal housing 14. Dowel pin
: Apply sealant 99000-31260 referring to “Main Bearing, Crankshaft and
Cylinder Block Removal and Installation”: K14B (Page 1D-49).
6. Main bearing cap bolt 15. Spring pin
: Check main bearing cap bolt for deformation to reuse. )(Page 1D-52)
: Apply engine oil to bolt thread and seat.
: For tightening order, refer to “Main Bearing, Crankshaft and Cylinder Block
Removal and Installation”: K14B (Page 1D-49).
7. Main bearing cap : 20 N⋅m → 40 N⋅m → +60° (2.0 kgf-m → 4.1 kgf-m →
+60°, 15.0 lbf-ft → 29.5 lbf-ft → +60°)
8. Crankshaft : 11 N⋅m (1.1 kgf-m, 8.5 lbf-ft)
: Apply engine oil to sliding surface
9. Thrust bearing : Do not reuse.
: Install thrust bearing with oil grooves facing out.
: Apply engine oil to sliding surface.
1D-49 Engine Mechanical: K14B

Main Bearing, Crankshaft and Cylinder Block Installation

Removal and Installation
AENBL80A1416040 ! CAUTION
! CAUTION • Apply engine oil to the following parts:
Parts must go back in the position where – Crankshaft journal
they were. Keep them in the following order: – Main bearing
• Main bearing – Thrust bearing
• Thrust bearing • Do not apply engine oil to the following
spots:
Removal – Mating surfaces between main bearing
1) Remove engine assembly from vehicle. )(Page 1D- and cylinder block
18) – Mating surfaces between main bearing
2) Remove flywheel. )(Page 1D-25) and main bearing cap
3) Remove pistons and connecting rods. )(Page 1D- – Mating surfaces between connecting rod
39) bearing and connecting rod
4) Remove engine rear crankshaft oil seal housing (1). – Mating surfaces between connecting rod
bearing and connecting rod cap
• Install the following parts in the position
where they were:
– Main bearing
– Thrust bearing

1) Install sensor plate (1) to crankshaft (3) and tighten

bolts to specified torque, if removed.

! CAUTION
1 • Align spring pin hole (4) on sensor plate
with spring pin (2) on crankshaft.
I7V20A141105-01 • Inside edge (5) of sensor plate is bent.
5) Remove main bearing cap bolts in numerical order Install sensor plate properly.
gradually as indicated in figure.
Tightening torque
“7” “9” “5”
Sensor plate bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-
ft)
“3” “1”

6 3

“4” “2” 5 1

“8” “10” “6” (a)

I9P60A141012-01

6) Remove crankshaft from cylinder block. (a)

2
7) Remove sensor plate from crankshaft, if necessary.
4

1
(a)
IAP70B140038-01

6. Crankshaft side
 Engine Mechanical: K14B 1D-50

2) Install main bearings to cylinder block and main 5) Install crankshaft to cylinder block.
bearing cap. 6) Install bearing cap to cylinder block, making sure to
point arrow mark (on each cap) to crankshaft pulley
NOTE
side. Fit them sequentially in ascending order, 1, 2,
• Install main bearing halves with oil groove 3, 4 and R, starting from pulley side.
to cylinder block. 7) After applying engine oil to main bearing cap bolts
• Install other main bearing halves to main (“1” through “10”) tighten them as follows.
bearing cap.
NOTE
a) Fit the tab (1) on each bearing into recess (2) in If main bearing cap bolt is reused, check
cylinder block and main bearing cap. main bearing cap bolt for deformation
b) Press bearing end (3) until it fully seat in cylinder referring to “Main bearing cap bolt” under
block and main bearing cap. “Main Bearing Inspection”: K14B (Page 1D-
c) Apply engine oil to sliding surface (4) of main 52).
bearing halves.
a) Tighten bolts to 20 N⋅m (2.0 kgf-m, 15.0 lbf-ft)
! CAUTION according to numerical order as shown in figure
using a 12-point socket wrench.
Do not apply engine oil to mating surface (5)
b) In the same manner as Step a), tighten them to
between bearing half and cylinder block or
40 N⋅m (4.0 kgf-m, 29.5 lbf-ft).
main bearing cap.
c) In the same manner as Step a), retighten them to
60°.
Tightening torque
Main bearing cap bolt*: 20 N⋅m → 40 N⋅m →
1 3 +60° (2.0 kgf-m → 4.0 kgf-m →+60°, 14.5 lbf-ft
4
→ 29.0 lbf-ft →+60°)

2 ! CAUTION

5
After tightening cap bolts, check to be sure
I8T401142036-01 that crankshaft rotates smoothly when
3) Install thrust bearings (1) to cylinder block between turning it by 12 N⋅m (1.2 kgf-m, 9.0 lbf-ft)
No.2 and No.3 cylinders. torque or below.

NOTE
“4” “2” “6”
Be sure to face oil groove (2) side to crank
web.
“8” “10”
4) Confirm that dowel pins (3) are installed to intake
side of each journal.

“7” “9”
2

“3” “1” “5”

1 3 I9P60A141013-01

8) Clean sealing surface between engine rear

crankshaft oil seal housing (2) and cylinder block.
9) Apply engine oil to new rear oil seal (1) and install it
to engine rear crankshaft oil seal housing (2) using
special tool.
I7V20A141108-01
Special tool
(A): 09911M16300
Engine rear crankshaft oil seal installing position
(dimension)
“a”: 2.0 mm (0.08 in.)
1D-51 Engine Mechanical: K14B

(A)
(A)

(A) 1
1
“a”

2 (A)

2 1 2,(a)

I7V20A141112-01

I7V20A141110-01 3: Crankshaft side

10) Install dowel pin (2) to engine rear crankshaft oil seal
housing (1) as shown in figure.
11) Apply sealant to mating surface of engine rear
crankshaft oil seal housing (1).
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for rear oil seal housing
Width: “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
“a”
“A”
“A”
14) Install flywheel. )(Page 1D-25)
15) Install pistons and connecting rods. )(Page 1D-39)
16) Install cylinder head. )(Page 1D-31)
17) Install camshafts and tappets. )(Page 1D-10)
18) Install timing chain. )(Page 1D-26)
19) Install timing chain cover. )(Page 1D-22)
20) Install cylinder head cover. )(Page 1D-8)
21) Install oil pan. )(Page 1E-6)
22) Install engine assembly to vehicle. )(Page 1D-18)
“b”
Crankshaft Inspection
AENBL80A1416041
Crankshaft Runout
1 Using a dial gauge, measure runout at center journal.
Rotate crankshaft slowly. If runout exceeds its limit,
replace crankshaft.
2
Crankshaft runout
Limit: 0.02 mm (0.0008 in.)
I7V20A141111-01

12) Apply engine oil to oil seal lip, then install engine rear
crankshaft oil seal housing (1) using special tool.
13) Tighten new engine rear crankshaft oil seal housing
bolts (2) to specified torque.

NOTE
Confirm that engine rear crankshaft oil seal
lip is not turned over after engine rear
crankshaft oil seal housing is installed.
I7V20A141113-01
Special tool
(A): 09911M97720 Crankshaft Thrust Play
Tightening torque 1) Assemble crankshaft, main bearings, thrust bearings
Engine rear crankshaft oil seal housing bolt: 11 and main bearing cap. )(Page 1D-49)
N·m (1.1 kgf-m, 8.5 lbf-ft) 2) Using dial gauge (1), measure crankshaft thrust play
(2) as shown in figure.
If measured thrust play exceeds limit, replace thrust
bearing with new one (standard size or over size) to
obtain standard thrust play.
Recheck crankshaft thrust play.
 Engine Mechanical: K14B 1D-52

Crankshaft thrust play • Upper bearing half (1) has oil groove (2) as shown in
Standard: 0.11 – 0.31 mm (0.0043 – 0.0122 in.) figure.
Limit: 0.35 mm (0.0137 in.) Install this half with oil groove to cylinder block (3).
• Lower bearing half does not have an oil groove.

1 2 3

2
I8C50A140074-01

I7V20A141117-01
Thrust bearing thickness
Standard size: 2.470 – 2.520 mm (0.9724 – 0.9921
Visual Inspection
in.)
Check bearings for pitting, scratches, wear or damage.
Oversize (0.125 mm, 0.00492 in.): 2.533 – 2.583
If any defect is found, replace both upper and lower
mm (0.0997 – 0.1016 in.)
halves. Never replace either half without replacing the
other half.
Out-of-Roundness and Taper (Uneven Wear) of
Journals
Main Bearing Clearance
An unevenly worn crankshaft journal shows up as a
difference in diameter at a cross section or along its NOTE
length (or both). This difference, if any, is determined by
Do not rotate crankshaft while gauging
taking micrometer readings. If any one of journals is
plastic is installed.
badly damaged or uneven wear exceeds its limit, regrind
or replace crankshaft. Check clearance using gauging plastic according to the
Crankshaft journal outside diameter following procedure.
Standard: 45.000 – 45.018 mm (1.7716 – 1.7723 in.) 1) Remove main bearing caps.
Limit: 44.99 mm (1.771 in.) 2) Clean bearings and main journals.
Crankshaft out-of-roundness ([1] – [2]) and taper ([a] 3) Place a piece of gauging plastic (1) the full width of
– [b]) bearing (parallel to crankshaft) on journal, avoiding
Limit: 0.01 mm (0.0003 in.) oil hole.

[a] [b]
1

[1]

I7V20A141118-01
[2] 4) Install main bearing cap. )(Page 1D-49)
5) After three minutes, remove main bearing cap and
using scale (2) on gauging plastic envelope (1),
I8C50A140075-01
measure gauging plastic width at its widest point.
Main Bearing Inspection Main bearing clearance
AENBL80A1416042 Standard: 0.016 – 0.034 mm (0.0006 – 0.0013 in.)
Limit: 0.050 mm (0.0020 in.)
General Information
• Service main bearings are available in standard size
and 0.25 mm undersize, and each of them has 5 kinds
of bearings differing in tolerance.
1D-53 Engine Mechanical: K14B

1
2

I7V20A141119-01

If measured clearance is less than standard or more I9P60A141014-01

than service limit, replace main bearings with new 1. Crankshaft pulley side
ones referring to “Selection of Main Bearing”: K14B
(Page 1D-53) and recheck main bearing clearance. 2) Check bearing cap bore diameter without bearing.
If measured clearance with new bearing is out of On mating surface of cylinder block, five alphabets
standard, select other bearing according to the are stamped as shown in figure (1).
following procedure and recheck main bearing Six kinds of alphabets (“A” through “F”) or numbers
clearance. (“1” through “6”) represent the following cap bore
• More than standard: diameters.
Replace bearing with one size thicker or regrind Stamped alphabets or numbers on cylinder block
crankshaft journal to undersize and use 0.25 mm represent bearing cap bore diameter marked with an
undersize bearing. arrow in figure respectively.
• Less than standard: For example, stamped “A” or “1” indicates that
Replace bearing with one size thinner or regrind corresponding bearing cap bore diameter is 49.000
crankshaft journal to undersize and use 0.25 mm – 49.003 mm (1.92913 – 1.92925 in.).
undersize bearing. Crankshaft bearing cap bore
Stamped Bearing cap bore diameter (without
Selection of Main Bearing number bearing)
Standard size bearing A or 1 49.000 – 49.003 mm (1.92913 – 1.92925 in.)
If engine is under one of the following conditions, select B or 2 49.003 – 49.006 mm (1.92925 – 1.92937 in.)
a new standard bearing as follows, and install it. C or 3 49.006 – 49.009 mm (1.92937 – 1.92948 in.)
• Bearing is defective. D or 4 49.009 – 49.012 mm (1.92948 – 1.92960 in.)
• Bearing clearance is not as specified. E or 5 49.012 – 49.015 mm (1.92960 – 1.92972 in.)
F or 6 49.015 – 49.018 mm (1.92972 – 1.92984 in.)
• Crankshaft or cylinder block is replaced.
1) Check journal diameter. As shown in figure, crank
web No.4 has stamped numbers.
Six kinds of numbers (“1” through “6”) represent the
following journal diameters.
Stamped numbers on crank web No.4 represent
diameters of journal indicated with an arrow in figure
2
respectively.
For example stamped number “1” indicates that
corresponding journal diameter is 45.015 – 45.018
mm (1.7722 – 1.7723 in.).
Crankshaft journal diameter
1
Stamped
Journal diameter I9P60A141015-01
numbers
2. Crankshaft pulley side
1 45.015 – 45.018 mm (1.7722 – 1.7723 in.)
2 45.012 – 45.015 mm (1.7721 – 1.7722 in.)
3 45.009 – 45.012 mm (1.7720 – 1.7721 in.)
4 45.006 – 45.009 mm (1.7719 – 1.7720 in.)
5 45.003 – 45.006 mm (1.7718 – 1.7719 in.)
6 45.000 – 45.003 mm (1.7717 – 1.7718 in.)
 Engine Mechanical: K14B 1D-54

3) There are 5 kinds of standard bearings differing in

thickness. To distinguish them, they are painted in
the following colors at the position as indicated in
figure.
Each color indicated the following thickness at the
center of bearing.
Standard size crankshaft main bearing thickness
Color
Bearing thickness
painted I2RH01140191-01
Pink 1.990 – 1.993 mm (0.07835 – 0.07846 in.)
1. Paint
Purple 1.993 – 1.996 mm (0.07846 – 0.07858 in.)
Brown 1.996 – 1.999 mm (0.07858 – 0.07870 in.)
Green 1.999 – 2.002 mm (0.07870 – 0.07881 in.)
Black 2.002 – 2.005 mm (0.07881 – 0.07894 in.)

4) From number stamped on crank web No.4 and alphabets stamped on cylinder block, determine new standard
bearing to be installed to journal, by referring to the table shown.
For example, if number stamped on crank web No.4 is “1” and alphabet stamped on cylinder block is “B”, install a
new standard bearing painted in “Pink” to its journal.
Main bearing cross – reference selection table (standard size)
Number stamped on crank web No.4
1 2 3 4 5 6
Upper Pink Pink Pink Purple Purple Brown
A or 1
Lower Pink Pink Purple Purple Brown Brown
Upper Pink Pink Purple Purple Brown Brown
B or 2
Alphabet Lower Pink Purple Purple Brown Brown Green
or number Upper Pink Purple Purple Brown Brown Green
C or 3
stamped Lower Purple Purple Brown Brown Green Green
on Upper Purple Purple Brown Brown Green Green
D or 4
cylinder Lower Purple Brown Brown Green Green Black
block Upper Purple Brown Brown Green Green Black
E or 5
Lower Brown Brown Green Green Black Black
Upper Brown Brown Green Green Black Black
F or 6
Lower Brown Green Green Black Black Black

5) Using scale (2) and gauging plastic (1), check bearing clearance with newly selected standard bearing.
If clearance still exceeds its limit, use next thicker bearing and recheck clearance, referring to “Main Bearing
Clearance”: K14B (Page 1D-52).

1
2

I7V20A141119-01

Undersize bearing (0.25 mm)

• 0.25 mm undersize bearing is available, in five kinds varying in thickness.
To distinguish them, each bearing is painted in the following colors at such position as indicated in figure.
Each color represents the following thickness at the center of bearing.
Undersize of crankshaft main bearing thickness
Color painted Bearing thickness
Red & Pink 2.1150 – 2.1180 mm (0.08327 – 0.08339 in.)
Red & Purple 2.1180 – 2.1210 mm (0.08339 – 0.08350 in.)
1D-55 Engine Mechanical: K14B

Color painted Bearing thickness

Red & Brown 2.1210 – 2.1240 mm (0.08350 – 0.08362 in.)
Red & Green 2.1240 – 2.1270 mm (0.08362 – 0.08374 in.)
Red & Black 2.1270 – 2.1300 mm (0.08374 – 0.08386 in.)

I2RH01140192-01

1. Paint

• If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows.
1) Regrind journal to the following finished diameter.
Finished journal diameter
44.750 – 44.768 mm (1.76181 – 1.76252 in.)
2) Using micrometer, measure regrind journal diameter.
Measurement should be taken in two directions perpendicular to each other in order to check for out-of-roundness.
3) Using journal diameter measured above and alphabets stamped on cylinder block, select an undersize bearing by
referring to the following table.
Check bearing clearance with newly selected undersize bearing.

I2RH0B140144-01

Main bearing cross – reference table (undersize)

Measured journal diameter
44.765 – 44.762 – 44.759 – 44.756 – 44.753 – 44.750 –
44.768 mm 44.765 mm 44.762 mm 44.759 mm 44.756 mm 44.753 mm
(1.76240 – (1.76228 – (1.76217 – (1.76205 – (1.76193 – (1.76181 –
1.76252 in.) 1.76240 in.) 1.76228 in.) 1.76217 in.) 1.76205 in.) 1.76193 in.)
Upper Red & Pink Red & Pink Red & Pink Red & Purple Red & Purple Red & Brown
A or 1
Lower Red & Pink Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown
Upper Red & Pink Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown
Alphabet B or 2
Lower Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown Red & Green
or
Upper Red & Pink Red & Purple Red & Purple Red & Brown Red & Brown Red & Green
number C or 3
Lower Red & Purple Red & Purple Red & Brown Red & Brown Red & Green Red & Green
stamped
Upper Red & Purple Red & Purple Red & Brown Red & Brown Red & Green Red & Green
on D or 4
Lower Red & Purple Red & Brown Red & Brown Red & Green Red & Green Red & Black
cylinder
Upper Red & Purple Red & Brown Red & Brown Red & Green Red & Green Red & Black
block E or 5
Lower Red & Brown Red & Brown Red & Green Red & Green Red & Black Red & Black
Upper Red & Brown Red & Brown Red & Green Red & Green Red & Black Red & Black
F or 6
Lower Red & Brown Red & Green Red & Green Red & Black Red & Black Red & Black
 Engine Mechanical: K14B 1D-56

Main Bearing Cap Bolt Timing Chain Jet Inspection

Measure each thread diameter at specified points on AENBL80A1416045
Check that there is no blocking in the timing chain jet
main bearing cap bolts (1) using a micrometer (3).
passage.
Calculate difference in diameters (“c” – “d”).
If venturi plug passage is blocked, clean or replace
If it exceeds limit, replace main bearing cap bolt with new
timing chain jet plug.
one.
Main bearing cap bolt diameter measurement points
“a”: 40 mm (1.57 in.)
“b”: 64 mm (2.52 in.)
Main bearing cap bolt diameter difference
Limit (“c” – “d”): 0.2 mm (0.008 in.) I7V20A141124-01

1 Cylinder Block Inspection

“c” “d” AENBL80A1416046

Distortion of Gasket Surface

Using straightedge and feeler gauge, check gasket
“a”
surface for distortion. If flatness exceeds its limit, repair
“b” it.
I9P60A141079-01 If repair is not possible, replace cylinder block.
Cylinder block flatness
3 Limit: 0.03 mm (0.0012 in.)

I9T401142032-01

2. Thread

Sensor Plate Inspection

AENBL80A1416043
Check sensor plate for crack and damage. I7V20A141125-01

If any defect is found, replace it.

I7V20A141122-01 I7V20A141126-01

Rear Oil Seal Inspection

AENBL80A1416044
Carefully inspect oil seal (1) for wear and damage. If its
lip is worn or damaged, replace it.

I7V20A141123-01
1D-57 Engine Mechanical: K14B

Specifications
Tightening Torque Specifications
AENBL80A1417001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Cylinder head cover bolt* 5.0 N⋅m → 8.0 N⋅m → 11.0 N⋅m (0.51 kgf-m )
→ 0.82 kgf-m→ 1.1 kgf-m, 4.0 lbf-ft → 6.0
lbf-ft → 8.5 lbf-ft)
PCV valve 2.5 0.25 2.0 )
VVT actuator bolt 60 6.1 44.5 )
Camshaft housing bolt* 11 1.1 8.5 )
Exhaust camshaft timing sprocket bolt 60 6.1 44.5 )
Timing chain cover plug 25 2.5 18.5 )
Engine harness ground bolt 11 1.1 8.5 )
Engine right mounting bracket bolt and nut 55 5.6 40.5 )
Engine left mounting bracket bolt and nut 55 5.6 40.5 )
Timing chain cover bolt* 25 2.5 18.5 )
Crankshaft pulley bolt 150 15.3 111.0 )
OCV bolt 11 1.1 8.5 )
Flywheel or Drive plate bolt 70 7.1 52.0 )
Timing chain guide bolt 11 1.1 8.5 )
Timing chain tensioner bolt 25 2.5 18.5 )
Timing chain tensioner adjuster bolt 11 1.1 8.5 )
Cylinder head bolt* 20 N⋅m → 40 N⋅m → +60° → +60° (2.0 kgf- )
m → 4.0 kgf-m → +60° → +60°, 14.5 lbf-ft
→ 29.0 lbf-ft → +60° →+60°)
Venturi plug 3.5 0.36 2.5 )
Connecting rod bolt* 15 N⋅m → +65° (1.5 kgf-m → +65°, 11.0 lbf- )
ft → +65°)
Sensor plate bolt 11 1.1 8.5 )
Main bearing cap bolt* 20 N⋅m → 40 N⋅m → +60° (2.0 kgf-m → 4.0 )
kgf-m →+60°, 14.5 lbf-ft → 29.0 lbf-ft
→+60°)
Engine rear crankshaft oil seal housing bolt 11 1.1 8.5 )

NOTE
The tightening torque(s) also specified in:
“Air Cleaner Components”: K14B
“Cylinder Head Cover Components”: K14B
“Camshaft, Tappet and Shim Components”: K14B
“Engine Mounting Components”: K14B
“Timing Chain Cover Components”: K14B
“Timing Chain and Chain Tensioner Components”: K14B
“Valve and Cylinder Head Components”: K14B
“Piston, Piston Ring, Connecting Rod and Cylinder Components”: K14B
“Main Bearing, Crankshaft and Cylinder Block Components”: K14B

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
 Engine Mechanical: K14B 1D-58

Special Tools and Equipment

Recommended Service Material
AENBL80A1418001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 )/)/)
Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140 )

NOTE
Required service material(s) also described in:
“Cylinder Head Cover Components”: K14B
“Camshaft, Tappet and Shim Components”: K14B
“Timing Chain Cover Components”: K14B
“Timing Chain and Chain Tensioner Components”: K14B
“Valve and Cylinder Head Components”: K14B
“Piston, Piston Ring, Connecting Rod and Cylinder Components”: K14B
“Main Bearing, Crankshaft and Cylinder Block Components”: K14B

Special Tool
AENBL80A1418002
09911M05120 09911M16300
Box end wrench (14 mm) Oil seal installer
) )

09911M97720 09913M75810
Oil seal installer Bearing installer
) )

09914M06310 09915M64512
Guide, camshaft sprocket Compression gauge
) )

09915M64530 09915M64550
Compression gauge hose Compression gauge
attachment (B)
) )

09915M67311 09916M14510
Vacuum gauge Valve lifter
) )/)
1D-59 Engine Mechanical: K14B

09916M14522 09916M34542
Valve spring compressor Reamer handle
attachment
)/) )/)

09916M34570 09916M37320
Valve guide reamer (5 mm) Valve guide outer reamer
(10.5 mm)
) )

09916M44310 09916M56011
Valve guide remover (5 mm) Valve guide installer
attachment (protrusion: 11.5
mm)
) )

09916M57330 09916M77310
Valve guide installer handle Piston ring compressor (50 -
125 mm)
)/) )

09916M84511 09917M68221
Forceps Camshaft pulley holder
)/) )/)

09917M98221 09924M17811
Valve guide stem Flywheel holder
attachment
) )/)

09926M37610M001 09926M58010
Bearing puller Bearing remover attachment
) )
 Engine Mechanical: D13A 1D-60

D13A
Diagnostic Information and Procedures
Compression Check
AENBL80A1424001
Check compression pressure on all 4 cylinders as
follows: (B)
1) Warm up engine.
2) Stop engine after warming up.
(A)
NOTE
After warming up engine, place transmission
gear shift lever in “Neutral” and set parking
brake and block drive wheels.

3) Disconnect negative (–) cable at battery. (A)

4) Disconnect glow plug control module connector.
“Glow Plug Removal and Installation”: D13A in
(B)
Section 1C (Page 1C-19)
5) Remove all glow plugs. “Glow Plug Removal and
Installation”: D13A in Section 1C (Page 1C-19)
6) Disconnect connectors from ECM (1) as follows.
I5RS0B140002-01
a) Pull out lock slider to release locking of lock lever
a). 8) Connect negative (–) cable at battery.
b) Pull up the lock lever b). 9) Disengage clutch (1) in order to lighten starting load
on engine.
1

a)

b)

I7V20A142001-04

7) Install special tools into glow plug hole.

I3RB0A143003-01
Special tool
(A): 09915M68610 10) Crank engine with fully charged battery and read
(B): 09912M57822 highest pressure on compression gauge.
11) Carry out Steps 7) to 10) on each cylinder in order to
obtain 4 readings.

NOTE
• For measuring compression pressure,
crank engine at least 200 rpm. by using
fully charged battery.
• If measured compression pressure is
excessively low at one of 4 cylinder, check
installation condition of special tool.
If it is properly installed, possibility is
compression pressure leakage from where
piston ring, valve contact and cylinder
head gasket.

Compression pressure
Standard: 1650 kPa (16.5 kgf/cm2, 239.3 psi)
1D-61 Engine Mechanical: D13A

Max. difference between any two cylinders: 150
kPa (1.5 kgf/cm2, 21.3 psi)
12) Disconnect negative (–) cable at battery.
13) After checking, install glow plugs. “Glow Plug
Removal and Installation”: D13A in Section 1C
(Page 1C-19)
14) Connect ECM connectors.
15) Connect glow plug control module connector. “Glow
Plug Control Module Removal and Installation”:
D13A in Section 1C (Page 1C-24)
16) Connect negative (–) cable at battery.
9) Insert special tool to hole of transaxle case (1) with
lightly swing crankshaft pulley by hand.
And, confirm special tool is inserted in proper
position as shown in figure.
Special tool
(A): 09912M46310
If not, adjust timing by reinstalling timing chain.
)(Page 1D-82)

Timing Check
AENBL80A1424002
Check timing between camshafts and crankshaft as
follows.
1) Disconnect negative (–) cable at battery.
2) Remove right side engine under cover.
3) Remove common rail. “Common Rail Removal and I5RS0B140003-01
Installation”: D13A in Section 1G (Page 1G-47)
4) Remove engine hook (1) and common rail bracket [A] [B]
(2) from camshaft housing.

1 “a” 2 2
“b”
1 1

(A)
2 (A)

I7V20A142002-01

1. Transaxle case [A]: Proper position “a”: 2 mm (0.079 in.)

2. Fly wheel [B]: Improper position “b”: 10 mm (0.393 in.)

I3RB0A143007-01
10) After checking, remove all special tools inserted in
5) Disconnect wiring harness connector of injectors, Step 8) and 9).
CMP sensor and glow plugs.
11) Apply thread lock compound to thread part of
6) Remove camshaft housing plugs (1). camshaft housing plugs (1), and tighten them to
7) Align camshaft housing plug hole (2) with camshaft specified torque.
gap (3) turning crankshaft pulley clockwise as shown
“A”: Thread lock cement (Loctite omnifit 100M
in figure.
spezial®)
8) Lock camshafts (4) inserting special tools (A) to plug
holes. Tightening torque
Camshaft housing plug (a): 18 N·m (1.8 kgf-m,
Special tool 13.0 lbf-ft)
(A): 09917M68610
1, “A”, (a)
2
(A)

4
3
1 (A)
(A) 1, “A”, (a)

1
I3RB0A143031-03

12) Connect wiring harness connector of injectors, CMP

I3RB0A143010-01
sensor and glow plugs.
 Engine Mechanical: D13A 1D-62

13) Install common rail bracket (2) and engine hook (1)
to camshaft housing. Tighten common rail bracket
bolts to specified torque.
Tightening torque
Common rail bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lbf-ft)
14) Install common rail. “Common Rail Removal and
Installation”: D13A in Section 1G (Page 1G-47)
15) Install right side engine under cover.
16) Connect negative (–) cable at battery.

1 (a)

(a)

I3RB0A143034-01
1D-63 Engine Mechanical: D13A

Repair Instructions
Air Cleaner Components
AENBL80A1426001

10

12

4
3

6 2

13

11

5
IBL80A142001-01
 Engine Mechanical: D13A 1D-64

1. Air cleaner assembly 6. Air cleaner outlet hose 11. To turbocharger

2. Air cleaner mounting bolt 7. Hose clamp 12. To engine
:Be sure to position clamp screw in
specified place as shown in the figure.
3. MAF sensor 8. Breather hose 13. Air cleaner filter
4. MAF sensor O-ring 9. Breather hose clip : 4 N⋅m (0.41 kgf-m, 3.0 lbf-ft)
:Be sure to position clip in specified
direction as shown in the figure.
5. Air cleaner bracket 10. Breather pipe : Do not reuse.

Air Cleaner Filter Removal and Installation Inspection

AENBL80A1426002 Check air cleaner filter for dirt and replace if necessary.
Removal
1) Loosen air cleaner assembly bolts (1). Air Cleaner Assembly Removal and Installation
2) Open air cleaner assembly (2). AENBL80A1426004

1 Removal
2
1) Disconnect negative (–) cable at battery.
2) Remove engine cover.
3) Disconnect MAF sensor and IAT sensor(1).
4) Remove air cleaner case screws (3) from air cleaner
assembly (2).
5) Detach water hose (5) and remove air cleaner
assembly (2) with air cleaner outlet hose (4) and
MAF sensor and IAT sensor.

4 1
3

1
I9P60A142003-01

3) Remove air cleaner filter from air cleaner assembly.

Installation
Reverse removal procedure noting the following points.
• Tighten air cleaner assembly screw (1) to specified
torque.
Tightening torque
Air cleaner assembly screw (a): 1.7 N·m (1.17 kgf-
m, 1.5 lbf-ft) 5

1, (a) 2
3
IBP80A142019-01

Installation
Reverse removal procedure for installation noting the
following.
• Clamp each hose securely.
• Tighten air cleaner outlet hose clamp to specified
torque. )(Page 1D-63)

1, (a)
I9P60A142065-01

Air Cleaner Filter Inspection and Cleaning

AENBL80A1426003
1D-65 Engine Mechanical: D13A

Intercooler Components
AENBL80A1426005

11
8

11

14

9 13

11

11
11
3

12

5
11
2 10

11

IBL80A142002-02

1. Intercooler 7. Intercooler outlet No.1 hose 13. To air intake manifold

2. Intercooler bolt
3. Intercooler inlet No.1 hose
4. Intercooler inlet No.2 hose
5. Intercooler inlet pipe
6. Cross member
8. Intercooler outlet No.2 hose 14. Air intake joint
9. Intercooler outlet pipe : 3.1 N⋅m (0.31 kgf-m, 2.3 lbf-ft)
10. Intercooler mounting : Do not reuse.
11. Hose clamp
: Be sure to position clamp screw in specified position as shown
in the figure
12. To turbocharger
 Engine Mechanical: D13A 1D-66

Intercooler Removal and Installation Vacuum Pump Removal and Installation

AENBL80A1426006 AENBL80A1426007
! CAUTION
Removal
Never disassemble vacuum pump.
1) Remove front bumper. “Front Bumper Removal and
Disassembly will spoil its original function.
Installation” in Section 9H (Page 9H-1)
If faulty condition is found, replace it with
2) Remove intercooler bracket (1) new one.
1
Removal
1) Disconnect negative (–) cable from battery.
2) Disconnect brake booster hose (1) from vacuum
pump & pipe to vacuum reservoir for VGT actuation.

I9P60A142007-01

1) Disconnect intercooler outlet hose (1) from

intercooler and inlet hose (2) from intercooler inlet
pipe (3).
2) Remove intercooler with intercooler inlet hose.
I9P60A142012-01
1 4
3

2
3

1
IBP80A142012-01

3) Remove vacuum pump (2) from camshaft housing.

I9P60A142008-01
Installation
Installation 1) Install new gasket to vacuum pump.
Reverse removal procedure for installation noting the 2) Install vacuum pump (1) to camshaft housing.
following. Fit the protrusion of vacuum pump coupling (2) into
• Tighten hose clamps to specified torque. )(Page 1D- the slot (3) of camshaft.
65)
• Install front bumper. “Front Bumper Removal and
Installation” in Section 9H (Page 9H-1)
1D-67 Engine Mechanical: D13A

5) Install air cleaner assembly. )(Page 1D-64)

6) Connect negative (–) cable to battery.

3 Vacuum Pump Inspection

AENBL80A1426008
1) Start engine and warm it up to normal operating
temperature.
2) Stop engine.
3) Connect vacuum gauge (2) to brake booster hose
(1) and start the engine.

2 1

I7V20A142010-01

3) Tighten vacuum pump bolts (1) to specified torque. 2

a) Tighten vacuum pump bolts to 5 N⋅m (0.5 kgf-
m,4.0 lbf-ft).
1
b) Tighten vacuum pump bolts to 20 N⋅m (2.0 kgf-
m,14.5 lbf-ft)
Tightening torque
Vacuum pump bolt (a): 5 N·m (0.5 kgf-m, 4.0 lbf-
ft)
and then (a): 20 N·m (2.0 kgf-m, 14.5 lbf-ft) I6RS0E120003-02

4) Connect brake booster hose (2) & vacuum reservoir
for VGT actuation to vacuum pump.
1,(a)
4) Check vacuum pressure. If vacuum pressure is not
as specified, replace vacuum pump.
Vacuum pressure specification
More than –50 kpa (–0.5 kgf/cm2, –7.25 psi –0.5
bar) within 5 seconds at idle speed

2
IBP80A142011-01
 Engine Mechanical: D13A 1D-68

EGR Valve and EGR Cooler Components

AENBL80A1426009

5 8

6 (c)

5
(a)
9

3
4

2 (b)

IBP80A122001-01

1. EGR valve 5. Gasket 9. To Thermostat : Do not reuse.

2. EGR cooler 6. EGR pipe clamp : 22 N⋅m (2.2 kgf-m, 16.5 lbf-ft)
3. EGR cooler hose 7. To heater hose : 25 N⋅m (2.5 kgf-m, 18.5 lbf-ft)
4. Clamp 8. To intake manifold : 1.2 N⋅m (0.1 kgf-m, 1.0 lbf-ft)

EGR Valve and EGR Cooler Removal and

Installation
AENBL80A1426010

Removal
1) Remove battery from vehicle.“Battery Removal and
Installation”: D13A in Section 1J (Page 1J-25)
2) Drain cooling system. “Cooling System Draining”:
D13A in Section 1F (Page 1F-25)
3) Remove degassing tank (2).

2
IBP80A122003-01

4) Remove battery tray from vehicle.“Battery Removal

and Installation”: D13A in Section 1J (Page 1J-25)
1D-69 Engine Mechanical: D13A

5) Remove heater outlet pipe.“Cooling System Installation

Components”: D13A in Section 1F (Page 1F-23)
6) Disconnect water hose (1) and heater hose (2).
7) Disconnect EGR pipe (3) from intake manifold.
8) Disconnect connector from EGR valve.
9) Remove EGR valve (4) and EGR cooler together
from cylinder head.
3
Reverse removal procedure noting the following points.
• Clean mating surface of EGR valve and cylinder
head.
• Use new gaskets.
• Tighten EGR cooler bolts to specified torque, if
removed.
Tightening torque
EGR cooler bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)
• Tighten EGR valve bolts and EGR pipe bolts to
specified torque.
Tightening torque
EGR valve bolt (b): 22 N·m (2.2 kgf-m, 16.5 lbf-ft)
EGR pipe bolt (c): 1.2 N·m (0.1 kgf-m, 1.0 lbf-ft)

(c)

4 1 2
IBP80A122004-01

10) Remove EGR cooler (1) from EGR valve (2), if (a)
necessary.

2 (b)

IBP80A122006-01

• Refill cooling system. “Cooling System Refill”: D13A in

Section 1F (Page 1F-26)
• Check cooling system leakage. “Engine Cooling
System Inspection and Cleaning”: D13A in Section 1F
(Page 1F-24)

IBP80A122005-01
 Engine Mechanical: D13A 1D-70

Crankcase Ventilation System Components

AENBL80A1426011

(b)

6 10
5
1
(a)
7

12

4
(a)

2
11

(a)
I9P60A142023-02

1. Oil separator 6. Ventilation connector 11. To cylinder block

2. Clamp 7. O-ring 12. To breather hose
3. Crankcase ventilation cover 8. Hose bracket : 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft)
4. Ventilation hose No.1 9. Gasket : 8.5 N⋅m (0.85 kgf-m, 6.5 lbf-ft)
5. Ventilation hose No.2 10. To timing chain cover : Do not reuse.

Oil Separator and Crankcase Ventilation Cover 5) Disconnect ventilation connector(2)

Removal and Installation
AENBL80A1426012
Removal
1) Disconnect negative (–) cable at battery.
2) Remove ECM.
3) Remove cowl top panel.
4) Disconnect breather hose(1) from air cleaner outlet
pipe.
1D-71 Engine Mechanical: D13A

4) Disconnect hoses from oil separator if necessary.

1

Installation
Reverse removal procedure noting the following points.
• Clean mating surfaces of crankcase ventilation cover
and cylinder block.
• Use new crankcase ventilation cover gasket and
ventilation hose clamps.
• Tighten each bolts to specified torque.
Tightening torque
Crankcase ventilation cover mounting bolt (a): 10
N·m (1.0 kgf-m, 7.3 lbf-ft)
2 Oil separator mounting bolt (b): 10 N·m (1.0 kgf-
I9P60A142024-01 m, 7.3 lbf-ft)
1) Remove EGR valve and EGR cooler. Generator bracket mounting bolt (c): 22 N·m (2.24
2) Remove oil separator mounting bolts (1). kgf-m, 16.22 lbf-ft)

(c)

I9P60A142025-01

3) Remove oil separator assembly (1) by removing

crankcase ventilation cover mounting bolts (2).

1
(b)

(a)

I9P60A142027-01

2
I9P60A142026-01
 Engine Mechanical: D13A 1D-72

Turbocharger Components
AENBL80A1426013

IBL80A142009-02

1: Turbocharger 7. Catalytic convertor : 9 N⋅m (0.9 kgf-m, 6.6 lbf-ft)

: Do not disassemble
2. Gasket 8. Exhaust manifold gasket : 30 N⋅m (3.1 kgf-m, 22.1lbf-ft)
3. Lock plate 9. Exhaust manifold cover : 15 N⋅m (1.5 kgf-m, 11.0 lbf-ft)
: Bend lock part in order to prevent catalytic converter bolt
from loosening.
4. Turbocharger lubrication pipe 10. Spacer : 45 N⋅m (4.5 kgf-m, 33.0 lbf-ft)
5. Oil return pipe : 25 N⋅m (2.54 kgf-m, 18.4 lbf- : Do not reuse.
ft)
6. Exhaust manifold : 22 N⋅m (2.2 kgf-m, 16.2 lbf-ft)

Turbocharger Removal and Installation Removal

AENBL80A1426014
! WARNING
To avoid danger of being burned, do not
service exhaust system while it is still hot.
Service should be performed after system
cools down.

1) Disconnect negative (–) cable at battery.

1D-73 Engine Mechanical: D13A

2) Remove engine cover.

3) Remove air cleaner outlet pipe (1).

I3RM0B142015-01

10) Remove exhaust No.1 pipe.

11) Disconnect A/F sensor connector.
12) Remove catalytic convertor bracket.
13) Remove turbocharger 1) with catalytic convertor (2)
from exhaust manifold.

I5RS0B140013-01

4) Detach intercooler inlet hose from turbocharger.

5) Remove exhaust manifold side engine hanger.
6) Disconnect glow plug connectors.
7) Remove turbocharger oil intake pipe (1).

I5RS0B140015-01

Installation
Reverse removal procedure noting the following points.
• Clean mating surfaces of turbocharger (1), catalytic
convertor (2) and exhaust manifold.
IBP80A142022-02
• Tighten air cleaner outlet pipe clamp to specified
torque.
8) Remove vacuum hose from turbocharger control
diaphragm. • Use new gaskets.
• Use new oil return hose clamp.
• Use new turbocharger nuts.
• Tighten turbocharger nuts (3) and turbocharger oil
intake pipe bolts (4) to specified torque.
1
Tightening torque
Turbocharger nut (a): 25 N·m (2.55 kgf-m, 18.4 lbf-
ft)
Turbocharger oil intake pipe bolt (b): 22 N·m (2.2
kgf-m, 16.5 lbf-ft)

IAY40A140010-01

9) Remove exhaust manifold cover (1) from exhaust

manifold.
 Engine Mechanical: D13A 1D-74

I7V20A142024-01

Boost Pressure Control Valve

2
! CAUTION
Do not apply pressure more than 138 kPa
(1.38 kgf/cm2, 20.0 psi, 1.38 bar); otherwise
IAY40A140012-01 boost pressure control valve could be
damaged.

Measure stroke of boost pressure control valve rod (1)

as the following steps.
1) Set special tool as follows.
Special tool
(A): 09918M18111
a) Loosen adjusting screw (2) fully.
b) Connect air hose (3) to special tool.
c) Connect special tool to boost pressure control
valve (4).
IBP80A142023-01 2) Measure stroke of boost pressure control valve
• Check any leakage of oil & exhaust. when applying specified pressure by using special
• In case that turbocharger is replaced with the new tool and compressed air (5).
one, perform the following procedure. If measured stroke is out of specification, replace
Otherwise, remaining oil in turbine housing may leak turbocharger.
from turbocharger. Boost pressure control valve rod stroke:
a. Confirm the following points. 1.5 – 2.5 mm (0.059 – 0.098 in.) at 138 kPa (1.38
– Parking brake is applied. kgf/cm2, 20.0 psi, 1.38 bar)
– Drive wheels are blocked.
(A) 1
– M/T is in “Neutral” position.
b. Warm up engine. 3 2

c. After warming up engine, keep the engine speed

around 3000 rpm for 10 min.
While engine is running, check turbocharger for 5
abnormal noise.
d. After stopping engine, check turbocharger for oil
leak.

Turbocharger Inspection 4
AENBL80A1426015 I7V20A142027-02

Visual Inspection
Rotate turbine shaft (1) by hand and verify that it turns
smoothly without any abnormal noise and excessive run
out.
If a malfunction is found, replace the turbocharger.
1D-75 Engine Mechanical: D13A

Intake Manifold Components

AENBL80A1426016

4
8

1
3

7
6

5 (a)
IBL80A142007-02

1. Intake manifold 5. Bolt, intake manifold : 25 N⋅m (2.5 kgf-m, 18.4 lbf-ft)
2. Air intake joint 6. EGR pipe : Do not reuse.
3. Air intake joint gasket 7. EGR pipe gasket
4. Air intake bolt 8. Boost pressure sensor

Intake Manifold Removal and Installation

AENBL80A1426017 1

Removal
1) Disconnect negative (–) cable at battery.
2) Remove ECM.
3) Remove cowl top panel.
4) Remove engine cover.
5) Remove intercooler outlet pipe.
6) Remove EGR valve assembly.
7) Remove harness clamp (1) with wire harness from
intake manifold (2).
I9P60A142025-01

2 1) Remove oil level gauge guide (2) with level gauge.

2) Disconnect connector from boost pressure sensor
(3).

1
I5RS0B140019-01

8) Remove oil separator bolt (1) from intake manifold.

 Engine Mechanical: D13A 1D-76

2 1 “9”,(a) “5”,(a) “1”,(a) “4”,(a) “8”,(a)

I9P60A142038-01

3) Remove intake manifold (1) and gasket from cylinder

head.
“7”,(a) “3”,(a) “2”,(a) “6”,(a)
1 I9P60A142041-01

• Install oil level gauge guide (1) with level gauge and
tighten oil level gauge guide mounting bolt to specified
torque.
Tightening torque
Oil level gauge guide mounting bolt (a): 9.0 N·m (
0.9 kgf-m, 7.0 lbf-ft)

I9P60A142040-01

Installation
Reverse removal procedure for installation noting the
followings.
• Clean mating surfaces of intake manifold and cylinder
(a)
head. I9P60A142042-01

• Use new gasket for intake manifold, air intake joint • Install EGR valve assembly.
and EGR pipe. • Install engine cover.
• Tighten intake manifold bolts in numerical order • Check to ensure that all removed parts are back in
evenly and gradually to specified torque. place.
Tightening torque Reinstall any necessary parts which have not been
Intake manifold bolt (a): 25 N·m (2.5 kgf-m, 18.4 reinstalled.
lbf-ft) • Check to ensure that all removed parts are back in
place.
Reinstall any necessary parts which have not been
reinstalled.
1D-77 Engine Mechanical: D13A

Engine Mounting Components

AENBL80A1426018

IBL80A142010-02

1. Engine right mounting
2. Engine left mounting
3. Engine left mounting bracket
4. Engine rear mounting
5. Engine rear mounting No.1 bracket
6. Engine rear mounting No.2 bracket
7. Engine right mounting bolt
8. Engine right mounting nut
9. Engine left mounting nut
10. Engine left mounting bush bolt
11. Engine left mounting bracket and
transmission bolt
12. Engine rear mounting member and
body bolt
13. Engine rear mounting bush bolt
14. Engine rear mounting No. 1 bracket bolt
15. Engine rear mounting bracket to transmission
bolt
: 55 N⋅m (5.6 kgf-m, 40.5 lbf-ft)
: 93 N⋅m (9.5 kgf-m, 68.6 lbf-ft)

Engine Assembly Removal and Installation 3) Remove coolant reservoir.

AENBL80A1426019
Removal 4) Remove engine cover.
1) Disconnect negative (–) and positive (+) cable at 5) Remove air cleaner assembly with MAF sensor &
battery. IAT sensor-1. )(Page 1D-64)
2) Remove battery and battery tray from vehicle. 6) Remove intercooler.
 Engine Mechanical: D13A 1D-78

7) Remove ECM.
8) Remove cowl top panel. 7 1

9) Drain engine oil.

10) Drain transaxle oil, if necessary. “Manual Transaxle 2
Oil Change”: D13A Model in Section 5B (Page 5B-
52)
11) Drain cooling system. )(Page 1F-25)
12) Take out clutch fluid from brake master reservoir (1)
in space (A) as shown in the figure with syringe or 3

such.

! WARNING
Do not allow fluid to get on painted surface. It
may cause painted surface damage.

“A”

2
9

5 4 8 10
I9P60A142044-02
I5RS0B140024-01
19) Disconnect the following electric wires:
13) Remove right and left side engine under covers.
• Ground Wire (1)
14) Remove accessory drive belt.)(Page 1F-30)
• Electric load current sensor connector (2)
15) Remove turbocharger oil intake pipe.
• Individual circuit fuse box No.1 (3)
16) With hose connected, detach A/C compressor from
• Main fuse box (4)
its bracket (if equipped).
• Magnet clutch switch of A/C compressor (if
• Single A/C type: “A/C Compressor Assembly
equipped)
Removal and Installation”: Single A/C Type in
Section 7B (Page 7B-44) • Main harness (5)
• Dual A/C type: “A/C Compressor Assembly • Each wire harness clamps (6)
Removal and Installation”: Dual A/C Type in • Glow plug control module (7)
Section 7B (Page 7B-92)

! CAUTION
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

17) Disconnect the following pipes and hoses:

• Brake booster hose (1)
• Fuel feed hose (2)
• Fuel return hose (3)
• Radiator inlet hose (4) and outlet hose (5)
• Heater inlet hose (6) and outlet hoses (7)
• Clutch hose and pipe (8)
18) Disconnect the following cables from tansaxle:
• Gear select control cable (9)
• Gear shift control cable (10)
1D-79 Engine Mechanical: D13A

3 2
6 2 1 3

4
4

1
4 8 I9P60A142063-01

1) Remove engine left mounting bracket nuts (1) and

bolts (2).

7
1
2 1
5
I9P60A142045-03

20) Remove exhaust No.1,No.2 and center pipes.

“Exhaust Pipe and Muffler Removal and Installation”:
D13A in Section 1K (Page 1K-9)
21) Disconnect steering lower shaft from pinion shaft.
22) Remove stabilizer bar joints from stabilizer bar.
23) Disconnect tie-rod end from steering knuckle. I9P60A142046-01

24) Disconnect right and left drive shaft joints from

steering knuckle.“Front Drive Shaft Assembly
Removal and Installation”: Front in Section 3A (Page
3A-3)
25) Support front suspension frame(1), transaxle case
(2) and cylinder block (3) using jack.
26) Remove front suspension frame bolts (4)
 Engine Mechanical: D13A 1D-80

2) Remove engine right mounting bracket nuts (2) Tightening torque

Engine harness ground bolt (a): 11 N·m (1.1 kgf-
2 m, 8.5 lbf-ft)

1, (a)

I9P60A142064-01

6) Lift engine with transaxle into engine compartment

using chain hoist.

1
I9P60A142047-01
1) Before removing engine make sure all hoses,
electric wires and cables are disconnected from
engine.
2) Lower engine with transaxle, front suspension frame,
1) Install engine left mounting bracket nuts (1) and bolts
drive shafts, P/S gear case assembly all together.
! CAUTION
! CAUTION
Before lifting engine, in order to avoid
damage to A/C compressor, make clearance
between A/C compressor and engine by
suspending A/C compressor.
(2) and new engine right mounting bracket nuts (3).
Tighten these nuts to specified torque.

Before lowering the engine, in order to avoid Tightening torque

damage to A/C compressor, make clearance Engine left mounting bracket nut (a): 55 N·m (5.6
between A/C compressor and engine by kgf-m, 40.5 lbf-ft)
suspending A/C compressor. Engine left mounting bracket bolt (b): 55 N·m (
5.6 kgf-m, 40.5 lbf-ft)
1) Disconnect engine harness from engine and Engine right mounting bracket nut (b): 55 N·m (
transaxle, if necessary. 5.6 kgf-m, 40.5 lbf-ft)
2) Remove front drive shaft assembly, if necessary.
3) Remove front suspension frame, if necessary.
4) Disconnect transaxle from engine, if necessary.
“Manual Transaxle Unit Dismounting and
Remounting”: D13A Model in Section 5B (Page 5B-
55)
5) Remove clutch cover and clutch disk. “Clutch Cover
and Clutch Disc Removal and Installation”: D13A
Model in Section 5C (Page 5C-23)

Installation
1) Install clutch cover and clutch disk. “Clutch Cover
and Clutch Disc Removal and Installation”: D13A
Model in Section 5C (Page 5C-23)
2) Connect transaxle to engine. “Manual Transaxle Unit
Dismounting and Remounting”: D13A Model in
Section 5B (Page 5B-55)
3) Install front suspension frame, if removed.
4) Install front drive shaft assembly, if removed.
5) Install engine harness to engine and transaxle and
then tighten engine harness ground bolt (1) to
specified torque, if removed.
1D-81 Engine Mechanical: D13A

6) Connect steering lower shaft from pinion shaft.

2, (b)
7) Install exhaust pipe No.1 and No.2. “Exhaust Pipe
and Muffler Removal and Installation”: D13A in
Section 1K (Page 1K-9)
8) Install A/F sensor.
9) Reinstall disconnected hoses, pipes, cables and
electric wires.
Tightening torque
Engine rear mounting bush bolt: 55 N·m (5.6
kgf-m, 40.5 lbf-ft)
10) Install A/C compressor to its bracket (if equipped).
• Single A/C type: “A/C Compressor Assembly
Removal and Installation”: Single A/C Type in
Section 7B (Page 7B-44)
1, (a)
• Dual A/C type: “A/C Compressor Assembly
2, (b) 1, (a) Removal and Installation”: Dual A/C Type in
Section 7B (Page 7B-92)
11) Install accessory drive belt. )(Page 1F-30)
12) Install right and left side engine undercover.
13) Install intercooler. )(Page 1D-66)
14) Install front bumper.
15) Install cowl top panel.
16) Install ECM.
3, (c)
17) Install air cleaner assembly with MAF and IAT
sensor. )(Page 1D-64)
18) Install engine cover.
19) Refill engine with engine oil. )(Page 1E-16)
20) Refill transaxle with transaxle oil. “Manual Transaxle
Oil Change”: D13A Model in Section 5B (Page 5B-
52)
21) Refill cooling system with coolant. )(Page 1F-25)
22) Refill clutch fluid and bleed brake system.
23) Install battery tray and battery.
24) Connect positive (+) and negative (–) cable at
battery
25) Check any leakage of fuel, coolant, oil and exhaust.
• Fuel leak:
I9P60A142049-03 • Coolant leak:
2) Tighten suspension frame bolts to specified torque.
3) Connect right and left drive shaft joints to steering
knuckle.
4) Connect tie-rod end from steering knuckle.
5) Install stabilizer bar joints from stabilizer bar.
 Engine Mechanical: D13A 1D-82

Timing Chain Cover and Timing Chain Components

AENBL80A1426020

14

(a)
13 (b)

OIL
(a) 7
(d)

3 11

(a)

10 OIL

(c)

OIL
9
4 12

6
8 15
OIL

5 2
1
(a)
16 (e)
IBP80A142008-01

1. Crankshaft pulley 9. Timing chain guide : 9.0 N⋅m (0.92 kgf-m, 7.0 lbf-ft)
: Apply engine oil to sliding surface.
2. Crankshaft pulley side crankshaft 10. Timing chain tensioner : 15 N⋅m (1.5 kgf-m, 11.0 lbf-ft)
oil seal : Apply engine oil to sliding surface.
: Apply engine oil to oil seal lip.
3. Timing chain cover 11. Timing chain tensioner adjuster : 25 N⋅m (2.5 kgf-m, 18.5 lbf-ft)
4. Washer 12. Flywheel : 44 N⋅m (4.5 kgf-m, 32.5 lbf-ft)
5. Oil pump drive flange 13. Camshaft housing plug : 230 N⋅m (23.5 kgf-m, 170.0 lbf-ft)
: Apply Loctite omnifit 100M spezial®
to thread parts.
6. Timing chain cover gasket 14. Ventilation connector : Do not reuse.
7. Timing chain 15. Camshaft housing / cylinder head /
: Apply engine oil. cylinder block
: Apply sealant 99000-85E11 to
mating surfaces.
8. Crankshaft timing sprocket 16. Oil Pump flange bolt
:Turn oil pump flange bolt clockwise
in order to loosen it.

Timing Chain Cover and Timing Chain Removal

and Installation 1
AENBL80A1426021

Removal 2

1) Remove engine assembly from engine 3

compartment. )(Page 1D-77)
2) Remove. )(Page 1E-19)
3) Remove ventilation connector (1) and O-ring (2)
from timing chain cover (3).

I7V20A142036-01

4) Remove common rail. “Common Rail Removal and

Installation”: D13A in Section 1G (Page 1G-47)
5) Remove engine hook (1) and common rail bracket
(2) from camshaft housing.
1D-83 Engine Mechanical: D13A

1
2
(A)

4
2 3
1 (A)
(A)

I3RB0A143007-01 I3RB0A143010-01

6) Remove turbocharger. 14) Lock flywheel (1) using special tool (B).
7) Remove engine right mounting bracket (1). Special tool
8) Remove water pump (2). )(Page 1F-30) (A): 09916M98610
9) Remove accessory drive belt tensioner (3). )(Page
1F-30)

(B)
1

3 I3RB0A143011-01

I3RB0A143008-01
15) Remove special tools (A) installed at step 12).
10) Remove crankshaft pulley (1). 16) Loosen crankshaft pulley flange bolt (1) turning it
clockwise, and remove crankshaft pulley flange (2).

NOTE
1 Be sure to turn crankshaft pulley flange bolt
clockwise in order to loosen it.

1
I3RB0A143009-01

11) Remove camshaft housing plugs (1).

12) Align camshaft housing plug hole (2) with camshaft
gap (3) turning crankshaft clockwise as shown in
figure. I3RB0A143012-01

13) Lock camshafts (4) inserting special tools (A) to plug 17) Reinstall special tools (A) removed at step 15).
holes. 18) Remove flywheel (1), and then special tool (B)
installed at step 14).
Special tool
(A): 09917M68610
 Engine Mechanical: D13A 1D-84

3 1
1

2
(B)

I3RB0A143016-01
I3RB0A143013-01
22) Remove timing chain tensioner adjuster assembly
19) Lock crankshaft (1) installing special tool (C) as
(1).
shown in the figure.
23) Remove timing chain tensioner (2).
NOTE 24) Remove timing chain guide (3).
Be sure to align hole (2) of special tool with 25) Remove timing chain (4) with crankshaft timing
knock pin securely. sprocket (5).

Special tool
(C): 09912M38300

4
1

(C) 3

2 1

I3RB0A143014-01

20) Remove timing chain cover (1) and its gasket. 5

I3RB0A143017-01
1
Installation
1) Clean mating surface on timing chain cover, cylinder
block, cylinder head, camshaft housing and flywheel.
2) Confirm that special tools (A) and (B) are installed. If
special tool(s) is removed, install special tool(s)
referring to step (2) and step (8) of “Removal” in this
procedure.
Special tool
(A): 09917M68610
(B): 09912M38300
I3RB0A143015-01

21) Remove crankshaft pulley side crankshaft oil seal (1)

from timing chain cover (2) using flat-blade screw
driver (3) or the like, if necessary.
1D-85 Engine Mechanical: D13A

7) Apply engine oil to sliding surface of timing chain

(A)
tensioner (1), and install it.
Tightening torque
Movable guide mounting bolt (a): 28.0 N·m (2.8
kgf-m, 20.2 lbf-ft)

(A)
(A)
1

(a)
(B)

I3RB0A143018-01 I3RB0A143021-01

3) Install timing chain (1) to camshaft timing sprocket 8) Push plunger (1) in timing chain tensioner adjuster
(2). body (2) till plunger is held in place as shown in
figure.
4) Install crankshaft timing sprocket (5) to timing chain
with its long taper side (3) faced to outside (4) as
shown in the figure.

2 1

3 I3RB0A143022-01

5 9) Install timing chain tensioner adjuster (1) as follows.

4 a) Tighten upper chain tensioner adjuster mounting
bolt (2) by hand.
b) Push tensioner adjuster assembly in arrow
direction as shown in figure, and then tighten
5 tensioner adjuster bolts to specified torque.
I3RB0A143019-01

5) Insert crankshaft timing sprocket with timing chain to Tightening torque

crankshaft. Chain tensioner adjuster bolt (a): 28.0 N·m (
6) Apply engine oil to sliding surface of timing chain 2.9 kgf-m, 20.7 lbf-ft)
guide (1), and install it.
Tightening torque 2,(a)
Chain guide mounting bolt (a): 9.0 N·m (0.92 kgf-
m, 6.5 lbf-ft)
1

(a)

(a)
I3RB0A143025-01

10) Apply engine oil to timing chain.

11) Install new crankshaft pulley side crankshaft oil seal
(1) to timing chain cover (2) using special tool (C) as
I3RB0A143020-01 shown in figure, if removed.
 Engine Mechanical: D13A 1D-86

Special tool
(C): 09913M75510

(C)
1

1 (b)
2

(a)

I3RB0A143023-01

12) Apply sealant to camshaft housing / cylinder head /

cylinder block as shown in figure. 3 5 4

“A”: Sealant 99000–85E11 (Three Bond TB

1227®)

“A” 1
I3RB0A143026-01

2
14) Install knock pin (1) to crankshaft (2), if removed.
“A” 15) Remove special tool (B) confirmed at step 2).
16) Install flywheel (3) as follows.
“A”
NOTE
3 If flywheel is replaced, be sure to initialize
I3RB0A143024-01
flywheel data in ECM. For details, refer to
1. Camshaft housing 3. Cylinder block Flywheel Data initialization:D13A.
2. Cylinder head

a) Tighten new flywheel bolts (4) by hand.

13) Install timing chain cover (1) as follows.
b) Lock flywheel using special tool (D).
a) Fit timing chain cover and new gasket (2).
Special tool
b) Install crankshaft pulley flange (3).
(D): 09916M98610
NOTE c) Tighten flywheel bolts to specified torque.
When inserting oil pump drive flange, be
Tightening torque
careful not to damage to oil seal (4) installed
Flywheel bolts (a): 44 N·m (4.5 kgf-m, 32.5
in timing chain cover.
lbf-ft)
c) Tighten timing chain cover bolts and nuts to
specified torque.
2
Tightening torque
3
Timing chain cover bolt (a): 9.0 N·m (0.92
kgf-m, 6.5 lbf-ft)
Timing chain cover nut (b): 9.0 N·m (0.92
kgf-m, 6.5 lbf-ft)

4, (a)
1 (D)
I3RB0A143027-01

17) Remove special tools (A) confirmed at step 2).

18) Tighten crankshaft pulley flange bolt (1) turning it
counterclockwise.
1D-87 Engine Mechanical: D13A

Tightening torque
Oil pump flange bolt (a): 230 N·m (23.5 kgf-m,
170.0 lbf-ft) (B)

1, (a)

IBP80A142006-01

5) Remove special tools (A) installed at step 21) and

I3RB0A143028-01 (B) installed at step 22).
19) Install crankshaft pulley (1), and tighten crankshaft 6) Apply thread lock compound to thread part of
pulley bolts (2) to specified torque. camshaft housing plugs (1), and tighten camshaft
housing plugs to specified torque.
Tightening torque
Crankshaft pulley bolt (a): 25 N·m (2.5 kgf-m, 18.5 “A”: Thread lock cement (Loctite omnifit 100M
lbf-ft) spezial®)
Tightening torque
Camshaft housing plug (a): 18 N·m (1.8 kgf-m,
13.0 lbf-ft)
1
2, (a) 1, “A”, (a)

1, “A”, (a)
I3RB0A143032-01

1) Remove special tool (D) installed at step 16).

2) Turn crankshaft clockwise two revolutions. I3RB0A143031-03

3) Lock camshafts (3) inserting special tools (A) to 7) Install accessory drive belt tensioner (1). )(Page
camshaft housing plug holes after aligning camshaft 1F-30)
housing plug hole (1) with camshaft gap (2) as 8) Install water pump (2). )(Page 1F-30)
shown in figure.
9) Install engine right mounting bracket (3).
Special tool
Tightening torque
(A): 09917M68610
Engine right mounting bracket No.2 bolt (a): 55
N·m (5.6 kgf-m, 40.6 lbf-ft)
1
(A)

3 (a)
2
(A)
(A) (a) 2

I3RB0A143029-01 1

4) Check that special tool (B) can be inserted in holes I3RB0A143033-01

of flywheel and cylinder block smoothly. 10) Install oil pan. )(Page 1E-19)
If not, remove timing chain and flywheel and repeat
11) Install common rail bracket (2) and engine hook (1)
step 2) to 22).
to camshaft housing.
Special tool
Tightening torque
(B): 09912M38300
Common rail bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lbf-ft)
 Engine Mechanical: D13A 1D-88

1 (a)

(a)
I3RB0A143038-01

Timing Chain Tensioner Adjuster

Check that sliding surfaces are free from damage.
If any malcondition is found, replace timing chain
tensioner adjuster.
I3RB0A143034-01

12) Install common rail. “Common Rail Removal and

Installation”: D13A in Section 1G (Page 1G-47)
13) Install ventilation connector (1), with new O-ring.
14) Install turbocharger.
15) Install engine assembly to engine compartment.
)(Page 1D-77) I3RB0A143039-01

Timing Chain Cover and Timing Chain Timing Chain Guide

Inspection Check shoe (1) for wear or damage.
AENBL80A1426022 If any malcondition is found, replace timing chain guide.

Timing Chain Tensioner

Check shoe (1) for wear or damage.
If any malcondition is found, replace timing chain
tensioner.

I3RB0A143040-01

1
Flywheel
• Check sensor teeth for being missing damaged or
I3RB0A143036-01 deformed.
If malcondition is found, replace flywheel.
Crankshaft Timing Sprocket • Check gear for crack or wear.
Check teeth of sprocket for wear or damage. If malcondition is found, replace flywheel.
If any malcondition is found, replace crankshaft timing
sprocket. • Check surface for damage or excessively wear.
If malcondition is found, replace flywheel.

I3RB0A143037-01

IBP80A142007-01
Timing Chain
Check timing chain for wear or damage.
If any malcondition is found, replace timing chain.
1D-89 Engine Mechanical: D13A

Crankshaft Pulley Side Crankshaft Oil Seal

Check oil seal lip for fault or damage.
Replace as necessary.

I3RB0A143042-01

Camshaft Housing Components

AENBL80A1426023

(c)

OIL
11 (a) 7

12 (b)

OIL
5

OIL
8

OIL
6

(d)

10

I9P60A142058-01

1. Camshaft housing 7. Intake manifold side camshaft gear
: Apply engine oil to gear.
2. Camshaft timing sprocket 8. Exhaust manifold side camshaft gear
: Apply engine oil to gear.
3. Washer 9. Cylinder head
: 18 N⋅m (1.8 kgf-m, 13.5 lbf-ft)
: 25 N⋅m (2.5 kgf-m, 18.5 lbf-ft)
: 150 N⋅m (15.3 kgf-m, 111.0 lbf-ft)

4. Camshaft housing gasket
: “TOP” mark provided on gasket comes to
facing up.
5. Intake manifold side camshaft
: Apply engine oil to sliding surface.
6. Exhaust manifold side camshaft
: Apply engine oil to sliding surface.
10. Knock pin : 150 N⋅m (15.3 kgf-m, 111.0 lbf-ft)
11. Camshaft housing bolt : Do not reuse.
:For tightening order, refer to “Camshaft
Housing Assembly removal and
Instalaltion”:D13A(Page 1D-93)
12. Camshaft housing stud bolt
:For tightening order, refer to “Camshaft
Housing Assembly removal and
Instalaltion”:D13A(Page 1D-93)
 Engine Mechanical: D13A 1D-90

Camshaft Housing Assembly Removal and

Installation
AENBL80A1426024

Removal
1) Remove engine assembly from engine 3
compartment. )(Page 1D-77) 1
2) Remove timing chain. )(Page 1D-82)
3) Remove fuel injector. “Fuel Injector Removal and 2
Installation”: D13A in Section 1G (Page 1G-46)
4) Loosen camshaft housing bolt (1) and camshaft
housing stud bolt (2) in numerical order as shown in
figure, a little at a time, and remove them.

I7V20A142039-01

4) Install camshaft housing assembly (1) to cylinder

head (2) as follows.
a) Install camshaft housing assembly, and tighten
camshaft housing bolt (3) and camshaft housing
stud bolt (4) by hand.
b) Align end faces of camshaft housing assembly
(1) and cylinder head (2) using straightedge (5).
c) Tighten camshaft housing bolt (3) and camshaft
housing stud bolt (4) to specified torque
I3RB0A143044-01 according to numerical order as shown in the
5) Remove camshaft housing assembly (3) and figure.
camshaft housing gasket (4). Tightening torque
Camshaft housing bolt (a): 18 N·m (1.8 kgf-
m, 13.3 lbf-ft)
3 Camshaft housing stud bolt (b): 25 N·m (2.5
kgf-m, 18.0 lbf-ft)
4

I3RB0A143045-01

Installation
1) Clean mating surface of camshaft housing and
cylinder head.
2) Install knock pins (1) to cylinder head, if removed.
3) Install new camshaft housing gasket (2) to cylinder
head. “TOP” mark (3) provided on gasket comes to
facing up.
1D-91 Engine Mechanical: D13A

Camshaft Housing Assembly Disassembly and

Reassembly
AENBL80A1426025

Disassembly
1) Remove camshaft housing assembly. )(Page 1D-
90)
2) Remove vacuum pump. )(Page 1D-66)
3) Remove high pressure pump. “High Pressure Pump
Removal and Installation”: D13A in Section 1G
(Page 1G-48)
4) Remove CMP sensor. “CMP Sensor Removal and
Installation”: D13A in Section 1C (Page 1C-21)
5) Remove special tools from camshaft housing.
Special tool
(A): 09917M68610

(A)

I3RB0A143047-01

5) Measure bump “a” between camshaft housing (1) (A)

and cylinder head (2) (flatness) using dial gauge (3) I3RB0A143049-01
and special tool (A) as shown in figure. 6) Remove camshafts (1), camshaft timing sprocket
If it is out of specification, reinstall camshaft housing. and camshaft gears (2) from camshaft housing as
Special tool follows.
(A): 09910M26510 / OUT0000005
Step between camshaft housing and cylinder
head (flatness)
“a”: –0.1 to 0.1 mm (–0.0039 to 0.0039 in.)

1
“a” 2
I3RB0A143050-01
2 a) Lock camshaft timing sprocket (1) using special
tool.
3 Special tool
(A): 09917M68221
(A)
I7V20A142040-01
b) Loosen camshaft gear bolt (2) of intake manifold
6) Install fuel injector. “Fuel Injector Removal and side.
Installation”: D13A in Section 1G (Page 1G-46) c) Loosen camshaft gear bolt (3) of exhaust
7) Install timing chain and timing chain cover. )(Page manifold side.
1D-82) d) Loosen camshaft timing sprocket bolt (4), and
8) Install engine assembly to engine compartment. remove camshaft timing sprocket (1).
)(Page 1D-77)
 Engine Mechanical: D13A 1D-92

a) Align camshaft housing plug hole (1) with

camshaft gap (2) turning intake manifold side
and exhaust manifold side camshafts as shown
1 in figure.
b) Lock camshafts (3) inserting special tools (A) to
4 plug holes.
Special tool
(A): 09917M68610

(A) 1
(A)

3
2

(A)

3 2
3
(A)
I3RB0A143051-01

e) Remove camshafts and camshaft gears.

3
Reassembly
I3RB0A143053-01
1) Apply engine oil to sliding surface of each camshaft
and camshaft housing, and then install intake 3) Install intake manifold side camshaft gear (1) and
manifold side camshaft (1) and exhaust manifold exhaust manifold side camshaft gear (2) to camshaft
side camshaft (2) to camshaft housing (3). housing, and tighten camshaft gear bolts (3) by
hand.
NOTE
NOTE
Be sure to identify intake manifold side and
exhaust manifold side camshafts by marks • Be sure to identify intake and exhaust side
shown in the figure. camshaft gears by punched marks shown
in figure.
• Main gear (6) and sub gear (7) of intake
1
manifold side camshaft gear shift as
shown in figure when camshaft gears are
disengaged.
When engaging camshaft gears, rotate sub
gear in arrow direction and align match
marks (8) on main and sub gears.

7 2 3
6
1 4

2
I3RB0A143052-01

4. “LH” mark 6. Crankshaft pulley side

5. “RH” mark 7. Flywheel side

2) Install special tools (A) as follows.

1D-93 Engine Mechanical: D13A

4 5

1 1

2, (a)
2

1
(A)

7 6
7 6
3, (b) 4, (b)
I3RB0A143055-01

5) Install CMP sensor. “CMP Sensor Removal and

8
Installation”: D13A in Section 1C (Page 1C-21)
6) Install high pressure pump. “High Pressure Pump
Removal and Installation”: D13A in Section 1G
I9P60A142067-01
(Page 1G-48)
4. “IN” mark 5. “EX” mark
7) Install vacuum pump. )(Page 1D-66)
4) Tighten camshaft timing sprocket bolt and camshaft 8) Install camshaft housing assembly. )(Page 1D-90)
gear bolts as follows. 9) Install timing chain and timing chain cover. )(Page
a) Lock camshaft timing sprocket (1) using special 1D-82)
tool. 10) Install engine assembly to engine compartment.
)(Page 1D-77)
Special tool
(A): 09917M68221
Camshaft Inspection
b) Install camshaft timing sprocket (1), and tighten AENBL80A1426026
camshaft timing sprocket bolt (2) to specified
torque. Camshaft
• Check journals and cam faces for wear or damage.
Tightening torque
If any malcondition is found, replace camshaft.
Camshaft timing sprocket bolt (a): 150 N·m (
15.3 kgf-m, 110.6 lbf-ft) • Check CMP sensor pickup for being missing,
damaged or deformed.
c) Tighten exhaust manifold side camshaft gear If any malcondition is found, replace camshaft.
bolt (3) then intake manifold side camshaft gear
bolt (4) to specified torque.
Tightening torque
Camshaft gear bolt (b): 150 N·m (15.3 kgf-m,
110.6 lbf-ft)

I3RB0A143056-01
 Engine Mechanical: D13A 1D-94

Cam Wear
• Using micrometer, measure cam height “a” and cam
width “b”.
• Calculate valve lift “c” using the following formula.
“c” = “a” - “b”
• If valve lift “c” is below its specification, replace
camshaft.
Valve lift “c”
Intake cam: 6.4 mm (0.252 in)
Exhaust cam: 7.5 mm (0.295 in)

I3RB0A143127-02

1. Camshaft journal No.1 4. Intake manifold side camshaft

2. Camshaft journal No.2 5. Exhaust manifold side camshaft
3. Camshaft journal No.3 6. Crankshaft pulley side

Camshaft Housing
• Check camshaft journals and camshaft housings for
pitting, scratch, wear or damage.
If any malcondition is found, replace camshaft
housing.

I3RB0A143057-01

1. Intake cam 4. Exhaust manifold side

camshaft
2. Exhaust cam 5. Crankshaft pullet side
3. Intake manifold side
camshaft

Camshaft Journal I3RB0A143058-01

Check camshaft journal outside diameter using
micrometer.
If measured diameter is out of specification, replace
camshaft.
Camshaft journal outside diameter
No.1: 38.500 – 38.515 mm (1.5158 – 1.5163 in.)
No.2: 38.000 – 38.015 mm (1.4961 – 1.4966 in.)
No.3: 30.000 – 30.015 mm (1.1812 – 1.1816 in.)
• Check camshaft journal bore diameter using bore
gauge.
If measured diameter is out of specification, replace
camshaft housing.
Camshaft journal bore diameter
No.1: 38.545 – 38.570 mm (1.5176 – 1.5185 in.)
No.2: 38.045 – 38.070 mm (1.4979 – 1.4988 in.)
No.3: 30.045 – 30.070 mm (1.1829 – 1.1838 in.)
1D-95 Engine Mechanical: D13A

Camshaft Timing Sprocket

Check camshaft timing sprocket for pitting, scratch or
damage.
If any malcondition is found, replace camshaft timing
sprocket.

3 2 1

4
I3RB0A143060-01

Intake Manifold Side Camshaft Gear and Exhaust

1. Camshaft journal bore No.1
2. Camshaft journal bore No.2
I3RB0A143059-01
3. Camshaft journal bore No.3
4. Crankshaft pulley side
Manifold Side Camshaft Gear
Check intake manifold side and exhaust manifold side
camshaft gears for pitting, scratch or damage.
If any malcondition is found, replace intake manifold side
and/or exhaust manifold side camshaft gear.

I3RB0A143061-01
 Engine Mechanical: D13A 1D-96

Valve and Cylinder Head Components

AENBL80A1426027

OIL
3

OIL

OIL
2 4
10 (a) 15
5

OIL
6

OIL
7

15

11

OIL
8

15

OIL
9

12 13

13

14

I7V20A142041-04

1. Valve rocker arm 7. Valve stem seal 13. Knock pin

2. Hydraulic valve lash adjuster 8. Intake valve 14. Cylinder block
3. Valve cotter 9. Exhaust valve 15. Plug
: Apply sealant 99000-85E00 to all around
thread part.
4. Valve spring retainer 10. Cylinder head bolt : 40 N⋅m → +90° → +90° (4.1 kgf-m → +90°
→ +90°, 29.5 lbf-ft → +90°→ +90°)
5. Valve spring 11. Cylinder head : Do not reuse.
6. Valve spring seat 12. Cylinder head gasket : Apply engine oil to sliding surface.
: “TOP” mark provided on gasket comes to
crankshaft pulley side, facing up.

Valve and Cylinder Head Assembly Removal

and Installation
AENBL80A1426028
1D-97 Engine Mechanical: D13A

! CAUTION 11) Remove cylinder head (2) and cylinder head gasket
(3).
Note original position in which each valve
12) Remove knock pins (4), if necessary.
rocker arms and hydraulic valve lash
adjuster were installed, and then install them
1, “1”
to original position.
If each valve rocker arm or hydraulic valve “7” “4”
lash adjuster is not installed to original “9”
“5
position, engine will spoil its original
performance. “3”

Removal
1) Remove engine assembly from engine “6”

compartment. )(Page 1D-77) 2 “10”

“8”
2) Remove camshaft housing assembly. )(Page 1D- “2”
90) 3
3) Remove exhaust manifold. “Exhaust Manifold
Components”: D13A in Section 1K (Page 1K-6)
4) Remove thermostat assembly. )(Page 1F-26)
5) Remove oil separator. )(Page 1D-70) 4
I7V20A142042-01
6) Remove intake manifold. )(Page 1D-75) 13) Check all around cylinder head for any other parts
7) Remove oil pressure switch. )(Page 1E-17) required to be removed or disconnected.
8) Remove glow plugs. “Glow Plug Removal and
Installation”: D13A in Section 1C (Page 1C-19) Installation
9) Remove hydraulic valve lash adjuster (1) with valve 1) Clean mating surface of cylinder head and cylinder
rocker arm (2). block.
2) Install knock pins (1) to cylinder block (2), if
NOTE removed.
• Never disassemble hydraulic valve lash
adjuster. 1
• Don’t apply force (3) to body of hydraulic 1
valve lash adjuster. It will leak oil in high
pressure chamber. 2
• Immerse removed hydraulic valve lash
adjuster in clean engine oil and keep it
there till reinstalling it so as to prevent oil
leakage.

3 I3RB0A143065-01

3) Select and install new cylinder head gasket as

2 follows.
1 a) Remove special tool (A).
Special tool
(A): 09912M38300

I3RB0A143063-01

10) Loosen cylinder head bolts (1) according to

numerical order as shown in figure a little at a time,
and remove them.
 Engine Mechanical: D13A 1D-98

d) Select cylinder head gasket according to

maximum value of protrusion “a” measured at
step b).
Piston
Gasket thickness
protrusion
0.67 – 0.77 mm 0.028 – 0.127 mm
(A) Type A
(0.0264 – 0.0303 in.) (0.00111 – 0.00500 in)
0.77 – 0.87 mm 0.128 – 0.227 mm
Type B
(0.0304 – 0.0342 in.) (0.00501 – 0.00893 in.)
0.87 – 0.97 mm 0.228 – 0.327 mm
Type C
(0.0343 – 0.0381 in.) (0.00894 – 0.0128 in.)
I3RB0A143066-01

b) Using special tool and dial gauge, measure
piston protrusion “a” at specified measurement
positions (2) of TDC position as shown in figure.
Repeat this procedure in all pistons (1).
Special tool
(B): 09910M26550 /OUT0000005
e) Measure cylinder head height.
When cylinder head height is specified value or
less, cylinder head had been ground.
If cylinder head had been ground, change
cylinder head gasket selected at step d)
according to the following table or replace
cylinder head.

1
Cylinder head height “a”
1 “a”
2 Standard: 105.45 – 105.55 mm (4.152 – 4.155
in.)

4 3

(B)

I5RS0B140025-02

Selected cylinder Installed

Cylinder head
head gasket by cylinder head
height
I7V20A142043-03
step d) gasket
Type A Type B
3. Cylinder block 4. Crankshaft pulley side
105.35 – 105.45 mm Type B Type C
(4.147 – 4.151 in.) Replace
c) Lock crankshaft (1) using special tool. Type C
cylinder head
NOTE 105.25 –105.35 mm Type A Type C
(4.143 – 4.147 in.) Replace
Be sure to align hole (2) of special tool with Type B
cylinder head
knock pin securely. Replace
Type C
cylinder head
Special tool
105.25 mm
(A): 09912M38300 Replace cylinder head
(4.143 in.) or less

f) Install new cylinder head gasket (1) to cylinder

block.

(A)

1
2

I3RB0A143068-01
1D-99 Engine Mechanical: D13A

1 [A]

[B]

[C]

I3RB0A143069-01

[A]: Type A (without hole) [C]: Type C (with two holes)

[B]: Type B (with one hole)

4) Install cylinder head (1) to cylinder block (2) as

follows.
a) Install cylinder head, and tighten new cylinder
head bolts by hand.
b) Make end faces of cylinder head (1) and cylinder
I7V20A142044-01
block (2) flush using straightedge (3).
5) Measure step “a” between cylinder head (1) and
c) Tighten all bolts to 40 N⋅m (4.0 kgf-m, 29.0 lbf-ft)
cylinder block (2) (flatness) using dial gauge and
according to numerical order in the figure.
special tool as shown in figure.
d) Retighten all bolts 90° according to numerical If measured notch is out of specification, remove
order as shown in figure. cylinder head and return to step 4).
e) Repeat Step d).
Special tool
Tightening torque (A): 09910M26510 /OUT0000005
Cylinder head bolt* (a): 40 N⋅m → +90° →
+90° (41 kgf-m, → +90° → +90°, 29.5 lbf-ft → Notch between cylinder head and cylinder block
+90° → +90°) (flatness)
“a”: –0.1 to 0.1 mm (–0.0039 to 0.0039 in.)

“a”

(A)

I3RB0A143071-01

6) Apply engine oil around hydraulic valve lash adjuster

(1) and valve rocker arm (2), and install them to
cylinder head.

1
2
I3RB0A143072-01
7) Install glow plugs. “Glow Plug Removal and
Installation”: D13A in Section 1C (Page 1C-19)
8) Install oil pressure switch. )(Page 1E-17)
9) Install intake manifold. )(Page 1D-75)
10) Install oil separator. )(Page 1D-70)
11) Install thermostat assembly. )(Page 1F-26)
12) Install exhaust manifold. “Exhaust Manifold
Components”: D13A in Section 1K (Page 1K-6)
13) Install camshaft housing assembly. )(Page 1D-90)
14) Install engine assembly to engine compartment.
)(Page 1D-77)
Valve and Cylinder Head Assembly
Disassembly and Reassembly
AENBL80A1426029
! CAUTION
Note original position in which each valve
and valve spring seat were installed, and
then install them to original position.
If each valve or valve spring seat is not
installed to original position, engine will spoil
its original performance.
Disassembly
1) Using special tool (A) and (B), compress valve
springs and then remove valve cotters (1) using
special tool (C).
Special tool
(A): 09916M14510
(B): 09916M14521
(C): 09916M84511
I3RB0A143073-01
Engine Mechanical: D13A 1D-100
2) Release special tool, and remove valve spring
retainer and valve spring.
3) Remove valve from combustion chamber side.
4) Remove valve stem seal (1) from valve guide using
special tool, and then remove valve spring seat (2).
Special tool
(A): 09917M68610
2
(A)
I3RB0A143074-01
Reassembly
1) Install valve spring seats to cylinder head.
2) Install new valve stem seal (1) to valve guide.
After applying engine oil to seal and spindle of
special tool (valve guide installer handle), fit stem
seal to spindle, and then install seal to valve guide
by pushing special tool by hand.
After installing, check to be sure that seal is properly
installed to valve guide.
! CAUTION
When installing, never tap or hit special tool
with a hammer or the like. Install seal to
guide only by pushing special tool by hand.
Tapping or hitting special tool may cause
damage to seal.
NOTE
Do not reuse once-disassembled seal. Be
sure to install new seal.
Special tool
(A): 09916M58210
(B): 09917M98221
1D-101 Engine Mechanical: D13A

Valve and Guide Inspection

AENBL80A1426030

(A)
Valve Guide
Valve stem-to-guide clearance
Using a micrometer and bore gauge, measure diameter
(B) of valve stems and guides to check stem-to-guide
clearance.
Be sure to measure diameter at more than one place
1
along the length of each stem and guide.
If clearance is out of specification, replace valve and/or
cylinder head.
Valve stem diameter [A]
In and EX: 5.974 – 5.992 mm (0.2352 – 0.2359 in.)
Valve guide bore [B]
In and EX: 6.020 – 6.038 mm (0.2371 – 0.2377 in.)
I3RB0A143075-01
Stem-to-guide clearance
3) Apply engine oil to stem seal, valve guide bore and
In and EX: 0.028 – 0.064 mm (0.0012 – 0.0025 in.)
valve stem, and then install valve to valve guide.
4) Install valve spring and valve spring retainer.

I3RB0A143076-01

5) Using special tool (A) and (B), compress valve

spring. And, fit two valve cotters (1) into groove in
valve stem using special tool (C).
Special tool
(A): 09916M14510
(B): 09916M14521
(C): 09916M84511

I7V20A142058-01

Valve
Visual inspection
• Remove all carbon from valves.
• Inspect each valve for wear, burn or distortion at its
face and stem end.
If necessary, replaces it.
• Inspect valve stem end face for pitting and wear.
I3RB0A143077-01 If pitting or wear is found, valve stem end may be
resurfaced, but not too much to grind.
When it is worn out, replace valve.

I2RH01140135-01
Valve seat repair
A valve seat not producing a uniform contact with its
valve or showing width of seating contact that is not as
specified range must be repaired by regrinding or by
cutting and regrinding and finished by lapping.
1) Valve seat:
Use valve seat cutters (1) to make three cuts as
illustrated in figure. Three cutters must be used: the
1st for making 20° angle, the 2nd for making 60°
angle, and 3rd for making 45° angle.
Seat width for valve seat
“a”: 1.35 – 1.62 mm (0.0532 – 0.0637 in.)
2) Valve lapping:
Lap valve on seat in two steps, first with coarse size
lapping compound applied to face and the second
with fine-size compound, each time using valve
lapper according to usual lapping method.
I7V20A142045-01
Cylinder Head Inspection
AENBL80A1426031
• Remove all carbon deposits from combustion
chambers.
Engine Mechanical: D13A 1D-102
I3RB0A143078-01
NOTE
Do not use any sharp-edged tool to scrape
off carbon deposits. Be careful not to scuff or
nick metal surfaces when removing carbon
deposits. The same applies to valves and
valve seats, too.
• Check cylinder head for cracks on intake and exhaust
ports combustion chambers and head surface.
Using a straightedge and feeler gauge, check flatness
of cylinder head mating surface at a total of 2
locations.
If distortion limit, given below, is exceeded, replace
cylinder head or regrind cylinder head.
Limit of distortion for surface of cylinder head
piston side:
0.10 mm (0.00394 in.)
I3RB0A143079-01
1D-103 Engine Mechanical: D13A

NOTE
When cylinder head had been ground, it is
necessary to change gasket referring to Step
3) of “Installation” under “Valve and Cylinder
Head Assembly Removal and Installation”:
D13A (Page 1D-96).

Valve Spring Inspection

AENBL80A1426032
Valve Spring Free Length and Preload
By referring to data given below, check to be sure that
each spring is in good condition, free of any evidence of
breakage or weakening.
Remember, weakened valve springs can cause chatter,
not to mention possibility of reducing power output due
to gas leakage caused by decreased seating pressure.
Valve spring free length (In and Ex) “a”:
37.9 mm (1.492 in.)
Valve spring preload (In and Ex): I3RB0A143080-01

162 – 180 N (16.2 – 18.0 kgf) for 31.0 mm (35.7 – 39.7

lbf/1.220 in.) Hydraulic Valve Lash Adjuster and Valve Rocker
361 – 395 N (36.1 – 39.5 kgf) for 23.5 mm (79.6 – 87.1 Arm
lbf/0.925 in.) Check hydraulic valve lash adjuster (1) and valve rocker
arm (2) for pitting, scratches, wear or damage.
If any malcondition is found, replace them.

I3RB0A143081-01

Piston, Piston Ring, Connecting Rod and Cylinder Components

AENBL80A1426033
! CAUTION

• Connecting rod and connecting rod bearing cap must be replaced as a set when either replacement
becomes necessary.
• Note original position in which each piston, piston ring, connecting rod and connecting rod bearing
cap were installed, and install them to original position.
If each piston, piston ring, connecting rod and connecting rod bearing cap is not installed to original
position, engine will spoil its original performance.
 Engine Mechanical: D13A 1D-104

OIL
1

OIL
7

OIL
2

OIL
3

OIL
8

OIL
4 6
OIL

5
(a)

OIL
9
6

I7V20A142046-02

1. Top ring 5. Piston pin 9. Connecting rod bearing cap

2. 2nd ring 6. Piston pin circlip : 20 N⋅m → 40° (20 kgf-m → 40°, 15.0 lbf-ft → 40°)
3. Oil ring 7. Connecting rod : Do not reuse.
4. Piston 8. Connecting rod bearing : Apply engine oil to sliding surface.

Piston, Piston Ring, Connecting Rod and

Cylinder Removal and Installation 1
AENBL80A1426034

! CAUTION

• Connecting rod and connecting rod

bearing cap must be replaced as a set
when either replacement becomes
necessary.
• Note original position in which each
piston, piston ring, connecting rod and
connecting rod bearing cap were installed, I3RB0A143083-01
and install them to original position. 5) Remove special tool (A).
If each piston, piston ring, connecting rod
and connecting rod bearing cap is not Special tool
installed to original position, engine will (A): 09912M38300
spoil its original performance.

Removal
1) Remove engine assembly from engine
compartment. )(Page 1D-77)
2) Remove cylinder head. )(Page 1D-96) (A)

3) Remove oil pan. )(Page 1E-19)

4) Remove oil pan baffle plate (1) from lower
crankcase.

I3RB0A143084-01

6) Mark cylinder number on all pistons using silver

pencil or quick drying paint for installation.
7) Remove connecting rod bearing caps (1).
1D-105 Engine Mechanical: D13A

1
(A)

I3RB0A143085-01 I3RB0A143087-01

8) Decarbonize top of cylinder bore before removing
piston from cylinder.
9) Push piston and connecting rod assembly out
through the top of cylinder bore.
Installation
1) Apply engine oil to pistons, rings, cylinder walls,
connecting rod bearings and crank pins.
NOTE
Do not apply oil between connecting rod and
bearing or between bearing cap and bearing.
4) Install bearing cap (1) to applicable cylinder
matching cylinder number (2) on bearing cap and
connecting rod, and then tighten new bearing cap
bolts as follows.
a) Tighten all connecting rod bearing cap bolts (3)
to 20 N⋅m (2.0 kgf-m, 14.5 lbf-ft).
b) Retighten them by turning through 40°.
Tightening torque
Connecting rod bearing cap bolt* (a): 20 N⋅m
→ +40° (2.0 kgf-m → +40°, 15.0 lbf-ft → +40°)
3, (a) 3, (a)

2) When installing piston and connecting rod assembly

into cylinder bore, point arrow mark (1) on piston
head to crankshaft pulley side (2).

2
2
I3RB0A143086-01

3) Install piston and connecting rod assembly into

cylinder bore matching cylinder number marked in I3RB0A143088-01

removal. Use special tool (piston ring compressor) to 5) Lock crankshaft (1) using special tool.
compress rings. Guide connecting rod into place on
NOTE
crankshaft.
Using a hammer handle, tap piston head to install Be sure to align hole (2) of special tool with
piston into bore. Hold ring compressor firmly against knock pin securely.
cylinder block until all piston rings have entered
cylinder bore. Special tool
(A): 09912M38300
Special tool
(A): 09916M77310
 Engine Mechanical: D13A 1D-106

(A)

1
2
I3RB0A143091-01
I3RB0A143089-01

6) Install oil pan baffle plate (1) to lower crankcase. b) Remove piston pin (1) from piston (2) and
connecting rod.
Tightening torque
Oil pan baffle plate bolt (a): 9.0 N·m (0.92 kgf-m,
6.5 lbf-ft)

(a)

I3RB0A143092-01

Reassembly
I3RB0A143090-02
1) Clean carbon from piston head and ring grooves
using a suitable tool.
7) Install oil pan. )(Page 1E-19)
2) Install piston pin to piston and connecting rod as
8) Install cylinder head. )(Page 1D-96)
follows.
9) Install camshaft housing assembly. )(Page 1D-90)
a) After applying engine oil to piston pin, piston pin
10) Install timing chain and timing chain cover. )(Page holes in piston and connecting rod, fit connecting
1D-82) rod to piston so that cylinder number (2) of
11) Install engine assembly to engine compartment. connecting rod bearing and chip of piston skirt
)(Page 1D-77) (1) come on the opposite side (intake side), and
insert piston pin to piston and connecting rod.
Piston, Piston Ring, Connecting Rod and b) Install piston pin circlips (5).
Cylinder Disassembly and Reassembly c) Position opening (4) of piston pin circlip to
AENBL80A1426035
opposite side of removal and fitting channel (3).
Disassembly
1) Using piston ring expander, remove top and 2nd
compression rings and oil ring from piston.
2) Remove piston pin from piston and connecting rod 4
as follows.
a) Using flat head screw driver (2) or the like,
remove piston pin circlips (1). 1
5
2 3

I3RB0A143093-01

3) Install piston rings to piston.

1D-107 Engine Mechanical: D13A

NOTE If any of the following conditions is noted, rebore cylinder

block.
• As indicated in figure, 1st and 2nd rings
have “TOP” mark respectively. When • Cylinder bore diameter exceeds specification.
installing these piston rings to piston, • Difference of measurements at two positions exceeds
direct marked side of each ring toward top taper limit.
of piston. • Difference between thrust and axial measurements
• 1st ring (1) differs from 2nd ring (2) in exceeds out-of-round limit.
thickness and shape.
Distinguish 1st ring from 2nd ring by Cylinder bore diameter
referring to figure. Category (2) Cylinder bore diameter
• When installing oil ring, install spiral ring 69.600 – 69.610 mm
A
(3) first and then rail (4). (2.74016 – 2.74054 in.)
69.610 – 69.620 mm
B
(2.74055 – 2.74093 in.)
69.620 – 69.630 mm
C
(2.74094 – 2.74133 in.)

Cylinder taper difference

Limit: 0.001 mm (0.00004 in.)
Out-of-round difference
Limit: 0.005 mm (0.00020 in.)

1 NOTE
If any one of four cylinder has to be rebored,
2 3
rebore all four to the same next oversize.
4
This is necessary to make all the cylinders to
be uniform and balanced.
I3RB0A143094-01

4) After installing three rings (1st, 2nd and oil rings),

distribute their end gaps as shown in the figure. 2

2
1

“a” 1

“a”
2 2

I7V20A142047-01

1. Arrow mark 2. Ring end gap

“a”: 120°

3
Cylinder, Piston and Piston Ring Inspection
AENBL80A1426036

Cylinder
Visual inspection
Inspect cylinder walls for scratches, roughness or ridges
which indicate excessive wear.
If cylinder bore is very rough, deeply scratched or ridged, I7V20A142048-02
rebore cylinder and use oversize piston. 3. Crankshaft pulley side

Cylinder bore diameter, taper and out-of-round Pistons

Using a cylinder gauge (1), measure cylinder bore in
Visual inspection
thrust and axial directions at any positions as shown in
Inspect piston for faults, cracks or other damaged.
figure.
Damaged or faulty piston should be replaced.
 Engine Mechanical: D13A 1D-108

Piston diameter Oil ring: 0.03 – 0.07 mm (0.0018 – 0.00275 in.)

As indicated in figure, piston diameter should be
measured at a position 7.00 mm (0.28 in.) (“a”) from
piston skirt end in the direction perpendicular to piston 1
pin.
Piston diameter specification
Index (1) on piston
Piston diameter
head
69.582 – 69.592 mm
A
(2.73944 – 2.73983 in.)
69.592 – 69.602 mm
B
(2.73983 – 2.740228 in.) 2
69.602 – 69.612 mm
C
(2.740228 – 2.740622 in.)

Oversize (0.4 mm): 69.980 – 69.994 mm (2.75511 –

2.75566 in.) I3RB0A143097-01

Piston Rings
Piston ring end gap
To measure end gap, insert piston ring (1) into cylinder
bore and then measure the gap by using thickness
gauge (2).
If measured gap is out of specification, replace ring.

NOTE
Decarbonize and clean top of cylinder bore
before inserting piston ring.

Piston ring end gap

Top ring: 0.20 – 0.30 mm (0.0079 – 0.0118 in.)
2nd ring: 1.00 – 1.50 mm (0.0394 – 0.0590 in.)
Oil ring: 0.25 – 0.50 mm (0.0099 – 0.0196 in.)

I7V20A142049-01

Piston clearance
Measure cylinder bore diameter and piston diameter to
find their difference which is piston clearance. If it is out
of specification, rebore cylinder and/or use oversize
piston.

NOTE
Cylinder bore diameters used here are
measured in thrust direction at two positions.

Piston clearance:
0.1 mm (0.004 in.)
Ring groove clearance
Before checking, piston grooves must be clean, dry and
free of carbon deposits.
Fit new piston ring (1) into piston groove, and measure
clearance between ring and ring land by using thickness
gauge (2). If clearance is out of specification, replace
piston ring and/or piston.
Ring groove clearance
Top ring: 0.11 – 0.15 mm (0.0044 – 0.0059 in.)
2nd ring: 0.06 – 0.09 mm (0.0024 – 0.0035 in.)
I3RB0A143099-01
Piston Pin and Connecting Rod Inspection
AENBL80A1426037
Piston Pin Visual Inspection
Check piston pin, connecting rod small end bore and
piston bore for wear or damage, paying particular
attention to condition of small end bore bush. If pin,
connecting rod small end bore or piston bore is badly
worn or damaged, replace pin, connecting rod and/or
piston.
1D-109 Engine Mechanical: D13A

Piston Pin Clearance

Check piston pin clearance in small end and piston.
Replace connecting rod and/or piston if its small end is
badly worn or damage.
Piston pin clearance in connecting rod small end:
0.003 – 0.019 mm (0.00012 – 0.00074 in.)
Piston pin clearance in piston: 3
0.003 – 0.013 mm (0.00012 – 0.00055 in.)
Piston pin diameter:
1
22.982 – 22.987 mm (0.90481 – 0.90500 in.)
Connecting rod small-end bore:
23.006 – 23.012 mm (0.90575 – 0.90598 in.) 2
I3RB0A143100-01
Piston bore:
22.990 – 22.995 mm (0.90512 – 0.90531 in.) Crank Pin and Connecting Rod Bearing
Inspection
AENBL80A1426038
Connecting rod bearing general information
• Cap side connecting rod bearing (1) has oil hole (2) as
shown in figure.
Install this half with oil hole to connecting rod bearing
cap.
• Connecting rod side connecting rod bearing (3) does
not have oil hole.

3
I3RB0A143101-01
I3RB0A143098-01

Connecting Rod Crank Pin Diameter

Inspect crank pin for uneven wear or damage. Measure
• Connecting rod big end bore and length.
crank pin for out-of-round or taper with a micrometer.
a. Install bearing cap (2) to connecting rod (1). If crank pin is damaged or out-of round or taper is out of
b. Measure connecting rod big end bore by using specification, regrind or replace crankshaft.
bore gauge (3).
Crank pin diameter:
If measured bore is out of specification, replace
42.582 – 42.600 mm (1.6765 – 1.6771 in.)
connecting rod and bearing cap as a set.
Big end bore:
45.734 – 45.744 mm (1.8006 – 1.8009 in.)

I5RS0B140032-01

Big-end side clearance
Check big-end of connecting rod for side clearance, with
rod fitted and connected to its crank pin in normal
manner.
If measured clearance is out of specification, replace
connecting rod.
Big-end side clearance:
0.12 – 0.45 mm (0.0048 - 0.0177 in.)
I2RH0B140148-01
Connecting rod bearing visual inspection
Inspect bearing shells for signs of fusion, pitting, burn or
flaking and observe contact pattern. Bearing shells
found in defective condition must be replaced.
Selection of Connecting Rod Bearings
Connecting rod bearing clearance
NOTE
Do not rotate crankshaft while gauging
plastic is installed.
1) Before checking bearing clearance, clean bearing
and crank pin.
2) Install bearing in connecting rod and bearing cap.
3) Place a piece of gaging plastic (1) to full width of
crank pin as contacted by bearing (parallel to
crankshaft), avoiding oil hole.
Standard size of connecting rod bearing
1
I3RB0A143102-01
4) Install connecting rod and bearing cap. )(Page 1D-
103)
Engine Mechanical: D13A 1D-110
NOTE
It is not necessary to replace new bearing
cap bolts for measuring procedure.
5) Using a scale (1) on gauging plastic (2) envelope,
measure gauging plastic width at the widest point
(clearance) after removing cap.
If clearance exceed its specification, use a new
standard size bearing and/or crankshaft.
After selecting new bearing, recheck clearance.
Connecting rod bearing clearance:
0.030 – 0.062 mm (0.0012 – 0.0024 in.)
2
1
I3RB0A143103-01
NOTE
• If bearing is in malcondition or bearing
clearance is out of specification, select a
new standard bearing according to the
following procedure and install it.
• When replacing crankshaft or connecting
rod and its bearings due to any reason,
select new standard bearings to be
installed referring to alphabets stamped on
crank web No.4.
1) Check connecting rod big-end inside diameter.
If measured big-end inside diameter out of
specification, replace connecting rod and/or bearing
cap.
Connecting rod big-end inside diameter:
45.734 – 45.744 mm (1.8006 – 1.8009 in.)
2) Next, check crankshaft pin diameter. As shown in
figure, crank web No.4 has stamped alphabets.
Two kinds of alphabet “A” and “B” represent the
following crankshaft pin diameter respectively.
For example, stamped “A” indicates that
corresponding crankshaft pin diameter is 42.591 –
42.600 mm (1.6769 – 1.66771 in.).
Crankshaft pin diameter
Class Crankshaft pin diameter
42.591 – 42.600 mm
A
(1.6769 – 1.6771 in.)
1D-111 Engine Mechanical: D13A

Class Crankshaft pin diameter For example, if number stamped on crank web No.4
42.582 – 42.591 mm is “A“, install a new standard bearing painted in
B “Red” to its connecting rod big end inside.
(1.6765 – 1.6768 in.)
Specification of new standard connecting rod
bearing size
Alphabet stamped on
crank web No.4
Color painted
(Crankshaft pin
diameter)
1 A Red
B Blue

5) Check bearing clearance with newly selected

standard bearing. “Connecting rod bearing
clearance”: D13A (Page 1D-110). If clearance is out
of limit, use next thicker bearing and recheck
clearance.

2
1

I7V20A142050-01

1. Crankshaft pulley side

3) There are two kinds of standard bearings differing in

thickness. To distinguish them, they are painted in
the following colors at position as indicated in figure.
I5RS0B140033-01
Each color indicated the following thickness at the
center of bearing. Undersize bearing (0.127 mm)
Standard size of connecting rod bearing • 0.127 mm undersize bearing is available, in two kinds
thickness varying in thickness. To distinguish them, each
Color painted Bearing thickness bearing is painted in the following colors at such
1.546 – 1.552 mm position as indicated in figure. Each color represents
Red
(0.06087 – 0.06110 in.) the following thickness at the center of bearing.
1.550 – 1.556 mm
Blue Undersize of crankshaft main bearing thickness
(0.06103 – 0.06125 in.)
Color painted Bearing thickness
1.610 – 1.616 mm
Brown
(0.06338 – 0.06362 in.)
1.614 – 1.620 mm
Green
(0.06354 – 0.06377 in.)

I5RS0B140031-01

1. Paint

4) From alphabet stamped on crank web No.4,

determine new standard bearing to be installed to
I5RS0B140031-01
connecting rod big-end inside, by referring to the
1. Paint
table.
 Engine Mechanical: D13A 1D-112

• If necessary, regrind crankshaft pin and select Specification of new undersize connecting rod
undersize bearing to use with it as follows. bearing
1) Regrind crankshaft pin to the following finished Measured crankshaft
Color painted
diameter. pin diameter
42.464 – 42.473 mm
Finished diameter Brown
(1.6719 – 1.6721 in.)
42.455 – 42.473 mm (1.6715 – 1.6721 in.)
42.455 – 42.464 mm
Green
2) Using micrometer (1), measure regrind crankshaft (1.6715 – 1.6718 in.)
pin diameter. Measurement should be taken in two
directions perpendicular to each other in order to
check for out-of-round.
3) Using crankshaft pin diameter measured above,
select an undersize bearing by referring to table
given below. Check bearing clearance with newly
selected undersize bearing.

I5RS0B140032-01

Main Bearing, Crankshaft and Cylinder Block Components

AENBL80A1426039
! CAUTION
Note original position in which each main bearing were installed, and install them to original position.
If each main bearing is not installed to original position, engine will spoil its original performance.

OIL
1 3
OIL

13
5
OIL

(a)

OIL
OIL 4

10 5
OIL

6 5

8 (d)

(b)
11

7 (c)
I7V20A142051-02
1D-113 Engine Mechanical: D13A

1. Cylinder block 7. Crankcase bolt (M10) : 9.0 N⋅m (0.92 kgf-m, 7.0 lbf-ft)
: Apply sealant 99000-85E11. )(Page 1D-113)
2. Crankshaft 8. Crankcase bolt (M8) : 20 N⋅m (2.0 kgf-m, 15.0 lbf-ft)
: Apply engine oil to sliding surface.
3. Main bearing (with thrust bearing) 9. Oil jet : 30 N⋅m (3.1 kgf-m, 22.5 lbf-ft)
: Apply engine oil to sliding surface.
4. Flywheel side crankshaft oil seal 10. Timing chain oil jet : Do not reuse.
: Apply engine oil-to-oil seal lip.
5. Main bearing 11. Knock pin
: Apply engine oil to bearing inside surfaces.
6. Lower crankcase : 6 N⋅m (0.61 kgf-m, 4.5 lbf-ft)

Main Bearing, Crankshaft and Cylinder Block

Removal and Installation
AENBL80A1426040

! CAUTION
1
Note original position in which each main
bearing were installed, and install them to
original position.
If each main bearing is not installed to
original position, engine will spoil its original
performance.
I3RB0A143106-01

NOTE 9) Remove generator bracket (1) from cylinder block.

• All parts to be installed must be perfectly

clean. 1

• Be sure to apply oil to crankshaft journals,

main bearings, main bearing (with thrust
bearing), crankpins, connecting rod
bearings, pistons, piston rings and
cylinder bores.

Removal
1) Remove engine assembly from engine I3RB0A143107-01
compartment. )(Page 1D-77) 10) Remove crank ventilation cover from cylinder block.
2) Remove cylinder head assembly. )(Page 1D-96) )(Page 1D-70)
3) Remove CKP sensor. “CKP Sensor Removal and 11) Remove piston and connecting rod. )(Page 1D-
Installation”: D13A in Section 1C (Page 1C-22) 104)
4) Remove oil cooler. )(Page 1E-18) 12) Loosen crankcase bolt (M10) and crankcase bolt
5) Remove generator. “Generator Removal and (M8) in numerical order as shown in figure a little at a
Installation”: D13A in Section 1J (Page 1J-27) time, and remove them.
6) Remove starting motor. “Starting Motor Removal and
“1” “3”
Installation”: D13A in Section 1I (Page 1I-11) “6”
“10” “7”
7) Remove A/C compressor bracket (1), if equipped.

“15” “12” “14”

“17” “20”

“19” “18”

“13” “11” “16”

“8”
I9P60A142055-01 “5” “9”
“4” “2”
8) Remove timing chain oil jet (1) from cylinder block. I3RB0A143108-01
 Engine Mechanical: D13A 1D-114

13) Remove lower crankcase (1) from cylinder block

using special tool. 1
(a)

Special tool
(A): 09912M96510

1 2 1

I3RB0A143112-01

3) Install main bearings (3) and main bearings (with

thrust bearing) (4) to cylinder block and lower
(A) crankcase aligning tab (1) with gap (2).
I3RB0A143109-01
NOTE
14) Remove crankshaft (1) and flywheel side crankshaft
oil seal (2) from cylinder block. • One of two halves of main bearing has an
15) Remove main bearings (3) and main bearing (with oil groove (5).
thrust bearing) (4) from cylinder block and lower Install it to cylinder block, and the other
crankcase. half without oil groove to lower crankcase.
Make sure that two halves are painted in
2 the same color.
• Be sure to oil crankshaft journals, journal
bearings, thrust bearings, crankpins,
1
connecting rod bearings, pistons, piston
rings and cylinder bores.

3
1
2

4
3
I3RB0A143110-01
3
16) Remove oil jet (1) from cylinder block, if necessary.
17) Remove knock pin (2) from cylinder block, if
necessary. 3

4
1 2 I3RB0A143113-01

4) Install knock pin (1) to crankshaft, if removed.

I3RB0A143111-01

Installation
1) Install knock pin (1) to cylinder block, if removed.
2) Install oil jet (2) to cylinder block, if removed.
Tightening torque
Oil jet bolt (a): 9.0 N·m (0.92 kgf-m, 6.5 lbf-ft)
1D-115 Engine Mechanical: D13A

NOTE c) Tighten crankcase bolts (M8) to 15 N⋅m (1.5 kgf-

Be sure to install knock pin to ø 6.75 mm m, 11.0 lbf-ft)
(0.266 in.) hole of crankshaft. d) Retighten crankcase bolts (M8) to 30 N⋅m (3.0
kgf-m, 22.0 lbf-ft).
Tightening torque
Crankcase bolt (M10)*: 20 N⋅m → +80° (2.0
kgf-m → +80°, 15.0 lbf-ft → +80°)
Crankcase bolt (M8)*: 15 N⋅m → 30 N⋅m (1.5
kgf-m → 3.1 kgf-m, 11.0 lbf-ft → 22.5 lbf-ft)

NOTE
After tightening lower crankcase bolts, check
1 to be sure that crankshaft rotates smoothly.

I3RB0A143114-01
“20” “18”
“15”
5) Install crankshaft (1) to cylinder block. “11” “14”

“6” “9” “7”

“1”
“4”

“2” “3”

I3RB0A143115-01

6) Apply sealant to cylinder block (1) as shown in “8” “10” “5”

figure.
“13”
“A”: Sealant 99000–85E11 (Three Bond TB “17” “19” “16” “12”
1227®) I3RB0A143117-01

9) Using special tools, install flywheel side crankshaft

1
oil seal (1) as follows.
Special tool
“A” “A” (A): 09913M58620
(B): 09924M74510
“a” a) Fit crankshaft oil seal to special tool (A).
“A” b) Install special tool (B) to special tool (A), and
install crankshaft oil seal by tapping special tool
(B) lightly with a plastic hammer.
I3RB0A143116-01 c) Remove special tool (A) and (B).
“a”: 3.0 mm (0.118 in.)

1
7) Install lower crankcase to cylinder block.
8) Tighten new crankcase bolts (M10) (“1” – “10”) and (A)

new crankcase bolts (M8) (“11” – “20”) as follows.

(B)
NOTE
Tighten these bolts in numerical order as
indicated in the figure in this procedure.

a) Tighten crankcase bolts (M10) to 20 N⋅m (2.0 I3RB0A143118-01

kgf-m, 14.8 lbf-ft). 10) Install timing chain oil jet (1) to cylinder block.
b) Retighten by turning crankcase bolts (M10) to
80°.
 Engine Mechanical: D13A 1D-116

Tightening torque 17) Install oil cooler. )(Page 1E-18)

Oil jet union bolt (a): 6.0 N·m (0.61 kgf-m, 4.5 lbf- 18) Install CKP sensor. “CKP Sensor Removal and
ft) Installation”: D13A in Section 1C (Page 1C-22)
19) Install cylinder head assembly. )(Page 1D-96)
20) Install engine assembly to engine compartment.
)(Page 1D-77)

1
Main Bearing, Crankshaft and Cylinder Block
(a)
Inspection
AENBL80A1426041

Crankshaft Thrust Play

1) Install main bearing, main bearing (with thrust
I3RB0A143119-01 bearing), crankshaft and lower crankcase. )(Page
11) Install piston and connecting rod. )(Page 1D-104) 1D-113)
12) Install crank ventilation cover to cylinder block. 2) Using a dial gauge, measure displacement in axial
)(Page 1D-104) (thrust) direction of crankshaft.
13) Install generator bracket (1) to cylinder block. If measured value is out of specification, replace
main bearing (with thrust bearing).
Tightening torque
Generator bracket bolt (a): 25 N·m (2.5 kgf-m, Crankshaft thrust play:
18.0 lbf-ft) 0.135 – 0.305 mm (0.00531 – 0.012007 in.)
Thickness of crankshaft thrust bearing
1
Stamped
alphabet (1) of Bearing thickness
crank web
2.31 – 2.36 mm
Standard R
(0.0909 – 0.0929 in.)
2.44 – 2.47 mm
(a) Oversize RM
(0.0961 – 0.0972 in.)

I3RB0A143120-01

14) Install A/C compressor bracket (1), if removed.

Tightening torque
A/C compressor bracket bolt (a): 20 N·m (2.0
kgf-m, 14.8 lbf-ft)

(a)

I7V20A142053-02

Crankshaft journal bore

1 Inspect crankshaft journal bore for uneven wear or
damage. Measure crankshaft journal bore. If crankshaft
journal bore is damaged or diameter is out of
specification, replace cylinder block.
Crankshaft journal bore diameter
54.710 – 54.714 mm
Class A
(2.1540 – 2.1540 in.)
(a) 54.714 – 54.718 mm
I9P60A142056-01 Class B
(2.1541 – 2.1542 in.)
15) Install starting motor. “Starting Motor Removal and
54.718 – 54.722 mm
Installation”: D13A in Section 1I (Page 1I-11) Class C
(2.1543 – 2.1544 in.)
16) Install generator. “Generator Removal and
Installation”: D13A in Section 1J (Page 1J-27)
1D-117 Engine Mechanical: D13A

I5RS0B140029-01 I3RB0A143124-01

4) Install lower crankcase. )(Page 1D-113)

Main Bearing Inspection
AENBL80A1426042
General information
• Service main bearings are available in standard size
and 0.127 mm undersize, and standard size and
undersize has 3 kinds of bearings differing in
thickness.
• Upper half of bearing (1) has oil groove (2) as shown
in figure.
Install this half with oil groove to cylinder block.
• Lower half of bearing does not have oil groove.
1
NOTE
It is not necessary to replace new crankcase
bolts for measuring procedure.
5) Remove cap and using a scale (1) on gauging
plastic (2) envelope, measure gauging plastic width
at the widest point (clearance).
If clearance is out of specification, replace bearing.
Always replace both upper and lower bearing as a
set.
Main bearing clearance:
0.028 – 0.048 mm (0.00111 – 0.00188 in.)

I3RB0A143123-01

Visual inspection 2
I3RB0A143125-01
Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and
Selection of Main Bearings
lower halves.
Standard bearing
Never replace either half without replacing the other half.
If bearing is in malcondition, or bearing clearance is out
of specification, select a new standard bearing according
Main bearing clearance
to the following procedure and install it.
NOTE 1) First check journal diameter. As shown in figure,
Do not rotate crankshaft while gauging crank web No.4 has stamped alphabets.
plastic is installed. Three kinds of alphabets (“A”, “B” and “C”) represent
the following journal diameters.
1) Before checking bearing clearance, clean bearing Stamped alphabets on crank web No.4 represent
and crankshaft journal. journal diameters marked with an arrow in figure
2) Install bearing to cylinder block and main bearing respectively. For example, stamped alphabet “A”
cap. )(Page 1D-113) indicates that corresponding journal diameter is
50.994 – 51.0000 mm (2.0077 – 2.0078 in.).
3) Place a piece of gauging plastic (1) to full width of
crankshaft journal as contacted by bearing (parallel Crankshaft journal diameter
to crankshaft), avoiding oil hole. Stamped
Journal diameter
alphabet
50.994 – 51.000 mm
A
(2.0077 – 2.0078 in.)
50.988 – 50.994 mm
B
(2.0074 – 2.0076 in.)
 Engine Mechanical: D13A 1D-118

Stamped
Journal diameter
alphabet
50.982 – 50.998 mm
C
(2.0072 – 2.0074 in.)

I7V20A142054-01

1. Crankshaft pulley side

I7V20A142055-01

2) Next, check journal bore diameter. On mating 1. Crankshaft pulley side

surface of cylinder block, three numbers are
stamped as shown in figure. 3) There are 3 kinds of standard bearings differing in
Three kinds of numbers (“1”, “2” and “3”) represent thickness. To distinguish them, they are painted in
the following journal bore diameters. the following colors at the position as indicated in
Stamped numbers on cylinder block represent figure.
journal bore diameter marked with an arrow in figure Each color indicated the following thickness at the
respectively. center of bearing.
For example, stamped “1” indicates that Standard size of crankshaft main bearing
corresponding journal bore diameter is 54.710 – thickness
54.714 mm (2.5140 – 2.1540 in.).
Color painted Bearing thickness
Crankshaft journal bore 1.836 – 1.841 mm
Stamped Red (0.07229 – 0.07248
Journal bore diameter in.)
number
54.710 – 54.714 mm 1.841 – 1.846 mm
1 Blue (0.07249 – 0.07267
(2.1540 – 2.1540 in.)
54.714 – 54.718 mm in.)
2 1.846 – 1.851 mm
(2.1540 – 2.1542 in.)
54.718 – 54.722 mm Yellow (0.07268 – 0.07287
3 in.)
(2.1543 – 2.1544 in.)
1D-119 Engine Mechanical: D13A

I7V20A142056-02

[A]: Without thrust bearing [B]: With thrust bearing

4) From alphabet stamped on crank web No.4 and numbers stamped on cylinder block, determine new standard
bearing to be installed to journal, by referring to the table shown.
For example, if alphabet stamped on crank web No.4 is “A” and number stamped on cylinder block is “1”, install a
new standard bearing painted in “Red” or “Red / White” for upper and “Red” for lower to its journal.
Main bearing cross-reference table (standard size)
Alphabet stamped on crank web No.4 (Journal diameter)
A B C
Upper Red Red Blue
1
Lower Red Blue Blue
Number stamped on
Upper Red Blue Blue
cylinder block (Cap bore 2
Lower Blue Blue Yellow
dia.)
Upper Blue Blue Yellow
3
Lower Blue Yellow Yellow

2
I5RS0B140036-01

Undersize bearing (0.127 mm)

• 0.127 mm undersize bearing is available, in three kinds varying in thickness. To distinguish them, each bearing is
painted in the following colors at such position as indicated in figure. Each color represents the following thickness
at the center of bearing.
 Engine Mechanical: D13A 1D-120

Undersize of crankshaft main bearing thickness

Color
Bearing thickness
painted
1.899 – 1.904 mm
Brown
(0.07477 – 0.07496 in.)
1.904 – 1.909 mm
Green
(0.07497 – 0.07515 in.)
1.909 – 1.914 mm
Black
(0.07516 – 0.07535 in.)

I7V20A142056-02

[A]: Without thrust bearing 1. Paint

[B]: With thrust bearing

• If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows.
1) Regrind journal to the following finished diameter.
Finished diameter
50.855 – 50.873 mm (2.00216 – 2.00287 in.)
2) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions
perpendicular to each other in order to check for out-of-round.
3) Using journal diameter measured above, select an undersize bearing by referring to table given below. Check
bearing clearance with newly selected undersize bearing.
Main bearing cross-reference table (undersize)
Alphabet stamped on crank web No.4 (Journal diameter)
50.867 – 50.873 mm 50.861 – 50.867 mm 50.855 – 50.861 mm
(2.0027 – 2.0028 in.) (2.0024 – 2.0026 in.) (2.0022 – 2.0024 in.)
Upper Brown Brown Green
1
Lower Brown Green Green
Number stamped on
Upper Brown Green Green
cylinder block (Cap bore 2
Lower Green Green Black
dia.)
Upper Green Green Black
3
Lower Green Black Black
1D-121 Engine Mechanical: D13A

Flywheel side crankshaft oil seal

Carefully inspect flywheel side crankshaft oil seal (1) for
wear or damage.
If its lip is worn or damaged, replace it.

I2RH01140157-01

“a”: 7 mm (0.287 in)

1
3) Using micrometer, measure piston diameter.
4) Rebore and hone cylinder to the following
I3RB0A143126-01 dimension.
Cylinder bore diameter to be rebored:
Cylinder Block Inspection 69.998 – 70.012 mm (2.74287 – 2.75637 in.)
AENBL80A1426043
Honing or reboring cylinder NOTE
1) When any cylinder needs reboring, all other cylinder
Before reboring, install all main bearing caps
must also be rebored at the same time.
in place and tighten to specification to avoid
2) Use oversized piston according to amount of distortion of bearing bores.
cylinder wear.
Oversize piston diameter 5) Measure piston clearance after honing. If clearance
is out of specification, replace cylinder block and all
Size Piston diameter
pistons.
69.944 – 69.958 mm
Oversize 0.40
(2.7538 – 2.7541 in.) Piston clearance:
0.054 mm (0.00212 in.)

Specifications
Tightening Torque Specifications
AENBL80A1427001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Camshaft housing plug 18 1.8 13.0 )/)
Common rail bracket bolt 25 2.5 18.0 )/)
Air cleaner assembly screw 1.7 1.17 1.5 )
Vacuum pump bolt 5 0.5 4.0 )
and then 20 2.0 14.5 )
EGR cooler bolt 25 2.5 18.5 )
EGR valve bolt 22 2.2 16.5 )
EGR pipe bolt 1.2 0.1 1.0 )
Crankcase ventilation cover mounting bolt 10 1.0 7.3 )
Oil separator mounting bolt 10 1.0 7.3 )
Generator bracket mounting bolt 22 2.24 16.22 )
Turbocharger nut 25 2.55 18.4 )
Turbocharger oil intake pipe bolt (b) 22 2.2 16.5 )
Intake manifold bolt 25 2.5 18.4 )
Oil level gauge guide mounting bolt 9.0 0.9 7.0 )
Engine harness ground bolt 11 1.1 8.5 )
Engine left mounting bracket nut 55 5.6 40.5 )
Engine left mounting bracket bolt 55 5.6 40.5 )
Engine right mounting bracket nut 55 5.6 40.5 )
Engine rear mounting bush bolt 55 5.6 40.5 )
Chain guide mounting bolt 9.0 0.92 6.5 )
 Engine Mechanical: D13A 1D-122

Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Movable guide mounting bolt 28.0 2.8 20.2 )
Chain tensioner adjuster bolt 28.0 2.9 20.7 )
Timing chain cover bolt 9.0 0.92 6.5 )
Timing chain cover nut 9.0 0.92 6.5 )
Flywheel bolts 44 4.5 32.5 )
Oil pump flange bolt 230 23.5 170.0 )
Crankshaft pulley bolt 25 2.5 18.5 )
Engine right mounting bracket No.2 bolt 55 5.6 40.6 )
Camshaft housing bolt 18 1.8 13.3 )
Camshaft housing stud bolt 25 2.5 18.0 )
Camshaft timing sprocket bolt 150 15.3 110.6 )
Camshaft gear bolt 150 15.3 110.6 )
Cylinder head bolt* 40 N⋅m → +90° → +90° (41 kgf-m, → +90° )
→ +90°, 29.5 lbf-ft → +90° → +90°)
Connecting rod bearing cap bolt* 20 N⋅m → +40° (2.0 kgf-m → +40°, 15.0 lbf- )
ft → +40°)
Oil pan baffle plate bolt 9.0 0.92 6.5 )
Oil jet bolt 9.0 0.92 6.5 )
Crankcase bolt (M10)* 20 N⋅m → +80° (2.0 kgf-m → +80°, 15.0 lbf- )
ft → +80°)
Crankcase bolt (M8)* 15 N⋅m → 30 N⋅m (1.5 kgf-m → 3.1 kgf-m, )
11.0 lbf-ft → 22.5 lbf-ft)
Oil jet union bolt 6.0 0.61 4.5 )
Generator bracket bolt 25 2.5 18.0 )
A/C compressor bracket bolt 20 2.0 14.8 )

NOTE
The tightening torque(s) also specified in:
“Air Cleaner Components”: D13A
“Intercooler Components”: D13A
“EGR Valve and EGR Cooler Components”: D13A
“Crankcase Ventilation System Components”: D13A
“Turbocharger Components”: D13A
“Intake Manifold Components”: D13A
“Engine Mounting Components”: D13A
“Timing Chain Cover and Timing Chain Components”: D13A
“Camshaft Housing Components”: D13A
“Valve and Cylinder Head Components”: D13A
“Piston, Piston Ring, Connecting Rod and Cylinder Components”: D13A
“Main Bearing, Crankshaft and Cylinder Block Components”: D13A

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Recommended Service Material
AENBL80A1428001
Material SUZUKI recommended product or Specification Note
Sealant Three Bond TB 1227® P/No.: 99000–85E11 )/)
Thread lock cement Loctite omnifit 100M spezial® — )/)
1D-123 Engine Mechanical: D13A

NOTE
Required service material(s) also described in:
“Timing Chain Cover and Timing Chain Components”: D13A
“Camshaft Housing Components”: D13A
“Valve and Cylinder Head Components”: D13A
“Piston, Piston Ring, Connecting Rod and Cylinder Components”: D13A
“Main Bearing, Crankshaft and Cylinder Block Components”: D13A

Special Tool
AENBL80A1428002
09910M26510 09910M26550
Dial gauge support Dial gauge support
OUT 0000005) / ) )

09912M38300 09912M46310
Crankshaft locking tool TDP definition pin
)/)/)/)/)/)/) EN-46785)

09912M57822 09912M96510
Compression gauge Injection pump pulley
remover
) Mot. 1525)

09913M58620 09913M75510
Oil seal installer Bearing installer
) )

09915M68610 09916M14510
Dummy heater plug Valve lifter
) )/)

09916M14521 09916M58210
Valve spring compressor Valve guide installer handle
attachment
)/) )
 Engine Mechanical: D13A 1D-124

09916M77310 09916M84511
Piston ring compressor (50 - Forceps
125 mm)
) )/)

09916M98610 09917M68221
Flywheel locking tool Camshaft pulley holder
KM-652) / ) )/)

09917M68610 09917M98221
Camshaft locking tool Valve guide stem
attachment
EN-46781) / ) / ) / ) / ) )
/)/)

09918M18111 09924M74510
Air pressure regulator Bearing and oil seal handle
) )
1E-1 Engine Lubrication System: K14B

Engine Lubrication System

Engine

K14B
General Description
Engine Lubrication Description
AENBL80A1511001
The oil pump is of a trochoid type, and rotates with the crankshaft. Oil is drawn up through the oil pump strainer and
passed through the pump to the oil filter.
The filtered oil flows into two paths in cylinder block.
In one path, oil reaches the crankshaft main bearings. Oil from the crankshaft main bearings is supplied to the
connecting rod bearings by means of intersecting passages drilled in the crankshaft, and then injected from the big
end of connecting rod to lubricate piston, rings and cylinder wall.
In the other path, oil goes up to the cylinder head and lubricates valves and camshafts etc., after passing through the
internal oil way of camshafts.
An oil relief valve is provided on the oil pump. This valve starts relieving oil pressure when the pressure exceeds
specified pressure.

Diagnostic Information and Procedures

Oil Pressure Check
AENBL80A1514001
! WARNING
2
To avoid danger of being burned, do not
touch the exhaust system when the system is
hot.

NOTE
Prior to checking oil pressure, check the
following. 1
• Oil level in oil pan I7V20A151002-01
If oil level is low, add oil up to full level 7) Install special tools to threaded hole where oil
mark (hole) (1) on oil level gauge. )(Page pressure switch was removed.
1E-2)
Special tool
• Oil quality
(A): 09915M77311
If oil is discolored or deteriorated, change
(B): 09915M78211
it. )(Page 1E-2)
• Oil leaks
(B)
If leak is found, repair leaky point. (A)

1) Place gear shift lever in “Neutral” and apply parking

brake.
2) Disconnect OCV connector.
3) Remove front bumper. “Front Bumper Removal and
Installation” in Section 9H (Page 9H-1)
4) Remove engine front cover.
5) Disconnect oil pressure switch lead wire (1).
6) Remove oil pressure switch (2) from cylinder block. I7V20A151003-01

8) Start engine and warm engine up to normal

operating temperature.
9) After warming up, raise engine speed to 4,000 rpm
and measure oil pressure.
 Engine Lubrication System: K14B 1E-2

Oil pressure specification 12) Connect oil pressure switch lead wire (1).
More than 300 – 500 kPa (3.1 – 5.1 kgf/cm2, 43.5 –
72.5 psi) at 4,000 rpm.
1
10) After checking oil pressure, stop engine and remove
special tools.
11) Apply sealant to thread portion of oil pressure switch
(1), and then tighten oil pressure switch to specified
torque.

! CAUTION
Do not apply sealant to oil pressure switch
hole.
I7V20A151005-01

13) Start engine and check oil pressure switch for oil
“A”: Thread lock cement 99000–32110 (Thread
leakage. If oil leakage is found, repair correct
Lock Cement Super 1322)
installation of oil pressure switch.
Tightening torque 14) Check DTC. “DTC Check”: K14B in Section 1A
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5 (Page 1A-18)
lbf-ft) If any DTC is displayed, clear DTC. “DTC
Clearance”: K14B in Section 1A (Page 1A-19)
“A” 1

1, (a)

I9R90A150004-01

Repair Instructions
Engine Oil and Filter Change Tightening torque
AENBL80A1516001 Engine oil drain plug (a): 35 N·m (3.6 kgf-m, 26.0
! WARNING lbf-ft)

• New and used engine oil can be

hazardous.
Be sure to read “WARNING” in “General
Precautions” in Section 00 (Page 00-1) and
observe what is written there.
• Step 1) – 8) must be performed with
ENGINE NOT RUNNING.
For Step 9), be sure to have adequate
ventilation while engine is running.
1, (a)

Before draining engine oil, check engine for oil leakage. I8C50B150002-01

If any evidence of leakage is found, make sure to correct 3) Loosen oil filter using special tool and remove oil
defective part before proceeding to the following filter.
procedure.
Special tool
1) Drain engine oil by removing drain plug (1). (A): 09915M47341
2) After draining oil, wipe drain plug clean. Reinstall
drain plug with new gasket and tighten drain plug to
specified torque.
1E-3 Engine Lubrication System: K14B

8) Replenish oil until oil level is brought to FULL level

mark (hole) on oil level gauge (oil pan and oil filter
capacity). Oil filler port is at top of cylinder head
cover. It is recommended to use engine oil of SG,
(A) SH, SJ, SL or SM grade. Select appropriate oil
viscosity according to engine oil viscosity chart [A]
below.
SAE 5W-30 oil is the best choice for good fuel
economy and good starting in cold weather.

NOTE
• Engine oil capacity is as specified below.
I7V20A151009-02
However, note that actual amount of oil
4) Wipe clean oil filter mounting surface on oil pan. required during oil change may somewhat
5) Apply engine oil to new oil filter gasket. differ from that indicated below depending
on such factors as temperature, viscosity,
etc.
• Engine oil specification and viscosity chart
[A] indicated in this manual are typical
ones.
For the specific information on the engine
oil and proper engine oil viscosity, refer to
“Engine Oil and Filter” section of the
Owner's Manual.

Engine oil specification

IYSQ01020009-01
6) Install new filter on oil filter stand by hand until filter
O-ring contacts mounting surface.
! CAUTION
To tighten oil filter properly, it is important to
accurately identify the position at which filter
O-ring first contacts mounting surface.
Oil pan capacity: About 2.9 liters (6.13 / 5.10 US /
Imp pt.)
Oil filter capacity: About 0.2 liter (0.42 / 0.35 US /
Imp pt.)
Others: About 0.3 liter (0.63 / 0.53 US / Imp pt.)
Total: About 3.4 liters (7.19 / 5.98 US / Imp pt.)
[A]

7) Tighten oil filter (1) 3/4 of a turn (2) from point of 10W-40
contact with mounting surface using special tool. 10W-30

Special tool 5W-30

o
(A): 09915M47341 C -30 -20 -10 0 10 20 30 40
o
F -22 -4 14 32 50 68 86 104
I8C50A150009-01
Tightening torque
Oil filter* (a): 14 N·m (1.4 kgf-m, 10.5 lbf-ft) 9) Start engine and run it for 5 minutes. Stop it and wait
another 5 minutes before checking oil level. Add oil,
if necessary, to bring oil level to FULL level mark
(hole) (1) on oil level gauge.

(A)
1, (a)

I7V20A151010-01
IYSQ01020012-01

2. Low level mark (hole)

10) Check oil filter and drain plug for oil leakage.
 Engine Lubrication System: K14B 1E-4

Oil Pressure Switch On-Vehicle Inspection

AENBL80A1516002
1) Disconnect oil pressure switch lead wire (1).
2) Check for continuity between oil pressure switch 2
terminal (2) and cylinder block (3) as shown. 4 1
If check result is not as specified, replace oil
pressure switch (4). 3

Oil pressure sensor specification

During engine running: No continuity
At engine stop: Continuity

I7V20A151006-01

Oil Pan and Oil Pump Strainer Components

AENBL80A1516003

OIL
1

3 1217G

4
OIL

1 5
(b)

(b)
(b)

(f)

11 (a) 8 (d)
2 (b) 6

10 (b) (b)
OIL

9 (c)
OIL

7 (e)
I9P60A151001-02

1. O-ring 7. Drain plug : 11 N⋅m (1.1 kgf-m, 8.5 lbf-ft)

: Apply engine oil. : Apply engine oil to mating surface.
2. Strainer 8. Oil filter stand : 14 N⋅m (1.4 kgf-m, 10.5 lbf-ft)
3. Oil pan 9. Oil filter : 18 N⋅m (1.8 kgf-m, 13.5 lbf-ft)
: Apply sealant 99000-31260 to mating : For tightening order, refer to “Engine Oil and
surface. Filter Change”: K14B (Page 1E-2).
: Apply engine oil to oil filter gasket.
4. Dowel pin 10. Oil pump strainer bolt : 35 N⋅m (3.6 kgf-m, 26.0 lbf-ft)
: For tightening order, refer to “Oil Pan and Oil
Pump Strainer Removal and Installation”: K14B
(Page 1E-5).
5. Oil pan baffle plate 11. Oil pump strainer bracket nut : 55 N⋅m (5.6 kgf-m, 40.5 lbf-ft)
: For tightening order, refer to “Oil Pan and Oil
Pump Strainer Removal and Installation”: K14B
(Page 1E-5).
6. Gasket : 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft) : Do not reuse.
1E-5 Engine Lubrication System: K14B

Oil Pan and Oil Pump Strainer Removal and

Installation
AENBL80A1516004

Removal
1) Remove oil level gauge.
2) Remove right engine undercover. 1,(a)

3) Drain engine oil by removing drain plug.

4) Remove exhaust pipe No.1. )(Page 1K-2) 2

5) Remove oil filter. )(Page 1E-2)

3,(b)
6) Remove transaxle bolts (1) and oil pan bolts (2). I9P60A151002-01

3) Apply engine oil to new O-ring (1) and then install O-

rings to oil pump strainer (2).
4) Install oil pump strainer with O-ring to oil pump and
tighten bolt (3) first and then nut (4) to specified
2
torque.
Tightening torque
Oil pump strainer bolt* (a): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)
Oil pump strainer bracket nut* (b): 10 N·m (1.0
1 kgf-m, 7.5 lbf-ft)
I7V20A151012-01

7) Remove oil pan (1) from cylinder block using special

tool and hammer.
Special tool
(A): 09921M96510

(A)

2
3,(a) 4,(b)
I9P60A151003-01

1 5) Install dowel pins (1) to oil pan and cylinder block.

I7V20A151013-02

8) Remove oil pump strainer, if necessary.

1
9) Remove oil pan baffle plate and oil pan baffle plate
stud bolts, if necessary.

Installation
1) Install oil pan baffle plate stud bolt (1) if removed,
and then tighten oil pan baffle plate stud bolt to
specified torque.
Tightening torque
Oil pan baffle plate stud bolt (a): 11 N·m (1.1 kgf-
m, 8.5 lbf-ft)
2) Install oil pan baffle plate (2) and then tighten oil pan 1
baffle plate bolts (3) to specified torque. I9P60A151004-01

Tightening torque 6) Apply engine oil to new O-ring (1) and then install O-
Oil pan baffle plate bolt (b): 11 N·m (1.1 kgf-m, ring to position as shown in figure.
8.5 lbf-ft) 7) Apply sealant to mating surface of oil pan as shown
in figure.
 Engine Lubrication System: K14B 1E-6

NOTE
• Before applying sealant, make sure mating
surface is clean and dry.
• Wipe off excessive sealant.
• Install oil pan within 2 minutes after
applying sealant.

“A”: Sealant 99000–31260 (SUZUKI Bond

No.1217G) 1, (a)

Sealant amount for oil pan I9P60A151006-01

Width “a”: 3 mm (0.12 in.) 10) Install oil filter. )(Page 1E-2)
Height “b”: 2 mm (0.08 in.) 11) Install exhaust pipe No.1. )(Page 1K-2)
12) Install right engine undercover.
1
13) Install drain plug and refill engine with engine oil.
)(Page 1E-2)
14) Install oil level gauge.
15) Verify that there is no engine oil leakage and exhaust
gas leakage at each connection.

“A” “a”
“A”
“b”

I7V20A151017-01

8) Install oil pan to cylinder block and then tighten oil

pan bolts in numerical order (“1” – “17”) evenly and
gradually to specified torque.
Tightening torque
Oil pan bolt* (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)

“8” “4” “2” “6” “10”

“16”

“14”
“12”

“13”
“15”

“17”

“9” “5” “1 ”, (a) “3” “7” “11”

I9P60A151005-01

9) Tighten transaxle bolts (1) to specified torque.

Tightening torque
Transaxle bolt (a): 55 N·m (5.6 kgf-m, 40.5 lbf-ft)
1E-7 Engine Lubrication System: K14B

Oil Pump Assembly Components

AENBL80A1516005

1
5 (a)

OIL
6
2

OIL
7

OIL
3
8 (b)

OIL
4

IAP70B150002-01

1. Rotor plate 5. Oil pump case (Timing chain cover) : 11 N⋅m (1.1 kgf-m 8.5 lbf-ft)
2. Dowel pin 6. Relief valve : 28 N⋅m (2.9 kgf-m 21.0 lbf-ft)

3. Outer rotor 7. Spring : Apply thin coat of engine oil to sliding surface.

4. Inner rotor 8. Retainer

Oil Pump Assembly Removal and Installation NOTE

AENBL80A1516006
Oil pump is incorporated in timing chain cover.
For removal and installation, refer to “Timing Chain
Cover Removal and Installation”: K14B in Section 1D
(Page 1D-22).
A matchmark (3) is supposed to be up-
pointing. Put a line mark (4) to help engage in
the original position of each rotor when
reinstalling.

Oil Pump Assembly Disassembly and 1

Reassembly
AENBL80A1516007

Disassembly
3
1) Remove rotor plate (1) by removing rotor plate
mounting bolts (2).

1 4
I8C50A150022-02
2
4) Remove relief valve (1) and spring (2) by removing
retainer (3) from rotor plate (4).

I7V20A151020-01

2) Using quick-drying ink pen, make matchmark (4) on

outer rotor and inner rotor as shown in figure.
3) Remove outer rotor (1) and inner rotor (2).
 Engine Lubrication System: K14B 1E-8

4 4 2

3,(a)
1 I7V20A151023-01

7) Install rotor plate and tighten rotor plate bolts to

2
specified torque. After installing plate, check that
rotors can be turned smoothly by hand (Torque: 0.3
N⋅m (0.03 kgf-m, 0.25 lbf-ft) or less).
3

I8C50A150023-02 Tightening torque

Oil pump rotor plate bolts (a): 11 N·m (1.1 kgf-
Reassembly m, 8.5 lbf-ft)
1) Wash clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to the following parts.
• Inner rotor
• Outer rotor
• Inside surfaces of oil pump case. (a)
3) Align matchmarks (4) on outer rotor and inner rotor
as shown in figure.
I8C50A150024-02
4) Install outer rotor (1) and inner rotor (2) to oil pump
case.
Oil Pump Inspection
NOTE AENBL80A1516008

When installing the outer rotor (1) and the Oil Seal
inner rotor (2), face the matchmark (3) Check oil seal lip for defects and damage. Replace if
upward and align the line marks (4) to each necessary.
other.

2 I2RH0B150023-01

Oil Pump
4
I8C50A150022-02 • Check outer (1) and inner rotors (2), rotor plate and oil
5) Apply engine oil to relief valve (1) and spring (2), and pump case for excessive wear or damage.
install them to rotor plate (4).
6) Tighten retainer (3) to specified torque.
Tightening torque
Oil relief valve retainer (a): 28 N·m (2.9 kgf-m,
21.0 lbf-ft)
1E-9 Engine Lubrication System: K14B

Side clearance of oil pump inner rotor

1 Standard: 0.045 – 0.100 mm (0.0018 – 0.0039 in.)
Limit: 0.120 mm (0.0047 in.)

I8C50A150028-01

• Check that relief valve (1) is not excessively worn or

damaged and operates smoothly. 2
I7V20A151027-01

Rotor plate clearance

Check clearance between inner rotor (1) and rotor plate
(2) as follows.
1) Measure outside diameter “a” of inner rotor (1) using
micrometer.
2) Measure inside diameter “b” of rotor plate (2) using
micrometer.
1
3) Calculate difference between measurements in Step
1) and Step 2).
If clearance is out of specification, replace oil pump
assembly.
Rotor plate clearance
I8C50A150029-01 Standard
Inner rotor outside 42.920 – 42.950 mm
Radial clearance diameter “a” (1.6900 – 1.6909 in.)
Check radial clearance between outer rotor (1) and case Rotor plate inside diameter 43.000 – 43.030 mm
(2) using feeler gauge. “b” (1.6929 – 1.6941 in.)
If clearance is out of specification, replace oil pump 0.050 – 0.110 mm
assembly. Clearance “b” – “a”
(0.0020 – 0.0043 in.)
Radial clearance between outer rotor and case of oil
pump
Standard: 0.120 – 0.190 mm (0.0047 – 0.0075 in.)
Limit: 0.210 mm (0.0083 in.)

2
I7V20A151026-01

Side clearance
Using straightedge (1) and feeler gauge (2), measure
side clearance.
If side clearance is out of specification, replace oil pump
assembly.
 Engine Lubrication System: K14B 1E-10

Relief valve spring free length and load

Check free length and load of relief valve spring as
shown in figure. If any of measurement is smaller than
specification, replace relief valve spring.
Relief valve spring free length and load
Standard Limit
32.7 mm
Free length —
(1.29 in.)
Load at spring 52.9 – 56.1 N 48.3 N
1
length (5.40 – 57.2 kgf, (4.9 kgf, 10.9
“a” 26.0 mm (1.02 in.) 11.9 – 12.6 lbf) lbf)

“b”
I9P60A151009-01

I2RH01150023-01

Specifications
Tightening Torque Specifications
AENBL80A1517001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Oil pressure switch 13 1.3 9.5 )
Engine oil drain plug 35 3.6 26.0 )
Oil filter* 14 1.4 10.5 )
Oil pan baffle plate stud bolt 11 1.1 8.5 )
Oil pan baffle plate bolt 11 1.1 8.5 )
Oil pump strainer bolt* 11 1.1 8.5 )
Oil pump strainer bracket nut* 10 1.0 7.5 )
Oil pan bolt* 11 1.1 8.5 )
Transaxle bolt 55 5.6 40.5 )
Oil relief valve retainer 28 2.9 21.0 )
Oil pump rotor plate bolts 11 1.1 8.5 )

NOTE
The tightening torque(s) also specified in:
“Oil Pan and Oil Pump Strainer Components”: K14B
“Oil Pump Assembly Components”: K14B

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
1E-11 Engine Lubrication System: K14B

Special Tools and Equipment

Recommended Service Material
AENBL80A1518001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 )
Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 )

NOTE
Required service material(s) also described in:
“Oil Pan and Oil Pump Strainer Components”: K14B
“Oil Pump Assembly Components”: K14B

Special Tool
AENBL80A1518002
09915M47341 09915M77311
Oil filter wrench socket Oil pressure gauge
)/) )

09915M78211 09921M96510
Oil pressure gauge Oil pan seal cutter
attachment
) )
 Engine Lubrication System: D13A 1E-12

D13A
Diagnostic Information and Procedures
Oil Pressure Check
AENBL80A1524001
! WARNING
To avoid danger of being burned, do not
touch exhaust manifold when exhaust
system is hot. (B)

1) Prior to checking oil pressure, check the following

items. (A)

• Oil level in oil pan

If oil level is low, add oil up to full level mark (1) on I5RS0B150001-01
oil level gauge (3). 4) Start engine and warm it up to normal operating
• Oil quality temperature.
If oil is discolored or deteriorated, change it. For
particular oil to be used, refer to “Engine Oil and NOTE
Filter Change”: D13A (Page 1E-13). Be sure to place transmission gear shift lever
• Oil leaks in “Neutral” and set parking brake and block
If leak is found, repair it. drive wheels.

5) After warming up, measure oil pressure at specified

engine speed.

NOTE
For specified idle speed, refer to “Idle Speed
Inspection”: D13A in Section 1A (Page 1A-
283).

Oil pressure specification:

I3RB0A153001-01
2. Low level mark
2) Remove oil pressure switch. “Oil Pressure Switch
Removal and Installation”: D13A (Page 1E-14)
3) Install special tools to vacated threaded hole.
! CAUTION
Be careful not to make special tool touch
exhaust manifold when installing because
exhaust manifold becomes very hot.
Minimum: 180 kPa (1.84 kgf/cm2, 26.1 psi, 1.80
bar) at 2000 rpm.
Minimum: 280 kPa (2.9 kgf/cm2, 40.6 psi, 2.80 bar)
at 4000 rpm.
6) Stop engine, and remove oil pressure gauge and
attachment.
7) Install oil pressure switch. )(Page 1E-14)
8) Start engine, and check oil pressure switch for oil
leakage.
If oil leakage is found, repair it.

Special tool
(A): 09915M77311
(B): 09919M46010
1E-13 Engine Lubrication System: D13A
Repair Instructions
Engine Oil and Filter Change
AENBL80A1526001
! WARNING
• New and used engine oil can be
hazardous.
Be sure to read “WARNING” in “General
Precautions” in Section 00 (Page 00-1) and
observe what is written there.
• Step 1) – 6) outlined below must be
performed with engine not running. For
Step 7), be sure to have adequate
ventilation while engine is running.
Before draining engine oil, check engine for oil leakage.
If any evidence of leakage is found, make sure to correct
defective part before proceeding to the following work.
1) Remove oil filter element.
a) Place oil collecting basin under filter.
b) Loosen and remove oil filter housing cover (1).
1
I3RM0B020002-01
c) Pull out oil filter (2) from cover.
IBP80A152001-01
2) Drain engine oil by removing drain plug (1).
3) After draining oil, wipe drain plug clean and replace
seal ring with a new one. Reinstall drain plug, and
tighten it securely as specified below.
Tightening torque
Engine oil drain plug (a): 24 N·m (2.44 kgf-m,
17.7 lbf-ft)
1, (a)
I5RS0B020001-01
4) Install oil filter.
a) Replace seal ring (1) of oil filter housing cover (3)
with new one and apply engine oil to seal ring.
b) Install new oil filter (2) to cover.
2
1
3
I3RM0B020005-01
c) Install oil filter housing cover with oil filter.
Tightening torque
Oil filter housing cover (a): 25 N·m (2.5 kgf-
m, 18.5 lbf-ft)
(a)
I3RM0B020006-01
5) Replenish oil until oil level is brought to FULL level
mark on dipstick. (about 3.1 liters (6.55/5.46 US/Imp
pt.)) The filler inlet is by the engine oil filter.
Use engine oil of ACEA B4 (Synthetic oil). Select the
appropriate oil viscosity according to the proper
engine oil viscosity chart [A].
NOTE
Note that the amount of oil required when
actually changing oil may somewhat differ
from the data depending on various
conditions (temperature, viscosity, etc.)
Engine oil specification (Z13DTJ)
Oil pan capacity: About 2.9 liters
Oil filter capacity: About 0.2 liter
Others: About 0.4 liter
Total: About 3.5 liters
 Engine Lubrication System: D13A 1E-14

Oil Pressure Switch Removal and Installation

[A] AENBL80A1526003
Removal
5W-40
1) Disconnect negative (–) cable at battery.
o
C -30 -20 -10 0 10 20 30 40 2) Remove engine cover.
o
F -22 -4 14 32 50 68 86 104 3) Disconnect oil pressure switch connector.
IBL80A152002-01
4) Remove oil pressure switch (1) from cylinder head.
6) Check oil filter and drain plug for oil leakage.
7) Start engine and run it for 3 minutes. Stop it and wait
5 minutes before checking oil level. Add oil, as
necessary, to bring oil level to FULL level mark (1)
on dipstick.
1

1 2

I5RS0B150002-01

Installation
I3RM0B020008-01
Reverse removal procedure for installation noting the
2. Low level mark following.
• Check oil pressure switch gasket for deterioration and
Oil Pressure Switch On-Vehicle Inspection damage. If malfunction is found, replace oil pressure
AENBL80A1526002
switch.
1) Disconnect oil pressure switch (1) lead wire.
• Tighten oil pressure switch (1) to specified torque.
2) Check for continuity between oil pressure switch
terminal (2) and cylinder block (3) as shown. Tightening torque
If check result is not as specified, replace oil Oil pressure switch (a): 32 N·m (3.3 kgf-m, 24.0
pressure switch (1). lbf-ft)
Oil pressure sensor specification
During engine running: No continuity
At engine stop: Continuity

1, (a)

I5RS0B150003-01
1 • Install engine cover.
Tightening torque
Engine cover bolt: 8.0 N·m (0.82 kgf-m, 6.0 lbf-ft)
• Check to make sure that there is no engine oil
3
1 leakage.

I5RS0B930002-01
1E-15 Engine Lubrication System: D13A

Oil Cooler Components

AENBL80A1526004

1 4 (a)

(b)
2
5
6

7
3

(c)

I7V20A152003-01

1. Filler cap 4. Oil filter housing cover 7. Oil cooler assembly : 9.0 N⋅m (0.92 kgf-m, 7.0 lbf-ft)
: Never disassemble oil cooler assembly.
2. O-ring 5. Oil filter : 25 N⋅m (2.5 kgf-m, 18.5 lbf-ft) : Do not reuse.
3. Gasket 6. Coolant feed pipe : 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft)

Oil Cooler Removal and Installation 5) Remove oil cooler assembly (3).
AENBL80A1526005

! CAUTION
Never disassemble oil cooler assembly.
Disassembly will spoil its original function.
If faulty condition is found, replace it with
new one.

Removal
1) Disconnect negative (–) cable at battery.
2) Drain coolant. )(Page 1F-25)
3) Remove coolant feed pipe (1) and radiator outlet
hose.

I7V20A152005-01

Installation
1) Install oil cooler assembly (1) using new gasket.
Tightening torque
Oil cooler bolt (a): 9.0 N·m (0.92 kgf-m, 7.0 lbf-ft)
2) Connect wire harness clamp (3) to filler port (2).
I3RM0B152005-01

4) Disconnect wire harness clamps (1) from filler port

(2).
 Engine Lubrication System: D13A 1E-16

4) Install coolant feed pipe (1) and lower hose.

Tightening torque
Coolant feed pipe bolt (a): 9 N·m (0.92 kgf-m, 7.0
lbf-ft)

I3RM0B152018-01
I7V20A152006-01
5) Install lubrication pipe. )(Page 1D-72)
3) Install oil filter, oil filter housing cover (4), with new 6) Refill cooling system. )(Page 1F-25)
O-ring referring to “Engine Oil and Filter Change” in
Section 0B (Page 0B-3) 7) Connect negative (–) cable at battery.
8) Check to make sure that there is no oil leakage and
coolant leakage at each connection.

Oil Pan Components

AENBL80A1526006

4 (b) 5 (b)
3

2 (a)
I7V20A152007-01

1. Oil pan 3. O-ring : 9.0 N⋅m (0.92 kgf-m, 6.5 lbf-ft)

: Apply sealant 99000-85E11 to mating surface.
2. Drain plug : 24 N⋅m (2.44 kgf-m, 17.7 lbf- : Do not reuse.
ft)

Oil Pan Removal and Installation

AENBL80A1526007

Removal
1) Remove oil level gauge.
2) Hoist vehicle.
3) Drain engine oil. )(Page 1E-13)
4) Remove exhaust No.1 pipe. “Exhaust Pipe and
Muffler Removal and Installation”: D13A in Section
1K (Page 1K-9)
5) Remove transaxle stiffener. “Manual Transaxle Unit I5RS0B150009-01

Dismounting and Remounting”: D13A Model in 7) Cut sealant at hatched part shown in the figure using
Section 5B (Page 5B-55) special tool (A) and hammer (1).
6) Remove oil pan bolts and nuts.
1E-17 Engine Lubrication System: D13A

Special tool : Sealant 99000–85E11 (Three Bond TB 1227®)

(A): 09921M96510
“A”
NOTE
Be careful not to damage stud bolt (4)
between oil pan and crankcase when cutting
sealant.

8) Remove oil pan (2) from lower crankcase (3).

I5RS0B150012-01
3
3) After fitting oil pan to lower crankcase, run in
securing bolts and start tightening at the center:
move wrench outward, tightening one bolt at a time.
(A) Tighten oil pan bolts and nuts to specified torque.
Tightening torque
1 Oil pan bolt and nut (a): 9.0 N·m (0.92 kgf-m, 7.0
lbf-ft)
2
4) Install new O-ring and drain plug (1) to oil pan.
Tighten drain plug to specified torque.
Tightening torque
Drain plug (b): 24 N·m (2.44 kgf-m, 17.7 lbf-ft)

(a)

I5RS0B150010-01

Installation
1, (b)
1) Clean mating surfaces of oil pan and lower I5RS0B150013-01
crankcase. 5) Install transaxle stiffener. “Manual Transaxle Unit
Dismounting and Remounting”: D13A Model in
Section 5B (Page 5B-55)
6) Install exhaust No.1 pipe. “Exhaust Pipe and Muffler
Removal and Installation”: D13A in Section 1K (Page
1K-9)
7) Connect oil level switch connector.
8) Install oil level gauge.
9) Refill engine with engine oil. )(Page 1E-13)
10) Check to make sure that there is no engine oil
leakage and exhaust gas leakage at each
connection.

I5RS0B150011-01

2) Apply sealant to oil pan mating surface continuously

as shown in the figure.
 Engine Lubrication System: D13A 1E-18

Oil Pump / Oil Pump Strainer Components

AENBL80A1526008
3

(a)

2
1

I3RB0A153005-01

Oil Pump Disassembly and Reassembly

AENBL80A1526010
Disassembly
1) Remove rotor plate (1) by removing its mounting
bolts (2).
2) Remove outer rotor (3) and inner rotor (4) from
I7V20A152008-01 timing chain cover.
1. Timing chain cover : 9.0 N⋅m (0.92 kg-m,
: Oil pump is incorporated with 7.01 lbf-ft)
timing chain cover.
2. Oil pump strainer gasket : Do not reuse.
3. Oil pump strainer

Oil Pump / Oil Pump Strainer Removal and

Installation
AENBL80A1526009

Removal
1) Remove timing chain cover. )(Page 1D-82)
2) Remove oil pump strainer (1) and gasket (2) from
rotor plate (3).

I5RS0B150015-01

Reassembly
For reassembly, reverse disassembly procedure noting
2
1
the following.
• Wash, clean and then dry all disassembled parts.
I3RB0A153004-01
• Apply thin coat of engine oil to inner and outer rotors,
Installation oil seal lip portion, inside surfaces of timing chain
Reverse removal procedure for installation noting the cover and rotor plate.
following. • Tighten rotor plate bolts to specified torque.
• Clean mating surfaces of timing chain cover (3) and Tightening torque
oil pump strainer (1). Rotor plate bolt: 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
• Install oil pump strainer with new gasket (2) to timing
chain cover.
• Tighten oil strainer bolts to specified torque.
Tightening torque
Oil strainer bolt (a): 9.0 N·m (0.92 kgf-m, 7.0 lbf-ft)
1E-19 Engine Lubrication System: D13A

Oil Pump Strainer Cleaning Radial clearance between outer rotor and timing
AENBL80A1526011 chain cover for oil pump:
Clean oil pump strainer screen.
0.12 – 0.19 mm (0.005 – 0.007 in.)

I3RB0A153006-01

Oil Pump Inspection

AENBL80A1526012

Oil Seal
Refer to “Timing Chain Cover and Timing Chain
Inspection”: D13A in Section 1D (Page 1D-88).

Oil Pump I5RS0B150016-01

Check rotor turn smoothly by hand.

If rotors is not smoothly, replace timing chain cover.
Side clearance
Using straightedge (1) and thickness gauge (2),
measure side clearance. If side clearance is out of
specification, replace timing chain cover.
Side clearance for oil pump inner rotor:
0.050 – 0.105 mm (0.0020 – 0.0041 in.)

I3RB0A153007-01

Radial clearance
Check radial clearance between outer rotor (1) and
timing chain cover (2) using thickness gauge (3). If
clearance is out of specification, replace timing chain
cover.
I5RS0B150017-01

Specifications
Tightening Torque Specifications
AENBL80A1527001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Engine oil drain plug 24 2.44 17.7 )
Oil filter housing cover 25 2.5 18.5 )
Oil pressure switch 32 3.3 24.0 )
Engine cover bolt 8.0 0.82 6.0 )
Oil cooler bolt 9.0 0.92 7.0 )
Coolant feed pipe bolt 9 0.92 7.0 )
Oil pan bolt and nut 9.0 0.92 7.0 )
Drain plug 24 2.44 17.7 )
Oil strainer bolt 9.0 0.92 7.0 )
Rotor plate bolt 10 1.0 7.5 )
 Engine Lubrication System: D13A 1E-20

NOTE
The tightening torque(s) also specified in:
“Oil Cooler Components”: D13A
“Oil Pan Components”: D13A
“Oil Pump / Oil Pump Strainer Components”: D13A

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Recommended Service Material
AENBL80A1528001
Material SUZUKI recommended product or Specification Note
Sealant Three Bond TB 1227® P/No.: 99000–85E11 )

NOTE
Required service material(s) also described in:
“Oil Pan Components”: D13A

Special Tool
AENBL80A1528002
09915M77311 09919M46010
Oil pressure gauge Fuel pressure hose
attachment
) )

09921M96510
Oil pan seal cutter
)
 Engine Cooling System: K14B 1F-1

Engine Cooling System

Engine

K14B
Precautions
Precautions for Cooling System
AENBL80A1610001
! WARNING

• Be sure to check coolant level only on coolant reservoir (a translucent container) and add coolant
only into the reservoir when replenishment is needed. Never remove radiator cap to check coolant
level or add coolant, as doing so is very dangerous for the following reasons:
– Coolant in cooling system may be extremely high in temperature, even exceeding the boiling
point as it is under pressure. If radiator cap is removed in this condition, high-temperature and
high-pressure coolant will instantaneously boil up and gush out; you could then be seriously
scalded by hot coolant and steam.
Furthermore, as coolant contains flammable anti-freeze material, coolant splashing over engine
and fenders can start fire.
• Be sure to check that engine coolant is cold before removing any part of cooling system.
• Be sure to disconnect negative (–) cable at battery before removing any part of cooling system.

General Description
Cooling System Description NOTE
AENBL80A1611001
The cooling system consists of the radiator, coolant Coolant must be mixed with demineralized
reservoir, water pump, cooling fan and thermostat. The water or distilled water.
radiator is of a tube-and-fin type.
Coolant table
°C –14.5
Coolant Description Freezing temperature
AENBL80A1611002 °F –5.9
As coolant becomes hot and expands, it overflows the Anti-freeze / Anti-corrosion
% 30
radiator and the overflow goes into the reservoir. When coolant concentration
the cooling system cools down, the coolant in the
reservoir is drawn back into the radiator. Coolant capacity
The cooling system is filled with a coolant that is a 70/30 Engine, radiator and heater: 4.4 liters (9.30/7.75 US/
mixture of water and ethylene glycol. This coolant can Imp pt.)
protect the system from freezing even at a temperature Reservoir: 0.7 liters (1.48/1.23 us/Imp pt.)
as low as –14.5 °C (–5.9 °F). Total: 5.1 liters (10.78/8.98 US/Imp pt.)
This coolant has a characteristic of minimizing the loss
due to boiling and can protect the system from corrosion Cooling Fan Operation Description
regardless of the ambient temperature. AENBL80A1611003
When replenishing the system due to loss of coolant, the Radiator cooling fan motors are controlled by ECM as
same ethylene glycol base coolant should be used in follows.
order to ensure the same level of protection against
freezing and corrosion. [A]

! CAUTION [B]
Alcohol or methanol base coolant or plain
water alone should not be used in cooling [C]
system at any time as damage to cooling
95.3 96.8 99.8 102.0 (°C)
system could occur. 203.5 206.2 211.6 215.6 (°F)
I9P60A161001-01

[A]: High [B]: Low [C]: OFF

1F-2 Engine Cooling System: K14B

Following controls are also performed when A/C switch Cooling fan speed changes from low to high speed when
is ON. A/C refrigerant pressure exceeds specified value of 1.5
Low speed: MPa (15.3 kgf/cm2, 218 psi).
Cooling fan operates at low speed when A/C refrigerant
pressure is more than specified value of 1.1 MPa (11.2 Fail-Safe
kgf/cm2, 160 psi). Cooling fan operates at high speed if malfunction related
High speed: to ECT sensor is detected.

Schematic and Routing Diagram

Coolant Circulation
AENBL80A1612001

[A]
11
7

9
4
10 3

6 5

2
1

12

[B]
11
7

9
4
10 3

6 5

2
1

12

I7V20A161001-02

[A]: Engine is cool (thermostat closed) 4. Throttle body outlet hose 9. Heater core inlet hose
[B]: Engine is normal at operating temperature (thermostat open) 5. Thermostat 10. Heater core outlet hose
1. Radiator inlet hose 6. Water pump 11. Heater core
2. Radiator outlet hose 7. Throttle body 12. Radiator
3. Throttle body inlet hose 8. Engine
 Engine Cooling System: K14B 1F-3

Radiator Cooling Fan Control System Circuit Diagram

AENBL80A1612002

9
GRN BLK/WHT E01-5

1 6
10
BLK/YEL BLK/YEL BRN/WHT E01-54

WHT BLK/YEL BLK/RED E01-56 12V

5V
BLK/RED E01-55
BLK BLK/RED
2
12 LT GRN E01-42
11
GRY
E1 A1 BLU
GRN
3 D1 B1 D1 4 GRN E01-41
L+
H+ L-
BLU/BLK 5 BLK
E1 C01-53 BLK
A2 H- C1 C2 C01-51 BLK
B2
BLU/WHT C01-50 BLK
8 5V
A3
LT GRN C01-32

BEG C01-20

[A] C01 E01

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

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

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

IAP70B160001-03

[A]: ECM connector (View: [a]) D1: Radiator cooling fan relay No.2 and No.3 power 7. ECM
supply circuit (coil side)
A1: Radiator cooling fan relay No.1 power supply circuit (switch side) E1: Radiator cooling fan relay No.2 and No.3 drive circuit 8. ECT sensor
A2: Radiator cooling fan relay No.2 power supply circuit (switch side) 1. Ignition switch (ignition switch model) or IG1 relay 9. “IG COIL” fuse
(keyless push start model)
A3: Radiator cooling fan relay No.3 power supply circuit (switch side) 2. Radiator cooling fan relay No.1 10. “FI” fuse
B1: Radiator cooling fan motor drive circuit (low speed) 3. Radiator cooling fan relay No.2 11. “RDTR” fuse
B2: Radiator cooling fan motor drive circuit (high speed) 4. Radiator cooling fan relay No.3 12. “IG1 ACC” fuse
C1: Radiator cooling fan motor ground circuit 5. Radiator cooling fan motor
C2: Radiator cooling fan relay No.3 ground circuit 6. Main relay
1F-4 Engine Cooling System: K14B

Diagnostic Information and Procedures

Engine Cooling Symptom Diagnosis
AENBL80A1614001

Condition Possible cause Correction / Reference Item

Engine overheats Loose or broken water pump belt Adjust or replace water pump belt. )(Page 1J-
(Radiator fan operates) 10)
Not enough coolant Check coolant level and add if necessary.
)(Page 1F-8)
Faulty thermostat Replace thermostat assembly. )(Page 1F-10)
Faulty water pump Replace water pump. )(Page 1F-13)
Dirty or bent radiator fins Clean or repair. )(Page 1F-12)
Coolant leakage on cooling system Check cooling system for leakage. )(Page
1F-9)
Clogged radiator Replace radiator. )(Page 1F-13)
Faulty radiator cap Check radiator cap. )(Page 1F-9)
Dragging brakes Check brake. “Brakes Symptom Diagnosis” in
Section 4A (Page 4A-2)
Slipping clutch Check clutch.“Clutch System Symptom
Diagnosis”: K14B Model in Section 5C (Page
5C-2)
Poorly charged battery Check battery. )(Page 1J-6)
Poor electricity generated by generator Check generator. )(Page 1J-8)
Faulty ECT sensor Check ECT sensor.“ECT Sensor Inspection”:
K14B in Section 1C (Page 1C-6)
Faulty radiator cooling fan motor Check radiator cooling fan motor. )(Page 1F-
11)
Faulty ECM Check ECM and its circuit. “Inspection of ECM
and Its Circuits”: K14B in Section 1A (Page 1A-
109)
Faulty radiator cooling fan relay Check radiator cooling fan relay. )(Page 1F-
12)
Faulty wiring or grounding Repair wiring.
Too many optional electric devices Remove electrical devices.
Engine overheats Fuse blown Check fuse.
(Radiator fan does not Faulty radiator cooling fan relay Check radiator cooling fan relay. )(Page 1F-
operate) 12)
Faulty ECT sensor Check ECT sensor. “ECT Sensor Inspection”:
K14B in Section 1C (Page 1C-6)
Faulty radiator cooling fan motor Check radiator cooling fan motor. )(Page 1F-
11)
Faulty wiring or grounding Repair wiring.
Faulty ECM Check ECM and its circuit.“Inspection of ECM
and Its Circuits”: K14B in Section 1A (Page 1A-
109)
 Engine Cooling System: K14B 1F-5

Radiator Cooling Fan System Check

AENBL80A1614002
Circuit Diagram

9
GRN BLK/WHT E01-5

1 6
10
BLK/YEL BLK/YEL BRN/WHT E01-54

WHT BLK/YEL BLK/RED E01-56 12V

5V
BLK/RED E01-55
BLK BLK/RED
2
12 LT GRN E01-42
11
GRY
E1 A1 BLU
GRN
3 D1 B1 D1 4 GRN E01-41
L+
H+ L-
BLU/BLK 5 BLK
E1 C01-53 BLK
A2 H- C1 C2 C01-51 BLK
B2
BLU/WHT C01-50 BLK
8 5V
A3
LT GRN C01-32

BEG C01-20

[A] C01 E01

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

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

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

IAP70B160001-03

[A]: ECM connector (View: [a]) D1: Radiator cooling fan relay No.2 and No.3 power 7. ECM
supply circuit (coil side)
A1: Radiator cooling fan relay No.1 power supply circuit (switch side) E1: Radiator cooling fan relay No.2 and No.3 drive circuit 8. ECT sensor
A2: Radiator cooling fan relay No.2 power supply circuit (switch side) 1. Ignition switch (ignition switch model) or IG1 relay 9. “IG COIL” fuse
(keyless push start model)
A3: Radiator cooling fan relay No.3 power supply circuit (switch side) 2. Radiator cooling fan relay No.1 10. “FI” fuse
B1: Radiator cooling fan motor drive circuit (low speed) 3. Radiator cooling fan relay No.2 11. “RDTR” fuse
B2: Radiator cooling fan motor drive circuit (high speed) 4. Radiator cooling fan relay No.3 12. “IG1 ACC” fuse
C1: Radiator cooling fan motor ground circuit 5. Radiator cooling fan motor
C2: Radiator cooling fan relay No.3 ground circuit 6. Main relay

Troubleshooting

! WARNING
Keep hands, tools, and clothing away from radiator cooling fan to prevent personal injury. This fan is
driven by electric motor that can turn on whether or not the engine is running. The fan motor can start
automatically in response to ECT sensor signal if ignition is “ON”.
1F-6 Engine Cooling System: K14B

NOTE
• For details about engine cooling fan operation, refer to “Cooling Fan Operation Description”: K14B
(Page 1F-1).
• Before beginning troubleshooting, be sure to read “Precautions for Engine (K14B)” in Section 1
(Page 1-1).
• When measuring circuit voltage, resistance and/or pulse signal of ECM, refer to “Inspection of ECM
and Its Circuits”: K14B in Section 1A (Page 1A-109).

Step Action Yes No

1 DTC check Go to applicable DTC Go to Step 2.
1) Set ignition “OFF” and connect SUZUKI scan tool to troubleshooting and
DLC. recheck DTC.
2) Set ignition “ON” and check DTC.

Is there DTC(s)?
2 Radiator cooling fan low-speed operation control check Go to Step 3. Go to Step 4.
1) Check radiator cooling fan control for low-speed
operation. )(Page 1F-11)

Is it in good condition?
3 Radiator cooling fan high-speed operation control Radiator cooling fan Go to Step 8.
check control system is in
1) Check radiator cooling fan control for high-speed good condition.
operation. )(Page 1F-11)

Is it in good condition?
4 Radiator cooling fan relay No.1 power supply circuit Go to Step 5. Repair “A1” circuit.
(switch side) check
1) Set ignition “OFF” and remove radiator cooling fan relay
No.1 from individual circuit fuse box No.1.
2) Check for proper connection to radiator cooling fan relay
No.1 at each terminal.
3) If OK, measure voltage between “A1” circuit and ground.

Is it 10 – 14 V?
5 Radiator cooling fan relay No.1 check Go to Step 6. Replace radiator cooling
1) Check radiator cooling fan relay No.1. )(Page 1F-12) fan relay No.1.

Is it in good condition?
6 Radiator cooling fan motor drive circuit (low speed) Go to Step 7. Repair “B1” circuit.
check
1) Set ignition “OFF” and disconnect ECM connector. “ECM
Removal and Installation”: K14B in Section 1C (Page
1C-1)
2) Disconnect radiator cooling fan motor connector.
3) Check for proper connection to radiator cooling fan
motor at each terminal.
4) If OK, check the following points.
• Resistance of “B1” circuit: 1 Ω or less
• Resistance between “B1” circuit and ground: infinity
• Voltage of “B1” circuit: approx. 0 V (with ignition “ON”)

Are they in good condition?

7 Radiator cooling fan motor ground circuit check Go to Step 16. Repair “C1” circuit.
1) Measure resistance between “C1” circuit and ground.

Is resistance 1 Ω or less?
 Engine Cooling System: K14B 1F-7

Step Action Yes No

8 Radiator cooling fan relay No.2 power supply circuit Go to Step 9. Repair “A2” circuit.
(switch side) check
1) Set ignition “OFF” and remove radiator cooling fan relay
No.2 from individual circuit fuse box No.1.
2) Check for proper connection to radiator cooling fan relay
No.2 at each terminal.
3) If OK, measure voltage between “A2” circuit and ground.

Is it 10 – 14 V?
9 Radiator cooling fan relay No.2 check Go to Step 10. Replace radiator cooling
1) Check radiator cooling fan relay No.2. )(Page 1F-12) fan relay No.2.

Is it in good condition?
10 Radiator cooling fan motor drive circuit (high speed) Go to Step 11. Repair “B2” circuit.
check
1) Set ignition “OFF” and disconnect radiator cooling fan
motor connector.
2) Check for proper connection to radiator cooling motor at
each terminal.
3) If OK, check the following points.
• Resistance of “B2” circuit: 1 Ω or less
• Resistance between “B2” circuit and ground: infinity
• Voltage of “B2” circuit: approx. 0 V (with ignition “ON”)

Is it in good condition?
11 Radiator cooling fan relay No.3 power supply circuit Go to Step 12. Repair “A3” circuit.
(switch side) check
1) Check the following points.
• Resistance of “A3” circuit: 1 Ω or less
• Resistance between “A3” circuit and ground: infinity
• Voltage of “A3” circuit: approx. 0 V (with ignition “ON”)

Is it in good condition?
12 Radiator cooling fan relay No.3 check Go to Step 13. Replace radiator cooling
1) Check radiator cooling fan relay No.3. )(Page 1F-12) fan relay No.3.

Is it in good condition?
13 Radiator cooling fan relay No.3 ground circuit check Go to Step 14. Repair “C2” circuit.
1) Measure resistance between “C2” circuit and ground.

Is resistance 1 Ω or less?
14 Radiator cooling fan relay No.2 and No.3 power supply Go to Step 15. Repair “D1” circuit.
circuit (coil side) check
1) Set ignition “OFF” and remove radiator cooling fan relay
No.1 from individual circuit fuse box No.1.
2) Check the following points.
• Resistance of “D1” circuit: 1 Ω or less
• Resistance between “D1” circuit and ground: infinity
• Voltage of “D1” circuit: approx. 0 V (with ignition “ON”)

Is it in good condition?
1F-8 Engine Cooling System: K14B

Step Action Yes No

15 Radiator cooling fan relay No.2 and No.3 drive circuit Go to Step 16. Repair “E1” circuit.
check
1) Set ignition “OFF” and disconnect ECM connectors.
2) Check the following points.
• Resistance of “E1” circuit: 1 Ω or less
• Resistance between “E1” circuit and ground: infinity
• Voltage of “E1” circuit: approx. 0 V (with ignition “ON”)

Is it in good condition?
16 Radiator cooling fan motor check Replace ECM and Replace radiator cooling
1) Check radiator cooling fan motor. recheck radiator cooling fan motor.
fan system.
Is it in good condition?

Repair Instructions
Cooling System Components
AENBL80A1616001

(a)

(b)

2 1
9 1207F 10

7
5 11
6

13
8

12

3 11

13

IAP70A160001-01

1. Radiator 7. Gasket 13. To heater core

2. Radiator cap 8. O-ring : 11 N⋅m (1.1 kgf-m, 8.5 lbf-ft)
3. Drain plug 9. Water pump assembly : 25 N⋅m (2.5 kgf-m, 18.5 lbf-ft)
: Apply sealant 99000-31250 referring to “Water
Pump Removal and Installation”: K14B (Page
1F-13).
4. Reservoir 10. Water pump pulley : Do not reuse.
5. Radiator cooling fan assembly 11. To throttle body
6. Thermostat assembly (incorporating with ECT sensor) 12. To cylinder head

Coolant Level Check

AENBL80A1616002
 Engine Cooling System: K14B 1F-9

! WARNING
To avoid getting burned, do not remove
radiator cap while engine and radiator are
still hot. Scalding fluid and steam can gush
out under pressure if cap is taken off too
soon.

It is not necessary to remove radiator cap to check

coolant level.
When engine is cool, check coolant level in reservoir (1).
Normal coolant level should be between “FULL” mark (2)
and “LOW” mark (3) on reservoir (1).
If coolant level is below “LOW” mark (3), remove
reservoir cap (4) and add proper coolant to reservoir to
bring coolant level up to “FULL” mark (2).
NOTE
If proper quality antifreeze is used, there is
no need to add extra rust inhibitors or other
additives that claim to improve system. They
may be harmful to proper operation of
system, and are unnecessary expense.
I8T401162005-01
b) Check that cooling system holds the pressure.
If cooling system does not hold applied pressure,
check cooling system for coolant leaks.
5) Check radiator cap according to the following
procedure.
a) Attach pressure tester (1) to radiator cap (2), and
then apply specified pressure.
Radiator cap holding pressure
93 – 123 kPa (0.9 – 1.3 kgf/cm2, 13.5 – 17.8
psi)

4 1

I8T401162006-01

3 b) Check that radiator cap holds applied pressure.

If the pressure at which radiator cap releases air
is higher or lower than holding pressure, replace
radiator cap.
I9P60A161004-01 6) Detach pressure tester and rinse off spilled coolant.
7) Install radiator cap on water filler.
Engine Cooling System Inspection
AENBL80A1616003
Cooling System Draining
! WARNING AENBL80A1616004

To avoid getting burned, do not remove ! WARNING

radiator cap while engine and radiator are
still hot. Scalding fluid and steam can gush
out under pressure if cap is taken off too
soon.
1) Check cooling system for leakage or damage.
2) Remove radiator cap.
3) Check coolant for proper level and freeze protection.
4) Check coolant leaks from cooling system according
to the following procedure.
a) Attach pressure tester (1) to water filler, and then
apply specified pressure to cooling system.
Cooling system holding pressure
123 kPa (1.3 kgf/cm2, 17.8 psi)
To avoid getting burned, do not remove
radiator cap while engine and radiator are
still hot. Scalding fluid and steam can gush
out under pressure if cap is taken off too
soon.
1) Remove radiator cap.
2) Drain coolant from radiator drain plug (1).
3) After draining coolant, be sure to tighten drain plug
(1) securely.
1F-10 Engine Cooling System: K14B

9) Confirm that coolant level in reservoir is at “FULL”

mark. If coolant is insufficient, add coolant.
10) Check for coolant leaks. )(Page 1F-9)

Cooling Water Pipe or Hose Removal and

Installation
AENBL80A1616006

1 2) To remove cooling water pipes or hoses, loosen
I4RS0A160003-01
Cooling System Refilling
AENBL80A1616005
! WARNING
To avoid getting burned, do not remove
radiator cap while engine and radiator are
still hot. Scalding fluid and steam can gush
out under pressure if cap is taken off too
soon.
1) Fill reservoir (1) with coolant up to “FULL” mark (2).
2) Install reservoir cap (3) on reservoir (1).
3 1
2 (3) from thermostat assembly (1).
Removal
1) Drain coolant. )(Page 1F-9)
clamp on each hose and pull hose end off.
Installation
Reverse removal procedure noting the following points.
• Tighten each clamp securely and in proper direction.
)(Page 1F-8)
• Refill cooling system with coolant. )(Page 1F-10)
• Check cooling system for leakage. )(Page 1F-9)
Thermostat Assembly (Incorporating with ECT
Sensor) Removal and Installation
AENBL80A1616007
Removal
1) Drain coolant. )(Page 1F-9)
2) Disconnect ECT sensor connector.
3) Remove radiator inlet hose (2) and heater inlet hose
4) Remove thermostat assembly (1) from cylinder
head.

1
2

I9P60A161006-01

3) Fill radiator with coolant up to bottom of radiator filler

neck and install radiator cap.
Coolant specification
3
Freezing temperature: –14.5 °C (–5.9 °F)
Antifreeze / anti-corrosion coolant
IAP70P160003-01
concentration: 30%
Coolant capacity Installation
Engine, radiator and heater: 4.4 liters (9.30/7.75 Reverse removal procedure noting the following points.
US/Imp pt.) • Use new gasket.
Reservoir: 0.7 liters (1.48/1.23 US/Imp pt.)
• Refill cooling system with coolant. )(Page 1F-10)
Total: 5.1 liters (10.78/8.98 US/Imp pt.)
• Check cooling system for leakage. )(Page 1F-9)
4) Run engine at idle speed.
5) Run engine until radiator fan motor is operated. Thermostat Assembly (Incorporating with ECT
6) Stop engine and wait until engine comes cooled Sensor) Inspection
down to avoid getting burned. AENBL80A1616008

7) Add coolant to radiator up to bottom of radiator filler • Check that air bleed valve (1) of thermostat assembly
neck, and install radiator cap. is clean.
8) Repeat Step 4) through 7). • Check that valve seat (2) is free from foreign matter
that would prevent valve from seating tight.
 Engine Cooling System: K14B 1F-11

(A)
3

I7V20A161006-01

3. Wax pellet

• Check thermostat assembly as follows. IAP70P180002-01

a. Immerse thermostat assembly (1) in water, and 2) Set ignition “ON” and clear DTC. “DTC Clearance”:
heat water gradually. K14B in Section 1A (Page 1A-19)
! CAUTION 3) Select the “Radiator Fan” function in “Active Test”.
4) Check radiator cooling fan operation at low and high
Never immerse connector of ECT sensor in
modes.
water.
If any abnormality is found, check cooling fan control
system. )(Page 1F-5)
b. Check that wax pellet starts to open at specific
temperature. Radiator cooling fan operation
Temperature at which valve starts to open (lift Radiator cooling fan motor
0.05 mm (0.002 in)): OFF OFF
86.5 – 89.5 °C (187.7 – 193.1 °F) Low mode Low speed
High mode High speed
Temperature at which valve becomes fully
open: Radiator Cooling Fan Motor
100 °C (212 °F) 1) Disconnect radiator cooling fan motor connector (1).
Valve lift:
More than 8 mm (0.3 in) at 100 °C (212 °F)

I7V20A161007-01

2. Heater 3. Thermometer 1
IAP70P160004-01

• If check result is not satisfactory, replace thermostat 2) Using service wire, connect radiator cooling fan
assembly. )(Page 1F-10) motor connector and battery as shown in figure.

Radiator Cooling Fan Assembly On-Vehicle

Inspection
AENBL80A1616009
Radiator Cooling Fan Operation
1) Connect scan tool to DLC (1) with ignition “OFF”.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
1F-12 Engine Cooling System: K14B

Installation
[A] [B] Reverse removal procedure noting the following points.
• Refill cooling system with coolant. )(Page 1F-10)
• Check cooling system for leakage. )(Page 1F-9)

Radiator Cooling Fan Disassembly and

Reassembly
AENBL80A1616012

Disassembly
IAP70A160002-01
1) Remove fan (1) from cooling fan motor (2).
[A]: Low speed [B]: High speed
2) Remove cooling fan motor (2) from cooling fan
shroud (3).
3) Check that radiator cooling fan motors rotate
1
smoothly and properly.
If any abnormality is found, replace radiator cooling 3
fan motor.
Reference: Fan motor specified current at 12 V
Low speed: 4.8 – 7.8 A
High speed: 7.4 – 10.9 A

Radiator Cooling Fan Relay Inspection

AENBL80A1616010
Refer to “Control Relay Inspection” in Section 10B (Page
2
10B-30).
IAP70P160006-01

Radiator Cooling Fan Assembly Removal and

Reassembly
Installation Reverse disassembly procedure noting the following
AENBL80A1616011
point.
Removal • Tighten fan nut and radiator cooling fan motor bolts to
1) Disconnect negative (–) cable at battery. specified torque.
2) Drain coolant. )(Page 1F-9) Tightening torque
3) Disconnect radiator cooling fan motor connector (1). Fan nut (a): 6.0 N·m (0.61 kgf-m, 4.5 lbf-ft)
4) Remove reservoir (2). Radiator cooling fan motor bolt (b): 4.0 N·m (0.41
kgf-m, 3.0 lbf-ft)
5) Disconnect radiator inlet hose (3) from radiator.

(a)

(b)

IAP70P160010-03

Radiator On-Vehicle Inspection and Cleaning

AENBL80A1616013
Inspection
1 Check radiator for leakage or damage. Straighten bent
IAP70P160005-01
fins, if any.
6) Remove radiator cooling fan assembly from radiator.
Cleaning
Clean frontal area of radiator cores.
 Engine Cooling System: K14B 1F-13

I2RH01160014-01 3

Radiator Removal and Installation

AENBL80A1616014

Removal
I7V20A161014-01
1) Remove cooling fan assembly. )(Page 1F-12)
2) Remove A/C condenser assembly. Installation
• Single A/C Model: “Condenser Assembly 1) Apply sealant to mating surface of water pump as
Removal and Installation”: Single A/C Type in shown in figure.
Section 7B (Page 7B-31)
“A”: Water tight sealant 99000–31250 (SUZUKI
• Dual A/C model: “Condenser Assembly Removal Bond No.1207F)
and Installation”: Dual A/C Type in Section 7B
(Page 7B-83)
3) Remove radiator outlet hose from radiator. “A”

4) Remove radiator upper brackets (1).

5) Remove radiator (2) from vehicle.
“a”
1
“b”

“A”
2
I7V20A161015-01

“a”: 3 mm (0.12 in.) “b”: 2 mm (0.08 in.)

2) Install water pump assembly (1) with generator

bracket (3) to cylinder block and tighten bolts and
nuts to specified torque.

NOTE
For installation procedure of generator
bracket (3), refer to “Generator Bracket
IAP70P160007-01
Removal and Installation”: K14B in Section
1J (Page 1J-12).
Installation
Reverse removal procedure noting the following points. Tightening torque
• Refill cooling system with coolant. )(Page 1F-10) Water pump bolt and nut (a): 25 N·m (2.5 kgf-m,
• Check cooling system for leakage. )(Page 1F-9) 18.5 lbf-ft)
3) Install water pump pulley (2) and tighten bolts to
Water Pump Removal and Installation specified torque.
AENBL80A1616015
Removal Tightening torque
1) Disconnect negative (–) cable at battery. Water pump pulley bolt (b): 11 N·m (1.1 kgf-m,
2) Drain coolant. )(Page 1F-9) 8.5 lbf-ft)
3) Remove water pump / generator drive belt. )(Page
1J-11)
4) Remove water pump pulley (2).
5) Remove water pump assembly (1) with generator
bracket (3).
1F-14 Engine Cooling System: K14B

Water Pump Inspection

1 AENBL80A1616016
(a)
Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
abnormal noise, replace it.
2

(b)
(a)

I7V20A161016-02 I2RH0B160019-01

4) Install water pump / generator drive belt. )(Page 1J-

11)
5) Connect negative (–) cable at battery.
6) Refill cooling system with coolant. )(Page 1F-10)
7) Check cooling system for leakage. )(Page 1F-9)

Specifications
Tightening Torque Specifications
AENBL80A1617001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Fan nut 6.0 0.61 4.5 )
Radiator cooling fan motor bolt 4.0 0.41 3.0 )
Water pump bolt and nut 25 2.5 18.5 )
Water pump pulley bolt 11 1.1 8.5 )

NOTE
The tightening torque(s) also specified in:
“Cooling System Components”: K14B

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Recommended Service Material
AENBL80A1618001
Material SUZUKI recommended product or Specification Note
Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250 )

Special Tool
AENBL80A1618002
 Engine Cooling System: K14B 1F-15

SUZUKI scan tool (SUZUKI- 6

SDT)
— 1 2
This kit includes following
4
items. 1. SUZUKI-SDT 2. 3
DLC cable 3. USB cable 4. 5
AC/DC power supply 5.
Voltage meter probe 6.
Storage case)
1F-16 Engine Cooling System: D13A

D13A
Precautions
Precautions for Cooling System
AENBL80A1620002
! WARNING

• Coolant in cooling system may be extremely high in temperature, even exceeding the boiling point
as it is under pressure. If degassing tank cap is removed in this condition, high-temperature and
high-pressure coolant will instantaneously boil up and gush out; you could then be seriously
scalded by hot coolant and steam.
Furthermore, as coolant contains flammable anti-freeze material, coolant splashing over engine and
fenders can start fire.
• Be sure to check that engine coolant is cold before removing any part of cooling system.
• Be sure to disconnect negative (–) cable at battery before removing any part of cooling system.

General Description
Cooling System Description Coolant capacity
AENBL80A1621001 Total: Engine, radiator, heater and degassing tank
The cooling system consists of the radiator, degassing
etc.: 6.3 liters (13.32/11.10 US/Imp pt.)
tank, hoses, water pump, cooling fan and thermostat.
The radiator is of tube-and-fin type.
Coolant Degassing Tank Description
AENBL80A1621003
Coolant Description The degassing tank (1) consists of a “see-through”
AENBL80A1621002 plastic tank, a hose and a degassing tank cap (2).
When the system cools down, the coolant is drawn back
During operation, inside of the degassing tank is under
into the radiator.
pressure.
The cooling system has been filled at the factory with a
As the coolant warms up and expands, the coolant level
quality coolant that is a 50/50 mixture of water and
in the degassing tank rises. On the other hand, it lowers
ethylene glycol antifreeze.
as the coolant cools down and contracts. When the
This 50/50 mixture coolant solution provides freezing
pressure applied to the inside of the degassing tank
protection to –36 °C (–33 °F).
constantly exceeds the specified value, the pressure is
• This 50/50 mixture coolant also provides protection relieved through the degassing tank cap. Therefore,
against corrosion and loss of coolant from boiling. cooling level should be between FULL (3) and LOW (4)
Keep cooling system filled with this coolant even marks on the degassing tank.
where freezing temperatures are not expected.
• When replenishing the system due to loss of coolant,
the same ethylene glycol base coolant should be used
in order to ensure the same level of protection against 2
freezing and corrosion. 3

NOTE
1
• Alcohol or methanol base coolant or plain
water alone should not be used in cooling
system at any time as damage to cooling 4
system could occur.
• Coolant must be mixed with demineralized IBP80A162001-01
water or distilled water.

Anti-freeze proportioning table

°C –36
Freezing temperature
°F –33
Anti-freeze / Anti-corrosion
% 50
coolant concentration
 Engine Cooling System: D13A 1F-17

Schematic and Routing Diagram

Coolant Circulation
AENBL80A1622001

[A]

4
6
5

3
1

[B]

4
6
5

3
1

I7V20A162011-02

[A]: Thermostat: close 3. Engine oil cooler 7. Water pump

[B]: Thermostat: open 4. Engine 8. Heater core
1. Radiator 5. Degassing tank 9. EGR cooler
2. Thermostat 6. Degassing tank cap
1 F -1 8 E n g in e C o o lin g S y s te m : D 1 3 A

Diagnostic Information and Procedures

Engine Cooling Symptom Diagnosis
AENBL80A1624001

Condition Possible cause Correction / Reference Item

Engine overheats (It is in Loose or broken accessory drive belt Replace accessory drive belt and/or accessory
case that radiator fan drive belt tensioner.
operates) Accessory drive belt: “Accessory Drive Belt
Removal and Installation”: D13A in Section 1J
(Page 1J-26)
Accessory drive belt tensioner: “Accessory
Drive Belt Tensioner Removal and Installation”:
D13A in Section 1J (Page 1J-26)
Not enough coolant Check coolant level and add coolant as
necessary. )(Page 1F-20)
Faulty thermostat Replace thermostat assembly. )(Page 1F-22)
Faulty water pump Replace water pump. “Water Pump Removal
and Installation”: D13A (Page 1F-25)
Dirty or bent radiator fins Clean or repair radiator. )(Page 1F-24)
Coolant leakage Repair cooling system.
Clogged radiator Check and replace radiator as necessary.
Check: )(Page 1F-24)
Replace: )(Page 1F-24)
Faulty degassing tank cap Replace degassing tank cap.
Dragging brakes Check brake. “Brakes Symptom Diagnosis” in
Section 4A (Page 4A-2)
Slipping clutch Replace clutch cover and clutch disc. “Clutch
Cover and Clutch Disc Removal and
Installation”: D13A Model in Section 5C (Page
5C-23)
Poor charged battery Check and replace battery as necessary.
Check: “Battery Inspection”: D13A in Section
1J (Page 1J-23)
Replace: “Battery Removal and Installation”:
D13A in Section 1J (Page 1J-25)
Poor electricity generated by generator Check and replace generator if necessary.
Replace: “Generator Removal and
Installation”: D13A in Section 1J (Page 1J-27)
Check: “Generator Test”: D13A in Section 1J
(Page 1J-24)
Faulty ECT sensor Check and replace ECT sensor if necessary.
Check: “ECT Sensor Inspection”: D13A in
Section 1C (Page 1C-21)
Replace: “ECT Sensor Removal and
Installation”: D13A in Section 1C (Page 1C-20)
Faulty radiator cooling fan motor Check and replace radiator cooling fan motor if
necessary.
Check: )(Page 1F-22)
Replace: “Radiator Cooling Fan Assembly
Removal and Installation”: D13A (Page 1F-23)
Faulty radiator cooling fan relay Check and replace radiator cooling fan relay if
necessary. “Control Relay Inspection” in
Section 10B (Page 10B-30)
Faulty ECM Check and replace ECM if necessary.
Faulty wiring or grounding Repair wiring.
Equipped with too much electric load Dismount.
part(s)
 Engine Cooling System: D13A 1F-19

Condition Possible cause Correction / Reference Item

Engine overheats (It is in Blown fuse
case that radiator fan
won’t operate) Faulty radiator cooling fan relay
Faulty ECT sensor
Faulty radiator cooling fan motor
Faulty wiring or grounding
Faulty ECM
Check fuse of relay/fuse box and check for
short circuit to ground.
Check and replace radiator cooling fan relay if
necessary. “Control Relay Inspection” in
Section 10B (Page 10B-30)
Check and replace ECT sensor if necessary.
Check: “ECT Sensor Inspection”: D13A in
Section 1C (Page 1C-21)
Replace: “ECT Sensor Removal and
Installation”: D13A in Section 1C (Page 1C-20)
Check and replace radiator cooling fan motor if
necessary.
Check: )(Page 1F-22)
Replace: “Radiator Cooling Fan Assembly
Removal and Installation”: D13A (Page 1F-23)
Repair wiring.
Check and replace ECM if necessary.

Radiator Fan Control System Inspection

AENBL80A1624002
! WARNING
Keep hand, tools, and clothing away from engine cooling fan to help prevent personal injury. This fan
is electric and can come on whether or not the engine is running. The fan can start automatically in
response to the ECM with the ignition switch in the ON position.

Check system for operation. “Table C-9: Radiator Cooling Fan Operation Check”: D13A in Section 1A (Page 1A-269)
1F-20 Engine Cooling System: D13A
Repair Instructions
Cooling System Components
1. Radiator
2. Radiator cooling fan
3. Degassing tank
4. Degassing tank cap
5. Drain plug
6. Thermostat assembly
: Do not disassemble.
11. Degassing tank outlet hose
12. Engine to degassing No.1 hose
13. Heater inlet hose
14. Heater outlet No.1hose
15. Heater outlet pipe
16. Heater outlet No.2 hose
AENBL80A1626001
IBL80A162002-02
21. To degassing tank
22. Degassing tank hose
23. Battery tray
24. Radiator support upper RH
bracket
25. Radiator support upper LH
bracket
26. Radiator support upper mount
 Engine Cooling System: D13A 1F-21

7. ECT sensor 17. To engine side 27. Upper cross member

: For detail of servicing, refer to “ECT Sensor
Removal and Installation”: D13A in Section 1C
(Page 1C-20) and “Table C-3: ECT Sensor
Check”: D13A in Section 1A (Page 1A-257).
8. Radiator inlet hose 18. To heater core 28. Radiator support lower mount
9. Radiator outlet hose 19. To EGR cooler 29. Degassing tank bracket
10. Radiator to degassing tank hose No.1 20. Hose clamps 33 N⋅m (3.4 kgf-m, 24.3 lbf-ft)

Coolant Level Check Engine Cooling System Inspection and

AENBL80A1626002
Cleaning
! WARNING AENBL80A1626003
! WARNING
To help avoid danger of being burned, do not
remove degassing tank cap while engine and To help avoid danger of being burned, do not
radiator are still hot. Scalding fluid and steam remove degassing tank cap while engine and
can be blown out under pressure if cap is radiator are still hot. Scalding fluid and steam
taken off too soon. can be blown out under pressure if cap is
taken off too soon.
To check level, lift hood and look at “see-through”
degassing tank (1). inspect cooling system as follows.
It is not necessary to remove degassing tank cap (2) to 1) Check cooling system for leakage or damage.
check coolant level.
2) Wash degassing tank cap and filler neck with clean
When engine is cool, check coolant level in degassing
water by removing degassing tank cap when engine
tank.
is cold.
A normal coolant level should be between FULL mark
(3) and LOW mark (4) on degassing tank (1). 3) Check coolant for proper level and freeze protection.
If coolant level is below LOW mark, remove degassing 4) Using special tool, check holding pressure of cooling
tank cap (2) and add recommended coolant to tank to system and degassing tank cap (2),use attachment
bring coolant level up to FULL mark. Then, install (1).
degassing tank cap turning it clockwise up to stop. • If cooling system does not hold applied pressure,
NOTE repair leakage.
• If degassing tank does not hold applied pressure,
If proper quality antifreeze is used, there is
replace cap with new one.
no need to add extra inhibitors or additives
that claim to improve system. They may be Special tool
harmful to proper operation of system, and (A): 09918M78211
are unnecessary expense.
Cooling system and degassing tank cap holding
pressure (for inspection)
140 kPa (1.4 kgf/cm2, 20.3 psi, 1.4 bar)

(A)

IBP80A162001-01

(A) 1
2

IBP80A162004-01
1F-22 Engine Cooling System: D13A

5) Install degassing tank cap to degassing tank turning 6) Drain system and then close radiator drain plug (1)
it clockwise up to stop. tightly.
6) Clean frontal area of radiator core.

Cooling System Draining

AENBL80A1626004
! WARNING
To avoid getting burned, do not remove
degassing tank cap while engine and radiator
are still hot. Scalding fluid and steam can
gush out under pressure if cap is taken off
too soon.

1) Remove degassing tank cap by turning it

counterclockwise slowly in order to release any 1 2
pressure. IBP80A162005-01

2) Loosen drain plug (1) on radiator (2) to drain coolant. 2. Radiator

3) After draining coolant, be sure to tighten drain plug

securely. 7) Disconnect coolant hose of upper side from
thermostat case. If it is hard to disconnect it after
removing clip, push to insert hose to pipe a little
further in order to unstick hose from pipe and
disconnect it.
8) Pour coolant (50/50 mixture of good quality ethylene
glycol antifreeze and water) to degassing tank up to
FULL mark (3). Put a shop cloth under disconnected
hose end so that coolant is not spilled on engine and
floor because a small amount of air bubbles and/or
coolant may come out of it.
9) Connect hose to thermostat case.
10) Run engine, with degassing tank cap (2) removed,
until radiator inlet hose is hot.
1 2
IBP80A162005-01
11) With engine idling, add coolant to degassing tank (1)
until level reaches FULL mark (3).
Cooling System Flush and Refill Install degassing tank cap (2) turning it clockwise up
AENBL80A1626006 to stop.
! WARNING
To help avoid danger of being burned, do not
remove degassing tank cap while engine and 2
radiator are still hot. Scalding fluid and steam
3
can be blown out under pressure if cap is
taken off too soon.
1

1) Remove degassing tank cap by turning it

counterclockwise slowly in order to release any
4
pressure.
2) With degassing tank cap removed, run engine until
IBP80A162001-01
upper radiator hose is hot (this shows that
thermostat is open and coolant is flowing through
system).
Cooling System Refill
AENBL80A1626005
3) Stop engine and drain coolant. 1) Add 50/50 mixture of good quality ethylene glycol
4) Close radiator drain plug (1). Add water until system antifreeze and water to degassing tank (1).
is filled and run engine until upper radiator hose is Fill to FULL mark (3).
hot again. Coolant capacity
5) Repeat Steps 3) and 4) several times until drained Total: Engine, radiator, heater and degassing
liquid is nearly colorless. tank etc.: 6.3 liters (13.32/11.10 US/Imp pt.)
 Engine Cooling System: D13A 1F-23

2) Run engine, with degassing tank cap (2) removed,

until radiator upper hose is hot.
3
3) With engine idling, add coolant to degassing tank (1) 1
until level reaches FULL mark (3).
Install degassing tank cap (2) turning it clockwise up
to stop. 2

2
4 5 6
3 I5RS0B160006-01

1 Installation
Reverse removal procedure for installation noting the
following.
4
• Use new O-ring when installing.
• Use new hose clamp (1).
IBP80A162001-01
• Tighten thermostat bolts to specified torque.
Cooling Water Pipe or Hose Removal and Tightening torque
Installation Thermostat bolt (a): 28 N·m (2.9 kgf-m, 21.0 lbf-ft)
AENBL80A1626007
Removal • If ECT sensor has been removed, replace new ECT
1) Drain coolant. )(Page 1F-21) sensor. “ECT Sensor Removal and Installation”: D13A
in Section 1C (Page 1C-20)
2) To remove these pipes or hoses, loosen clip on each
hose and pull hose end off.

Installation
Reverse removal procedure for installation noting the
following.
• Connect each clip securely. )(Page 1F-19)
(A)
• Refill cooling system. )(Page 1F-21)

Thermostat Assembly Removal and Installation

AENBL80A1626008
! CAUTION
1
Do not disassemble thermostat assembly. IBP80A162008-01
Disassembly will spoil it original function. If • Refill cooling system. )(Page 1F-21)
any malcondition is found in thermostat
• Verify that there is no coolant leakage at each
assembly, replace if as assembly.
connection.
Removal
Radiator Cooling Fan Assembly On-Vehicle
1) Drain coolant. )(Page 1F-21)
Inspection
2) Remove air cleaner assembly with MAF and IAT AENBL80A1626009
sensor. )(Page 1D-64) 1) Disconnect negative (–) cable at battery.
3) Remove heater outlet pipe. )(Page 1F-19) 2) Remove air cleaner assembly with MAF and IAT
4) Disconnect engine outlet hose (2), radiator inlet hose sensor. )(Page 1D-64)
(3), coolant feed hose (4), ECT sensor connector (5) 3) Check low speed operation of radiator cooling fan as
and EGR cooler hose (6) from thermostat assembly. follows.
5) Remove thermostat assembly (1). a) Connect battery to fan motor coupler as shown
in figure [A].
b) Check that radiator cooling fan rotates smoothly.
If any abnormality is found, replace fan
assembly.
4) Check high speed operation of radiator cooling fan
as follows.
1F-24 Engine Cooling System: D13A

a) Connect battery to fan motor coupler as shown

in figure [B].
4
b) Check that radiator cooling fan rotates smoothly
2 3
and its rotational speed is faster than low speed
operation. 3
If any abnormality is found, replace fan
assembly.
Reference: Fan motor specified current at 12
V
Low speed operation: MAX 12 A
High speed operation: MAX 16 A

[A] [B]
1 5

IBP80A162018-01

7) Disconnect radiator inlet hose (1) and degassing

tank hose (2) from radiator.
8) Remove radiator brackets (3).

I9P60A162009-01
3
[A]: Low speed operation [B]: High speed operation
3
1
Radiator Cooling Fan Relay Inspection
AENBL80A1626010
For Inspection of radiator cooling fan relay referring to
“Control Relay Inspection” in Section 10B (Page 10B-
2
30).

Radiator Cooling Fan Assembly Removal and

Installation
AENBL80A1626011
IBP80A162009-01
Removal 9) Remove cooling fan mounting bolts (1) and then
1) Disconnect negative (–) cable at battery. remove radiator cooling fan assembly (2).
2) Drain coolant. “Cooling System Draining”: D13A
(Page 1F-21) ! CAUTION
3) Remove air cleaner assembly. “Air Cleaner Be sure not to damage condenser outlet pipe
Assembly Removal and Installation”: D13A in when removing radiator cooling fan
Section 1D (Page 1D-64) assembly.
4) Disconnect cooling fan motor connector (1) and
clamps (3).
5) Remove A/F sensor connector (2) from A/F sensor
bracket (4).
6) Detach degassing tank outlet hose from hose clamp
(5).
 Engine Cooling System: D13A 1F-25

Inspection
1 Check radiator for leakage or damage. Straighten bent
fins, if any.

Cleaning
Clean frontal area of radiator cores.

I2RH01160014-01

1
IBP80A162010-01 Radiator Removal and Installation
AENBL80A1626013

Installation
Removal
Reverse removal procedure for installation noting the
following. 1) Disconnect negative (–) cable at battery.
• Tighten cooling fan mounting bolts (1) to specified 2) Drain coolant. )(Page 1F-21)
torque. 3) Remove front bumper. “Front Bumper Removal and
Installation” in Section 9H (Page 9H-1)
Tightening torque
Cooling fan mounting bolt (a): 6.9 N·m (0.7 kgf- 4) Remove radiator cooling fan. )(Page 1F-23)
m, 5.0 lbf-ft) 5) Disconnect radiator outlet hose (1) and degassing
tank outlet hose (2) from radiator.
1, (a)

2
1

IBP80A162013-01

6) Remove condenser assembly mounting bolts (1).

1, (a)
IBP80A162011-01

• When installing water hoses, align matchmarks on the

hoses with those of the corresponding pipes and set
each clamp to the original position.
• Install air cleaner assembly referring to “Air Cleaner
Assembly Removal and Installation”: D13A in Section
1D (Page 1D-64).
• Refill cooling system with coolant. “Cooling System
Refill”: D13A (Page 1F-21) 1
• After installation, check cooling system for leakage. I5RS0B160012-01

7) Remove radiator lifting from the vehicle.

Radiator On-Vehicle Inspection and Cleaning
AENBL80A1626012
1F-26 Engine Cooling System: D13A

Installation
Reverse removal procedures for installation noting the
following.
• When installing water hoses, align matchmarks on the
hoses with those of the corresponding pipes and set
each clamp to the original position.
• Install radiator cooling fan assembly referring to
“Radiator Cooling Fan Assembly Removal and
Installation”: D13A (Page 1F-23).
• Refill cooling system. )(Page 1F-21)
• After installation, check each joint for leakage. I7V20A162010-01

Water Pump Removal and Installation Water Pump Inspection

AENBL80A1626014 AENBL80A1626015
Removal
! CAUTION
1) Disconnect negative (–) cable at battery.
Do not disassemble water pump.
2) Drain coolant. )(Page 1F-21)
If any repair is required on pump, replace it
3) Remove intercooler. )(Page 1D-66) as assembly.
4) Disconnect radiator outlet hose from oil cooler.
5) Remove right side engine under cover. Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
6) Remove accessory drive belt. “Accessory Drive Belt
abnormal noise, replace it.
Removal and Installation”: D13A in Section 1J (Page
1J-26)
7) With hose connected, detach A/C compressor from
its bracket (if equipped).
• Single A/C type: “A/C Compressor Assembly
Removal and Installation”: Single A/C Type in
Section 7B (Page 7B-44)
• Dual A/C type: “A/C Compressor Assembly I3RM0B162021-01
Removal and Installation”: Dual A/C Type in
Section 7B (Page 7B-92)
8) Remove water pump (1).

I3RM0B162019-01

Installation
Reverse removal procedure for installation noting the
following.
• Use new O-ring (1) when installing
• Tighten water pump nuts to specified torque.
Tightening torque
Water pump nut (a): 9.0 N·m (0.92 kgf-m, 7.0 lbf-ft)
 Engine Cooling System: D13A 1F-27

Specifications
Tightening Torque Specifications
AENBL80A1627001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Thermostat bolt 28 2.9 21.0 )
Cooling fan mounting bolt 6.9 0.7 5.0 )
Water pump nut 9.0 0.92 7.0 )

NOTE
The tightening torque(s) also specified in:
“Cooling System Components”: D13A

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Special Tool
AENBL80A1628001
09918M78211
Radiator cap tester kit
)
1G-1 Fuel System: K14B

Fuel System
Engine

K14B
Precautions
Precautions for Fuel System Service
AENBL80A1710001
! WARNING
Before servicing on fuel system, the following points should be always observed in order to reduce the
risk of fire and personal injury.
• Disconnect negative (–) cable at battery.
• Do not smoke, and place NO SMOKING signs near work area.
• Be sure to have CO2 fire extinguisher handy.
• Be sure to perform work in a well-ventilated area and away from any open flames (such as gas
heater).
• Wear safety glasses.
• To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then
reinstall it.
• As fuel feed line is still under high fuel pressure even after stopping engine, loosening or
disconnecting fuel feed line directly may cause dangerous spout of fuel. Before loosening or
disconnecting fuel feed line, make sure to relieve fuel pressure. )(Page 1G-14)
• A small amount of fuel may be released when the fuel line is disconnected. In order to reduce the
risk of personal injury, cover the fitting to be disconnected with shop cloth. Be sure to put that cloth
in approved container after disconnecting.
• Never perform service work when engine and exhaust system are hot.
• Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each
hose correctly.)(Page 1G-12)
After connecting, make sure that it has no twist or kink.
• When installing injector or fuel feed pipe, lubricate its new O-ring with gasoline (petrol).
• When servicing fuel tank it should be treated carefully. Pay attention not to contact with sharp edges
or hot surfaces. In addition, fuel tank should not be dropped since fuel tank, fuel pump and other
components can be damaged by the impact. If dropped, all components should be replaced because
there is a risk of damage.

! CAUTION
Use unleaded fuel only. Leaded or low lead fuel can result in engine damage and reduce the
effectiveness of the emission control system.

General Description
Fuel System Description The fuel delivery system consists of the fuel tank, fuel
AENBL80A1711001 pump assembly (with fuel level sensor and fuel pressure
The main components of the fuel system are fuel tank,
regulator), fuel filter, delivery pipe, injectors and fuel feed
fuel pump assembly (with fuel level sensor and fuel
line.
pressure regulator), fuel filter, fuel feed line and fuel
The fuel in the fuel tank is pumped up by the fuel pump,
vapor line.
sent into fuel filter beside the tank and delivery pipe via
For the details of fuel flow, refer to “Fuel Delivery System
fuel feed line and then injected by the injectors.
Diagram”: K14B (Page 1G-2).
The fuel feed line is connected to the pressure regulator
in the fuel pump assembly and the fuel pressure is
Fuel Delivery System Description regulated to the specified level.
AENBL80A1711002
 Fuel System: K14B 1G-2

The excess fuel at fuel pressure regulation process is Fuel Pump Description
returned back into the fuel tank. AENBL80A1711003

Also, fuel vapor generated in fuel tank is led through the The fuel pump (1) is an in-tank type electric pump.
fuel vapor line into the EVAP canister. Incorporated in the pump assembly are;
For system diagram, refer to “Fuel Delivery System Fuel pressure regulator (2) and fuel level sensor (3).
Diagram”: K14B (Page 1G-2).

1
3

IBP80A171001-01

Schematic and Routing Diagram

Fuel Delivery System Diagram
AENBL80A1712001

13 15 10

11 12 16

14
6 7
2

8 3

9
1

5
IBP80A171002-01

1. Fuel tank 7. Fuel filter 13. EVAP canister purge valve

2. Fuel pump assembly 8. Fuel level sensor 14. Vapor control valve
3. Fuel pressure regulator 9. Fuel pump 15. EVAP canister purge valve chamber
4. Delivery pipe 10. Fuel vapor line 16. Fuel Return Line
5. Fuel injector 11. Intake manifold
6. Fuel feed line 12. EVAP canister

Fuel Injector Control System Circuit Diagram

AENBL80A1712002
1G-3 Fuel System: K14B

10

A1 6 A2
C01-13 BLU/YEL
B1 7 B2
C01-37 BLU/WHT
C1 8 C2
C01-25 BLU/RED
D1 9 D2
C01-1 LT GRN/BLK
5
E01-54 BRN/WHT
4
E01-56 BLK/RED
12V
5V E01-55 BLK/RED
3.3V
E01-5 BLK/WHT

3
2

C01-50 BLK
C01-51 BLK
C01-53 BLK

[A] C01 E01

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

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

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

I9P60A171011-03

[A]: ECM connector (View: [a]) D1: Fuel injector No.4 drive circuit 6. Fuel injector No.1
A1: Fuel injector No.1 drive circuit D2: Fuel injector No.4 power supply circuit 7. Fuel injector No.2
A2: Fuel injector No.1 power supply circuit 1. Main fuse box 8. Fuel injector No.3
B1: Fuel injector No.2 drive circuit 2. Ignition switch (Ignition switch model) or IG1 relay (Keyless push start model) 9. Fuel injector No.4
B2: Fuel injector No.2 power supply circuit 3. “IG COIL” fuse 10. ECM
C1: Fuel injector No.3 drive circuit 4. “FI” fuse
C2: Fuel injector No.3 power supply circuit 5. Main relay

Fuel Pump Control System Circuit Diagram

AENBL80A1712003
 Fuel System: K14B 1G-4

B1 A1
6
E01-49 YEL/RED
BLK 7 PNK

B3 B2 A2
5
E01-54 BRN/WHT
4
E01-56 BLK/RED
12V
5V E01-55 BLK/RED
3.3V
E01-5 BLK/WHT

3
2

C01-50 BLK
C01-51 BLK
C01-53 BLK

[A] C01 E01

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

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

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

I9P60A171012-03

[A]: ECM connector (View: [a]) B3: Fuel pump ground circuit 5. Main relay
A1: Fuel pump relay power supply circuit (coil side) 1. Main fuse box 6. Fuel pump relay
A2: Fuel pump relay power supply circuit (switch side) 2. Ignition switch (Ignition switch model) or IG1 relay (Keyless push 7. Fuel pump
start model)
B1: Fuel pump relay drive circuit 3. “IG COIL” fuse 8. ECM
B2: Fuel pump power supply circuit 4. “FI” fuse

Diagnostic Information and Procedures

Fuel System Inspection
AENBL80A1714001

Step Action Yes No

1 Fuel pump inspection Go to Step 2. Check fuel pump circuit.
1) Remove fuel filler cap and set ignition “ON”. )(Page 1G-8)
2) Confirm that fuel pump operating sound can be heard
from fuel filler port for about 2 seconds before stopping.

Is check result OK?

2 Fuel pressure check Go to Step 3. Repair defective part.
1) Check fuel pressure. )(Page 1G-10)

Is check result OK?

3 Power balance test Fuel system is in good Go to Step 4.
1) Check power balance. )(Page 1G-5) condition.

Is check result OK?

1G-5 Fuel System: K14B

Step Action Yes No

4 Fuel injector circuit check Go to Step 5. Repair defective part.
1) Check fuel injector circuit. )(Page 1G-6)

Is check result OK?

5 Fuel injector check Replace ECM and Replace fuel injector.
1) Check fuel injector. )(Page 1G-16) recheck power balance. )(Page 1G-15)
)(Page 1C-1)
Is check result OK?

Power Balance Test 3) Clear DTC. )(Page 1A-19)

AENBL80A1714002
! CAUTION
When performing power balance test, do not
increase engine speed higher than set idling
speed. Doing so may damage engine.
1) Place gear shift lever in “Neutral” and apply parking
brake.
2) Connect SUZUKI scan tool to DLC (1) with ignition
“OFF”.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
4) Warm up engine to normal operating temperature.
5) Using SUZUKI scan tool, select “Fuel Injector” in
“Active Test” and turn off each fuel injector.
6) With each fuel injector turned off, confirm that engine
speed falls lower than specified idle speed.
7) If rates of engine speed decrease are not in scale,
check following items.
• Fuel injector circuit: )(Page 1G-6)
• Fuel injector: )(Page 1G-16)
• Spark plug: )(Page 1H-6)
• Ignition coil circuit: )(Page 1H-4)
• Ignition coil: )(Page 1H-7)
• Engine compression: )(Page 1D-1)

(A)

IBP80A121001-01
 Fuel System: K14B 1G-6

Fuel Injector Circuit Check

AENBL80A1714003
Circuit Diagram

10

A1 6 A2
C01-13 BLU/YEL
B1 7 B2
C01-37 BLU/WHT
C1 8 C2
C01-25 BLU/RED
D1 9 D2
C01-1 LT GRN/BLK
5
E01-54 BRN/WHT
4
E01-56 BLK/RED
12V
5V E01-55 BLK/RED
3.3V
E01-5 BLK/WHT

3
2

C01-50 BLK
C01-51 BLK
C01-53 BLK

[A] C01 E01

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

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

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

I9P60A171011-03

[A]: ECM connector (View: [a]) D1: Fuel injector No.4 drive circuit 6. Fuel injector No.1
A1: Fuel injector No.1 drive circuit D2: Fuel injector No.4 power supply circuit 7. Fuel injector No.2
A2: Fuel injector No.1 power supply circuit 1. Main fuse box 8. Fuel injector No.3
B1: Fuel injector No.2 drive circuit 2. Ignition switch (Ignition switch model) or IG1 relay (Keyless push start model) 9. Fuel injector No.4
B2: Fuel injector No.2 power supply circuit 3. “IG COIL” fuse 10. ECM
C1: Fuel injector No.3 drive circuit 4. “FI” fuse
C2: Fuel injector No.3 power supply circuit 5. Main relay

Troubleshooting
Step Action Yes No
1 Fuel injector check for operating sound Fuel injectors circuit is Go to Step 2.
1) Using sound scope, check each injector for operating in good condition.
sound at engine cranking.

Do all injectors make operating sound?

2 Fuel injector resistance check Go to Step 3. Replace fuel injector.
1) When ignition is “OFF”, disconnect connectors from fuel )(Page 1G-15)
injectors.
2) Check for proper terminal connection to fuel injector
connectors.
3) If OK, check all fuel injectors for resistance. )(Page 1G-
15)

Is check result OK?

1G-7 Fuel System: K14B

Step Action Yes No

3 Fuel injector insulation resistance check Go to Step 4. Replace fuel injector.
1) Check that resistance between each fuel injector )(Page 1G-15)
terminal and ground is infinity.

Is check result OK?

4 Fuel injector power supply circuit check Go to Step 5. Repair fuel injector
1) Set ignition “ON”. power supply circuit.
2) Check that voltage between each of “A2”, “B2”, “C2” and If it is in good condition,
“D2” and ground is battery voltage. go to “ECM Power
Supply and Ground
Is check result OK? Circuit Check”: K14B in
Section 1A (Page 1A-
119).
5 Fuel injector drive circuit check Go to Step 6. Repair fuel injector drive
1) When ignition is “OFF”, disconnect “C01” and “E01” circuit.
connectors from ECM.
2) If connections are OK, check the following points.
• Resistance of “A1”, “B1”, “C1” and “D1”: less than 1 Ω
• Resistance between each of “A1”, “B1”, “C1” and “D1”
circuits and ground: infinity
• Resistance between each of “A1” circuit terminal and
other terminal at fuel injector connector: infinity
• Resistance between each of “B1” circuit terminal and
other terminal at fuel injector connector: infinity
• Resistance between each of “C1” circuit terminal and
other terminal at fuel injector connector: infinity
• Resistance between each of “D1” circuit terminal and
other terminal at fuel injector connector: infinity
• Voltage of “A1” – “D1” circuits: approx. 0 V (when
ignition is “ON”)

Is check result OK?

6 Fuel injector check Replace ECM and Replace fuel injector.
1) Check fuel injector. )(Page 1G-16) recheck fuel injector )(Page 1G-15)
circuit. )(Page 1C-1)
Is check result OK?
 Fuel System: K14B 1G-8

Fuel Pump and Its Circuit Check

AENBL80A1714004
Circuit Diagram

B1 A1
6
E01-49 YEL/RED
BLK 7 PNK

B3 B2 A2
5
E01-54 BRN/WHT
4
E01-56 BLK/RED
12V
5V E01-55 BLK/RED
3.3V
E01-5 BLK/WHT

3
2

C01-50 BLK
C01-51 BLK
C01-53 BLK

[A] C01 E01

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

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

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

I9P60A171012-03

[A]: ECM connector (View: [a]) B3: Fuel pump ground circuit 5. Main relay
A1: Fuel pump relay power supply circuit (coil side) 1. Main fuse box 6. Fuel pump relay
A2: Fuel pump relay power supply circuit (switch side) 2. Ignition switch (Ignition switch model) or IG1 relay (Keyless push 7. Fuel pump
start model)
B1: Fuel pump relay drive circuit 3. “IG COIL” fuse 8. ECM
B2: Fuel pump power supply circuit 4. “FI” fuse

Troubleshooting
Step Action Yes No
1 Fuel pump control system check for operation Fuel pump circuit is in Go to Step 2.
1) Remove fuel filler cap. good condition.
Reinstall fuel filler cap.
2) Set ignition “ON”.
3) Confirm that fuel pump operating sound is heard from
fuel filler for about 2 seconds and then it stops.

Is check result OK?

1G-9 Fuel System: K14B

Step Action Yes No

2 Fuel pump relay power supply circuit check Go to Step 3. Repair fuel pump relay
1) Reinstall fuel filler cap. power supply circuit.
2) Set ignition “OFF”.
3) Remove fuel pump relay from individual circuit fuse box
No.1.
4) Check for proper terminal connection to fuel pump relay
connector.
5) If OK, set ignition “ON”.
6) Check that voltage between each of “A1” and “A2” and
ground is battery voltage.

Is check result OK?

3 Fuel pump relay check Go to Step 4. Replace fuel pump
1) Check fuel pump relay. )(Page 10B-30) relay.

Is check result OK?

4 Fuel pump relay drive circuit check Go to Step 5. Repair fuel pump relay
1) Set ignition “OFF”. drive circuit.
2) Disconnect “C01” and “E01” connectors from ECM.
3) Check for proper terminal connection to “C01” and “E01”
connectors.
4) If connections are OK, check the following points.
• Resistance of “B1” circuit: less than 1 Ω
• Resistance between “B1” circuit and ground: infinity
• Voltage of “B1” circuit: approx. 0 V (When ignition is
“ON”)

Is check result OK?

5 Fuel pump relay drive circuit signal check Go to Step 6. Replace ECM and
1) Set ignition “OFF”. recheck fuel pump
operation. )(Page 1C-
2) Connect “C01” and “E01” connectors to ECM.
1)
3) Using service wire, connect fuel pump relay.
4) Check that voltage between “B1” and ground is approx.
0 V for 2 sec. after the ignition is “ON”.

Is check result OK?

6 Fuel pump power supply circuit check Go to Step 7. Repair fuel pump power
1) Confirm that ignition is “OFF”. supply circuit.
2) Remove fuel tank.
3) Disconnect fuel pump connector.
4) Check that resistance between “B2” and ground is
infinity.

Is check result OK?

7 Fuel pump power supply circuit check Go to Step 8. Repair fuel pump power
1) Connect service wire between “B1” and ground. supply circuit.
2) Set ignition “ON”.
3) Check that voltage between “B2” and ground is battery
voltage.

Is check result OK?

 Fuel System: K14B 1G-10

Step Action Yes No

8 Fuel pump ground circuit check Replace fuel pump. Repair fuel pump
1) Set ignition “OFF”. )(Page 1G-21) ground circuit.
2) Check that resistance between “B3” and ground is less
than 1 Ω.

Is check result OK?

Fuel Pressure Check

AENBL80A1714005
System Diagram
Special tool
(A): 09912M58442
(B): 09912M58432
(C): 09912M58490

I3RM0A110081-01

1. Fuel injector 2. Fuel delivery pipe 3. Fuel pump assembly

Troubleshooting

NOTE
Before using the following flow chart, confirm that battery voltage is 11 V or more. If it is lower, fuel
pressure becomes lower than specification even if fuel pump and line are in good condition.

Step Action Yes No

1 Was “Fuel Pump and Its Circuit Check” performed? Go to Step 2. Go to “Fuel Pump and
Its Circuit Check”: K14B
(Page 1G-8).
2 Fuel pressure check 1 Go to Step 3. Go to Step 5.
1) Check fuel pressure. )(Page 1G-11)

Is check result OK?

1G-11 Fuel System: K14B

Step Action Yes No

3 Fuel pressure check 2 Go to Step 4. Fuel pressure regulator
1) Start engine and warm up to normal operating is in faulty condition,
temperature. replace fuel pump
assembly. )(Page 1G-
2) Keep engine speed at 4,000 rpm.
21)
Does fuel pressure show about same value as Step 2?
4 Fuel line check Fuel system is in good Repair defective part.
1) Check fuel pipe and joint for fuel leakage, damage or condition.
deformation.

Is check result OK?

5 Fuel line check Clogged fuel filter, faulty Repair defective part.
1) Check fuel pipe and joint for damage or deformation. fuel pump, faulty fuel
pressure regulator or
Is check result OK? fuel leakage from pipe
connection in fuel tank.

Fuel Pressure Basic Check 4) Check that battery voltage is 11 V or more.

AENBL80A1714006
5) Measure fuel pressure as follows.
! WARNING If measured pressure is out of specification, refer to
When performing the following procedure, be “Fuel Pressure Check”: K14B (Page 1G-10) and
sure to observe “Precautions for Fuel check each possibly defective part. Replace if found
System Service”: K14B (Page 1G-1) to reduce defective.
the risk of fire and personal injury. a) Set ignition “ON” to operate fuel pump and after
2 seconds turn it OFF. Repeat this 3 or 4 times
1) Relieve fuel pressure from fuel feed line. )(Page and then check fuel pressure.
1G-14) Fuel pressure specification
2) Disconnect fuel feed hose from fuel delivery pipe. With fuel pump operating and engine
3) Connect special tools and hose between fuel feed stopped: 375 – 385 kPa (3.8 – 3.9 kgf/cm2,
hose (1) and fuel delivery pipe as shown in figure, 54.4 – 55.8 psi)
and clamp hoses securely in order to ensure that no
6) After checking fuel pressure, remove fuel pressure
leaks occur during checking.
gauge.
Special tool
(A): 09912M58442 ! WARNING
(B): 09912M58432 As fuel feed line is still under high fuel
(C): 09912M58490 pressure, make sure to release fuel pressure
according to the following procedure.
1. Place fuel container under joint.
(A)
2. Cover joint with rag (1) and loosen joint
(B)
nut slowly in order to release fuel
pressure gradually.

(C)
I7V20A171002-01

I5RW0A170003-01
 Fuel System: K14B 1G-12

7) Remove special tools from fuel delivery pipe and fuel 9) With engine stopped and ignition “ON”, check for fuel
feed hose. leaks. )(Page 1G-14)
8) Connect fuel feed hose to fuel delivery pipe and
clamp it securely.

Repair Instructions
Fuel System Components
AENBL80A1716001

22

18
17

20
19

18

14

8
10 9

11
26

25 7

6
4
3

2 23 1
24
11
15
12

16
13
IBL80A171002-02

1. Fuel tank 12. Fuel feed line (pump to filter) 23. To EVAP canister
2. Fuel pump assembly 13. Fuel feed line (filter to 3 way) 24. To fuel pump assy.
3. O-ring (fuel tank) 14. Fuel feed line (3 way to delivery pipe) 25. To fuel feed line
4. Fuel pump lock nut 15. Fuel vapor line 26. From 3 Way
: For tightening procedure, refer to “Fuel Pump
Assembly Removal and Installation”: K14B
(Page 1G-21).
5. Breather hose 16. Fuel Filter : 45 N⋅m (4.6 kgf-m, 33.5 lbf-ft)
6. Fuel tank filler hose 17. Fuel delivery pipe : 25 N⋅m (2.5 kgf-m, 18.5 lbf-ft)
7. Fuel filler neck 18. Fuel Injector : 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)
8. Fuel filler cap 19. Injector Cushion : 3.0 N⋅m (0.31 kgf-m, 2.5 lbf-ft)
9. Fuel tank belt 20. Fuel delivery pipe insulator : Do not reuse.
10. 21. O-ring (fuel injector)
Heat Insulator
: Apply a bit of gasoline to install.
11. Fuel tank Bolt 22. Fuel delivery pipe nut

Fuel Hose Disconnection and Reconnection

AENBL80A1716002
! WARNING
Before starting the following procedure, be sure to observe “Precautions for Fuel System Service”:
K14B (Page 1G-1) in order to reduce the risk of fire and personal injury.
1G-13 Fuel System: K14B

Non-Quick Joint Connections

Clamp around fuel tank

NOTE
• Be sure to install hose in the raised part of pipe securely.
• Fit the clamp so that the center between both ends of the clamp (8) or the center of the screw thread
of the clamp (9) is positioned in range “e” shown in figure below.

3 1 6

“a” 7
3 “e”
“e”
8 “a” 8
2
2
1

“b” 5
9
“b” 4 (a) 5
“e” 1
1 2 “d”
3
9 “e”
2

IBL80A171003-01

1. Pipe 5. Vehicle leftward “b”: 5 – 12 mm (0.20 – 0.47 in.)

2. Hose 6. Vehicle rightward “d”: 8 – 12 mm (0.35 – 0.47 in.)
3. Clamp 7. Vehicle backward “e”: 45°
4. Fuel filler hose clamp screw “a”: 3 – 7 mm (0.12 – 0.28 in.) : 2.0 N⋅m (0.20 kgf-m, 1.5 lbf-ft)

Clamp other than around fuel tank [A]: With short pipe, fit hose as far as it 1. Pipe
reaches the end of pipe joint as shown.
[B]: With the following type pipe, fit hose as 2. Hose
far as it reaches bulge on fuel pipe.
“a”: 3 – 7 mm (0.12 – 0.28 in.) 3. Clamp

Quick Joint (Disconnect with hand)

Disconnection
1) Remove mud, dust and/or foreign material between
pipe (1) and quick joint (2) using compressed air.
2) Disconnect quick joint from fuel pipe while pushing
lock button (3) on joint.

I7V20A171005-01
 Fuel System: K14B 1G-14

6) Start engine and run it until engine stops for lack of

1 fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time in order to dissipate fuel pressure
in lines. Fuel connections are now safe for servicing.
7) After servicing, install fuel pump relay (1) to
individual circuit fuse box No.1 and install individual
2 circuit fuse box No.1 cover.
3
I8T401171011-01

1
Reconnection 2
Insert quick joint to fuel pipe until they lock securely (a
click is heard), and confirm that quick joint is not
disconnected by hand.

Quick Joint (Disconnect with special tool)

Disconnection
1) Remove mud, dust and/or foreign material between
pipe (1) and quick joint (2) using compressed air. I9P60A171005-02

2) Unlock joint lock by inserting special tool between

pipe and quick joint. Fuel Leakage Check Procedure
AENBL80A1716004
Special tool After performing any service on fuel system, check that
(A): 09919M47020 there are no fuel leaks as follows.
1) Set ignition “ON” for 3 seconds (to operate fuel
3) Disconnect quick joint from pipe.
pump) and then to “OFF”. Repeat this cycle of
operation 3 or 4 times.
1
Fuel pressure should now be established in fuel
2 (A)
system and felt by hand on fuel feed hose.
2) Check that there are no fuel leaks from any part of
fuel system.
2
1 Fuel Lines On-Vehicle Inspection
I4RS0A170019-01 AENBL80A1716005
! WARNING
Reconnection
Insert quick joint to fuel pipe until they lock securely (a As feed line (1) is under high pressure, use
click is heard), and confirm that quick joint is not special care when servicing it.
disconnected by hand.
Visually inspect fuel lines for evidence of fuel leakage,
Fuel Pressure Relief Procedure hose crack and deterioration or damage.
AENBL80A1716003 Make sure all clamps are secure.
! CAUTION Replace parts as needed.
Never perform this work when engine is hot.
1
Doing so may cause adverse effect to
catalyst.

1) Make sure that engine is cold.

2) Place gear shift lever in “Neutral” and apply parking
brake and block drive wheels.
3) Remove individual circuit fuse box No.1 cover.
4) Remove fuel pump relay (1) from individual circuit I4RS0B170006-01
fuse box No.1 (2).
5) Remove fuel filler cap in order to release fuel vapor Fuel Pipe Removal and Installation
AENBL80A1716006
pressure from fuel tank, and then reinstall fuel filler
cap.
1G-15 Fuel System: K14B

! WARNING
When performing the following procedure, be
sure to observe “Precautions for Fuel
System Service”: K14B (Page 1G-1) to reduce
the risk of fire and personal injury.

Removal
1) Relieve fuel pressure from fuel feed line. )(Page
1G-14)
2) Disconnect negative (–) cable at battery.
3) Disconnect fuel hoses (3) from fuel pipes (2) at both
front and rear ends of each fuel pipe. )(Page 1G-
12)
4) Mark the location of clamps (1) on fuel pipes (2), so
that the clamps can be reinstalled to the original
position.
5) Remove clamps (1) from vehicle body and fuel
pipes.
I2RH0B170007-01
2) Disconnect connector (1) from injector, connect
ohmmeter between terminals of injector and check
resistance.
If resistance is out of reference value greatly,
replace.
Reference resistance of fuel injector
11.6 – 12.4 Ω at 20 °C (68 °F)

! CAUTION
Be careful not to bend and damage fuel pipes
when removing clamp.

6) Remove fuel pipes (2).

3 2

I2RH0B170008-01

3) Connect connector to injector securely.

1

Fuel Injector Removal and Installation

AENBL80A1716008
I4RS0B170007-01

! WARNING
Installation
When performing the following procedure, be
1) Install clamps to marked position on pipes. If clamp
sure to observe “Precautions for Fuel
is deformed or has bent or broken claws, replace it
System Service”: K14B (Page 1G-1) in order
with new one.
to reduce the risk of fire and personal injury.
2) Install pipes with clamp to vehicle.
3) Connect fuel hoses to pipes. )(Page 1G-12) Removal
4) Connect negative (–) cable at battery. 1) Relieve fuel pressure. )(Page 1G-14)
5) With engine stopped, set ignition “ON” and check for 2) Disconnect negative (–) cable at battery.
fuel leaks. )(Page 1G-14) 3) Remove air cleaner assembly. )(Page 1D-5)
4) Disconnect fuel injector connectors.
Fuel Injector On-Vehicle Inspection
AENBL80A1716007 5) Disconnect fuel feed hose (4) from fuel delivery pipe
1) Using sound scope (1) or the like, check operating (1).
sound of injector (2) when engine is running or 6) Remove fuel delivery pipe nuts (2).
cranking. 7) Remove fuel injector(s) (3).
Cycle of operating sound should vary according to
engine speed.
If no sound or unusual sound is heard, check injector
circuit (wire or connector) or injector.
 Fuel System: K14B 1G-16

3
4

I7V20A171006-01

Installation
Reverse removal procedure noting following points.
• Replace injector O-ring (1) and cushion (2) with new
ones being careful not to damage them.
• Apply thin coat of fuel to O-rings (1), and then install
injectors (3) into delivery pipe (4) and cylinder head.
Make sure that injectors can be rotated smoothly (6).
If not, probable cause is incorrect installation of O-
ring. Replace O-ring with new one.
• Tighten fuel delivery pipe nuts (5) to specified torque
and make sure that injectors can be rotated smoothly.
Tightening torque
Fuel delivery pipe nut (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)
I7V20A171007-02

• After completing installation, check fuel line

connections for leaks with engine not running and
ignition “ON”. )(Page 1G-14)

Fuel Injector Inspection

AENBL80A1716009

! WARNING

• When performing the following procedure,

be sure to observe “Precautions for Fuel
System Service”: K14B (Page 1G-1) in
order to reduce the risk of fire and
personal injury.
• Put injector and battery as far away as
possible in order to reduce risk of fire and
personal injury when connecting /
disconnecting test harness to / from
battery.

1) Remove fuel injector. )(Page 1G-15)

2) Set special tools as follows.
Special tool
(A): 09912M58421
(B): 09912M57610
(C): 09930M86310
1G-17 Fuel System: K14B

a) Fit washer (1) (inside diameter 13.5 – 14.5 mm

(0.531 – 0.570 in.)) to injector (2), and then
install injector to special tool (A).
b) Connect special tool (C) to injector.
c) Install special tool (B) to special tool (A).
d) Connect fuel feed hose to special tool (A).

(A)
(B)

(A)

IBP80A121001-01
2 (C)
Not using SUZUKI scan tool:
1 a) Remove fuel pump relay from connector.
b) Connect two terminals of relay connector using
service wire (1) as shown in figure.

! CAUTION
(A)
Check that connection is made between
correct terminals. Wrong connection can
I6RW0B170014-01
cause damage to ECM, wire harness, etc.
3) Install suitable vinyl tube onto injector nozzle to
c) Set ignition “ON”.
prevent fuel from splashing out during injection.
4) Put graduated cylinder under injector.
1
5) Connect one of terminal of special tool (C) to battery
positive (+) terminal.
6) Operate fuel pump and apply fuel pressure to
injector as follows:
Using SUZUKI scan tool:
a) Connect scan tool to DLC (1) with ignition “OFF”.
b) Set ignition “ON”, clear DTC and select “ACTIVE
TEST” mode on scan tool.
c) Turn fuel pump ON using scan tool.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
I9P60A171007-02

7) Apply battery voltage to injector (1) for 15 sec. and

measure injected fuel volume with graduated
cylinder. Test each injector two or three times. If
injected volume is out of reference value greatly,
replace injector.
Reference injected fuel volume
56 – 58 cm3/15 sec. (0.119/0.099 – 0.122/0.102 US/
Imp pt/15 sec.)
8) Check fuel leakage from injector nozzle. Do not
operate injector for this check (but fuel pump should
be at work). If fuel leaks (1) more than the following
specification, replace injector.
Fuel leakage
Less than 1 drop/min.
 Fuel System: K14B 1G-18

I2RH01170008-01

I2RH0B170013-01

9) Remove injector from special tool (A) and disconnect
special tool (C) from injector.
! WARNING
As fuel feed line is still under high fuel
pressure even after inspection, removing
injector immediately may cause dangerous
spout of fuel. Before removing injector, be
sure to relieve fuel pressure as follows.
1. Stop operation of fuel pump.
2. Put graduated cylinder under injector.
3. Apply battery voltage to injector until no
fuel is injected from injector.
10) Carry out Steps 2) through 9) on each injector to
obtain 4 readings.
11) After checking, remove special tools from fuel
injector and fuel feed pipe.
12) Install fuel injectors to cylinder head. )(Page 1G-15)
13) Connect fuel feed hose to delivery pipe.
14) Check for fuel leaks. )(Page 1G-14)
Fuel Tank Removal and Installation
AENBL80A1716011
! WARNING
When performing the following procedure, be
sure to observe “Precautions for Fuel
System Service”: K14B (Page 1G-1) to reduce
the risk of fire and personal injury.
Removal
1) Relieve fuel pressure from fuel feed line. )(Page
1G-14)
2) Disconnect negative (–) cable at battery.
3) Remove fuel filler cap.
4) Insert hose of a hand operated pump into fuel filler
hose (1) and pump out fuel in space “A” shown in
figure.
! CAUTION
Do not force pump hose into fuel tank.

Fuel Filler Cap Inspection

AENBL80A1716010
! WARNING

• When performing the following procedure,

I7V20A171010-01
be sure to observe “Precautions for Fuel
System Service”: K14B (Page 1G-1) to 5) Hoist vehicle, and remove clamps (2), fuel filler hose
reduce the risk of fire and personal injury. (1) and breather hose (3) from fuel filler neck.
• If cap requires replacement, only a cap
2
with the same features should be used.
Failure to use correct cap can result in fire 2
and personal injury.
3

Remove cap (1), and check gasket for even filler neck
imprint, deterioration or any damage. If gasket (2) is
defective, replace cap.

1
I4RS0B170010-01

6) Disconnect ground cable (1) from fuel filter bracket.

1G-19 Fuel System: K14B

1
IBP80A171012-01

7) Remove exhaust center pipe. )(Page 1K-4)

8) Disconnect quick joint (1) from fuel pipes (2).
)(Page 1G-12)
2
IBL80A172012-01
! WARNING
12) Cover fuel pipe open ends with plugs and, using a
Never store fuel in an open container. Fuel in cord, bind fuel pipe ends at higher position.
such container may easily cause fire or 13) Remove fuel tank from vehicle.
explosion.
Installation

1 2 ! CAUTION
Clean outside surfaces of pipe where joint is
to be fitted, push joint into pipe till joint lock
clicks, and check that pipes are connected
securely. Failure to do this way result in fuel
leakage.

1) Raise fuel tank (1) with jack (2) and connect fuel
I4RS0B170011-01 pump connector and clamp wire harness.
9) Support fuel tank (1) with jack (2) and remove its 2) Install fuel tank to vehicle and tighten fuel tank bolts
mounting bolts. to specified torque.

! CAUTION
Fuel tank bolts are precoated with friction
stabilizer. Never reuse removed bolts,
otherwise bolts may loosen.

Tightening torque
Fuel tank bolt (a): 45 N·m (4.6 kgf-m, 33.5 lbf-ft)

1
2
I4RS0B170012-01

10) Lower fuel tank a little to disconnect wire harness at

connector (1), then remove fuel tank.
11) Disconnect fuel pipes (2). “Fuel Hose Disconnection
and Reconnection”: K14B (Page 1G-12)

2
1

(a)
I9P60A171015-01
 Fuel System: K14B 1G-20

3) Connect fuel filler hose (1) and vapor hose (2)

inserting quick joint to each pipe until they lock 3

securely (a click is heard) and confirm that it is not

disconnected by hand and then clamp the pipes in
the original position.
(a)
For proper installation, refer to “Fuel Hose 2
Disconnection and Reconnection”: K14B (Page 1G-
12).

3
1
IBP80A171016-01

8) Connect negative cable at battery.

2
9) Install fuel filler cap.
10) With engine stopped, set ignition “ON” and check for
fuel leaks. )(Page 1G-14)

Fuel Tank Inspection

AENBL80A1716012
1
IAP70A170006-01 • Check fuel tank for cracks, deformation or damage.
4) Connect fuel feed hose (1) and vapor hose (2) to • Check fuel tank inlet valve for damage, smooth
each pipe as shown in figure, and clamp them opening and closing.
securely. If faulty condition is found, replace fuel tank.
• Check fuel pump O-ring for fuel leaks.
2
1 If faulty condition is found, replace O-ring and fuel
pump lock nut.
• Check hoses and pipes connected to fuel tank for
leaks, loose connections, deterioration or damage.
If faulty condition is found, replace hoses and/or
pipes.

Fuel Tank Flushing Procedure

I4RS0B170014-01 AENBL80A1716013
5) Install exhaust center pipe. )(Page 1K-4)
! WARNING
6) Connect ground cable (1) to fuel filter bracket.
• When performing the following procedure,
be sure to observe “Precautions for Fuel
System Service”: K14B (Page 1G-1) to
reduce the risk of fire and personal injury.
• This flushing procedure will not remove all
fuel vapor.
Do not attempt any repair on tank using
heat of flame. Failure to observe this
precaution can result in explosion and
consequent personal injury.
1
IBP80A171012-01

7) Connect fuel filler hose (1) and breather hose (2) to ! CAUTION
filler neck as shown in figure and clamp them Never leave water in fuel tank after flushing.
securely. Water may cause corrosion inside fuel tank.
Tightening torque
Fuel filler hose clamp (a): 1.5 N·m (0.15 kgf-m, 1) After removing fuel tank, remove all hoses, pipes
1.5 lbf-ft) and fuel pump assembly from fuel tank.
2) Drain all remaining fuel from tank.
3) Place fuel tank to flushing area.
1G-21 Fuel System: K14B

4) Fill tank with warm water or tap water, agitate water Fuel Pump Assembly Removal and Installation
vigorously, and drain water out of tank. Repeat this AENBL80A1716015

process until inside of tank is clean. ! WARNING

5) Completely flush out remaining water after washing.
When performing the following procedure, be
6) Dry fuel tank assembly thoroughly in a place free of
sure to observe “Precautions for Fuel
direct sunlight.
System Service”: K14B (Page 1G-1) to reduce
the risk of fire and personal injury.
Fuel Pump On-Vehicle Inspection
AENBL80A1716014
! WARNING ! CAUTION

When performing the following procedure, be
sure to observe “Precautions for Fuel
System Service”: K14B (Page 1G-1) to reduce
the risk of fire and personal injury.
Removal
NOTE
Fuel pressure regulator is an integral part of
fuel pump assembly.
Fuel pressure regulator cannot be
individually inspected.
Never disassemble fuel pump assembly
except fuel level sensor. If faulty condition is
found, replace it with new one.
1) Remove fuel tank from vehicle. )(Page 1G-18)
2) Remove fuel pump cover bolts (1) from fuel tank (2).
1
2

1) Remove fuel filler cap and set ignition “ON”. Fuel

pump operation sound should be heard from fuel
filler for about 2 seconds and then stop. Be sure to
reinstall fuel filler cap after checking.
If check result is not satisfactory, go to “Fuel Pump
and Its Circuit Check”: K14B (Page 1G-8).

IAY40A170022-01

1 3) Remove fuel pump assembly (1) from fuel tank (2).

I8G001170030-01

2) Set ignition “OFF” and leave it over 10 minutes as it 1

is.
3) Fuel pressure should be felt at fuel feed hose (1) for
about 2 seconds after setting ignition to “ON”. 2
If fuel pressure is not felt, go to “Fuel Pressure
Check”: K14B (Page 1G-10).

IAY40A170023-01

I7V20A171014-01
 Fuel System: K14B 1G-22

Installation

! CAUTION
1
Clean outside surface of pipe where joint is
to be fitted, push joint into pipe until joint
lock clicks. And check that pipes are
connected securely. Failure to do this may
result in fuel leakage.

1) Clean mating surfaces of fuel pump assembly (1) 2

and fuel tank.

2) Install fuel pump assembly (2) to fuel tank (3).
3) Install new fuel pump cover O-ring (4) to fuel pump. IAW101170039-01

4) Install fuel pump cover bolts (5) and tighten as per

the torque. Removal
1) Remove fuel pump assembly from fuel tank. )(Page
Tightening torque
1G-21)
Fuel pump cover bolt (a): 10 N·m (1.0 kgf-m, 7.3
lbf-ft) 2) Disconnect fuel level sensor connector (1).
3) Release lock (2), remove fuel level sensor (3) from
5 fuel pump (4) by sliding it in arrow direction as shown
in figure.

4
1

1
2

3
2

3
4
IAW101170040-01

Installation
Reverse removal procedure.

Fuel Level Sensor Inspection

IAY40A170024-01 AENBL80A1716018
5) Install fuel tank to vehicle. )(Page 1G-18) • Check that resistance between terminals “a” and “b”
of fuel level sensor changes depending on float
Fuel Pump Inspection position.
AENBL80A1716016 • Check resistance between terminals “a” and “b” at
• Check fuel pump assembly for damage. each float position in the following table.
• Check fuel suction filter for contamination. If check result is not as specified, replace fuel level
If contaminated, replace or clean the filter and check sensor.
fuel tank inside for presence of dirt.
Fuel level sensor specifications
Float Position Resistance (Ω)
Fuel Level Sensor Removal and Installation “c” 19.5 mm 266.7 ± 2.7
AENBL80A1716017
! CAUTION “d” 67 mm 160 ± 2
“e” 106.8 mm 53.3 ± 0.5
Do not touch resister plate (1) and cause
deformation of arm (2). It may cause fuel level
sensor to fail.
1G-23 Fuel System: K14B

“a” “b” 1

1
3 2
1
“e”
“d”
“c”

I9P60A171010-02

1. Fuel pump 2. Float

Fuel Filter Removal and Installation IBP80A171023-02

AENBL80A1716019
Removal
Installation
1) Relieve fuel pressure from fuel feed line. )(Page
1G-14) 1) Install fuel filter to fuel filter bracket.
2) Disconnect negative (-) cable at battery. 2) Connect fuel filter hoses to fuel filter.
3) Disconnect fuel filter hoses (1) from fuel filter (2). 3) Connect negative (-) cable at battery.
4) Push and pull out fuel filter from fuel filter bracket (3). 4) With engine stopped, set ignition “ON” and check for
fuel leaks.)(Page 1G-14)

Specifications
Tightening Torque Specifications
AENBL80A1717001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Fuel delivery pipe nut 25 2.5 18.5 )
Fuel tank bolt 45 4.6 33.5 )
Fuel filler hose clamp 1.5 0.15 1.5 )
Fuel pump cover bolt 10 1.0 7.3 )

NOTE
The tightening torque(s) also specified in:
“Fuel System Components”: K14B
“Fuel Hose Disconnection and Reconnection”: K14B

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
 Fuel System: K14B 1G-24

Special Tools and Equipment

Special Tool
AENBL80A1718001
09912M57610 09912M58421
Injector checking tool plate Checking tool set
) This kit includes the
following items. 1. Tool body
and washer, 2. Body plug, 3.
Body attachment-1, 4.
Holder, 5. Return hose and
clamp, 6. Body attachment-2
and washer, 7. Hose
attachment-1, 8. Hose
attachment-2)
09912M58432 09912M58442
Fuel pressure gauge hose Fuel pressure gauge
This tool is included in fuel This tool is included in fuel
pressure gauge set (09912- pressure gauge set (09912-
58413).) / ) 58413).) / )

09912M58490 09919M47020
3-way joint & hose Quick joint remover
)/) )

09930M86310 SUZUKI scan tool (SUZUKI- 6

SDT)
Injector test harness — 1 2
) This kit includes following
4
items. 1. SUZUKI-SDT 2. 3
DLC cable 3. USB cable 4. 5
AC/DC power supply 5.
Voltage meter probe 6.
Storage case) / )
1G-25 Fuel System: D13A

D13A
Precautions
Precautions for Fuel System Service
AENBL80A1720001
! WARNING

• Before attempting service of any type on fuel system, the following precautions should be always
observed in order to reduce the risk or fire and personal injury.
– Disconnect negative (–) cable at battery.
– Do not smoke, and place no smoking signs near work area.
– Be sure to have CO2 fire extinguisher handy.
– Be sure to perform work in a well-ventilated area and away from any open flames (such as gas hot
heater).
– Wear safety glasses.
– To release fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then
reinstall it.
– As fuel feed line is still under high fuel pressure even after engine was stopped, loosening or
disconnecting fuel feed line directly after stopping engine may cause dangerous spout of fuel.
Before loosening or disconnecting high pressure fuel line, be sure to release fuel pressure.
)(Page 1G-36)
– A small amount of fuel may be released after the fuel line is disconnected. In order to reduce the
chance of personal injury, cover the fitting to be disconnected with a lint-free cloth. Be sure to put
the used cloth in an approved container when disconnection is completed.
– Never run engine with fuel main relay disconnected when engine and exhaust system are hot.
– Fuel hose connection varies with type of pipe. Be sure to connect and clamp each hose correctly.
)(Page 1G-34)
After connecting hose, make sure that it has no twist or kink.
– When installing fuel feed pipe, lubricate its O-ring with fuel.
– When connecting fuel pipe flare nut, first tighten flare nut by hand and then tighten it to specified
torque.
– The system can inject the diesel fuel into the engine at a pressure up to 140,000 kPa (1427.6 kgf/
cm2, 20,305 psi, 1400 bar). Before carrying out any work, check that the injector rail is not under
pressure and that the fuel temperature is not too high.
– Do not place your hand near any leakage point on high pressure fuel circuit.
– Do not run engine with disconnecting fuel pipe and/or removing fuel system components.
– Do not expose removed fuel system parts to dust. Keep them always clean.
– Handle fuel tank carefully not to let it contact with sharp edges or hot surfaces. Also avoid
dropping fuel tank because not only the tank but also fuel pump and other inside components
may be damaged by impact. If fuel tank is dropped, replace all components including the tank
itself.
– Fuel tank is made of plastic.
Be sure not to allow solvent such as grease and sealant to contact fuel tank as some chemical
reaction may occur, causing fuel tank to be swollen, hardened or deformed, resulting in fuel
leakage from fuel tank.
• Keep sparks and flames away from working area. Fuel vapor that may be present there from spilled
fuel or fuel line leakage is very easy to ignite and could cause serious injuries or death and damage
to property.
• Fuel will irritate skin and eyes. Protect your hands and eyes appropriately against contact with fuel.

• Fuel system must be checked for fuel leakage after service work. )(Page 1G-37)
• Fuel system is very sensitive to contamination. Problems caused by introduction of contamination into the system
include:
 Fuel System: D13A 1G-26

– Damage to or destruction of high pressure injection system and engine.

– Seized or leaky component.
• When servicing high pressure direct injection system, perform operation in very clean condition. Never allow any
contamination to get into fuel system during removal of components and disconnection of unions. Maintaining
cleanliness is especially important when servicing any part between fuel filter and injectors.
• Avoid especially the following contaminants.
– Metal or plastic chips
– Paint
– Fibres from boxes, brushes, paper, clothing or cloths
– Hair
– Dust brought by air
• Do not clean engine using high pressure washing machine because of the risk of damage to and moisture collection
in connections. This may also create electrical connection problems.
• Wear clean overalls.
• Have plug caps (special tool) to be prepared for closing disconnected unions to prevent any entry of impurities into
fuel system.
Plug caps should be used once only. Be sure to dispose of used plug caps and also unused ones that are brought
by you (they are soiled and cleaning is insufficient to make them reusable).
• Plug unions as soon as possible when removing / disconnecting fuel system component in order to prevent dust
from entering.
Similarly, remove plug cap only immediately before installing / connecting fuel system component.
Special tool
(A): 09919M46310
1G-27 Fuel System: D13A

(A)

[a] [d] [g] [j] [l]

[b]
[e] [h]

[c] [f] [i] [k]

[l]
[c]
2

[a]
3

[e]
[e] 6

4
[i]

[d]
[b]
[j] [l]
[f] 10
8
[l] [l] [h] [k]
9
8

[h]
[l]
[k] [j]

[l]
[l]

7
IBL80A172006-02

1. Fuel injector 4. Fuel return hose of fuel injector 7. Fuel pipe 10. Fuel damper
2. Common rail 5. Fuel filter assembly 8. Fuel feed joint : Do not reuse.
3. High pressure pump 6. Quick joint 9. Fuel hose

• Keep removed fuel system parts in plastic bags with hermetically closing fasteners to protect them from impurities.
Plastic bags must be used only once.

I3RB0A173003-01

• Use only lint-free cloth for wiping fuel system parts. Never use any other wiping materials. Lint-free cloth must be
used only once.
• Keep plug cap installed unless its removal is absolutely necessary to prevent impurities from entering the system.
 Fuel System: D13A 1G-28

• Be sure to follow the instructions below before opening the fuel circuit.
– Use new thinner from clean receptacle every time connection is cleaned (used thinner contains impurities).
– Use only clean brush in good condition (without loose bristles) for applying thinner.
– Use brush and thinner to clean connections to be opened.
– Blow compressed air over cleaned parts (connections and injection system area including tools). Check that no
bristles remain on cleaned surfaces.
– Wash your hands before and during the operation if necessary.
– When wearing leather gloves, cover them with latex gloves.
• Be sure to follow the instructions below during operation.
– As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system using
plug caps. Do not reuse removed plugs.
– Close plastic bag every time it is opened, even if it has to be reopened shortly afterwards.
Ambient air carries contamination.
– All removed components of injection system must be kept in a plastic bag with hermetically closing fastener once
openings are closed with plugs.
– The use of brush, thinner, bellows, sponge or normal cloth is strictly forbidden once fuel system circuit has been
opened. These items are likely to allow impurities to enter the system.
– Open package of replacement part only immediately before installation.

General Description
Fuel System Description
AENBL80A1721001
Low-Pressure Fuel Supply Circuit [A]
The fuel pump in the fuel tank (1) pumps fuel into the fuel supply circuit [A] through the fuel filter (2).
The fuel pump assembly (4) is composed of a fuel pump (3), a fuel suction filter (5) and a fuel level gauge (6). The fuel
pump is an electric pump.

High-Pressure Fuel Supply Circuit [B]

The high pressure pump (7) driven by the engine boosts pressure of low pressure fuel to create high pressure fuel.
The high pressure fuel is supplied to the common rail (8) through the high pressure fuel pipe. The injectors (9) atomize
the fuel to charge the cylinders.
1G-29 Fuel System: D13A

7
9

10

4
1 11

8 [A]

[B]

[C]

6 3 5
IBL80A172008-02

[C]: Return circuit 10. Fuel damper 11. Fuel pressure sensor
 Fuel System: D13A 1G-30

Diagnostic Information and Procedures

Low-Pressure Fuel Supply Circuit Check
AENBL80A1724001
System Diagram

: [A]

[E] 3 : [B]

: [C]
[D] [F] 4

2
5

2
[D]
[F]

4
3
[E]

IBL80A172042-01

[A]: Fuel feed line [D]: Measurement point [D] 1. Fuel tank 4. Common rail
[B]: Fuel return line [E]: Measurement point [E] 2. Fuel filter 5. Fuel injector
[C]: Fuel high pressure line [F]: Pinching point [F] 3. High pressure pump

Troubleshooting

! WARNING
Before performing the following troubleshooting, be sure to read “Precautions for Fuel System
Service”: D13A (Page 1G-25).

NOTE
Before performing the following check, confirm that battery voltage is 11 V or more.

Step Action Yes No

1 Preliminary check Go to Step 2. Fuel tank contains
1) Check that fuel tank contains correct type of fuel. improper substances
(petrol, other fluids).
Is check result OK? Clean fuel tank and refill
it correctly.
1G-31 Fuel System: D13A

Step Action Yes No

2 Preliminary check Go to Step 3. Add fuel up to more
1) Check that fuel remaining in tank is more than 5 liters than 5 liters (10.67/8.80
(10.67/8.80 US/Imp pt.). US/Imp pt.).

Is check result OK?

3 Preliminary check Go to Step 4. Repair or, if necessary,
1) Check the following. replace faulty
components.
• Check fuel leaks in fuel circuit.
• Check hoses and pipes for obstructions, damage,
leaks, breaks, scratches, etc.
• Check fittings and seals for correct installation.
• Check for blockages, air or water in fuel system.

Is check result OK?

4 Fuel pump operation check Go to Step 5. Go to “Table A-1: Fuel
1) Check fuel pump operation. )(Page 1G-51) Pump Relay Operation
Check”: D13A in
Is check result OK? Section 1A (Page 1A-
236).
5 Fuel pressure check End. • If fuel pressure is
1) Set ignition “OFF”. higher than 495 kPa
(5.0 kgf/cm2, 71.8 psi,
2) Connect special tools to measurement point [D] as
4.95 bar), go to Step
shown in figure.
6.
Special tool • If fuel pressure is
: 09912M58432 lower than 405 kPa
: 09914M08410 (4.1 kgf/cm2, 58.7 psi,
: 09919M48410 4.05 bar), go to Step
3) With engine idling, check that fuel pressure is within 405 7.
to 495 kPa (4.1 to 5.0 kgf/cm2, 58.7 to 71.8 psi, 4.05 to
4.95 bar).

Is check result OK?

6 Fuel pressure check Replace fuel filter. Replace high pressure
1) Set ignition “OFF”. )(Page 1G-52) pump. )(Page 1G-44)
2) Remove special tools connected at Step 5.
3) Connect special tools to measurement point [E] as
shown in figure.
Special tool
: 09912M58432
: 09914M08410
: 09919M48410
4) With engine idling, check that fuel pressure.

Measured fuel pressure is lower than 30 kPa (0.3 kgf/cm2,

4.35 psi, 0.3 bar) from value of measured fuel pressure in
Step 5?
7 Fuel pressure check Replace high pressure Replace fuel pump.
1) Set ignition “OFF”. pump. )(Page 1G-44) )(Page 1G-51)
2) Pinch fuel hose at pinching point [F] by hand in order to
block up fuel flow.
3) Within 20 sec. after setting ignition “ON”, check that fuel
pressure is within 720 to 780 kPa (734.2 to 795.4 kgf/
cm2, 10,400 to 11,300 psi, 720 to 780 bar).

Is check result OK?

 Fuel System: D13A 1G-32

High-Pressure Fuel Supply Circuit Check

AENBL80A1724002
! WARNING
Before troubleshooting, be sure to read “Precautions for Fuel System Service”: D13A (Page 1G-25).

Troubleshooting

NOTE
• Before troubleshooting, be sure to check low-pressure fuel circuit. )(Page 1G-30)
• Before troubleshooting, confirm that battery voltage is 11 V or more.

Step Action Yes No

1 Fuel injector calibration code check Go to Step 2. Register correct fuel
1) Using SUZUKI scan tool, check that fuel injector injector calibration
calibration codes registered in ECM correspond with codes in ECM. “Fuel
calibration codes stamped on fuel injectors. Injector Registration”:
D13A in Section 1C
Is check result OK? (Page 1C-16)
2 Fuel injector check Go to Step 3. Replace faulty fuel
1) Check fuel injector for resistance. )(Page 1G-41) injector. )(Page 1G-42)

Is check result OK?

1G-33 Fuel System: D13A

Step Action Yes No

3 Fuel injector leak check Go to Step 4. Replace faulty fuel
1) Relieve fuel pressure. )(Page 1G-36) injector. )(Page 1G-42)
2) Set ignition “OFF”.
3) Disconnect fuel injector connectors referring to Step 4)
of “Removal” under “Fuel Injector Removal and
Installation”: D13A (Page 1G-42).
4) After removing clips, disconnect fuel return hose (1) from
all fuel injectors.
5) Plug fuel return hose with plug cap (2) so that no fuel
comes out during this check. For details, refer to
“Precautions for Fuel System Service”: D13A (Page 1G-
25).
6) Connect special tool to fuel injectors.

NOTE
For adapters (3) between special tool and
injectors, use return fuel hose supplied as spare
part.

Special tool
(A): 09912M96540

(A)
I6RS0E110014-01

7) Crank engine for 5 seconds.

8) Check that quantities of return fuel from all injectors are
almost the same.

Is check result OK?

4 Fuel injector leak check Go to Step 5. Replace faulty fuel
1) Set ignition “OFF”. injector. )(Page 1G-42)
2) Connect connectors to all injectors.
3) Check that quantities of return fuel from all injectors are
almost the same under each of the following condition
respectively as same manner as in Step 3.
• Engine running at idle speed for 3 min.
• Engine running at 1,500 rpm for 3 min.
• Engine running at 3,000 rpm for 3 min.

Is check result OK?

 Fuel System: D13A 1G-34

Step Action Yes No

5 High pressure fuel circuit check End. Go to Step 6.
1) Set ignition “OFF”.
2) Disconnect fuel injector connector referring to Step 4) of
“Removal” under “Fuel Injector Removal and
Installation”: D13A (Page 1G-42).
3) Connect SUZUKI scan tool to DLC.
4) Crank engine for 5 seconds.
5) Check that “Fuel Rail Pressure” displayed on SUZUKI
scan tool is higher than 30 MPa (300 bar) at engine
speed higher than 200 rpm.

Is check result OK?

6 Fuel pressure sensor circuit check Go to Step 7. Repair or replace
1) Check fuel pressure sensor circuit. )(Page 1A-241) defective wire harness.

Is check result OK?

7 Fuel pressure regulator operation check End. Repair or replace
1) Check fuel pressure regulator operation. )(Page 1A- defective part.
243)

Is check result OK?

Repair Instructions
Fuel Hose Disconnecting and Reconnecting
AENBL80A1726001
! WARNING
Before starting the following procedure, be sure to observe “Precautions for Fuel System Service”:
D13A (Page 1G-25) in order to reduce the risk or fire and personal injury.
1G-35 Fuel System: D13A

Connection Other than Quick Joint

Fuel tank system

NOTE
Make sure that fuel hose end makes contact with bulge on fuel pipe or pipe joint end when connecting
fuel hose to pipe.

9 7 12

“d”
8 “a”

2 4

“b” “c” 11
10 (a) 11
“e”
7

7
8 8
10 (b) “d”
IBL80A172044-01

1. Fuel tank 6. Fuel tank protector 11. Vehicle leftward “c”: 5 – 12 mm (0.20 – 0.47 in.)
2. Breather hose 7. Pipe 12. Vehicle rightward “d”: 0 – 45°
3. Fuel tank filler hose 8. Hose 13. Vehicle backward “e”: 45°
4. Fuel filler neck 9. Clamp “a”: 3 – 7 mm (0.12 – 0.28 in.) : 2.0 N⋅m (0.20 kgf-m, 1.5 lbf-ft)
5. Fuel filler cap 10. Fuel filler hose clamp screw “b”: 5 – 10 mm (0.20 – 0.39 in.) : 1.5 N⋅m (0.15 kgf-m, 1.5 lbf-ft)
 Fuel System: D13A 1G-36

Clamps in other areas than areas around fuel tank

1

3 2
2

(A)

1
(A)
I7V20A172006-01

Reconnecting
Insert quick joint to pipe until they lock securely (a click is
heard), and confirm that quick joint is not disconnected
by hand.
I9P60A172004-01

[A]: For connection to short pipe, fit hose as far as it reaches pipe joint as For Quick Joint (Fuel Pump)
shown.
Disconnecting
[B]: For connection to the following type pipe, fit hose as far as it reaches
bulge on pipe. 1) Remove mud, dust and/or foreign material between
“a” 2 – 4 mm (0.08 – 0.16 in.) pipe (1) and quick joint (fuel pump) (2) by blowing
“b” 3 – 7 mm (0.12 – 0.28 in.) compressed air.
1. Pipe
2. Hose
2) Disconnect fuel return pipe quick joint (3) from fuel
3. Clamp pump while joint lock is unlocked by pushing lock
button (4) of joint.
For Quick Joint (Fuel Pipe) 3) Release fuel feed pipe quick joint lock pin (5) in
Disconnecting arrow direction as shown in figure, and disconnect
1) Remove mud, dust and/or foreign material between fuel feed pipe (6) from fuel pump.
pipe (1) and quick joint (fuel pipe) (2) by blowing
6 5 4
compressed air. 3
1
2) Disconnect quick joint (fuel pipe) while pushing lock
button (3).

2
1
3 2
I5RW0B170006-02
IBL80A172034-01

Reconnecting
Insert quick joint (fuel pipe) to fuel pipe until they lock Reconnecting
securely (a click is heard), and confirm that quick joint 1) Insert return pipe quick joint to fuel pump until they
(fuel pipe) is not disconnected by hand. lock securely (a click is heard), and confirm that
quick joint is not disconnected by hand.
For Quick Joint (Fuel Filter) 2) For fuel feed pipe, connect quick joint and push lock
Disconnecting pin to its original position.
1) Remove mud, dust and/or foreign material between
pipe (1) and quick joint (2) by blowing compressed Fuel Pressure Relief Procedure
AENBL80A1726002
air.
1) Check that engine is cold.
2) Unlock quick joint lock (3) using special tool between
pipe (1) and quick joint (2) as shown in figure. 2) Connect SUZUKI scan tool to DLC (1) with ignition
“OFF”.
Special tool
(A): 09912M58310 Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
1G-37 Fuel System: D13A

Water Draining of Fuel Filter

AENBL80A1726004
1) Disconnect negative (–) cable at battery.
2) Hoist vehicle.
3) Place container under drain screw (1), and drain out
water by loosening drain screw from lower side of
engine until fuel flows out.
(A)
4) Tighten drain screw (1) to specified torque.
Tightening torque
1
Drain screw (a): 1.5 N·m (0.15 kgf-m, 1.5 lbf-ft)

IAP70P180002-01

3) Set ignition “ON”.

4) Confirm that fuel pressure line is not under pressure
using “Fuel Rail Pressure” parameter of SUZUKI
scan tool.

Fuel Leakage Check Procedure 1 , (a)

AENBL80A1726003
IBL80A172043-01
1) Set ignition “ON”. 5) Lower vehicle.
2) Check for fuel leakage in each part, which was 6) Connect negative (–) cable at battery.
serviced.
3) Start engine, and then check for fuel leakage in each Air Bleeding of Fuel System
part, which was serviced. AENBL80A1726005

4) Run engine at 4,000 rpm. for about 30 seconds and
then stop engine.
5) Check for fuel leakage in each part, which was
serviced.
Air bleeding must be carried out when fuel system has
been disassembled or when vehicle ran out of fuel.
Set ignition “ON” to operate fuel pump and after about 5
seconds set ignition “OFF”. Repeat this operation 6
times and then check that engine starts.

Fuel System Components

AENBL80A1726006
! WARNING
Before starting the following procedure, be sure to observe “Precautions for Fuel System Service”:
D13A (Page 1G-25) in order to reduce the risk or fire and personal injury.
 Fuel System: D13A 1G-38

Low-Pressure Fuel Supply Circuit

(d)

4 5
7 (a)

3 3

(c)

(b)

14

10

F
9

12

11 8

11

13
13

IBL80A172035-01
1G-39 Fuel System: D13A

F: Forward 7. Fuel filter fastener 14. To fuel damper

1. Fuel tank 8. Fuel filter bracket : 30 N⋅m (3.1 kgf-m, 22.5 lbf-ft)
2. Fuel pump 9. Fuel pipe cover : 45 N⋅m (4.6 kgf-m, 33.5 lbf-ft)
3. O-ring 10. To fuel filter : 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)
4. Fuel pump lock nut 11. To fuel tank : 3.0 N⋅m (0.31 kgf-m, 2.5 lbf-ft)
5. Fuel filter 12. To dash panel : Do not reuse.
6. Fuel filter element 13. To high pressure pump

High-Pressure Fuel Supply Circuit

(c)

(i)

5 (d)
9 (e)
7

11
12

(f)
(d)

(g)
(h)
8

(f) (a)

12 4 (h)
1
(g)
6
1
(a)

4 11
2

7 10 3

2
3
IBL80A172045-01

1. Fuel injector 8. Common rail bracket : 22 N⋅m (2.2 kgf-m, 16.5 lbf-ft)
2. Sealing ring 9. Fuel pressure sensor : 70 N⋅m (7.1 kgf-m, 52.0 lbf-ft)
3. Sealing washer 10. Fuel injector bracket : 28 N⋅m (2.9 kgf-m, 21.0 lbf-ft)
4. Washer 11. Engine side hook : 24 N⋅m (2.4 kgf-m, 18.0 lbf-ft)
5. Common rail 12. High pressure pipe : 15 N⋅m (1.5 kgf-m, 11.0 lbf-ft)
: For tightening order, refer to “High Pressure Pipe
Removal and Installation”: D13A (Page 1G-39)
6. High pressure pump : 20 N⋅m (2.0 kgf-m, 15.0 lbf-ft) : 9 N⋅m (0.9 kgf-m, 7.0 lbf-ft)
7. Fuel damper : 25 N⋅m (2.5 kgf-m, 18.5 lbf-ft) : Do not reuse.

High Pressure Pipe Removal and Installation

AENBL80A1726007
 Fuel System: D13A 1G-40

! WARNING • For high pressure pipe between high pressure

pump and common rail.
Before servicing fuel system, be sure to a. Loosen high pressure pipe union nuts (1), and
observe “Precautions for Fuel System remove high pressure pipe (2).
Service”: D13A (Page 1G-25).
! CAUTION
Removal
When loosing union nut on high pressure
! CAUTION pump side, hold union nut (3) with wrench.

As small amount of fuel may come out during

removal of high pressure pipes, cover high 1
pressure pipes with plug caps.
2

1) Release fuel pressure. )(Page 1G-36)

2) Disconnect negative (–) cable at battery.
3) Remove engine cover and engine cover bracket.
3
)(Page 1D-63)
4) Remove intercooler outlet pipe bolts (1) and then
detach intercooler outlet pipe (2).

1 IBL80A172025-02

1
Installation

! CAUTION

2 • Do not touch pipes with wrench when

IBL80A172024-07
5) Remove high pressure pipes as follows.
• For high pressure pipes between fuel injector and
common rail.
a. Loosen high pressure pipe union nuts (1) from
fuel injectors.
! CAUTION
When loosening each union nut on fuel
injector side, hold union nut (5) with wrench;
otherwise pipe may bend or break.
tightening union nuts to avoid damage to
high pressure pipe.
• When using extension special tool with
torque wrench, torque wrench reading
should be smaller than specified
tightening torque. Correct reading value
should be calculated according to the
formula below.
• When tightening union nuts on high
pressure pump side and injector side, hold
each union nut (1) with wrench.

b. Loosen high pressure pipe union nuts (2) from Tightening torque formula.
common rail (3), and remove high pressure M = T x L / (L + “a”)
pipes (4). M: Value indicated on torque wrench
T: Specified tightening torque
2 L: Length of torque wrench
“a”: Length of special tool
3
“b”: Length of special tool
4
Special tool
(A): 09911M75420
(B): 09950M76510

IBL80A172022-02
1G-41 Fuel System: D13A

1) Using sound scope or the like, check operating

sound of fuel injectors when engine is running or
“a” cranking.
Cycle of operating sound should vary according to
engine speed.
L
If no sound or an unusual sound is heard, check that
result of each step is in good condition. )(Page 1A-
238)
(A)

1
(A) “a” (B)
“b”

I7V20A172015-02
I3RM0B172008-01
“a”: 19.5 mm (0.768 in.) “b”: 20.3 mm (0.799 in.)
2) Disconnect connector from fuel injector as follows.
Reverse removal procedure noting the following points. a) Move connector lock pin (1) in arrow direction as
• Use new high pressure pipe. shown in figure.
• Tighten injector side union nuts and high pressure b) Push connector lock lever (2) and disconnect
pump side union nut to specified torque. connector from fuel injector (3).

Special tool
: 09950M76510 1 2

Tightening torque 3

High pressure pipe union nut (fuel injector side

and high pressure pump side) (a): 24 N·m (2.4
kgf-m, 18.0 lbf-ft)
• Tighten common rail side union nuts to specified
torque.
Special tool
: 09911M75420
Tightening torque
High pressure pipe union nut (common rail side)
(b): 28 N·m (2.9 kgf-m, 21.0 lbf-ft)
IBP80A172013-02
(b)
3) Connect ohmmeter between terminals of fuel injector
and check resistance.
If resistance is out of specification, replace fuel
injector.
Resistance of fuel injector
About 0.215 – 0.295 Ω
(a)

IBL80A172036-01

• Tighten engine cover bolts to specified torque.

)(Page 1D-63)
• Check for fuel leakage. )(Page 1G-37)

Fuel Injector On-Vehicle Inspection

AENBL80A1726008
 Fuel System: D13A 1G-42

IBP80A172014-01

4) Connect connector to fuel injector securely.

Fuel Injector Removal and Installation

AENBL80A1726009

! WARNING I3RM0B172010-01

Before starting the following procedure, be

Removal
sure to observe “Precautions for Fuel
System Service”: D13A (Page 1G-25) in order 1) Disconnect negative (–) cable at battery.
to reduce the risk of fire and personal injury. 2) Remove engine cover and engine cover bracket.
)(Page 1D-63)
NOTE 3) Remove high pressure pipes between fuel injectors
The calibration code (1) is given to each fuel and common rail. )(Page 1G-39)
injector, and it represents the performance 4) Disconnect connector from fuel injectors as follows.
characteristics of the fuel injector. It is a) Move connector lock pin (1) in arrow direction as
registered in ECM, and ECM controls fuel shown in figure.
injection according to the performance b) Push connector lock lever (2) and disconnect
characteristics of the fuel injector. connector from fuel injector (3).
Therefore, after removing fuel injectors, be
sure to install them as they were. In case that
the fuel injectors is replaced with new one, 1 2
be sure to register each calibration code in 3
ECM. For details, refer to “Description of
ECM Registration”: D13A in Section 1C (Page
1C-14). If it is not registered correctly, DTC is
stored in ECM.
Also calibration codes registration in ECM
can be checked by SUZUKI scan tool.

IBP80A172013-02

5) Remove clips (1), and then disconnect return hose

(2) from fuel injectors.
1G-43 Fuel System: D13A

6, (a)
7

5
1

4
IBP80A172015-01

6) Remove fuel injector bracket nuts (1) and washers

(2).
7) Remove fuel injectors and brackets (3) together from
camshaft housing. 1 3

8) Remove sealing rings (4) from camshaft housing. 2

IBP80A172017-02
1 9) Connect return hose (2) to fuel injectors, and then
install clips (1) to fuel injectors.

2
3 2

4 1
IBP80A172016-01

Installation
1) Install new sealing washers (2) to fuel injectors (1).
2) Install new sealing rings (3) to camshaft housing.
3) Set fuel injector brackets (4) to fuel injectors.
4) Install fuel injectors to camshaft housing.
5) Install washers (5) and fuel injector bracket nuts (6),
and then tighten fuel injector bracket nuts
temporarily by hand.
6) Install new high pressure pipes (7) and tighten each
union nut temporarily by hand.
7) Tighten fuel injector bracket nut to specified torque.
Tightening torque
Fuel injector bracket nut (a): 20 N·m (2.0 kgf-m,
15.0 lbf-ft)
IBP80A172015-01
10) Connect fuel injector connectors.
11) Install engine cover bracket and engine cover, and
then tighten engine cover bolts to specified torque.
)(Page 1D-63)
12) Connect negative (–) cable at battery.
13) Check for fuel leakage. )(Page 1G-37)
14) When replacing any one of injectors, register injector
calibration code in ECM. “Fuel Injector Registration”:
D13A in Section 1C (Page 1C-16)
Common Rail Removal and Installation
AENBL80A1726010
! WARNING

8) Tighten high pressure pipe union nuts to specified Before starting the following procedure, be
torque. )(Page 1G-39) sure to observe “Precautions for Fuel
System Service”: D13A (Page 1G-25) in order
to reduce the risk or fire and personal injury.
 Fuel System: D13A 1G-44

Removal
1) Release fuel pressure. )(Page 1G-36)
3(a)
2) Disconnect negative (–) cable at battery.
3) Remove engine cover and engine cover bracket.
1
)(Page 1D-63)
4) Remove high pressure pipes. )(Page 1G-39)
5) Disconnect fuel return hose (7) from common rail.
6) Disconnect connectors from fuel pressure sensor
and fuel pressure regulator as follows.
2
a) Move connector lock pin (1) in arrow direction as
shown in figure. IBL80A172031-02

b) Push connector lock lever (2) and disconnect
each connector from fuel pressure sensor (3)
and fuel pressure regulator (4).
7) Remove common rail (5) from its bracket (6).
6) Install engine cover bracket and engine cover, and
then tighten engine cover bolts to specified torque.
)(Page 1D-63)
7) Connect negative (–) cable at battery.
8) Check for fuel leakage. )(Page 1G-37)

1 2 High Pressure Pump Removal and Installation

AENBL80A1726011
3
! WARNING
Before starting the following procedure, be
sure to observe “Precautions for Fuel
System Service”: D13A (Page 1G-25) in order
to reduce the risk of fire and personal injury.
4
Removal
1) Release fuel pressure. )(Page 1G-36)
5
2) Remove battery from vehicle. )(Page 1J-25)
3) Remove engine cover.
4) With hose connected, move degassing tank (1) in
the direction of arrow to release it from stay.
IBL80A172037-01
1

Installation
1) Install common rail (1) to its bracket (2) and tighten
common rail bolts (3) temporarily by hand.
2) Install each new high pressure pipe. Tighten each
union nut temporarily by hand.

! CAUTION
Do not reuse high pressure pipe.

3) Tighten common rail bolts to specified torque.

IBP80A172020-01
Tightening torque
5) Remove intercooler outlet pipe bolts (1) and then
Common rail bolt (a): 25 N·m (2.5 kgf-m, 18.0 lbf-
detach intercooler outlet pipe (2) from cylinder head
ft)
cover.
4) Tighten high pressure pipe union nuts to specified
torque. )(Page 1G-39)
5) Connect connectors to fuel pressure sensor.
1G-45 Fuel System: D13A

4) Tighten high pressure pump bolts to specified

torque.
Tightening torque
High pressure pump bolt (a): 15 N·m (1.5 kgf-m,
11.0 lbf-ft)
1

1
2

2
IBL80A172024-07

6) Disconnect fuel feed hose (2) from high pressure

pump.
7) Remove high pressure pipe (1) between common
rail and high pressure pump. )(Page 1G-39)
8) Disconnect fuel return hose (3) from high pressure 3
pump.

IBL80A172041-01

IBL80A172038-01 5) Install new high pressure pipe (1) between high

9) Remove vacuum pump. )(Page 1D-66) pressure pump and common rail. )(Page 1G-39)
10) Remove high pressure pump (1) from camshaft 6) Connect fuel feed hose (2) and return hose (3) to
housing. high pressure pump.

IBL80A172038-01

IBL80A172039-01 ! CAUTION

Installation Do not reuse high pressure pipe.

1) Clean mating surfaces of high pressure pump and
7) Install intercooler outlet pipe bolts (1) and fuel pipe
camshaft housing.
bolts (2).
2) Install new gasket (1) to high pressure pump.
3) Install high pressure pump (2) to camshaft housing.
Fit dogs (3) of high pressure pump coupling into the
grooves (4) in camshaft.
 Fuel System: D13A 1G-46

1 2
3

3
IBL80A172040-01

8) Install degassing tank to degassing tank bracket.

9) Install engine cover, and then tighten engine cover I9P60A172018-03
bolts to specified torque.
10) Connect negative (–) cable at battery. Installation
11) Check for fuel leakage. )(Page 1G-37) 1) Install fuel pressure sensor (1) to common rail (2).
Tighten fuel pressure sensor to specified torque.
Fuel Pressure Sensor Removal and Installation Tightening torque
AENBL80A1726012
Fuel pressure sensor (a): 70 N·m (7.1 kgf-m,
! WARNING 52.0 lbf-ft)
Before starting the following procedure, be
sure to observe “Precautions for Fuel
System Service”: D13A (Page 1G-25) in order 2
to reduce the risk of fire and personal injury.

NOTE
1, (a)
If fuel pressure sensor is replaced, be sure to
initialize fuel pressure sensor data in ECM.
For details, refer to “Description of ECM
Registration”: D13A in Section 1C (Page 1C-
I3RM0B172023-01
14).
When replacing fuel pressure sensor, 2) Connect fuel pressure sensor connector.
initialize fuel pressure sensor data in ECM. 3) Install engine cover bracket and engine cover, and
“Fuel Pressure Sensor Initialization”: D13A in then tighten engine cover bolts to specified torque.
Section 1C (Page 1C-17) )(Page 1D-63)
4) Connect negative (–) cable at battery.
Removal
5) Check for fuel leakage. )(Page 1G-37)
1) Relieve fuel pressure. )(Page 1G-36)
2) Disconnect negative (–) cable at battery. Fuel Flow Actuator On-Vehicle Inspection
AENBL80A1726031
3) Remove engine cover and engine cover bracket.
Check resistance between terminals of fuel actuator.
)(Page 1D-63)
If check result is not as specified, replace high pressure
4) Disconnect connector from fuel pressure sensor as pump.“High Pressure Pump Removal and Installation”:
follows. D13A (Page 1G-44)
a) Move connector lock pin (1) in arrow direction as
Fuel flow actuator resistance
shown in figure.
2.5 – 3.1 Ω at 20°C (68°F)
b) Push connector lock lever (2) and disconnect
connector from fuel pressure sensor (3).
5) Remove fuel pressure sensor (3) from common rail
(4).
1G-47 Fuel System: D13A

! WARNING

• Before starting the following procedure, be

sure to observe “Precautions for Fuel
System Service”: D13A (Page 1G-25) in
order to reduce the risk of fire and
personal injury.
• A small amount of fuel may be released
after fuel hose is disconnected. In order to
reduce the chance of personal injury,
cover hose and pipe to be disconnected
with a lint-free cloth.
Be sure to put the used cloth in an
approved container when disconnection is
completed.

Removal
1) Disconnect negative (–) cable at battery.
I9P60A172019-01
2) Remove fuel pipe cover (1) from vehicle.

1
Fuel Line and Connection Inspection
AENBL80A1726015
! WARNING
Before starting the following procedure, be
sure to observe “Precautions for Fuel
System Service”: D13A (Page 1G-25) in order
to reduce the risk of fire and personal injury.

! CAUTION
Due to the fact that fuel feed line (1) is under I5RS0B170007-01
high pressure, use special care when 3) Disconnect fuel pipe joints (3) from fuel pipes (2) at
servicing it. both front and rear ends of each fuel pipe. )(Page
1G-34)
Visually inspect fuel lines and connections for evidence
4) Mark the location of clamps (1) on fuel pipes, so that
of fuel leakage, cracks and deterioration of hose or other
the clamps can be reinstalled to original positions.
damage.
Make sure all clamps are secure.
Replace hoses that shows sign of cracks.

1
2
I9P60A172023-02

5) Remove fuel pipes (2) together with clamps (1) from

I9P60A172022-02 vehicle.

Fuel Pipe Removal and Installation

AENBL80A1726016

2
1 personal injury.
IBP80A172027-01
6) Remove clamps from pipes.
Installation
1) Install clamps to marked locations on pipes. Replace
any clamp that is deformed or its claw is bent or
broken with new one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel pipes to respective pipes. )(Page 1G-
34)
! CAUTION
When connecting joint, clean outside
surfaces of pipe where joint is to be inserted,
push joint into pipe till joint lock clicks and
check to ensure that pipes are connected
securely, or fuel leak may occur.
4) Install fuel pipe cover (1) to vehicle.
I5RS0B170007-01
5) Check for fuel leakage. )(Page 1G-37)
Fuel Filler Cap Inspection
AENBL80A1726017
! WARNING
Before starting the following procedure, be
sure to observe “Precautions for Fuel
System Service”: D13A (Page 1G-25) in order
to reduce the risk of fire and personal injury.
Remove cap (1), and check gasket for deterioration or
any damage. If gasket (2) is defective, replace cap.
Fuel System: D13A 1G-48
NOTE
If cap requires replacement, only a cap with
the same features should be used. Failure to
use correct cap can result in fire and
I2RH01170008-01
Fuel Tank On-Vehicle Inspection
AENBL80A1726018
Check fuel tank for damage, cracks, fuel leakage, and
looseness of tank bolts and fixer belts.
Repair or replace fuel tank if defective.
I9P60A172025-01
Fuel Tank Removal and Installation
AENBL80A1726019
Removal
! WARNING
• Before starting the following procedure, be
sure to observe “Precautions for Fuel
System Service”: D13A (Page 1G-25).
• A small amount of fuel may be released
after the fuel hose is disconnected. In
order to reduce the chance of personal
injury, cover the hose and pipe to be
disconnected with a lint-free cloth.
Be sure to put used cloth in an approved
container when disconnection is
completed.
1) Relieve fuel pressure from fuel fee line.“Fuel
Pressure Relief Procedure”: D13A (Page 1G-36)
1G-49 Fuel System: D13A

2) Disconnect negative (–) cable at battery.

1
3) Remove fuel filler cap.
4) Insert hose of a hand operated pump into fuel filler
hose (1) and drain fuel in space “a” as shown in the
figure.

! CAUTION

• Do not force pump hose into fuel tank.

• Never drain or store fuel in an open
container due to possibility of fire or
explosion. 2
I9P60A172027-01

9) Lower fuel tank (1) until fuel level (2) in fuel tank is
lower than installation position of quick joint (fuel
pipe) (3) in order to prevent fuel from flowing out.

! CAUTION
Be sure not to lower fuel tank (1) more than
instructed level (6) as wiring harness (4) of
fuel pump (5) is still connected.

IBP80A172028-02

5) Hoist vehicle, and remove clamps (2), fuel filler hose 5

4
(1) and breather hose (3) from fuel filler neck.
3
1
3

6
2
I5RS0B170012-02

10) Disconnect fuel pump / fuel level sensor connector

(1).
11) Disconnect fuel pipes (2). )(Page 1G-34)

1
2
I9P60A172026-02

6) Remove exhaust pipe No.2. )(Page 1K-9)

7) Disconnect fuel pipes (1) from fuel tank (2).

2
IBL80A172012-01

1 12) Cover fuel pipe open ends with plugs and, using a
I5RS0B170010-01 cord, bind fuel pipe ends at higher position.
8) Support fuel tank (1) with jack (2) and remove fuel 13) Remove fuel tank from vehicle.
tank bolts.
 Fuel System: D13A 1G-50

Installation
1
! CAUTION
When connecting joint, clean outside
surfaces of pipe where joint is to be inserted,
push joint into pipe till joint lock clicks and
check to ensure that pipes are connected
securely, or fuel leak may occur.

1) If parts have been removed from fuel tank, install

them before installing fuel tank to vehicle.
2) Raise fuel tank with jack, connect fuel pump / fuel
level sensor connector (3) and clamp wire harness.
3) Remove plugs, covered fuel pipe open ends at pipe
removal, then connect fuel feed pipe (1) and fuel
return pipe (2) to fuel pump. )(Page 1G-34) 2, (a) 2, (a)
I9P60A172030-01

3 5) Connect fuel filler hose (1) and breather hose (2) to

filler neck (3) as shown in the figure and clamp them
securely. )(Page 1G-34)
Tightening torque
Fuel filler hose clamp bolt (a): 1.5 N·m (0.15 kgf-
m, 1.5 lbf-ft)

2 1
IBL80A172013-01

4) Install fuel tank (1) to vehicle, and tighten new fuel

tank bolts (2) to specified torque.
! CAUTION
Fuel tank bolts are precoated with friction
stabilizer. Never reuse removed bolts,
otherwise bolts may loosen.
3
1 (a)
IBP80A172030-01
6) Install exhaust pipe No.2. )(Page 1K-9)
7) Connect negative (–) cable at battery.
8) Check for fuel leakage. )(Page 1G-37)

Tightening torque Fuel Tank Inspection

AENBL80A1726020
Fuel tank bolt (a): 45 N·m (4.6 kgf-m, 33.5 lbf-ft)
• After removing fuel tank, check hoses and pipes
connected to fuel tank for fuel leakage, loose
connections, deterioration or damage. Also check fuel
pump assembly gaskets for fuel leakage and visually
inspect fuel tank for fuel leakage and damage.
If check result is not OK, replace defective parts.
• Check fuel tank inlet valve for damage, smooth
opening and closing.

Fuel Tank Flushing Procedure

AENBL80A1726021
1G-51 Fuel System: D13A

! WARNING

• Before starting the following procedure, be

sure to observe “Precautions for Fuel
System Service”: D13A (Page 1G-25) in
order to reduce the risk of fire and
1
personal injury.
• This flushing procedure will not remove all
fuel vapor.
• Do not attempt any repair on tank using
heat of flame there is a risk of an explosion
that could result in personal injury.
IBP80A172031-02
Use the following procedure for flushing fuel tank.
1) After removing fuel tank, remove all hoses, pipes Fuel Pump Assembly Removal and Installation
and fuel pump assembly from fuel tank. AENBL80A1726023

2) Drain all remaining fuel from tank. ! WARNING

3) Place fuel tank in flushing area.
4) Fill tank with warm water or tap water, and agitate
vigorously and drain out water. Repeat this operation
until inside of tank is clean.
5) Completely empty tank of remaining water.
6) Dry fuel tank assembly thoroughly in a place not
exposed to direct sunlight.
Fuel Pump On-Vehicle Inspection
AENBL80A1726022
1) Remove fuel filler cap and set ignition “ON”. Fuel
pump operation sound should be heard from fuel
filler (1) for about 20 seconds and then stop. Be sure
to reinstall fuel filler cap after this checking. If check
result is not satisfactory, go to “Low-Pressure Fuel
Supply Circuit Check”: D13A (Page 1G-30).
1 tightening. Therefore, install lock nut right
Before starting the following procedure, be
sure to observe “Precautions for Fuel
System Service”: D13A (Page 1G-25).
! CAUTION
• Never disassemble fuel pump assembly. If
it is found faulty, replace it with new
assembly.
• Use only new fuel pump lock nut. Reusing
removed fuel pump lock nut may result in
fuel leakage.
NOTE
Without installation of lock nut, threaded
portion of the tank may swell and this
swelling causes difficulty of the nut
after removal of fuel pump assembly. In spite
of that, time taken in removal and
reinstallation of fuel pump should be within
12 min.

Removal
1) Remove fuel tank from vehicle. )(Page 1G-48)
I8G001170030-01
2) Remove fuel pump cover bolts (1) from fuel tank (2).
2) Check that fuel pressure is felt at fuel feed hose (1)
for about 20 seconds after setting ignition “ON”. 1
If fuel pressure is not felt, check fuel line for fuel 2
leakage and clogging.

IAY40A170022-01

3) Remove fuel pump assembly (1) from fuel tank (2).

 Fuel System: D13A 1G-52

1
2

2 IAY40A170025-01

6) Install fuel tank to vehicle.“Fuel Tank Removal and

Installation”: D13A (Page 1G-48)

Fuel Pump Inspection

AENBL80A1726024
• Check fuel pump assembly for damage.
• Check fuel suction filter for evidence of dirt and
IAY40A170023-01
contamination. If check result is not OK, clean and
check for presence of dirt in fuel tank.
Installation
1) Clean mating surfaces of fuel pump assembly (1)
Fuel Level Sensor Inspection
and fuel tank. AENBL80A1726025
2) Install fuel pump assembly (2) to fuel tank (3). Check resistance between terminals “3” and “4” at each
float position indicated below.
3) Install new fuel pump cover O-ring (4) to fuel pump.
If check result is not as specified, replace fuel pump.
4) Install fuel pump cover bolts (5) and tighten as per
the torque. Fuel level sensor specifications
Float position Resistance (Ω)
Tightening torque
“a” 105.9 mm 105.9
Fuel pump cover bolt (a): 10 N·m (1.0 kgf-m, 7.3
“b” 56.7 mm 158.0 – 162.0
lbf-ft)
“c” 16.3 mm 264.0 – 269.4
5

3 4

1
1

“a”

2 “b”

IAY40A170024-01 “c”

5) Connect fuel feed pipe (1) and return pipe (2) to fuel I9P60A172037-02
pump assembly (3).
1. Fuel pump 2. Float

Fuel Filter Element Removal and Installation

AENBL80A1726026
1G-53 Fuel System: D13A

! WARNING

• Before starting the following procedure, be

sure to observe “Precautions for Fuel
System Service”: D13A (Page 1G-25) in
order to reduce the risk of fire and
personal injury.
• This work must be performed in a well-
1
ventilated area and away from any open
flames (such as gas hot water heaters).

Removal IBL80A172015-02

1) Disconnect negative (–) cable at battery. 9) By turning fuel filter fastener (1) counterclockwise,
2) Remove ECM. )(Page 1C-14) remove fuel filter fastener (1) from fuel filter case (4)
using special tool and vise (5).
3) Remove cowl top panel. )(Page 9H-3)
4) Place container under drain screw (1), and drain out Special tool
fuel by loosening drain screw. (A): 09919M48610
10) Remove fuel filter cap (2) and fuel filter element (3).

(A)

1
1

5
IBL80A172018-01

5) Disconnect fuel filter joints (1) from fuel filter

assembly (2). )(Page 1G-34)
6) Disconnect fuel temperature sensor connector (3)
from fuel filter assembly.
7) Release connector lock pin (4) and disconnect 1
connector (5) from water detection sensor in fuel
filter assembly.

1 2

2
4
IBL80A172019-01
1
Installation
5 Reverse removal procedure noting the following points.
• Clean fuel filter case as follows.
4
IBP80A172034-02
a. Place container under drain screw, and drain out
fuel by loosening drain screw.
8) Remove fuel filter assembly (1).
b. Tighten drain screw.
c. Clean fuel filter case with brush.
d. Dry and wipe out fuel filter case.
• Replace fuel filter element and O-ring with new ones.
 Fuel System: D13A 1G-54

• Tighten fuel filter fastener (1) to specified torque using Installation

special tool and vise (2). Reverse removal procedure.
Special tool
(A): 09919M48610 Fuel Temperature Sensor Inspection
AENBL80A1726029
Tightening torque 1) Remove fuel temperature sensor. )(Page 1G-54)
Fuel filter fastener (a): 30 N·m (3.1 kgf-m, 22.5 lbf- 2) Check resistance between fuel temperature sensor
ft) terminals.
If check result is not as specified, replace fuel filter
assembly.
Fuel temperature sensor resistance
Fuel temperature °C (°F) Resistance (kΩ)
–30 (–22) 23.5 – 28.6
0 (32) 5.46 – 6.32
(A) 25 (77) 1.94 – 2.17
60 (140) 0.57 – 0.61
1, (a) 100 (212) 0.18 – 0.19
115 (239) 0.12 – 0.13
2

IBL80A172020-01

• Install cowl top panel. )(Page 9H-3)

• Install ECM referring to “ECM Removal and
Installation”: D13A in Section 1C (Page 1C-14).
• Bleed fuel system of air. )(Page 1G-37) I9P60A172039-01

• Check for fuel leakage. )(Page 1G-37)

Fuel Filter Water Detection Sensor Inspection
AENBL80A1726030
Fuel Filter Assembly Removal and Installation
AENBL80A1726027 1) Connect battery and voltmeter to connector (1) of
! WARNING water detection sensor on fuel filter assembly as
shown in figure.
Before starting the following procedure, be
2) Check voltage between terminal (2) and battery
sure to observe “Precautions for Fuel
negative (–) terminal.
System Service”: D13A (Page 1G-25) in order
to reduce the risk of fire and personal injury.

Removal
1) Remove fuel filter assembly in the same manner as
Steps 1) through 8) of “Removal” under “Fuel Filter
Element Removal and Installation”: D13A (Page 1G-
52).

Installation 2 1
Reverse removal procedure noting the following points.
• Bleed fuel in system of air. )(Page 1G-37)
• Check for fuel leakage. )(Page 1G-37)

Fuel Temperature Sensor Removal and IBP80A172038-01

Installation If the voltage is not normal, drain water. )(Page 1G-

AENBL80A1726028
Removal 37)
Remove fuel temperature sensor (included in fuel filter Fuel filter water detection sensor voltage
cap). )(Page 1G-52) Normal voltage: 12 V (Battery voltage)
Alarm condition (trapped water exceeds limit):
Lower than above voltage
1G-55 Fuel System: D13A

Specifications
Tightening Torque Specifications
AENBL80A1727001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Drain screw 1.5 0.15 1.5 )
High pressure pipe union nut (fuel injector side )
24 2.4 18.0
and high pressure pump side)
High pressure pipe union nut (common rail side) 28 2.9 21.0 )
Fuel injector bracket nut 20 2.0 15.0 )
Common rail bolt 25 2.5 18.0 )
High pressure pump bolt 15 1.5 11.0 )
Fuel pressure sensor 70 7.1 52.0 )
Fuel tank bolt 45 4.6 33.5 )
Fuel filler hose clamp bolt 1.5 0.15 1.5 )
Fuel pump cover bolt 10 1.0 7.3 )
Fuel filter fastener 30 3.1 22.5 )

NOTE
The tightening torque(s) also specified in:
“Fuel Hose Disconnecting and Reconnecting”: D13A
“Fuel System Components”: D13A

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Special Tool
AENBL80A1728001
09911M75420 09912M58310
Crowfoot flare-nut wrench Remover (fuel line)
18.17) / ) (KM-796-A))

09912M58432 09912M96540
Fuel pressure gauge hose Injector flow measuring kit
This tool is included in fuel Mot. 1711)
pressure gauge set (09912-
58413).) / )

09914M08410 09919M46310
Gauge, diesel fuel pressure Fuel system, plug set
)/) )
 Fuel System: D13A 1G-56

09919M48410 09919M48610
Fuel pressure gauge Fuel filter locking tool
adapter set
)/) (EN-46784)) / )

09950M76510 SUZUKI scan tool (SUZUKI- 6

SDT)
Pipe spanner — 1 2
OUT0000148) / ) This kit includes following
4
items. 1. SUZUKI-SDT 2. 3
DLC cable 3. USB cable 4. 5
AC/DC power supply 5.
Voltage meter probe 6.
Storage case)
1H-1 Ignition System:

Ignition System
Engine

General Description
Ignition System Construction
AENBL80A1801001
The ignition system is of an electronic ignition type which consists of the following components.
• ECM
It monitors the engine and vehicle conditions through the signals from the sensors, determines the most suitable
ignition timing and duration and sends a signal to the ignition coil assembly.
• Ignition coil assembly
One ignition coil assembly is provided for each cylinder.
The ignition coil assembly turns ON and OFF the current to the primary coil according to the signal from ECM.
When the current flow to the primary coil is turned OFF, a high voltage is induced in the secondary coil.
• Spark plugs
• CMP sensor and CKP sensor
Using signals from these sensors, ECM identifies the specific cylinder whose piston is in the compression stroke,
detects the crank angle and adjusts initial ignition timing automatically.
• TP sensor, ECT sensor, MAP sensor, IAT sensor, knock sensor and other sensors / switches
Using signals from these sensors / switches, the ECM corrects the initial ignition timing and sets the optimum timing
according to the engine conditions.
 Ignition System: 1H-2

Schematic and Routing Diagram

Ignition System Circuit Diagram
AENBL80A1802001

A1
A2 6
BLK/WHT 7 14
B1
B2 10
5V
11 C1 5V
GRN/YEL C01-4
C2
GRN/WHT C01-17
A3
A4 8
BLK/WHT 9 B3
B4 12
5V
13 C3 5V
BRN C01-5
C4
LT GRN C01-6
15
BLK/WHT E01-5
2 3
16
BLK BLK/YEL BRN/WHT E01-54

12V
WHT BLK/YEL BLK/RED E01-56
5V
BLK/RED E01-55
5V
1 4
RED/YEL C01-8

C01-50 BLK
5V
C01-51 BLK
5
PNK C01-9
C01-53 BLK

GRY

[A] C01 E01

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

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

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

IBP80A180001-02

[A]: ECM connector (View: [a]) 4. CMP sensor 11. Spark plug No.2
A1 – A4: Ignition coil assembly power supply circuits 5. CKP sensor 12. Spark plug No.3
B1 – B4: Ignition coil assembly drive circuits 6. Ignition coil assembly No.1 13. Spark plug No.4
C1 – C4: Ignition coil assembly ground circuits 7. Ignition coil assembly No.2 14. ECM
1. Main fuse box 8. Ignition coil assembly No.3 15. “IG COIL” fuse
2. Ignition switch 9. Ignition coil assembly No.4 16. “FI” fuse
3. Main relay 10. Spark plug No.1
1H-3 Ignition System:

Component Location
Ignition System Component Location
AENBL80A1803001

3
4

5 6 7 8
IBL80A180001-01

1: ECM 4. DLC 7. Ignition coil assembly No.3

2: Knock sensor 5. Ignition coil assembly No.1 8. Ignition coil assembly No.4
3. CKP sensor 6. Ignition coil assembly No.2 9. CMP sensor
 Ignition System: 1H-4

Diagnostic Information and Procedures

Ignition System Check
AENBL80A1804001
Circuit Diagram

A1
A2 6
BLK/WHT 7 14
B1
B2 10
5V
11 C1 5V
GRN/YEL C01-4
C2
GRN/WHT C01-17
A3
A4 8
BLK/WHT 9 B3
B4 12
5V
13 C3 5V
BRN C01-5
C4
LT GRN C01-6
15
BLK/WHT E01-5
2 3
16
BLK BLK/YEL BRN/WHT E01-54

12V
WHT BLK/YEL BLK/RED E01-56
5V
BLK/RED E01-55
5V
1 4
RED/YEL C01-8

C01-50 BLK
5V
C01-51 BLK
5
PNK C01-9
C01-53 BLK

GRY

[A] C01 E01

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

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

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

IBP80A180003-01

[A]: ECM connector (View: [a]) 4. CMP sensor 11. Spark plug No.2
A1 – A4: Ignition coil assembly power supply circuits 5. CKP sensor 12. Spark plug No.3
B1 – B4: Ignition coil assembly drive circuits 6. Ignition coil assembly No.1 13. Spark plug No.4
C1 – C4: Ignition coil assembly ground circuits 7. Ignition coil assembly No.2 14. ECM
1. Main fuse box 8. Ignition coil assembly No.3 15. “IG COIL” fuse
2. Ignition switch 9. Ignition coil assembly No.4 16. “FI” fuse
3. Main relay 10. Spark plug No.1
1H-5 Ignition System:

Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”: K14B in
Section 1A (Page 1A-
15).
2 Ignition spark test 1 Go to Step 3. Go to Step 4.
1) Perform ignition spark test. )(Page 1H-6)

Is test result OK?

3 Ignition timing check Ignition system is in Repair or replace
1) Check ignition timing. )(Page 1H-7) good condition. defective part.

Is check result OK?

4 Confirmation of malfunctioning cylinder Go to Step 7. Go to Step 5.
1) Confirm cylinder(s) that failed in ignition spark test.

Are all cylinders?

5 Ignition spark test 2 Replace spark plug. Go to Step 6.
1) Replace spark plug of each malfunctioning cylinder with )(Page 1H-6)
normal cylinder’s one.
2) Perform ignition spark test. )(Page 1H-6)

Is test result OK?

6 Ignition spark test 3 Replace ignition coil. Go to Step 7.
1) Replace ignition coil of each malfunctioning cylinder with )(Page 1H-7)
normal cylinder’s one.
2) Perform ignition spark test. )(Page 1H-6)

Is test result OK?

7 Ignition coil assembly power supply and ground circuits Go to Step 8. Repair or replace
check defective part.
1) Check power supply (A1, A2, A3 and A4) and ground
(C1, C2, C3 and C4) circuits of each ignition coil
assembly for open, short and poor connection.

Are check results OK?

8 Ignition coil assembly drive circuits check Go to Step 9. Repair or replace
1) When ignition is “OFF”, check the following points. defective part.
• Resistance of “B1”, “B2”, “B3” and “B4” circuits: less
than 1 Ω
• Resistance between each of “B1”, “B2”, “B3” and “B4”
circuits and ground: infinity
• Resistance between “B1” circuit terminal and other
terminal at Ignition coil connector: infinity
• Resistance between “B2” circuit terminal and other
terminal at Ignition coil connector: infinity
• Resistance between “B3” circuit terminal and other
terminal at Ignition coil connector: infinity
• Resistance between “B4” circuit terminal and other
terminal at Ignition coil connector: infinity
• Voltage of “B1”, “B2”, “B3” and “B4” circuits: approx. 0
V (When ignition is “ON”)

Are check results OK?

 Ignition System: 1H-6

Step Action Yes No

9 CKP sensor and CMP sensor check Replace ECM and Replace CKP sensor or
1) Check CKP sensor and CMP sensor. recheck ignition spark. CMP sensor.
)(Page 1C-1)
• CKP sensor: )(Page 1C-8)
• CMP sensor: )(Page 1C-8)

Is check result OK?

Ignition Spark Test

AENBL80A1804002
1) Remove air cleaner assembly )(Page 1D-5)
2) Disconnect all injector connectors from injectors.

! WARNING
Without disconnection of injector connectors, combustible gas may come out from spark plug holes
during this test and may get ignited in engine room.

3) Remove spark plugs. )(Page 1H-6)

4) Inspect spark plugs. )(Page 1H-6)
5) Disconnect all injector connectors.
6) Connect ignition coil connector (1) to ignition coil assembly (3).
7) Connect spark plug (2) to ignition coil assembly, and ground spark plug.

3 2
I9P60A180004-01

8) Crank engine and check if each spark plug sparks.

9) If no spark is emitted, inspect the related parts. )(Page 1H-4)

Repair Instructions
Spark Plug Removal and Installation 2) Install ignition coil assemblies. )(Page 1H-7)
AENBL80A1806001
Removal
Spark Plug Inspection
1) Remove ignition coil assemblies. )(Page 1H-7) AENBL80A1806002
2) Remove spark plugs. Inspect spark plug for:
• Electrode wear
Installation • Carbon deposits
1) Install spark plugs and tighten them to specified • Insulator damage
torque. If any abnormality is found, adjust air gap, clean with
Tightening torque spark plug cleaner or replace it with new plug.
Spark plug: 18 N·m (1.8 kgf-m, 13.5 lbf-ft)
1H-7 Ignition System:

Spark plug air gap “a” Ignition Timing Inspection

: 0.95 to 1.05 mm (0.037 to 0.041 in.) AENBL80A1806005
NOTE
Spark plug type
NGK: Nickel KR6A-10 • Ignition timing is not adjustable. If ignition
timing is not as specified, check
components related to ignition system.
“a” • Before starting engine, place transmission
gear shift lever in neutral and set parking
brake.
• For identification of each cylinder, refer to
“Statement on Cleanliness and Care”:
K14B in Section 1A (Page 1A-1).

1) Connect scan tool to DLC (1) with ignition “OFF”.

Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)

I8T401182005-01

Ignition Coil Assembly Removal and Installation

AENBL80A1806003
Removal
1) Disconnect negative (–) cable at battery. (A)
2) Remove air cleaner assembly. )(Page 1D-5)
3) Disconnect ignition coil connectors. 1
4) Remove ignition coil bolts (1) and then pull out
ignition coil assemblies (2).

IAP70P180002-01

2) Start engine and warm it up to normal operating

temperature.
3) Make sure that all electrical loads except ignition
system are switched off.
4) Check that idle speed is within specification referring
to “Idle Speed and IAC Throttle Valve Opening
Inspection”: K14B in Section 1A (Page 1A-122).
2 5) Check ignition timing as following step.
I7V20A180004-01 If either of check result is out of specification, check
the following points.
Installation
• CKP sensor
Reverse removal procedure noting following point.
• CKP sensor plate
• Tighten ignition coil bolt to specified torque.
• ECM and its circuit
Tightening torque
• CMP sensor
Ignition coil bolt: 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
• CMP sensor rotor tooth of camshaft
Ignition Coil Assembly Inspection • Crankshaft
AENBL80A1806004 • Crankshaft pulley
Check ignition coil assembly for the following points:
• Crankshaft pulley key
• Damage
a) Check that ignition timing is within specification
• Deterioration using SUZUKI scan tool.
• Corrosion on terminals b) Set timing light (1) to ignition coil harness for
If check result is not OK, replace ignition coil assembly. No.1 cylinder and check that ignition timing is
within specification.
 Ignition System: 1H-8

Ignition timing 6) With engine idling, check that increasing engine

: 5° ± 3° BTDC (at specified idle speed) speed advances ignition timing.
If the check result is not satisfactory, check the
Ignition order
following points.
1–3–4–2
• ECM and its circuit: )(Page 1A-109)
Special tool
• TP sensor: )(Page 1C-2)
(A): 09930M76420
• APP sensor: )(Page 1C-4)
1, (A)

I7V20A180007-01

Specifications
Tightening Torque Specifications
AENBL80A1807001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Spark plug 18 1.8 13.5 )
Ignition coil bolt 11 1.1 8.5 )

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Special Tool
AENBL80A1808001
09930M76420 SUZUKI scan tool (SUZUKI- 6
SDT)
Timing-light (dry cell type) — 1 2
) This kit includes following
4
items. 1. SUZUKI-SDT 2. 3
DLC cable 3. USB cable 4. 5
AC/DC power supply 5.
Voltage meter probe 6.
Storage case)
1I-1 Starting System: K14B

Starting System
Engine

K14B
Schematic and Routing Diagram
Cranking System Circuit Diagram
AENBL80A1912001

IBL80A191001-01

1. Pinion drive lever 5. Plunger 9. Starting motor control relay

2. Pinion & over-running clutch 6. Magnetic switch contacts 10. Ignition & starter switch
3. Magnetic switch 7. Pull-in coil 11. Battery
4. Hold-in coil 8. Starting motor 12. To ECM

Diagnostic Information and Procedures

Cranking System Symptom Diagnosis
AENBL80A1914001
Possible symptoms due to starting system trouble would be as follows:
• Starting motor does not run (or runs slowly)
• Starting motor runs but fails to crank engine
• Abnormal noise is heard
Proper diagnosis must be made to determine exactly where the cause of each trouble lies in battery, wiring harness,
(including starting motor switch), starting motor or engine.
Do not remove motor just because starting motor does not run. Check the following items and narrow down scope of
possible causes.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine side) and starting motor terminals
3) Discharge of battery
4) Mounting of starting motor
 Starting System: K14B 1I-2

Condition Possible cause Correction / Reference Item

Motor not running (No Battery run down Recharge battery.
operating sound of Battery voltage too low due to battery Replace battery.
magnetic switch) deterioration
Poor contact in battery terminal Retighten or replace.
connection
Loose grounding cable connection Retighten.
Fuse set loose or blown off Tighten or replace.
Poor contacting action of ignition switch Replace.
and magnetic switch
Lead wire coupler loose in place Retighten.
Open-circuit between ignition switch and Repair.
magnetic switch
Open-circuit in pull-in coil Replace magnetic switch.
Brushes are seating poorly or worn Repair or replace.
down
Poor sliding of plunger and/or pinion Repair.
Faulty starting motor control relay “Control Relay Inspection” in Section 10B
(Page 10B-30).
Faulty ECM and its circuit
Motor not running Battery run down Recharge battery.
(Operating sound of Battery voltage too low due to battery Replace battery.
magnetic switch heard) deterioration
Loose battery cable connections Retighten.
Burnt main contact point, or poor Replace magnetic switch.
contacting action of magnetic switch
Brushes are seating poorly or worn Repair or replace.
down
Weakened brush spring Replace.
Burnt commutator Replace armature.
Layer short-circuit of armature Replace.
Crankshaft rotation obstructed Repair.
Starting motor running Insufficient contact of magnetic switch Replace magnetic switch.
but too slow (small main contacts
torque) (If battery and Layer short-circuit of armature Replace.
wiring are satisfactory, Disconnected, burnt or worn Repair commutator or replace armature.
inspect starting motor) commutator
Worn brushes Replace brush.
Weakened brush springs Replace spring.
Burnt or abnormally worn end bush Replace bush.
Starting motor running, Worn pinion tip Replace over-running clutch.
but not cranking engine Poor sliding of over-running clutch Repair.
Over-running clutch slipping Replace over-running clutch.
Worn teeth of ring gear Replace flywheel.
Noise Abnormally worn bush Replace bush.
Worn pinion or worn teeth of ring gear Replace over-running clutch, flywheel.
Poor sliding of pinion (failure in return Repair or replace.
movement)
Worn internal or planetary gear teeth Replace.
Lack of oil in each part Lubricate.
Starting motor does not Fused contact points of magnetic switch Replace magnetic switch.
stop running Short-circuit between turns of magnetic Replace magnetic switch.
switch coil (layer short-circuit)
Failure of returning action in ignition Replace.
switch
1I-3 Starting System: K14B

Cranking System Test

AENBL80A1914002
! CAUTION
Each test must be performed within 3 – 5
seconds to avoid coil from burning.

Pull-In Test

NOTE
Before testing, disconnect lead wire (3) from
terminal “M” (2).
I2RH01190004-01

Connect battery to the magnetic switch as shown.

No-Load Performance Test
Check that plunger and pinion move outward.
Connect battery and ammeter to starter as shown.
If plunger and pinion don’t move, replace the magnetic
Check that starter rotates smoothly and steadily with
switch.
pinion moving out. Check that ammeter indicates
specified current.
Specified current (No-load performance test)
70 A MAX. at 11 V

I2RH01190002-01
I6RW0B190001-01
1. Terminal “S”

Hold-In Test
While connected as the figure with plunger out,
disconnect negative lead from terminal “M”.
Check that plunger and pinion remain out.
If plunger and pinion return inward, replace the magnetic
switch.

I2RH01190003-01

Plunger and Pinion Return Test

Disconnect negative lead from starting motor body.
Check that plunger and pinion return inward.
If plunger and pinion don’t return, replace the magnetic
switch.
 Starting System: K14B 1I-4

Repair Instructions
Starting Motor Components
AENBL80A1916001

13

11

12 4 8

5 1

10

I9Y40A190001-02

1. Yoke assembly :5. Washer 9. Stud 13. Starting motor battery cable nut
2. Rear bracket 6. Magnetic switch 10. Armature : Tightening torque
assembly
3. Gear Shaft 7. Front bracket 11. Plunger : Do not reuse.
assembly
4. Lever 8. Screw 12. Gear : Apply grease 99000-25011 to
sliding surface of each part.

Starting Motor Removal and Installation

AENBL80A1916002
Removal
1) Disconnect negative (–) battery lead at battery.
2) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals.
3) Detach gear shift control cable bracket.
4) Remove starting motor mount bolt (3).
5) Remove starting motor (4).

Installation
Reverse the removal procedure.
Tightening torque
Starting motor battery cable nut (a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
Starting motor bolt (b): 50 N·m (5.0 kgf-m, 36.0 lbf-ft)
1I-5 Starting System: K14B

IBL80A191003-01

Starting Motor Inspection

AENBL80A1916003

Plunger
Inspect plunger for wear. Replace if necessary.

I2RH01190010-01

Hold-in coil open circuit test

Check for continuity across magnetic switch “S” terminal
(1) and coil case. If no continuity, coil is open and should
be replaced.
I2RH01190008-01

Magnetic Switch
Push in plunger and release it. The plunger should
return quickly to its original position. Replace if
necessary.

I2RH01190011-01

Rear Bracket Bush

Inspect bush for wear or damage. Replace if necessary.

I2RH01190009-01

Pull-in coil open circuit test

Check for continuity across magnetic switch “S” terminal
(1) and “M” terminal (2). If no continuity, coil is open and
should be replaced.

I2RH01190012-01
 Starting System: K14B 1I-6

Brush
• Check brushes for wear.
Measure length of brushes and if below the limit,
replace the brush.
Brush length
Standard: 12.4 mm (0.488 in.)
Limit: 6.0 mm (0.24 in.)

I6RW0B190005-01

1. Sandpaper of #300 – 400

• Check commutator for uneven wear with armature (1)

supported on V-blocks (2). If deflection of dial gauge
(4) pointer exceeds limit, repair or replace.

NOTE
I2RH01190013-01 The following specification presupposes that
• Install brushes to each brush holder and check for the armature is free from bend. Bent
smooth movement. armature must be replaced.

Spring Commutator out of round

Inspect brush springs for wear, damage or other Standard: 0.05 mm (0.002 in.) or less
abnormal conditions. Replace if necessary. Limit: 0.1 mm (0.004 in.)

Brush spring tension

Standard: 17.5 N (1.78 kgf)
Limit: 14 N (1.43 kgf)

Brush Holder
• Check movement of brush in brush holder. If brush
movement within brush holder is sluggish, check
brush holder for distortion and sliding faces for
contamination.
Clean or correct as necessary.
• Check for continuity across insulated brush holder I2RH01190016-01
(positive side) and grounded brush holder (negative
3. Magnetic stand
side).
If continuity exists, brush holder is grounded due to
• Inspect the commutator for wear. If diameter is below
defective insulation and should be replaced.
limit, replace the armature.
Commutator outside diameter
Standard: 29.4 mm (1.16 in.)
Limit 27.4 mm (1.08 in.)

I6RW0B190004-01

Armature
• Inspect commutator for dirt or burn. Correct with
sandpaper or lathe, if necessary. I2RH01190017-01

• Inspect the commutator (1) for insulator (2) depth.

Correct or replace if below limit.
1I-7 Starting System: K14B

Commutator insulator depth “a”

Standard: 1.5 mm (0.06 in.)
Limit: 0.5 mm (0.02 in.)

I2RH01190021-01

Pinion and Over-Running Clutch

• Inspect the pinion for wear, damage or other abnormal
conditions.
Check that clutch locks up when turned in direction of
drive and rotates smoothly in reverse direction.
Replace if necessary.

I3RH0A190005-01

[A]: Correct
[B]: Incorrect

• Check the commutator and armature core. If there is

continuity, the armature is grounded and must be
replaced.

I2RH01190022-01

• Inspect the spline teeth for wear or damage. Replace

if necessary.
Inspect the pinion for smooth movement.

I2RH01190019-01

• Check for continuity between segments. If there is no

continuity at any test point, there is an open circuit
and the armature must be replaced. I2RH01190023-01

Front Housing Needle Bearing or Bush

Inspect the needle bearing for wear or damage. Replace
if necessary.

I2RH01190020-01

Gears
Inspect the internal gear and the planetary gears for
wear, damage or other abnormal conditions. Replace if I2RH01190024-01
necessary.
 Starting System: K14B 1I-8

Specifications
Cranking System Specifications
AENBL80A1917001
Voltage 12 volts
Output 1.2 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Brush length Standard: 12.4 mm (0.49 in.) Limit: 6.0 mm (0.24 in.)
Number of pinion teeth 8
Performance Condition Guarantee
70 A maximum
No load characteristic 11.0 V
2,400 rpm minimum
7.5 V 9.3 N⋅m (0.95 kgf-m, 6.9 lbf-ft) minimum
Around at 20 °C Load characteristic
300 A 1,000 rpm minimum
(68 °F)
700 A maximum
Locked characteristic 4.0 V
20.6 N⋅m (2.1 kgf-m, 15.2 lbf-ft) minimum
Magnetic switch operating voltage 8 volts maximum

Tightening Torque Specifications

AENBL80A1917002
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Starting motor battery cable nut 11 1.1 8.0 )
Starting motor bolt 50 5.0 36.0 )

NOTE
The tightening torque(s) also specified in:
“Starting Motor Components”: K14B

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Recommended Service Material
AENBL80A1918001
NOTE
Required service material(s) also described in:
“Starting Motor Components”: K14B
1I-9 Starting System: D13A

D13A
General Description
Cranking System Description
AENBL80A1921001
Cranking Circuit
The cranking circuit consists of the battery, starting motor, starting motor control relay, ignition switch and related
electrical wiring.

Starting Motor Circuit

In the circuit shown in “Cranking System Circuit Diagram”: D13A (Page 1I-9), the coil of the magnetic switch in starting
motor is energized when the ignition switch is turned to “START” position. The resulting movement of the plunger and
pinion drive lever causes the pinion to engage with the engine flywheel gear while closing the contacts of the magnetic
switch. This causes the starting motor to rotate to crank the engine.
When the engine starts, the pinion overrunning clutch protects the armature from excessive speed until the switch is
opened, at which time the return spring causes the pinion to disengage.

Schematic and Routing Diagram

Cranking System Circuit Diagram
AENBL80A1922001

8
6 7
BRN RED/WHT BLK
WHT/BLU
4
WHT RED
5

BLK
BLK
YEL

3
2

1
M

IBP80A192001-01

1. Battery 3. Starting motor 5. “IG2 SIG” fuse 7. “ST SIG” fuse

2. Main fuse box 4. “ST MOT” fuse 6. Ignition switch 8. Starting motor control relay

Diagnostic Information and Procedures

Cranking System Symptom Diagnosis
AENBL80A1924001
Possible symptoms of starting system trouble are as follows:
• Starting motor does not run (or runs slowly).
• Starting motor runs but fails to crank engine.
• Abnormal noise is heard.
• Starting motor does not stop running.
Proper diagnosis must be made to determine in which of the battery, wiring harness, starting motor (including
magnetic switch) and engine the cause of each trouble lies.
Before removing the starting motor, check the following items to identify most possible causes of trouble.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine) and starting motor terminals
 Starting System: D13A 1I-10

3) Discharge of battery
4) Mounting of starting motor
Condition Possible cause Correction / Reference Item
Starting motor not Battery voltage is too low Check battery. )(Page 1J-23)
running (No operating Impossible charging due to deteriorated Replace battery. )(Page 1J-25)
sound of magnetic battery
switch) Poor battery terminal connection Check terminal connection or replace battery.
)(Page 1J-25)
Poor ground cable connection Tighten ground cable.
Blown fuse Replace fuse and check its circuit.
Faulty magnetic switch Check magnetic switch. )(Page 1I-18)
Poor magnetic switch lead wire Check connector connection. )(Page 1I-11)
connector connection
Open-circuit in pull-in coil Check pull-in coil circuit. )(Page 1I-18)
Poor sliding of plunger and/or pinion Check plunger and pinion. )(Page 1I-18)
Faulty starting motor control relay Check starting motor control relay. )(Page 1I-
11)
Faulty ignition switch Check ignition switch. )(Page 6B-12)
Starting motor not Battery voltage is too low Check battery. )(Page 1J-23)
running (Operating sound Impossible charging due to deteriorated Replace battery. )(Page 1J-25)
of magnetic switch heard) battery
Poor battery terminal connection Check terminal connection or replace battery.
)(Page 1J-25)
Poor ground terminal connection Tighten ground cable.
Defective magnetic switch Check magnetic switch. )(Page 1I-18)
Defective brushes and/or brush springs Check brushes and brush springs. )(Page 1I-
18)
Faulty brush holder Check brush holder. )(Page 1I-18)
Burnt commutator Check commutator. )(Page 1I-18)
Short-circuit between commutator and Check commutator. )(Page 1I-18)
armature
Poor starting motor cable connection Check starting motor cable connection.
)(Page 1I-11)
Open circuit between battery and Repair circuit.
magnetic switch
Obstructed crankshaft rotation Repair engine assembly.
Starting motor running Faulty magnetic switch Check magnetic switch. )(Page 1I-18)
but too slowly (small Low battery voltage Check battery. )(Page 1J-23)
torque) Impossible charging due to deteriorated Replace battery. )(Page 1J-25)
battery
Poor battery terminal connection Check terminal connection or replace battery.
)(Page 1J-25)
Short-circuit between commutator and Check commutator. )(Page 1I-18)
armature
Burnt commutator Check commutator. )(Page 1I-18)
Defective brushes and/or brush springs Check brushes and brush springs. )(Page 1I-
18)
Defective brush holder Check brush holder. )(Page 1I-18)
Defective rear bracket bushing Check rear bracket bushing. )(Page 1I-18)
Starting motor running, Worn pinion tip Replace overrunning clutch. )(Page 1I-14)
but not cranking engine Poor sliding of overrunning clutch Replace overrunning clutch. )(Page 1I-14)
Slipping overrunning clutch Replace overrunning clutch. )(Page 1I-14)
Worn teeth of ring gear Replace flywheel. )(Page 1D-82)
Noise Abnormally worn bushing Replace starter housing or rear bracket.
)(Page 1I-14)
Worn teeth of pinion Replace overrunning clutch. )(Page 1I-14)
Worn teeth of ring gear Replace flywheel. )(Page 1D-82)
1I-11 Starting System: D13A

Condition Possible cause Correction / Reference Item

Starting motor does not Faulty magnetic switch Check magnetic switch. )(Page 1I-18)
stop running Faulty ignition switch Check ignition switch. )(Page 6B-12)
Faulty starting motor control relay Check starting motor control relay. )(Page 1I-
11)

Repair Instructions
Starting Motor Control Relay Inspection
AENBL80A1926001
Refer to “Control Relay Inspection” in Section 10B (Page 10B-30).

Starting Motor Removal and Installation

AENBL80A1926002
Removal
1) Remove battery and battery tray. )(Page 1J-25)
2) Remove gear shift and select control cable bracket (1).

IBP80A192032-01

3) Remove plug (1) from transaxle.

4) Remove starting motor mounting upper bolt (2) from starting motor.
5) Disconnect magnetic switch lead wire (3) and starting motor cable (4) from starting motor terminals.
6) Remove starting motor mounting lower bolt (5) from starting motor.
7) Remove starting motor (6).
 Starting System: D13A 1I-12

1 2

4
IBP80A192002-01

Installation
Reverse removal procedure noting the following points.
• Tighten starting motor mounting bolts (1), magnetic switch lead wire nut (2) and starting motor cable nut (3) to
specified torques.
Tightening torque
Starting motor mount bolt (a): 25 N·m (2.5 kgf-m, 18.0 lbf-ft)
Magnetic switch lead wire nut (b): 5.8 N·m (0.58 kgf-m, 4.5 lbf-ft)
Starting motor cable nut (c): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
1I-13 Starting System: D13A

1,(a)

1,(a) 2,(b)
3,(c)
IBP80A192003-01
 Starting System: D13A 1I-14

Starting Motor Components

AENBL80A1926003

(a) 15

14

13
12

11

10

9 8 A

7 A

6 A

(c) 2
1
(b)

5 A
4

18

17

16

A
IBP80A192004-03

1. Starter housing 9. Plate 17. Yoke

2. Seal rubber
3. Snap ring
4. Pinion stop ring
5. Overrunning clutch
6. Internal gear
7. Gear shaft
8. Planetary gear
10. Drive lever 18. Rear bracket assembly
11. Plunger : 8.0 N⋅m (0.82 kgf-m, 6.0 lbf-ft)
12. Cover disc : 7.0 N⋅m (0.71 kgf-m, 5.5 lbf-ft)
13. Boot : 7.3 N⋅m (0.74 kgf-m, 5.5 lbf-ft)
14. Return spring : Do not reuse.
15. Magnetic switch : Apply grease 99000-25011 to sliding surface of each part.
16. Armature
1I-15 Starting System: D13A

Starting Motor Disassembly and Reassembly 4) Remove seal rubber (1) from starter housing (2).
AENBL80A1926004

Disassembly
1) Remove nut (1) and disconnect lead wire (2) from
magnetic switch (3).
2
3 1

IBP80A192008-01

5) Remove gear shaft assembly (1) together with drive

lever assembly (2) from starter housing (3).

2
3

IBP80A192005-01
1
2) Remove bolts (1), and then remove magnetic switch
(2), boot (3), cover disc (4) and return spring (5).

IBP80A192011-01

2 6) Separate plunger (1) from drive lever turning it in

arrow direction.

5
4
3

IBP80A192006-01 IBP80A192009-01

3) Remove bolts (1), and then separate yoke (2) from 7) Remove planetary gears (1).
starter housing (3).

3
2

IBP80A192007-01
 Starting System: D13A 1I-16

2
IBP80A192012-01

1
Reassembly
I9P60A191027-01 1) Assemble armature (1), yoke (2) and rear bracket
8) With pinion stop ring (3) moved to overrunning clutch assembly (3).
(4) side indicated by arrow, remove snap ring (2) by
using snap ring pliers (5).
9) Remove pinion stop ring (3), overrunning clutch (4)
and internal gear (1) from gear shaft.

2
IBP80A192012-01
I8C50B190012-01
2) Install plate (1) to yoke (2).
10) Remove plate (1) from yoke (2).
2 1
2 1

IBP80A192013-01
IBP80A192010-01
3) Apply grease to spline of gear shaft (1), spline of
11) Separate armature (1) and yoke (2) from rear
overrunning clutch (2) and teeth of internal gear (3).
bracket assembly (3).
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)

IBP80A192014-02
1I-17 Starting System: D13A

4) Fit internal gear (1), overrunning clutch (2), new

pinion stop ring (3) and new snap ring (5) to gear
shaft (4) in order. Fix stop ring over snap ring using 2
3
special tool.
1
NOTE
Install pinion stop ring in the direction and
position as shown in figure.

Special tool
(A): 09913M66710 IBP80A192011-01

8) Install seal rubber (1) to starter housing (2).

2
1

IBP80A192008-01

9) Install yoke (2) to starter housing (3), and then

tighten rear bracket bolts (1) to specified torque.
Tightening torque
Rear bracket bolt (a): 7.3 N·m (0.74 kgf-m, 5.5
lbf-ft)

IBP80A192017-01

5) Apply grease to planetary gears (1) and internal gear 3

(2), and assemble them. 2

“A”: Grease 99000–25011 (SUZUKI Super

Grease A) 1, (a)

1, (a)
“A” IBP80A192020-01

10) Install return spring (1), cover disc (2), boot (3) and
magnetic switch (4) to starter housing (5).

NOTE
When installing Magnetic switch, locate “B”
“A” terminal (6) upward.

11) Tighten new magnetic switch bolts (7) to specified

torque.
1
IBP80A192019-01 Tightening torque
6) Install plunger to drive lever. Magnetic switch bolt (a): 7.0 N·m (0.71 kgf-m,
5.5 lbf-ft)
7) Insert gear shaft assembly (1) into starter housing
(3) with drive lever assembly (2) set as shown in the
figure.
 Starting System: D13A 1I-18

c) Check that plunger and pinion move outward.

7, (a) If plunger and pinion do not move, replace
magnetic switch.

4
5

5
1
2
3
4
I5RS0B190002-01

1. “S” terminal

6 2) Perform hold-in test as follows.

a) From the state of Step 1) with plunger and pinion
IBP80A192021-01 in “out” position, disconnect negative (–) lead
12) Connect lead wire (1) to magnetic switch (2), and from “M” terminal.
then tighten lead wire nut (3) to specified torque. b) Check that plunger and pinion remain in “out”
Tightening torque position.
Lead wire nut (a): 8.0 N·m (0.82 kgf-m, 6.0 lbf-ft) If plunger and pinion return inward, replace
magnetic switch.
2

3, (a)

I5RS0B190003-01

3) Perform plunger and pinion return test as follows.

a) From the Step 2) with plunger and pinion in “out”
position, disconnect negative (–) lead from
IBP80A192022-01
starting motor body.
b) Check that plunger and pinion return inward. If
Starting Motor Inspection plunger and pinion do not return, replace
AENBL80A1926005
magnetic switch.
Starting Motor Operation Check

! CAUTION

• When connecting cables to battery for

operation check, be careful not to cause
accidental short circuit.
• Each test must be performed within 3 to 5
seconds to avoid burning of coil.

1) Perform pull-in test as follows.

a) Disconnect lead wire (3) from “M” terminal (2). I5RS0B190004-01

b) Connect battery to magnetic switch as shown in 4) Perform non-load performance test as follows.
figure.
1I-19 Starting System: D13A

! CAUTION
Use thick cable such as jumper cable, as
large current may flow.

a) Fix starting motor with vice or the like.

b) Connect battery and ammeter to starting motor
as shown in figure.
c) Check that starting motor rotates smoothly and
steadily with pinion moving out.
d) Check that ammeter indicates specified current.
If check result is not as specified, repair or
replace starting motor.
I5JB0B190019-01
Specified current (No-load performance test)
72 A MAX. at 11.6 V Pull-in coil open circuit test
Check for continuity between magnetic switch “S”
terminal (1) and “M” terminal (2). If there is no continuity,
replace magnetic switch.

2
I9P60A192023-01

I9P60A192025-01
Plunger
Check plunger for wear. Replace magnetic switch if
Hold-in coil open circuit test
defective.
Check for continuity between magnetic switch “S”
terminal (1) and coil case. If there is no continuity,
replace magnetic switch.

I5JB0B190018-01

Magnetic Switch 1

Check that plunger quickly returns to its original position

when plunger is pushed in with a finger and released. If
check result is not OK, replace magnetic switch.
I9P60A192026-01

Rear Bracket Bushing

• Check rear bracket bushing for wear or damage. If
check result is not OK, replace rear bracket assembly.
 Starting System: D13A 1I-20

IBP80A192023-01
IBP80A192026-01
• Check rear bracket assembly for brush movement,
distortion and dirt. • Check for continuity between segments. If there is no
Clean or replace rear bracket assembly, as continuity at any test point, replace armature.
necessary.
• Check for continuity between insulated brush (positive
(+) side) and grounded brush (negative (–) side).
If there is continuity, replace rear bracket assembly.

IBP80A192027-01

Gears
Check internal gear and planetary gears for wear,
damage and other abnormal conditions. Replace
armature or gear shaft assembly if defective.

IBP80A192024-01

Armature
• Check commutator for dirt or burn. Correct
commutator (1) with sandpaper (#300 – 400), if
defective.

I2RH01190021-01

Pinion and Overrunning Clutch

1
IBP80A192025-01
• Check insulation between commutator and armature
core. If there is continuity, replace armature.
• Check pinion for wear, damage and other abnormal
conditions.
• Check that clutch locks when turned in normal rotation
direction and rotates freely when turned in opposite
direction. Replace pinion and overrunning clutch if
defective.
1I-21 Starting System: D13A

Starter Housing Bushing

! CAUTION
Do not remove bushing from starter housing.

Check bushing for wear or damage. Replace starting

motor assembly if defective.

I2RH01190022-01

• Check spline teeth for wear or damage. Replace

overrunning clutch if defective.
• Check pinion for smooth movement.

I2RH01190024-01

I2RH01190023-01

Specifications
Cranking System Specifications
AENBL80A1927001
Voltage 12 V
Output 1.2 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion end
Number of pinion teeth 9
Test condition Performance
No-load at 21 °C (69.8 °F) 11.5 V Max. 77 A Min. 3,350 rpm
Cranking at 21 °C (69.8 °F) 1650 rpm Max. 290 A Min. 5.5 N⋅m

Tightening Torque Specifications

AENBL80A1927002
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Starting motor mount bolt 25 2.5 18.0 )
Magnetic switch lead wire nut 5.8 0.58 4.5 )
Starting motor cable nut 11 1.1 8.0 )
Rear bracket bolt 7.3 0.74 5.5 )
Magnetic switch bolt 7.0 0.71 5.5 )
Lead wire nut 8.0 0.82 6.0 )

NOTE
The tightening torque(s) also specified in:
“Starting Motor Components”: D13A

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
 Starting System: D13A 1I-22

Special Tools and Equipment

Recommended Service Material
AENBL80A1928001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 )/)

NOTE
Required service material(s) also described in:
“Starting Motor Components”: D13A

Special Tool
AENBL80A1928002
09913M66710
Bearing puller
)
1J-1 Charging System: K14B

Charging System
Engine

K14B
Precautions
Precautions for Handling Battery
AENBL80A1A10001
! WARNING

• Battery produces hydrogen gas. Never expose battery to open flame or electric spark because
hydrogen gas produced by battery is flammable and explosive.
• Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive
acid. Flush any contacted area with water immediately and thoroughly.
• Batteries should always be kept out of reach of children.

1) The battery is a very reliable component, but needs periodical attentions.

• Keep battery carrier clean.
• Prevent rust formation on the terminal posts.
• Keep electrolyte up to upper level uniformly in all cells (If cell caps are equipped).
• When keeping battery on vehicle over a long period of time, follow instructions given below.
– Weekly, start the engine and run it until it reaches normal operating temperature with engine speed of 2,000
to 3,000 rpm. Make sure all electric switches are turned off before storing the vehicle.
– Recharge the battery twice a month to prevent it from discharging excessively. This is especially important
when ambient temperature is low.
The battery discharges even when it is not used, while vehicles are being stored. Battery electrolyte can
freeze and battery case can crack at cold ambient condition if the battery is not properly charged.
2) Keep the battery cable connections clean.
The cable connections, particularly at the positive (+) terminal post, tend to become corroded. The corrosion or
rust on the mating faces of conductors resists the flow of current.
Clean the terminals and fittings periodically to ensure good metal-to-metal contact, and grease the connections
after each cleaning to protect them against rusting.
3) Periodically check the state of charge of battery. The simplest way to tell the state of charge is to carry out a
hydrometer test. The hydrometer is an instrument for measuring the specific gravity of the battery electrolyte. The
specific gravity of the electrolyte is indicative of the state of charge. )(Page 1J-3)

General Description
Battery Description
AENBL80A1A11001
The battery has three major functions in the electrical
system.
• It is a source of electrical energy for cranking the
engine.
• It acts as a voltage stabilizer for the electrical system.
• It can, for a limited time, provide energy when the
electrical load exceeds the output of generator.
Carrier and Hold-Down Clamp
The battery carrier should be in good condition so that it
will support the battery securely and keep it level. Before
installing battery, check that the battery carrier and hold-
down clamp are clean and free from corrosion and that
there are no foreign matter in the carrier.
To prevent battery from shaking in its carrier, the hold-
down clamp bolts should be tight enough but not over-
tightened.
Electrolyte Freezing
The freezing point of electrolyte depends on its specific
gravity. Since freezing may ruin a battery, it should be
protected against freezing by keeping it in a fully
charged condition. If a freezes accidentally, it should not
be charged until it will unfreeze.
Sulfation
If battery is left for a long period in discharged condition,
the lead sulfate becomes converted into a hard,
crystalline substance, which will not easily turn back to
the active material again during the subsequent
 Charging System: K14B 1J-2

recharging. “Sulfation” means the result as well as the

process of that reaction. Such a battery can be revived
by very slow charging and may be restored to usable
condition but its capacity will be lower than before.

Generator Description
AENBL80A1A11002
The generator is of a small and high performance type with an IC regulator incorporated. The internal components are
connected electrically as shown in the following figure.
The generator features are as follows:
• Solid state regulator is mounted inside the generator.
• All regulator components are enclosed into a solid mold.
• The IC regulator along with the brush holder assembly is attached to the rear housing.
• The IC regulator uses integrated circuits and controls the voltage produced by the generator, and the voltage setting
cannot be adjusted.
• The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication. Two brushes
carry current through the two slip rings to the field coil mounted on the rotor, and under normal conditions they will
provide long period of attention-free service.
• The stator windings are assembled on the inside of a laminated core that forms part of the generator frame.

1
B
7 8
IG
12
4 6
L
3

9
2 10 11

FR

IAP70B1A0001-01

1. Generator 4. Diode 7. Ignition switch 10. BCM

2. IC regulator 5. Field coil (rotor coil) 8. Battery 11. Combination meter
3. Stator coil 6. Charge warning light 9. Electric load 12. CAN driver
1J-3 Charging System: K14B
1. Pulley 6. Field coil
2. Pulley nut 7. Regulator
3. Rotor fan 8. Brush
4. Stator coil 9. Drive end frame
5. Stator core 10. Rear end frame
Diagnostic Information and Procedures
Battery Inspection
AENBL80A1A14001
Common Causes of Failure
There are the following causes for the fall of the battery
function.
• Accessories left on overnight or for an extended
period without generator operation.
• Frequent driving at slow speed for short periods.
• Electrical load exceeds generator output, particularly
due to additional fitting of aftermarket equipment.
• Defects in charging system. )(Page 1J-4)
• Failure to keep terminals clean or making hold-down
clamps too loose or too tight.
• Mechanical problems in electrical system such as
short-circuit or pinched wires.
• Deterioration of battery due to long-term use.
• Deterioration of battery due to long-term storage.
Visual Inspection
Check for visible damage, such as a cracked or broken
case or cover, which may lead to loss of electrolyte. If
visible damage is noted, replace battery. Determine
cause of damage and make corrections as needed.
How to use the temperature-corrected state-of-
charge graph
Suppose your specific gravity reading is 1.28 and the
battery temperature is –5 °C (23 °F). Locate the
I9P60A1A1002-01
11. Rectifier 16. Generator cut terminal
12. Generator output (“B” terminal) 17. Field duty measured terminal
13. Ground
14. Ignition terminal
15. Light terminal
Hydrometer Test
The direct method of checking the battery for state of
charge is to carry out a high rate discharge test, which
involves a special precise voltmeter and an expensive
instrument used in the service shops, but not
recommendable to the user of the vehicle.
At 20 °C of battery temperature (electrolyte
temperature):
• The battery is in FULLY CHARGED STATE if specific
gravity of the electrolyte is 1.280.
• The battery is in HALF CHARGED STATE if the
specific gravity of the electrolyte is 1.220.
• The battery is in NEARLY DISCHARGED STATE if
the specific gravity of the electrolyte is 1.150 and is in
danger of freezing.
As the specific gravity varies with the temperature, if
battery temperature is not at 20 °C (68 °F), you have to
correct your specific gravity reading (taken with your
hydrometer) to the value at 20 °C (68 °F) and apply the
corrected specific gravity value to the three-point guide
stated value.
For the manner of correction, refer to the graph showing
the relation between specific gravity value and
temperature.
intersection of the –5 °C (23 °F) line and the 1.28
specific gravity line.
The intersection is within the [A] zone (shaded area in
the graph) and that means CHARGED STATE.
 Charging System: K14B 1J-4

To know how much the battery is charged, draw a line

parallel to the zone demarcation line and extend it to the 1.32
right till it meets with the percentage scale. In the present
1.30 [B]
example, the line meets at about 85% point on the
1.28
percentage scale. Therefore, the battery is charged up to
the 85% level. 1.26 100%
[D] [A]
1.24

1.22

1.20 50%
[C]
1.18

-15 -5 0 5 10 15 20 25 30 35 40 45 (°C)
5 23 32 41 50 59 68 77 86 95 104 113 (°F)
[E]
IAP70B1A0002-01

[B]: Overcharged [D]: Specific gravity

[C]: Should be charged [E]: Temperature

Generator Symptom Diagnosis

AENBL80A1A14002
Trouble in charging system will show up as one or more of the following conditions.

Charging Warning Light Operation

Condition Possible cause Correction / Reference Item
Charge warning light Blown fuse Replace fuse.
does not light with Faulty combination meter Replace combination meter. )(Page 9C-10)
ignition ON and engine off Faulty BCM Check BCM.
Ignition switch model: )(Page 10B-20)
Faulty CAN communication line Repair or replace CAN communication line.
)(Page 10H-7)
Faulty wiring Repair or replace wiring.
Faulty IC regulator or field coil Repair or replace generator. )(Page 1J-9)
Charge warning light Loose or worn drive belt Adjust or replace drive belt. )(Page 1J-6)
does not go out with Faulty combination meter Replace combination meter. )(Page 9C-10)
engine running (battery Faulty BCM • Check BCM.
requires frequent – Ignition switch model: )(Page 10B-20)
recharging) Faulty IC regulator or generator Repair or replace generator. )(Page 1J-9)
Faulty wiring Repair or replace wiring.

Battery Charge Failure

Condition
Undercharged battery
Overcharged battery
Possible cause Correction / Reference Item
Loose or worn drive belt Adjust or replace drive belt. )(Page 1J-6)
Loose or corroded battery terminal Tighten battery terminal or replace battery.
)(Page 1J-6)
Faulty rectifier, rotor and/or IC regulator Repair or replace generator. )(Page 1J-9)
Faulty IC regulator Repair or replace generator. )(Page 1J-9)

Noise
Condition Possible cause Correction / Reference Item
Noisy generator Loose mounting bolts Tighten mounting bolts. )(Page 1J-7)
Dirty, worn and/or faulty bearings Repair or replace generator. )(Page 1J-9)
Faulty rotor, diode and/or stator Repair or replace generator. )(Page 1J-9)
1J-5 Charging System: K14B

Generator Test
AENBL80A1A14003
This condition, as evidenced by slow cranking or low
specific gravity, can be caused by one or more of the
following conditions even though warning light may be
operating normal. The following procedure also applies
to cars with voltmeter and ammeter.
• Make sure that undercharged condition has not been
caused by accessories being left on for extended
period of time.
• Check drive belt for wear and tension. )(Page 1J-6)
I9P60A1A1018-01
• If battery defect is suspected, refer to “Battery
1. Generator 6. Switch
Description”: K14B (Page 1J-1).
4. Battery 7. “B” terminal
• Inspect wiring for defects. Check all connections for
tightness and cleanliness, battery cable connections 5) Run engine around 2,000 rpm and read meters.
at battery, starting motor and ignition ground cable.
• If voltage is higher than standard value, check
ground circuit of brushes. )(Page 1J-12)
No-Load Check
If brushes are not grounded, replace IC regulator.
NOTE • If voltage is lower than standard value, inspect
Use fully charged battery. rotor, stator, rectifier, bushings and regulator.
)(Page 1J-12)
1) Check for DTC. )(Page 1A-18) Specification for undercharged battery (No-load
If there is any DTC, perform troubleshooting for check)
applicable DTC and then clear DTC. Current: 10 A
• Troubleshooting: )(Page 1A-19) Regulated voltage: 14.2 – 14.8 V (at 25 °C, 77 °F)
• DTC clearance: )(Page 1A-19)
2) Turn off all electrical loads (5). Load Check
3) Connect voltmeter (3) and ammeter (2) as shown in NOTE
figure.
Use fully charged battery.
4) Start engine and warm it up to normal operating
temperature. 1) Connect ammeter in the same way as “No-Load
Check”: K14B (Page 1J-5).
2) Run engine around 2,000 rpm and turn on the
following electrical loads.
• Headlight (High beam)
• Rear window defogger
• Blower motor (Maximum speed)
3) Read ammeter.
If meter reading is less than 20 A, repair or replace
generator.

Repair Instructions
Jump-Starting in Case of Emergency Both booster and discharged battery should be treated
AENBL80A1A16001 carefully when using jumper cables. Follow the
With Booster Battery
procedure outlined as follows, being careful not to cause
! CAUTION sparks.

If vehicle is M/T model, do not push or tow it

to start. This may cause damage to emission
control system and/or to other components.
 Charging System: K14B 1J-6

! WARNING Battery Removal and Installation

AENBL80A1A16002
Removal
• Departure from these conditions and
procedure described below could result in 1) Disconnect negative (–) cable (1) at battery (4).
serious personal injury (particularly to 2) Disconnect positive (+) cable (2) at battery.
eyes) or property damage by battery 3) Remove retainer (3).
explosion, battery acid or electrical burns. 4) Remove battery.
• Remove rings, watches and other jewelry.
Be sure to wear approved eye protection. 1

3
! CAUTION

• Departure from these conditions and

procedure described below could result in
damage to electronic components of either
vehicle. 4
• Be careful not to allow metal tools or
jumper cables to contact positive (+)
battery terminal and any other metal on
vehicle, because a short circuit could
occur.

1) For M/T model, place gear shift lever in “Neutral”.

2
For A/T model, place select lever in “P”. IAP70A1A0001-01

2) Apply parking brake. 5) Remove battery tray (1).

3) Set ignition “OFF”. 6) Remove ECM (2). )(Page 1C-1)
4) Turn off lights and all other electrical loads. 7) Remove battery bracket (3) if necessary.
5) For battery with cell caps, check electrolyte level. If it
is below low level line, add distilled water. 2
3
6) Attach end of one jumper cable to positive (+)
terminal of booster battery and other end of the
same cable to positive (+) terminal of discharged
battery (Use 12-volt battery only to jump-start
engine).
7) Attach one end of the remaining negative (–) cable to
negative (–) terminal of booster battery, and other
end to solid engine ground (such as exhaust 1
manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
IAP70A1A0002-02
8) Start engine of vehicle with booster battery and turn
off its electrical loads. Then try to start engine of
Installation
vehicle with discharged battery.
Reverse removal procedure noting the following points.
9) Disconnect jumper cables in exact reverse order.
• Tighten battery cables securely.
With Charging Equipment • Initialize electrical devices if necessary.

! CAUTION Water Pump / Generator Drive Belt Tension

When jump-starting engine with charging
equipment, be sure that equipment is for 12-
volt and negative (–) ground system. Do not
use 24-volt charging equipment. Using such
equipment can cause serious damage to
electrical system or electronic parts.
2) Check water pump / generator drive belt for tension.
Water pump / generator drive belt is in proper
tension when it deflects as follows under thumb
Inspection and Adjustment
AENBL80A1A16003
1) Inspect water pump / generator drive belt for cracks,
cuts, deformation, wear and cleanliness. If it is
necessary to replace water pump / generator drive
belt, refer to “Water Pump / Generator Drive Belt
Removal and Installation”: K14B (Page 1J-7).
pressure (about 100 N (98.07 kgf, 22.05 lbf).).
If belt tension is not as specified, go to next steps.
1J-7 Charging System: K14B
Water pump / generator drive belt tension “a”
Existing belt: 4.0 – 4.5 mm (0.16 – 0.18 in.) as
deflection / 100 N (98.07 kgf, 22.05 lbf)
New belt: 3.0 – 3.5 mm (0.12 – 0.14 in.) as
deflection / 100 N (98.07 kgf, 22.05 lbf)
“a”
Installation
I7V20A1A1006-01
3) Loosen generator bolt (1) and pivot bolt (2), and then
adjust belt tension to specification described at step
2) by loosening / tightening generator adjusting bolt
(3).
4) Tighten generator bolt and pivot bolt to specified
torque.
Tightening torque
Generator bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)
Generator pivot bolt (b): 45 N·m (4.6 kgf-m, 33.5
lbf-ft)
5) Check belt tension for specification after turning
crankshaft two rotations clockwise.
1, (a)
3 2) Adjust belt tension. )(Page 1J-6)
2, (b)
I7V20A1A1007-01
6) Connect negative (–) cable at battery.
Generator Removal and Installation
Water Pump / Generator Drive Belt Removal and Removal
Installation
AENBL80A1A16004
Removal
1) Disconnect negative (–) cable at battery.
2) Remove right engine undercover.
3) Remove compressor drive belt.
• Single A/C model: )(Page 7B-43)
• Dual A/C model: )(Page 7B-92)
4) Loosen generator bolt (2) and generator pivot bolt
(3).
5) Loosen generator adjusting bolt (4), and then
remove water pump / generator drive belt (1).
2 1
4
3
I7V20A1A1008-01
1) Install water pump / generator drive belt (1) to water
pump pulley (2), crankshaft pulley (3) and generator
pulley (4).
NOTE
Make sure water pump / generator drive belt
is installed in grooves of each pulley
correctly.
1
2
4
3
I7V20A1A1009-01
3) Install compressor drive belt.
• Single A/C model: )(Page 7B-43)
• Dual A/C model: )(Page 7B-92)
4) Install right engine undercover.
5) Connect negative (–) cable at battery.
AENBL80A1A16005
1) Disconnect negative (–) cable at battery.
2) Remove right engine undercover.
3) Remove exhaust No.1 pipe. )(Page 1K-2)
4) Remove water pump / generator drive belt. )(Page
1J-7)
5) Disconnect “B” terminal wire (1) and connector (2)
from generator (3).
6) Remove generator (3) and take generator out of
engine compartment between front suspension
member and front drive shaft assembly.
 Charging System: K14B 1J-8

1
3
I9P60A1A1005-01
I9P60A1A1007-01
Installation
Reverse removal procedure noting the following points. Installation
• Tighten generator bolt and generator pivot bolt to Reverse removal procedure noting the following point.
specified torque. • Install generator bracket in the following procedure.
Tightening torque a. Position the generator bracket (1).
Generator bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-ft) b. Loosely tighten generator bolt (2).
Generator pivot bolt (b): 45 N·m (4.6 kgf-m, 33.5 c. Tighten generator bracket nuts (3) to specified
lbf-ft) torque. )(Page 1F-13)
• Connect wire (1) to generator as shown in figure, and
1 3
tighten “B” terminal nut to specified torque.
2
Tightening torque
“B” terminal nut (c): 7.9 N·m (0.81 kgf-m, 6.0 lbf-
ft)

(c)
1 (a)

I9P60A1A1016-01

(b)
I9P60A1A1006-02

Generator Bracket Removal and Installation

AENBL80A1A16006
Removal
1) Disconnect negative (–) cable at battery.
2) Remove right engine undercover.
3) Remove water pump / generator drive belt. )(Page
1J-7)
4) Remove water pump pulley (1). )(Page 1F-13)
5) Remove generator bolt (2).
6) Remove generator bracket (3).
1J-9 Charging System: K14B

Generator Components
AENBL80A1A16007

12

10

(d)

8
5
4 11
9
(c)

3
7

1
6

(a)
(a) (b)
I7V20A1A1011-01

1. Pulley 5. Bearing retainer 9. Rectifier : 118 N⋅m (12.0 kgf-m, 87.0 lbf-ft)
2. Drive end frame 6. Rotor 10. IC regulator : 4.5 N⋅m (0.46 kgf-m, 3.5 lbf-ft)
3. Stator 7. Rear end bearing 11. Brush : 3.5 N⋅m (0.36 kgf-m, 2.5 lbf-ft)
4. Drive end bearing 8. Rear end frame 12. “B” terminal : 8.0 N⋅m (0.82 kgf-m, 6.0 lbf-ft)

Generator Disassembly and Reassembly

AENBL80A1A16008

Disassembly
1) To facilitate reinstallation, provide match marks (3)
on drive end frame (1) and rear end frame (2) as
shown.

I3RB0A1A0009-01

3) With lever (1) inserted between stator core (2) and

drive end frame (3), separate generator into drive
end frame and rear side.

IYSQ011A0018-01

2) Remove end frame bolts (1) from generator.

 Charging System: K14B 1J-10

I3RB0A1A0011-01

7) Remove drive end bearing from drive end frame (1)

using special tool and hydraulic press (2).
Special tool
(A): 09943–88211

(A)

I3RB0A1A0010-01

4) Remove pulley as follows.

a) Hold rotor (2) using vise (4).

! CAUTION
I9P60A1A1013-01
• When using vise, put clean cloth (3)
8) Remove rear end bearing (1) using hydraulic press
between rotor and vise so as not to cause
(2), general rod (3) and general tool (4).
damage to rotor.
• Be sure to hold the location (5). Do not
hold the location (6) as it does not have
enough structural strength.

b) Loosen pulley nut and remove pulley (1).

IYSQ011A0023-01

9) Remove “B” terminal (1).

I9P60A1A1012-01

5) Remove drive end frame from rotor.

6) Remove bearing retainer screws (1) and bearing
retainer.
1J-11 Charging System: K14B

Reassembly
1 Reverse disassembly procedure noting the following
points.
• Tighten each bolt, nut and screw to specified torque
referring to “Generator Components”: K14B (Page 1J-
9).
• Be sure to install brushes (1) in the proper direction as
shown and solder brush wires (2) and stator leads (3).

I9P60A1A1008-01

10) Remove three screws (1).

I9P60A1A1009-02

11) Remove stator with IC regulator assembly and

rectifier assembly from rear end frame.
12) Unsolder stator leads (1) and remove stator (2) from
rectifier assembly. IAY3011A0012-01

• Install drive end bearing to drive end frame (1) using

special tool and hydraulic press (2).
Special tool
(A): 09913–76010

IAY3011A0011-02 (A)
13) To remove brush, remove holder (1) from brush
holder (2) and then disconnect brush wire (3) from
regulator terminal using soldering iron.

I9P60A1A1010-01

• Push brushes into brush holder, and then support

brushes by inserting appropriate wire (1) before
installing IC regulator assembly (2) to rear end frame
(3).

I3RB0A1A0014-01
 Charging System: K14B 1J-12

NOTE • After assembling generator, make sure that rotor turns

After installing rotor, remove wire. smoothly.

Generator Inspection
AENBL80A1A16009

Rotor
1) Using ohmmeter (1), check for continuity between
slip rings (2) of rotor. If there is no continuity, replace
rotor.
Standard resistance between slip rings of rotor
2.2 – 2.6 Ω

I4RS0B1A0005-01

2) Using ohmmeter (1), check that there is no continuity

between slip ring (2) and rotor core (3). If there is
I3RB0A1A0017-01
continuity, replace rotor.
• Heat bearing box part (1) of rear end frame (2) to a
temperature of 50 – 60 °C (122 – 140 °F) and install
rear end bearing (3) with rotor into bearing box.

! CAUTION

• Be sure to install rear end bearing with

bearing box heated. If not, it may cause
damage to rear end bearing.
• Do not apply grease to rear end bearing.
Remove oil completely if found in bearing
box of rear end frame. I4RS0B1A0008-01

3) Check slip rings for roughness or scoring. If rough or

NOTE scored, replace rotor.
Check that match marks on front and rear
end frame are aligned.

1
I9P60A1A1014-01
1J-13 Charging System: K14B

Bearing Brush and Brush Holder

Check bearing for smooth rotation. Check each brush (1) for wear by measuring its length
If any abnormality is found, replace bearing. as shown. If brush has worn down to service limit,
replace brushes.
Stator
Exposed brush length “a”
1) Using ohmmeter (1), check all leads (2) for Standard: 16 mm (0.63 in.)
continuity. If there is no continuity, replace stator. Limit: 2.0 mm (0.8 in.)
1

I9P60A1A1017-01

I8T4011A0018-01 Rectifier
2) Using ohmmeter (1), check that there is no continuity Using ohmmeter, check continuity between “B” terminal
between coil leads (2) and stator core (3). If there is (1) or “E” terminal (2) and each diode lead (3). Check
continuity, replace stator. both directions by reversing probes of ohmmeter and
there should be only one-way continuity in each case. If
1 check result is not satisfactory, replace rectifier (4).

NOTE
2 If multifunctional tester is used, choose its
diode range for this check.

4
3

2
3
I8T4011A0019-01
2
3 1
I8T4011A0021-01
 Charging System: K14B 1J-14

Specifications
Charging System Specifications
AENBL80A1A17001
Battery
Battery specification
: 38B20L (28AH/5HR)

Generator
Type 80 A type
Rated voltage 12 V
Nominal output 80 A
Permissible max. speed 18,000 r/min.
No-load speed 1,200 r/min.
Regulated voltage 14.2 – 14.8 V at 25 °C (77 °F)
Permissible ambient temperature –30 to 120 °C (–22 to 248 °F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side

Tightening Torque Specifications

AENBL80A1A17002
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Generator bolt 25 2.5 18.5 )/)
Generator pivot bolt 45 4.6 33.5 )/)
“B” terminal nut 7.9 0.81 6.0 )

NOTE
The tightening torque(s) also specified in:
“Generator Components”: K14B

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Special Tool
AENBL80A1A18001
09913–76010 09943–88211
Bearing installer Pinion bearing installer
) )
1J-15 Charging System: D13A

D13A
Precautions
Precautions for Handling Battery
AENBL80A1A20001
! WARNING

• Battery produces hydrogen gas. Never expose battery to open flame or electric spark because
hydrogen gas produced by battery is flammable and explosive.
• Do not allow battery fluid to contact eyes, skin, fabrics or painted surfaces as fluid is a corrosive
acid. Flush any contacted area with water immediately and thoroughly.
• Batteries should always be kept out of reach of children.

1) The battery is a very reliable component, but needs periodical attentions.

• Keep the battery tray clean.
• Prevent rust formation on the terminal posts.
• Keep electrolyte up to the upper level uniformly in all cells. (If cell caps are equipped)
• When keeping battery on vehicle over a long period of time, follow instructions given below.
– Weekly, start the engine and run it until it reaches normal operating temperature with engine speed of 2,000
to 3,000 rpm. Make sure all electric switches are turned off before storing the vehicle.
– Recharge the battery twice a month to prevent it from discharging excessively. This is especially important
when ambient temperature is low.
The battery discharges even when it is not used, while vehicles are being stored. Battery electrolyte can
freeze and battery case can crack in cold ambient condition if the battery is not properly charged.
2) Keep the battery cable connections clean.
The cable connections, particularly at the positive (+) terminal post, tend to become corrode. The corrosion or rust
on the mating faces of conductors resists the flow of current.
Clean the terminals and fittings periodically to ensure good metal-to-metal contact, and grease the connections
after each cleaning to protect them against rusting.
3) Periodically check the state of charge of the battery. The simplest way to tell the state of charge is to carry out a
hydrometer test. The hydrometer is an instrument for measuring the specific gravity of the battery electrolyte. The
specific gravity of the electrolyte is indicative of the state of charge. )(Page 1J-17)

General Description
Battery Description
AENBL80A1A21001
The battery has three major functions in the electrical
system.
• It is a source of electrical energy for cranking the
engine.
• It acts as a voltage stabilizer for the electrical system.
• It can, for a limited time, provide energy when the
electrical load exceeds the output of generator.
Carrier and Hold-Down Clamp
The battery carrier should be in good condition so that it
will support the battery securely and keep it level. Before
installing the battery, check that the battery carrier and
hold-down clamp are clean and free from corrosion and
that there are no foreign matter in the carrier.
To prevent the battery from shaking in its carrier, the
hold-down clamp bolts should be tight enough but not
over-tightened.
Electrolyte Freezing
The freezing point of electrolyte depends on its specific
gravity. Since freezing may ruin a battery, it should be
protected against freezing by keeping it in a fully
charged condition. If the battery freezes accidentally, it
should not be charged until it will unfreeze.
Sulfation
If the battery is left for a long period in discharged
condition, the lead sulfate becomes converted into a
hard, crystalline substance, which will not easily turn
back to the active material again during the subsequent
recharging. “Sulfation” means the result as well as the
process of that reaction. Such a battery can be revived
by very slow charging and may be restored to usable
condition but its capacity will be lower than before.
 Charging System: D13A 1J-16

Generator Description
AENBL80A1A21002
The generator is of a small and high performance type with an IC regulator incorporated. The internal components are
connected electrically as shown in the following figure.
The generator features are as follows:
• Solid state regulator is mounted inside the generator.
• All regulator components are enclosed into a solid mold.
• The IC regulator along with the brush holder assembly is attached to the rear end frame.
• The IC regulator uses integrated circuits and controls the voltage produced by the generator, and the voltage setting
cannot be adjusted.
• The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication. Two brushes
carry current through the two slip rings to the field coil mounted on the rotor, and under normal conditions will
provide long period of attention-free service.
• The stator windings are assembled on the inside of a laminated core that forms part of the generator frame.

1
B
7 8
IG
12
4 6
L
3

9
2 10 11

IBP80A1A2001-01

1. Generator 4. Diode 7. Ignition switch 10. BCM

2. IC regulator 5. Field coil (rotor coil) 8. Battery 11. Combination meter
3. Stator coil 6. Charge warning light 9. Electric load 12. CAN driver

IBP80A1A2002-01
1J-17 Charging System: D13A

1. Pulley 6. Regulator 11. Ignition terminal

2. Rotor fan 7. Brush 12. Generator output (“B” terminal)
3. Stator coil 8. Rear end frame 13. Ground
4. Stator core 9. Drive end frame
5. Field coil 10. Light terminal

Diagnostic Information and Procedures

Battery Inspection
AENBL80A1A24001
Common Causes of Failure
The following are the most common causes of battery
failures.
• Accessories left on overnight or for an extended
period without the generator operation.
• Frequent driving at slow speeds for short periods.
• Electrical load exceeds generator output, particularly
due to additional fitting of aftermarket equipment.
• Defects in charging system. )(Page 1J-17)
• Failure to keep terminals clean or making hold-down
clamps too loose or too tight.
• Mechanical problems in electrical system such as
short-circuit or pinched wires.
• Deterioration of battery due to long-term use.
• Deterioration of battery due to long-term storage.
Visual Inspection
Check for visible damage, such as a cracked or broken
case or cover, make corrections loss of electrolyte. If
visible damage is noted, replace battery. Determine
cause of damage and make corrections as needed.

Generator Symptom Diagnosis

AENBL80A1A24002
Trouble in charging system will show up as one or more of the following conditions.

Charging Warning Light Operation Failure

Condition Possible cause Correction / Reference Item
Charge warning light Blown fuse Check fuse.
does not light with Faulty combination meter Replace combination meter. )(Page 9C-10)
ignition ON and engine off Faulty BCM Check BCM. )(Page 10B-20)
Faulty CAN communication line Repair or replace CAN communication line.
)(Page 10H-28)
Faulty wiring Repair wiring.
Faulty IC regulator or field coil Repair or replace generator. )(Page 1J-22)
Charge warning light Loose or worn accessory drive belt Replace accessory drive belt and/or accessory
does not go out with drive belt tensioner.
engine running (battery Accessory drive belt: )(Page 1J-20)
requires frequent Accessory drive belt tensioner: )(Page 1J-20)
recharging) Faulty combination meter Replace combination meter. )(Page 9C-10)
Faulty BCM Check BCM. )(Page 10B-20)
Faulty IC regulator or generator Repair or replace generator. )(Page 1J-22)
Faulty wiring Repair wiring.

Battery Charging Failure

Condition Possible cause Correction / Reference Item
Undercharged battery Loose or worn accessory drive belt Replace accessory drive and/or accessory
drive belt tensioner.
Accessory drive belt: )(Page 1J-20)
Accessory drive belt tensioner: )(Page 1J-20)
Faulty one way clutch pulley Replace one way clutch pulley. )(Page 1J-22)
Loosen or corroded battery terminals Tighten battery terminals or replace battery.
)(Page 1J-19)
Faulty rectifier, rotor or IC regulator Repair or replace generator. )(Page 1J-22)
Overcharged battery Faulty IC regulator Repair or replace generator. )(Page 1J-22)

Noise
Condition Possible cause
Noisy generator Loosen mounting bolts
Faulty rotor, diode or stator
Dirty, worn or faulty bearings
Faulty one way clutch pulley
Generator Test
AENBL80A1A24003
This condition, as evidenced by slow cranking or low
specific gravity, can be caused by one or more of the
following conditions even though charge warning light
may be operating normal.
• Make sure that undercharged condition has not been
caused by accessories being left on for extended
period of time.
• Check drive belt for wear and tension. )(Page 1J-20)
• If battery defect is suspected, refer to “Battery
Description”: D13A (Page 1J-15).
• Inspect wiring for defects. Check all connections for
tightness, cleanliness, battery cable connections at
battery and starting motor ground cable.
No-Load Check
NOTE
Use fully charged battery.
1) Check for DTC. )(Page 1A-134)
If there is any DTC, perform troubleshooting for
applicable DTC and then clear DTC.
• Troubleshooting: )(Page 1A-135)
• DTC clearance: )(Page 1A-134)
2) Turn off all electrical loads (5).
3) Connect voltmeter (3) and ammeter (2) as shown in
figure.
4) Start engine and warm it up to normal operating
temperature.
I2RH011A0006-01
1. Generator 6. Switch
4. Battery
Charging System: D13A 1J-18
Correction / Reference Item
Tighten mounting bolts. )(Page 1J-21)
Repair or replace generator. )(Page 1J-22)
Repair or replace generator. )(Page 1J-22)
Replace one way clutch pulley. )(Page 1J-22)
5) Run engine around 2,000 rpm and read meters.
• If voltage is higher than standard value, check
ground circuit of brushes. )(Page 1J-27)
If brushes are not grounded, replace IC regulator.
• If voltage is lower than standard value, inspect
rotor, stator, rectifier, brush and regulator. )(Page
1J-27)
Specification for undercharged battery (No-load
check)
Current: 10 A
Regulated voltage: 14.2 – 14.8 V (at 25 °C, 77 °F)
Load Check
NOTE
Use fully charged battery.
1) Connect ammeter in the same way as “No-Load
Check”: D13A (Page 1J-18).
2) Run engine around 2,000 rpm and turn on the
following electrical loads.
• Headlight (High beam)
• Rear window defogger (If equipped)
• Blower motor (Maximum speed)
3) Read ammeter. If meter reading is less than 20 A,
repair or replace generator.
1J-19 Charging System: D13A

Repair Instructions
Jump-Starting in Case of Emergency With Charging Equipment
AENBL80A1A26001
With Booster Battery ! CAUTION
! CAUTION When jump starting engine with charging
equipment, be sure that equipment is for 12-
Do not push or tow the vehicle to start it. This
volt and negative (–) ground system. Do not
may cause damage to emission control
use 24-volt charging equipment. Using such
system and/or to other components.
equipment can cause serious damage to
electrical system or electronic parts.
Both booster and discharged battery should be treated
carefully when using jumper cables. Follow the
procedure outlined as follows, being careful not to cause Battery Removal and Installation
sparks. AENBL80A1A26002
Removal
! WARNING 1) Disconnect negative (–) cable (1) at battery (4).
2) Disconnect positive (+) cable (2) at battery.
• Departure from these conditions and
procedures described below could result 3) Remove retainer (3).
in serious personal injury (particularly to 4) Remove battery.
eyes) or property damage by battery
explosion, battery acid or electrical burns. 1
3
• Remove rings, watches and other jewelry.
• Be sure to wear approved eye protection. 2

! CAUTION

• Departure from these conditions or 4

procedure described below could result in
damage to electronic components of either
vehicle.
• Be careful not to allow metal tools or
jumper cables to contact positive (+)
battery terminal and any other metal on IBP80A1A2003-01
vehicle, because a short circuit could 5) Remove battery tray (1).
occur.
6) Disconnect degassing tank (2) from bracket (4) if
necessary.
1) Place gear shift lever in “Neutral”.
7) Remove battery bracket (3) together with degassing
2) Apply parking brake.
tank bracket, if necessary.
3) Set ignition “OFF”.
4) Turn off lights and all other electrical loads. 2
5) For battery with cell caps, check electrolyte level. If it
4
is below low level line, add distilled water.
3
6) Attach end of one jumper cable to positive (+)
terminal of booster battery and the other end of the
1
same cable to positive (+) terminal of discharged
battery (Use 12-volt battery only to jump-start
engine).
7) Attach one end of the remaining negative (–) cable to
negative (–) terminal of booster battery, and the
other end to a solid engine ground, such as pulley
side engine hook, at least 45 cm (18 in.) away from
battery of vehicle being started.
8) Start engine of vehicle with booster battery and turn
IBP80A1A2005-01
off its electrical loads. Then start engine of vehicle
with discharged battery. Installation
9) Disconnect jumper cables in the exact reverse order. Reverse removal procedure noting the following points.
 Charging System: D13A 1J-20

• Tighten battery cables securely.

• Initialize electrical devices if necessary.

Accessory Drive Belt Tension Inspection

AENBL80A1A26003
1) Inspect drive belt (1) for tension, cracks, cuts,
deformation, wear and cleanliness. If any defect
exists, replace belt and/or belt tensioner.
• Accessory drive belt )(Page 1J-20)
• Accessory drive belt tensioner )(Page 1J-20)

IBP80A1A2007-01

3) Install right engine undercover.

1 Accessory Drive Belt Tensioner Removal and

Installation
AENBL80A1A26005
! CAUTION
Do not disassemble accessory drive belt
I3RM0B162015-01
tensioner.
If accessory drive belt tensioner has any part
Accessory Drive Belt Removal and Installation requiring repair, replace it with assembly.
AENBL80A1A26004
Removal
Removal
1) Remove right engine undercover.
1) Remove accessory drive belt. )(Page 1J-20)
2) Remove accessory drive belt (2) while turning
tensioner (1) clockwise until it stops. 2) Remove accessory drive belt tensioner (1).

I3RM0B162017-01

IBP80A1A2007-01
Installation
Reverse removal procedure noting the following points.
Installation
• Tighten accessory drive belt tensioner bolt (2) to
1) Install accessory drive belt (2) while turning
specified torque.
tensioner (1) clockwise until it stops.
Tightening torque
NOTE Accessory drive belt tensioner bolt (a): 50 N·m (
Make sure drive belt is installed in grooves of 5.1 kgf-m, 37.0 lbf-ft)
each pulley correctly.

2) Check accessory drive belt tension. )(Page 1J-20)

1J-21 Charging System: D13A

Installation
Reverse removal procedure noting the following point.
• Tighten each bolt and nut to specified torque.
Tightening torque
Generator bolt (a): 20 N·m (2.0 kgf-m, 15.0 lbf-ft)
“B” terminal nut (b): 7.9 N·m (0.81 kgf-m, 6.0 lbf-
ft)

I3RM0B162018-01

1. Accessory drive belt tensioner

(b)
• Install accessory drive belt. )(Page 1J-20)
• Check accessory drive belt. )(Page 1J-20)

Generator Removal and Installation

AENBL80A1A26006
Removal
1) Disconnect negative (–) cable at battery.
2) Remove right engine undercover.
(a)
3) Remove accessory drive belt. )(Page 1J-20) IBP80A1A2009-01

4) Remove exhaust pipe No.1. )(Page 1K-6)

5) Disconnect “B” terminal wire (1) and connector (2)
from generator (3).
6) Remove generator and take generator out of engine
compartment.

3
2

IBP80A1A2008-01
 Charging System: D13A 1J-22

Generator Components
AENBL80A1A26007

(f)
1 (g)

(b)
4

5
7
3 6
7
8

(e)

10
13

9
11 12

(a)

14 15

(a) 16
(a)

13

(c)
(a)
17

(e)
(d)
I9P60A1A2007-01

1. Pulley
2. Drive end frame
3. Drive end bearing
4. Bearing retainer
5. Rotor
6. Rear end bearing
7. Bearing cover
8. Wave washer 15. Rear end cover : 4.5 N⋅m (0.46 kgf-m, 3.5 lbf-ft)
9. Rear end frame 16. Bushing : 8.8 N⋅m (0.90 kgf-m, 6.5 lbf-ft)
10. Rectifier holder 17. Terminal plate : 110 N⋅m (11.2 kgf-m, 81.5 lbf-ft)
11. IC regulator : 2.0 N⋅m (0.20 kgf-m, 1.5 lbf-ft) : Do not reuse.
12. Brush holder : 2.6 N⋅m (0.27 kgf-m, 2.0 lbf-ft)
13. Seal ring : 3.6 N⋅m (0.37 kgf-m, 3.0 lbf-ft)
14. Insulator : 3.9 N⋅m (0.40 kgf-m, 3.0 lbf-ft)

Generator Disassembly and Reassembly

AENBL80A1A26008 (A)

Disassembly
1) Remove pulley using following procedure:
a) Secure special tool in vice as shown in figure.
Special tool
(A): 09932M96810
(B)
(B): 09932M96820

I9P60A1A2008-02

b) Set generator (1) on special tool.

1J-23 Charging System: D13A

c) Loosen pulley (2), and then remove pulley.

3 1 4 1 2

IBP80A1A2010-01
I9P60A1A2009-01
8) Remove rectifier holder screws (1).
2) Remove B terminal inner nut (1) and bushing (2).
9) Remove rectifier holder (2).
3) Remove rear end cover nuts (3) and terminal plate
bolt (4). 2
4) Remove terminal plate (6) and rear end cover (5).

3
4 1
1
2
6
1

IBP80A1A2011-01

10) Remove seal ring (1) and insulators (2).

I9P60A1A2010-01

5) Remove seal ring from brush holder. 2

6) Remove IC regulator screws (1) and brush holder
screw (2).

NOTE
These screws are different in type. When
assembling, install them to their original
positions. 2

7) Remove brush holder (3) and IC regulator (4). IBP80A1A2012-01

11) Remove rear end frame nuts (3).

12) Remove rear end frame (1) with rotor by tapping
shaft (2) lightly using plastic hammer.
 Charging System: D13A 1J-24

I8C50A1A0015-01

13) Separate rear end frame from rotor evenly using I8C50B1A0004-01

plastic hammer.
Reassembly
! CAUTION 1) Install new rear end bearing (1) and bearing covers
Do not hit shaft at slip ring side when using special tools and hydraulic press (2), if
separating rotor and rear end frame. removed.
Special tool
14) Use special tool to remove rear end bearing (1) and (A): 09925M96710
bearing covers (2) if replacement of bearing is (B): 09924M74590
required.

! CAUTION
2
Be careful not to distort cooling fan blade
while applying puller.
(A)
Special tool
(A): 09913M66710
1

(B)

I9P60A1A2028-01

2) Check that rear end bearing (1) turns smoothly.

(A)

2
1

I8C50A1A0018-01

I9P60A1A2027-02
3) Press-fit drive end bearing by using special tool and
hydraulic press (1), if removed.
15) Remove bearing retainer (1), and then remove drive
end bearing (2) if replacement of bearing is required. Special tool
(A): 09913M75810
! CAUTION

• Heating drive end frame (3) may facilitate

removal of bearing. (below 130 °C (266 °F))
• Do not exceed 130 °C (266 °F) when
heating drive end frame. Excessive heating
may damage stator coil.
1J-25 Charging System: D13A

(A)

I8C50A1A0021-01

9) Install seal ring (1) and insulators (2).

IBP80A1A2013-03
1
4) Check that drive end bearing (1) turns smoothly.
5) Install bearing retainer (2), and then tighten bearing
retainer screws to specified torque.
2
Tightening torque
Bearing retainer screw (a): 2.6 N·m (0.27 kgf-m,
2.0 lbf-ft)

IBP80A1A2012-01

10) Install rectifier holder (1), and then tighten rectifier

holder screws to specified torque.
Tightening torque
Rectifier holder screw (a): 2.0 N·m (0.20 kgf-m,
I9P60A1A2014-01
1.5 lbf-ft)
6) Install rotor (1) to drive end frame (2).
1

(a)

(a)

I8C50A1A0020-01 IBP80A1A2014-01

7) Install rear end frame to drive end frame.
8) Tighten rear end frame nuts to specified torque.
Tightening torque
Rear end frame nut (a): 4.5 N·m (0.46 kgf-m, 3.5
lbf-ft)
11) Place IC regulator (1) together with brush holder (2)
horizontally on rear end frame (3).
12) Tighten IC regulator screws and brush holder screw
to specified torque.
Tightening torque
IC regulator screw (a): 2.0 N·m (0.20 kgf-m, 1.5
lbf-ft)
Brush holder screw (b): 2.0 N·m (0.20 kgf-m, 1.5
lbf-ft)
 Charging System: D13A 1J-26

(B): 09932M96820
(b)
(A)
(a)

(B)
1 2

3
I9P60A1A2008-02

b) Install new pulley to generator.

c) Set generator (1) on special tool.
d) Tighten pulley (2) to specified torque.
Tightening torque
Pulley (a): 110 N·m (11.2 kgf-m, 81.5 lbf-ft)

IBP80A1A2015-01
13) Install seal ring to brush holder.
14) Install rear end cover (1) and terminal plate (2).
15) Tighten rear end cover nuts (3) and terminal plate
bolt (4) to specified torque.
Tightening torque
Rear end cover nut (a): 4.5 N·m (0.46 kgf-m, 3.5
lbf-ft)
Terminal plate bolt (b): 3.9 N·m (0.40 kgf-m, 3.0
lbf-ft)
16) Install bushing (5), and then tighten “B” terminal
inner nut (6) to specified torque.
Tightening torque
“B” terminal inner nut (c): 3.6 N·m (0.37 kgf-m,
3.0 lbf-ft)
! CAUTION
When using special tool (extension) with
torque wrench, the value indicated on the
torque wrench is smaller than the actually
applied torque. Use the following formula
and calculate the value to be indicated on the
torque wrench to correctly apply the
specified tightening torque.
Formula for reading value of torque wrench.
M = T X L / (L + “a”)
• M: Value indicated on torque wrench
• T: Specified torque
• L: Torque wrench length
• “a”: Dimension of special tool
L “a”

3, (a)
4, (b)
6, (c)

5
2 I9P60A1A2019-01

“a”: 70 mm (2.8 in.)

I9P60A1A2017-01

17) Install new pulley using following procedure:

a) Secure special tool in vice as shown in figure.
Special tool
(A): 09932M96810
1J-27 Charging System: D13A

Limit: 14.0 mm (0.551 in.)

2, (a)

IYSQ011A0044-01

I9P60A1A2020-01 Bearing
18) Make sure that rotor turns smoothly. Check bearing for smooth rotation.
If defective condition is found, replace it.
Generator Inspection
AENBL80A1A26009 Stator
1) Using ohmmeter, check all leads for continuity. If
Rotor there is no continuity, replace stator.
1) Using ohmmeter (1), check for continuity between
slip rings (2) of rotor. If there is no continuity, replace
rotor.
Standard resistance between slip rings of rotor
Approx, 2.9 Ω at 20 – 25 °C (68 °F – 77 °F)

IBP80A1A2019-01

2) Using ohmmeter, check that there is no continuity

between coil leads and stator core. If there is
I8G0011A0010-01 continuity, replace stator.
2) Using ohmmeter (1), check that there is no continuity
between slip ring (2) and rotor core (3). If there is
continuity, replace rotor.

IBP80A1A2016-02

I8G0011A0011-01 Brush
3) Check slip rings for roughness or scoring. If rough or Check each brush for wear by measuring its length as
scored, replace rotor. shown. If brush has worn down to service limit, replace
Using a vernier caliper, measure the slip ring brush holder.
diameter. If the diameter is less than minimum, Exposed brush length “a”
replace the rotor. Standard: 10.5 mm (0.413 in.)
Slip ring diameter Limit: 4.5 mm (0.177 in.)
Standard: 14.4 mm (0.566 in.)
 Charging System: D13A 1J-28

Regulator

NOTE
If multimeter is used, choose its diode range
for this check

1) Using multimeter or ohmmeter, check continuity

between terminal “F” (1) and terminal “B” (2).
Confirm that state of continuity is in the following
condition. If not, replace regulator (3).
I8C50A1A0028-01
• When positive and negative probe between
terminal “F” and terminal “B” are exchanged, there
Rectifier
is continuity in one direction but no continuity in
NOTE the other direction.
If multimeter is used, choose its diode range
B
for this check
B IG

1) Using multimeter or ohmmeter, connect one tester L

probe to the “B” terminal (1) and the other to each P
3
rectifier terminal (2).
1
1 F
E
2
1 2
E
IBP80A1A2017-01

2) Using multimeter or ohmmeter, check continuity

2 2 2 between terminal “E” (1) and terminal “F” (2).
2
Confirm that state of continuity is in the following
condition. If not, replace regulator (3).
2 • When positive and negative probe between
terminal “E” and terminal “F” are exchanged, there
I9P60A1A2023-01 is continuity in one direction but no continuity in
2) Reverse the polarity of tester probes and repeat Step the other direction.
1).
3) Check that one shows continuity and the other B
B IG
shows no continuity.
If not, replace rectifier holder. L
P
4) Using multimeter or ohmmeter, connect one tester 3
probe to negative terminal (1) and the other to each 1
rectifier terminal (2). 2
F
E

2 1 E
IBP80A1A2018-01

Pulley
2 2 2 • Check pulley for wear, damage or other abnormal
2
conditions. Replace pulley if necessary.
• Check pulley according to the following procedure.
1
2 a. Hold center of pulley.
b. Check that pulley locks up when turned clockwise
I9P60A1A2024-01
[b] and rotates smoothly when turned
5) Reverse the polarity of tester probes and repeat Step counterclockwise [a].
4). If any faulty condition is found, replace pulley.
6) Check that one shows continuity and the other
shows no continuity.
If not, replace rectifier holder.
1J-29 Charging System: D13A

[a]

[b]

IAW1011A0030-01

Specifications
Charging System Specifications
AENBL80A1A27001

Battery specification
Battery type: DIN 65 L-MF
Generator
Type 85 A type
Rated voltage 12 V
Nominal output 85 A
Permissible max. speed 18,000 r/min.
No-load speed 1,100 r/min.
Regulated voltage 14.2 – 14.8 V at 25 °C (77 °F)
Permissible ambient temperature –30 to 90 °C (–22 to 194 °F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side

Tightening Torque Specifications

AENBL80A1A27002
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Accessory drive belt tensioner bolt 50 5.1 37.0 )
Generator bolt 20 2.0 15.0 )
“B” terminal nut 7.9 0.81 6.0 )
Bearing retainer screw 2.6 0.27 2.0 )
Rear end frame nut 4.5 0.46 3.5 )
Rectifier holder screw 2.0 0.20 1.5 )
IC regulator screw 2.0 0.20 1.5 )
Brush holder screw 2.0 0.20 1.5 )
Rear end cover nut 4.5 0.46 3.5 )
Terminal plate bolt 3.9 0.40 3.0 )
“B” terminal inner nut 3.6 0.37 3.0 )
Pulley 110 11.2 81.5 )

NOTE
The tightening torque(s) also specified in:
“Generator Components”: D13A

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
 Charging System: D13A 1J-30

Special Tools and Equipment

Special Tool
AENBL80A1A28001
09913M66710 09913M75810
Bearing puller Bearing installer
) )

09924M74590 09925M96710
Input shaft oil seal installer Bearing installer
attachment
) )

09932M96810 09932M96820
Rotor shaft holder Generator pulley remover
)/) )/)
1K-1 Exhaust System: K14B

Exhaust System
Engine

K14B
General Description
Exhaust System Description
AENBL80A1B11001
The exhaust system consists of an exhaust manifold, a three-way catalytic converter (TWC) in the exhaust manifold,
exhaust pipes, a muffler and seals, gasket, and so on.
The three-way catalytic converter is emission control device added to the exhaust system to lower the levels of
Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in exhaust gases.

Diagnostic Information and Procedures

Exhaust System Check
AENBL80A1B14001
! WARNING
In order to avoid getting burned, do not work on exhaust system when it is hot. Exhaust system must
be sufficiently cool before beginning any service on it.

Exhaust system should be checked as follows at specified periodic maintenance intervals and on every occasion of
service operations performed with vehicle raised.
• Check rubber mountings for damage, deterioration, and dislocation.

IYSY011B0003-01

• Check mating surface of cylinder head with exhaust manifold for distortion.
• Check exhaust system for leakage, loose connection, dent and damage.
• If bolts or nuts are loosened, and then tighten them to specified torque. )(Page 1K-2)
• Check for any damages, holes or cracks, which may permit exhaust gas to enter the vehicle.
• Check that exhaust system components have enough clearance from underbody components to avoid overheating
and possible damage to these components.
• Any defects and fix them whenever.
 Exhaust System: K14B 1K-2

Repair Instructions
Exhaust System Components
AENBL80A1B16001

12

11

12

1 15
2
3 14 (a)

9 8

(b) (d)

13
(b) 5 5

4 8
6 4

10
8

7 (a)
16
IBL80A1B1001-01

1. Exhaust manifold cover 8. Gasket 15. Heat insulator

2. Exhaust manifold gasket 9. Exhaust No.1 pipe 16. Mounting No.2
3. Exhaust manifold 10. Exhaust center pipe : 45 N⋅m (46 kgf-m, 33.5 lbf-ft)
4. Exhaust manifold stiffener 11. Muffler : 60 N⋅m (6.1 kgf-m, 44.5 lbf-ft)
5. Exhaust manifold stiffener nut 12. Mounting No.1 : 43 N⋅m (4.4 kgf-m, 32.0 lbf-ft)
: For tightening order, refer to “Exhaust Manifold
Removal and Installation”: K14B (Page 1K-3).
6. Exhaust manifold stiffener bolt 13. Engine hook : 2.4 N⋅m (0.24 kgf-m, 2.0 lbf-ft)
: For tightening order, refer to “Exhaust Manifold
Removal and Installation”: K14B (Page 1K-3).
7. HO2S-2 (connector color: gray) 14. HO2S-1 (connector color: black) : Do not reuse.
1K-3 Exhaust System: K14B

Exhaust Manifold Removal and Installation

AENBL80A1B16002 3

Removal

! CAUTION
Be careful not to drop exhaust manifold. If it 4
is dropped, inside catalytic converter may be
damaged by impact.
1

1) Disconnect negative (–) cable at battery.

2) Disconnect HO2S-1 connector (1) (connector color:
black) and HO2S-2 connector (2) (connector color:
gray), and then detach them from their stay.
2

1 2
5
IAP70P1B0003-01

Installation
Reverse removal procedure noting the following points.
• Use new gasket.
• Tighten exhaust manifold bolts and nuts to specified
2 torque.
Tightening torque
Exhaust manifold bolt (a): 60 N·m (6.1 kgf-m, 44.5
IAP70P1B0002-01 lbf-ft)
3) Disconnect exhaust No.1 pipe (1) from exhaust Exhaust manifold nut (b): 60 N·m (6.1 kgf-m, 44.5
manifold. lbf-ft)

(a) (b) (a)

(b)

I7V20A1B1003-01

4) Remove exhaust manifold stiffeners (2). I9P60A1B1002-02

5) Remove exhaust manifold cover (3) from exhaust
manifold.
6) Remove HO2S-1 (4) and HO2S-2 (5) from exhaust
manifold, if necessary. )(Page 1C-6)
7) Remove exhaust manifold (1) and its gasket from
cylinder head.
• Install HO2S-1 and HO2S-2 if removed. )(Page 1C-
6)
• Install exhaust manifold stiffeners as follows.
a. Install exhaust manifold stiffeners (1), then tighten
exhaust manifold stiffener nuts (2) by hand.
b. Tighten exhaust manifold stiffener bolts (3), then
tighten exhaust manifold stiffener nuts (2).
 Exhaust System: K14B 1K-4

1 (a)
I9P60A1B1004-01

1
• Run engine and check for exhaust gas leakage.
2
IAP70P1B0004-01

• Tighten exhaust No.1 pipe bolts to specified torque.
Tightening torque
Exhaust No.1 pipe bolt (a): 43 N·m (4.4 kgf-m,
32.0 lbf-ft)
Exhaust Pipe and Muffler Removal and
Installation
AENBL80A1B16003
For replacement of exhaust pipe, and muffler, refer to
“Exhaust System Components”: K14B (Page 1K-2) and
the following.
• Tighten bolts and nuts to specified torque when
reassembling. )(Page 1K-2)
• Run engine and check for exhaust gas leakage.

Specifications
Tightening Torque Specifications
AENBL80A1B17001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Exhaust manifold bolt 60 6.1 44.5 )
Exhaust manifold nut 60 6.1 44.5 )
Exhaust No.1 pipe bolt 43 4.4 32.0 )

NOTE
The tightening torque(s) also specified in:
“Exhaust System Components”: K14B

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
1K-5 Exhaust System: D13A

D13A
General Description
Exhaust System Description The catalytic converter is an emission control device
AENBL80A1B21001 added to the exhaust system to lower the levels of
The exhaust system consists of an exhaust manifold, a
Hydrocarbon (HC) and Carbon Monoxide (CO)
catalytic converter, a turbocharger, an exhaust pipe, a
pollutants in the exhaust gas.
muffler, and seals, gaskets, etc.

Diagnostic Information and Procedures

Exhaust System Check
AENBL80A1B24001
! WARNING
In order to help avoid getting burned, do not work on exhaust system when it is hot. Exhaust system
must be sufficiently cool before beginning any service on it.

Check the exhaust system at every periodic vehicle inspection and when the vehicle is hoisted for other service noting
the following points:
• Check rubber mountings for damage, deterioration, and out of position.

IYSY011B0003-01

• Check exhaust system for exhaust gas leakage, loose connection, dent and damage.
• If bolts, nuts, clamp and sensors are loosened, tighten them to specified torque. )(Page 1K-6)
• Check nearby body areas for damaged, missing or improper installing part, open seam, hole or any other defect
which could permit exhaust fumes to penetrate into vehicle.
• Check that exhaust system components have enough clearance from other underbody components to avoid
overheating and possible damage to these components.
• Check for any defects and fix them whenever found.
 Exhaust System: D13A 1K-6

Repair Instructions
Exhaust System Components
AENBL80A1B26001

10

8
5

3 1

2
IBL80A1B2003-02

1. Catalytic convertor cover 6. Heat insulator : 60 N⋅m (6.1 kgf-m, 44.5 lbf-ft)
2. Catalytic convertor 7. Exhaust pipe No.2 : 55 N⋅m (5.6 kgf-m, 40.5 lbf-ft)
3. Catalytic convertor brace 8. Mounting No.1 : 2.4 N⋅m (0.24 kgf-m, 2.0 lbf-ft)
4. Exhaust pipe No.1 9. Muffler : Do not reuse.
5. Gasket 10. Mounting No.2
1K-7 Exhaust System: D13A

Exhaust Manifold Components

AENBL80A1B26002

1 3

2
(b)

(a)

(c)
I7V20A1B2002-02

1. Exhaust manifold cover : 30 N⋅m (3.05 kgf-m, 22.13 lbf-ft)

2. Exhaust manifold gasket : 9 N⋅m (0.9 kgf-m, 7 lbf-ft)
3. Exhaust manifold : Do not reuse.
4. Engine hanger

Exhaust Manifold Removal and Installation 5) Remove coolant feed pipe (1)
AENBL80A1B26006

Removal 1

! WARNING
To avoid danger of being burned, do not
service exhaust system while it is still hot.
Service should be performed after system
cools down.

1) Disconnect negative (–) cable at battery.

2) Drain engine coolant. )(Page 1F-22)
IAY40A1B0001-01
3) Remove air cleaner assembly with MAF and IAT
6) Remove exhaust manifold (1) and exhaust manifold
sensor. )(Page 1D-64)
gasket (2).
4) Remove turbocharger. )(Page 1D-72)

I3RM0B1B2004-01
Installation
1) Install exhaust manifold (1) with new gasket (3).
2) Tighten new exhaust manifold nut (2).
Tightening torque
Exhaust manifold nut (a): 30 N·m (3.05 kgf-m,
22.13 lbf-ft)
I3RM0B1B2005-01
3) Install coolant feed pipe (1).
Tightening torque
Coolant feed pipe bolt (a): 9 N·m (.9 kgf-m, 7.0
lbf-ft)
4) Install turbocharger. )(Page 1D-72)
5) Install air cleaner assembly with MAF sensor.
)(Page 1D-64)
6) Refill cooling system for equipped with A/C. )(Page
1F-22)
7) Connect negative (–) cable at battery.
8) Check to make sure that there is no oil leakage,
coolant leakage and exhaust gas leakage at each
connection.
Exhaust Manifold Inspection
AENBL80A1B26005
Check exhaust manifold for crack and damage.
Replace exhaust manifold as necessary.
Catalytic Converter Removal and Installation
AENBL80A1B26003
Exhaust System: D13A 1K-8
! WARNING
To avoid the danger of being burned, do not
touch the exhaust system when the system is
hot. Any service on the exhaust system
should be performed when the system is
cool.
Removal
1) Disconnect negative (–) cable at battery.
2) Remove oil cooler. )(Page 1E-15)
3) Remove A/F sensor. )(Page 1B-9)
4) Remove catalytic converter (3) as follows:
a) Remove exhaust pipe No.1 clamp and catalytic
converter brace bolt. )(Page 1K-6)
b) Unbend caulking tabs of lock plate (1).
c) Remove bolts (2).
d) Remove catalytic converter (3) and gasket
together.
3
2
IBP80A1B2002-01
Installation
Reverse removal procedure noting the following points.
• Install new gasket and new lock plate (1).
NOTE
When installing catalytic converter with
gasket and lock plate, insertion of M6 bolts or
about 6 mm diameter pins to two bolt holes
as a guide will prevent the gasket and lock
plate from falling down.
• Tighten catalytic converter bolts (2) to specified
torque.
Tightening torque
Catalytic converter bolt (a): 30 N·m (3.1 kgf-m,
22.5 lbf-ft)
• Bend tabs (3) of lock plate to prevent catalytic
converter bolts from loosening.
• Tighten exhaust pipe No. 1 clamp nut to specified
torque. )(Page 1K-6)
• Tighten A/F sensor to specified torque. )(Page 1B-9)
1K-9 Exhaust System: D13A

For replacement of exhaust pipe, hoist vehicle and

2, (a) observe WARNING under “Exhaust System
3 Components”: D13A (Page 1K-6) and the following.
• Tighten each bolt and nut to specified torque when
reassembling. )(Page 1K-6)
• After installation, start engine and check each joint of
1 exhaust system for exhaust gas leakage.
3

2, (a)

IBP80A1B2003-01

• Run engine and check for exhaust gas leakage.

Exhaust Pipe and Muffler Removal and

Installation
AENBL80A1B26004

Specifications
Tightening Torque Specifications
AENBL80A1B27001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Exhaust manifold nut 30 3.05 22.13 )
Coolant feed pipe bolt 9 .9 7.0 )
Catalytic converter bolt 30 3.1 22.5 )

NOTE
The tightening torque(s) also specified in:
“Exhaust System Components”: D13A
“Exhaust Manifold Components”: D13A

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Section 2
Suspension
CONTENTS
Precautions .................................................2-1
Precautions............................................................. 2-1
Precautions for Suspension .................................. 2-1
Suspension General Diagnosis.............. 2A-1
Diagnostic Information and Procedures............2A-1
Suspension, Wheel and Tire Symptom
Diagnosis .......................................................... 2A-1
Repair Instructions ..............................................2A-3
Suspension System Check ................................. 2A-3
Front Suspension .................................... 2B-1
General Description .............................................2B-1
Front Suspension Description ............................. 2B-1
Front Wheel Alignment Description..................... 2B-1
Repair Instructions ..............................................2B-1
Front Wheel Alignment Inspection and
Adjustment ........................................................ 2B-1
Front Strut Assembly Components ..................... 2B-4
Front Strut Assembly Removal and
Installation......................................................... 2B-4
Front Strut Assembly Disassembly and
Reassembly ...................................................... 2B-6
Front Strut Inspection.......................................... 2B-7
Coil Spring, Strut Bearing and Strut Support
Check................................................................ 2B-7
Suspension Arm Components ............................ 2B-8
Suspension Arm Removal and Installation ......... 2B-8
Suspension Arm Check ...................................... 2B-9
Suspension Arm Front Bushing Removal and
Installation....................................................... 2B-10
Suspension Arm Joint Dust Cover Removal
and Installation................................................ 2B-10
Front Suspension Frame and Stabilizer Bar
Components.................................................... 2B-11
Front Suspension Frame, Stabilizer Bar and
Bushing Removal and Installation................... 2B-12
Stabilizer Bar Bushing Removal and
Installation....................................................... 2B-14
Front Suspension Frame Check ....................... 2B-15
Front Stabilizer Bar, Bushing and Joint Check .. 2B-15
Front Suspension Fasteners Check.................. 2B-15
Specifications.....................................................2B-15
Table of Contents 2- i
Tightening Torque Specifications......................2B-15
2
Special Tools and Equipment ...........................2B-16
Recommended Service Material .......................2B-16
Special Tool ......................................................2B-16
Rear Suspension ..................................... 2C-1
General Description .............................................2C-1
Rear Suspension Description..............................2C-1
Repair Instructions ..............................................2C-1
Rear Wheel Alignment Inspection.......................2C-1
Rear Suspension Components ...........................2C-2
Rear Shock Absorber Removal and
Installation .........................................................2C-2
Rear Shock Absorber Inspection ........................2C-4
Rear Coil Spring and Spring Seat Removal
and Installation ..................................................2C-5
Rear Coil Spring and Spring Seat Check............2C-6
Rear Axle Removal and Installation ....................2C-6
Rear Axle Check .................................................2C-7
Rear Suspension Fasteners Inspection ..............2C-7
Specifications.......................................................2C-7
Tightening Torque Specifications........................2C-7
Wheels and Tires ..................................... 2D-1
Precautions...........................................................2D-1
Precautions for Servicing Wheel and Tire...........2D-1
General Description .............................................2D-1
Tire Description ...................................................2D-1
Replacement Tire Description.............................2D-1
Wheel Description ...............................................2D-1
Replacement Wheel Description.........................2D-2
Wheel-Tire Assembly Description (for Vehicle
Equipped with Steel Wheels) ............................2D-2
Repair Instructions ..............................................2D-2
Wheel (with Tire) Removal and Installation.........2D-2
Tire Inspection.....................................................2D-2
Wheel Inspection.................................................2D-3
Wheel Balance Inspection and Adjustment.........2D-4
Tire Rotation........................................................2D-4
Tire Mounting and Dismounting ..........................2D-4
Tire Repair ..........................................................2D-5
Specifications.......................................................2D-5
Tightening Torque Specifications........................2D-5
2-1 Precautions:

Precautions
Suspension

Precautions
Precautions for Suspension
AENBL80A2000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Fastener Caution
Refer to “Fastener Caution” in Section 00 (Page 00-5).

Suspension Caution
Refer to “Suspension Caution” in Section 00 (Page 00-5).

Warning for Wheel (with Tire) Removal

Refer to “Warning for Wheel (with Tire) Removal” in Section 00 (Page 00-5).

Wheels and Brake Caution

Refer to “Wheel and Brake Caution” in Section 00 (Page 00-5).

Air Bag Warning

Refer to “Air Bag Warning” in Section 00 (Page 00-5).

Suspension General Diagnosis
Suspension
Diagnostic Information and Procedures
Suspension, Wheel and Tire Symptom Diagnosis
Condition Possible cause
Vehicle pulls to one side Mismatched or unevenly worn tires
(leads) Tires not adequately inflated
Broken or sagging coil springs
Abnormal lateral force created by radial Replace tire. )(Page 2D-2)
tire
Disturbed wheel alignment
Brake dragging in one road wheel
Loose, bent or broken front or rear
suspension parts
Excessive tire wear Broken or sagging coil springs
Wheel out of balance
Disturbed wheel alignment
Faulty front strut assembly (shock
absorber)
Hard driving
Overloaded vehicle
Not rotated tires
Worn or loose wheel bearing
Wheel or tire wobbles
Tires not adequately inflated
Wheel tramp Blister or bump on tire
Improper front strut assembly (shock
absorber) action
Shimmy, shake or Wheel out of balance
vibration
Loose wheel bearings
Worn tie-rod ends
Worn suspension arm joints
Excessive tire or wheel run-out
Blister or bump on tire
Excessive radial runout of tire / wheel Replace tire or wheel.
assembly
Disturbed wheel alignment
Loose or worn steering linkage
Loose steering gear case bolts
Suspension General Diagnosis: 2A-1
AENBL80A2104001
Correction / Reference Item
Replace tires. )(Page 2D-2)
Adjust tire pressure.
Replace coil springs.
Front: )(Page 2B-6)
Rear: )(Page 2C-5)
Check wheel alignment.
Front: )(Page 2B-1)
Rear: )(Page 2C-1)
Adjust or repair brake.
Tighten or replace related suspension parts.
)(Page 2A-3)
Replace coil springs.
Front: )(Page 2B-6)
Rear: )(Page 2C-5)
Adjust balance or replace tire.
Check wheel alignment.
Front: )(Page 2B-1)
Rear: )(Page 2C-1)
Replace front strut assembly (shock absorber).
)(Page 2B-4)
Replace tires. )(Page 2D-2)
Replace tires. )(Page 2D-2)
Replace or rotate tires.
Replace wheel bearing.
Front: )(Page 3A-14)
Rear: )(Page 3A-19)
Replace wheel or tire.
Adjust tire pressure.
Replace tire. )(Page 2D-2)
Replace front strut assembly (shock absorber).
)(Page 2B-4)
Balance wheel(s) or replace tire(s) and/or
wheel(s).
Replace wheel bearings.
Front: )(Page 3A-14)
Rear: )(Page 3A-19)
Replace tie-rod ends. )(Page 6C-24)
Replace suspension arm. )(Page 2B-8)
Repair or replace wheel and/or tire.
Replace tire. )(Page 2D-2)
Check and adjust wheel alignment. )(Page
2B-1)
Inspect steering system. )(Page 6A-3)
Tighten steering gear case bolts. )(Page 6C-
25)
2A-2 Suspension General Diagnosis:
Condition Possible cause
Abnormal noise, front end Damaged front strut assembly (shock
absorber) or mountings
Worn, sticky or loose tie-rod ends
Worn or damaged suspension arm joints Replace suspension arm. )(Page 2B-8)
Worn, sticky or loose tie-rod ball joints Replace steering gear case assembly. )(Page
Worn, sticky or loose drive shaft joints Replace drive shaft joints. )(Page 3A-3)
Worn suspension arm front bushings
Worm suspension arm rear bushings
Loose stabilizer bar
Loose wheel nuts
Loose suspension bolts or nuts
Broken or damaged wheel bearings
Broken coil springs
Poorly lubricated or worn strut bearings Replace strut bearings. )(Page 2B-6)
Power steering system malfunction
Too low or uneven trim Broken or sagging coil springs
heights
NOTE Overloaded vehicle
See NOTE *1. Incorrect coil springs
Poorly inflated tires
Too soft ride Faulty front strut assembly (shock
absorber)
Suspension bottoms Overloaded vehicle
Faulty front strut assembly (shock
absorber)
Incorrect, broken or sagging coil springs Replace coil springs.
Body leans or sways in Loose stabilizer bar
corners
Faulty front strut assembly (shock
absorber) or mounting
Broken or sagging coil springs
Overloaded vehicle
Cupped tires Faulty front strut assembly
Worn wheel bearings
Excessive tire or wheel run-out
Worn suspension arm joints
Wheel out of balance
Correction / Reference Item
Repair or replace front strut assembly (shock
absorber) or mountings. )(Page 2B-4)
Replace tie-rod ends. )(Page 6C-24)
6C-25)
Replace suspension arm front bushings.
)(Page 2B-10)
Replace suspension arm. )(Page 2B-8)
Tighten bolts or nuts and/or replace bushings.
)(Page 2B-11)
Tighten wheel nuts. )(Page 2D-2)
Tighten suspension bolts or nuts. )(Page 2B-
8)
Replace wheel bearings. )(Page 3A-14)
Replace coil springs. )(Page 2B-6)
Check and correct malfunction. )(Page 6C-4)
Replace coil springs.
Front: )(Page 2B-6)
Rear: )(Page 2C-5)
Check loading.
Replace coil springs.
Front: )(Page 2B-6)
Rear: )(Page 2C-5)
Adjust tire pressure.
Replace front strut assembly (shock absorber).
)(Page 2B-4)
Check loading.
Replace front strut assembly (shock absorber).
)(Page 2B-4)
Front: )(Page 2B-6)
Rear: )(Page 2C-5)
Tighten stabilizer bar bolts or nuts, or replace
bushings. )(Page 2B-11)
Replace front strut assembly (shock absorber)
or tighten mounting. )(Page 2B-4)
Replace coil springs.
Front: )(Page 2B-6)
Rear: )(Page 2C-5)
Check loading.
Replace front strut assembly. )(Page 2B-4)
Replace wheel bearings.
Front: )(Page 3A-14)
Rear: )(Page 3A-19)
Repair or replace tire and/or wheel.
Replace suspension arm. )(Page 2B-8)
Adjust balance or replace tire.
 Suspension General Diagnosis: 2A-3

NOTE
*1: Right-to-left trim height (“h”) difference should be within 15 mm (0.6 in.) with curb weight. (The
same applies to both front and rear suspensions.)

I8C50A210002-01

Repair Instructions
Suspension System Check
AENBL80A2106001
Hoist vehicle and check the following parts. Retighten, repair or replace with new one if necessary.
Front suspension
• Front suspension frame: )(Page 2B-15)
• Suspension arm: )(Page 2B-9)
• Front strut assembly: )(Page 2B-7)
• Coil spring, strut bearing and strut support: )(Page 2B-7)
• Front stabilizer bar and joint: )(Page 2B-15)

IBL80A210001-01
2A-4 Suspension General Diagnosis:

Rear suspension
• Rear axle: )(Page 2C-7)
• Rear shock absorber )(Page 2C-4)
• Rear coil spring: )(Page 2C-6)

I9P60A210002-01
 Front Suspension: 2B-1

Front Suspension
Suspension

General Description
Front Suspension Description
AENBL80A2201001
• Front suspension employs a McPherson strut type
combined with suspension frame (1).
• The suspension frame supports steering gear case
assembly (2), engine rear mounting (3) and
suspension arms (4), in order to reduce vehicle
vibration.
• Front strut assembly consists of a sealed cylindrical
strut (5) filled with high-pressure gas and a coil spring
(6).
• The front suspension also includes stabilizer bar (7),
to improve anti-rolling performance of vehicle.
6 before inspection.
Front Wheel Alignment Description
AENBL80A2201002
Among factors for front wheel alignment, only toe setting
can be adjusted. Camber and caster cannot be adjusted.
Therefore, should camber or caster be out of
specification due to the damage caused by hazardous
road conditions or collision, whether the damage is in
body or in suspension should be determined and
damaged body should be repaired or damaged
suspension should be replaced.
NOTE
To prevent possible incorrect reading of toe,
camber or caster, vehicle front and rear end
must be moved up and down a few times

5
2

4 1
IBL80A220001-01

Repair Instructions
Front Wheel Alignment Inspection and • Check that each suspension part is free from bend,
Adjustment dent, wear or damage.
AENBL80A2206001
• Place vehicle in non-loaded state on level surface.
Preparation for Front Wheel Alignment Inspection
and Adjustment • Set steering wheel in straight ahead position.
Perform the following before inspecting and adjusting • Bounce vehicle up and down several times to stabilize
front wheel alignment. suspension.
• Check that tire is of specified size. Replace tire with • Check that ground clearance at the right and left is
correct one if necessary. almost the same.
• Check that tire is inflated correctly. Adjust pressure if
necessary. Toe Inspection
Measure toe using toe-in gauge (1).
• Check that tire does not have abnormal wear and is
If toe is out of specification, adjust it at tie-rod.
not worn more than the other tires. Replace tire with
proper one if necessary.
• Check that tire is of the same brand as the other tires.
Replace tire with one of correct brand if necessary.
• Check that wheel bearing is not damaged. Replace
wheel bearing if defective.
• Check wheel (with tire) for deflection. If necessary,
repair or replace.
• Check if each suspension part is installed properly. If
I6RS0C220007-01
defective, repair or replace.
2B-2 Front Suspension:

Front toe (total) “b” – “a” Front toe angle (Each wheel)
: IN 2 ± 2mm (IN 0.04 ± 0.04 in.) : IN 0° 06’ ± 0° 05’

[f]
If front toe angle is out of specification, measure total toe
using toe-in gauge and then adjust it at the tie-rod.

“a” Camber Caster and Kingpin Inclination Angle

Inspection
Check camber, caster and kingpin inclination angle
using camber caster kingpin gauge (1) and turning
radius gauge (2). If measured value is out of specified
value, check following items for damage, deformation
and cracks. Repair or replace any defective part.
• Strut assembly components
• Suspension arms and bushings
“b” • Front suspension frame
I7V10A220002-02 • Front wheel hubs, steering knuckles and wheel
[f]: Forward bearings
• Vehicle body
Toe Adjustment

! CAUTION

• Never adjust only right side or left side tie-

rod. Be sure to adjust both tie-rods by the
same amount. 1

• Make sure that rack boot is not twisted.

Otherwise, rack boot may be broken. 2

1) Loosen tie-rod end lock nuts.

2) Tighten or loosen right and left tie-rods by the same I7RS0A220003-01
amount to adjust toe to specification.
Front camber “a”
3) Check that length “a” on right tie-rod is equal to that : +0° 24’
on left tie-rod. If they are not equal, readjust toe.
Front caster “b”
“a” : 4° 55’
Kingpin inclination angle “c”
Front: 12° 00’

NOTE
Camber, caster and kingpin inclination angle
I9P60A220002-02
are not adjustable. If they are out of
4) After adjustment, tighten tie-rod end lock nuts to specification, repair vehicle body or replace
specified torque. )(Page 6C-23) related part.

Reference Information
Side slip
When checked using side slip tester, side slip should be
within the following specification.
Side slip (On one person)
: 0 to IN 3 mm/m (0 to IN 0.12 in./3.3 ft.)
If side slip deviates from specification greatly, front wheel
alignment may be out of specification.

Toe angle
Reference front toe angle when measured using total
wheel alignment tester or the like, is as follow.
 Front Suspension: 2B-3

Steering Angle Inspection and Adjustment

[A] [k]
2
When tie-rod or tie-rod end is replaced, check toe and
then also steering angle using turning radius gauge. If
“c”
measured value is out of specified value, inspect and
[t] adjust toe.
Inside steering angle
: 41° 6’ ± 2°
[s]
Outside steering angle
: 33° 18’ ± 2°

“d” 1

“a”

[B] “b”

[f]

“d”

I7V10A220004-02

[A]: Camber and kingpin [f]: Forward

inclination angle (Front view)
[B]: Caster (Side view)
“d”: 90°
1. Suspension arm joint
2. Strut support
[k]: Center line of kingpin
[s]: Vehicle body center
[t]: Center line of wheel
2B-4 Front Suspension:

Front Strut Assembly Components

AENBL80A2206002

(a)
9
(a)

7
6

1
4

13

3
(a)
11

2 (b)

10
[f]

12

IBL80A220002-01

[f]: Forward 6. Strut bearing 12. Steering knuckle

1. Front strut 7. Strut bearing plate 13. Damper cap
2. Coil spring 8. Strut support : 50 N⋅m (5.1 kgf-m, 37.0 lbf-ft)
: For installing direction of coil spring, refer
to )(Page 2B-6).
3. Bump stopper 9. Rebound stopper : 90 N⋅m (9.2 kgf-m, 66.5 lbf-ft)
4. Strut dust cover 10. Strut bracket bolt : Do not reuse.
: Set strut dust cover over of damper cap : Insert from vehicle front side.
5. Coil spring upper seat 11. Stabilizer joint

Front Strut Assembly Removal and Installation NOTE

AENBL80A2206003
When servicing strut assembly components,
! CAUTION loosen strut support upper nut a little before
removing strut assembly. This will facilitate
• When rebound stopper and front strut service work. Note that the nut must not be
assembly are removed, check that strut removed at this point.
support lower nut is tightened to specified
torque before installing strut assembly. 2) Remove front wheel. )(Page 2D-2)
)(Page 2B-6) 3) Remove stabilizer joint nut while holding stud using
• Strut bracket nut is precoated with friction hexagon wrench (2) and then disconnect stabilizer
stabilizer. Do not reuse nut, otherwise nut upper joint (1) from strut (3).
may loosen.

Removal
1) Hoist vehicle, allowing front suspension to be free of
vehicle weight.
 Front Suspension: 2B-5

• Insert strut bracket bolts (1) in the direction shown in

figure.
• Use new strut bracket nuts (4).
2 3 • Tighten all fasteners to specified torque.
1 Tightening torque
Strut bracket nut (a): 90 N·m (9.2 kgf-m, 66.5 lbf-
ft)
Brake hose mounting bolt (c): 26 N·m (2.7 kgf-m,
19.5 lbf-ft)
Stabilizer joint nut (d): 50 N·m (5.1 kgf-m, 37.0 lbf-
ft)
I9P60A220004-01

4) Remove brake hose mounting bolt (1), to detach NOTE

brake hose (2). • Do not twist brake hose and front wheel
5) For ABS model, remove front wheel speed sensor speed sensor harness (with ABS) when
harness (3) and clip (7) from front strut (4). installing them.
6) Remove strut bracket nuts (5) and bolts (6). • Install front wheel speed sensor harness
by fitting its grommet (3) on hook of
bracket (2) (with ABS).
3 4
• Tighten wheel nuts to specified torque. )(Page 2D-2)
• Lower hoist with vehicle in unloaded condition, then
7 tighten strut support upper nut to specified torque.
Tightening torque
Strut support upper nut (b): 50 N·m (5.1 kgf-m,
4
37.0 lbf-ft)

1
6
5
I9P60A220005-01
(b)

7) Remove strut support upper nut (1) and rebound

stopper (2), then remove front strut assembly from 3 2
vehicle.
[f]
! CAUTION
Hold strut with hands to prevent it from
falling off.

(d)
2

4,(a)
(c)

I9P60A220007-02
1
I9P60A220006-01 [f]: Forward

Installation • After completing installation, check front wheel

Reverse removal procedure, noting the following points. alignment. )(Page 2B-1)
2B-6 Front Suspension:

Front Strut Assembly Disassembly and Special tool

Reassembly (A): 09943M25010
AENBL80A2206004
Length
! WARNING “a”: About 260 mm (10.2 in.)
When compressing coil spring, observe the “a”
following points to avoid personal injury.
• Attach spring compressor to coil spring
securely.
• Do not use impact wrench for compressing (A)
[u] [l]
it.
• Use commercially available spring
compressor strictly following
manufacturer’s instructions. I9P60A220009-02

[u]: Upper side (large diameter)

! CAUTION [l]: Lower side (small diameter)

Strut support lower nut is precoated with

friction stabilizer. Do not reuse nut, otherwise 2) Install compressed coil spring to front strut by fitting
nut may loosen. coil spring end (2) onto spring lower seat (1) as
shown in figure.
Disassembly NOTE
1) Attach special tool (A) to coil spring as shown. Screw
Spring end should not ride on step in spring
in special tool bolts (1) alternately until coil spring
lower seat.
tension is released from strut. Rotate strut to confirm
that it is free of coil spring tension.
Special tool
(A): 09943M25010

(A)
1

1 1 2

I9P60A220010-01
I9P60A220008-02
3) Set bump stopper. )(Page 2B-4)
2) While keeping coil spring compressed using special
4) Set strut dust cover (1) over three claws (2) of
tool, remove strut support lower nut using hexagon
damper cap (3).
wrench as shown in figure.

1
1 3

I5RW0A220008-01

3) Disassemble front strut assembly. )(Page 2B-4) I9P60A220011-02

5) Pull strut rod as far up as possible and use care not

Reassembly to allow it to retract into strut.
1) Compress coil spring using special tool (spring 6) Install coil spring upper seat.
compressor) until total length “a” becomes about 260
mm (10.2 in.).

7) Install strut bearing, strut bearing plate, strut support
and new strut support lower nut in this sequence.
)(Page 2B-4)
Then tighten strut support lower nut to specified
torque while holding stud using hexagon wrench.
Tightening torque
Strut support lower nut (a): 50 N·m (5.1 kgf-m,
37.0 lbf-ft)
(a)
I9P60A220038-01
8) Remove special tool (spring compressor) from coil
spring.
Front Strut Inspection
AENBL80A2206005
! WARNING
Since high-pressure gas is sealed inside
front strut (1), there is risk of personal injury
if it is handled without observing the
following precautions.
• Do not disassemble front strut.
• Do not put front strut into fire.
• Do not store front strut where it gets hot.
• Before disposing of front strut, be sure to
drill an approximately 3 mm (0.1 in.)
diameter hole (2) in it at point indicated in
the figure to let gas out of the cylinder
together with oil. Be sure to wear eye
shield when drilling hole because metal
chips produced by drilling can injure your
eyes although the gas itself is harmless.
2 damage.
1
I9P60A220039-01
Front Suspension: 2B-7
• Check each front strut for oil leakage, damage or
deformation. If check result is not OK, replace front
strut as an assembly, as it is not repairable.
I9P60A220013-01
• Inspect front strut function as follows. If check result is
not OK, replace front strut as an assembly, because it
cannot be disassembled.
a. Check and adjust tire pressures as specified.
b. Bounce vehicle body up and down 3 or 4 times
continuously by pushing front end of vehicle side
body to check front strut.
Also, note how many times vehicle body rebounds
to stop after force application.
c. Repeat the same procedure to the other front strut
to confirm that both struts equally function.
If conditions of front struts are in doubt, compare
them with known-good vehicle or front strut.
Coil Spring, Strut Bearing and Strut Support
Check
AENBL80A2206006
• Check coil spring for weakening, crack, deformation
and damage.
• Check bump stopper, strut dust cover, coil spring
upper seat and strut support for crack, deformation
and damage.
• Check strut bearing for wear, abnormal noise and
If check result is not OK, replace defective parts with
new one.
2B-8 Front Suspension:

Suspension Arm Components ! CAUTION

AENBL80A2206007
When fitting of ball joint is released by
2 tightening of the puller, the puller may come
off. Suspend it with a piece of string in order
to prevent it from falling down.

(a)
(a) 4 NOTE
(b) Before fitting puller, install removed joint nut
1
3 upside down to ball joint stud until nut end
[f] becomes flush with stud end. This nut
I9P60A220014-01
protect thread end of the stud against
deformation. After disconnecting suspension
[f]: Forward 4. Clip
arm joint, discard the nut.
1. Suspension arm : 95 N⋅m (9.7 kgf-m, 70.0 lbf-ft)
2. Suspension arm front : 55 N⋅m (5.6 kgf-m, 40.5 lbf-ft)
bushing
3. Suspension arm joint : Do not reuse.
dust cover
: Apply grease from the
service kit to spare part.

2
Suspension Arm Removal and Installation
AENBL80A2206008
! CAUTION

• When removing and installing suspension 3

arm, be careful not to damage suspension
arm joint dust cover. 1
Otherwise, grease may flow out, resulting I9P60A220016-01

in damage to the joint. 5) Remove suspension arm front bushing bolt (2) and
• Suspension arm front bushing bolt, suspension arm rear bushing bolt (3), then remove
suspension arm rear bushing bolt and suspension arm (1).
suspension arm joint nut are precoated
with friction stabilizer. Do not reuse bolt
and nut. Otherwise, bolt and nut may
loosen. 2

Removal
1) Hoist vehicle and remove front wheel. )(Page 2D-2)
2) Remove engine undercover (if equipped).
3) Remove clip (2) and suspension arm joint nut (1).

3 1
I9P60A220017-02

2 Installation
1) Install suspension arm (1) and tighten new
suspension arm front bushing bolt (2) and
1
suspension arm rear bushing bolt (3) temporarily by
hand.

I9P60A220015-03

4) Disconnect suspension arm joint (1) from steering

knuckle (2) using puller (3).
 Front Suspension: 2B-9

2 (a)

3 1 (b) 1
I9P60A220017-02 I9P60A220019-01

2) Connect suspension arm joint to steering knuckle 1. Suspension arm

and then tighten new suspension arm joint nut (1) to
specified torque. 6) Hoist vehicle again, then install engine undercover.
Tightening torque 7) Lower hoist, then check front wheel alignment.
Suspension arm joint nut (a): 55 N·m (5.6 kgf-m, )(Page 2B-1)
40.5 lbf-ft)
Suspension Arm Check
NOTE AENBL80A2206009

If grease is stuck on taper surface of

suspension arm joint and knuckle, remove it Arm
before connecting these parts. Check body of suspension arm (1) for damage and
deterioration. Replace suspension arm if check result is
3) Insert clip (2) to suspension arm joint. not OK.

Bushing
Check suspension arm front bushing (2) for damage,
wear and deterioration. Replace bushing if check result
2 is not OK.
Check suspension arm rear bushing (3) for damage,
wear and deterioration. Replace suspension arm
1, (a) assembly if check result is not OK.

I9P60A220018-03

4) Install front wheel and tighten wheel nuts to specified

torque. )(Page 2D-2)
5) Lower hoist and bounce vehicle up and down
several times to stabilize suspension. Then, tighten
suspension arm front bushing bolt and suspension
arm rear bushing bolt to specified torques.
Tightening torque
Suspension arm front bushing bolt (a): 95 N·m (
9.7 kgf-m, 70.0 lbf-ft)
Suspension arm rear bushing bolt (b): 95 N·m (
9.7 kgf-m, 70.0 lbf-ft)
2
I9P60A220040-01
Joint
• Check that suspension arm joint (1) is not stuck, is not
damaged and does not have play. Replace
suspension arm assembly if check result is not OK.
• Check suspension arm joint dust cover (2) for cracks
and damage. Replace suspension arm joint dust
cover and dust cover clip (3) if check result is not OK.
2B-10 Front Suspension:

NOTE Installation
Suspension arm and arm joint cannot be 1) Press-fit front suspension arm front bushing (1)
separated. using special tools and hydraulic press (2).

! CAUTION
1 Do not reuse bushing.

2
Special tool
(A): 09943M76310
(B): 09913M75821

NOTE
3
Before installing bushing, apply soap water
I9P60A220021-01
on its circumference to facilitate installation.

Suspension Arm Front Bushing Removal and

2
Installation
AENBL80A2206010
(B)
NOTE
1
Suspension arm rear bushing is not
individually replaceable. Replace suspension
(A)
arm if the bushing is defective.

Removal
1) Cut off flange of front suspension arm front bushing
I9P60A220024-01
(rubber) (1) using knife.
2) Press-fit front suspension arm front bushing (1) so
that dimensions “a” and “b” in figure become equal.

“a” “b”

I7V10A220012-01
I9P60A220022-01

2) Push out front suspension arm front bushing (1) Suspension Arm Joint Dust Cover Removal and
using hydraulic press (2) and special tools. Installation
AENBL80A2206011
Special tool
(A): 09943M76310 Removal
(B): 09913M75821 1) Remove clip (1) from suspension arm joint dust
cover.
2 2) Remove suspension arm joint dust cover (2) using
flat-bladed screwdriver or the like.
(B)

(A)

I9P60A220023-01
 Front Suspension: 2B-11

NOTE Installation
Suspension arm and arm joint cannot be Reverse removal procedure, noting the following point.
separated. • If suspension arm joint dust cover is replaced, apply a
generous amount of grease (included in suspension
arm joint dust cover set) to suspension arm joint and
inside of suspension arm joint dust cover.

I9P60A220025-01

Front Suspension Frame and Stabilizer Bar Components

AENBL80A2206012

(a)
3

6 (c)

7
(b)

[f]
(e)

(d)
(e)
5

IBL80A220003-01

[f]: Forward 5. Suspension arm : 50 N⋅m (5.1 kgf-m, 37.0 lbf-ft)

1. Stabilizer bar 6. Front suspension frame : 60 N⋅m (6.1 kgf-m, 44.2 lbf-ft)
2. Stabilizer bar bushing 7. Suspension frame : 55 N⋅m (5.6 kgf-m, 40.6 lbf-ft)
3. Stabilizer mounting bracket : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft) : Do not reuse.
: For correct installing direction of stabilizer mounting
bracket, refer to “Front Suspension Frame, Stabilizer Bar
and Bushing Removal and Installation” (Page 2B-12).
4. Stabilizer joint : 95 N⋅m (9.7 kgf-m, 70.0 lbf-ft)
2B-12 Front Suspension:

Front Suspension Frame, Stabilizer Bar and NOTE

Bushing Removal and Installation • Be careful not to damage hood with a
AENBL80A2206013
chain hoist or an engine crane.
! WARNING • For D13A model, place a cloth between
chain and intercooler outlet pipe (2) and
• When installing front suspension frame,
protect the paint surface from damage.
support the frame on transmission jack at
well-balanced position in the center
section of front suspension frame.
[A]
Improperly supported frame could drop
and cause personal injury.
• Make sure exhaust system is cool before
starting service operation, in order to
avoid burn by hot exhaust system
components.

! CAUTION

• When removing and installing suspension

arm, be careful not to damage dust cover
of suspension arm joint by drive shaft dust
cover and brake dust cover.

Removal
1) Disconnect negative (–) cable at battery. 1
2) For D13A model, remove engine cover. [B]
3) Disconnect steering lower shaft from pinion shaft. 2
)(Page 6B-13) 1
4) Hoist vehicle and remove front wheels. )(Page 2D-
2)
5) Remove engine undercover.
6) Remove muffler mounting from front suspension
frame.
• K14B model: )(Page 1K-2)
• D13A model: )(Page 1K-6)
7) Disconnect stabilizer joints from stabilizer bar.
8) Disconnect right and left tie-rod ends from steering
knuckles. )(Page 6C-24)
1
9) Remove right and left suspension arms. )(Page 2B- IBP80A220003-02
8) [A]: K14B model
10) Bring hood up to upright position and hold it at the [B]: D13A model
position with rope.
11) Support engine assembly using a chain hoist (1) or 12) Remove engine rear mounting bolts.
an engine crane. • K14B model: )(Page 1D-18)
• D13A model: )(Page 1D-77)
13) Support front suspension frame (2) using
transmission jack (1).
 Front Suspension: 2B-13

NOTE
2
• Install stabilizer bar (1) with identification
painting (5) facing up.
• Install stabilizer bar bushing (2) with its
end closely fitted against ring (4) of
stabilizer bar.

3) Tighten stabilizer bar mounting bracket bolts to

specified torque in numerical order of (“1” and “2”) as
shown in figure.
Tightening torque
Stabilizer bar mounting bracket bolt* (a): 23 N·m
1 (2.3 kgf-m, 17.0 lbf-ft)
I9P60A220028-01

14) Remove suspension frame mounting bolts (1) and

(2), then lower transmission jack to remove
“1”,(a) 6
suspension frame (3) together with stabilizer bar and 2
[f] 2
3
steering gear case from vehicle body.

1
4
“2”,(a) [f]

3 2

5
1

I9P60A220029-02
IBP80A220004-01
15) Remove front stabilizer bar (1) and bushing from
front suspension frame (2). [f]: Forward 6. Slit

4) Put front suspension frame (2) on transmission jack

(1) and raise jack.

I9P60A220030-01

16) Remove steering gear case assembly from front

suspension frame. )(Page 6C-25) 1
I9P60A220032-01
Installation 5) Align right and left bosses (1) of front suspension
1) Install steering gear case assembly to front frame with holes (2) in vehicle body.
suspension frame. )(Page 6C-25)
2) Install front stabilizer bar (1), bushing (2) and
mounting brackets (3) to front suspension frame as
shown in figure.
2B-14 Front Suspension:

16) Install front wheels and tighten wheel nuts to

2 specified torque. )(Page 2D-2)
17) Connect steering lower shaft to pinion shaft. )(Page
6B-13)
18) For D13A model, install engine cover. )(Page 1D-
63).
19) Lower hoist and bounce vehicle up and down
several times to stabilize suspension. And then,
tighten suspension arm front bushing bolt and rear
bushing bolt to specified torque. )(Page 2B-8)
20) Connect negative (–) cable at battery.
1
21) Check front wheel alignment. )(Page 2B-1)
I9P60A220033-01

6) Install new suspension frame mounting No.1 bolt (1)

Stabilizer Bar Bushing Removal and Installation
and nuts (2) and tighten them to specified torque. AENBL80A2206014
Removal
Tightening torque
Suspension frame mounting No. 1 bolt (a): 95 1) For K14B model, remove exhaust No.1 pipe and
N·m (9.7 kgf-m, 70.0 lbf-ft) exhaust center pipe. )(Page 1K-2)
Suspension frame mounting nuts (b): 60 N·m ( 2) For D13A model, remove exhaust pipe No.1 and
6.1 kgf-m, 44.2 lbf-ft) exhaust pipe No.2. )(Page 1K-6)
3) Remove stabilizer bar mounting bracket (3) and bolts
1, (a) (5).
4) Remove stabilizer bar bushings (2).
2, (b)

[f] 5
2

4
5
4 1

5
I9P60A220034-02

7) Lower transmission jack.

8) Install engine rear mounting bolts to specified torque.
• K14B model: )(Page 1D-18) 3 2
• D13A model: )(Page 1D-77)
9) Remove chain hoist from engine assembly and undo
rope pulling hood.
10) Install suspension arms to front suspension frame,
then finger tighten new suspension arm front I9P60A220037-03
bushing bolt and suspension arm rear bushing bolt [f]: Forward 4. Ring
temporarily by hand. )(Page 2B-8) 1. Stabilizer bar
11) Connect suspension arm joints to steering knuckles.
)(Page 2B-8) Installation
12) Connect right and left tie-rod ends to steering Reverse removal procedure noting the following point.
knuckles. )(Page 6C-24) • When installing stabilizer bar bushing and stabilizer
13) Connect stabilizer joints to each stabilizer bar. bar mounting bracket, refer to steps 2) and 3) of
)(Page 2B-4) Installation procedure in Front Suspension Frame,
Stabilizer Bar and Bushing Removal and Installation.
14) Install muffler mounting to front suspension frame.
)(Page 2B-12)
• K14M model: )(Page 1K-2)
• D13A model: )(Page 1K-6)
15) Install engine undercover (if equipped).
 Front Suspension: 2B-15

Front Suspension Frame Check Stabilizer Joint

AENBL80A2206015
Check front suspension frame for crack, deformation
and damage. Replace front suspension frame if check
result is not OK. )(Page 9K-36)
• Check ball stud for smooth movement.
• Check ball stud for looseness.
• Check dust cover for damage and crack.
• Check rod for damage and deformation.

NOTE
Stabilizer joint cannot be disassembled.

If check result is not OK, replace stabilizer joint

assembly.

Front Suspension Fasteners Check

AENBL80A2206017
Check bolts and nuts fastening suspension parts for
tightness. Tighten loose fastener, if any, to specified
I9P60A220035-01
torque.
For specified torque, refer to:
Front Stabilizer Bar, Bushing and Joint Check
AENBL80A2206016 • “Front Strut Assembly Components” (Page 2B-4)
Stabilizer Bar • “Suspension Arm Components” (Page 2B-8)
Check stabilizer bar for damage and deformation.
Replace stabilizer bar if check result is not OK. • “Front Suspension Frame and Stabilizer Bar
Components” (Page 2B-11)
Stabilizer Bar Bushing
Check stabilizer bar bushing for damage and
deterioration. Replace stabilizer bar bushing if check
result is not OK.

Specifications
Tightening Torque Specifications
AENBL80A2207001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Strut bracket nut 90 9.2 66.5 )
Brake hose mounting bolt 26 2.7 19.5 )
Stabilizer joint nut 50 5.1 37.0 )
Strut support upper nut 50 5.1 37.0 )
Strut support lower nut 50 5.1 37.0 )
Suspension arm joint nut 55 5.6 40.5 )
Suspension arm front bushing bolt 95 9.7 70.0 )
Suspension arm rear bushing bolt 95 9.7 70.0 )
Stabilizer bar mounting bracket bolt* 23 2.3 17.0 )
Suspension frame mounting No. 1 bolt 95 9.7 70.0 )
Suspension frame mounting nuts 60 6.1 44.2 )

NOTE
The tightening torque(s) also specified in:
“Front Strut Assembly Components”:
“Suspension Arm Components”:
“Front Suspension Frame and Stabilizer Bar Components”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
2B-16 Front Suspension:

Special Tools and Equipment

Recommended Service Material
AENBL80A2208001
NOTE
Required service material(s) also described in:
“Suspension Arm Components”:

Special Tool
AENBL80A2208002
09913M75821 09943M25010
Bearing installer attachment Spring compressor
)/) )/)

09943M76310
Bush remover
)/)
 Rear Suspension: 2C-1

Rear Suspension
Suspension

General Description
Rear Suspension Description
AENBL80A2301001
Rear suspension is of a torsion beam type having rear axle connected with torsion beam.

Repair Instructions
Rear Wheel Alignment Inspection Inspection
AENBL80A2306001 Measure toe and camber. )(Page 2B-1)
Preparation
Before inspecting rear wheel alignment, perform the NOTE
following items.
Rear toe and camber are not adjustable. If
• Empty luggage compartment. they are out of specification, replace
• Check tires for specified size. reference part.
If not, replace tires with those of the specified size.
• Check that inflation pressure of each tire is adjusted Rear Toe (Total)
properly. If necessary, adjust tire pressure, repair or IN: 4.0 ± 4.0 mm (IN 0.157 ± 0.157 in)
replace tire. Rear camber
• Check all tires for even wear and that they are of the : –1° 15’
same brand. Replace tire(s) if necessary. If measured value is out of specified value, check the
• Check that wheel bearing is not damaged. Replace following parts for damage, deformation and crack.
wheel bearing if defective. • Rear axle (torsion beam)
• Check each wheel (with tire) for deflection. If • Wheel hub or wheel bearing
necessary, repair or replace wheel.
• Vehicle body
• Check that each suspension part is installed properly.
If defective, repair or replace part. Reference information
• Check that each suspension part is free from bend, Toe angle
dent, wear or damage. Reference rear toe angle when measured with total
• Place vehicle in non-loaded state on level surface. wheel alignment tester or the like, is as follows.
• Bounce vehicle up and down several times to stabilize Rear toe angle (Each wheel)
suspension. : IN 0° 12’
• Check that ground clearance at the right and left is
almost the same.
2C-2 Rear Suspension:

Rear Suspension Components

AENBL80A2306002

10

(b)

9
8

[f]

11

(a) (c)

(c)

5
IBL80A230001-01

1. Rear coil spring
2. Rear spring lower seat
: For installing direction of rear spring
lower seat. )(Page 2C-4)
3. Rear spring upper seat
: For installing direction of rear spring
upper seat. )(Page 2C-4)
4. Rear axle
5. Wheel hub assembly
6. Brake back plate
7. Rear shock absorber : 28 N⋅m (2.9 kgf-m, 21.0 lbf-ft)
8. Shock absorber upper bushing : 90 N⋅m (9.2 kgf-m, 66.5 lbf-ft)
: For installing direction of shock absorber upper bushings.
)(Page 2C-2)
9. Shock absorber upper washer : Do not reuse.
: For installing direction of shock absorber upper washer.
)(Page 2C-2)
10. Shock absorber cap [f]: Forward
11. Shock absorber lower washer
: For installing direction of shock absorber lower washer
)(Page 2C-2)
: 88 N⋅m (9.0 kgf-m, 65.0 lbf-ft)

Rear Shock Absorber Removal and Installation

AENBL80A2306003
Removal
1) Hoist vehicle and remove rear wheels. )(Page 2D-
2)
2) Remove armrest (1) in quarter inner lower trim (2)
after opening the bolt (3)
 Rear Suspension: 2C-3

3 1

1
2
IBL80A230002-01

3) Support rear axle using floor jack to prevent it from IBL80A230004-01

lowering.
4) Remove rear shock absorber lower nut (1) and lower Installation
washer (5).
! CAUTION
5) Remove shock absorber cap.
6) Remove rear shock absorber upper nut (2), shock Rear shock absorber upper nut is self-
absorber (3) and shock absorber upper washer (4). locking nut. Do not reuse nut. Otherwise, nut
may loosen.

1) Install shock absorber upper bushings (6), shock

2 absorber (1), shock absorber upper washer (2) and
shock absorber lower washer (7) as shown in figure.
4
Tighten new shock absorber upper nut (4) and lower
nut (5) temporarily at this step.

NOTE
Refer to the following figure for installing
direction of shock absorber upper bushings,
washer (2) and washer (7).

3
4 2

6 3

1
1

5 7

IBL80A230003-01

7) Remove shock absorber upper bushings (1).

5
IBL80A230005-01

3. Body panel
2C-4 Rear Suspension:

2) Remove floor jack from rear axle. ! WARNING

3) Install rear wheels. )(Page 2D-2)
Since high-pressure gas is sealed inside rear
4) Lower hoist. With vehicle in unloaded condition,
shock absorber (1), there is risk of personal
tighten rear shock absorber upper nuts and lower
injury if it is handled without observing the
nuts to specified torques.
following precautions.
Tightening torque • Do not disassemble rear shock absorber.
Rear shock absorber upper nut (a): 28 N·m (2.9
• Do not put rear shock absorber into fire.
kgf-m, 21.0 lbf-ft)
Rear shock absorber lower nut (b): 90 N·m (9.2 • Do not store rear shock absorber where it
kgf-m, 66.5 lbf-ft) gets hot.
• Before disposing of rear shock absorber,
be sure to drill an approximately 3 mm (0.1
in.) diameter hole (2) in it at point indicated
(a) in the figure to let gas out of shock
absorber together with oil. Be sure to wear
eye shield when drilling hole because
metal chips produced by drilling can injure
your eyes although the gas itself is
harmless.

2
1
(b)
IBL80A230006-01

5) Install shock absorber cap.

6) Install armrest in quarter inner lower trim, and tighten
the bolt.
I9P60A230016-01

Rear Shock Absorber Inspection

AENBL80A2306004 • Inspect shock absorber for deformation or damage.
• Inspect shock absorber upper bushing for wear or
damage.
• Inspect shock absorber for evidence of oil leakage.
• Inspect shock absorber for deterioration.
If check result is not OK, replace shock absorber with
new one.

Rear Coil Spring and Spring Seat Removal and

Installation
AENBL80A2306005
! CAUTION
Be careful not to let rear axle down too much.
It may cause damage to brake flexible hose,
wheel speed sensor lead (with ABS) and
parking brake cable.
 Rear Suspension: 2C-5

Removal
1) Hoist vehicle and remove rear wheels. )(Page 2D-
2) 1

2) Support both ends of rear axle (1) using two floor

jacks (2) to prevent it from lowering.

2 1
2
I9P60A230009-02

3) Remove rear shock absorber lower nut and lower 2

washer. )(Page 2C-2) I9P60A230011-01

4) Detach lower end of shock absorber (1) from rear

Installation
axle.
5) Lower rear axle gradually as far down if necessary ! CAUTION
for removing coil spring (2).
Install spring seat in specified direction.
6) Remove coil spring. Otherwise, noise may occur from coil spring
while vehicle is moving.

1 1) Install spring upper seat (1) to vehicle body and

spring lower seat (2) to rear axle.
2) Install coil spring (3) on spring lower seat of rear
axle. Place coil spring end (4) onto spring lower seat
as shown in figure.

I9P60A230010-03
4
7) Remove spring upper seat (1) from vehicle body and 4
3
spring lower seat (2) from rear axle.
3

2 2
[A] [B]
I9P60A230012-02

[A]: Left side [u]: Upward

[B]: Right side [f]: Forward

3) Jack up rear axle and then install shock absorber (1)

lower end to rear axle.
Install lower washer and tighten shock absorber
lower nut (2) temporarily by hand.
2C-6 Rear Suspension:

3) Remove wheel speed sensor clamp (4) (with ABS),

rear wheel speed sensor harness (5) (with ABS) and
1 parking brake cable clamp (6) from each of both right
and left sides of rear axle.
4) Remove parking brake cable for each of right and left
rear wheels. )(Page 4D-2)
5) Disconnect brake pipe (1) from brake hose (2), and
then remove E-ring (3) at both sides as shown.

2 2 3 1 6 5 4

I9P60A230013-01

4) Remove floor jacks from rear axle.

5) Install rear wheels. )(Page 2D-2)
6) Lower hoist and bounce vehicle up and down
several times to stabilize suspension.
7) Tighten shock absorber lower nuts to specified
torque.

NOTE
When tightening these nuts, be sure that IBP80A230003-02
vehicle is not on hoist and in unloaded 6) Disconnect shock absorber lower end from rear axle
condition. and remove coil spring at both sides. )(Page 2C-4)
7) Remove rear fender lining at both sides.
Tightening torque
Rear shock absorber lower nut: 90 N·m (9.2 kgf- 8) While supporting rear axle at both ends, remove rear
m, 66.5 lbf-ft) axle bolts (1), and then remove rear axle from
vehicle body by lowering floor jack gradually.
Rear Coil Spring and Spring Seat Check
AENBL80A2306006
• Check rear coil spring for crack, damage and
deformation.
• Check spring seat for crack, damage and
deformation.
If check result is not OK, replace rear coil spring and/or
spring seat with new one.
1

Rear Axle Removal and Installation

AENBL80A2306007
! CAUTION
I9P60A230008-02

• Brake fluid is extremely damaging to

painted surfaces. If brake fluid contacts Installation
painted surface, immediately wipe it off 1) Place rear axle on floor jacks.
and flush the surface with water Then install rear axle with new right and left rear axle
thoroughly. bolts (1) and tighten bolts temporarily by hand.
• Rear axle bolts are pre-coated with friction
stabilizer. Do not reuse rear axle bolts,
otherwise bolts may loosen.

Removal
1) Hoist vehicle and remove rear wheels. )(Page 2D-
2)
2) Remove rear brake back plate for each of right and
left rear wheels. )(Page 4C-6)
 Rear Suspension: 2C-7

Tightening torque
Rear axle bolt: 90 N·m (9.2 kgf-m, 66.5 lbf-ft)
13) Install rear fender lining at each of both sides.
14) Check that rear brakes are free from dragging and
proper braking is obtained.
15) Check all installed parts for brake fluid leakage.

1 Rear Axle Check

AENBL80A2306008
• Inspect rear axle (1) for deformation and damage.
• Inspect rear axle bushings (2) for crack, deformation
I9P60A230008-02
and damage. If check result is not OK, replace rear
2) Install coil spring and connect shock absorber lower axle assembly with new one.
end to rear axle at each of both sides. )(Page 2C-4)
3) Connect brake pipes to brake hoses, and then install
E-rings. Tighten rear brake pipe flare nuts to
specified torque. )(Page 4A-12)
4) Install wheel speed sensor clamps (with ABS) and
parking brake cable clamps to rear axle.
5) Install parking brake cable for each of right and left
1
rear wheels. )(Page 4D-2) 2

6) Install rear brake back plate for each of right and left
rear wheels. )(Page 4C-6)
7) After installing brake parts, bleed air from brake
system. )(Page 4A-5)
8) Adjust parking brake. )(Page 4D-2)
9) Install rear wheels. )(Page 2D-2)
2
10) Lower hoist and bounce vehicle up and down I9P60A230015-01
several times to stabilize suspension.
11) Tighten shock absorber lower nuts to specified Rear Suspension Fasteners Inspection
torque. )(Page 2C-2) AENBL80A2306009
Check each bolt and nut fastening suspension parts for
12) Tighten rear axle bolts to specified torque. tightness. Tighten loose one, if any, to specified torque.
)(Page 2C-2)

Specifications
Tightening Torque Specifications
AENBL80A2307001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Rear shock absorber upper nut 28 2.9 21.0 )
Rear shock absorber lower nut 90 9.2 66.5 )/)
Rear axle bolt 90 9.2 66.5 )

NOTE
The tightening torque(s) also specified in:
“Rear Suspension Components”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
2D-1 Wheels and Tires:

Wheels and Tires

Suspension

Precautions
Precautions for Servicing Wheel and Tire
AENBL80A2400001
! WARNING

• Do not use different types of tires on the same vehicle such as radial / bias and bias-belted tires
except in emergencies.
Using different types of tire seriously affects the handling of vehicle and could lead even to loss of
control.
• Repairs by any means including welding, heating, or peening are not permitted. All damaged wheels
should be replaced.

General Description
Tire Description Correct tire pressures and driving habits have an
AENBL80A2401001 important influence on tire life. Hard cornering,
This vehicle is equipped with tubeless tires of the
excessively rapid acceleration, and unnecessary hard
following specifications.
braking increase tire wear.
Tire specifications
: 185/65 R15 88S Replacement Tire Description
AENBL80A2401002
NOTE Refer to the “Tire Placard”. Replacement tires should be
of the same size, load range and construction as those
• Tire inflation pressure should be checked originally installed on the vehicle. Using tires of any other
when tires are cool. size or type may affect ride, handling, speedometer /
• The tire inflation pressure will change due odometer calibration, vehicle ground clearance and tire
to changes in atmospheric pressure and or snow chain clearance to the body and chassis.
temperature as well as in temperature of It is recommended that new tires be installed in pairs on
tire itself when driving. It is important to the same axle. If replacing only one tire is unavoidable, it
check and adjust the tire pressures when should be paired with the tire of the best tread condition
the tires are cold. Tires that appear to be at to equalize tire-road friction during braking.
the specified pressure when checked after The tire inflation pressure is indicated in kilo-pascal
driving (when the tires are warm) will have (kPa) while it is also indicated in kgf/cm2 and psi on the
pressure below the specification when the Tire Placard. Metric tire gauges are available from tool
tires cool down. Also, tires that are inflated suppliers. The following table shows unit conversion for
to the specified pressure in a warm garage commonly used inflation pressures.
may have pressure below the specification kPa kgf/cm2 psi
when the vehicle is driven outside in very Conversion: 160 1.6 23
cold temperature. If the tire pressure is 1 psi = 6.895 kPa 180 1.8 26
adjusted in a place warmer than the 1 kgf/cm2 = 98.066 kPa 200 2.0 29
outside, add 6.9 kpa (1 psi) to the 220 2.2 32
recommended cold tire inflation pressure 240 2.4 35
for every 5.6 °C (42 °F) increase in the 260 2.6 38
temperature of the adjustment place 280 2.8 41
compared to the outside temperature. 300 3.0 44
• Specified tire inflation pressure is 320 3.2 47
indicated on the tire placard or in the 340 3.4 50
vehicle’s owner’s manual.
Wheel Description
The tires are of a tubeless type. The tires are designed AENBL80A2401003
to operate satisfactorily with loads up to the full rated Wheel Maintenance
load capacity when inflated to the recommended Wheels must be replaced if they have any of the
inflation pressure. following conditions: bends, dents, excessive lateral or
radial runout, air leaks through welds, elongated bolt
 Wheels and Tires: 2D-2

holes, failure of lug nuts to stay tight, heavy rusts. The “high spot” is marked by a paint dot on the outboard
Wheels with great runout will cause objectionable sidewall of the tire.
vibrations. The “low spot” is marked by a paint dot on the wheel’s
rim-flange. The wheel’s paint dot (1) should be aligned
Wheel specifications
with the tire’s paint dot (2) as shown in the figure when
: 15 x 5 1/2J (Alloy & Steel)
the wheel and tire are properly assembled.
As these marks may become invisible over time, put a
Replacement Wheel Description line mark across the wheel and tire before separating
AENBL80A2401004
Replacement wheels must be equivalent to the originally them so that the tire can be match-mounted again on the
installed wheels in load capacity, diameter, rim width, wheel.
offset and mounting configuration.
A wheel of improper size or type may affect its and
bearing life, brake cooling performance, speedometer /
odometer calibration, ground clearance and clearance to
the body.

Wheel-Tire Assembly Description (for Vehicle

Equipped with Steel Wheels)
AENBL80A2401005
Tires are match mounted on wheels at the assembly
plant.
This means that the tire’s radially stiffest point, or “high
spot”, is aligned with the wheel’s smallest radius point, or
“low spot” to ensure smooth ride.
IYSQ01240005-01

Repair Instructions
Wheel (with Tire) Removal and Installation NOTE
AENBL80A2406001
Removal Before installing wheels, remove any build-
up of corrosion on wheel mounting surface
1) Loosen wheel nuts by approximately 180° (half a
and brake disc mounting surface by scraping
rotation).
and wire brushing.
Installing wheels without good metal-to-metal
contact at mounting surfaces can cause
wheel nuts to loosen, which can later allow
wheel to come off while vehicle is moving.

Tightening order
“1” – “2” – “3” – “4”
Tightening torque
Wheel nut (a): 85 N·m (8.7 kgf-m, 63.0 lbf-ft)

I7V10A240001-01

2) Hoist vehicle.
3) Remove wheel with tire.

NOTE
Never use heat to loosen tight wheel because
application of heat to wheel can shorten life
of wheel and damage wheel bearings.
I8C50A240002-01
Installation
Wheel nuts must be tightened in sequence and to proper Tire Inspection
torque to avoid bending wheel or brake disc as shown in AENBL80A2406002

the figure.
2D-3 Wheels and Tires:

Irregular and / or Premature Wear

Irregular and / or premature wear occurs due to incorrect
inflation pressures, lack of tire rotation, rough driving,
improper alignment. If one of the following conditions is
noted, rotation is necessary.
• Front tires wear differently from rear tires.
• Uneven wear between both sides of tread on the
same tire.
• Both front tires wear unevenly.
• Both rear tires wear unevenly.
• Abnormal wear such as cupping and flat spotting is
I2RH01240005-01
noted.
Wheel alignment should be checked if one of the
following conditions is noted. Wheel Inspection
AENBL80A2406003
• Front tires wear unevenly. Visual Inspection
• Uneven wear between both sides of tread on the Inspect wheels for cracks, bends, dents, wheel nut hole
same front tire. deformation or other damages.
• Front tire treads show scuffs with “feather” edges on Replace any wheel with defect(s).
one side of tread ribs or blocks.
Wheel Runout Inspection
1) Check wheel bearing for looseness.
• Front wheel bearing: )(Page 3A-13)
• Rear wheel bearing: )(Page 3A-19)
2) Install wheel (either with or without tire) on wheel
balancer or other appropriate equipment.
3) Set dial gage applying its plunger to wheel at angles
“a” and “b” as shown in figure.
4) Give wheel a full turn slowly and record the
maximum dial gauge reading for each of the angle
“a” (lateral runout) measurement and the angle “b”
(radial runout) measurement.
5) Replace wheel if either or both of the recorded dial
gauge readings exceed the following limits.
Wheel runout
Lateral runout Radial runout
limit “a” limit “b”
I3RH0A240002-01 0.9 mm 0.70 mm
Steel wheel
[A]: Hard cornering, under inflation or non-rotated tires (0.035 in.) (0.027 in.)
[B]: Incorrect wheel alignment, use of tires of different types or Aluminum 0.3 mm 0.3 mm
wheel heavy acceleration wheel (0.012 in.) (0.012 in.)

Wear Indicators
Originally installed tires have built-in tread wear
indicators (1).
These indicators appear as 7 mm (0.27 in) wide bands
when the tire tread depth becomes 1.6 mm (0.063 in). If
a tire has indicators (1) appearing across 3 or more tread
grooves at 6 locations, replacement of the tire is
recommended.
Tire wear limit
limit: 1.6 mm (0.063 in)
 Wheels and Tires: 2D-4

! CAUTION
Using on-vehicle balancing method with
ignition “ON” may set diagnostic trouble
code (DTC) of ABS even when system is in
good condition.
Never set ignition to “ON” while spinning
wheel.

Tire Rotation
AENBL80A2406005
To equalize tire wear, rotate tires periodically as shown
“a” in the figure.
“b”

IAW101240001-02

Wheel Balance Inspection and Adjustment

AENBL80A2406004
! WARNING
Stones in the tread of a tire may injure the
operator when the wheel is spun for
balancing. Remove all stones from the tire
tread before starting the operation. This is
also important to obtain a good balancing
result.

Before starting operation of wheel balance inspection

and adjustment, remove all mud and other deposits from
the rim inside area. Also check that tire is free of
damage.
Follow recommendations of wheel balancing
equipment’s manufacturer. IBP80A240001-04

[f]: Vehicle forward [B]: 4-tire rotation

Off-Vehicle Balancing
Electronic off-vehicle wheel balancers are easy to use.
Most of them provide dynamic, two-plane balancing with
high accuracy (usually capable of detecting imbalance of
within 1/8 ounce), although they cannot be used for
correcting brake disc imbalance unlike with on-vehicle
wheel balancers.
On-Vehicle Balancing
On-vehicle balancing methods vary with equipment and
tool manufacturers. Be sure to follow each
manufacturer’s instructions during balancing operation.
! WARNING
If a drive wheel is spun at a speed higher
than 55 km/h (34 mph), there is a risk of tire
disintegration and differential system failure,
eventually resulting in serious personal
injuries and/or extensive vehicle damage
including differential failure. Be sure to limit
the spinning speed of a drive wheel to 55 km/
h (34 mph).
[A]: 5-tire rotation
Tire Mounting and Dismounting
AENBL80A2406006
! WARNING
• Do not stand over a tire being inflated. Tire
bead may break when the bead snaps over
rim’s safety hump and cause serious
personal injury.
• Do not inflate tires exceeding 330 kPa (48
psi). If tire bead does not seat even when a
330 kPa (48 psi) pressure is reached,
deflate the tire, re-lubricate the bead and
reinflate the tire. Over-inflation may cause
the bead to break, which may cause
serious personal injury.
2D-5 Wheels and Tires:

! CAUTION Tire Repair

AENBL80A2406007

• Do not try to change tires using hand tools There are many different materials and techniques on
or tire irons alone, as doing so may the market to repair tires. As not all of these work on all
damage tire beads or wheel rim. types of tires, tire manufacturers have published detailed
instructions on how and when to repair tires. These
• Rim bead seats should be cleaned using instructions can be obtained from the tire manufacturer.
wire brush or coarse steel wool to remove
lubricants, old rubber and light rust.
Before mounting or dismounting tire, bead
area should be well lubricated with
approved tire lubricant.
• After mounting tire, inflate it to 300 kPa (44
psi) so that beads are completely seated.
Then adjust pressure to specification
indicated on tire placard.
• Valve caps should always be installed on
valves to keep dust and water out.

Specifications
Tightening Torque Specifications
AENBL80A2407001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Wheel nut 85 8.7 63.0 )

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Section 3
Driveline / Axle
CONTENTS
Precautions .................................................3-1
Precautions............................................................. 3-1
Precautions for Driveline / Axle ............................. 3-1
Drive Shaft / Axle ..................................... 3A-1
Front .........................................................................3A-1
General Description .............................................3A-1
Front Drive Shaft Construction............................ 3A-1
Diagnostic Information and Procedures............3A-1
Front Drive Shaft Symptom Diagnosis ................ 3A-1
Repair Instructions ..............................................3A-2
Front Drive Shaft Components ........................... 3A-2
Front Drive Shaft Assembly On-Vehicle
Inspection.......................................................... 3A-3
Front Drive Shaft Assembly Removal and
Installation......................................................... 3A-3
Front Drive Shaft Disassembly and
Reassembly ...................................................... 3A-4
Drive Intermediate Shaft Assembly Removal
and Installation (Diesel Model).......................... 3A-8
Table of Contents 3- i
Drive Intermediate Shaft Assembly
Disassembly and Reassembly (Diesel
Model) .............................................................3A-10
Front Wheel Hub and Steering Knuckle
Components....................................................3A-13
Front Wheel Bearing Check ..............................3A-13 3
Front Wheel Hub, Steering Knuckle and
Wheel Bearing Removal and Installation ........3A-14
Specifications.....................................................3A-17
Tightening Torque Specifications......................3A-17
Special Tools and Equipment ...........................3A-17
Recommended Service Material .......................3A-17
Special Tool ......................................................3A-17
Rear ........................................................................3A-19
Repair Instructions ............................................3A-19
Rear Axle Components .....................................3A-19
Rear Wheel Bearing Check...............................3A-19
Rear Wheel Hub Assembly Removal and
Installation .......................................................3A-19
Specifications.....................................................3A-20
Tightening Torque Specifications......................3A-20
3-1 Precautions:

Precautions
Driveline / Axle

Precautions
Precautions for Driveline / Axle
AENBL80A3000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Fastener Caution
Refer to “Fastener Caution” in Section 00 (Page 00-5).

Air Bag Warning

Refer to “Air Bag Warning” in Section 00 (Page 00-5).

Reassembling Note for Wiring Harness

Be sure to observe the Wiring Diagram Manual whenever installing wiring whenever installing wiring harness.
Otherwise, electrical trouble may occur.
 Drive Shaft / Axle: Front 3A-1

Drive Shaft / Axle

Driveline / Axle

Front
General Description
Front Drive Shaft Construction
AENBL80A3111001
Both right and left side drive shaft assemblies use a constant velocity ball joint on the wheel side and a tripod type
constant velocity joint on the differential side. The tripod joint allows each drive shaft to slide in the extension /
contraction direction.

Diagnostic Information and Procedures

Front Drive Shaft Symptom Diagnosis
AENBL80A3114001

Condition Possible cause Correction / Reference Item

Abnormal noise Wear or breakage of drive shaft joint Replace. )(Page 3A-3)
Wear or breakage of intermediate shaft Replace. )(Page 3A-8)
bearing (Diesel model)
Wear or breakage of the wheel bearing Replace. )(Page 3A-13)
3A-2 Drive Shaft / Axle: Front

Repair Instructions
Front Drive Shaft Components
AENBL80A3116001

[B]

2
[A] 3

4 5

6 7
7
8
10 (a)
7 8
9 5

5 9

10 (a) [A]
7

6
5
[D]
1 [C] 4
3
2
3
2

5
4
[A] 7
6

8 8
10 (a)
5
7
9 9

5 10 (a)
[A]

[E] 5

4
3

[F] 1
[G]

15 15
[A] [A]

1 12 (c) 1
12 (c)

17 17
11
11 13
13
16
16 15
14 15 14

IBL80A311001-01

[A]: Wheel side 8. Wheel side boot

: Apply black grease in the service kit to wheel side boot.
 Drive Shaft / Axle: Front 3A-3

[B]: Diesel model - Left side 9. Wheel side joint assembly

: Never disassemble.
: Apply black grease in the service kit to wheel side boot.
[C]: Diesel model - Right side 10. Drive shaft nut
: After tightening nut to specified torque, caulk nut securely.
[D]: Petrol model - Left side 11. Drive intermediate shaft
[E]: Petrol model - Right side 12. Intermediate support bolt
: For tightening order, refer to )(Page 3A-8).
[F]: Diesel model 13. Intermediate shaft bearing support
[G]: Petrol model 14. Intermediate shaft bearing
: Apply grease 99000-25011 to side space.
1. Circlip 15. Dust seal
2. Differential side (or drive intermediate shaft side) joint housing 16. Dust cover
3. Snap ring 17. Bearing support circlip
4. Tripod joint : 200 N⋅m (20.4 kgf-m, 148.0lbf-ft)
: Never disassemble.
: Apply brown grease in the service kit to tripod joint. (diesel
model)
: Apply dark gray grease in the service kit to tripod joint. (petrol
model)
5. Boot band (Big) : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
6. Differential side (or drive intermediate shaft side) boot : Do not reuse.
: Apply brown grease in the service kit to differential side (or
drive intermediate shaft side) boot. (diesel model)
: Apply dark gray grease in the service kit to differential side
boot. (petrol model)
7. Boot band (Small)

Front Drive Shaft Assembly On-Vehicle 3) Drain transaxle oil.

Inspection • Diesel model: )(Page 5B-52)
AENBL80A3116002
• Petrol model: )(Page 5B-7)
• Check boots for grease leakage, tear or deterioration.
4) For vehicle with ABS, remove front wheel speed
• Check boot bands for looseness, crack or damage.
sensor from steering knuckle. )(Page 4E-35)
• Check drive shafts for damage.
5) Disconnect suspension arm joint from steering
• Check wheel side joint for smooth rotation without knuckle. )(Page 2B-8)
rattle.
6) Pull out drive shaft joint (2) using tire lever (1) or
• Check differential side joint for smooth rotation. plastic hammer (3).
Replace differential side (or drive intermediate shaft
side) joint if defective. NOTE
Turning drive shaft joint while pulling out
Front Drive Shaft Assembly Removal and drive shaft may facilitate release of the circlip
Installation fitting of joint spline.
AENBL80A3116003

Removal [A] 2 [B]

2
1) Hoist vehicle and remove front wheel. )(Page 2D-2)
2) Release caulking (1) and remove drive shaft nut (2)
with brake pedal depressed.

1
3

1
I9P60A311003-02

[A]: Left side shaft [B]: Right side shaft

2 7) Remove drive shaft assembly.

IBP80A311002-01
3A-4 Drive Shaft / Axle: Front

Installation – Petrol model: )(Page 5B-7)

• Check front wheel alignment. )(Page 2B-1)
! CAUTION

• Before inserting drive shaft, confirm that Front Drive Shaft Disassembly and Reassembly
AENBL80A3116004
there is no foreign materials around
encoder (1) on wheel bearing.
Disassembly

! CAUTION
1 • Disassembly of wheel side joint is not
allowed. If any noise or damage exists in
wheel side joint, replace the joint as drive
shaft assembly.
1 • Do not disassemble tripod joint. If any
defect is found in tripod joint, replace
tripod joint assembly.
IBP80A311003-01

• Be careful not to damage oil seals and

boots. NOTE
• Do not hit joint boot with hammer. On diesel model with welded type boot band,
Inserting joint only by hands is allowed. use nippers to cut boot band. Take care not
to damage boot while cutting band.
• Make sure that differential side joint is
inserted fully and its circlip is seated as it Differential side joint
was installed.
1) Remove boot big band (1) of differential side (or
Reverse removal procedure, noting the following points. drive intermediate shaft side) as follows.
To disengage hook, pinch band as shown in figure
• Use new differential side (or drive intermediate shaft and remove band.
side) joint circlip.
• Tighten new drive shaft nut (1) to specified torque.
Tightening torque
Drive shaft nut (a): 200 N·m (20.4 kgf-m, 148.0 lbf-
ft)
• Caulk drive shaft nut (1) as shown.

! CAUTION
Be sure not to crack caulking part (2) of drive
shaft nut while caulking it. Replace it with
new one if it cracks.
I9P60A311025-02

2) Remove differential side (or drive intermediate shaft

side) joint housing from tripod joint.
3) Wipe off grease from shaft and take off snap ring (1)
using snap ring pliers (2).

1,(a)
IBP80A311004-01

• Connect suspension arm joint. )(Page 2B-8)

• For vehicle with ABS, install front wheel speed sensor.
)(Page 4E-35)
• Install front wheel. )(Page 2D-2) I7RW01311003-01

• Fill transaxle with transaxle oil as specified. 4) Remove tripod joint (1) using 3-arm puller (2).
– Diesel model: )(Page 5B-52)
 Drive Shaft / Axle: Front 3A-5

! CAUTION
To prevent any problem caused by washing
solution, do not wash tripod joint except its
housing. Degreasing of tripod joint with shop
cloth is allowed.

I9P60A311025-02

2) Use flat-bladed screwdriver (1) or the like to release

caulking (2) of wheel side boot small band (3).

I9P60A311005-01

5) Remove boot small band of differential side (or drive

intermediate shaft side) boot as follows. 2
Diesel model 1
Use flat-bladed screwdriver (1) or the like to release
caulking (2) of boot small band (3).
3

I8V101311031-01

3) Pull out wheel side boot from shaft.

2
1 Reassembly
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
3 after disassembly, prepare replacing parts and proceed
I8V101311031-01 to reassembly.
Petrol model Make sure that wheel side joint assembly (1) and
To disengage hook, pinch band (1) as shown in housing of tripod joint (2) are washed thoroughly and air
figure and remove band. dried.

! CAUTION

• To prevent any problem caused by

washing solution, do not wash tripod joint
except its housing.
Degreasing of tripod joint with shop cloth
is allowed.
• Do not wash boots in degreaser such as
gasoline or kerosene, etc. Washing in
degreaser causes boot deterioration.
• To ensure full performance of joint as
1 originally designed, apply the specified
I9P60A311023-02 amount of grease to respective joint
6) Pull out differential side boot (or drive intermediate according to the following procedure.
shaft side boot) from shaft.
7) Remove damper from shaft. (petrol model-right side)

Wheel side joint

1) Remove boot big band (1) of wheel side as follows.
To disengage hook, pinch band as shown in figure
and remove band.
3A-6 Drive Shaft / Axle: Front

I9P60A311006-02
2 8) Fasten boot band noting the following points.

! CAUTION
Do not squeeze or distort boot when
fastening boot with boot bands. Squeezing
boot to force air out may distort boot and
I9P60A311027-01
reduce its durability.
[A]: Wheel side
[B]: Differential side a) Fasten boot big band (1) by pinching hooks (2)
with special tool and engage hook (3) as shown
Wheel side joint in figure.
1) Wash disassembled parts (except boots). After
Special tool
washing parts, air dry them completely.
(A): 09943M57021
2) Clean boots with shop cloth.
3) Apply grease in the service kit to wheel side joint.
Grease specification for front drive shaft wheel
side joint (A)
Grease
Model Grease amount
color
Diesel model Black 70 – 90 g (2.82 – 3.53 oz)
Petrol model Black 60 – 80 g (2.12 – 2.82 oz)

4) Install wheel side boot on shaft.

5) Fill boot inside with specified grease.
6) Insert flat-bladed screwdriver into boot (2) and allow 1
air to enter boot so that air pressure in boot becomes
the same as the atmospheric pressure.

2 3 2

I8C50A311034-01

b) Fasten boot small band (5) using special tool as

shown in figure.
Install each boot band using the appropriate
I9P60A311028-01 method referring to the following table
7) Place new boot big band (3) and small band (4) onto Model Band Method
wheel side boot so that outer end (1) of each band Diesel model Big band a
faces in the direction opposite to the forward rotating Small band b
direction (2) as shown in figure. Petrol model Big band a
Small band b

Special tool
(B): 09943M57011
 Drive Shaft / Axle: Front 3A-7

“a”

5
I4RS0B310003-01

(B)
7) Fit boot (1) to grooves of shaft and differential side
I8C50A311004-02 (or drive intermediate shaft side) joint housing (2).
8) Insert flat-bladed screwdriver or the like into boot (1)
Differential side joint and allow air to enter boot so that air pressure in
1) Wash disassembled parts (except boots) and air dry boot becomes the same as atmospheric pressure.
them completely. Drive shaft boot fixing position (distance
2) Clean boots with shop cloth. between differential side joint end and boot small
3) For diesel model, install boot insert on differential band center)
side (or drive intermediate shaft side) joint housing. Model Drive shaft Fixing position “a”
4) Install differential side (or drive intermediate shaft Diesel RH 179.5 – 189.5 mm (7.06 – 7.46
side) boot on shaft. model in.)
5) Install tripod joint (1) on shaft using special tool with LH 163.0 – 173.0 mm (6.41 – 6.81
hammer, directing its chamfered spline (3) toward in.)
wheel side, and then fasten tripod joint with new Petrol RH 177.0 – 187.0 mm (6.96 – 7.36
snap ring (2) using snap ring pliers (4). model in.)
LH 161.4 – 171.4 mm (6.35 – 6.75
Special tool in.)
(A): 09925M98221

I8G001311014-01

“a”

I9P60A311029-01

I8C50A311007-01

6) Using specified grease included in service kit, apply

grease “A” to tripod joint, differential side joint
housing (1) and boot.
Grease specification for front drive shaft
2
differential side (or drive intermediate shaft side) I8C50A311008-01
joint
[A]: Drive shaft inserted into differential side
Grease [B]: Drive shaft inserted into drive intermediate shaft side
Model Grease amount
color
Diesel model Brown 85 – 105 g (2.99 – 3.70 oz)
Petrol model Dark 70 – 90 g (2.47 – 3.17 oz)
gray
3A-8 Drive Shaft / Axle: Front

9) Place new boot big band (3) and small band (4) onto b) Fasten boot band (5) using special tool as shown
differential side (or drive intermediate shaft side) in figure
boot so that outer end (1) of each band faces in the
Boot band fastening distance “a”
direction opposite to the forward rotating direction (2)
: 1.0 – 4.0 mm (0.03 – 0.15 in.)
as shown in figure.
Special tool
(B): 09943M57011
4

“a”

5
I9P60A311006-02

10) Fasten boot big band and boot small band noting the (B)
following points. I8C50A311004-02

! CAUTION Drive Intermediate Shaft Assembly Removal

Do not squeeze or distort boot when and Installation (Diesel Model)
AENBL80A3116005
fastening boot with boot bands. Squeezing
boot to force air out may distort boot and ! CAUTION
reduce its durability. Be careful not to damage differential side oil
seal when removing and installing drive
Install each boot band using the appropriate intermediate shaft assembly.
method referring to the following table
Model Band Method Removal
Diesel model Big band b 1) Drain transaxle oil. )(Page 5B-52)
Small band b 2) Remove right side front drive shaft assembly.
Petrol model Big band a )(Page 3A-3)
Small band a
3) Remove intermediate support bolts (1) and drive
a) Fasten boot band (1) by pinching hooks (2) with intermediate shaft assembly (2) from transaxle.
special tool and engage hook (3) as shown in Diesel Model
figure. 1

Special tool
(A): 09943M57021

(A)

2
IBP80A311006-01

3 2

I8C50A311034-01
 Drive Shaft / Axle: Front 3A-9

Petrol Model Petrol Model

1
1,“3”,(a)
1,“1”,(a)

1,“2”,(a)

IBL80A311002-01 IBL80A311003-01

Installation Drive Intermediate Shaft Assembly

Reverse removal procedure, noting the following points. Disassembly and Reassembly (Diesel Model)
• Use new circlip. AENBL80A3116006

• Tighten intermediate support bolts (1) in numerical

Disassembly
order as shown in figure.
1) Remove circlip (1) from drive intermediate shaft (2).
1) Temporarily tighten intermediate support bolts in
numerical order (“1” – “3”).
2) Tighten intermediate support bolts to specified
torque in numerical order (“4” – “6”).
Tightening torque
Intermediate support bolt (a): 23 N·m (2.3 kgf- 1
m, 17.0 lbf-ft)
2

Diesel Model
1,“2”,“5”,(a) 1,“3”,“6”,(a)
1,“1”,“4”,(a)

IBP80A311034-03

2) Using hydraulic press (1), remove drive intermediate

shaft (2) from intermediate shaft bearing.

IBP80A311007-01

IBP80A311008-01

3) Remove dust seals (1) from intermediate shaft

bearing support using special tool.
Special tool
(A): 09913M50121
3A-10 Drive Shaft / Axle: Front

1
(A)

IBP80A311025-01
IBP80A311033-01

4) Remove bearing support circlip (1) using snap ring Reassembly

pliers (2). 1) Install new dust cover (1) onto drive intermediate
shaft, if removed, by tapping flat-surface of dust
cover indicated by arrow in figure, along the circle
little by little using flat-end rod covered with cloth (2)
so as not to warp it.

! CAUTION

• Denting or scratching the oil seal contact

surface of drive intermediate shaft will oil
leakage.
Do not damage the contact surface when
I6RS0B310006-03 installing the dust cover.
5) Using hydraulic press and special tool, remove • Incomplete installation of the dust cover
intermediate shaft bearing from intermediate shaft will damage the oil seal and result in oil
bearing support (1) by pushing the bearing from leakage.
transaxle side. Confirm the dust cover end (3) contacts
with the shoulder (4) of the shaft evenly.
Special tool
(A): 09913M75810

(A)

IBP80A311012-01 4
6) Remove dust cover (1) from drive intermediate shaft
using flat-bladed screwdriver or the like, if necessary.
3
1
IBP80A311026-02

2) Using hydraulic press and special tool, install new

intermediate shaft bearing to intermediate shaft
bearing support (1) by pushing the bearing from
drive shaft side.
Special tool
(A): 09913M75520
 Drive Shaft / Axle: Front 3A-11

(A)

(A)

IBP80A311010-01
“a”
3) Install new bearing support circlip (1) in groove (2) of IBP80A311029-01
intermediate shaft bearing support. 6) Install new dust seal (1) to specified position on drive
shaft side of intermediate shaft bearing support in
specified direction as shown in figure using special
1 tools.
Special tool
(A): 09926M27610
(B): 09924M74510
2 Distance
“a”: 0.5 – 1.5 mm (0.02 – 0.05 in.)

(A)

(B)

IBP80A311027-02

4) Apply grease to space on bearing as shown in figure.

“A”: Grease 99000–25011 (SUZUKI Super
Grease A)

“a”
“A” “A” IBP80A311032-02

7) Press-fit drive intermediate shaft (2) into inner race

(1) of intermediate shaft bearing from transaxle side
using hydraulic press and special tool.
IBP80A311028-02

5) Install new dust seal (1) to specified position on Special tool

transaxle side of intermediate shaft bearing support (A): 09913M84510
in specified direction as shown in figure using special
tool.
Special tool
(A): 09925M15410
Distance
“a”: 4 – 5 mm (0.16 – 0.19 in.)
3A-12 Drive Shaft / Axle: Front

2 1
1

(A) IBP80A311035-02

(A)

IBP80A311030-02

8) Install new circlip (1) to drive intermediate shaft (2).

Front Wheel Hub and Steering Knuckle Components

AENBL80A3116007

6
1

IBL80A311004-01

1. Front wheel hub 5. Steering knuckle

2. Circlip 6. Hub bolt
3. Wheel bearing : Do not reuse.
4. Front brake dust cover

Front Wheel Bearing Check Front wheel bearing thrust play

AENBL80A3116008 Limit: 0.1 mm (0.004 in.)
1) Confirm tightness of wheel nuts and, if necessary,
retighten them to specified torque. )(Page 2D-2)
2) Hoist vehicle.
3) Check wear of wheel bearing. When measuring
thrust play, apply a dial gauge to front wheel as
shown in figure.
If check result is not as specified, replace bearing.
 Drive Shaft / Axle: Front 3A-13

I3RM0A230049-01
IBP80A311013-01
4) Check wheel bearing noise and smooth rotation by 5) Disconnect tie-rod end from steering knuckle.
rotating wheel. )(Page 6C-24)
If check result is not OK, replace bearing.
6) For vehicle with ABS, remove front wheel speed
sensor from steering knuckle. )(Page 4E-35)
7) Remove strut bracket nuts and bolts. )(Page 2B-4)
8) Disconnect suspension arm joint from steering
knuckle. )(Page 2B-8)
9) Remove steering knuckle from drive shaft.
10) Uncaulk 4 caulking points (1) with a chisel or the like.
11) Remove front brake dust cover (2).

I3RM0A230050-01

Front Wheel Hub, Steering Knuckle and Wheel 1

Bearing Removal and Installation

AENBL80A3116009

2
! CAUTION
IBP80A311014-01
When removing and installing steering
12) Remove circlip (1) from steering knuckle.
knuckle, be careful not to deform front brake
dust cover.

Removal 1

1) Hoist vehicle and remove front wheel. )(Page 2D-2)

2) Remove drive shaft nut. )(Page 3A-3)
3) Remove brake disc. )(Page 4B-6)
4) Pull out wheel hub (1) with special tools.

NOTE
Outer side of wheel bearing inner race comes
out together with wheel hub.

Special tool I9P60A311016-02

(A): 09943M17912 13) Using hydraulic press (1) and special tool, push out
(B): 09942M15511 wheel bearing.
Special tool
(A): 09913M75810
3A-14 Drive Shaft / Axle: Front

2) For vehicle with ABS, put new wheel bearing (1) on

1 steering knuckle (2) with encoder (3) side facing
down in figure below.
(A)
! CAUTION
Do not reuse wheel bearing to avoid noise or
damage.

NOTE
For vehicle without ABS, new wheel bearing
IBP80A311015-01
can be installed in either direction.
14) Pry wheel bearing outside inner race (1) a little using 3) Press-fit wheel bearing into steering knuckle using
chisel or the like. special tools as shown in figure.
15) Remove wheel bearing outside inner race (1) from
wheel hub using special tools as shown in figure. Special tool
(A): 09913M75510
Special tool (B): 09926M68310
(A): 09913M65810 (C): 09951M18211
(B): 09926M37610M003
1 2

(A)

(B) 3 (C)

IBP80A311018-02

4) Install circlip (1).

IBP80A311016-01

16) Remove hub bolts (1) with copper hammer or 1

hydraulic press, if necessary.

Installation
1) Insert new hub bolt (1) in hub hole. Rotate hub bolt
slowly to assure that serrations are aligned with
those made by original bolt, if removed.

I9P60A311016-02

5) Set new front brake dust cover (2) on steering

knuckle (3) so that dimensions “a” and “b” become
equal as shown in figure.

! CAUTION
When press-fitting front brake dust cover, be
careful not to deform it.
IBP80A311017-01
 Drive Shaft / Axle: Front 3A-15

6) Press-fit new front brake dust cover into steering ! CAUTION

knuckle using hydraulic press (1) and special tools.
Before inserting drive shaft, confirm that
Special tool there is no foreign materials around encoder
(A): 09951M17010 (1) on wheel bearing.
(B): 09944M77030

1
1

(A) 2

1
“a”

IBP80A311022-01

(B) 3
10) Connect steering knuckle to suspension arm.
“b”
)(Page 2B-8)
11) Install strut bracket bolts and nuts. )(Page 2B-4)
2
12) For vehicle with ABS, install front wheel speed
IBP80A311020-01 sensor. )(Page 4E-35)
7) Caulk more than 4 places with a small cold chisel. 13) Connect tie-rod end to steering knuckle. )(Page
6C-24)
14) Install brake disc and brake caliper. )(Page 4B-6)
15) Tighten new drive shaft nut. )(Page 3A-3)
16) Install front wheel. )(Page 2D-2)
17) Confirm front wheel alignment. )(Page 2B-1)

IBP80A311023-01

1. Caulking

8) Using special tools and hydraulic press, press-fit

wheel hub (1) into wheel bearing (2).
Special tool
(A): 09913M75810
(B): 09951M18211

(B)
IBP80A311021-01

9) Connect steering knuckle to drive shaft.

3A-16 Drive Shaft / Axle: Front

Specifications
Tightening Torque Specifications
AENBL80A3117001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Drive shaft nut 200 20.4 148.0 )
Intermediate support bolt 23 2.3 17.0 )

NOTE
The tightening torque(s) also specified in:
“Front Drive Shaft Components”: Front

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Recommended Service Material
AENBL80A3118001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 )

NOTE
Required service material(s) also described in:
“Front Drive Shaft Components”: Front

Special Tool
AENBL80A3118002
09913M50121 09913M65810
Oil seal remover Crankshaft bearing puller
) )

09913M75510 09913M75520
Bearing installer Bearing installer
) )

09913M75810 09913M84510
Bearing installer Bearing installer
)/)/) )
 Drive Shaft / Axle: Front 3A-17

09924M74510 09925M15410
Bearing and oil seal handle Oil seal installer
) )

09925M98221 09926M27610
Bearing installer Oil seal installer
) )

09926M37610M003 09926M68310
Bearing remover attachment Differential bevel pinion
bearing installer
) )

09942M15511 09943M17912
Sliding hammer Wheel hub remover
) )

09943M57011 09943M57021
Band compressor Low-profile clamp pliers
)/) )/)

09944M77030 09951M17010
Bearing / cover installer Brake disk dust cover
support installer
) )

09951M18211
Oil seal remover & installer
No. 2
)/)
3A-18 Drive Shaft / Axle: Rear

Rear
Repair Instructions
Rear Axle Components
AENBL80A3126001

[A]

5
(a) 6

IBL80A312001-01

[A]: Vehicle forward 4. Rear wheel hub assembly

1. Trailing arm 5. Hub bolt
2. Rear brake drum 6. Rear wheel hub bolt
3. Rear drum brake assembly : 88 N⋅m (9.0 kgf-m, 65.0 lbf-ft)

Rear Wheel Bearing Check

AENBL80A3126002
Check rear wheel bearing in the same manner as front
wheel bearing. )(Page 3A-12) 1

Rear wheel bearing thrust play

Limit: 0.1 mm (0.004 in.)

Rear Wheel Hub Assembly Removal and

Installation
AENBL80A3126003
Removal
IBL80A312002-01
1) Hoist vehicle and remove rear wheel. )(Page 2D-2)
5) Remove hub bolt (1) with copper hammer or
2) Remove rear brake drum. )(Page 4C-2)
hydraulic press, if necessary.
3) For vehicle with ABS, remove rear wheel speed
sensor from rear wheel hub assembly. )(Page 4E-
36)
4) Remove rear wheel hub bolts (1), then remove rear
wheel hub assembly.

! CAUTION 1

To prevent deformation of brake pipe, hang

removed rear drum brake assembly using
wire.

IBP80A312004-01
 Drive Shaft / Axle: Rear 3A-19

Installation Tightening torque

1) Insert new hub bolt (1) in hub hole. Rotate hub bolt Wheel hub bolt (a): 88 N·m (9.0 kgf-m, 65.0 lbf-ft)
slowly to assure that serrations are aligned with
those made by original bolt and then press-fit, if
necessary.
(a)

1
IBL80A312003-01

3) For vehicle with ABS, install rear wheel speed

IBP80A312005-01
2) Install rear drum brake assembly (1) and rear wheel
hub assembly and tighten new rear wheel hub bolts
to specified torque.
sensor. )(Page 4E-36)
4) Install rear brake drum. )(Page 4C-2)
5) Install rear wheel. )(Page 2D-2)
6) Confirm rear wheel alignment. )(Page 2C-1)

Specifications
Tightening Torque Specifications
AENBL80A3127001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Wheel hub bolt 88 9.0 65.0 )

NOTE
The tightening torque(s) also specified in:
“Rear Axle Components”: Rear

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Section 4
Brakes
CONTENTS
Precautions .................................................4-1
Precautions............................................................. 4-1
Precautions for Brakes.......................................... 4-1
Brake Control System and Diagnosis ... 4A-1
Precautions...........................................................4A-1
Precautions for Brake Service ............................ 4A-1
General Description .............................................4A-1
Brake System Description................................... 4A-1
Diagnostic Information and Procedures............4A-2
Brakes Symptom Diagnosis ................................ 4A-2
Repair Instructions ..............................................4A-4
Brake Fluid Level Inspection ............................... 4A-4
Brake Fluid Level Switch Inspection ................... 4A-4
Brake Fluid Replacement.................................... 4A-4
Air Bleeding of Brake System ............................. 4A-5
Brake Pedal Components ................................... 4A-7
Brake Pedal Assembly Removal and
Installation......................................................... 4A-7
Brake Pedal Assembly Disassembly and
Reassembly ...................................................... 4A-8
Brake Pedal Free Height Inspection ................... 4A-9
Brake Pedal Play Inspection ............................... 4A-9
Excessive Pedal Travel Inspection ................... 4A-10
Brake Light Switch Removal and Installation .... 4A-10
Brake Light Switch Inspection ........................... 4A-11
Brake Hose and Pipe Components................... 4A-12
Brake Flexible Hose and Pipe Removal and
Installation....................................................... 4A-13
Brake Flexible Hose and Pipe Inspection ......... 4A-13
Brake Master Cylinder Components ................. 4A-14
Brake Master Cylinder Assembly On-Vehicle
Inspection........................................................ 4A-14
Brake Master Cylinder Assembly Removal
and Installation................................................ 4A-14
Brake Master Cylinder Reservoir Removal
and Installation................................................ 4A-16
Brake Master Cylinder Assembly Inspection..... 4A-16
Brake Booster Components .............................. 4A-17
Brake Booster Function Check ......................... 4A-18
Brake Booster Removal and Installation ........... 4A-19
Brake Booster Inspection .................................. 4A-25
Specifications.....................................................4A-25
Tightening Torque Specifications...................... 4A-25
Table of Contents 4- i
Special Tools and Equipment ...........................4A-26
Recommended Service Material .......................4A-26
Special Tool ......................................................4A-26
Front Brakes ............................................ 4B-1
Repair Instructions ..............................................4B-1
Front Disc Brake Components ............................4B-1
Front Brake Pad On-Vehicle Inspection..............4B-2
Front Brake Pad Removal and Installation..........4B-2
Front Brake Pad Inspection.................................4B-3 4
Front Brake Caliper Removal and Installation.....4B-3
Front Brake Caliper Disassembly and
Reassembly ......................................................4B-4
Front Brake Caliper Inspection............................4B-6
Front Brake Disc Removal and Installation .........4B-6
Front Brake Disc Inspection ................................4B-7
Specifications.......................................................4B-8
Tightening Torque Specifications........................4B-8
Special Tools and Equipment .............................4B-8
Recommended Service Material .........................4B-8
Special Tool ........................................................4B-8
Rear Brakes.............................................. 4C-1
Repair Instructions ..............................................4C-1
Rear Drum Brake Components...........................4C-1
Rear Brake Drum Removal and Installation........4C-2
Rear Brake Drum and Shoe Inspection ..............4C-3
Rear Brake Shoe On-Vehicle Inspection ............4C-4
Rear Brake Shoe Removal and Installation ........4C-4
Rear Brake Shoe Inspection ...............................4C-5
Wheel Cylinder Removal and Installation ...........4C-5
Wheel Cylinder Inspection ..................................4C-6
Brake Back Plate Removal and Installation ........4C-6
Specifications.......................................................4C-7
Tightening Torque Specifications........................4C-7
Special Tools and Equipment .............................4C-7
Recommended Service Material .........................4C-7
Parking Brake .......................................... 4D-1
General Description .............................................4D-1
Parking Brake Description...................................4D-1
Repair Instructions ..............................................4D-1
Parking Brake Components ................................4D-1
Parking Brake Inspection ....................................4D-2
Parking Brake Adjustment...................................4D-2
4-ii Table of Contents
Parking Brake Cable Removal and
Installation .........................................................4D-2
Parking Brake Lever Removal and Installation ....4D-3
Parking Brake Switch Inspection.........................4D-4
Specifications.......................................................4D-4
Tightening Torque Specifications........................4D-4
ABS............................................................4E-1
Precautions........................................................... 4E-1
Precautions in Diagnosing Troubles ................... 4E-1
General Description ............................................. 4E-1
ABS Description .................................................. 4E-1
OBD System Description .................................... 4E-2
Warning Light Description ................................... 4E-2
DLC Description .................................................. 4E-3
CAN Communication System Description........... 4E-3
Schematic and Routing Diagram........................ 4E-3
ABS Diagram ...................................................... 4E-3
ABS Input / Output Diagram................................ 4E-4
ABS Circuit Diagram ........................................... 4E-5
Component Location ........................................... 4E-7
ABS Component Location................................... 4E-7
Diagnostic Information and Procedures............ 4E-7
ABS Check.......................................................... 4E-7
Visual Inspection ............................................... 4E-10
ABS Symptom Diagnosis .................................. 4E-10
Warning Light Check......................................... 4E-11
DTC Check........................................................ 4E-12
DTC Clearance ................................................. 4E-12
DTC Table......................................................... 4E-13
Fail-Safe Table.................................................. 4E-14
Scan Tool Data ................................................. 4E-15
ABS Warning Light Does Not Come ON after
Setting Ignition “ON” ....................................... 4E-16
ABS Warning Light Comes ON Steady............. 4E-17
EBD Warning Light (Brake Warning Light)
Does Not Come ON after Setting Ignition
“ON” ................................................................ 4E-19
EBD Warning Light (Brake Warning Light)
Comes ON Steady .......................................... 4E-20
DTC C1021 / C1022 / C1025 / C1026 / C1031
/ C1032 / C1033 / C1035 / C1036...................4E-21
DTC C1041 / C1042 / C1045 / C1046 / C1051
/ C1052 / C1055 / C1056 / C1063...................4E-24
DTC C1057 .......................................................4E-25
DTC C1061 .......................................................4E-25
DTC C1062 .......................................................4E-26
DTC C1071 .......................................................4E-27
DTC C1090 / C1091 / C1094 ............................4E-27
DTC U0073 .......................................................4E-28
DTC U0100 .......................................................4E-28
ABS Control Module Power Supply and
Ground Circuit Check......................................4E-28
Repair Instructions ............................................4E-29
ABS Hydraulic Unit Operation Check................4E-29
ABS Hydraulic Unit / Control Module
Assembly Components ...................................4E-30
ABS Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection ....................4E-30
ABS Hydraulic Unit / Control Module
Assembly Removal and Installation ................4E-31
Front and Rear Wheel Speed Sensor On-
Vehicle Inspection ...........................................4E-32
Front Wheel Speed Sensor Removal and
Installation .......................................................4E-33
Rear Wheel Speed Sensor Removal and
Installation .......................................................4E-33
Front and Rear Wheel Speed Sensor
Inspection........................................................4E-34
Front Wheel Speed Sensor Encoder Removal
and Installation ................................................4E-34
Rear Wheel Speed Sensor Encoder Removal
and Installation ................................................4E-34
Front and Rear Wheel Speed Sensor
Encoder Inspection .........................................4E-34
Specifications .....................................................4E-34
Tightening Torque Specifications......................4E-34
Special Tools and Equipment ...........................4E-36
Special Tool ......................................................4E-36
 Precautions: 4-1

Precautions
Brakes

Precautions
Precautions for Brakes
AENBL80A4000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Fastener Caution
Refer to “Fastener Caution” in Section 00 (Page 00-5).

Wheel and Brake Caution

Refer to “Wheel and Brake Caution” in Section 00 (Page 00-5).

Air Bag Warning

Refer to “Air Bag Warning” in Section 00 (Page 00-5).

Reassembling Note for Wiring Harness

Be sure to observe the Wiring Diagram Manual whenever installing wiring whenever installing wiring harness.
Otherwise, electrical trouble may occur.

Precautions for CAN Communication System

Refer to “Precautions for CAN Communication System” in Section 00 (Page 00-8).
4A-1 Brake Control System and Diagnosis:

Brake Control System and Diagnosis

Brakes

Precautions
Precautions for Brake Service
AENBL80A4100001
Road Test

NOTE
Brakes should be tested on dry, clean, reasonably level, and smooth roadway. Road test brakes by
applying brake with both light and heavy pedal forces at various speeds to determine if the vehicle
stops evenly and effectively. Also drive vehicle to see if it pulls to one side without brake application. If
it does, check the tire pressure, front wheel alignment and installing condition of front suspensions.
See diagnosis table for other causes.

Brake Fluid Leaks

NOTE
Check the brake fluid level. Although a slight drop results from normal lining wear, an abnormally low
level indicates a leak of brake fluid. In such a case, check the entire brake system for leakage. If even a
slight evidence of leakage is noted, the cause should be corrected or defective parts should be
replaced.

Substandard or Contaminated Brake Fluid

Substandard or contaminated brake fluid with mineral oil or moisture will lower fade resistance or deteriorate rubber
parts resulting in the leakage of brake fluid.
In case improper brake fluid as mentioned above entered into the brake system, or in case such doubt exists,
disassemble the system and clean the parts with alcohol. For the parts which cannot be disassembled, replace them
as an assembly. Rubber parts and brake hoses should be replaced with new ones.

General Description
Brake System Description
AENBL80A4101001
When the foot brake pedal is depressed, hydraulic pressure is developed in the brake master cylinder to actuate
pistons (two in front disc brakes or four in rear drum brakes).
The brake master cylinder is a tandem master cylinder. Brake pipes are connected to the brake master cylinder and
they make two independent circuits. One connects front right and rear left brakes and the other connects front left and
rear right brakes.

[A] [B]

[C] [C]

9 5
3
4 4 7
7
1 1
3 6
6
2 2

7 7
8 8

IBP80A410001-01
 Brake Control System and Diagnosis: 4A-2

[A]: Without ABS 2. Brake master cylinder 6. Parking brake lever

[B]: With ABS 3. Secondary side 7. Parking brake cable
[C]: Vehicle forward 4. Primary side 8. Brake 4-way joint
1. Brake booster 5. ABS hydraulic unit / control module assembly 9. Proportioning valve

Diagnostic Information and Procedures

Brakes Symptom Diagnosis
AENBL80A4104001

Condition Possible cause Correction / Reference Item

Not enough braking force Brake fluid leakage from brake lines
Brake disc or pads stained with fluid,
grease or other oil
Overheated brakes
Poor contact of shoes on brake drum
Brake drum or shoe stained with oil or
wet with water
Badly worn brake pad and/or shoe
Defective wheel cylinders
Malfunctioning brake caliper assembly
Malfunctioning brake master cylinder
Air in brake system
Brake booster internal failure
Negative pressure for brake booster is
inadequate
Malfunctioning ABS (with ABS)
Vehicle pulls to one side Pad, disc, shoe and/or drum are wet
(Brakes not working with water or stained with oil in some
uniformly) brakes
Drum-to-shoe clearance is out of
adjustment in some brake
(Malfunctioning auto adjusting
mechanism)
Disc and/or drum are out of round in
some brakes
Tires are inflated unequally
Malfunction in wheel cylinders
Disturbed front wheel alignment
Unmatched tires on same axle
Restricted brake pipes or hoses
Malfunctioning caliper assembly
Loose suspension parts
Loose calipers
Noise (High pitched Contact of wear indicator to brake disc
squeak without brake Worn rear brake shoe
applied)
Excessive pedal travel Partial brake system failure
(Pedal stroke too large) Leaking brake fluid
Air in brake system (soft / spongy pedal)
Rear brake system not adjusted
(malfunctioning auto adjusting
mechanism)
Bent brake shoes
Repair the leaking point, and bleed air.
Clean or replace.
Determine cause and repair.
Repair for proper contact.
Clean or replace.
Replace.
Repair or replace.
Repair or replace.
Replace and bleed air.
Bleed air from brake system.
Replace brake booster.
Check engine condition and vacuum hose.
Check system and replace if necessary.
Clean or replace.
Check for inoperative auto adjusting
mechanism.
Replace.
Inflate equally.
Repair or replace.
Adjust as specified.
Tires with approximately the same amount of
tread should be used on the same axle.
Check for soft hoses and damaged lines.
Replace with new hoses and new brake piping.
Check for stuck or sluggish pistons and proper
lubrication of caliper slide pin.
Check all suspension mountings.
Check and tighten bolts to specifications.
Replace brake pad.
Replace brake shoe.
Check brake systems and repair if necessary.
Repair the leaking point, and bleed air.
Bleed air from brake system.
Repair auto adjusting mechanism.
Adjust rear brakes.
Replace brake shoes.
4A-3 Brake Control System and Diagnosis:

Condition Possible cause Correction / Reference Item

Brake locked Malfunctioning ABS (with ABS) Check ABS system and replace if necessary.
)(Page 4E-8)
Malfunctioning proportioning valve Replace proportioning valve.
(without ABS)
Dragging brakes (A very Master cylinder pistons are not returning Replace brake master cylinder.
light drag is present in all correctly
brakes immediately after Restricted brake pipes or hoses Check for soft hoses or damaged pipes and
pedal is released) replace with new hoses and/or new brake
piping.
Incorrect parking brake adjustment on Check and adjust to correct specifications.
rear brakes
Weakened or broken return springs in Replace.
the brake
Sluggish parking brake cables or linkage Repair or replace.
Sticking wheel cylinder or caliper piston Repair or replace.
Badly worn piston seal in caliper Replace piston seal.
Improper brake pedal free height Check brake pedal free height.
Pedal pulsation (Pedal Damaged or loose wheel bearings Replace wheel bearings.
pulsates when depressed Distorted steering knuckle or rear wheel Replace knuckle or rear wheel hub assembly.
for braking) hub assembly
Excessive disc lateral runout Check per instructions. If not within
specifications, replace disc.
Rear drums out of round Check runout.
Repair or replace drum if necessary.
Braking noise Glazed brake pad and/or brake shoe Repair or replace brake pad and/or brake
shoe.
Worn or distorted brake shoe Replace brake shoe.
Loose front wheel bearings Replace wheel bearings.
Distorted back plates or loose mounting Replace back plate(s) or tighten mounting
bolts bolts.
Contact of wear indicator to brake disc Replace brake pads.
ABS warning light Faulty ABS function Perform ABS check. )(Page 4E-8)
remains ON (for more Faulty ABS control module power Check ABS control module power supply and
than 2 sec) after setting supply and ground circuit ground circuit. )(Page 4E-30)
ignition to “ON” (with Faulty combination meter Replace combination meter. )(Page 9C-10)
ABS)
ABS warning light does Faulty combination meter power supply Check combination meter and its circuit.
not turn ON after setting and ground circuit )(Page 9C-3)
ignition to “ON” (with Faulty combination meter Replace combination meter. )(Page 9C-10)
ABS) Malfunctioning CAN communication Check CAN communication system. )(Page
system 10H-6) / )(Page 10H-27)
Blown fuse Check “MTR” fuse and circuit led to “MTR”
fuse: replace if necessary.
Brake warning light ABS control module connector is not Connect ABS control module connector again.
remains ON (for more connected properly (with ABS)
than 2 sec) after starting Parking brake is applied Release parking brake and check that warning
engine lamp goes off.
Insufficient amount of brake fluid Check brake fluid level. )(Page 4A-4)
Faulty parking brake switch and/or Check brake switch and/or brake fluid level
brake fluid level switch switch.
Parking brake switch: )(Page 4D-4)
Brake fluid level switch: )(Page 4A-4)
Malfunctioning CAN communication Check CAN communication system. )(Page
system 10H-6) / )(Page 10H-27)
Faulty combination meter Replace combination meter. )(Page 9C-10)
Faulty ABS control module (with ABS) Replace ABS control module. )(Page 4E-33)

Condition Possible cause
Brake warning light does Faulty combination meter power supply
not turn ON after setting and ground circuit
ignition to “ON” Faulty combination meter
Faulty ABS control module (with ABS)
Repair Instructions
Brake Fluid Level Inspection
AENBL80A4106001
! WARNING
Never use brake fluid other than specified.
Otherwise, brake hose and rubber parts may
get damaged or brake system may not
operate normally.
! CAUTION
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid. If any fluid is spilled, flush it
with water immediately.
• Be sure to use brake fluid indicated on brake master
cylinder reservoir cap (of the vehicle) or in owner’s
manual.
• Check that brake fluid level is between MAX and MIN
marks on reservoir of brake master cylinder.
NOTE
If brake warning light comes on during
driving or brake fluid level on brake master
cylinder reservoir is “MIN” or lower, check
the following points:
• Thickness of front brake pads and rear
brake shoes
• Fluid leakage from piston seal of front
brake caliper
• Fluid leakage from rear brake wheel
cylinder
• Cracks or damage to brake hoses and
brake pipes
• Damage to clutch hose and clutch pipe
(diesel model)
• Fluid leakage from brake master cylinder
and reservoir
In case any abnormality is found, repair or
replace affected parts.
After the check and repair are completed,
replenish the brake system with brake fluid
so that fluid level is fall between “MAX” and
“MIN” marks on brake master cylinder
reservoir.
Brake Control System and Diagnosis: 4A-4
Correction / Reference Item
Check combination meter and its circuit.
)(Page 9C-3)
Replace combination meter. )(Page 9C-10)
Replace ABS control module. )(Page 4E-33)
Brake Fluid Level Switch Inspection
AENBL80A4106002
Check continuity between terminals of brake fluid level
switch connector (1). If check result is not as specified,
replace reservoir.
Brake fluid level switch specification
MAX position (float up): No continuity
MIN position (float down): Continuity exists
1
IBP80A410002-03
Brake Fluid Replacement
AENBL80A4106003
! WARNING
Never use brake fluid other than specified.
Otherwise, brake hose and rubber parts may
get damaged or brake system may not
operate normally.
! CAUTION
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid. If any fluid is spilled, flush it
with water immediately.
NOTE
• When replacing brake fluid, start with the
brake closest to the brake master cylinder.
• To prevent air getting into reservoir, be
careful not to let the reservoir be short of
fluid while operating brake pedal.
1) Using a syringe or such, extract some brake fluid
from reservoir of brake master cylinder.
4A-5 Brake Control System and Diagnosis:

! CAUTION

• Brake fluid is extremely damaging to paint.

Do not allow brake fluid to get on painted
surface. Painted surfaces will be damaged
by brake fluid. If any fluid spilled, flush it
with water immediately.
• If ABS depressurization check is
performed when air is trapped in brake
line, air may be taken in hydraulic unit. To
prevent this, be sure to bleed brake system
before performing hydraulic unit operation
check.

Hydraulic brake system must be bled whenever air

IBP80A410003-02 enters the system.
2) Add new brake fluid to reservoir of brake master As the system is of a diagonal split configuration, if pipe
cylinder. or hose is disconnected from one brake, the line
concerned must be bled not only at the end of that brake
Brake fluid
but also at the end of the diagonally opposite brake.
: Refer to reservoir cap
If any joint on master cylinder or any intermediate joint
3) Remove bleeder plug cap on brake caliper. Attach a between master cylinder and a brake is disconnected,
vinyl tube (1) to bleeder plug, and insert the other then the system must be bled at all four brakes.
end into container (2).
NOTE
Perform bleeding operation starting from the
brake farthest from brake master cylinder
and then at the brake on the same brake line.
Do the same on the other brake line.

I2RH01410015-01

4) Depress brake pedal several times with bleeder plug

loosened.
5) When new brake fluid starts coming out, tighten
bleeder plug to specified torque.
• Front: )(Page 4B-1)
• Rear: )(Page 4C-1)
6) Perform Steps 3) – 5) for remaining wheels as well.
7) If necessary, bleed air from brake system. )(Page
4A-5)

Air Bleeding of Brake System

AENBL80A4106004
! WARNING
Never use brake fluid other than specified.
Otherwise, brake hose and rubber parts may
get damaged or brake system may not
operate normally.
 Brake Control System and Diagnosis: 4A-6

2) Remove bleeder plug cap. Attach a vinyl tube (1) to

[A] bleeder plug, and insert the other end into container
[C] (2).

1 3

2 4 I2RH01410015-01

3) Depress brake pedal several times, and then while

[B] holding it depressed, loosen bleeder plug about one-
third to one-half a turn.
[C]
4) When fluid pressure in cylinder is almost released,
1 3 retighten bleeder plug.
5) Repeat this operation until air is completely removed
from hydraulic line.

2 4
IBP80A410004-01

[A]: Without ABS 2. Front left brake caliper

I2RH01410016-01
[B]: With ABS 3. Rear right wheel cylinder
[C]: Vehicle forward 4. Rear left wheel cylinder 6) When air bubbles disappear from fluid flowing into
1. Front right brake caliper container, depress and hold brake pedal and tighten
bleeder plug.
1) Fill brake master cylinder reservoir with new brake • Front: )(Page 4B-1)
fluid and keep the reservoir at least one-half full of • Rear: )(Page 4C-1)
fluid during bleeding operation.
Brake fluid
: Refer to reservoir cap (1) of brake master
cylinder or owner’s manual.

I2RH01410017-01

7) Attach bleeder plug cap.

8) After completing bleeding operation, apply fluid
pressure to brake lines and check for leakage.
9) Replenish reservoir with new fluid up to specified
level. )(Page 4A-4)
IBP80A410005-01 10) Check brake pedal stroke. If the stroke is so large,
repeat entire procedure of bleeding.
4A-7 Brake Control System and Diagnosis:

Brake Pedal Components

AENBL80A4106005

6 (a)

5 (a)

8 3
(b)

4 (a)
4 (a)

10 9
9

11

IBP80A410051-02

1. Brake pedal assembly 6. Cowl upper stiffener bolt 11. Pedal spring
: Tighten brake booster nut, brake pedal bracket nut : Apply grease 99000-25011 to
and cowl upper stiffener bolt in this order. inside of pedal spring.
2. Pedal pad 7. Pedal shaft : 13 N⋅m (1.3 kgf-m, 9.5 lbf-ft)

3. Brake light switch 8. Brake pedal shaft nut : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)

Brake booster nut 9. Pedal bushing

4. : Tighten brake booster nut, brake pedal : Apply grease 99000-25011 to outside of bushing.
bracket nut and cowl upper stiffener bolt
in this order.
Brake pedal bracket nut 10. Pedal shaft spacer
5. : Tighten brake booster nut, brake pedal
bracket nut and cowl upper stiffener bolt
in this order.

Brake Pedal Assembly Removal and Installation

AENBL80A4106006
Removal
1) Remove combination meter cluster panel. )(Page
9C-10)
2) Remove steering column hole cover. )(Page 6B-8) 1
3) Remove brake light switch. )(Page 4A-10)
4) Remove clip, clevis pin and brake booster nuts.
)(Page 4A-18)
5) Remove steering column reinforcement (1).

IBP80A410007-01
 Brake Control System and Diagnosis: 4A-8

6) Remove brake pedal bracket nut and brake booster Tightening torque
nuts. Steering column reinforcement bolt (a): 5.5 N·m
7) Remove cowl upper stiffener bolt. (0.56 kgf-m, 4.0 lbf-ft)
Steering column reinforcement nut (b): 5.5 N·m (
8) While an assistant holding brake booster pulled to
0.56 kgf-m, 4.0 lbf-ft)
engine compartment side to facilitate removal,
remove brake pedal assembly. (b)

Installation
1) Install brake pedal assembly and install brake
booster.
2) Tighten brake booster nuts (1) to specified torque.
Tightening torque
Brake booster nuts (a): 13 N·m (1.3 kgf-m, 9.5
lbf-ft) (a)

IBP80A410008-01

7) Bleed air from brake system. )(Page 4A-5)

8) Check brake pedal free height and play.
• Brake pedal free height: )(Page 4A-9)
• Brake pedal play: )(Page 4A-9)
1,(a)
9) Install brake light switch. )(Page 4A-10)
IBP80A410052-01 10) Check all connections for fluid leakage and make
3) Tighten brake pedal bracket nut to specified torque. sure that brake system operates properly.
Tightening torque 11) Install steering column hole cover. )(Page 6B-8)
Brake pedal bracket nut (a): 13 N·m (1.3 kgf-m, 12) Install combination meter cluster panel. )(Page 9C-
9.5 lbf-ft) 10)
4) Tighten cowl upper stiffener bolt to specified torque.
Brake Pedal Assembly Disassembly and
Tightening torque Reassembly
Cowl upper stiffener bolt (b): 13 N·m (1.3 kgf-m, AENBL80A4106007
9.5 lbf-ft)
Disassembly
1) Remove brake pedal assembly. )(Page 4A-7)
2) Loosen brake pedal shaft nut (4).
(a)
3) Remove brake pedal (1) by pulling out pedal shaft
(2).
4) Remove pedal pad (3) from brake pedal, if
necessary.

(b)

I9P60A410010-01

5) Install clevis pin and new clip. )(Page 4A-18)

6) Tighten steering column reinforcement bolt and nut
to specified torque.
4A-9 Brake Control System and Diagnosis:

(a)
2

“A”,1
“A”,1

“A”,2

3
IBP80A410053-01 IBP80A410054-01

• Install brake pedal assembly. )(Page 4A-7)

Reassembly
Reverse removal procedure, noting the following points.
Brake Pedal Free Height Inspection
• Apply grease to outside of pedal bushings(1) and AENBL80A4106008
inside of pedal spring (2). Check brake pedal free height. If it is out of specification,
check and adjust the following items.
“A”: Grease 99000–25011 (SUZUKI Super Grease
• Brake booster for installation.
A)
• Length of brake booster push rod.
• Tighten brake pedal shaft nut to specified torque.
Brake pedal free height “a” from carpet (1)
Tightening torque : 124.4 mm (4.89 in.)
Brake pedal shaft nut (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)

“a”

I8G001410006-01

Brake Pedal Play Inspection

AENBL80A4106009
With engine stopped, depress brake pedal several
times.
Depress brake pedal with a finger until resistance is felt
and measure distance to that point.
If brake pedal play is not as specified, check push rod
length. )(Page 4A-25)
 Brake Control System and Diagnosis: 4A-10

If push rod length is as specified, check cylinder push

rod clevis and pin for installation condition and
looseness. Replace cylinder push rod clevis or pin if they
are loose.
Brake pedal play “a”
: 1 – 8 mm (0.04 – 0.31 in.)

“a”
IBP80A410011-01

Brake Light Switch Removal and Installation

AENBL80A4106011
Removal
“a” 1) Remove steering column hole cover. )(Page 6B-8)
I3RH0A410010-01
2) Disconnect brake light switch connector (1).
Excessive Pedal Travel Inspection 3) Remove brake light switch (2) from bracket turning it
AENBL80A4106010 counterclockwise viewed from above by approx. 90°.
NOTE
The brake pedal-to-dash panel clearance 1

must be measured at the point (1) shown in

the figure below.

1 IBP80A410012-01
IBP80A410009-01
Installation
1) Start engine. 1) While pulling up brake pedal fully, install brake light
2) Depress brake pedal a few times. switch pressing it to pedal bracket so that the switch
3) With brake pedal depressed with force of about 300 stroke becomes 0 and turning it clockwise viewed
N (30.6 kgf, 67.4 lbf), measure clearance “a” from above by approx. 90°.
between brake pedal and carpet. If clearance “a” is
less than specification, check the following items.
• Bleed brake system. )(Page 4A-5)
• Check for booster push rod length. )(Page 4A-
25)
Brake pedal arm to carpet clearance “a” 1
When pedal is depressed at 300 N (30.6 kgf, 67.4
lbf): over 59 mm (2.32 in.)
2

IBP80A410013-01
4A-11 Brake Control System and Diagnosis:

NOTE Lighting Inspection

While installing brake light switch turning it Depress the brake pedal until brake light turns on and
clockwise, the switch body rises from the measure the brake pedal stroke (a) to that point.
pedal bracket by approx. 1.5 mm. If the pedal stroke is not as specified, remove and
This movement automatically creates reinstall brake light switch.
specified clearance below. Brake pedal stroke until brake light turns on
Clearance between switch screw end and Petrol model: 5.33 – 18.65 mm (0.21 – 0.73 in.)
pedal bracket “a”: Diesel model: 6.39 – 15.98 mm (0.25 – 0.63 in.)
0.8 to 1.8 mm (0.031 to 0.071 in.) for Petrol
model
1.0 to 2.0 mm (0.039 to 0.078 in.) for Diesel
model

“a”
I3RH0A410010-01

“a”

IBP80A410014-01

2) Connect brake light switch connector.

3) Install steering column hole cover. )(Page 6B-8)

Brake Light Switch Inspection

AENBL80A4106012
Continuity Inspection
Check brake light switch for continuity between terminals
at each shaft condition.
If check result is not as specified, replace switch.

[A] [B]

4 4 3

3 2 1

Terminal
1 2 3 4
Shaft condition
Free
Pushed
IBP80A410015-02

[A]: Petrol model [B]: Diesel model

I8C50A410013-01
 Brake Control System and Diagnosis: 4A-12

Brake Hose and Pipe Components

AENBL80A4106013

(a)
17
[A]
12

(a)
(a)
5 (a) (a)
(a)
17 12 18

12 16

(a) (a)
1 12 18
(a)
12 (a)
16 (a)
2 12
16
(a)
15
14
(a) 16 (a)

12

7
[B]

8 (a)
(a) 11 4 2
12 9

3
1
(a)
10 (a)
12 6

(b)
13 (c)
(a)
10

(a)
(c)
7
13

4
8
11
9

IBL80A410001-01

[A]: With ABS 7. Brake master cylinder 15. From joint right to rear brake flexible hose
right pipe
[B]: Without ABS 8. From ABS control module or proportioning 16. Rear brake flexible hose
valve to joint left pipe
1. From master cylinder primary to ABS 9. From ABS control module or proportioning 17. From rear brake flexible hose to rear wheel
control module or proportioning valve valve to joint right pipe cylinder right pipe
2. From master cylinder secondary to ABS 10. Front brake flexible hose 18. From rear brake flexible hose to rear wheel
control module or proportioning valve cylinder left pipe
3. From ABS control module or proportioning 11. Brake 4-way joint : 16 N⋅m (1.6 kgf-m, 12.0 lbf-ft)
valve to front brake flexible hose right pipe
4. From ABS control module or proportioning 12. E-ring : 11 N⋅m (1.1 kgf-m, 8.5 lbf-ft)
valve to front brake flexible hose left pipe
5. ABS control module 13. Flexible hose gasket : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
6. Proportioning valve 14. From joint left to rear brake flexible hose left : Do not reuse.
pipe

Brake Flexible Hose and Pipe Removal and ! CAUTION

Installation
AENBL80A4106014 Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid. If any fluid is spilled, flush it
with water immediately.
4A-13 Brake Control System and Diagnosis:

Removal Brake Flexible Hose and Pipe Inspection

AENBL80A4106015
1) Hoist vehicle and remove wheel. )(Page 2D-2)

NOTE Flexible Hose

Check the following points. If check result is not OK,
This operation is not necessary when replace brake flexible hose.
removing pipes connecting to brake master
• Connection for leakage and other damage.
cylinder.
• Blister, cracks and other damage.
2) Remove dirt and foreign material from fittings at both
flexible hose end and pipe end.
3) Drain brake fluid in reservoir. )(Page 4A-4)
4) Remove brake flexible hose or pipe.
Special tool
: 09950M78220

Installation
Reverse removal procedure, noting the following points.
• Install brake pipe clamps properly. )(Page 4A-12)
• Make sure that steering wheel is in straight-forward
I9P60A410017-01
position and flexible hoses are not twisted or kinked.
• Make sure that flexible hose is not in contact with any Pipe
part of suspension. Check brake pipe for damage, cracks, dents and
• Bleed brake system. )(Page 4A-5) corrosion. If check result is not OK, replace pipe.
• Make sure that brake system operates properly and
there is no fluid leakage.

Brake Master Cylinder Components

AENBL80A4106016
! CAUTION
Never disassemble brake master cylinder. Disassembly will spoil its original performance.
If faulty condition is observed, replace it with a new assembly.
 Brake Control System and Diagnosis: 4A-14

9
2

[A]
7
6

5 FLD

(a)

IBP80A410017-01

[A]: Diesel model 5. Grommet: Apply brake fluid. : 18 N⋅m (1.8 kgf-m, 13.5 lbf-ft)

1. Brake master cylinder 6. Clutch reservoir hose : Apply grease to piston rod included in spare parts for
brake master cylinder or brake booster.
2. Reservoir 7. Hose clamp : Do not reuse.
3. Spring pin 8. Reservoir cap
4. O-ring 9. Reservoir filter

Brake Master Cylinder Assembly On-Vehicle ! CAUTION

Inspection
AENBL80A4106017 • Never disassemble brake master cylinder.
Check brake master cylinder for crack, damage and Disassembly will spoil its original
brake fluid leakage. If check result is not OK, replace performance.
brake master cylinder. If faulty condition is observed, replace
master cylinder with a new assembly.
• Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be
damaged by brake fluid. If any fluid is
spilled, flush it with water immediately.

Removal
1) Clean external surface of brake master cylinder.
2) Disconnect brake fluid level switch connector (1) on
reservoir.

IBP80A410018-01

Brake Master Cylinder Assembly Removal and

Installation
AENBL80A4106018
4A-15 Brake Control System and Diagnosis:

1
2
1
IAP70B410006-02

2) Install brake master cylinder to brake booster.

3) Tighten brake master cylinder fixing nuts to specified
IBP80A410002-03
torque.
3) Drain brake fluid in reservoir.
4) For diesel model, disconnect clutch reservoir hose Tightening torque
(3) from reservoir. Brake master cylinder fixing nut (a): 18 N·m (1.8
kgf-m, 13.5 lbf-ft)
5) Using special tool, loosen flare nuts and disconnect
brake pipes (1) from brake master cylinder. 4) Connect brake pipes (1) to brake master cylinder
and tighten flare nuts to specified torque using
Special tool special tool.
: 09950M78220
Special tool
6) Remove brake master cylinder fixing nuts (2). : 09950M78220
Tightening torque
Brake pipe flare nut (b): 16 N·m (1.6 kgf-m, 12.0
lbf-ft)

2
1
IBP80A410020-02

7) Remove brake master cylinder (1) and O-ring (2). (b)

(a)
1
IBP80A410021-01

5) For diesel model, connect clutch reservoir hose to

reservoir.
6) Connect brake fluid level switch connector.
7) After installation, bleed brake system. )(Page 4A-5)
2 8) Check installed parts for brake fluid leakage.
1 9) Check brake pedal for play. )(Page 4A-9)
IAP70B410006-02
10) Make sure that brake system operates properly
Installation without fluid leakage.
1) Install new O-ring (2) to brake master cylinder
assembly (1). Brake Master Cylinder Reservoir Removal and
Installation
AENBL80A4106019
 Brake Control System and Diagnosis: 4A-16

! CAUTION
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid. If any fluid is spilled, flush it
with water immediately.

Removal
1) Clean outside surface of reservoir.
2) Remove master cylinder together with reservoir from
brake booster. )(Page 4A-14) I8C50A410025-01

3) Remove spring pin (1) by using special tool. 4) Install master cylinder with reservoir to brake
booster. )(Page 4A-14)
Special tool
(A): 09916M44310 Brake Master Cylinder Assembly Inspection
AENBL80A4106020

! CAUTION
After inspection, be sure to wash brake fluid
from special tool. Brake fluid remaining on
special tool may cause damage to it.

No-Load Inspection
1) Fit special tool to primary port (1) as shown below.
Special tool
1 (A): 09918M78211
(B): 09952M46010
(A)
IBP80A410022-01

4) Remove reservoir (1) and grommets (2).

3
1

1
2
(A)

(B)
IBP80A410026-01
2
2. Secondary port 3. Brake master cylinder assembly

2) Apply pressure to brake master cylinder assembly

with special tool (A) and confirm that pressure does
not build up in cylinder.
If pressure builds up, brake master cylinder
assembly is defective and must be replaced.
IBP80A410023-01
3) Repeat Steps 1) and 2) for secondary port as well.
Installation
Air Tightness Inspection
1) Lubricate new grommets with the same fluid as the
one to fill reservoir with before fitting grommets into 1) With brake master cylinder assembly (1) fixed in vise
master cylinder. (2) as shown below, fit special tool to primary port.
2) Install reservoir to master cylinder. NOTE
3) Install new spring pin (2) by using special tool, until When using vise, put clean cloth between
both of its ends at the right and left of reservoir (1) brake master cylinder and vise so as not to
becomes the same length. cause damage to brake master cylinder.
Special tool
(A): 09916M44310 Special tool
(A): 09918M78211
4A-17 Brake Control System and Diagnosis:

(B): 09952M46010 2) Using special tool, apply pressure of 50 kPa (0.5 kgf/
cm2, 7.25 psi, 0.5 bar) to brake master cylinder
“a” assembly.
2
If above pressure does not build up, brake master
1
cylinder assembly is defective and must be replaced.
3) Repeat Steps 1) and 2) for secondary port.

(A)

(B)

IBP80A410024-01

“a”: 50 mm (2.0 in.)

Brake Booster Components

AENBL80A4106021
! CAUTION
Never disassemble brake booster. Disassembly will spoil its original function. If faulty condition is
observed, replace it with a new assembly.

5 6 7

3 2
1 4

(a)

(b)
IBP80A410025-01

1. Brake booster 5. Check valve : 13 N⋅m (1.3 kgf-m, 9.5 lbf-ft)

2. Gasket 6. Hose clamp : 18 N⋅m (1.8 kgf-m, 13.5 lbf-ft)
3. Clevis pin 7. Vacuum hose : Do not reuse.
4. Clip 8. O-ring

Brake Booster Function Check Air Tightness Check

AENBL80A4106022
NOTE 1) Start engine.
2) Stop engine after running for 1 to 2 minutes.
Make sure that no air is in hydraulic line
before doing this check.
 Brake Control System and Diagnosis: 4A-18

3) Depress brake pedal several times with the same 2) Start engine while depressing brake pedal. If pedal
force as in ordinary braking to see how pedal travel travel increases a little, brake booster operation is
changes. Brake booster is air tight if pedal travel satisfactory. No change in pedal travel indicates
decreases every time the pedal is depressed. malfunction of brake booster.

I2RH01410005-01 I2RH01410008-01

1. 1st 2. 2nd 3. 3rd

Air Tightness Check Under Loaded Condition
4) If pedal travel does not change, brake booster is 1) With engine running, depress brake pedal. Then
defective in air tightness. stop engine while holding brake pedal depressed.

NOTE
If defective, inspect vacuum lines and sealing
parts, and replace the faulty part. After this,
repeat the entire test.

I2RH01410009-01

H: Hold

2) Hold brake pedal depressed for 30 seconds. If pedal

height does not change, brake booster is in good
I2RH01410006-01
condition. If pedal height changes, brake booster is
not in good condition.
1. 1st, 2nd, 3rd

Operation Check
1) With engine stopped, depress brake pedal several
times with the same force and make sure that pedal
travel does not change.

I2RH01410010-01

H: Hold T: 30 seconds

Brake Booster Removal and Installation

AENBL80A4106023

I2RH01410007-01
4A-19 Brake Control System and Diagnosis:

Removal
Petrol model
1) Disconnect brake pipes (1) from ABS hydraulic unit /
control module assembly (2) (with ABS) or
proportioning valve (3) (without ABS) using special
tool.
Special tool
: 09950M78220

[A] [B]

2 3

1
IBP80A410056-01

8) Remove vacuum check valve (1) from brake booster

(2).
1

1
IBP80A410027-01 2

[A]: With ABS [B]: Without ABS

1
2) Remove brake master cylinder assembly from
booster. )(Page 4A-14)
3) Recover refrigerant from A/C system. )(Page 7B-
24)
4) Remove A/C suction hose and A/C liquid pipe from
HVAC unit. )(Page 7B-30)
IBP80A410033-01
5) Disconnect vacuum hose from brake booster.
6) Remove clip (2) and push rod clevis pin (1). Diesel model
1) Disconnect brake pipes (1) from ABS hydraulic unit/
2 control module assembly (2) (with ABS) or
proportioning valve (3) (without ABS) using special
tool.
Special tool
1 : 09950M78220

[A] [B]

2 3

IBP80A410055-01 1
7) Remove brake booster nuts (1) and remove brake
1
booster from dash panel. IBP80A410034-01

[A]: With ABS [B]: Without ABS

2) Remove brake master cylinder assembly from

booster. )(Page 4A-14)
3) Recover refrigerant from A/C system. )(Page 7B-
24)
4) Remove A/C suction hose and A/C liquid pipe from
HVAC unit. )(Page 7B-30)
5) Disconnect vacuum hose from brake booster.
 Brake Control System and Diagnosis: 4A-20

6) Pull out oil level gauge (1) and remove oil level 12) Remove clip (2) and clevis pin (1).
gauge guide mounting bolt (2).
2
1

IBP80A410058-01
2
IBP80A410057-01 13) Remove brake booster nuts (1).
7) Pull out oil level gauge guide a little to facilitate brake
booster removal.
8) Wrap the oil level gauge guide end (5) with adhesive
plaster or the like to protect brake booster from
scratching.
9) Disconnect engine harness (1) and crankcase
ventilation connector (2). )(Page 1D-70)
10) Remove engine hook (3) and intake manifold bolt
(4).

5 2
1

1
IBP80A410059-01
4
14) Support engine with a chain hoist or an engine crane
as follows.
a) Remove engine right mounting bracket bolt (2).
b) Install the removed engine hook (1) with engine
right mounting bracket bolt (2) to support engine
steady.

3
IBP80A410036-01

11) Remove actuator bracket bolt (1) (with ABS) or

proportioning valve bracket bolt (2) (without ABS).

[A] [B]

1 2
1 2
1
IBP80A410038-01

IBP80A410037-02

[A]: With ABS [B]: Without ABS

4A-21 Brake Control System and Diagnosis:

NOTE
2
Instead of step 14), engine can be supported 1
using engine hooks of exhaust manifold side
and common rail side with a chain hoist or an
engine crane. In this case, to avoid
interference between hood end and chain
hoist, bring hood up to upright position and
hold it at the position with rope.

15) Remove engine right mounting bracket nuts (1) and

then lower engine carefully until end of stud bolts (2)
are flush with surface of mounting. IAP70B410011-01

3) Install vacuum check valve (1) to brake booster (2).

1
2
1

IBP80A410040-01
IBP80A410039-01
4) Install brake booster to dash panel. Then connect
16) Moving oil level gauge aside, remove brake booster push rod clevis (3) to pedal arm with clevis pin (2)
from dash panel. and new clip (1).
17) Remove vacuum check valve (1) from brake booster
(2).
3
1

2
1

IBP80A410040-01
IBP80A410060-01
Installation 5) Tighten brake booster nuts (1) to specified torque.

Petrol model Tightening torque

Brake booster nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf-
1) Remove combination meter cluster panel. )(Page
ft)
9C-10)
2) Loosen brake pedal bracket nut (1) and cowl upper
stiffener bolt (2).
 Brake Control System and Diagnosis: 4A-22

[A] [B]

2 3

1,(a)

1,(a)
IBP80A410041-01

[A]: With ABS [B]: Without ABS

1,(a)
IBP80A410061-01 12) After installation, bleed brake system. )(Page 4A-5)
6) Tighten brake pedal bracket nut to specified torque. 13) Check installed parts for brake fluid leakage.
Tightening torque 14) Check brake pedal for play. )(Page 4A-9)
Brake pedal bracket nut (a): 13 N·m (1.3 kgf-m, 15) Make sure that brake system operates properly
9.5 lbf-ft) without brake fluid leakage.
7) Tighten cowl upper stiffener bolt to specified torque. 16) Install A/C suction hose and A/C liquid pipe. )(Page
7B-30)
Tightening torque
17) Evacuate and charge the A/C system. )(Page 7B-
Cowl upper stiffener bolt (b): 13 N·m (1.3 kgf-m,
24)
9.5 lbf-ft)
Diesel model
1) Remove combination meter cluster panel. )(Page
(a) 9C-10)
2) Loosen brake pedal bracket nut (1) and cowl upper
stiffener bolt (2).

2
1

(b)

I9P60A410042-02

8) Install combination meter cluster panel.

9) Connect vacuum hose to brake booster. IAP70B410011-01
10) Install brake master cylinder assembly to brake 3) Install vacuum check valve (1) to brake booster (2).
booster.
11) Connect brake pipes (1) to ABS hydraulic unit /
control module assembly (2) (with ABS) or
2
proportioning valve (3) (without ABS) using special
tool.
1
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 12.0
lbf-ft)
Special tool
: 09950M78220

IBP80A410042-01

4) Holding brake booster (1) in a position as illustrated,

carefully install it to dash panel.
4A-23 Brake Control System and Diagnosis:

! CAUTION
1,(a)
When installing brake booster, its painted
surface may contact with oil level gauge
guide. Wrap the guide end with adhesive
plaster or the like to protect the booster
surface from scratching.

IBP80A410046-01

7) Connect clevis (3) to brake pedal arm with clevis pin

(2) and new clip (1).

3
1

IBP80A410043-01

5) Lift up engine and tighten engine right mounting 2

bracket nuts to specified torque.
Tightening torque
Engine right mounting bracket nut (a): 55 N·m (
5.6 kgf-m, 40.5 lbf-ft)

(a)

IBP80A410062-01

8) Tighten brake booster nuts (1) to specified torque.

Tightening torque
Brake booster nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf-
ft)

IBP80A410044-01

6) After removing a chain hoist or an engine crane and

engine hook, tighten engine right mounting bracket
bolt (1) to specified torque.
Tightening torque
Engine right mounting bracket bolt (a): 60 N·m (
6.1 kgf-m, 44.5 lbf-ft)

1,(a)
IBP80A410063-01

9) Tighten brake pedal bracket nut to specified torque.

Tightening torque
Brake pedal bracket nut (a): 13 N·m (1.3 kgf-m,
9.5 lbf-ft)
10) Tighten cowl upper stiffener bolt to specified torque.
 Brake Control System and Diagnosis: 4A-24

Tightening torque
Cowl upper stiffener bolt (b): 13 N·m (1.3 kgf-m,
3
9.5 lbf-ft)

2,(a)

(a)

4,(b) 1
(b) IBP80A410048-02

17) Push oil level gauge guide (1), pulled out before,
I9P60A410010-01
back to original position and tighten oil level gauge
11) Install combination meter cluster panel. guide mounting bolt to specified torque. And then,
12) Connect vacuum hose to brake booster. insert oil level gauge.
13) Tighten actuator bracket bolt (with ABS) or Tightening torque
proportioning valve bracket bolt (without ABS) to Oil level gauge guide mounting bolt (a): 9.0 N·m
specified torque. (0.92 kgf-m, 7.0 lbf-ft)
Tightening torque
1
Actuator bracket bolt (a): 26 N·m (2.7 kgf-m, 19.5
lbf-ft)
Proportioning valve bracket bolt (b): 26 N·m (2.7
kgf-m, 19.5 lbf-ft)

[A] [B]

(a) (b)
(a)

(a)
IBP80A410064-01
IBP80A410047-01
18) Install brake master cylinder assembly to brake
[A]: With ABS [B]: Without ABS
booster.
19) Connect brake pipes (1) to ABS hydraulic unit /
14) Tighten intake manifold bolt (2) to specified torque.
control module assembly (2) (with ABS) or
Tightening torque proportioning valve (3) (without ABS) using special
Intake manifold bolt (a): 25 N·m (2.5 kgf-m, 18.5 tool.
lbf-ft)
Tightening torque
15) Install engine hook (1) and tighten engine hook bolt Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 12.0
(4) to specified torque. lbf-ft)
Tightening torque Special tool
Engine hook bolt (b): 25 N·m (2.5 kgf-m, 18.5 lbf- : 09950M78220
ft)
16) Install engine harness and crankcase ventilation
connector (3). )(Page 1D-70)
4A-25 Brake Control System and Diagnosis:

Brake Booster Inspection

[A] [B] AENBL80A4106024

2 3 • Check brake booster for damage.

• Check brake booster for operation referring to
“Operation Check” under “Brake Booster Function
Check” (Page 4A-17).
• Check boot for damage and deterioration.
• Check for push rod length.
1,(a)
If check result is not as specified, replace brake
1,(a) booster.
IBP80A410050-01
Push rod length
[A]: With ABS [B]: Without ABS
“a”: 114.5 – 115.5 mm (4.507 – 4.547 in.)
20) After installation, bleed brake system. )(Page 4A-5)
21) Check installed parts for brake fluid leakage.
22) Check brake pedal for play. )(Page 4A-9)
23) Make sure that brake system operates properly
without brake fluid leakage.
24) Install A/C suction hose and A/C liquid pipe. )(Page
7B-30)
25) Evacuate and charge the A/C system. )(Page 7B-
24) I3RM0A410056-01

Specifications
Tightening Torque Specifications
AENBL80A4107001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Brake booster nuts 13 1.3 9.5 )
Brake pedal bracket nut 13 1.3 9.5 )/)/)
Cowl upper stiffener bolt 13 1.3 9.5 )/)/)
Steering column reinforcement bolt 5.5 0.56 4.0 )
Steering column reinforcement nut 5.5 0.56 4.0 )
Brake pedal shaft nut 23 2.3 17.0 )
Brake master cylinder fixing nut 18 1.8 13.5 )
Brake pipe flare nut 16 1.6 12.0 )/)
Brake booster nut 13 1.3 9.5 )/)
Brake pipe flare nut 16 1.6 12.0 )
Engine right mounting bracket nut 55 5.6 40.5 )
Engine right mounting bracket bolt 60 6.1 44.5 )
Actuator bracket bolt 26 2.7 19.5 )
Proportioning valve bracket bolt 26 2.7 19.5 )
Intake manifold bolt 25 2.5 18.5 )
Engine hook bolt 25 2.5 18.5 )
Oil level gauge guide mounting bolt 9.0 0.92 7.0 )

NOTE
The tightening torque(s) also specified in:
“Brake Pedal Components”:
“Brake Hose and Pipe Components”:
“Brake Master Cylinder Components”:
“Brake Booster Components”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
 Brake Control System and Diagnosis: 4A-26

Special Tools and Equipment

Recommended Service Material
AENBL80A4108001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 )

NOTE
Required service material(s) also described in:
“Brake Pedal Components”:
“Brake Master Cylinder Components”:

Special Tool
AENBL80A4108002
09916M44310 09918M78211
Valve guide remover (5 mm) Radiator cap tester kit
)/) )/)

09950M78220 09952M46010
Flare nut wrench (10 x 12 Master cylinder attachment
mm)
)/)/)/)/)/)/) )/)
4B-1 Front Brakes:

Front Brakes
Brakes

Repair Instructions
Front Disc Brake Components
AENBL80A4206001

IBL80A420001-01

1. Caliper 9. Disk brake piston 17. Brake flexible hose

: Apply brake fluid to contact face of : Be sure to direct mark (18) to
cylinder. inside of vehicle “I” as shown in
figure.
2. Caliper pin bolt 10. Pad spring : 27 N⋅m (2.7 kgf-m, 19.9 lb-ft)
: Apply brake fluid to contact parts of brake
piston.
3. Boot 11. Brake disc : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Slide pin No.1 12. Brake caliper carrier : 8.5 N⋅m (0.86 kgf-m, 6.27 lb-ft)
: Apply rubber grease included in slide pin / boot
set.
5. Brake pad 13. Caliper carrier bolt : 85 N⋅m (8.5kgf-m, 61.5 lb-ft)
6. Shim 14. Bleeder plug : Do not reuse.
7. Cylinder boot 15. Flexible hose joint bolt
: Apply small amount of brake fluid.
8. Piston seal 16. Hose washer
: Apply small amount of brake fluid.
 Front Brakes: 4B-2

Front Brake Pad On-Vehicle Inspection 4) Remove brake pads (3).

AENBL80A4206002
Inspect pad linings (1) periodically according to
4
maintenance schedule whenever wheels are removed 2
(for tire rotation or other reason). Take a look through
each end and inspection hole of caliper and check lining
thickness of outside and inside pads.
If lining is worn and its thickness (“a” in figure) is less
than limit, all pads must be replaced at the same time.
3
Front brake pad thickness “a” (lining thickness)
Standard: 10 mm (0.39 in.)
1
Limit: 1.5mm (0.06 in.)
I7RW01420010-01

Installation
1) Set brake pad springs (1), and install brake pads (2)
and shim (4).

NOTE
Install the brake pad with wear indicator (3) to
the vehicle center side of front right and left
brake pad.

I7RW01420009-01

Front Brake Pad Removal and Installation

AENBL80A4206003

NOTE
When replacing brake pad, replace it on the
right and left.

Removal
1) Hoist vehicle and remove front wheel. I7RW01420012-01

2) Remove caliper pin bolts (1). 2) Install caliper and tighten caliper pin bolts to
specified torque.
Tightening torque
Caliper pin bolt (a): 27 N·m (2.7 kgf-m, 19.9 lbf-ft)

(a)

I7RW01420003-01

3) Remove caliper (1) from caliper carrier (2).

NOTE I7RW01420005-02
Hang removed caliper (1) with a wire hook (4)
or the like so as to prevent brake hose from
bending and twisting excessively or being
pulled.
Don’t operate brake pedal with brake pads
removed.
4B-3 Front Brakes:

3) Install front wheel referring to “Wheel (with Tire)

Removal and Installation” in Section 2D (Page 2D-
2).
4) After completion of installation, check for brake
effectiveness.

Front Brake Pad Inspection

AENBL80A4206004
Check pad lining for wear. When the wear exceeds limit,
replace with new one.

! CAUTION
I7RW01420006-01
Never polish pad lining with sandpaper. If 3) Remove caliper pin bolts (1).
lining is polished with sandpaper, hard
particles of sandpaper will be deposited in
lining and may damage disc. When pad lining
requires correction, replace it with a new one.

Front brake pad thickness (lining thickness)

1
Standard: 10 mm (0.39 in.)
Limit: 1.5 mm (0.06 in.)

NOTE
When pads are removed, visually inspect
I7RW01420003-01
caliper for brake fluid leak. Correct leaky
point, if any. 4) Remove caliper from caliper carrier.

Installation
1) Install caliper to caliper carrier.
2) Torque caliper pin bolts to specification.

NOTE
Make sure that boots are fit into groove
securely.

Tightening torque
Caliper pin bolt (a): 27 N·m (2.7 kgf-m, 19.9 lbf-ft)

I2RH01420005-01

Front Brake Caliper Removal and Installation

AENBL80A4206005

(a)
Removal
1) Hoist vehicle and remove front wheel.
2) Remove brake flexible hose joint bolt (1) from caliper
(2). As this will allow fluid to flow out of hose (3),
have a container ready beforehand. I7RW01420005-02
 Front Brakes: 4B-4

3) Connect flexible hose (3) with new hose washer (4) Front Brake Caliper Disassembly and
to caliper as shown in figure. Reassembly
AENBL80A4206006
4) Torque flexible hose joint bolt to specification.
Tightening torque Disassembly
Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft) ! CAUTION

• Clean around caliper with brake fluid

! WARNING
• Make sure that flexible hose is not twisted
when tightening joint bolt. If it is twisted,
reconnect it using care not to twist it.
• Be sure to direct mark (1) to inside of
vehicle (2) as shown in figure.
before disassembly.
• Be careful not to damage inside (bore side)
of cylinder.
1) Remove disc brake piston with air blown into flexible
hose joint bolt installation hole.

! WARNING
5) Tighten bleeder plug to specified torque.
Do not apply too highly compressed air
Tightening torque
which will cause piston to jump out of
Bleeder plug (b): 8.5 N·m (0.86 kgf-m, 6.27 lbf-ft)
cylinder. Place a cloth (1) to prevent piston
from damage. It should be taken out
gradually with moderately compressed air.
Do not place your fingers in front of piston
when using compressed air.

I2RH01420011-01

2) Remove cylinder boot.

I6RW0B420001-02 3) Remove piston seal using a thin blade like a
6) Install front wheel referring to “Wheel (with Tire) thickness gauge, etc.
Removal and Installation” in Section 2D (Page 2D-
2).
7) After completing the installation, fill reservoir with
brake fluid and bleed air from brake system referring
to “Air Bleeding of Brake System” in Section 4A
(Page 4A-5).
8) Check every installed part for fluid leakage.
9) Perform brake test and check fluid leakage.

I2RH01420013-01

4) Remove bleeder plug and cap from caliper.

4B-5 Front Brakes:

Reassembly 2) Before inserting piston (1) into cylinder, brake fluid to

Assemble parts in reverse order of disassembly, new boot (a) and install it onto piston as shown.
observing the following instructions.

! CAUTION

• Wash each part cleanly before installation

in the same fluid as the one used in master
cylinder reservoir.
• Never use other fluid or thinner.
• Before installing piston seal and cylinder
boot to cylinder, apply rubber grease
included in piston seal set or brake fluid to
them. I4RS0B420015-01

• Install a new piston seal into groove in
cylinder securely making sure that it is not
twisted.
• After reassembling brake lines, bleed air
from them.
A: 1 grooved side directed cylinder side
B: 2 grooved side directed pad side
3) Fit boot as it is in figure into boot groove in cylinder
with fingers.

Before installing caliper to carrier, install slide pins with

rubber grease included in slide pin / boot set applied into
caliper carrier hole and check for its smooth movement
in thrust direction.

I2RH01420019-01

4) Insert piston into cylinder by hand and fit boot in boot

groove in piston.

NOTE
IYSQ01420021-01
Check that boot is fitted in boot groove
• Install piston seal, boot and piston to caliper referring securely all around piston and cylinder.
to the following instructions.
1) Replace with a new piston seal (1) at every overhaul.
After applying brake fluid, fit piston seal (1) into
groove in cylinder taking care not to twist it.

I2RH01420020-01

I2RH01420017-01
 Front Brakes: 4B-6

5) To confirm that boot is fitted in its groove in cylinder Front Brake Disc Removal and Installation
properly, pull piston out of cylinder a little but do not AENBL80A4206008

take it all out. ! CAUTION

NOTE During removal, be careful not to damage
Boot’s face (1) should be at the same level brake flexible hose and not to depress brake
from cylinder’s face (2) all around. pedal.

6) Insert piston into cylinder by hand. Removal

1) Hoist vehicle and remove front wheel.
2) Remove caliper assembly by removing caliper
carrier bolts (2 pcs).

NOTE
Hang removed caliper with a wire hook or the
like so as to prevent brake hose from
bending and twisting excessively or being
pulled.

I4RS0A420004-01

Front Brake Caliper Inspection

AENBL80A4206007

Pin Boot and Cylinder Boot

Check boots for breakage, crack and damage.
If defective, replace boots.

I4RS0B420010-01

3) Pull brake disc off by using 8 mm bolts (1) (2 pcs).

I2RH01420014-01

Piston Seal
Excessive or uneven wear of pad lining may indicate
unsmooth return of piston.
In such case, replace rubber seal.
I5RW0A420003-01

I2RH01420015-01
4B-7 Front Brakes:

Installation Front Brake Disc Inspection

AENBL80A4206009
1) Install disc to hub.
• Install wheel nuts to hub bolts and fasten to fix the
2) Install caliper assembly to steering knuckle. brake disc.
! CAUTION • Using magnetic stand and with dial gauge positioned
at about 10 mm (0.39 in.) inward from periphery of
Make sure that flexible hose is not twisted disc, measure deflection of disc.
when installing caliper assembly. If it is If it exceeds the limit, correct or replace the brake
twisted, reinstall it using care not to twist it. disc.
3) Torque caliper carrier bolts to specification. Front brake disc deflection
Limit: 0.10 mm (0.004 in.) max.
Tightening torque
Caliper carrier bolt (a): 85 N·m (8.5 kgf-m, 61.5 Special tool
lbf-ft) (A): 09900M20607
(B): 09900M20701

I4RS0B420012-01
I4RS0B420013-01
4) Install front wheel referring to “Wheel (with Tire)
• Using micrometer, measure thickness of brake disc.
Removal and Installation” in Section 2D (Page 2D-
If it is less than limit, replace brake disc.
2).
5) Upon completion of installation, perform brake test. Front brake disc thickness
Standard: 22.0 mm (0.87 in.)
Limit: 20.0 mm (0.79 in.)

I4RS0B420014-01
 Front Brakes: 4B-8

Specifications
Tightening Torque Specifications
AENBL80A4207001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Caliper pin bolt 27 2.7 19.9 )/)
Flexible hose joint bolt 23 2.3 17.0 )
Bleeder plug 8.5 0.86 6.27 )
Caliper carrier bolt 85 8.5 61.5 )

NOTE
The tightening torque(s) also specified in:
“Front Disc Brake Components”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Recommended Service Material
AENBL80A4208001
NOTE
Required service material(s) also described in:
“Front Disc Brake Components”:

Special Tool
AENBL80A4208002
09900M20607 09900M20701
Dial gauge Magnetic stand
) )
4C-1 Rear Brakes:

Rear Brakes
Brakes

Repair Instructions
Rear Drum Brake Components
AENBL80A4306001

16 (b)

15 (a)

11
17

12
13 (c)
18
10

2
8

14 9

F 3
6

I6RW0B431001-02

1. Brake drum 9. Brake shoe lever 17. Rear axle

2. Brake shoe 10. Wheel cylinder 18. Plug
3. Shoe return spring 11. Brake back plate : 73 N⋅m (7.3 kgf-m, 53 lb-ft)
: Heat-resistant brake grease
4. Brake adjuster 12. Rear wheel hub : 12 N⋅m (1.2 kgf-m, 9.0 lb-ft)
5. Antirattle spring 13. Bleeder plug : 8 N⋅m (0.8 kgf-m, 6.0 lb-ft)
6. Hold down spring 14. Parking cable : Do not reuse.
7. Shoe hold down pin 15. Rear wheel hub mounting bolt
8. Push nut 16. Wheel cylinder mounting bolt

Rear Brake Drum Removal and Installation

AENBL80A4306002
Removal
1) Hoist vehicle and remove rear wheel.
2) Release parking brake lever.
3) Remove brake drum (1) by using 8 mm bolts (2) (2
pcs).
 Rear Brakes: 4C-2

2) Confirm that inside of brake drum and brake shoes

I7RW01431002-01
Installation
1) Before installing brake drum, to maximize brake
shoe-to-drum clearance, put screwdriver between
rod (1) and ratchet (2) and push down ratchet as
shown in figure.
are free from dirt and oil. And then install brake
drum.
3) Start engine and then depress brake pedal with
about 300 N (30 kg, 66 lbs) load at least 3 times until
adjuster actuator clicking sound from drum brake
can not be heard so as to obtain proper drum-to-
shoe clearance.
Adjust parking brake cable referring to “Parking
Brake Adjustment” in Section 4D (Page 4D-2).
4) Install rear wheel referring to “Wheel (with Tire)
Removal and Installation” in Section 2D (Page 2D-
2).
5) Check to ensure that brake drum is free from
dragging and proper braking is obtained. Perform
brake test (foot brake and parking brake).
Rear Brake Drum and Shoe Inspection
AENBL80A4306003

Brake Drum
Inspect brake drum for wear.
If drum inner diameter is exceeds the limit or uneven or
stepped wear is excessive, replace the drum.
2
Rear brake drum inner diameter “a”
Standard: 220 mm (8.66 in.)
Limit: 222 mm (8.74 in.)

1
I4RS0A430006-01

NOTE
The figure show ratchet position where brake
shoe-to-drum clearance is maximum.

IYSQ01430007-01

I2RH01430009-01

1. Rod 2. Ratchet
4C-3 Rear Brakes:

Cracked, Scored or Grooved Drum

A cracked drum is unsafe for further service and must be 2
replaced. Do not attempt to weld a cracked drum.
Smooth up any slight scores. Heavy or extensive scoring
will cause excessive brake lining wear and it will
probably be necessary to resurface drum braking
surface.
If brake linings are slightly worn and drum is grooved,
drum should be polished with fine emery cloth in the
direction of drum depth but not circumferentially along 1
drum inner. I4RS0B430004-01

NOTE
Rear Brake Shoe Removal and Installation
When drum is removed, visually inspect AENBL80A4306005
wheel cylinder for brake fluid leakage. NOTE
Correct leaky point, if any.
When replacing brake shoe, replace it on the
right and left.
Brake Shoe
Measure thickness of brake shoe (1). Also, check Removal
surface of lining for hardening, excessive wear and oil.
1) Remove brake drum referring to “Rear Brake Drum
Rear brake shoe lining thickness “a” Removal and Installation” (Page 4C-1).
Standard: 4.0 mm (0.157 in.) 2) Push and rotate 90° hold down pin (1) and remove
Limit: 1.0 mm (0.04 in.) hold down pin (1) and hold down spring (2).
! CAUTION
Never polish lining with sandpaper. If lining is
polished with sandpaper, hard particles of
sandpaper will be deposited in lining and
may damage drum. When it is required to
correct lining, replace it with a new one.

“a”
I7RW01431003-01

3) Remove return springs, brake shoes and adjuster.

4) Disconnect parking brake shoe lever (1) from
parking brake cable (2).

I5RW0A430005-01

Rear Brake Shoe On-Vehicle Inspection

AENBL80A4306004
Amount of brake shoe wear can be checked as follows.
1) Hoist vehicle. I2RH01430013-01

2) Remove rubber cover (plug) (1) from brake back 5) Remove push nut (1).
plate. 6) Remove parking brake shoe lever (2) from shoe rim
3) Through hole of back plate, visually check for (3).
thickness of brake shoe lining (2). If lining thickness
is less than specified wear limit, replace all brake
shoes with new ones.
Lining thickness “a”
Service limit: 1.0 mm (0.04 in.)
 Rear Brakes: 4C-4

Wheel Cylinder Removal and Installation

AENBL80A4306007
1

Removal
3 1) Remove brake drum referring to “Rear Brake Drum
Removal and Installation” (Page 4C-1).
2) Remove brake shoe referring to “Rear Brake Shoe
2
Removal and Installation” (Page 4C-3).
3) Loosen brake pipe flare nut (1) but only within the
extent that fluid does not leak.
4) Remove wheel cylinder mounting bolt (3).
I4RS0A430014-01
Disconnect brake pipe from wheel cylinder and put
Installation bleeder plug cap (2) onto pipe to prevent fluid from
Install parts in reverse order of removal, noting the spilling.
following.
3
• Before installing rear brake shoe to brake back plate, 1
clean brake back plate and apply heat-resistance
brake grease to A on which shoe rims rest.

A
2

I6JB0A430002-01

• Push and rotate 90° hold down pin and install hold
down pin and hold down spring.
• Install brake drum referring to “Rear Brake Drum
Removal and Installation” (Page 4C-1). Installation
Rear Brake Shoe Inspection
AENBL80A4306006
• Check ratchet of brake adjuster (1) assembly for wear
or damage.
• Check shoe return spring, anti-rattle spring, quadrant
spring and shoe hold down spring for damage,
corrosion and weakening.
• Check for smooth movement of brake shoe lever (2)
along shoe rim.
If any defective or malfunction is found, repair or replace.
I7RW01431004-01
1) Take off bleeder plug cap from brake pipe and
connect pipe to wheel cylinder (1) just enough to
prevent fluid from leaking.
2) Install wheel cylinder (1) to brake back plate (2), and
tighten wheel cylinder mounting bolt to specified
torque.
Tightening torque
Wheel cylinder mounting bolt (a): 12 N·m (1.2
kgf-m, 9.0 lbf-ft)
3) Tighten flare nut of brake pipe (3) to specified torque.
Tightening torque
Rear brake pipe flare nut (b): 16 N·m (1.6 kgf-m,
11.5 lbf-ft)
4) Install bleeder plug cap (4) taken off from pipe back
to bleeder plug.

I4RS0A430016-01
4C-5 Rear Brakes:

(a) 4 (a)
(b)
3
1
1

I7RW01431005-01
5) Install brake shoes. Refer to “Rear Brake Shoe
Removal and Installation” (Page 4C-3).
6) Install brake drum. Refer to “Rear Brake Drum
Removal and Installation” (Page 4C-1).
7) Fill reservoir with brake fluid and bleed brake
system. For bleeding operation refer to “Air Bleeding
of Brake System” in Section 4A (Page 4A-5).
8) Upon completion of all jobs, start engine and then
depress brake pedal with about 300 N (30 kg, 66 lbs)
load at least 15 times until adjuster actuator clicking
sound from drum brake can not be heard so as to
obtain proper drum-to-shoe clearance.
Adjust parking brake cable referring to “Parking
Brake Adjustment” in Section 4D (Page 4D-2).
9) Install rear wheel referring to “Wheel (with Tire)
Removal and Installation” in Section 2D (Page 2D-
2).
I4RS0A430020-01
5) Remove rear wheel hub referring to “Rear Wheel
Hub Assembly Removal and Installation”: Rear in
Section 3A (Page 3A-18).
6) Remove brake back plate.
Installation
1) Install brake back plate (1) and rear wheel hub
referring to “Rear Wheel Hub Assembly Removal
and Installation”: Rear in Section 3A (Page 3A-18).
2) Install parking brake cable (1) to brake back plate.
Tightening torque
Parking cable cap nut (a): 11 N·m (1.1 kgf-m, 8.0
lbf-ft)
1

10) Check to ensure that brake drum is free from

dragging and proper braking is obtained. Remove
vehicle from hoist and perform brake test (foot brake
and parking brake).
(a)

Wheel Cylinder Inspection

AENBL80A4306008
• Inspect wheel cylinder for wear, cracks, corrosion or
damage, and check for fluid leakage.
• Inspect boots for breakage, crack and damage.
If any malcondition is found, replace wheel cylinder.
Brake Back Plate Removal and Installation
AENBL80A4306009
Removal
1) Remove brake drum referring to “Rear Brake Drum
Removal and Installation” (Page 4C-1).
2) Remove brake shoe referring to “Rear Brake Shoe
Removal and Installation” (Page 4C-3).
3) Remove wheel cylinder referring to “Wheel Cylinder
Removal and Installation” (Page 4C-4).
4) Remove parking brake cable (1) from brake back
plate.
I4RS0A430024-01
3) Install wheel cylinder and connect brake pipe flare
nut, and then tighten wheel cylinder bolts and flare
nut to specified torque referring to “Wheel Cylinder
Removal and Installation” (Page 4C-4).
4) Install brake shoe referring to “Rear Brake Shoe
Removal and Installation” (Page 4C-3).
5) Install brake drum referring to “Rear Brake Drum
Removal and Installation” (Page 4C-1).
6) Fill reservoir with brake fluid and bleed brake
system. For bleeding operation refer to “Air Bleeding
of Brake System” in Section 4A (Page 4A-5).
 Rear Brakes: 4C-6

7) Upon completion of all jobs, start engine and then
depress brake pedal with about 300 N (30 kg, 66 lbs)
load at least 3 times until adjuster actuator clicking
sound from drum brake can not be heard so as to
obtain proper drum-to-shoe clearance.
Adjust parking brake cable referring to “Parking
Brake Adjustment” in Section 4D (Page 4D-2).
8) Install rear wheel referring to “Wheel (with Tire)
Removal and Installation” in Section 2D (Page 2D-
2).
9) Check to ensure that brake drum is free from
dragging and proper braking is obtained. Perform
brake test (foot brake and parking brake).

Specifications
Tightening Torque Specifications
AENBL80A4307001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Wheel cylinder mounting bolt 12 1.2 9.0 )
Rear brake pipe flare nut 16 1.6 11.5 )
Parking cable cap nut 11 1.1 8.0 )

NOTE
The tightening torque(s) also specified in:
“Rear Drum Brake Components”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Recommended Service Material
AENBL80A4308001
NOTE
Required service material(s) also described in:
“Rear Drum Brake Components”:
 Parking Brake: 4D-1

Parking Brake
Brakes

General Description
Parking Brake Description
AENBL80A4401001
The parking brake system is mechanically controlled. The system applies braking force to only the rear wheels by
means of cable and mechanical linkage. The same brake shoes are used for parking and foot brakes.

Repair Instructions
Parking Brake Components
AENBL80A4406001

(a)
1

(a)

(b)
(b)

(b)
(b)
5 (b)

(b)

(b)

6
2 5
4
3

IBP80A440001-01

1. Parking brake lever 4. Grommet 7. Parking brake cable end (Shoe lever side)
2. Equalizer 5. Parking brake cable : 26 N⋅m (2.7 kgf-m, 19.5 lbf-ft)
3. Parking brake cable end (equalizer side) 6. Brake shoe lever : 11 N⋅m (1.1 kgf-m, 8.5 lbf-ft)
4D-2 Parking Brake:

Parking Brake Inspection c. Parking brake lever switch

AENBL80A4406002
NOTE
Parking Brake Adjustment
Check the following conditions before
parking brake inspection and adjustment.
• No air is trapped in brake system.
• Brake pedal travel is proper.
• Rear brake shoes are not worn beyond
limit.
Inspection
NOTE
Brake warning light should be checked when
ignition is “ON”.
• With parking brake lever pulled up, inspect the
following items. If check result is not OK, adjust or
replace parking brake cable.
a. Operation of parking brake lever is smooth.
b. Rear wheels are locked firmly.
c. Operate parking brake lever with force of 200 N
(20.4 kgf, 45.0 lbf) as shown, counting number of
clicks ratchet notches generate.
AENBL80A4406003
1) Remove floor console rear box. )(Page 9H-10)
2) Release parking brake.
3) Loosen adjusting nut (1) until parking brake cable
becomes free of tension.
4) Start engine and depress brake pedal more than 15
times with about 150 N (15.3 kgf, 33.7 lbf) so as to
obtain proper drum-to-shoe clearance.
5) Stop engine and adjust parking brake lever stroke to
specified value with adjusting nut (1).
NOTE
Parking brake lever must be released while
adjusting.
6) Check equalizer (2) inclination angle. If angle is not
as specified, inspect parking brake cable and rear
brake shoe linings. )(Page 4C-3)
Equalizer inclination angle
“a”: within 15 degrees

NOTE
1
One click sound corresponds to one notch.

Parking brake stroke “a”

When lever is pulled up at 200 N (20.4 kgf, 45.0
lbf): 4 to 9 notches

2
“a”

I9P60A440002-02

7) After completion of adjustment, make sure that brake

drum is not dragging.

Parking Brake Cable Removal and Installation

AENBL80A4406004
I7V20A440002-01
! WARNING
• Release parking brake lever and make sure brake
warning light turns off. Then check that brake warning Make sure of the following conditions before
light turns on within 1 notch when parking brake lever removing parking brake cable:
is pulled up. If check result is not OK, check and repair 1. Work on a flat place
the following items.
2. Place gear shift lever in “1st” gear
NOTE
Check that ABS warning light (if equipped) is
turned off. Removal
1) Remove floor console rear box. )(Page 9H-10)
a. Remaining amount of brake fluid 2) Loosen the parking cable from lever side by after
b. Brake fluid switch (attached to brake master loosening adjuster nut.
cylinder reservoir)
 Parking Brake: 4D-3

3) Disconnect parking brake cable from rear brake

shoe lever. )(Page 4C-2) 2

4) Disconnect parking brake cable from vehicle.

)(Page 4D-1)

NOTE
1
If necessary to remove both right and left
parking brake cables, repeat above steps.

Installation
Reverse removal procedure, noting the following points. 3
• Check that parking brake cable end is installed to
equalizer and brake shoe lever securely. 1
• Assemble clamps and casing cap properly. )(Page
4D-1)
• Tighten each bolt to specified torque. )(Page 4D-1)
• Adjust parking brake cable. )(Page 4D-2)
IBP80A440003-01
• After completion of the installation and adjustment of
parking brake lever stroke, make sure that brake
Installation
system operates properly.
1) Tighten parking brake lever bolts (1) to specified
torque.
Parking Brake Lever Removal and Installation
AENBL80A4406005
Tightening torque
! WARNING Parking brake lever bolt (a): 26 N·m (2.7 kgf-m,
Make sure of the following conditions before 19.5 lbf-ft)
removing parking brake lever.
• Work on a flat place.
• Place gear shift lever in “1st”.
• Block wheels.
1,(a)

Removal
1) Remove floor console rear box. )(Page 9H-10)
2) Disconnect parking brake switch connector from
parking brake lever.
3) Loosen parking brake cable adjusting nut (1).
1,(a)

IBP80A440002-01

2) Connect parking brake cable to equalizer, then

adjust parking brake cable. )(Page 4D-2)
3) Make sure that brake system operates properly.
4) Fit parking brake switch connector to parking brake
lever
5) Install floor console rear box. )(Page 9H-10)

I9P60A440004-01

4) Remove parking brake lever bolts (1) and then

remove parking brake lever (2) together with
equalizer (3).
4D-4 Parking Brake:

Parking Brake Switch Inspection

AENBL80A4406006 2
Check for continuity between parking brake switch
terminal and vehicle body ground as shown in figure. If
check result is not as specified, replace parking brake
lever assembly.
Parking brake switch specification
Parking brake released: No continuity
Parking brake lever pulled up: Continuity

I9P60A440007-02

1. Parking brake switch 2. Parking brake lever

Specifications
Tightening Torque Specifications
AENBL80A4407001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Parking brake lever bolt 26 2.7 19.5 )

NOTE
The tightening torque(s) also specified in:
“Parking Brake Components”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
 ABS: 4E-1

ABS
Brakes

Precautions
Precautions in Diagnosing Troubles When connecting the connector, set the connector in
AENBL80A4500001 position on ABS hydraulic unit / control module
To ensure that the trouble diagnosis is done accurately
assembly and pull down the lock lever (2) until it locks.
and smoothly, observe the following and follow “ABS
Check” (Page 4E-8). [A] 1 [B]
• Before using SUZUKI scan tool, read its “Operator’s 2
(Instruction) Manual” to know how to use it.
• If the vehicle was operated in any of the following
conditions, ABS warning light may light momentarily [D]
[C]
but this does not indicate any fault in ABS.
– The vehicle is driven with parking brake applied.
– The vehicle is driven with brake dragging.
– The vehicle is stuck in mud, sand, etc.
– Wheel spins while driving. I9P60A460001-02

– Wheels are rotated while the vehicle is jacked up. [A]: Disconnect [C]: Pull down to lock
[B]: Connect [D]: Pull up to unlock
• Be sure to follow trouble diagnosis procedure
described in “ABS Check” (Page 4E-8). If trouble
• Communication of ABS control module and other
diagnosis procedure is not followed properly, incorrect
control module is established by CAN.
diagnosis may result. (If incorrect procedure is
Therefore, be sure to read “Precautions for Installing
performed, other DTC may be stored in the ABS
Mobile Communication Equipment” in Section 00
hydraulic unit / control module assembly.)
(Page 00-9) before inspection and handling CAN
• When disconnecting ABS control module connector communication line.
(1), pull up the lock lever (2) of connector.

General Description
ABS Description • ABS hydraulic unit is composed of inlet solenoid
AENBL80A4501001 valves (4) (normally-opened valves), outlet solenoid
The ABS (Anti-lock Brake System) controls the fluid
valves (5) (normally-closed valves), pumps (3), pump
pressure applied to the caliper or wheel cylinder of each
motor (2), reservoirs (6) and check valves (7). It
brake from the master cylinder so that each wheel is not
activates the inlet and outlet solenoid valves by the
locked even when hard braking is applied.
signals from ABS hydraulic unit / control module
This ABS is equipped with EBD (Electronic Brake force
assembly and controls the brake fluid pressure
Distributions) function.
applied on each wheel brake. (The following figure
While brake pedal is depressed not so hard as to
shows the circuit for one wheel, with inlet and outlet
activate ABS control, brake force is proportionally
solenoid valves in OFF positions.)
distributed between the front and rear brakes to prevent
rear wheels from being locked too early for better
stability of the vehicle.
If the EBD system fails, the EBD warning light (brake
warning light) lights to inform the driver of abnormality.

ABS Hydraulic Unit / Control Module Assembly

• ABS hydraulic unit / control module assembly detects
wheel slip by the signal from wheel speed sensor of
each wheel and sends control signals to the hydraulic
unit.
ABS hydraulic unit / control module assembly also
monitors system conditions and stops the function of
ABS and lights the ABS warning light in case it judges
that the system is faulty.
4E-2 ABS:

N 4

S
7
2 N

S 1
7 3
3 2
4 N

7 S

I8C50B450012-03

6 5
8 3. Integrated Circuit 4. Magnetic field lines

IAW101460011-01
OBD System Description
AENBL80A4501002
1. Master cylinder 8. Caliper or wheel cylinder ABS control module is built in ABS hydraulic unit /
control module assembly and has the following
The hydraulic pressure control is performed in 3 modes: functions.
pressure increase, pressure holding and pressure
reduction. Self-Diagnosis Function
• In the pressure increase mode, inlet and outlet ABS hydraulic unit / control module assembly monitors
solenoid valves are turned OFF, and the brake fluid each input and output signal. When ABS hydraulic unit /
pressure applied from the master cylinder to the control module assembly detects any malfunction, ABS
caliper or wheel cylinder is increased. warning light (2) and/or EBD warning light (brake
warning light) (1) are turned ON to indicate the
• In the pressure holding mode, the inlet solenoid valve
abnormality to the driver.
is turned ON, and the brake fluid pressure in the
caliper or wheel cylinder is kept constant. • When ignition is set “ON” ABS warning light and EBD
warning light (brake warning light) turn ON for 2
• In the pressure reduction mode, inlet and outlet
seconds to check its circuit.
solenoid valves are turned ON, and the brake fluid
pressure applied to the caliper or wheel cylinder is • When no abnormality is detected (the system is in
released to the reservoir. Thus the brake pressure good condition), these lights turn OFF after 2
applied to the wheel likely to be locked is reduced. seconds. However, when parking brake is operated,
The brake fluid temporarily stored in the reservoir is EBD warning light (brake warning light) remains ON.
pumped back to the master cylinder. • When an abnormality in the system is detected, ABS
warning light and/or EBD warning light (brake warning
Wheel Speed Sensor light) are turned ON and DTC is stored in ABS
All wheel speeds are detected by the Magnetic hydraulic unit / control module assembly.
Resistive Effect element type wheel speed sensor (1)
and encoder (2). The wheel speed sensor is fixed to
each steering knuckle and rear wheel hub assembly.
The encoder consists of a permanent magnet which has
south poles and north poles. As it is located on the wheel
hubs it turns along with the wheel.
The wheel speed sensor feeds pulse signals in
proportion to the wheel speed to the ABS control
module, which then calculates the wheel speed based
on such signal information.
 ABS: 4E-3

Fail-Safe Mode
[A] If ABS hydraulic unit / control module assembly stores a
DTC, ABS hydraulic unit / control module assembly
stops ABS and/or EBD function corresponding to the
faulty area. It is possible to confirm the stopped
function(s) by the warning lights in combination meter.
)(Page 4E-3)

1 2

[B]

1 2

IAP70B450001-01

[A]: Without tachometer [B]: With tachometer

Warning Light Description

AENBL80A4501003
There are two warning lights controlled by ABS hydraulic unit / control module assembly in combination meter. They
give warning to driver by changing their modes: light ON / blinking / light OFF.

[A] [B]

1 2
1 2

IAP70B450002-01

[A]: Without tachometer 1. EBD warning light (brake warning light)

[B]: With tachometer 2. ABS warning light

Condition and Operation of Warning Lights

Warning light Condition and operation
ABS warning light If ABS has abnormality, the light turns “ON”.
EBD warning light (brake warning • If EBD system has abnormality, the light turns “ON”.
light) • If brake fluid level in reservoir is lower than minimum level, the light turns “ON”.
• If parking brake lever is pulled up, the light turns “ON”.

DLC Description CAN Communication System Description

AENBL80A4501004 AENBL80A4501005
Refer to “DLC Description”: K14B in Section 1A (Page Refer to “Communication System Description”: K14B
1A-4) / “DLC Description”: D13A in Section 1A (Page Model in Section 10H (Page 10H-1) / “Communication
1A-125). System Description”: D13A Model in Section 10H (Page
10H-21) for CAN communication system description.
4E-4 ABS:

Schematic and Routing Diagram

ABS Diagram
AENBL80A4502001

8 8
6
5

1 2
4
3

8
8

9 10 11
IAP70B450003-01

1. ABS hydraulic unit / control module assembly 5. BCM 9. Electronic signal

2. ABS control module 6. Combination meter 10. CAN signal
3. Hydraulic unit 7. Brake light switch 11. Hydraulic circuit
4. ECM 8. Wheel speed sensor
 ABS: 4E-5

ABS Input / Output Diagram

AENBL80A4502002

INPUT OUTPUT
ABS hydraulic unit / control module assembly

Battery power supply Solenoid valve power

supply driver

Right-Front inlet solenoid valve

Right-Front outlet solenoid valve

Left-Front inlet solenoid valve

Left-Front outlet solenoid valve

Wheel speed sensor (Right-Front)
Wheel speed sensor (Left-Front)
Wheel speed sensor (Right-Rear)
Wheel speed sensor (Left-Rear)
Solenoid valve Right-Rear inlet solenoid valve
driver
Right-Rear outlet solenoid valve
CPU
Left-Rear inlet solenoid valve
Left-Rear outlet solenoid valve

Pump motor Pump motor

driver

ECM
ECM
· Engine torque signal CAN driver · Torque up request signal
· Brake light switch signal

Combination meter
BCM · Warning light signal (ABS/EBD)
· Parking brake switch signal

DLC
: CAN communication
IBP80A450007-01
4E-6 ABS:

ABS Circuit Diagram

AENBL80A4502003

2
WHT/RED
31
WHT/BLU
32

3 4
34
33 35 21
36

PNK
E24-14 BLK
RED/BLK
E24-3 E24-27 BLK
BEG

6
1
7 8 E24-13
11 E24-26

9
GRY
5
4
12 30 25

RED M
22 24
WHT

+BB 20
WHT/BLK 23
RED/BLK

26
10
14
RED/BLK
15 27
RED/BLK

RED
WHT
28
RED E24-1
5 5
WHT E24-15
13

RED E24-2
5
WHT E24-16
[A] E24

26 13
RED E24-20
16
1 RED/BLK E24-34
28 15
2
29 16 WHT E24-17
3 17
30 17 WHT/BLK E24-30
4
31 18 29
5
32 19 LT GRN E24-6
6 18
33 20 LT GRN/BLK E24-19
7 [a]
34 21
8 YEL E24-18
35 22 19
9 BRN E24-4
36 23
10
37 24
11
38 25
12

27 14

: 37 : 38 : 5V : 12V
IBP80A450002-02

[A]: ABS control module connector (View: [a]) 13. ECM 26. Solenoid valve power supply relay
1. Battery 14. Brake fluid level switch 27. Solenoid valve
2. Individual circuit fuse box No.1 15. Parking brake switch 28. Solenoid valve relay
3. Ignition switch 16. Left-front wheel speed sensor 29. Wheel speed sensor driver
 ABS: 4E-7

4. J/B 17. Right-front wheel speed sensor 30. P/S control module
5. CAN driver 18. Left-rear wheel speed sensor 31. “ABS1” fuse
6. Combination meter 19. Right-rear wheel speed sensor 32. “ABS2” fuse
7. ABS warning light 20. DLC 33. “IGN” fuse
8. EBD warning light (Brake warning light) 21. ABS hydraulic unit / control module assembly 34. “ABS” fuse
9. CPU (combination meter) 22. CPU 35. “MTR” fuse
10. BCM 23. Internal memory 36. “STOP” fuse
11. Brake light switch 24. Pump motor relay 37. Engine ground
12. Brake light 25. Pump motor 38. Ground

Terminal Wire color Circuit

1 RED CAN communication line (high) for BCM
2 RED CAN communication line (high) for ECM
3 BEG Ignition power supply circuit
4 BRN Right-rear wheel speed sensor signal circuit
6 LT GRN Left-rear wheel speed sensor power supply circuit
13 WHT/BLU Solenoid valve power supply circuit
14 BLK ABS control module ground circuit 1
15 WHT CAN communication line (low) for BCM
16 WHT CAN communication line (low) for ECM
17 WHT Right-front wheel speed sensor power supply circuit
18 YEL Right-rear wheel speed sensor power supply circuit
19 LT GRN/BLK Left-rear wheel speed sensor signal circuit
20 RED Left-front wheel speed sensor power supply circuit
26 WHT/RED Pump motor power supply circuit
27 BLK ABS control module ground circuit 2
30 WHT/BLK Right-front wheel speed sensor signal circuit
34 RED/BLK Left-front wheel speed sensor signal circuit
4E-8 ABS:

Component Location
ABS Component Location
AENBL80A4503001

[B]

1 2 1 2

[A]
3

6
5

IBL80A450001-01

[A]: K14B model 3. Rear wheel speed sensor 7. ABS hydraulic unit / control module assembly
[B]: D13A model 4. BCM 8. ECM
1. EBD warning light (brake warning light) 5. Front wheel speed sensor
2. ABS warning light 6. Brake light switch

Diagnostic Information and Procedures

ABS Check
AENBL80A4504001
Refer to the description after the following general flow for details of each step.
Step Action Yes No
1 Malfunction analysis )(Page 4E-9) Inspect and repair Go to Step 2.
1) Perform “Customer complaint analysis” (Page 4E-9). referring to applicable
DTC troubleshooting,
2) Perform “Problem symptom confirmation” (Page 4E-10).
and then go to Step 6.
3) Perform “DTC check, record and clearance” (Page 4E-
10) and recheck DTC.

Is same DTC detected again after performing DTC

clearance?
2 Visual inspection )(Page 4E-10) Repair or replace Go to Step 3.
1) Perform “Visual Inspection” (Page 4E-11). malfunction part, and
then go to Step 6.
Is there any faulty condition?
 ABS: 4E-9

Step Action Yes No

3 Driving test )(Page 4E-11) Repair or replace Go to Step 4.
1) Perform “Step 3: Driving Test” (Page 4E-11). malfunction part, and
then go to step 6.
Is malfunction detected?
4 Brakes diagnosis )(Page 4E-11) Repair or replace Go to Step 5.
1) Inspect and repair brake system referring “Brakes malfunction part, and
Symptom Diagnosis” in Section 4A (Page 4A-2). then go to step 6.

Is malfunction detected?
5 Intermittent problem check )(Page 4E-11) Repair or replace Go to Step 6.
1) Check for intermittent troubles referring to “Intermittent malfunction part, then
Connection and Poor Contact Inspection” in Section 00 go to step 6.
(Page 00-11).

Is malfunction detected?
6 Final confirmation test )(Page 4E-11) Go to Step 4. End.
1) Perform “Step 6: Final Confirmation Test” (Page 4E-11).

Does trouble recur?

Step 1: Malfunction Analysis

Customer complaint analysis
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form as shown in the following table will facilitate collecting information
to the point required for proper analysis and diagnosis.
4E-10 ABS:

Customer questionnaire (Example)

IAP70B450007-01

Problem symptom confirmation

If symptom in “Customer Questionnaire” is found or reproduced in the vehicle, confirm the symptom is problem or not.
(This step should be done with the customer if possible.) Check warning light related to brake system referring to “EBD
Warning Light (Brake Warning Light) Check” and “ABS Warning Light Check” under “Warning Light Check” (Page 4E-
12).

DTC check, record and clearance

Perform “DTC Check” (Page 4E-13) procedure, record it and then clear it. )(Page 4E-13)
Recheck DTC. )(Page 4E-13)
When DTC which is recorded at DTC check procedure is detected again after performing DTC clearance, go to “DTC
Check” (Page 4E-13) to proceed the diagnosis.
When DTC which is recorded at DTC check procedure is not indicated anymore after performing DTC clearance, ABS
control module does not perform the system diagnosis, or temporary abnormality may occur, therefore go to “Step 3:
Driving Test” (Page 4E-11) to proceed to the diagnosis.

Step 2: Visual Inspection

As a preliminary step, be sure to perform visual check of the items that support proper function of the ABS. )(Page
4E-11)
 ABS: 4E-11

Step 3: Driving Test

Test the vehicle at 40 km/h (25 mph) for at least two minutes including a turn to the right, a turn to the left and a vehicle
stop using foot brake at least once to check if any trouble symptom (such as ABS warning light) exists.

Step 4: Brakes Diagnosis

Check the parts or system suspected as a possible cause referring to “Brake System Description” in Section 4A (Page
4A-1) and based on symptoms appearing on the vehicle (symptoms observed through Steps 1 to 3). Repair faulty
parts or replace them, if necessary).

Step 5: Intermittent Problem

Check parts that are prone to cause intermittent trouble (e.g. wire harness, connector), referring to “Intermittent
Connection and Poor Contact Inspection” in Section 00 (Page 00-11) and the related circuit of which DTC is recorded
in Step 1 to 5.

Step 6: Final Confirmation Test

Confirm that the problem symptom is not observed any more and ABS is free from any abnormal conditions. If what
has been repaired is related to malfunction DTC, clear the DTC referring to “DTC Clearance” (Page 4E-13) and
perform test driving and confirm that the DTC is not indicated.

Visual Inspection
AENBL80A4504002
Check the following parts and systems visually.
Inspection Item Referring section
“Battery Inspection”: K14B in Section 1J (Page 1J-6) /
Battery Level, leakage
“Battery Inspection”: D13A in Section 1J (Page 1J-23)
Connectors of electric wire “Intermittent Connection and Poor Contact Inspection” in
Disconnection, friction
harness Section 00 (Page 00-11)
Fuses Burning
Brake fluid Level, leakage “Brake Fluid Level Inspection” in Section 4A (Page 4A-4)
ABS warning light Operation “Warning Light Check” (Page 4E-12)
EBD warning light Operation
Other parts that can be checked visually

ABS Symptom Diagnosis

AENBL80A4504003

Condition Possible cause Correction / Reference Item

ABS warning light Malfunctioning ABS function Perform ABS check. )(Page 4E-8)
remains lit for more than 2 Malfunctioning ABS warning light circuit Check ABS warning light circuit. )(Page 4E-
seconds after setting 19)
ignition “ON”
ABS warning light does Malfunctioning ABS function Perform ABS check. )(Page 4E-8)
not turn ON after setting Malfunctioning CAN communication Check CAN communication system.
ignition “ON” system function K14B model: )(Page 10H-6)
D13A model: )(Page 10H-26)
Malfunctioning ABS warning light circuit Check ABS warning light circuit. )(Page 4E-
17)
ABS warning light blinks Improper air bleed from ABS hydraulic Perform ABS hydraulic unit operation check.
unit / control module assembly )(Page 4E-31)
4E-12 ABS:

Condition Possible cause Correction / Reference Item

EBD warning light (Brake Parking brake applied Release parking brake and check that EBD
warning light) remains lit warning light (brake warning light) turns OFF.
for more than 2 seconds Insufficient amount of brake fluid Check brake fluid level. )(Page 4A-4)
after setting ignition “ON” Faulty parking brake switch circuit and/ Check BCM and its circuit. )(Page 10B-20)
or brake fluid level switch circuit
Faulty parking brake switch and/or Check parking brake switch and/or brake fluid
brake fluid level switch level switch.
Parking brake switch: )(Page 4D-4)
Brake fluid level switch: )(Page 4A-4)
Malfunctioning EBD system Perform ABS check. )(Page 4E-8)
Faulty ABS control module power Check ABS control module power supply and
supply and ground circuit ground circuit. )(Page 4E-30)
Malfunctioning CAN communication Check CAN communication system.
system K14B model: )(Page 10H-6)
D13A model: )(Page 10H-26)
Faulty BCM Check BCM and its circuit. )(Page 10B-20)
Faulty ABS control module Replace ABS control module. )(Page 4E-33)
Malfunctioning EBD warning light circuit Check EBD warning light circuit. )(Page 4E-
21)
EBD warning light (Brake Malfunctioning EBD function Perform ABS check. )(Page 4E-8)
warning light) does not Malfunctioning CAN communication Check CAN communication system.
turn ON after setting system K14B model: )(Page 10H-6)
ignition “ON” D13A model: )(Page 10H-26)
Malfunctioning EBD warning light circuit Check EBD warning light circuit. )(Page 4E-
20)

Warning Light Check

AENBL80A4504004 [A]
ABS Warning Light
1) Set ignition “ON”.
2) Check that ABS warning light (1) comes ON for
about 2 seconds and then goes OFF. If ABS warning
light never lights up, go to “ABS Warning Light Does
Not Come ON after Setting Ignition “ON”” (Page 4E-
17). If ABS warning light remains ON and no DTC is 1
stored in ABS control module, go to “ABS Warning
Light Comes ON Steady” (Page 4E-19).

[B]

IAP70B450008-01

[A]: Without tachometer [B]: With tachometer

 ABS: 4E-13

EBD Warning Light (Brake Warning Light)

NOTE
Perform this check on a level place.

1) Check brake fluid level. )(Page 4A-4)

2) Pull parking brake lever.
(A)
3) Set ignition “ON”.
4) Check that EBD warning light (brake warning light)
1
(1) comes ON. If EBD warning light (brake warning
light) never lights up, go to “EBD Warning Light
(Brake Warning Light) Does Not Come ON after
Setting Ignition “ON”” (Page 4E-20).

[A]
IAP70P450005-01

3) Set ignition “ON”.

4) Read DTC according to instructions displayed on
SUZUKI scan tool and print it or write it down. Refer
to SUZUKI scan tool operator’s manual for further
details. If communication between scan tool and
1
ABS control module is not possible, check power
supply and ground circuits of ABS control module.
)(Page 4E-30) If check result is OK, go to
“Troubleshooting for Communication Bus Off”: K14B
Model in Section 10H (Page 10H-14) /
[B]
“Troubleshooting for Communication Bus Off”: D13A
Model in Section 10H (Page 10H-34).
5) Confirm that ignition is “OFF” and disconnect
SUZUKI scan tool from DLC after completing check.

DTC Clearance
AENBL80A4504006
1
! WARNING
When performing a road test, select a place
IAP70B450009-01 where there is no traffic or possibility of a
[A]: Without tachometer [B]: With tachometer traffic accident and be very careful during
testing to avoid occurrence of an accident.
5) Release parking brake lever and check that EBD
warning light goes OFF. If EBD warning light (brake 1) Confirm that ignition is “OFF”.
warning light) remains ON and no DTC is stored in 2) Connect SUZUKI scan tool to DLC.
ABS control module, go to “EBD Warning Light 3) Set ignition “ON”.
(Brake Warning Light) Comes ON Steady” (Page 4E-
4) Clear DTC according to instructions displayed on
21).
scan tool. Refer to scan tool operator’s manual for
further details.
DTC Check
AENBL80A4504005 5) Perform “Step 3: Driving Test” in “ABS Check” (Page
1) Confirm that ignition is “OFF”. 4E-8) and “DTC Check” (Page 4E-13) and confirm
that NO DTC is displayed on scan tool.
2) Connect SUZUKI scan tool to DLC (1).
6) Disconnect SUZUKI scan tool from DLC after
Special tool completing the DTC clearance.
(A): SUZUKI scan tool (SUZUKI-SDT)
4E-14 ABS:

DTC Table
AENBL80A4504007
! CAUTION
Be sure to perform “ABS Check” (Page 4E-8) before starting DTC diagnosis.

NOTE
*: Whether ABS warning light or EBD warning light (brake warning light) lights up or not depends on
DTC detecting condition.

ABS EBD
DTC DTC name DTC detecting condition warning warning
light light
C1021 )(Page 4E- Right-Front Wheel Speed Sensor Wheel speed sensor signal is out of
Lights up OFF
23) Circuit Voltage specified range.
C1022 )(Page 4E- Right-Front Wheel Speed Sensor or Abnormal wheel speed sensor signal
Lights up OFF
23) Encoder Signal Performance is detected continuously.
C1025 )(Page 4E- Left-Front Wheel Speed Sensor Wheel speed sensor signal is out of
Lights up OFF
23) Circuit Voltage specified range.
C1026 )(Page 4E- Left-Front Wheel Speed Sensor or Abnormal wheel speed sensor signal
Lights up OFF
23) Encoder Signal Performance is detected continuously.
C1031 )(Page 4E- Right-Rear Wheel Speed Sensor Wheel speed sensor signal is out of
Lights up OFF
23) Circuit Voltage specified range.
C1032 )(Page 4E- Right-Rear Wheel Speed Sensor or Abnormal wheel speed sensor signal
Lights up OFF
23) Encoder Signal Performance is detected continuously.
Abnormal wheel speed sensor signal
is detected continuously at two or
more wheel speed sensors.
C1033 )(Page 4E- ABS control is activated for more
Wheel Speed Sensor Deviation * *
23) than specified time.
Wheel speed sensor driver power
supply voltage is out of specified
range.
C1035 )(Page 4E- Left-Rear Wheel Speed Sensor Wheel speed sensor signal is out of
Lights up OFF
23) Circuit Voltage specified range.
C1036 )(Page 4E- Left-Rear Wheel Speed Sensor or Abnormal wheel speed sensor signal
Lights up OFF
23) Encoder Signal Performance is detected continuously.
C1041 )(Page 4E- Right-Front Inlet Solenoid Valve Solenoid output and solenoid monitor
Lights up Lights up
25) Circuit Correlation data disagree.
C1042 )(Page 4E- Right-Front Outlet Solenoid Valve Solenoid output and solenoid monitor
Lights up Lights up
25) Circuit Correlation data disagree.
C1045 )(Page 4E- Left-Front Inlet Solenoid Valve Circuit Solenoid output and solenoid monitor
Lights up Lights up
25) Correlation data disagree.
C1046 )(Page 4E- Left-Front Outlet Solenoid Valve Solenoid output and solenoid monitor
Lights up Lights up
25) Circuit Correlation data disagree.
C1051 )(Page 4E- Right-Rear Inlet Solenoid Valve Solenoid output and solenoid monitor
Lights up Lights up
25) Circuit Correlation data disagree.
C1052 )(Page 4E- Right-Rear Outlet Solenoid Valve Solenoid output and solenoid monitor
Lights up Lights up
25) Circuit Correlation data disagree.
C1055 )(Page 4E- Left-Rear Inlet Solenoid Valve Circuit Solenoid output and solenoid monitor
Lights up Lights up
25) Correlation data disagree.
C1056 )(Page 4E- Left-Rear Outlet Solenoid Valve Solenoid output and solenoid monitor
Lights up Lights up
25) Circuit Correlation data disagree.
ABS control module power supply
voltage is higher than specified
C1057 )(Page 4E-
Power Supply Voltage value. * *
26)
ABS control module power supply
voltage is lower than specified value.
 ABS: 4E-15

ABS EBD
DTC DTC name DTC detecting condition warning warning
light light
Pump motor power supply voltage is
out of specified range.
C1061 )(Page 4E- Pump motor is activated although
Pump Motor Circuit Performance Lights up Lights up
27) pump motor control relay is OFF.
Pump motor is not activated although
pump motor control relay is ON.
Solenoid valve is activated for more
C1062 )(Page 4E- Solenoid Valve Continuous Operation than specified time using “Hydraulic
Lights up Lights up
28) Failure control test” under “Utility” mode of
SUZUKI scan tool.
Solenoid valve power supply relay
output is “ON”, although monitored
C1063 )(Page 4E- Solenoid Valve Power Supply Driver output is “OFF”.
Lights up Lights up
25) Circuit Performance Solenoid valve power supply relay
output is “OFF”, although monitored
output is “ON”.
C1071 )(Page 4E- ABS control module internal failure is
ABS Control Module Internal Failure Lights up Lights up
29) detected.
C1090 )(Page 4E- ECM Detect Rolling Counter Failure ABS control module sends invalid
OFF OFF
29) from ABS Control Module CAN data to ECM.
C1091 )(Page 4E- DTC concerned with ECM is
CAN Invalid Data from ECM OFF OFF
29) detected.
ABS control module receives invalid
C1094 )(Page 4E-
Torque Request Reject Status CAN data from ECM (about engine OFF OFF
29)
torque control).
U0073 )(Page 4E- Control Module Communication Bus Impossible to receive and transmit
OFF OFF
30) Off CAN data.
U0100 )(Page 4E- ECM message data is missing from
Lost Communication With ECM OFF OFF
30) CAN communication.

Fail-Safe Table
AENBL80A4504008
When any of the following DTCs is detected, ABS control module changes the control to the fail-safe mode and ABS
and EBD functions are deactivated until ABS control module judges the system is normal.

NOTE
• O: Activated
• –: Deactivated
• *: Whether ABS is engaged in fail-safe mode or not depends on malfunction part. Fail-safe mode can
be checked by lighting status of ABS warning light or EBD warning light (brake warning light).
– When ABS warning light lights up, ABS control is deactivated.
– When EBD warning light (brake warning light) lights up, EBD control is deactivated.

Fail-safe
DTC operation Fail-safe cancel condition
ABS EBD
C1021 )(Page When ABS control module judges the system to be normal after switching ignition from
– ○
4E-23) “OFF” to “ON”.
C1022 )(Page When ABS control module judges the system to be normal and “Driving Test” under
– ○
4E-23) “ABS Check” (Page 4E-8) is performed after switching ignition from “OFF” to “ON”.
C1025 )(Page When ABS control module judges the system to be normal after switching ignition from
– ○
4E-23) “OFF” to “ON”.
C1026 )(Page When ABS control module judges the system to be normal and “Driving Test” under
– ○
4E-23) “ABS Check” (Page 4E-8) is performed after switching ignition from “OFF” to “ON”.
C1031 )(Page When ABS control module judges the system to be normal after switching ignition from
– ○
4E-23) “OFF” to “ON”.
4E-16 ABS:

Fail-safe
DTC operation Fail-safe cancel condition
ABS EBD
C1032 )(Page When ABS control module judges the system to be normal and “Driving Test” under
– ○
4E-23) “ABS Check” (Page 4E-8) is performed after switching ignition from “OFF” to “ON”.
C1033 )(Page When ABS control module judges the system to be normal after switching ignition from
* *
4E-23) “OFF” to “ON”.
C1035 )(Page When ABS control module judges the system to be normal after switching ignition from
– ○
4E-23) “OFF” to “ON”.
C1036 )(Page When ABS control module judges the system to be normal and “Driving Test” under
– ○
4E-23) “ABS Check” (Page 4E-8) is performed after switching ignition from “OFF” to “ON”.
C1041 )(Page
– –
4E-25)
C1042 )(Page
– –
4E-25) When ABS control module judges the system to be normal after switching ignition from
C1045 )(Page “OFF” to “ON”.
– –
4E-25)
C1046 )(Page
– –
4E-25)
C1051 )(Page
– –
4E-25) When ABS control module judges the system to be normal after switching ignition from
C1052 )(Page “OFF” to “ON”.
– –
4E-25)
C1055 )(Page
– –
4E-25) When ABS control module judges the system to be normal after switching ignition from
C1056 )(Page “OFF” to “ON”.
– –
4E-25)
C1057 )(Page When ABS control module judges the system to be normal when ABS control module
* *
4E-26) detects system as normal after switching ignition from “OFF” to “ON”.
C1061 )(Page When ABS control module judges the system to be normal and “Driving Test” under
– –
4E-27) “ABS Check” (Page 4E-8) is performed after switching ignition from “OFF” to “ON”.
When solenoid valve is sufficiently cooled down. (After continuous operation, inlet
C1062 )(Page
– – solenoid valve requires 300 seconds of suspension and outlet solenoid valve requires
4E-28)
50 seconds of suspension.)
C1063 )(Page When ABS control module judges the system to be normal and “Driving Test” under
– –
4E-25) “ABS Check” (Page 4E-8) is performed after switching ignition from “OFF” to “ON”.
C1071 )(Page When ABS control module judges the system to be normal after switching ignition from
– –
4E-29) “OFF” to “ON”.
C1090 )(Page When ABS control module judges the system to be normal after switching ignition from
○ ○
4E-29) “OFF” to “ON”.
C1091 )(Page When ABS control module judges the system to be normal after switching ignition from
○ ○
4E-29) “OFF” to “ON”.
C1094 )(Page When ABS control module judges the system to be normal after switching ignition from
○ ○
4E-29) “OFF” to “ON”.
U0073 )(Page When ABS control module judges the system to be normal after switching ignition from
○ ○
4E-30) “OFF” to “ON”.
U0100 )(Page When ABS control module judges the system to be normal after switching ignition from
○ ○
4E-30) “OFF” to “ON”.

Scan Tool Data

AENBL80A4504009
As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles
by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases
where the checked value does not fall within each specified data range. Therefore, judgment as abnormal should not
be made by checking with these data alone.
Scan tool data Vehicle condition Condition / reference values
RF Wheel Speed At stop (Stationary vehicle) 0 km/h (0 mph)
LF Wheel Speed At stop (Stationary vehicle) 0 km/h (0 mph)
RR Wheel Speed At stop (Stationary vehicle) 0 km/h (0 mph)
LR Wheel Speed At stop (Stationary vehicle) 0 km/h (0 mph)
 ABS: 4E-17

Scan tool data Vehicle condition Condition / reference values

Battery Voltage Ignition “ON” (Engine stopped) 10.0 – 14.0 V
Inactive (Pump motor not working) 0.0 V
Pump Motor Driver
Active (Pump motor working) 13.0 – 15.0 V
Depressed brake pedal ON
Brake Switch
Released brake pedal OFF

Scan Tool Data Definition
RF Wheel Speed, LF Wheel Speed, RR Wheel Speed
and LR Wheel Speed (km/h, MPH): Wheel speed
is ABS control module internal parameter. It is
computed by reference pulses from the wheel speed
sensor.
Battery Voltage (V): Battery voltage is an analog input
signal read by ABS control module. ABS control
module functions may be stopped if battery voltage
falls below or rises above programmed thresholds.
Pump Motor Driver (V): This parameter indicates
operational condition of pump motor driver
(transistor).
Brake Switch (ON, OFF): These switch signals are
provided to ABS control module whether the brake is
active or not.

ABS Warning Light Does Not Come ON after Setting Ignition “ON”
AENBL80A4504010
Circuit Diagram

2
WHT/RED
16
WHT/BLU
17

3 4
19
18 20 14

A1 E24-14 BLK
RED/BLK
E24-3 E24-27 BLK
BEG

6 G240-3
1
7 8 E24-13
[A] E24
A2 E24-26

9 G240-5 26 13
GRY
5 1
28 15
15 2
29 16
3
RED 30 17
4
31 18
WHT 5
32 19
6
33 20
+BB 13 7
34 21
WHT/BLK 8
35 22
RED/BLK 9
36 23
10
B1 37 24
10 11
11 [a] 38 25
E04-11 RED/BLK 12
12
RED/BLK 27 14
L01-24
B2
RED
[B] G240
WHT
RED E24-1 1 2 3 4 5 6 7 8 9 10 11 12
5 5
WHT E24-15 13 14 15 16 17 18 19 20 21 22 23 24
IBP80A450004-02
4E-18 ABS:

[A]: ABS control module connector (View: [a]) 4. J/B 13. DLC
[B]: Combination meter connector (View: [a]) 5. CAN driver 14. ABS control module
A1: Combination meter power supply circuit 6. Combination meter 15. P/S control module
A2: Combination meter ground circuit 7. ABS warning light 16. “ABS1” fuse
B1: Brake fluid level switch signal circuit 8. EBD warning light 17. “ABS2” fuse
B2: Parking brake switch signal circuit 9. CPU (combination meter) 18. “IGN” fuse
1. Battery 10. BCM 19. “ABS” fuse
2. Individual circuit fuse box No.1 11. Brake fluid level switch 20. “MTR” fuse
3. Ignition switch 12. Parking brake switch

Circuit Description
Operation (ON/OFF) of ABS warning light is controlled by ABS control module through light driver module in
combination meter.
If ABS is in good condition, ABS control module turns ON ABS warning light when ignition “ON”, keeps the light ON for
2 seconds and then turns it OFF. If any abnormality in the system is detected, ABS warning light is turned ON
continuously by ABS control module. Also, the light is turned ON continuously by light driver module when the
connector of ABS control module is disconnected.

Troubleshooting
Step Action Yes No
1 Warning light check Go to Step 2. Go to Step 4.
1) Set ignition “ON”.

Do other indicator lights light up?

2 DTC check • K14B model: Go to Go to Step 3.
1) Check DTC. )(Page 4E-13) “Troubleshooting for
Communication Bus
Is DTC U0073 detected? Off”: K14B Model in
Section 10H (Page
10H-14)
• D13A model: Go to
“Troubleshooting for
Communication Bus
Off”: D13A Model in
Section 10H (Page
10H-34)
3 Combination meter check Replace ABS hydraulic End.
1) Replace combination meter. )(Page 9C-10) unit / control module
assembly and recheck
2) Set ignition “ON”.
warning light operation.
Does warning light stay OFF? )(Page 4E-33)
4 Fuse check Go to Step 5. Replace “MTR” fuse
and check for short
Is “MTR” fuse is good condition? circuit to ground.
5 Combination meter power supply circuit check Replace combination Go to Step 6.
1) Remove combination meter. )(Page 9C-10) meter and recheck
warning light operation.
2) Check for proper connection to “G240” connector.
)(Page 9C-10)
3) If check result is OK, set ignition “ON”.
4) Measure voltage between “G240-3” and “G240-5”
terminals.

Is it battery voltage?
6 Combination meter ground circuit check Repair “A1” circuit. Repair “A2” circuit.
1) Set ignition “OFF”.
2) Measure resistance between “G240-5” terminal and
ground.

Is it 1 Ω or less?
 ABS: 4E-19

ABS Warning Light Comes ON Steady

AENBL80A4504011
Circuit Diagram

2
WHT/RED
16
WHT/BLU
17

3 4
19
18 20 14

A1 E24-14 BLK
RED/BLK
E24-3 E24-27 BLK
BEG

6 G240-3
1
7 8 E24-13
[A] E24
A2 E24-26

9 G240-5 26 13
GRY
5 1
28 15
15 2
29 16
3
RED 30 17
4
31 18
WHT 5
32 19
6
33 20
+BB 13 7
34 21
WHT/BLK 8
35 22
RED/BLK 9
36 23
10
B1 37 24
10 11
11 [a] 38 25
E04-11 RED/BLK 12
12
RED/BLK 27 14
L01-24
B2
RED
[B] G240
WHT
RED E24-1 1 2 3 4 5 6 7 8 9 10 11 12
5 5
WHT E24-15 13 14 15 16 17 18 19 20 21 22 23 24
IBP80A450004-02

[A]: ABS control module connector (View: [a]) 4. J/B 13. DLC
[B]: Combination meter connector (View: [a]) 5. CAN driver 14. ABS control module
A1: Combination meter power supply circuit 6. Combination meter 15. P/S control module
A2: Combination meter ground circuit 7. ABS warning light 16. “ABS1” fuse
B1: Brake fluid level switch signal circuit 8. EBD warning light 17. “ABS2” fuse
B2: Parking brake switch signal circuit 9. CPU (combination meter) 18. “IGN” fuse
1. Battery 10. BCM 19. “ABS” fuse
2. Individual circuit fuse box No.1 11. Brake fluid level switch 20. “MTR” fuse
3. Ignition switch 12. Parking brake switch

Circuit Description
Refer to “Circuit Description” under “ABS Warning Light Does Not Come ON after Setting Ignition “ON”” (Page 4E-17).
4E-20 ABS:

Troubleshooting
Step Action Yes No
1 ABS control module connector check Go to Step 2. Connect connector
1) Check for proper connection to ABS control module securely.
connector.

Is connection in good condition?

2 DTC check for ABS Go to applicable DTC Go to Step 3.
1) Perform “DTC Check” (Page 4E-13). troubleshooting.

Is there any DTC(s)?

3 ABS control module power supply and ground circuit Go to Step 4. Repair or replace
check defective wire harness.
1) Check ABS control module power supply circuit and
ground circuit. )(Page 4E-30)

Are the circuits in good condition?

4 Combination meter check Replace ABS hydraulic End.
1) Replace combination meter. )(Page 9C-10) unit / control module
assembly and recheck
2) Set ignition “ON”.
warning light operation.
Does warning light stay on? )(Page 4E-33)

EBD Warning Light (Brake Warning Light) Does Not Come ON after Setting Ignition “ON”
AENBL80A4504012
Circuit Diagram
Refer to “Circuit Diagram” under “ABS Warning Light Does Not Come ON after Setting Ignition “ON”” (Page 4E-17).

Circuit Description
Refer to “Circuit Description” under “EBD Warning Light (Brake Warning Light) Comes ON Steady” (Page 4E-21).

Troubleshooting
Refer to “Troubleshooting” under “ABS Warning Light Does Not Come ON after Setting Ignition “ON”” (Page 4E-17).
 ABS: 4E-21

EBD Warning Light (Brake Warning Light) Comes ON Steady

AENBL80A4504013
Circuit Diagram

2
WHT/RED
16
WHT/BLU
17

3 4
19
18 20 14

A1 E24-14 BLK
RED/BLK
E24-3 E24-27 BLK
BEG

6 G240-3
1
7 8 E24-13
[A] E24
A2 E24-26

9 G240-5 26 13
GRY
5 1
28 15
15 2
29 16
3
RED 30 17
4
31 18
WHT 5
32 19
6
33 20
+BB 13 7
34 21
WHT/BLK 8
35 22
RED/BLK 9
36 23
10
B1 37 24
10 11
11 [a] 38 25
E04-11 RED/BLK 12
12
RED/BLK 27 14
L01-24
B2
RED
[B] G240
WHT
RED E24-1 1 2 3 4 5 6 7 8 9 10 11 12
5 5
WHT E24-15 13 14 15 16 17 18 19 20 21 22 23 24
IBP80A450004-02

[A]: ABS control module connector (View: [a]) 4. J/B 13. DLC
[B]: Combination meter connector (View: [a]) 5. CAN driver 14. ABS control module
A1: Combination meter power supply circuit 6. Combination meter 15. P/S control module
A2: Combination meter ground circuit 7. ABS warning light 16. “ABS1” fuse
B1: Brake fluid level switch signal circuit 8. EBD warning light 17. “ABS2” fuse
B2: Parking brake switch signal circuit 9. CPU (combination meter) 18. “IGN” fuse
1. Battery 10. BCM 19. “ABS” fuse
2. Individual circuit fuse box No.1 11. Brake fluid level switch 20. “MTR” fuse
3. Ignition switch 12. Parking brake switch

Circuit Description
EBD warning light (brake warning light) is controlled by ABS control module and BCM through light driver module in
combination meter.
If EBD system is in good condition, ABS control module turns ON EBD warning light (brake warning light) when
ignition is set “ON”, keeps it ON for 2 seconds and then turns it OFF.
EBD warning light (brake warning light) is turned ON continuously in the following conditions.
• EBD system has an abnormality
• Parking brake lever is pulled up
• Brake fluid level is lower than minimum level
The information of parking brake switch and brake fluid level is transmitted from BCM to light driver module in
combination meter through CAN communication line.
4E-22 ABS:

Also, the warning light is turned ON continuously by light driver module when the connector of ABS control module is
disconnected.

Troubleshooting
Step Action Yes No
1 ABS control module connector check Go to Step 2. Connect connector
1) Check for proper connection to ABS control module securely.
connector.

Is connection in good condition?

2 Parking brake and brake fluid level check Go to Step 3. Release parking brake
1) Check the following points. and check brake fluid
level.
• Parking brake is completely released.
• Brake fluid level is above minimum level. )(Page 4A-
4)

Are check results OK?

3 ABS warning light operation check Perform “ABS Warning Go to Step 4.
1) Set ignition “ON”. Light Comes ON
Steady” (Page 4E-19).
Does ABS warning light come ON steady?
4 Parking brake switch signal circuit and brake fluid level Go to Step 5. • Check each
switch signal circuit check applicable circuit for
1) Confirm that ignition is “OFF”. short to ground.
2) Disconnect “E04” and “L01” connectors. If OK, check parking
brake switch and/or
3) Check the following points.
brake fluid level
• Resistance between “B1” circuit and ground: infinity switch.
• Resistance between “B2” circuit and ground: infinity
– Parking brake
Is check result OK? switch: )(Page
4D-4)
– Brake fluid level
switch: )(Page
4A-4)
5 CAN communication circuit check • K14B model: Go to Go to Step 6.
1) Connect “E04” connector. “Troubleshooting for
Communication Bus
2) Perform “DTC Check” (Page 4E-13).
Off”: K14B Model in
Is DTC U0073 detected? Section 10H (Page
10H-14)
• D13A model: Go to
“Troubleshooting for
Communication Bus
Off”: D13A Model in
Section 10H (Page
10H-34)
6 DTC check for BCM • K14B model: Go to Go to Step 7.
1) Check DTC for BCM. )(Page 10B-10) “Troubleshooting for
Communication Bus
Is DTC U0073 detected? Off”: K14B Model in
Section 10H (Page
10H-14).
• D13A model: Go to
“Troubleshooting for
Communication Bus
Off”: D13A Model in
Section 10H (Page
10H-34)
 ABS: 4E-23

Step Action Yes No

7 Combination meter check Replace ABS hydraulic End.
1) Replace combination meter. )(Page 9C-10) unit / control module
assembly and recheck
2) Set ignition “ON”.
warning light operation.
Does EBD warning light stay on? )(Page 4E-33)

DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1033 / C1035 / C1036
AENBL80A4504014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1021/ C1025 / C1031/ C1035: Right-Front / Left-Front / Right-Rear / Left- • Wheel speed sensor
Rear Wheel Speed Sensor Circuit Voltage • Wheel speed sensor circuit
Wheel speed sensor signal is out of specified range.
• Wheel speed sensor encoder
C1022 / C1026 / C1032 / C1036: Right-Front / Left-Front / Right-Rear / Left-
Rear Wheel Speed Sensor or Encoder Signal Performance • ABS control module
Abnormal wheel speed sensor signal is detected continuously.
C1033: Wheel Speed Sensor Deviation
• Abnormal wheel speed sensor signal is detected continuously at two or
more wheel speed sensors.
• ABS control is activated for more than specified time.
• Wheel speed sensor driver power supply voltage is out of specified range.

NOTE
When vehicle was placed in any of the following conditions, one of these DTCs may be set although
sensor is in good condition. If such possibility is suspected, clear DTC once )(Page 4E-13) and check
whether any abnormality exists or not by performing driving test as described in Step 3 of “ABS
Check” (Page 4E-8).
• Vehicle was driven with parking brake lever pulled.
• Wheel spin occurred while driving.
• Wheel(s) was turned while vehicle was jacked up.

Circuit Diagram

5 [A] E24

A1 12V [a]
26 13
RED E24-20
1 1
RED/BLK E24-34 28 15
2
A2 29 16
3
B1 30 17
4
WHT E24-17 31 18
2 5
WHT/BLK E24-30 32 19
6
B2 33 20
6 7
C1 34 21
8
LT GRN E24-6 35 22
3 9
LTGRN/BLK E24-19 36 23
10
C2 37 24
11
D1 38 25
12
YEL E24-18
4 27 14
BRN E24-4
D2

IAP70A460008-03

[A]: ABS control module connector (View: [a])
A1: Left-front wheel speed sensor power supply circuit
A2: Left-front wheel speed sensor signal circuit
B1: Right-front wheel speed sensor power supply circuit
B2: Right-front wheel speed sensor signal circuit
C1: Left-rear wheel speed sensor power supply circuit
C2: Left-rear wheel speed sensor signal circuit
D1: Right-rear wheel speed sensor power supply circuit
D2: Right-rear wheel speed sensor signal circuit
1. Left-front wheel speed sensor
2. Right-front wheel speed sensor
3. Left-rear wheel speed sensor
4. Right-rear wheel speed sensor
5. ABS control module
6. Wheel speed sensor driver
4E-24 ABS:

DTC Confirmation Procedure

NOTE
Confirm that the following condition is met in this “DTC Confirmation Procedure”.
• DTC C1057 is not detected.

1) Set ignition “ON”.

2) Drive vehicle at 20 km/h or higher for more than 1 min.
3) Stop vehicle and turn ignition OFF.
4) Repeat Step 1) through Step 3) for 7 times.

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-8).
2 Tire pressure check Go to Step 3. Adjust tire pressure or
1) Check that tire pressure is at specified value. replace tire and recheck
DTC.
Is check result OK?
3 Wheel speed sensor power supply circuit and signal Go to Step 4. Repair or replace
circuit check defective wire harness.
1) Set ignition “OFF”.
2) Disconnect “E24” and each of wheel speed sensor
connectors.
3) Check for proper connection to “E24” and each of wheel
speed sensor connectors.
4) If connections are OK, check the following points.
• Resistance of “A1”, “A2”, “B1”, “B2”, “C1”, “C2”, “D1”
and “D2” circuits: less than 1 Ω
• Resistance between each of “A1”, “A2”, “B1”, “B2”,
“C1”, “C2”, “D1” and “D2” circuits and ground: infinity
• Resistance between “A1” circuit terminal and other
terminal at left-front wheel speed sensor connector:
infinity
• Resistance between “B1” circuit terminal and other
terminal at right-front wheel speed sensor connector:
infinity
• Resistance between “C1” circuit terminal and other
terminal at left-rear wheel speed sensor connector:
infinity
• Resistance between “D1” circuit terminal and other
terminal at right-rear wheel speed sensor connector:
infinity
• Voltage of “A1”, “A2”, “B1”, “B2”, “C1”, “C2”, “D1” and
“D2” circuits: approx. 0 V (When ignition is “ON”)

Is check result OK?

4 Wheel speed sensor signal check Replace ABS hydraulic Go to Step 5.
1) Check applicable wheel speed sensor for output voltage unit / control module
and waveform. )(Page 4E-35) assembly and recheck
DTC. )(Page 4E-33)
Is check result as specified?
 ABS: 4E-25

Step Action Yes No

5 Wheel speed sensor check Go to Step 6. • Clean, repair or
1) Check applicable wheel speed sensor. )(Page 4E-36) replace wheel speed
sensor.
Is check result OK?
– Front wheel speed
sensor: )(Page
4E-35)
– Rear wheel speed
sensor: )(Page
4E-36)
6 Wheel speed sensor encoder check Replace ABS hydraulic • Clean, repair or
1) Check applicable wheel speed sensor encoder. )(Page unit / control module replace wheel speed
4E-37) assembly and recheck sensor encoder.
DTC. )(Page 4E-33) – Front wheel speed
Is check result OK?
sensor encoder:
)(Page 4E-36)
– Rear wheel speed
sensor encoder:
)(Page 4E-37)

DTC C1041 / C1042 / C1045 / C1046 / C1051 / C1052 / C1055 / C1056 / C1063
AENBL80A4504015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1041 / C1045 / C1051 / C1055: Right-Front / Left-Front / Right-Rear / • ABS control module power supply
Left-Rear Inlet Solenoid Valve Circuit Correlation circuit
C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / • ABS control module ground circuit
Left-Rear Outlet Solenoid Valve Circuit Correlation
• ABS control module
Solenoid output and solenoid monitor data disagree.
C1063: Solenoid Valve Power Supply Driver Circuit Performance
• Solenoid valve power supply relay output is “ON”, although monitored
output is “OFF”.
• Solenoid valve power supply relay output is “OFF”, although monitored
output is “ON”.
4E-26 ABS:

Circuit Diagram

2 A1 4

3
1 WHT/BLU E24-13
[a]
5V

5
[A] E24

6 26 13

1
28 15
6 2
29 16
3
30 17
6 4
31 18
7 5
32 19
6 6
33 20
7
6 34 21
8
35 22
9
36 23
6 10
37 24
11
38 25
B1 12
6
BLK E24-14 27 14
BLK E24-27 6

B2

IAP70B450011-01

[A]: ABS control module connector (View: [a]) 1. Lead to battery 5. Solenoid valve power supply relay
A1: Solenoid valve power supply circuit 2. Individual circuit fuse box No. 1 6. Solenoid valve
B1: ABS control module ground circuit 1 3. “ABS2” fuse 7. CPU
B2: ABS control module ground circuit 2 4. ABS control module

DTC Troubleshooting
Step Action No Yes
1 Was “ABS System Check” performed? Go to Step 2.
Go to “ABS Check”
(Page 4E-8).
2 Solenoid valve power supply and ABS control module Replace ABS hydraulic Repair or replace
ground circuits check unit / control module defective wire harness.
1) Check solenoid valve power supply and ground circuits assembly and recheck
under “ABS Control Module Power Supply and Ground DTC. )(Page 4E-33)
Circuit Check” (Page 4E-30).

Are check results OK?

DTC C1057
AENBL80A4504016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1057: Power Supply Voltage • ABS control module power supply circuit
• ABS control module power supply voltage is higher • ABS control module ground circuit
than specified value. • Charging system
• ABS control module power supply voltage is lower than • ABS control module
specified value.
 ABS: 4E-27

Circuit Diagram

4 [A] E24
2 A1
[a]
8 26 13
WHT/BLU E24-13 6
1 7 1
WHT/RED E24-26 5 28 15
2
A2 29 16
C1 3
BLK E24-14 30 17
4
BLK E24-27 31 18
5
32 19
C2 6
3 B1 33 20
7
9 34 21
10 BEG E24-3 8
35 22
9
36 23
10
37 24
11
38 25
12

27 14

IBP80A450008-01

[A]: ABS control module connector (View: [a]) 1. Lead to battery 7. “ABS1” fuse
A1: Solenoid valve power supply circuit 2. Individual circuit fuse box No.1 8. “ABS2” fuse
A2: Pump motor power supply circuit 3. J/B 9. “ABS” fuse
B1: Ignition power supply circuit 4. ABS control module 10. Ignition power supply
C1: ABS control module ground circuit 1 5. Lead to pump motor relay
C2: ABS control module ground circuit 2 6. Lead to solenoid valve power supply relay

DTC Troubleshooting
Step Action Yes No
1 Was “ABS System Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-8).
2 ABS control module power supply and ground circuits Go to Step 3. Repair or replace
check defective wire harness.
1) Check ABS control module power supply circuit and
ground circuit. )(Page 4E-30)

Are they in good condition?

3 ABS control module power supply voltage check Replace ABS hydraulic • Check charging
1) Measure battery voltage with engine running at 3,000 unit / control module system.
rpm. assembly and recheck – K14B model:
DTC. )(Page 4E-33) “Generator Test”:
Is voltage between 9.3 V and 16.8 V?
K14B in Section 1J
(Page 1J-8)
– D13A model:
)(Page 1J-24)

DTC C1061
AENBL80A4504017
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1061: Pump Motor Circuit Performance • ABS control module (pump motor)
• Pump motor power supply voltage is out of specified range. power supply circuit
• Pump motor is activated although pump motor control relay is OFF. • ABS control module ground circuit
• Pump motor is not activated although pump motor control relay is ON. • ABS control module
4E-28 ABS:

Circuit Diagram

1
[A] E24
[a]
A1 26 13
7
6 1
5 WHT/RED E24-26 28 15
2
29 16
3
5V 30 17
4
31 18
5
32 19
6
2 3 33 20
7
34 21
8
35 22
B1 9
36 23
M 10
BLK E24-14 37 24
4 11
BLK E24-27 38 25
12
B2
27 14

IAP70A460013-02

[A]: ABS control module connector (View: [a]) 1. ABS control module 5. Lead to battery
A1: Pump motor power supply circuit 2. CPU 6. “ABS1” fuse
B1: ABS control module ground circuit 1 3. Pump motor relay 7. Individual circuit fuse box No.1
B2: ABS control module ground circuit 2 4. Pump motor

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Drive vehicle at 40 km/h or higher for more than 1 min.

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-8).
2 Pump motor power supply circuit check Go to Step 3. Repair or replace “A1”
1) Confirm that ignition is “OFF”. circuit.
2) Disconnect “E24” connector.
3) Check for proper connection to “E24-26” terminal.
4) If connection is OK, measure voltage between “E24-26”
terminal and ground.

Is it 10 – 14 V?
3 ABS control module ground circuit check Replace ABS hydraulic Repair or replace “B1”
1) Measure resistance between each of “E24-14” and unit / control module circuit and/or “B2”
“E24-27” terminals and ground. assembly and recheck circuit.
DTC. )(Page 4E-33)
Is resistance less than 1 Ω?

DTC C1062
AENBL80A4504018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1062: Solenoid Valve Continuous Operation Failure • ABS control module
Solenoid valve is activated for more than specified time
using “Hydraulic control test” under “Utility” mode of
SUZUKI scan tool.
 ABS: 4E-29

DTC Troubleshooting
Step Action Yes No
1 DTC check Replace ABS hydraulic End.
1) Confirm that ignition is “OFF”. unit / control module
assembly and recheck
2) Leave vehicle for more than 5 minutes, for cooling down
DTC. )(Page 4E-33)
of ABS.
3) Perform “DTC Check” (Page 4E-13).

Is DTC C1062 detected?

DTC C1071
AENBL80A4504019
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1071: ABS Control Module Internal Failure ABS control module
ABS control module internal failure is detected.

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-8).
2 DTC check Go to applicable DTC Replace ABS hydraulic
1) Perform “DTC Check” (Page 4E-13). troubleshooting. unit / control module
assembly and recheck
Is there DTC(s) other than C1071? DTC. )(Page 4E-33)

DTC C1090 / C1091 / C1094

AENBL80A4504020
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1090: ECM Detect Rolling Counter Failure from ABS Control Module • CAN communication circuit
ABS control module sends invalid CAN data to ECM. • ECM
C1091: CAN Invalid Data from ECM
• ABS control module
DTC concerned with ECM is detected.
C1094: Torque Request Reject Status
ABS control module receives invalid CAN data from ECM (about engine
torque control).

DTC Troubleshooting
Step Action Yes No
1 Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”
(Page 4E-8).
2 DTC check Go to applicable DTC Go to Step 3.
1) Perform “DTC Check” (Page 4E-13). troubleshooting.

Is there DTC(s) other than C1090, C1091 or C1094?

4E-30 ABS:

Step Action Yes No

3 DTC check for ECM • K14B model: Go to Replace ABS hydraulic
1) Check DTC for ECM. “Troubleshooting for unit / control module
Communication Bus assembly and recheck
• K14B model: )(Page 1A-18)
Off”: K14B Model in DTC. )(Page 4E-33)
• D13A model: )(Page 1A-134) Section 10H (Page
Is DTC U0073 or U0121 detected? 10H-14) or
“Troubleshooting for
Lost
Communication”:
K14B Model in
Section 10H (Page
10H-9).
• D13A model: Go to
“Troubleshooting for
Communication Bus
Off”: D13A Model in
Section 10H (Page
10H-34) or
“Troubleshooting for
Lost
Communication”:
D13A Model in
Section 10H (Page
10H-29).

DTC U0073
AENBL80A4504021
Refer to “Troubleshooting for Communication Bus Off”: K14B Model in Section 10H (Page 10H-14) / “Troubleshooting
for Communication Bus Off”: D13A Model in Section 10H (Page 10H-34).

DTC U0100
AENBL80A4504022
Refer to “Troubleshooting for Lost Communication”: K14B Model in Section 10H (Page 10H-9) / “Troubleshooting for
Lost Communication”: D13A Model in Section 10H (Page 10H-29).

ABS Control Module Power Supply and Ground Circuit Check

AENBL80A4504023
Circuit Diagram

4 [A] E24
2 A1
[a]
8 26 13
WHT/BLU E24-13 6
1 7 1
WHT/RED E24-26 5 28 15
2
A2 29 16
C1 3
BLK E24-14 30 17
4
BLK E24-27 31 18
5
32 19
C2 6
3 B1 33 20
7
9 34 21
10 BEG E24-3 8
35 22
9
36 23
10
37 24
11
38 25
12

27 14

IBP80A450008-01
 ABS: 4E-31

[A]: ABS control module connector (View: [a]) 1. Lead to battery 7. “ABS1” fuse
A1: Solenoid valve power supply circuit 2. Individual circuit fuse box No.1 8. “ABS2” fuse
A2: Pump motor power supply circuit 3. J/B 9. “ABS” fuse
B1: Ignition power supply circuit 4. ABS control module 10. Ignition power supply
C1: ABS control module ground circuit 1 5. Lead to pump motor relay
C2: ABS control module ground circuit 2 6. Lead to solenoid valve power supply relay

Circuit Description
When the ignition is set “ON”, power is supplied to ABS control module. Then power is supplied to pump motor and
solenoid valve in other line by the switching function in ABS control module.

Troubleshooting
Step Action Yes No
1 Fuse check Go to Step 2. Replace fuse and check
for short circuit to
Are “ABS1” fuse, “ABS2” fuse and “ABS” fuse in good ground.
condition?
2 Ignition power supply circuit check Go to Step 3. Repair or replace “B1”
1) Confirm that ignition is “OFF”. circuit.
2) Disconnect “E24” connector.
3) Check for proper terminal connection to “E24” connector.
4) If connections are OK, set ignition “ON”.
5) Measure voltage between “E24-3” terminal and ground.

Is it 10 – 14 V?
3 Pump motor and solenoid valve power supply circuit Go to Step 4. Repair or replace “A1”
check circuit and/or “A2”
1) Confirm that ignition is “OFF”. circuit.
2) Measure voltage between each of “E24-26” and “E24-
13” terminals and ground.

Are they 10 – 14 V?
4 ABS control module ground circuit check ABS control module Repair or replace “C1”
1) Measure resistance between each of “E24-14” and power supply and circuit and/or “C2”
“E24-27” terminals and ground. ground circuits are in circuit.
good condition.
Is resistance less than 1 Ω?

Repair Instructions
ABS Hydraulic Unit Operation Check NOTE
AENBL80A4506001
! CAUTION • Operation check must be performed by 2
persons.
Make sure of the following conditions before
• Lighting or blinking of warning light stops
ABS hydraulic unit operation check.
when ignition is set “ON” after completing
Otherwise, ABS hydraulic unit operation
ABS hydraulic unit operation check.
check cannot be performed properly.
• No air is trapped in brake system. 1) Set ignition “ON”.
• Battery voltage is 11 V or more. 2) Connect SUZUKI scan tool to DLC (1) located
• Brakes are not dragged. around bottom of instrument panel on driver’s seat
• ABS hydraulic unit / control module side.
assembly does not detect DTC. Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
4E-32 ABS:

Step on brake pedal (1) and then select testing

wheel by SUZUKI scan tool and the wheel (2)
should be turned by another person’s hand. At this
time, check whether the wheel rotates freely due
to brake depressurization.

NOTE
(A)
Depressurization by SUZUKI scan tool is
available for 0.5 seconds.
1

IAP70P450005-01

3) Hoist vehicle until tire can be rotated.

4) Set transmission to neutral and release parking
brake.
5) Set ignition “ON”, and select “Depressurization
I4RH01450021-01
check” in “Hydraulic control test” under “Utility” mode
7) Check for all 4-wheels respectively.
of SUZUKI scan tool.
Refer to SUZUKI scan tool operator’s manual for 8) Confirm ABS warning light is turned off after
further details. switching ignition from “OFF” to “ON”. Check for
DTC and repair problem if lights are still lit.
6) Perform the following checks with help of another
person. 9) If any faulty condition is found in Steps 6) and 7),
replace ABS hydraulic unit /control module
• Depressurization check
assembly.
10) After completing the check, confirm that ignition is
“OFF” and then disconnect SUZUKI scan tool from
DLC.

ABS Hydraulic Unit / Control Module Assembly Components

AENBL80A4506002
! CAUTION
Never disassemble ABS hydraulic unit / control module assembly, loosen blind plug or remove motor.
Failure to observe this precaution will spoil original performance of ABS hydraulic unit / control
module assembly.
 ABS: 4E-33

(a)

(a)

(c)
(b)

(c)
(a)

2
IBP80A450005-01

1. ABS hydraulic unit / control module assembly : 16 N⋅m (1.6 kgf-m, 12.0 lbf-ft) : 26 N⋅m (2.7 kgf-m, 19.5 lbf-ft)
2. Actuator bracket : 9.0 N⋅m (0.92 kgf-m, 7.0 lbf-ft)

ABS Hydraulic Unit / Control Module Assembly ABS Hydraulic Unit / Control Module Assembly
On-Vehicle Inspection Removal and Installation
AENBL80A4506003 AENBL80A4506004
Check the following points. Repair or replace defective
parts if defective. ! CAUTION
• Check ABS hydraulic unit / control module assembly • Be careful not to allow dust to enter ABS
(1) for dents, crack, deformation and leakage. hydraulic unit / control module assembly.
• Check actuator bracket (2) and its mounting surface • Do not place ABS hydraulic unit / control
for dents, crack and deformation. module assembly on its side or turn it
• Check ABS hydraulic unit / control module assembly upside down. Handling it in inappropriate
nuts and actuator bracket bolts for looseness. way will spoil its original performance.
• Check ABS control module connector (ABS control • Never disassemble ABS hydraulic unit /
module side and harness side) and its connector lock control module assembly, loosen blind
mechanism for damage or crack. plug or remove motor. Failure to observe
• Check connector terminals for bend, corrosion or rust. this precaution will spoil original
performance of ABS hydraulic unit /
1 control module assembly.
• Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be
damaged by brake fluid. Flush painted
surface with water immediately if any fluid
is spilled.
• Be sure to tighten every fastener to
2
specified torque using torque wrench to
IAP70B450013-01 avoid damage.
• Do not give an impact to hydraulic unit.
4E-34 ABS:

Removal NOTE
1) Disconnect negative (–) cable at battery. If ABS hydraulic unit / control module
2) For D13A model, remove lamp support member. assembly nuts are not removed, loosen each
)(Page 9K-38) nut to the end of screw (4) as shown in figure.
3) Disconnect ABS control module connector (1) by
pulling up the lock lever (2).
3
1
2

[A]

4
1

2 5
I9P60A460021-01

[A]: Pull up to disconnect

4) Loosen flare nuts (1) using special tool and

disconnect brake pipes (2) from ABS hydraulic unit /
control module assembly (3).
Special tool
IAP70P450013-01
(A): 09950M78220

NOTE Installation
Put bleeder plug cap or the like onto each Reverse removal procedures noting the following points.
pipe to prevent fluid from spilling. • Tighten brake pipe flare nuts, ABS hydraulic unit /
control module assembly nuts and actuator bracket
2
bolts to specified torque.
Use special tool for flare nut tightening.
(A)
Special tool
1 : 09950M78220
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 12.0
lbf-ft)
ABS hydraulic unit / control module assembly nut
(b): 9.0 N·m (0.92 kgf-m, 7.0 lbf-ft)
3 Actuator bracket bolt (c): 26 N·m (2.7 kgf-m, 19.5
lbf-ft)

! CAUTION
IAP70B450014-01
Be careful not to deform or scratch bushing
5) Remove ABS hydraulic unit / control module (1) when installing ABS hydraulic unit /
assembly and actuator bracket together. )(Page control module assembly.
4E-32)
6) Remove or loosen ABS hydraulic unit / control
module assembly nuts (1) and remove ABS
hydraulic unit / control module assembly (3) from
actuator bracket (2).

! CAUTION
Be careful not to damage bushing (5).
 ABS: 4E-35

Voltage at resistance (100 Ω) without wheel

(a) rotation
600 to 800 mV or 1200 to 1600 mV
6) Measure voltage at both ends of resistance while
(a)
rotating wheel rotation and check that high (1) and
low (2) voltages are as specified. Confirm that
waveform is not disordered.
Voltage at resistance (100 Ω) with wheel rotating
Low voltage: 600 to 800 mV
(c)
High voltage: 1200 to 1600 mV
1

(b)
1
(a)
IBP80A450006-01

• Tighten lamp support member bolts to specified

torque. )(Page 9K-38)
• Bleed air out of brake system. )(Page 4A-4)
• Check for leakage of brake fluid and perform ABS
hydraulic unit operation check. )(Page 4E-31)

Front and Rear Wheel Speed Sensor On-Vehicle IAP70A460015-01

Inspection
AENBL80A4506005
! CAUTION
Front Wheel Speed Sensor Removal and
Installation
Incorrect voltage and/or wrong connection AENBL80A4506006
cause damage to wheel speed sensor. ! CAUTION
Output Voltage Inspection Do not pull or twist wire harness strongly
1) Disconnect negative (–) cable at battery. when removing or installing wheel speed
sensor.
2) Hoist vehicle until tire can be rotated.
3) Disconnect wheel speed sensor connector (1). Removal
4) Set up measuring devices as shown in figure. 1) Disconnect negative (–) cable at battery.
2) Hoist vehicle a little and remove wheel.
[a] 3) Remove front fender lining. )(Page 9J-2)
1
4) Remove clips (1) and disconnect front wheel speed
sensor connector (2).
[A]
5) Remove front wheel speed sensor bolt (3).
6) Remove front wheel speed sensor (4) from steering
3 knuckle.

IAP70A460014-02

[A]: Wheel speed sensor connector (View: [a])

2. Resistance (100 Ω)
3. Power supply (12 V)

5) Measure voltage at both ends of resistance without

wheel rotation. If check result is not as specified,
check sensor, mating encoder and their installation
conditions.
4E-36 ABS:

Removal
[B] 5
2 1) Disconnect negative (–) cable at battery.
2) Hoist vehicle a little and remove wheel.
3) Remove clips (1) and disconnect rear wheel speed
sensor connector (2).
4) Remove rear wheel speed sensor bolt (3).
5) Remove rear wheel speed sensor (4) from rear
wheel hub assembly.
1

1 2
[A]

1
1
4
3
4 2 3

I9P60A460026-01
IAP70A460016-01

[A]: Right side 5. Individual circuit fuse box No.1

Installation
[B]: Left side
Reverse removal procedures noting the following points.
Installation • Check that no iron powder attaches to sensing area of
Reverse removal procedures noting the following points. wheel speed sensor (2).
• Check that no iron powder attaches to sensing area of • Tighten wheel speed sensor bolt (1) to specified
wheel speed sensor (1). torque.
• Tighten front wheel speed sensor bolt (2) to specified Tightening torque
torque. Rear wheel speed sensor bolt (a): 11 N·m (1.1 kgf-
m, 8.5 lbf-ft)
Tightening torque
Front wheel speed sensor bolt (a): 11 N·m (1.1 • Confirm that there is no space between rear wheel
kgf-m, 8.5 lbf-ft) speed sensor and rear wheel hub assembly (3).
• Confirm that there is no space between front wheel [A] [B]
speed sensor and steering knuckle (3). 2 1,(a) 2 1,(a)
3 3

[A] [B]
1 2,(a) 1 2,(a)
3 3

I9P60A460033-01

[A]: OK [B]: NG

I9W10P460009-02
• Install wheel. )(Page 2D-2)
[A]: OK [B]: NG

• Install wheel. )(Page 2D-2) Front and Rear Wheel Speed Sensor Inspection
AENBL80A4506008
Replace or clean wheel speed sensor if sensing area of
Rear Wheel Speed Sensor Removal and front and rear wheel speed sensor(s) is damaged or
Installation covered with iron powder.
AENBL80A4506007

Front Wheel Speed Sensor Encoder Removal

! CAUTION and Installation
AENBL80A4506009
Do not pull or twist wire harness strongly
when removing or installing wheel speed
sensor.
 ABS: 4E-37

NOTE Front and Rear Wheel Speed Sensor Encoder

Front wheel speed sensor encoder and wheel Inspection
AENBL80A4506011
bearing are unified as an assembly.
If encoder replacement is necessary, replace Front Wheel Speed Sensor Encoder
encoder as a wheel bearing assembly. Check front wheel speed sensor encoders for crack,
damage, or deformation.
Refer to “Front Wheel Hub, Steering Knuckle and Wheel
Replace front wheel bearing if defective.
Bearing Removal and Installation”: Front in Section 3A
(Page 3A-14).
Rear Wheel Speed Sensor Encoder
Check rear wheel speed sensor encoder, referring to
Rear Wheel Speed Sensor Encoder Removal “Front and Rear Wheel Speed Sensor On-Vehicle
and Installation Inspection” (Page 4E-35).
AENBL80A4506010
NOTE
Rear wheel speed sensor encoder and rear
wheel hub assembly are unified as an
assembly. If encoder replacement is
necessary, replace encoder as a rear wheel
hub assembly.

For removal and Installation of rear wheel speed sensor

encoder (included in rear wheel hub assembly), refer to
“Rear Wheel Hub Assembly Removal and Installation”:
Rear in Section 3A (Page 3A-19).

Specifications
Tightening Torque Specifications
AENBL80A4507001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Brake pipe flare nut 16 1.6 12.0 )
ABS hydraulic unit / control module assembly )
9.0 0.92 7.0
nut
Actuator bracket bolt 26 2.7 19.5 )
Front wheel speed sensor bolt 11 1.1 8.5 )
Rear wheel speed sensor bolt 11 1.1 8.5 )

NOTE
The tightening torque(s) also specified in:
“ABS Hydraulic Unit / Control Module Assembly Components”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
4E-38 ABS:

Special Tools and Equipment

Special Tool
AENBL80A4508001
09950M78220 SUZUKI scan tool (SUZUKI- 6
SDT)
Flare nut wrench (10 x 12 — 1 2
mm)
4
)/) This kit includes following 3
items. 1. SUZUKI-SDT 2. 5
DLC cable 3. USB cable 4.
AC/DC power supply 5.
Voltage meter probe 6.
Storage case) / )

Section 5
Transmission / Transaxle
CONTENTS
Precautions .................................................5-1
Precautions............................................................. 5-1
Precautions for Transmission / Transaxle............. 5-1
Manual Transmission/Transaxle ............ 5B-1
K14B Model..............................................................5B-1
General Description .............................................5B-1
Manual Transaxle Construction .......................... 5B-1
Diagnostic Information and Procedures............5B-4
Manual Transaxle Symptom Diagnosis............... 5B-4
Repair Instructions ..............................................5B-6
Manual Transaxle Oil Level Check ..................... 5B-6
Manual Transaxle Oil Change ............................ 5B-7
Differential Side Oil Seal Replacement ............... 5B-8
Gear Shift Control Lever and Cable
Components...................................................... 5B-8
Gear Shift Control Lever and Cable Removal
and Installation.................................................. 5B-9
Gear Select Control Cable Adjustment ............. 5B-10
Back Up Light Switch Removal and
Installation....................................................... 5B-11
Back Up Light Switch Inspection....................... 5B-11
Manual Transaxle Unit Components................. 5B-12
Manual Transaxle Unit Dismounting and
Remounting..................................................... 5B-12
Gear Shift and Select Shaft Assembly
Components.................................................... 5B-14
Gear Shift and Select Shaft Assembly
Removal and Installation................................. 5B-15
Manual Transaxle Assembly Components........ 5B-17
Fifth Gear Disassembly and Reassembly ......... 5B-18
Manual Transaxle Assembly Disassembly
and Reassembly ............................................. 5B-21
Transaxle Right Case Disassembly and
Reassembly .................................................... 5B-29
Transaxle Left Case Disassembly and
Reassembly .................................................... 5B-30
Input Shaft and Countershaft Components....... 5B-32
Input Shaft Disassembly and Reassembly........ 5B-33
Countershaft Disassembly and Reassembly .... 5B-35
Gear Shift Shaft Components ........................... 5B-40
5th and Reverse Gear Shift Shaft
Disassembly and Reassembly ........................ 5B-40
Gear Shift Shaft and Fork Inspection ................ 5B-41
Differential Components ................................... 5B-42
Table of Contents 5- i
Differential Disassembly and Reassembly........5B-42
Specifications.....................................................5B-44
Tightening Torque Specifications......................5B-44
Special Tools and Equipment ...........................5B-45
Recommended Service Material .......................5B-45
Special Tool ......................................................5B-45
D13A Model............................................................5B-48
General Description ...........................................5B-48
Manual Transaxle Construction ........................5B-48
Diagnostic Information and Procedures ..........5B-51
Manual Transaxle Symptom Diagnosis.............5B-51
Repair Instructions ............................................5B-52
Manual Transaxle Oil Level Check ...................5B-52
Manual Transaxle Oil Change...........................5B-52 5
Differential Side Oil Seal Replacement .............5B-52
Gear Shift Control Lever and Cable
Components....................................................5B-53
Gear Shift Control Lever and Cable Removal
and Installation ................................................5B-53
Gear Select Control Cable Adjustment .............5B-54
Back Up Light Switch Removal and
Installation .......................................................5B-54
Back Up Light Switch Inspection.......................5B-54
Manual Transaxle Unit Components.................5B-55
Manual Transaxle Unit Dismounting and
Remounting.....................................................5B-55
Gear Shift and Select Shaft Assembly
Components....................................................5B-56
Gear Shift and Select Shaft Assembly
Removal and Installation.................................5B-56
Manual Transaxle Assembly Components........5B-58
Fifth Gear Disassembly and Reassembly .........5B-59
Manual Transaxle Assembly Disassembly
and Reassembly .............................................5B-62
Transaxle Right Case Disassembly and
Reassembly ....................................................5B-66
Transaxle Left Case Disassembly and
Reassembly ....................................................5B-67
Input Shaft and Countershaft Components.......5B-69
Input Shaft Disassembly and Reassembly........5B-69
Countershaft Disassembly and Reassembly ....5B-72
Gear Shift Shaft Components ...........................5B-76
5th and Reverse Gear Shift Shaft
Disassembly and Reassembly ........................5B-76
Gear Shift Shaft and Fork Inspection ................5B-76
5-ii Table of Contents
Differential Components.................................... 5B-77
Differential Disassembly and Reassembly........ 5B-77
Specifications.....................................................5B-79
Tightening Torque Specifications...................... 5B-79
Special Tools and Equipment ...........................5B-80
Recommended Service Material ....................... 5B-80
Special Tool ...................................................... 5B-80
Clutch ....................................................... 5C-1
K14B Model..............................................................5C-1
General Description .............................................5C-1
Clutch Construction.............................................5C-1
Diagnostic Information and Procedures............5C-2
Clutch System Symptom Diagnosis ....................5C-2
Repair Instructions ..............................................5C-3
CPP Switch Removal and Installation.................5C-3
CPP Switch Inspection and Adjustment..............5C-3
Clutch Pedal Inspection ......................................5C-3
Clutch Fluid Level Inspection ..............................5C-4
Air Bleeding of Clutch System.............................5C-4
Clutch Fluid Pipe and Hose Components ...........5C-5
Clutch Fluid Pipe and Hose Removal and
Installation .........................................................5C-5
Clutch Fluid Pipe and Hose Inspection ...............5C-6
Clutch Master Cylinder Removal and
Installation .........................................................5C-6
Clutch Master Cylinder Inspection ......................5C-7
Clutch Operating Cylinder Assembly
Removal and Installation...................................5C-7
Clutch Operating Cylinder Assembly
Inspection..........................................................5C-8
Clutch Pedal Assembly Components..................5C-8
Clutch Pedal Assembly Removal and
Installation .........................................................5C-9
Clutch Cover and Clutch Disc Components......5C-10
Clutch Cover and Clutch Disc Removal and
Installation .......................................................5C-10
Clutch Cover and Clutch Disc Inspection..........5C-11
Input Shaft Bearing Removal and Installation ...5C-11
Input Shaft Bearing Inspection ..........................5C-12
Specifications .....................................................5C-12
Tightening Torque Specifications......................5C-12
Special Tools and Equipment ...........................5C-13
Recommended Service Material .......................5C-13
Special Tool ......................................................5C-13
D13A Model............................................................5C-14
General Description ...........................................5C-14
Clutch (Hydraulic Type) Construction ...............5C-14
Diagnostic Information and Procedures ..........5C-15
Clutch System Symptom Diagnosis ..................5C-15
Repair Instructions ............................................5C-15
Clutch Pedal Position (CPP) Switch Removal
and Installation ................................................5C-15
Clutch Pedal Position (CPP) Switch
Inspection........................................................5C-15
Clutch Pedal Inspection ....................................5C-16
Clutch Fluid Level Inspection ............................5C-17
Air Bleeding of Clutch System...........................5C-17
Clutch Fluid Pipe and Hose Components .........5C-17
Clutch Fluid Pipe Removal and Installation.......5C-17
Clutch Fluid Pipe Inspection..............................5C-18
Clutch Master Cylinder Removal and
Installation .......................................................5C-18
Clutch Operating Cylinder Assembly
Removal and Installation.................................5C-19
Clutch Operating Cylinder Assembly
Inspection........................................................5C-20
Clutch Pedal Assembly Components................5C-20
Clutch Pedal Assembly Removal and
Installation .......................................................5C-20
Clutch Cover and Clutch Disc Components ......5C-20
Clutch Cover and Clutch Disc Removal and
Installation .......................................................5C-21
Clutch Cover and Clutch Disc Inspection ..........5C-22
Specifications .....................................................5C-22
Tightening Torque Specifications......................5C-22
Special Tools and Equipment ...........................5C-23
Recommended Service Material .......................5C-23
Special Tool ......................................................5C-23
 Precautions: 5-1

Precautions
Transmission / Transaxle

Precautions
Precautions for Transmission / Transaxle
AENBL80A5000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Fastener Caution
Refer to “Fastener Caution” in Section 00 (Page 00-5).

Air Bag Warning

Refer to “Air Bag Warning” in Section 00 (Page 00-5).

Reassembling Note for Wiring Harness

Be sure to observe the Wiring Diagram Manual whenever installing wiring whenever installing wiring harness.
Otherwise, electrical trouble may occur.

Precautions for CAN Communication System

Refer to “Precautions for CAN Communication System” in Section 00 (Page 00-8).
5B-1 Manual Transmission/Transaxle: K14B Model

Manual Transmission/Transaxle
Transmission / Transaxle

K14B Model
General Description
Manual Transaxle Construction
AENBL80A5211001
The transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three
shafts - input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a
sliding idler gear arrangement.
The low speed sleeve & hub is mounted on countershaft and engaged with countershaft 1st gear or 2nd gear, while
the high speed sleeve & hub is mounted on input shaft and engaged with input shaft 3rd gear or 4th gear. The 5th
speed sleeve & hub on input shaft is engaged with input shaft 5th gear mounted on the input shaft.
To prevent the cracking noise from the reverse gear when shifting transaxle gear into the reverse gear, the reverse
shift braking device is used. This device utilizes the 5th synchromesh, which is the lever synchro type, to apply the
brake on the input shaft rotation.
The double cone synchronizing mechanism is provided to 2nd gear synchromesh device for high performance of
shifting to 2nd gear.
For servicing, it is necessary to use genuine sealant or its equivalent on mating surfaces of transaxle case which is
made of aluminum. The case fastening bolts must be tightened to specified torque by means of torque wrench. It is
also important that all parts are thoroughly cleaned with cleaning fluid and air dried before reassembling.
Further, care must be taken to adjust preload of countershaft taper roller bearings. New synchronizer rings are
prohibited from being lapped with respective gear cones by using lapping compound before they are assembled.

IAP70A520001-01

1. Input shaft 6. Input shaft 3rd gear 11. Countershaft 16. Countershaft 2nd gear
2. 5th speed sleeve & hub 7. Left case 12. Side cover 17. Low speed sleeve & hub
3. Input shaft 5th gear 8. Reverse gear shaft 13. Countershaft 5th gear 18. Countershaft 1st gear
4. Input shaft 4th gear 9. Reverse idler gear 14. Countershaft 4th gear 19. Final gear
 Manual Transmission/Transaxle: K14B Model 5B-2

5. High speed sleeve & hub 10. Right case 15. Countershaft 3rd gear 20. Differential case

Gear Shift Mechanism

The gear shifting control system consists of the following main parts. Movement of gear shift control lever is
transmitted to gear shift & select shaft through gear shift and gear select cables.

14

5
3
5 7
6

10

8
12 13
11

IAP70A520002-01

1. Gear shift control cable
2. Gear select control cable
3. Select cable lever
4. Shift cable lever
5. 5th gear shift fork
6. Reverse gear shift lever
7. 5th & reverse gear shift guide shaft
8. 5th & reverse gear shift shaft
9. Gear shift & select shaft assembly
10. Gear shift interlock bolt
11. Gear shift & select lever
12. Low speed gear shift shaft
13. High speed gear shift shaft
14. Gear shift control lever assembly

Reverse Shift Prevention Mechanism

Construction
In the gear shift lever case, the reverse shift limit yoke
(2) which turns around reverse shift limit yoke (2)
retainer is provided.
This reverse shift limit yoke (2) restricts the movement of
gear shift & select lever (1) to prevent erroneous reverse
shifting.
5B-3 Manual Transmission/Transaxle: K14B Model

2) Then the cubic part of the gear shift & select lever (1)
3 pushes the projection of the reverse shift limit yoke
(2). The reverse shift limit yoke (2) rotates and
pushes the gear shift & select lever (1) toward the
neutral position.

[a]

[c] [b]
1 2

IAP70A520034-02

[a]: 5th [b]: Reverse [c]: 4th

3) If the reverse shifting force is still applied to the shift

lever, the cubic part of the gear shift & select lever
(1) rides over the projection of the reverse shift limit
yoke (2), and the gear is shifted into the 4th. The
I9P60A521054-01 reverse shift limit yoke (2) returns to its original
3. Gear shift & select shaft assembly position.

Operation [a]

1) If shifting directly from 5th [a] to reverse [b] is

attempted, the cubic part of the gear shift & select
lever (1) is blocked by the projection of the reverse 1 2
shift limit yoke (2).

1 [a] 1 [a]
[c] [b]

2 2

IAP70A520035-02
[c] [b] [c] [b]
[a]: 5th [b]: Reverse [c]: 4th

IAP70A520033-02

[c]: 4th

Diagnostic Information and Procedures

Manual Transaxle Symptom Diagnosis
AENBL80A5214001
 Manual Transmission/Transaxle: K14B Model 5B-4
Condition Possible cause
Gears slipping out of Worn shift fork shaft
mesh
Worn shift fork or synchronizer sleeve
Weak or damaged locating springs
Worn bearings on input shaft or
countershaft
Worn chamfered tooth on sleeve and
gear
Correction / Reference Item
• Replace shift fork or shift shaft.
– Low speed gear shift shaft: )(Page 5B-
19)
– High speed gear shift shaft: )(Page 5B-
19)
– 5th gear shift fork: )(Page 5B-34)
• Replace shift fork, shift shaft or synchronizer
sleeve & hub.
– Low speed gear shift shaft: )(Page 5B-
19)
– High speed gear shift shaft: )(Page 5B-
19)
– 5th gear shift fork: )(Page 5B-34)
– Low speed synchronizer sleeve & hub:
)(Page 5B-30)
– High speed synchronizer sleeve & hub:
)(Page 5B-28)
– 5th speed synchronizer sleeve & hub:
)(Page 5B-16)
Replace locating spring. )(Page 5B-19)
• Replace input shaft bearing or output shaft
bearing.
– Countershaft left bearing:
– Inner race: )(Page 5B-30)
– Outer race: )(Page 5B-19)
– Countershaft right bearing:
– Inner race: )(Page 5B-30)
– Outer race: )(Page 5B-23)
– Input shaft left bearing and right bearing:
)(Page 5B-28)
• Replace synchronizer sleeve & hub and
gear.
– Countershaft 1st gear and 2nd gear:
)(Page 5B-30)
– Input shaft 3rd gear and 4th gear:
)(Page 5B-28)
– Input shaft 5th gear: )(Page 5B-16)
– Low speed synchronizer sleeve & hub:
)(Page 5B-30)
– High speed synchronizer sleeve & hub:
)(Page 5B-28)
– 5th speed synchronizer sleeve & hub:
)(Page 5B-16)
5B-5 Manual Transmission/Transaxle: K14B Model
Condition Possible cause
Hard shifting Inadequate lubricant
Improper clutch pedal free travel
Distorted or broken clutch disc
Damaged clutch pressure plate
Worn synchronizer ring
Worn chamfered tooth on sleeve or gear • Replace synchronizer sleeve & hub and
Worn gear shift control shaft joint
bushing
Distorted shift shaft
Broken gear shift / select control cables Replace gear shift and select cable. )(Page
Correction / Reference Item
Replenish manual transaxle oil.
• Replace clutch pedal arm or clutch master
cylinder.
– Clutch pedal arm: )(Page 5C-3)
– Clutch master cylinder: )(Page 5C-6)
Replace clutch disc. )(Page 5C-9)
Replace clutch cover. )(Page 5C-9)
• Replace synchronizer ring.
– Low speed synchronizer ring and 2nd
gear synchronizer ring: )(Page 5B-30)
– High speed synchronizer ring: )(Page
5B-28)
– 5th speed synchronizer ring: )(Page 5B-
16)
gear.
– Countershaft 1st gear and 2nd gear:
)(Page 5B-30)
– Input shaft 3rd gear and 4th gear:
)(Page 5B-28)
– Input shaft 5th gear: )(Page 5B-16)
– Low speed synchronizer sleeve & hub:
)(Page 5B-30)
– High speed synchronizer sleeve & hub:
)(Page 5B-28)
– 5th speed synchronizer sleeve & hub:
)(Page 5B-16)
Replace gear shift control shaft joint bushing.
)(Page 5B-13)
• Replace shift fork or shift shaft.
– Low speed gear shift shaft: )(Page 5B-
19)
– High speed gear shift shaft: )(Page 5B-
19)
– 5th gear shift fork: )(Page 5B-34)
5B-9)
 Manual Transmission/Transaxle: K14B Model 5B-6

Condition Possible cause Correction / Reference Item

Noise Inadequate or insufficient lubricant
Damaged or worn bearing(s)
Damaged or worn gear(s)
Damaged or worn synchronizer parts
Replenish manual transaxle oil.
• Replace bearing.
– Countershaft left bearing:
– Inner race: )(Page 5B-30)
– Outer race: )(Page 5B-19)
– Countershaft right bearing:
– Inner race: )(Page 5B-30)
– Outer race: )(Page 5B-23)
– Input shaft left bearing and right bearing:
)(Page 5B-28)
– Differential side bearing:
– Inner race: )(Page 5B-35)
– Right side outer race: )(Page 5B-23)
– Left side outer race: )(Page 5B-24)
– Needle bearing:
– Countershaft 1st gear and 2nd gear:
)(Page 5B-28)
– Input shaft 3rd gear and 4th gear:
)(Page 5B-30)
– 5th gear: )(Page 5B-16)
• Replace gear.
– Countershaft 1st gear, 2nd gear, 3rd gear
and 4th gear: )(Page 5B-30)
– Input shaft 1st gear, 2nd gear, 3rd gear
and 4th gear: )(Page 5B-28)
– Input shaft 5th gear and countershaft 5th
gear: )(Page 5B-16)
• Replace synchronizer parts.
– Low speed synchronizer parts: )(Page
5B-30)
– High speed synchronizer parts: )(Page
5B-28)
– 5th speed synchronizer parts: )(Page
5B-16)

Repair Instructions
Manual Transaxle Oil Level Check Tightening torque
AENBL80A5216001 Transaxle oil level / filler plug (a): 21 N·m (2.1
1) Hoist vehicle and check manual transaxle for oil kgf-m, 15.5 lbf-ft)
leakage. Repair leaky point, if any.
2) Remove oil level / filler plug (1). Check oil
contamination and check that oil level reaches lower
end of oil level / filler plug hole (2).
If oil is excessively dirty or insufficient, change oil or
replenish specified oil up to plug hole.
3) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
5B-7 Manual Transmission/Transaxle: K14B Model

Viscosity chart
1, (a), “A”
75W - 80, 75W - 85, 75W - 90

C - 30 - 20 - 10 0 10 20 30 40
F - 22 -4 14 32 50 68 86 104
[a]
IAP70A520004-01

[a]: Out side temperature

7) Apply sealant to thread of level / filler plug, and then

tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
IAP70A520003-01
Tightening torque
Transaxle oil level / filler plug (b): 21 N·m (2.1
kgf-m, 15.5 lbf-ft)

2, (b), “A”

IAP70A320003-01

Manual Transaxle Oil Change 1, (a), “A”

AENBL80A5216002
1) Before changing oil, be sure to stop engine and hoist
vehicle horizontally.
2) With vehicle hoisted, check leakage.
If leakage exists, correct it.
3) Remove oil level / filler plug (2). IAP70A520005-01
4) Remove drain plug (1), and drain oil.
5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m, IAP70A320006-01
15.5 lbf-ft)
6) Replenish new specified oil until oil level reaches Differential Side Oil Seal Replacement
AENBL80A5216003
lower end of oil filler plug hole (3) as shown in figure.
1) Hoist vehicle and drain transaxle oil.
NOTE 2) Remove left drive shaft assembly. “Front Drive Shaft
It is highly recommended to use “SUZUKI Assembly Removal and Installation”: Front in
GEAR OIL 75W-90”. Section 3A (Page 3A-3)
3) Remove oil seal (1) using special tool.
Transaxle oil specification
: API GL-4 (For SAE classification, refer to Special tool
viscosity chart.) (A): 09913M50121

Transaxle oil capacity

Reference: 2.6 liters (5.5/4.6 US/Imp. pt.)
 Manual Transmission/Transaxle: K14B Model 5B-8

Distance between case surface and oil seal

“a”: 0 – 1.0 mm (0 – 0.04 in.)
5) Apply grease to oil seal lip and check drive shaft
where oil seal contacts for smoothness.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)

“a”

(A)
1
I9P60A522004-01

4) Install new oil seal (1) using special tool.

(B)
NOTE (A) 1, “A”

• Be sure to install oil seal facing its spring

2
side inward.
I9P60A522005-02
• Be sure to install oil seal to surface of left
case (2) in parallel. 6) Insert left drive shaft assembly. “Front Drive Shaft
Assembly Removal and Installation”: Front in
Special tool Section 3A (Page 3A-3)
(A): 09944M88220 7) Replenish transaxle oil. )(Page 5B-7)
(B): 09924M74510

Gear Shift Control Lever and Cable Components

AENBL80A5216004

5 (a)
7 (b)

(d) 2 (c)
9

8
A

2 (c)

IAP70A520037-01
5B-9 Manual Transmission/Transaxle: K14B Model

1. Gear shift control lever knob
2. Cable bracket bolt
3. Gear shift control cable
: Apply grease 99000-25011 to cable end.
4. Gear select control cable
: Apply grease 99000-25011 to cable end.
5. Gear shift control lever assembly mounting nut
6. Gear shift control lever assembly
7. Cable grommet cover bolt
8. Cable bracket
9. Engine harness bracket
: 13 N⋅m (1.3 kgf-m, 9.5 lbf-ft)
: 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)
: 21 N⋅m (2.1 kgf-m, 15.5 lbf-ft)
: 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft)
: Do not reuse.

Gear Shift Control Lever and Cable Removal Gear Select Control Cable Adjustment
AENBL80A5216006
and Installation
AENBL80A5216005 1) Release lock plate (1) which restricts moving of
cable end holder (2).
Removal 2) Push cable end holder (2) out from adjuster (4) using
1) Remove ECM from battery tray. “ECM Removal and appropriate tool (3) to disengage cable.
Installation”: K14B in Section 1C (Page 1C-1)
2) Remove battery and battery tray. “Battery Removal
and Installation”: K14B in Section 1J (Page 1J-6)
3) Remove floor console front box. “Center Console
Box Removal and Installation” in Section 9H (Page
9H-9)
4) Disconnect gear shift and select control cable ends
(5) from pivot (6) of gear shift control lever assembly.
5) Disconnect gear shift and select control cables (1)
from gear shift control lever assembly (2) while
pulling quick joint (4) to arrow direction as shown in
figure.
6) Remove nuts (3) and remove gear shift control lever
assembly from floor panel.

3 I4RS0A520004-01

4 3 3) Apply grease to pivot (5) of gear shift control lever,

1
and then install adjuster (1) into pin of gear shift
2 control lever securely.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
4) Push cable end holder (2) in direction [a].
3
5 6
IAP70A520038-01 NOTE
7. Pin Do not apply force to adjuster in cable
operation direction [b].
7) Disconnect gear shift and select control cables from
transaxle. 5) Slide lock plate (3) in direction [c], until it gets over
8) Remove cable grommet bolt, and then remove gear the claw (4) of cable end holder.
shift and select control cables from floor panel.

Installation
Reverse removal procedure, noting the following points.
• Tighten each bolt and nut to specified torque. )(Page
5B-8)
• Adjust gear select control cable. )(Page 5B-9)
 Manual Transmission/Transaxle: K14B Model 5B-10

1 2, (a)

5,“ A” I3RH0A520006-01

1 2) Connect back up light switch connector.

3) Install battery tray and battery. “Battery Removal and
Installation”: K14B in Section 1J (Page 1J-6)
4) Install ECM to battery tray. “ECM Removal and
Installation”: K14B in Section 1C (Page 1C-1)

Back Up Light Switch Inspection

[b] AENBL80A5216008
Check back up light switch for function using ohmmeter.
Replace back up light switch if it is defective.
Back up light switch specification
Switch ON (Push): Continuity exists
5, “A” Switch OFF (Release): No continuity
3 4 1

[c]
3
[a] 2

IAP70A520039-01

Back Up Light Switch Removal and Installation

AENBL80A5216007
Removal
1) Remove ECM from battery tray. “ECM Removal and I4RS0A520011-01
Installation”: K14B in Section 1C (Page 1C-1)
2) Remove battery and battery tray. “Battery Removal
and Installation”: K14B in Section 1J (Page 1J-6)
3) Disconnect back up light switch connector (1).
4) Remove back up light switch (2).

IAP70A520006-01

Installation
1) Apply oil to new O-ring (1) and tighten back up light
switch (2) to specified torque.
Tightening torque
Back up light switch (a): 19 N·m (1.9 kgf-m, 14.0
lbf-ft)
5B-11 Manual Transmission/Transaxle: K14B Model

Manual Transaxle Unit Components

AENBL80A5216009

[a]
(a)
1
(a)

(a)
IAP70A520007-01

[a]: Vehicle forward 1. Engine 2. Transaxle : 55 N⋅m (5.6 kgf-m, 40.5 lbf-ft)

Manual Transaxle Unit Dismounting and 10) Remove right are left front drive shaft assembly.
Remounting “Front Drive Shaft Assembly Removal and
AENBL80A5216010 Installation”: Front in Section 3A (Page 3A-3)
Dismounting
11) Hang up engine with hoisting devise (1) so that
1) Open engine hood as wide as possible and hold it engine does not tilt.
using rope.
2) Remove battery and battery tray with ECM. “Battery
Removal and Installation”: K14B in Section 1J (Page
1J-6)
3) Remove air cleaner assembly. “Air Cleaner 1
Assembly Removal and Installation”: K14B in 1
Section 1D (Page 1D-5)
4) Disconnect back up light switch connector and
release wiring harness clamps. )(Page 5B-10)
5) Disconnect gear shift and gear select control cables
from transaxle. )(Page 5B-9)
6) Disconnect clutch fluid pipe. )(Page 5C-6)
7) Remove ground cable from transaxle.
8) Remove left side engine undercover. I9P60A521061-01

9) Drain transaxle oil. )(Page 5B-7) 12) Support transaxle with transmission jack.
13) Remove starting motor. “Starting Motor Removal and
Installation”: K14B in Section 1I (Page 1I-4)

14) Remove engine left mounting bracket. “Engine
Mounting Components”: K14B in Section 1D (Page
1D-18)
15) Remove transaxle-to-engine bolts (1) and nut (2),
and then lower transaxle.
1 Never reuse front suspension frame
2
1 1D-18)
IAP70A520008-01
1 6C-24)
IAP70A520009-01
16) Pull out transaxle from engine so as to disconnect
input shaft from clutch disc.
Remounting
Reverse dismounting procedure, noting the following
points.
! CAUTION
• Be careful not to damage differential side
oil seal and transfer side oil seal while
reinstalling drive shafts.
• Do not hit drive shaft joint with hammer
when installing it into differential gear and
intermediate shaft.
• Tighten transaxle–engine bolts and nut to specified
torque. )(Page 5B-11)
• Tighten engine left mounting bracket bolts, nuts and
engine left mounting bolt to specified torque. “Engine
Mounting Components”: K14B in Section 1D (Page
1D-18)
• Tighten starting motor mounting bolts and starting
motor cable nut to specified torque. “Starting Motor
Removal and Installation”: K14B in Section 1I (Page
1I-4)
Manual Transmission/Transaxle: K14B Model 5B-12
• Tighten front suspension frame mounting bolts to
specified torque. “Front Suspension Frame, Stabilizer
Bar and Bushing Removal and Installation” in Section
2B (Page 2B-12)
! CAUTION
mounting bolt to prevent it from loosening.
Be sure to front suspension frame mounting
bolt with a new one whenever loosening
once.
• Tighten engine rear mounting bracket bolts and
engine rear mounting bolt to specified torque. “Engine
Mounting Components”: K14B in Section 1D (Page
• Tighten front drive shaft nuts to specified torque, and
caulk drive shaft nuts. “Front Drive Shaft Assembly
Removal and Installation”: Front in Section 3A (Page
3A-3)
! CAUTION
Be sure to use new drive shaft nut.
• Tighten suspension arm ball joint bolts to specified
torque. “Front Wheel Hub, Steering Knuckle and
Wheel Bearing Removal and Installation”: Front in
Section 3A (Page 3A-13)
• Tighten tie-rod end nuts to specified torque. “Tie-Rod
End Removal and Installation” in Section 6C (Page
• Tighten front wheel speed sensor bolts to specified
torque.“Front Wheel Speed Sensor Removal and
Installation” in Section 4E (Page 4E-35)
• Tighten exhaust pipe bolts to specified torque.
“Exhaust System Components”: K14B in Section 1K
(Page 1K-2)
• Tighten wheel nuts to specified torque. “Wheel (with
Tire) Removal and Installation” in Section 2D (Page
2D-2)
• Tighten air cleaner outlet hose band to specified
torque. “Air Cleaner Components”: K14B in Section
1D (Page 1D-4)
• Set each clamp for wiring securely.
• Replenish the following oils.
– Transaxle: )(Page 5B-7)
• Bleed air from clutch system. )(Page 5C-4)
• Check function of engine, clutch and transaxle.
• Verify that there is no oil leakage, fluid leakage and
exhaust gas leakage at each connection.
• Confirm front wheel alignment. “Front Wheel
Alignment Inspection and Adjustment” in Section 2B
(Page 2B-1)
5B-13 Manual Transmission/Transaxle: K14B Model

Gear Shift and Select Shaft Assembly Components

AENBL80A5216011

3 (a)

2 (a)

3 (a)
5 (a)

2 (a)

6 (a)

4 (a)

4 (a) 3 (a)

IBL80A521001-01

1. Gear shift & select shaft assembly 6. 5th to reverse interlock guide bolt
2. Gear shift guide case No.1 bolt 7. Gasket
: For tightening order, refer to “Gear Shift and Select Shaft Assembly Removal and Installation”: K14B
Model (Page 5B-13).
3. Gear shift guide case No.2 bolt : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
: For tightening order, refer to “Gear Shift and Select Shaft Assembly Removal and Installation”: K14B
Model (Page 5B-13).
4. Gear shift guide case No.3 bolt : Do not reuse.
: For tightening order, refer to “Gear Shift and Select Shaft Assembly Removal and Installation”: K14B
Model (Page 5B-13).
5. Gear shift interlock bolt

Gear Shift and Select Shaft Assembly Removal

and Installation
AENBL80A5216012
4
Removal 4
1) Remove battery and battery tray with ECM. “Battery 3

Removal and Installation”: K14B in Section 1J (Page

1J-6)
2) Disconnect gear shift and gear select control cables
from transaxle.
3) Remove gear shift interlock bolt (1) and 5th to
reverse interlock guide bolt (2) from transaxle case. 1

4) Remove gear shift guide case bolts (4) and gear shift
& select shaft assembly (3).
2
IAP70A520011-01
 Manual Transmission/Transaxle: K14B Model 5B-14

Installation 3) Install new washer and 5th to reverse interlock guide

bolt and then tighten it to specified torque.
! CAUTION
! CAUTION
Be sure to use new bolt with pre-coated
adhesive. Otherwise, bolt may loosen. Be sure to use new 5th to reverse interlock
guide bolt with pre-coated adhesive.
1) Install gear shift & select shaft assembly in the Otherwise, bolt may loosen.
following procedure.
a) Install new gasket and gear shift & select shaft Tightening torque
assembly (1). 5th to reverse interlock guide bolt (e): 23 N·m (
b) Tighten gear shift guide case No.1, No.2 and 2.3 kgf-m, 17.0 lbf-ft)
No.3 bolts by hand.
(b)
! CAUTION
(c)
Be sure to use new gear shift guide case No.2
and No.3 bolts with pre-coated adhesive.
Otherwise, bolt may loosen.
1
(a)
c) Tighten gear shift guide case No.1 bolt to
specified torque.
Tightening torque
Gear shift guide case No.1 bolt* (a): 23 N·m (
(d)
2.3 kgf-m, 17.0 lbf-ft)
d) Tighten gear shift guide case No.2 and No.3
(e)
bolts to specified torque.
IAP70A520012-01

Tightening torque
Gear shift guide case No.2 bolt* (b): 23 N·m (
2.3 kgf-m, 17.0 lbf-ft)
Gear shift guide case No.3 bolt* (c): 23 N·m (
2.3 kgf-m, 17.0 lbf-ft)
2) Install new washer and gear shift interlock bolt, and
then tighten it to specified torque.
4) Connect gear shift and gear select control cables to
transaxle.
5) Install battery tray and battery. “Battery Removal and
Installation”: K14B in Section 1J (Page 1J-6)
6) Connect ECM connectors. “ECM Removal and
Installation”: K14B in Section 1C (Page 1C-1)

! CAUTION
Be sure to use new gear shift interlock bolt
with pre-coated adhesive. Otherwise, bolt
may loosen.

Tightening torque
Gear shift interlock bolt (d): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)
5B-15 Manual Transmission/Transaxle: K14B Model

Manual Transaxle Assembly Components

AENBL80A5216013

3
10 1217G (a)

32
6 (e)
39
40

OIL
7

33 A
43
2 1217G

35
8 34

14 (b)
38 (f)
5 1217G

34
41
9 1217G (a)
1 36
42 (c) 21 (d)

20

11 (c)

13 (c)
15 OIL
23
22 (c)
OIL

24
17 18
4 OIL
16
14 (b)
25
19

32
12 (b)
OIL

29 28
37 31 (b)
30
26
27 (b)

IAP70A520040-01

1. Transaxle right case 27. Reverse gear shift lever bolt

2. Transaxle left case 28. Reverse gear shaft
: Apply sealant 99000-31260 to mating surface of left case and right case.
3. Gear shift & select shaft assembly 29. Washer
: For details, refer to “Gear Shift and Select Shaft Assembly Removal and
Installation”: K14B Model (Page 5B-13).
4. Transaxle left case plate 30. Reverse idler gear
5. Transaxle side cover 31. Reverse gear shaft bolt
: Apply sealant 99000-31260 to mating surface of side cover and left case.
6. Back up light switch 32. Gasket
7. O-ring 33. Oil seal
: Apply transaxle oil to O-ring : Apply grease 99000-25011 to oil seal lip.
8. Differential assembly 34. Outer race
: For details, refer to “Differential Disassembly and Reassembly”: K14B Model
(Page 5B-35).
9. Oil level / filler plug 35. Shim
: Apply sealant 99000-31260 to threads.
10. Oil drain plug 36. Input oil gutter
: Apply sealant 99000-31260 to threads.
 Manual Transmission/Transaxle: K14B Model 5B-16

11. Oil gutter bolt 37. Input shaft & countershaft assembly
: For details, refer to “Input Shaft and Countershaft
Components”: K14B Model (Page 5B-26).
12. Left case plate bolt 38. Gear shift locating bolt
13. Side cover bolt 39. Breather plug
14. Transaxle case bolt 40. Breather hose
15. 5th speed synchronizer ring 41. Breather cover plate
16. 5th speed synchronizer lever 42. Breather cover plate bolt
17. 5th speed synchronizer sleeve & hub 43. Breather union
18. Circlip : 21 N⋅m (2.1 kgf-m, 15.5 lbf-ft)
19. Bearing set shim : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
20. Countershaft 5th gear : 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft)
21. Countershaft nut : 100 N⋅m (10.2 kgf-m, 74.0 lbf-ft)
: After tightening nut to specified torque, caulk nut securely.
22. 5th gear shift fork bolt : 19 N⋅m (1.9 kgf-m, 14.0 lbf-ft)
23. 5th gear shift fork : 13 N⋅m (1.3 kgf-m, 9.5 lbf-ft)
24. Needle bearing : Do not reuse.
25. Input shaft 5th gear : Apply transaxle oil.

26. Reverse gear shift lever

Fifth Gear Disassembly and Reassembly 3) Using snap ring pliers, remove circlip (1).
AENBL80A5216014
4) Remove 5th gear shift fork bolt (2).
Disassembly 5) Remove 5th gear shift fork (3) and 5th gear all
1) Remove gear shift & select shaft assembly. )(Page together. Use gear puller for removal if spline fitting
5B-13) of hub is tight.
2) Remove side cover bolts and take off transaxle side 3
cover (1) using special tool. 2

! CAUTION
1
Be sure not to distort side cover when it is
removed from transaxle left case.

Special tool
(A): 09921M96510

I4RH01520015-01

6) Unfasten caulking of countershaft nut (2), install

1
input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2).
Special tool
(A): 09927M76060

(A)
1

2
(A)

1
I9P60A522015-01
I4RH01520016-01
5B-17 Manual Transmission/Transaxle: K14B Model

7) Remove input shaft 5th gear, needle bearing and

then countershaft 5th gear (1). Gear puller (2) would
be necessary if spline fitting of countershaft 5th gear
is tight.

I9P60A522016-01

Reassembly
IAP70A520015-01
1) Install countershaft 5th gear (1) to countershaft as
6) Assemble 5th speed synchronizer sleeve (1), 5th
shown in figure.
speed synchronizer hub (2), 5th speed synchronizer
levers (3) and 5th speed synchronizer ring (4) as
[c]
follows.
[b]

[a]

IAP70A520014-01

[a]: Countershaft side [c]: Short flange (Outside)

[b]: Long flange (Inside)

2) Apply transaxle oil to needle bearing (3), and install it

to input shaft. I4RH01520054-01

3) Install input shaft 5th gear (1) to input shaft. a) Install 5th speed synchronizer hub (1) to 5th
speed synchronizer sleeve (2) in specified
4) Install special tool to stop shaft rotation.
direction as shown in figure.
Special tool
(A): 09927M76060 [b] 1

5) Tighten countershaft nut (2) to specified torque, and

[a]
caulk nut securely.
2
! CAUTION

• Be sure to use new countershaft nut.

• Be sure not to crack caulking part (4) of
countershaft nut while caulking it. Replace IAP70A520016-02

it with new one if it is cracked. [a]: Chamfered side [b]: Long boss

Tightening torque b) Fit 5th speed synchronizer levers (1) to 5th

Countershaft nut (a): 100 N·m (10.2 kgf-m, 74.0 speed synchronizer hub (2) by aligning
lbf-ft) protrusion (3) of 5th speed synchronizer levers
(1) with groove of 5th speed synchronizer hub
(2).
 Manual Transmission/Transaxle: K14B Model 5B-18

8) Tighten 5th gear shift fork bolt (2) to specified torque.

3
! CAUTION
Be sure to use new 5th gear shift fork bolt
1
3 with pre-coated adhesive. Otherwise, bolt
2 may loosen.

Tightening torque
5th gear shift fork bolt (a): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)
I9P60A522047-01
9) Using snap ring pliers, install new circlip (1) to input
c) Install 5th speed synchronizer ring (1) to 5th shaft (3) in specified direction as shown in figure.
speed synchronizer hub (2) in specified direction
as shown in figure. 2, (a) 3

3
5
2
1
4

I9P60A522050-02
I4RH01520055-01 4. 5th speed synchronizer hub 5. Polished surface
7) Fit 5th gear shift fork (1) to 5th speed synchronizer
sleeve (3) and 5th speed synchronizer hub (2) 10) Install side cover (1) to left case as follows.
assembly, and install them into input shaft and gear a) Clean mating surfaces of left case and side
shift shaft by aligning punch mark (4) with cover.
matchmark (5) on input shaft.
b) Apply specified amount of sealant to side cover
as shown in figure.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for side cover
“a”: 1.5 mm (0.059 in.)
c) Mate side cover with left case.
d) Tighten side cover bolts to specified torque.
Tightening torque
Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

“A”

“A”

(a)

IAP70A520017-01

11) Install gear shift & select shaft assembly. )(Page

5B-13)
I3RH0A520080-01
5B-19 Manual Transmission/Transaxle: K14B Model

Manual Transaxle Assembly Disassembly and

Reassembly (a
((a)
AENBL80A5216015 1a
a))

Disassembly
1) Remove gear shift & select shaft assembly. )(Page
5B-13)
2) Remove input shaft 5th gear and countershaft 5th
gear. )(Page 5B-16)
3) Remove left case plate bolts (3).
4) Remove left case plate (1) and bearing set shim (2).
5) Remove snap ring (6) using snap ring pliers (4).

3
1
5

3
I9P60A522018-02

2
5 4 IAP70A520018-02

7 9) Remove transaxle left case (1) from transaxle right

case (2) using special tool.
Special tool
(A): 09912M34510

I9P60A522019-01

5. Input shaft 7. Input shaft left bearing (A)

6) Remove back up light switch. )(Page 5B-10)

7) Remove reverse gear shaft bolt (1) with gasket.

2
IAP70A520019-01

I9P60A522021-01

8) Remove transaxle case bolts (1).

 Manual Transmission/Transaxle: K14B Model 5B-20

10) Remove reverse gear shift lever bolts (4) and

reverse gear shift lever (5).
11) Pull out reverse gear shaft (1) with washer (2), then
take off reverse idler gear (3).
12) Pull out 5th & reverse gear shift guide shaft (6)
together with 5th & reverse gear shift shaft (7).

NOTE
When removing 5th & reverse gear shift shaft I2RH01520035-01
(7) and guide shaft (6), push up high speed
15) Remove differential assembly from transaxle right
gear shift shaft and shift it to 4th to facilitate
case.
removal of 5th & reverse shift shaft.
Reassembly

! CAUTION
7
Be sure to use new bolt with pre-coated
adhesive. Otherwise, bolt may loosen.
6
1
2
1) Install differential assembly into transaxle right case.
3 2) Join input shaft (5), countershaft (4), low speed gear
5
shift shaft (2) and high speed gear shift shaft (3)
assemblies all together, then install them into
transaxle right case (1).

NOTE
• Be sure not to damage oil seal by input
shaft spline while installing.
• Make sure that countershaft is engaged
with final gear.
4
I9P60A522023-01

13) Remove countershaft left bearing outer race (1) from

transaxle left case (2) using special tool.
Special tool
(A): 09913M70123

I2RH01520080-01
2
(A) 3) Install 5th & reverse gear shift shaft (1) with 5th &
1 reverse gear shift guide shaft (2) into transaxle right
case (5). Reverse gear shift arm (4) has to be joined
with reverse gear shift lever (3) at the same time.

I9P60A522025-01

14) By tapping input shaft end with plastic hammer, push

it out as assembly from case a little, then remove
input shaft assembly (1), countershaft assembly (2),
high speed gear shift shaft (3) and low speed gear
shift shaft (4) all at once.
5B-21 Manual Transmission/Transaxle: K14B Model

6) Install right case to left case as follows.

a) Clean mating surfaces of right case and left
1 case.
b) Apply specified amount of sealant to left case (1)
2 as shown in figure.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
5
Sealant amount for left case
3
“a”: 1.5 mm (0.059 in.)

4
I9P60A522027-01

4) Mate reverse idler gear (1) with reverse gear shift

lever (2), insert reverse gear shaft (3) and washer (6)
into case (4) through idler gear and then align bolt
hole (7) on shaft with notch (8) on case. IAP70A520020-01

5) Tighten reverse gear shift lever bolts (5) to specified c) Mate right case with left case.
torque. 7) Tighten transaxle case bolts to specified torque.
! CAUTION Tightening torque
Transaxle case bolt (a): 23 N·m (2.3 kgf-m, 17.0
Be sure to use new reverse gear shift lever
lbf-ft)
bolt with pre-coated adhesive. Otherwise,
bolt may loosen.
(a)
Tightening torque
Reverse gear shift lever bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lbf-ft)

(a)

(a)

I9P60A522028-02

IAP70A520021-02
 Manual Transmission/Transaxle: K14B Model 5B-22

8) Install new reverse gear shaft bolt (1) and new

gasket, and tighten it to specified torque.
Tightening torque
Reverse gear shaft bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)

1,(a)
1
2

“a”

I9P60A521037-01
I9P60A522030-01

9) Install new snap ring (1) using snap ring pliers (4). b) Select a shim which fits the clearance measured
above.
2 4 Available shim thickness
3 Clearance Applicable shim
0.42 – 0.47 mm
0.55 mm (0.0217 in.)
(0.0166 – 0.0185 in.)
0.48 – 0.52 mm
0.60 mm (0.0236 in.)
(0.0189 – 0.0204 in.)
0.53 – 0.57 mm
1 0.65 mm (0.0256 in.)
(0.0209 – 0.0224 in.)
0.58 – 0.62 mm
0.70 mm (0.0276 in.)
(0.0229 – 0.0244 in.)
I7RW01520006-01 0.63 – 0.67 mm
0.75 mm (0.0295 in.)
2. Input shaft 3. Input shaft left bearing (0.0249 – 0.0263 in.)
0.68 – 0.72 mm
0.80 mm (0.0315 in.)
10) To seat countershaft left bearing outer race (1) to (0.0268 – 0.0283 in.)
bearing cone, tap countershaft left bearing outer 0.73 – 0.77 mm
0.85 mm (0.0335 in.)
race (1) using special tool and plastic hammer (3). (0.0288 – 0.0303 in.)
0.78 – 0.82 mm
Special tool 0.90 mm (0.0354 in.)
(0.0308 – 0.0322 in.)
(A): 09913M70123
0.83 – 0.87 mm
0.95 mm (0.0374 in.)
(0.0327 – 0.0342 in.)
0.88 – 0.92 mm
1.00 mm (0.0394 in.)
(0.0347 – 0.0362 in.)
3
0.93 – 0.97 mm
1.05 mm (0.0413 in.)
(0.0367 – 0.0381 in.)
2 0.98 – 1.02 mm
1.10 mm (0.0433 in.)
(0.0386 – 0.0401 in.)
1.03 – 1.07 mm
1.15 mm (0.0453 in.)
(0.0406 – 0.0421 in.)
1
I9P60A522031-01 c) Put the thickest spare part shim on bearing outer
2. Input shaft
race and install left case plate (2).
d) Tighten used bolts (1) to specified torque.
11) Select countershaft 5th gear shim as follows. Tightening torque
a) Push down bearing outer race and measure Left case plate bolt (a): 23 N·m (2.3 kgf-m,
clearance between transaxle right case and 17.0 lbf-ft)
bearing outer race using straight edge (1) and
feeler gauge (2). e) Turn countershaft (3) 10 times or more.
5B-23 Manual Transmission/Transaxle: K14B Model

NOTE
1, (a)
After tightening bolts, make sure that
countershaft (3) can be rotated by hand with
feeling certain load.

Tightening torque
Left case plate bolt (a): 23 N·m (2.3 kgf-m, 17.0
1, (a) lbf-ft)

1, (a)

1, (a)
I9P60A522032-01 1, (a)
4. Input shaft

f) Remove left case plate. 5

g) Place straight edge (1) over shim (3) and

3
compress it by hand through straight edge, and
measure “a” using feeler gauge (2).
1, (a)
Clearance between case surface and I9P60A522033-02
straightedge
5. Input shaft
“a”: 0.18 – 0.22 mm (0.0071 – 0.0087 in.)
h) If clearance “a” is out of specification, select 13) Install input shaft 5th gear and countershaft 5th gear.
suitable shim which adjusts clearance “a” to )(Page 5B-16)
specification and put it on bearing outer race. 14) Install gear shift & select shaft assembly. )(Page
5B-13)
NOTE
15) Install back up light switch. )(Page 5B-10)
Insert 0.2 mm (0.008 in.) feeler to know
whether or not a shim fulfills specification 16) Check input shaft for rotation in each gear position.
quickly. 17) Also confirm continuity of back up light switch with
gears in reverse position using ohmmeter.

Transaxle Right Case Disassembly and

Reassembly
AENBL80A5216016

Disassembly
1) Remove differential side bearing outer race (1) using
brass bar (2), if necessary.

1
I9P60A521048-02

12) Place left case plate (2) inserting its end in groove of
shift guide shaft (4), and then tighten new left case
plate bolts (1) to specified torque.
I9P60A522034-01

2) Remove input shaft oil seal using special tool, if

necessary.
 Manual Transmission/Transaxle: K14B Model 5B-24

Special tool
(A): 09913M75830

(A)

(B)
(A)

1
I9P60A522037-01

3) Install differential side bearing outer race using

special tool and hammer.
I9P60A522035-01

3) Pull out countershaft right bearing outer race using Special tool
special tools, if necessary. (A): 09924M74510
(B): 09925M14520
Special tool
(A): 09930M30104
(B): 09941M64511
(A)
(A)

(B)
(B)

I9P60A522038-01

Transaxle Left Case Disassembly and

I5RW0A520027-01 Reassembly
AENBL80A5216017
Reassembly
Disassembly
1) Install input shaft oil seal facing its spring side
upward until it becomes flush with case surface 1) Remove oil gutter (1) and breather cover plate (2), if
using special tool and hammer. Apply grease to oil necessary.
seal lip.
: Grease 99000–25011 (SUZUKI Super Grease A)
1
Special tool 2
(A): 09913M75830

(A)

IAP70A520022-01

2) Remove differential side oil seal. )(Page 5B-7).

3) Remove differential side bearing outer race (1) using
special tools, and then remove shim.
I9P60A522036-01
Special tool
2) Install countershaft right bearing outer race (1) using
(A): 09942M15511
special tools and hammer.
(B): 09944M96011
Special tool
(A): 09913M75821
(B): 09924M84510M004
5B-25 Manual Transmission/Transaxle: K14B Model

b) Measure distance “a” of differential assembly (1).

(A)
c) Measure depth “b” of left case (2) and “c” of right
case (3).
d) Calculate shim thickness by formula below.
(B)
Shim thickness = Depth “b” + Depth “c” – Distance “a”

1
I9P60A522040-01

Reassembly
1) Install oil gutter (1) and breather cover plate (2), if
removed.

! CAUTION
Be sure to use new oil gutter bolt and new
breather cover plate bolts with pre-coated
adhesive. Otherwise, bolt may loosen.

Tightening torque
Oil gutter bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
Breather cover plate bolt (b): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)

(a)

1
(b)
IAP70A520025-01
2
[a]: Press 35 N (3.6 kgf, 7.9 lbf)

3) Select shim closest to calculated shim thickness

from the following available sizes.
Available shim thickness
Calculated shim
Select shim
IAP70A520023-01 thickness
2) Select differential side shim as follows. 0.800 – 0.839 mm
1.00 mm (0.0394 in.)
a) Keep pressing outer race (4) with the power of (0.03150 – 0.03303 in.)
35 N (3.6 kgf, 7.9 lbf) by hand and turn 0.840 – 0.879 mm
1.04 mm (0.0409 in.)
differential case 10 times or more. (0.03307 – 0.03460 in.)
0.880 – 0.919 mm
1.08 mm (0.0425 in.)
(0.03465 – 0.03618 in.)
0.920 – 0.959 mm
1.12 mm (0.0441 in.)
(0.03622 – 0.03775 in.)
0.960 – 0.999 mm
1.16 mm (0.0457 in.)
(0.03780 – 0.03933 in.)
1.000 – 1.039 mm
1.20 mm (0.0472 in.)
(0.03938 – 0.04090 in.)
1.040 – 1.079 mm
1.24 mm (0.0488 in.)
(0.04095 – 0.04248 in.)
1.080 – 1.119 mm
1.28 mm (0.0504 in.)
(0.04252 – 0.04406 in.)
1.120 – 1.159 mm
1.32 mm (0.0520 in.)
(0.04410 – 0.04562 in.)
1.160 – 1.199 mm
1.36 mm (0.0535 in.)
(0.04567 – 0.04720 in.)
 Manual Transmission/Transaxle: K14B Model 5B-26

Calculated shim 4) Put shim, and then install differential side bearing
Select shim outer race using special tools.
thickness
1.200 – 1.239 mm Special tool
1.40 mm (0.0551 in.)
(0.04725 – 0.04877 in.) (A): 09924M74510
1.240 – 1.279 mm (B): 09925M14520
1.44 mm (0.0567 in.)
(0.04882 – 0.05035 in.)
1.280 – 1.319 mm
1.48 mm (0.0583 in.) (A)
(0.05040 – 0.05192 in.) (B)
1.320 – 1.359 mm
1.52 mm (0.0598 in.)
(0.05197 – 0.05350 in.)
1.360 – 1.399 mm
1.56 mm (0.0614 in.)
(0.05354 – 0.05508 in.)
1.400 – 1.439 mm
1.60 mm (0.0630 in.)
(0.05512 – 0.05665 in.)
1.440 – 1.479 mm
1.64 mm (0.0646 in.)
(0.05670 – 0.05822 in.) I5RW0A520032-01
1.480 – 1.529 mm 5) Install oil seal. )(Page 5B-7)
1.68 mm (0.0661 in.)
(0.05827 – 0.06019 in.)

Input Shaft and Countershaft Components

AENBL80A5216018

I3RH0A520017-01
5B-27 Manual Transmission/Transaxle: K14B Model
1. Input shaft
2. Oil seal
: Apply grease 99000-25011 to oil seal lip.
3. Input shaft right bearing
4. Input shaft 3rd gear
5. Needle bearing
6. High speed synchronizer ring
7. High speed synchronizer spring
8. High speed synchronizer sleeve & hub
9. High speed synchronizer key
10. Circlip
11. Input shaft 4th gear
12. Input shaft left bearing
13. Circlip
14. 5th gear spacer
15. Countershaft right bearing
16. Countershaft
17. Countershaft 1st gear
18. Low speed synchronizer ring
19. Low speed synchronizer spring
20. Low speed synchronizer sleeve & hub
21. Low speed synchronizer key
22. 2nd gear synchronizer outer ring
23. 2nd gear synchronizer center cone
24. 2nd gear synchronizer inner ring
25. Circlip
26. Countershaft 2nd gear
27. Countershaft 3rd gear
28. 3rd & 4th gear spacer
29. Countershaft 4th gear
30. Countershaft left bearing
: Do not reuse.
: Apply transaxle oil.
 Manual Transmission/Transaxle: K14B Model 5B-28

Input Shaft Disassembly and Reassembly

AENBL80A5216019

Disassembly
1) Remove input shaft right bearing (2) from input shaft
(1) using bearing puller (3) and hydraulic press.

I2RH01520097-01

1. Input shaft

6) Remove 3rd gear needle bearing from input shaft.

7) Disassemble synchronizer sleeve & hub assembly.

Reassembly
I4RH01520029-01
2) Remove 5th gear spacer (2), left bearing (3) and 4th
gear (4) all at once using puller (5) and hydraulic
press.
! CAUTION
To avoid gear teeth damage, support 4th gear
on flat side of bearing puller.
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new ones if
necessary.
2) Check clearance “a” between synchronizer ring (2)
and gear (1), key slot width “b” in synchronizer ring
and replace with new one, if necessary. Also, check
gear teeth for damage.
Clearance “a” between synchronizer ring and
gear
Standard: 1.0 – 1.4 mm (0.040 – 0.055 in.)
Service limit: 0.5 mm (0.020 in.)
Key slot width “b”
Standard: 10.0 – 10.2 mm (0.394 – 0.402 in.)
Limit: 10.45 mm (0.4114 in.)

I3RH0A520018-01

1. Input shaft

3) Remove 4th gear needle bearing and high speed

synchronizer ring.
4) Using snap ring pliers (2), remove circlip (1).

I5JB0A520054-01
I7RW01520007-01
3) To ensure lubrication of input shaft (1), blow air to oil
5) Remove high speed synchronizer sleeve & hub holes (2) as shown in figure and make sure that they
assembly (2) together with 3rd gear (3) using puller are free from any obstruction.
(4) and hydraulic press.

! CAUTION
To avoid gear teeth damage, support 3rd gear
on flat side of bearing puller.
5B-29 Manual Transmission/Transaxle: K14B Model

I2RH01520049-01

4) Fit high speed synchronizer sleeve (4) to hub (3), I3RH0A520019-01

insert 3 keys (2) in it and then set springs at
specified position (1) as shown in figure.
NOTE
• Be sure to assemble sleeve and hub in
correct direction. (No direction is specified
to each key.)
• High speed synchronizer sleeve, hub, keys
and springs are smaller in size than low
speed ones.
Synchronizer key installation position
“a” = “b”
6) Install 3rd gear needle bearing (4), apply oil to it,
then install 3rd gear (1) and synchronizer ring (2).
7) Install high speed sleeve & hub assembly (3) using
special tool and hydraulic press.
NOTE
• Make sure that synchronizer ring key slots
are aligned with keys (5) in sleeve & hub
assembly.
• Check free rotation of 3rd gear after press-
fitting sleeve & hub assembly.
Special tool
(A): 09913M84510

[c]
3 [a]

(A)

IAP70A520026-01

[a]: 4th gear side [c]: Projecting end

[b]: Short flange side
4 [b] 2
5) Install right bearing (1) to input shaft (2) using special IAP70A520027-01
tool and hydraulic press. [a]: 3rd gear side [c]: Long flange
[b]: Key way
Special tool
(A): 09913M80113
8) Install new circlip (1) to groove securely.
9) Install needle bearing (2), apply oil to it and then
install synchronizer ring (3) and 4th gear.
 Manual Transmission/Transaxle: K14B Model 5B-30

I2RH01520054-01
I2RH01520052-01
1. Countershaft
5. Input shaft

2) Apply puller (5) to 2nd gear (4), and remove 3rd &
10) Press-fit left bearing (2) using special tool and 4th gear spacer (2) and 3rd gear (3) together with
hydraulic press. 2nd gear using hydraulic press. Needle bearing
Special tool would come out with 2nd gear.
(A): 09913M80113 ! CAUTION
11) Using the same special tool at step 10), install 5th To avoid gear teeth damage, be sure to
gear spacer (1). support 2nd gear on flat side of bearing
! CAUTION puller.

To prevent 5th gear spacer (1) from being

distorted by excessive compression, do not
press-fit it with left bearing (2) at once.

I2RH01520055-01

1. Countershaft

3) Remove 2nd synchronizer outer ring, center cone

and inner ring.
4) Using snap ring pliers (3), remove circlip (1).
I3RH0A520020-01

Countershaft Disassembly and Reassembly

AENBL80A5216020

Disassembly
1) Remove left bearing cone (2) with 4th gear (3) using
puller (4) and hydraulic press.

! CAUTION
To avoid gear teeth damage, support 4th gear
I7RW01520008-01
(3) on flat side of puller.
2. Low speed synchronizer sleeve

5) Apply puller (3) to 1st gear (2) and remove low

speed synchronizer sleeve & hub assembly (1) with
1st gear using hydraulic press.
5B-31 Manual Transmission/Transaxle: K14B Model

! CAUTION Clearance “a” between synchronizer ring and

gear
To avoid gear teeth damage, support 1st gear Standard: 1.0 – 1.4 mm (0.040 – 0.055 in.)
on flat side of bearing puller. Service limit: 0.5 mm (0.020 in.)
• Key slot width
Key slot width “b”
Standard: 10.0 – 10.2 mm (0.394 – 0.401 in.)
Limit: 10.45 mm (0.411 in.)

I2RH01520057-01

6) Disassemble synchronizer sleeve & hub assembly.

7) Remove 1st gear needle bearing from shaft.
8) In order to remove right bearing (1) from
countershaft, grind with a grinder (2) one part “a” of
right bearing (1) as illustrated till it becomes thin.

! CAUTION
Be careful not to grind countershaft (3).

I5JB0A520079-01

• Each chamfered tooth of gear and synchronizer

3 2
ring for abnormal wear and damage
“a”
• Gear tooth for abnormal wear and damage
1
3 Replace it with new one if necessary.
1
3) Check the following:
• Difference between outer ring (1) and inner ring
I5RW0A520035-01 (3).
9) Break right bearing (2) at thin point with a chisel (1) Difference between synchronizer outer ring
to remove it. and inner ring (2nd) “a”
Standard: 0.95 – 1.25 mm (0.0375 – 0.0492 in.)
Service limit: 0.5 mm (0.0196 in.)
1

2
I5RW0A520036-01

Reassembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new one if IAP70A520028-01

necessary. 2. Center cone

2) Check the following:
• Clearance between synchronizer ring (2) and gear • Each chamfered tooth of gear and synchronizer
(1) ring for abnormal wear and damage
• Gear tooth for abnormal wear and damage
Replace it with new one if necessary.
 Manual Transmission/Transaxle: K14B Model 5B-32

4) To ensure lubrication of countershaft (1), blow air

into oil holes (2) as shown in figure and make sure
that they are free from any obstruction.
(A)

(B)
1

I2RH01520060-01
5) Fit low speed synchronizer sleeve (4) to hub (3),
insert 3 keys (2) in it and then set springs (1) at
specified position as shown in figure.
NOTE
• Be sure to assemble sleeve and hub in
correct direction. (No direction is specified
to each key.)
• Low speed synchronizer keys and springs
are larger than high speed ones in size.
Synchronizer key installation position
“a” = “b”
I5RW0A520038-01
7) Install needle bearing (4), apply oil to it, then install
1st gear (3).
8) Install synchronizer outer ring (2).
9) Install low speed sleeve & hub assembly (1) using
special tools and hydraulic press.
NOTE
• Support shaft with special tool as shown in
figure so that retainer of bearing cone will
be free from compression.
• Make sure that synchronizer ring key slots
(8) are aligned with keys (5) while press-
fitting sleeve & hub assembly.
• Check free rotation of 1st gear (3) after
press-fitting sleeve & hub assembly.

Special tool
(A): 09923M78210
(B): 09913M85210
(C): 09940M54910
(D): 09924M07710

IAP70A520029-01

[a]: 1st gear side

6) Install right bearing cone (1) to countershaft (2) using

special tools and hydraulic press.
Special tool
(A): 09913M76010
(B): 09924M07720

IAP70A520030-01

[a]: 1st gear side [b]: Short flange

5B-33 Manual Transmission/Transaxle: K14B Model

10) Install new circlip (1) to groove securely. 14) Press-fit 4th gear (2) using the same procedure as
11) Install needle bearing (2) and apply oil to needle step 11).
bearing. 15) Install left bearing cone (1) using special tool and
12) Install 2nd gear (6) with synchronizer outer ring (3), hydraulic press.
center cone (4) and inner ring (5) as shown in figure.
NOTE
For protection of bearing cone (3), be sure to
support shaft with special tool as shown in
figure.

Special tool
(A): 09923M78210
(E): 09913M80113

IAP70A520031-01

[A]: Section [a] – [a]

I2RH01520066-01

13) Press-fit 3rd gear (2) and spacer (1) using special
tools and hydraulic press.

NOTE
It is recommended to press-fit spacer and 3rd
gear first, and then 4th gear later separately
so that countershaft will not be compressed
excessively.

Special tool
(A): 09923M78210
(B): 09913M85210

I4RH01520036-01

3. 2nd gear
 Manual Transmission/Transaxle: K14B Model 5B-34

Gear Shift Shaft Components

AENBL80A5216021

7 (a)
6
8
9 (b)

3
1

10
5

I9P60A522043-01

1. Low speed gear shift shaft
2. High speed gear shift shaft
3. 5th & reverse gear shift shaft
4. 5th & reverse gear shift guide shaft
5. Reverse gear shift arm
6. 5th gear shift fork : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
7. Reverse gear shift lever bolt : 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft)
8. Reverse gear shift lever : Do not reuse.
9. 5th gear shift fork bolt
10. 5th & reverse gear shift yoke

5th and Reverse Gear Shift Shaft Disassembly NOTE

and Reassembly Install 2 steel balls (3) in reverse gear shift
AENBL80A5216022
Disassembly arm (1) without fail.
Disassemble component parts using special tool and
hammer.
Special tool
(A): 09922M85811 (A)

Reassembly
Reverse disassembly procedure noting the following
point.
• Use new spring pin.

I9P60A522044-01

2. Spring 6. 5th & reverse gear shift yoke

4. Spring pin 7. 5th & reverse gear shift guide shaft
5. 5th & reverse gear shift shaft
5B-35 Manual Transmission/Transaxle: K14B Model

Gear Shift Shaft and Fork Inspection

AENBL80A5216023
1) Using feeler gauge, check clearance between fork
(1) and sleeve (2) and replace those parts if it
exceeds specified value.
Clearance “a” between fork and sleeve
Service limit: 1.0 mm (0.039 in.)

I2RH01520068-01

2) Insert each gear shift shaft into case and check that
it moves smoothly. If it doesn’t, correct using
oilstone, reamer or the like.

Differential Components
AENBL80A5216024

1 2 3
4

8 (a)
2
10
1

3 9

4
5 7

5
I7V20A522033-01

1. Differential pinion washer 6. Differential case : 90 N⋅m (9.2 kgf-m, 66.5 lbf-ft)
2. Differential pinion 7. Final gear : Do not reuse.
3. Differential side gear 8. Final gear bolt : Apply transaxle oil.

4. Side gear washer 9. Differential pinion shaft

5. Differential side bearing 10. Differential pinion shaft pin

Differential Disassembly and Reassembly

AENBL80A5216025

Disassembly
(A)
1) Remove left bearing (1) using special tool. (B)
Special tool 1
(A): 09913M65135
(B): 09913M85230

I6RS0E520012-01
 Manual Transmission/Transaxle: K14B Model 5B-36

2) Remove right bearing in the same manner as step

1).
(A)
3) Support differential case (1) with soft jawed vise. [a]
4) Remove final gear bolts and remove final gear.
(B)
5) Remove differential pinion shaft pin using special
tool and hammer, and then disassemble
components parts.
Special tool
(A): 09922M85811

[b] (A)

(B)

I6RS0E520013-01 (C)
IAP70A520032-03
2. Differential side gear
2) Install new differential pinion shaft pin from right side
till the depth from differential case surface is about
Reassembly 1.2 mm (0.047 in.).
1) Install differential pinion, side gear and pinion shaft 3) Press-fit left bearing (1) using special tool and
to differential case, and measure backlash and thrust hydraulic press.
play of differential side gear using special tools as
follows. Special tool
If measured value is out of specification, select (A): 09951M16080
suitable side gear washer and check again.
Special tool
(A): 09900M20607
(B): 09900M20701
(C): 09952M06010
a) Differential side gear backlash [a]
• Hold differential assembly with soft jawed vise
and apply measuring tip of dial gauge to side
gear as shown in figure.
• Fixing differential pinion, turn side gear back
and forth and read dial gauge.
Differential side gear backlash
0.10 – 0.15 mm (0.0039 – 0.0059 in.)
b) Differential side gear thrust play [b]
• Hold differential assembly with soft jawed vise I2RH01520074-01

and apply measuring tip of dial gauge to side 2. Differential case

gear as shown in figure.
• Move side gear up and down by hand and 4) Press-fit right bearing (1) using special tools and
read dial gauge. hydraulic press.
Differential side gear thrust play Special tool
0.03 – 0.31 mm (0.001 – 0.012 in.) (A): 09925M15410
(B): 09940M54910
(C): 09913M85230
5B-37 Manual Transmission/Transaxle: K14B Model

! CAUTION
Be sure to use new bolt with pre-coated
adhesive. Otherwise, bolt may loosen.

Tightening torque
Final gear bolt (a): 90 N·m (9.2 kgf-m, 66.5 lbf-ft)

I6RS0E520038-01

2. Differential case 3. Differential side left bearing

5) Hold differential assembly with soft jawed vise (3),

I5RW0A520049-01
install final gear (2) and then tighten new final gear
bolts (1).

Specifications
Tightening Torque Specifications
AENBL80A5217001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Transaxle oil level / filler plug 21 2.1 15.5 )/)
Transaxle oil drain plug 21 2.1 15.5 )
Back up light switch 19 1.9 14.0 )
Gear shift guide case No.1 bolt* 23 2.3 17.0 )
Gear shift guide case No.2 bolt* 23 2.3 17.0 )
Gear shift guide case No.3 bolt* 23 2.3 17.0 )
Gear shift interlock bolt 23 2.3 17.0 )
5th to reverse interlock guide bolt 23 2.3 17.0 )
Countershaft nut 100 10.2 74.0 )
5th gear shift fork bolt 10 1.0 7.5 )
Side cover bolt 10 1.0 7.5 )
Reverse gear shift lever bolt 23 2.3 17.0 )
Transaxle case bolt 23 2.3 17.0 )
Reverse gear shaft bolt 23 2.3 17.0 )
Left case plate bolt 23 2.3 17.0 )/)
Oil gutter bolt 10 1.0 7.5 )
Breather cover plate bolt 10 1.0 7.5 )
Final gear bolt 90 9.2 66.5 )

NOTE
The tightening torque(s) also specified in:
“Gear Shift Control Lever and Cable Components”: K14B Model
“Manual Transaxle Unit Components”: K14B Model
“Gear Shift and Select Shaft Assembly Components”: K14B Model
“Manual Transaxle Assembly Components”: K14B Model
“Gear Shift Shaft Components”: K14B Model
“Differential Components”: K14B Model

Reference:
 Manual Transmission/Transaxle: K14B Model 5B-38

For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Recommended Service Material
AENBL80A5218001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 )/)/)
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 )/)/)/)/)

NOTE
Required service material(s) also described in:
“Gear Shift Control Lever and Cable Components”: K14B Model
“Manual Transaxle Assembly Components”: K14B Model
“Input Shaft and Countershaft Components”: K14B Model
“Differential Components”: K14B Model

Special Tool
AENBL80A5218002
09900M20607 09900M20701
Dial gauge Magnetic stand
) )

09912M34510 09913M50121
Case separator Oil seal remover
) )

09913M65135 09913M70123
Bearing puller Bearing installer
) )/)

09913M75821 09913M75830
Bearing installer attachment Steering pinion bush
installer
) )/)

09913M76010 09913M80113
Bearing installer Bearing installer
) )/)/)
5B-39 Manual Transmission/Transaxle: K14B Model

09913M84510 09913M85210
Bearing installer Bearing installer
) )/)

09913M85230 09921M96510
Bearing remover tool Oil pan seal cutter
)/) )

09922M85811 09923M78210
Spring pin remover (4.5 mm) Bearing installer
)/) )/)/)

09924M07710 09924M07720
Synchronizer hub installer Synchronizer hub installer
) )

09924M74510 09924M84510M004
Bearing and oil seal handle Bearing installer attachment
)/)/) )

09925M14520 09925M15410
Bearing and oil seal installer Oil seal installer
(80 x 50 mm)
)/) )

09927M76060 09930M30104
Gear holder Sliding shaft
)/) )

09940M54910 09941M64511
Front fork oil seal install Bearing and oil seal remover
driver (30 mm min.)
)/) )
 Manual Transmission/Transaxle: K14B Model 5B-40

09942M15511 09944M88220
Sliding hammer Oil seal installer
) )

09944M96011 09951M16080
Bearing outer race remover Bearing installer
) )

09952M06010
Dial gauge plate No.1
)
5B-41 Manual Transmission/Transaxle: D13A Model

D13A Model
General Description
Manual Transaxle Construction
AENBL80A5221001
The transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three
shafts - input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a
sliding idler gear arrangement.
The low speed sleeve & hub is mounted on countershaft and engaged with countershaft 1st gear or 2nd gear, while
the high speed sleeve & hub is mounted on input shaft and engaged with input shaft 3rd gear or 4th gear. The 5th
speed sleeve & hub on input shaft is engaged with input shaft 5th gear mounted on the input shaft.
To prevent the cracking noise from the reverse gear when shifting transaxle gear into the reverse gear, the reverse
shift braking device is used. This device utilizes the 5th synchromesh, which is the lever synchro type, to apply the
brake on the input shaft rotation.
The double cone synchronizing mechanism is provided to 1st and 2nd gear synchromesh device for high performance
of shifting to 1st and 2nd gear.
For servicing, it is necessary to use genuine sealant or its equivalent on mating surfaces of transaxle case which is
made of aluminum. The case fastening bolts must be tightened to specified torque by means of torque wrench. It is
also important that all parts are thoroughly cleaned with cleaning fluid and air dried before reassembling.
Further, care must be taken to adjust preload of countershaft taper roller bearings. New synchronizer rings are
prohibited from being lapped with respective gear cones by using lapping compound before they are assembled.

I9P60A522001-01

1. Input shaft 6. Input shaft 3rd gear 11. Countershaft 16. Countershaft 2nd gear
2. 5th speed sleeve & hub 7. Left case 12. Side cover 17. Low speed sleeve & hub
3. Input shaft 5th gear 8. Reverse gear shaft 13. Countershaft 5th gear 18. Countershaft 1st gear
 Manual Transmission/Transaxle: D13A Model 5B-42

4. Input shaft 4th gear 9. Reverse idler gear 14. Countershaft 4th gear 19. Final gear
5. High speed sleeve & hub 10. Right case 15. Countershaft 3rd gear 20. Differential case

Gear Shift Mechanism

The gear shifting control system consists of the following main parts. Movement of gear shift control lever is
transmitted to gear shift & select shaft through gear shift and gear select cables.

14

4 3

5 7
5
10

8
12

11 13

I9P60A522002-01

1. Gear shift control cable
2. Gear select control cable
3. Select cable lever
4. Shift cable lever
5. 5th gear shift fork
6. Reverse gear shift lever
7. 5th & reverse gear shift guide shaft
8. 5th & reverse gear shift shaft
9. Gear shift & select shaft assembly
10. Gear shift interlock bolt
11. Gear shift & select lever
12. Low speed gear shift shaft
13. High speed gear shift shaft
14. Gear shift control lever assembly

Reverse Shift Prevention Mechanism

Construction
In the gear shift lever case, the reverse shift limit yoke
(2) which turns around reverse shift limit yoke (2)
retainer is provided.
This reverse shift limit yoke (2) restricts the movement of
gear shift & select lever (1) to prevent erroneous reverse
shifting.
5B-43 Manual Transmission/Transaxle: D13A Model

3 [A]

1 2

[C] [B]

1 2 I9P60A521052-01

[A]: 5th [B]: Reverse [C]: 4th

3) If the reverse shifting force is still applied to the shift

lever, the cubic part of the gear shift & select lever
(1) rides over the projection of the reverse shift limit
yoke (2), and the gear is shifted into the 4th. The
reverse shift limit yoke (2) returns to its original
position.

[A]

I9P60A521054-01 2
3. Gear shift & select shaft assembly
1
Operation
1) If shifting directly from 5th [A] to reverse [B] is [C] [B]
attempted, the cubic part of the gear shift & select
lever (1) is blocked by the projection of the reverse
shift limit yoke (2).

1 [A] 1 [A]
I9P60A521053-01

2 2 [A]: 5th [B]: Reverse [C]: 4th

[C] [B] [C] [B]

I9P60A521051-01

[C]: 4th

2) Then the cubic part of the gear shift & select lever (1)
pushes the projection of the reverse shift limit yoke
(2). The reverse shift limit yoke (2) rotates and
pushes the gear shift & select lever (1) toward the
neutral position.
 Manual Transmission/Transaxle: D13A Model 5B-44
Diagnostic Information and Procedures
Manual Transaxle Symptom Diagnosis
Condition Possible cause
Gears slipping out of Worn shift fork shaft
mesh Worn shift fork or synchronizer sleeve
Worn bearings on input shaft or
countershaft
Worn chamfered tooth on sleeve and
gear
Hard shifting Inadequate lubricant
Improper clutch pedal free travel
Distorted or broken clutch disc
Damaged clutch pressure plate
Worn synchronizer ring
Worn chamfered tooth on sleeve or gear Replace synchronizer sleeve and gear
Worn gear shift control shaft joint
bushing
Distorted shift shaft
Broken gear shift / select control cables Replace gear shift and select cable. )(Page
AENBL80A5224001
Correction / Reference Item
Replace shift fork shaft. )(Page 5B-69)
Replace shift fork or synchronizer sleeve
referring to “Gear Shift Shaft Components”:
D13A Model (Page 5B-69), “Fifth Gear
Disassembly and Reassembly”: D13A Model
(Page 5B-52), “Input Shaft Disassembly and
Reassembly”: D13A Model (Page 5B-62) and/
or “Countershaft Disassembly and
Reassembly”: D13A Model (Page 5B-65).
Replace input shaft bearing or countershaft
bearing.
- Input shaft bearing: )(Page 5B-62)
- Countershaft bearing: )(Page 5B-65)
Replace synchronizer sleeve and gear
referring to “Fifth Gear Disassembly and
Reassembly”: D13A Model (Page 5B-52),
“Input Shaft Disassembly and Reassembly”:
D13A Model (Page 5B-62) and/or
“Countershaft Disassembly and Reassembly”:
D13A Model (Page 5B-65)
Replenish manual transaxle oil.
Replace clutch pedal arm or clutch master
cylinder.
- Clutch pedal arm: “Clutch Master Cylinder
Removal and Installation”: K14B Model in
Section 5C (Page 5C-6)
- Clutch master cylinder: “Clutch Master
Cylinder Removal and Installation”: D13A
Model in Section 5C (Page 5C-19)
Replace clutch disc. )(Page 5C-16)
Replace clutch cover. )(Page 5C-16)
Replace synchronizer ring.
- Input shaft bearing: )(Page 5B-62)
- Countershaft bearing: )(Page 5B-65)
referring to “Fifth Gear Disassembly and
Reassembly”: D13A Model (Page 5B-52),
“Input Shaft Disassembly and Reassembly”:
D13A Model (Page 5B-62) and/or
“Countershaft Disassembly and Reassembly”:
D13A Model (Page 5B-65)
Replace gear shift control shaft joint bushing.
)(Page 5B-49)
Replace shift shaft. )(Page 5B-69)
5B-47)
5B-45 Manual Transmission/Transaxle: D13A Model

Condition Possible cause Correction / Reference Item

Noise Inadequate or insufficient lubricant
Damaged or worn bearing(s)
Damaged or worn gear(s)
Damaged or worn synchronizer parts
Replenish manual transaxle oil.
Replace bearing referring to “Fifth Gear
Disassembly and Reassembly”: D13A Model
(Page 5B-52), “Input Shaft Disassembly and
Reassembly”: D13A Model (Page 5B-62) and/
or “Countershaft Disassembly and
Reassembly”: D13A Model (Page 5B-65)
Replace gear referring to “Fifth Gear
Disassembly and Reassembly”: D13A Model
(Page 5B-52), “Input Shaft Disassembly and
Reassembly”: D13A Model (Page 5B-62) and/
or “Countershaft Disassembly and
Reassembly”: D13A Model (Page 5B-65)
Replace synchronizer parts referring to “Fifth
Gear Disassembly and Reassembly”: D13A
Model (Page 5B-52), “Input Shaft Disassembly
and Reassembly”: D13A Model (Page 5B-62)
and/or “Countershaft Disassembly and
Reassembly”: D13A Model (Page 5B-65)

Repair Instructions
Manual Transaxle Oil Level Check
AENBL80A5226001
1) Hoist vehicle and check manual transaxle for oil
leakage. Repair leaky point, if any.
2) Remove oil level / filler plug (1). Check oil
contamination and check that oil level reaches lower
end of oil level / filler plug hole (2).
If oil is excessively dirty or insufficient, change oil or
replenish specified oil up to plug hole.
3) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (a): 21 N·m (2.1
kgf-m, 15.5 lbf-ft)
1, (a), “A”
Manual Transaxle Oil Change
AENBL80A5226002
1) Before changing oil, be sure to stop engine and hoist
vehicle horizontally.
2) With vehicle hoisted, check leakage.
If leakage exists, correct it.
3) Remove oil level / filler plug (2).
4) Remove drain plug (1), and drain oil.
5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m,
15.5 lbf-ft)
6) Replenish new specified oil until oil level reaches
lower end of oil filler plug hole (3) as shown in figure.
NOTE
It is highly recommended to use “API GL-4
75W-90 gear oil”.

Transaxle oil specification

: API GL-4 (For SAE classification, refer to
viscosity chart [A] in figure.)
Transaxle oil capacity (Reference)
: 2.6 liters (5.5/4.6 US/Imp. pt.)
2
7) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
I7V20A522003-01
 Manual Transmission/Transaxle: D13A Model 5B-46

Tightening torque NOTE

Transaxle oil level / filler plug (b): 21 N·m (2.1
kgf-m, 15.5 lbf-ft) • Be sure to install oil seal facing its spring
side inward.
• Be sure to install oil seal to surface of left
2, (b), “A” case (2) in parallel.

Special tool
(A): 09944M88220
(B): 09924M74510
Distance between case surface and oil seal
“a”: 0 – 1.0 mm (0 – 0.04 in.)
1, (a), “A” 5) Apply grease to oil seal lip and check drive shaft
where oil seal contacts for smoothness.

3
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)

“a”

[A]

(B)
(A) 1, “A”

2
IBP80A522004-01
I9P60A522005-02
[a]: Temperature
6) Insert left drive shaft assembly. )(Page 3A-3)
Differential Side Oil Seal Replacement 7) Replenish transaxle oil. )(Page 5B-45)
AENBL80A5226003
Left side Right side
1) Hoist vehicle and drain transaxle oil. 1) Remove drive intermediate shaft assembly. )(Page
2) Remove left drive shaft assembly. )(Page 3A-3) 3A-8)
3) Remove oil seal (1) by using special tool. 2) Remove rear engine mounting bracket.
Special tool 3) Remove oil seal (1) by using special tool.
(A): 09913M50121 Special tool
(A): 09913M50121

(A) 1
1
I9P60A522004-01

4) Install new oil seal (1) using special tool. (A)

I9P60A522006-01

4) Install new oil seal (1) using special tool.

5B-47 Manual Transmission/Transaxle: D13A Model

NOTE 3) Disconnect back up light switch connector (1).

• Be sure to install oil seal facing its spring 4) Remove back up light switch.
side inward.
• Be sure to install oil seal to surface of right
case (2) in parallel.

Special tool
(A): 09951M18211
Distance between case surface and oil seal
2 1
“a”: 0 – 1.0 mm (0 – 0.04 in.)
5) Apply grease to oil seal lip and check drive shaft
where oil seal contacts for smoothness.
“A”: Grease 99000–25011 (SUZUKI Super I9P60A522008-01

Grease A) 2. Gear shift & select shaft assembly

Installation
1) Apply oil to new O-ring (1) and tighten back up light
switch (2) to specified torque.
Tightening torque
(A) Back up light switch (a): 19 N·m (1.9 kgf-m, 14.0
lbf-ft)
“a”

2 1, “A” 1 2, (a)
I9P60A522007-02

6) Install rear engine mounting bracket. “Engine

Mounting Components”: D13A in Section 1D (Page
1D-77)
7) Install drive intermediate shaft assembly. )(Page
3A-8) I3RH0A520006-01

8) Install engine with transaxle. “Engine Assembly 2) Connect back up light switch connector.
Removal and Installation”: D13A in Section 1D 3) Install battery tray and battery, and then install
(Page 1D-77) coolant reservoir to battery tray. )(Page 1J-19)
9) Replenish transaxle oil. )(Page 5B-45)
Back Up Light Switch Inspection
AENBL80A5226008
Gear Shift Control Lever and Cable
Components
AENBL80A5226004
Refer to “Gear Shift Control Lever and Cable
Components”: K14B Model (Page 5B-8).

Gear Shift Control Lever and Cable Removal

and Installation
AENBL80A5226005
Refer to “Gear Shift Control Lever and Cable Removal
and Installation”: K14B Model (Page 5B-9)

Gear Select Control Cable Adjustment

AENBL80A5226006
Refer to “Gear Select Control Cable Adjustment”: K14B
Model (Page 5B-9).

Back Up Light Switch Removal and Installation

AENBL80A5226007
Removal
1) Remove coolant reservoir from coolant reservoir
bracket.
2) Remove battery and battery tray. )(Page 1J-19)
 Manual Transmission/Transaxle: D13A Model 5B-48

Manual Transaxle Unit Components

AENBL80A5226009

3 (b)

3 (b)
3 (a)
[A]

3 (b)

3 (a)
I9P60A522009-02

[A]: Forward 2. Transaxle : 55 N⋅m (5.6 kgf-m, 40.5 lbf-ft.)

1. Engine 3. Transaxle-engine bolt : 85 N⋅m (8.7 kgf-m, 63.0 lbf-ft)

Manual Transaxle Unit Dismounting and

Remounting
AENBL80A5226010
Dismounting
1) Remove engine with transaxle. “Engine Assembly
Removal and Installation”: D13A in Section 1D
(Page 1D-77)
2) Remove left drive shaft assembly and drive
intermediate shaft assembly.
- Left drive shaft assembly: )(Page 3A-3)
- Intermediate shaft assembly: )(Page 3A-8)
3) Remove starting motor. )(Page 1I-11)
4) Remove rear engine mounting bracket (1).

I9P60A522010-01

5) Remove other attached parts from transaxle, if any.

6) Remove transaxle-engine bolts.
7) Pull out transaxle from engine so as to disconnect
input shaft from clutch disc.
5B-49 Manual Transmission/Transaxle: D13A Model

Remounting • Tighten each bolt to specified torque. )(Page 5B-48)

Reverse dismounting procedure, noting the following • Set each clamp for wiring securely.
points.
• Check function of engine, clutch and transaxle.

Gear Shift and Select Shaft Assembly Components

AENBL80A5226011

(a) 2
3 (a)

1
4 (a)

5 (a)

IBP80A522001-01

1. Gear shift & select shaft assembly 5. 5th to reverse interlock guide bolt
2. Gear shift guide case No.1 bolt : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
3. Gear shift guide case No.2 bolt : Do not reuse.
4. Gear shift interlock bolt

Gear Shift and Select Shaft Assembly Removal

and Installation 3
AENBL80A5226012
5
Removal
1) Remove coolant reservoir from coolant reservoir 5
bracket. 4
2) Remove battery and battery tray. )(Page 1J-19)
3) Disconnect gear shift and gear select control cables
from transaxle.
4) Remove gear shift interlock bolt (1) and 5th to
2 1
reverse interlock guide bolt (2) from transaxle case. I9P60A522012-01
5) Remove gear shift guide case bolts (5) and gear shift 4. Transaxle side cover
& select shaft assembly (3).
 Manual Transmission/Transaxle: D13A Model 5B-50

Installation 4) Install new washer and new 5th to reverse interlock

! CAUTION
Be sure to use new bolt with pre-coated
adhesive. Otherwise, bolt may loosen.
guide bolt (4) and then tighten it to specified torque.
Tightening torque
5th to reverse interlock guide bolt (d): 23 N·m (
2.3 kgf-m, 17.0 lbf-ft)

1) Clean mating surface of gear shift guide case (1) and

transaxle left case (5), apply sealant to left case as
shown in figure, mate guide case with left case. 1

“B”: Sealant 99000–31260 (SUZUKI Bond 2,(c)

No.1217G)
Sealant amount for left case 6,(a)
“a”: 1.5 mm (0.059 in.)
2) Install gear shift & select shaft assembly in the 7,(b)
following procedure.
a) Hand-tighten new gear shift guide case No.1
bolts (6), (7) and No.2 bolts (2). 4,(d) 3,(e)
b) Tighten gear shift guide case No.1 bolt (6) to
specified torque.
Tightening torque
Gear shift guide case No.1 bolt (a): 23 N·m (
2.3 kgf-m, 17.0 lbf-ft)
c) Tighten gear shift guide case No.1 bolt (7) and
No.2 bolts (2) to specified torque.
Tightening torque
Gear shift guide case No.1 bolt (b): 23 N·m (2.3 I9P60A522013-03
kgf-m, 17.0 lbf-ft) 5) Connect gear shift and gear select control cables to
Gear shift guide case No.2 bolt (c): 23 N·m (2.3 transaxle.
kgf-m, 17.0 lbf-ft)
6) Install battery tray and battery, and then install
3) Install new washer and new gear shift interlock bolt coolant reservoir to coolant reservoir bracket.
(3), and then tighten it to specified torque. )(Page 1J-19)
Tightening torque 7) Check input shaft for rotation in each gear position.
Gear shift interlock bolt (e): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)
5B-51 Manual Transmission/Transaxle: D13A Model

Manual Transaxle Assembly Components

AENBL80A5226013

10 1217G (a)
3

6 (e)
41 42

OIL
7

33 A
45
2 1217G

35
37 (c) 34
OIL

7 8

14 (b)
40 (f)
38 5 1217G

34
43
9 1217G (a)
36
44 (c)
21 (d)

20
1 11 (c)
22 (c)
23
OIL
15
18 13 (c)
OIL

24
17
4 OIL
16
14 (b)
25
33 A
19

12 (b)
32

31 (b)
OIL

29 28
39 30
26
27 (b)

IBP80A522002-01

1. Transaxle right case 28. Reverse gear shaft

2. Transaxle left case 29. Washer
: Apply sealant 99000-31260 to mating surface of left case and right
case.
3. Gear shift & select shaft assembly 30. Reverse idler gear
: For details, refer to “Gear Shift and Select Shaft Assembly Removal
and Installation”: D13A Model (Page 5B-49).
4. Transaxle left case plate 31. Reverse gear shaft bolt
5. Transaxle side cover 32. Gasket
: Apply sealant 99000-31260 to mating surface of side cover and left
case.
6. Back up light switch 33. Oil seal
: Apply grease 99000-25011 to oil seal lip.
7. O-ring 34. Outer race
: Apply transaxle oil to O-ring
8. Differential assembly 35. Shim
: For details, refer to “Differential Disassembly and Reassembly”: D13A
Model (Page 5B-70).
9. Oil level / filler plug 36. Input oil gutter
: Apply sealant 99000-31260 to threads.
 Manual Transmission/Transaxle: D13A Model 5B-52

10. Oil drain plug 37. Sensor bolt

: Apply sealant 99000-31260 to threads.
11. Oil gutter bolt 38. VSS
12. Left case plate bolt 39. Input shaft & countershaft assembly
: For details, refer to “Input Shaft and Countershaft
Components”: D13A Model (Page 5B-62).
13. Side cover bolt 40. Gear shift locating bolt
14. Transaxle case bolt 41. Breather plug
15. 5th speed synchronizer ring 42. Breather hose
16. 5th speed synchronizer lever 43. Breather cover plate
17. 5th speed synchronizer sleeve & hub 44. Breather cover plate bolt
18. Circlip 45. Breather union
19. Bearing set shim : 21 N⋅m (2.1 kgf-m, 15.5 lbf-ft)
20. Countershaft 5th gear : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
21. Countershaft nut : 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft)
: After tightening nut to specified torque, caulk nut securely.
22. 5th gear shift fork bolt : 100 N⋅m (10.2 kgf-m, 74.0 lbf-ft)
23. 5th gear shift fork : 19 N⋅m (1.9 kgf-m, 14.0 lbf-ft)
24. Needle bearing : 13 N⋅m (1.3 kgf-m, 9.5 lbf-ft)
25. Input shaft 5th gear : Do not reuse.
26. Reverse gear shift lever : Apply transaxle oil.

27. Reverse gear shift lever bolt

Fifth Gear Disassembly and Reassembly 5) Remove 5th gear shift fork (3) and 5th gear all
AENBL80A5226014 together. Use gear puller for removal if spline fitting
of hub is tight.
Disassembly
1) Remove gear shift & select shaft assembly. )(Page 3
2
5B-49)
2) Remove side cover bolts and take off transaxle side
cover (1) using special tool. 1

! CAUTION
Be sure not to distort side cover when it is
removed from transaxle left case.

Special tool
(A): 09921M96510 I4RH01520015-01

6) Unfasten caulking of countershaft nut (2), install

input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
1 (2).
Special tool
(A): 09927M76060

(A)

2
1

(A)

I4RH01520016-01

7) Remove input shaft 5th gear, needle bearing and

I9P60A522015-01 then countershaft 5th gear (1). Gear puller (2) would
3) Using snap ring pliers, remove circlip (1). be necessary if spline fitting of countershaft 5th gear
4) Remove 5th gear shift fork bolt (2). is tight.
5B-53 Manual Transmission/Transaxle: D13A Model

I9P60A522016-01

Reassembly
1) Install countershaft 5th gear (1) to countershaft as
shown in figure.

I7V20A522015-01
[C] 6) Assemble 5th speed synchronizer sleeve (1), 5th
[B]
speed synchronizer hub (2), 5th speed synchronizer
levers (3) and 5th speed synchronizer ring (4) as
follows.
[A]

I9P60A522045-02

[A]: Countershaft side

[B]: Long flange (Inside)
[C]: Short flange (Outside)

2) Apply transaxle oil to needle bearing (3), and install it

to input shaft.
3) Install input shaft 5th gear (1) to input shaft.
4) Install special tool to stop shaft rotation. I4RH01520054-01

Special tool a) Install 5th speed synchronizer hub (1) to 5th

(A): 09927M76060 speed synchronizer sleeve (2) in specified
direction as shown in figure.
5) Tighten new countershaft nut (2) to specified torque,
and caulk nut securely. [B] 1

Tightening torque
Countershaft nut (a): 100 N·m (10.2 kgf-m, 74.0 [A]

lbf-ft)
2

I9P60A522046-02

[A]: Chamfered side

[B]: Long boss

b) Fit 5th speed synchronizer levers (1) to 5th

speed synchronizer hub (2) by aligning
protrusion (3) of 5th speed synchronizer levers
(1) with groove of 5th speed synchronizer hub
(2).
 Manual Transmission/Transaxle: D13A Model 5B-54

Tightening torque
3 5th gear shift fork bolt (a): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)

1 9) Using snap ring pliers, install new circlip (1) to input

3
shaft (3) in specified direction as shown in figure.
2
! CAUTION
If the circlip is expanded beyond necessity
while installing the circlip, the circlip will
remain deformed.
I9P60A522047-01 Do not expand the circlip beyond necessity.
c) Install 5th speed synchronizer ring (1) to 5th
speed synchronizer hub (2) in specified direction
as shown in figure. 2, (a) 3

3
5
2 1
4

I9P60A522050-02

I4RH01520055-01 4. 5th speed synchronizer hub 5. Polished surface

7) Fit 5th gear shift fork (1) to 5th speed synchronizer
sleeve (3) and 5th speed synchronizer hub (2)
assembly, and install them into input shaft and gear
shift shaft by aligning punch mark (4) with
matchmark (5) on input shaft.
10) Clean mating surface of both left case and side
cover (1), apply sealant to side cover as shown in
figure, mate it with left case, and then tighten side
cover bolts with specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for side cover
“a”: 1.5 mm (0.059 in.)
Tightening torque
Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

“B”

(a) (a)
1
(a)

(a)
(a)

(a)
I3RH0A520080-01

8) Tighten new 5th gear shift fork bolt (2) to specified (a) (a)
torque.
(a)
I9P60A522017-01
5B-55 Manual Transmission/Transaxle: D13A Model

11) Install gear shift & select shaft assembly. )(Page

5B-49)

Manual Transaxle Assembly Disassembly and

Reassembly
AENBL80A5226015

Disassembly
1) Remove gear shift & select shaft assembly. )(Page
5B-49)
2) Remove input shaft 5th gear and countershaft 5th I9P60A522021-01
gear. )(Page 5B-52) 8) Remove transaxle case bolts (1).
3) Remove left case plate bolts (3). 9) Remove transaxle left case (2) from transaxle right
4) Remove left case plate (1) and bearing set shim (2). case (3) using special tool.
5) Remove snap ring (6) using snap ring pliers (4). Special tool
(A): 09912M34510
3

2 (A)

3
3

1
1

3
I9P60A522018-02 1
1

2
5 4

1 1
I9P60A522022-03

6 10) Remove reverse gear shift lever bolts (4) and

reverse gear shift lever (5).
11) Pull out reverse gear shaft (1) with washer (2), then
I9P60A522019-01 take off reverse idler gear (3).
5. Input shaft 12) Pull out 5th & reverse gear shift guide shaft (6)
7. Input shaft left bearing together with 5th & reverse gear shift shaft (7).

6) Remove back up light switch. )(Page 5B-47)

7) Remove reverse gear shaft bolt (1) with gasket.
 Manual Transmission/Transaxle: D13A Model 5B-56

NOTE Reassembly
When removing 5th & reverse gear shift shaft ! CAUTION
(7) and guide shaft (6), push up high speed
gear shift shaft and shift it to 4th to facilitate Be sure to use new bolt with pre-coated
removal of 5th & reverse shift shaft. adhesive. Otherwise, bolt may loosen.

1) Install differential assembly into transaxle right case.

2) Join input shaft (5), countershaft (4), low speed gear
7 shift shaft (2) and high speed gear shift shaft (3)
assemblies all together, then install them into
6 transaxle right case (1).
1
2 NOTE
3
• Be sure not to damage oil seal by input
5 shaft spline while installing.
• Make sure that countershaft is engaged
with final gear.

4
I9P60A522023-01

13) Remove countershaft left bearing outer race (1) from

transaxle left case (2) using special tool. I2RH01520080-01

3) Install 5th & reverse gear shift shaft (1) with 5th &
Special tool
reverse gear shift guide shaft (2) into transaxle right
(A): 09913M70123
case (5). Reverse gear shift arm (4) has to be joined
with reverse gear shift lever (3) at the same time.

2
(A)
1
1
2

3
I9P60A522025-01

14) By tapping input shaft end with plastic hammer, push

it out as assembly from case a little, then remove
input shaft assembly (1), countershaft assembly (2),
high speed gear shift shaft (3) and low speed gear
shift shaft (4) all at once.

4
I9P60A522027-01

4) Mate reverse idler gear (1) with reverse gear shift

lever (2), insert reverse gear shaft (3) and washer (6)
into case (4) through idler gear and then align bolt
hole (7) on shaft with notch (8) on case.
5) Tighten new reverse gear shift lever bolts (5) to
I2RH01520035-01
specified torque.
15) Remove differential assembly from transaxle right
case.
5B-57 Manual Transmission/Transaxle: D13A Model

Tightening torque
Reverse gear shift lever bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lbf-ft)

8 3, (a)

3, (a) 3, (a)

1
3, (a) 3, (a)
I9P60A522029-02

8) Install new reverse gear shaft bolt (1), with new

gasket and tighten it to specified torque.
Tightening torque
I9P60A522028-02
Reverse gear shaft bolt (a): 23 N·m (2.3 kgf-m,
6) Clean mating surfaces of both transaxle right and left 17.0 lbf-ft)
cases, apply sealant to transaxle left case (2) as
shown in figure, then mate it with transaxle right
case (1).
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G) 1,(a)
Sealant amount for left case
“a”: 1.5 mm (0.059 in.)
7) Tighten transaxle case bolts (3) to specified torque.
Tightening torque
Transaxle case bolt (a): 23 N·m (2.3 kgf-m, 17.0
I9P60A522030-01
lbf-ft)
9) Install new snap ring (1) using snap ring pliers (4).

2 4

I7RW01520006-01

2. Input shaft
3. Input shaft left bearing
 Manual Transmission/Transaxle: D13A Model 5B-58

10) To seat countershaft left bearing outer race (1) to Clearance Applicable shim
bearing cone, and tap countershaft left bearing outer 0.73 – 0.77 mm
race (1) by using special tool and plastic hammer 0.95 mm (0.0374 in.)
(0.0287 – 0.0303 in.)
(3). 0.78 – 0.82 mm
1.00 mm (0.0393 in.)
Special tool (0.0307 – 0.0322 in.)
(A): 09913M70123 0.83 – 0.87 mm
1.05 mm (0.0413 in.)
(0.0326 – 0.0342 in.)
0.88 – 0.92 mm
1.10 mm (0.0433 in.)
(0.0346 – 0.0362 in.)
3
0.93 – 0.97 mm
1.15 mm (0.0452 in.)
(0.0366 – 0.0381 in.)
0.98 – 1.02 mm
1.20 mm (0.0472 in.)
2 (0.0385 – 0.0401 in.)

c) Put the thickest spare part shim on bearing outer

race and install left case plate (2).
1 d) Tighten used bolts (1) to specified torque.
I9P60A522031-01
Tightening torque
2. Input shaft
Left case plate bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)
11) Select countershaft 5th gear shim as follows.
a) Push down bearing outer race and measure e) Turn countershaft (3) 10 times or more.
clearance “a” between transaxle right case and
1, (a)
bearing outer race using straightedge (1) and
feeler gauge (2).

1, (a)

1
1, (a)
2 I9P60A522032-01

4. Input shaft
“a”

f) Remove left case plate.

I9P60A521037-01 g) Place straightedge (1) over shim (3) and
b) Select a shim which fits the clearance measured compress it by hand through straightedge, and
above. measure “a” using feeler gauge (2).
Available shim thickness Clearance between case surface and
Clearance Applicable shim straightedge
0.42 – 0.47 mm “a”: 0.18 – 0.22 mm (0.0071 – 0.0087 in.)
0.65 mm (0.0225 in.)
(0.0165 – 0.0185 in.) h) If clearance “a” is out of specification, select
0.48 – 0.52 mm suitable shim which adjusts clearance “a” to
0.70 mm (0.0275 in.)
(0.0188 – 0.0204 in.) specification and put it on bearing outer race.
0.53 – 0.57 mm
0.75 mm (0.0295 in.)
(0.0208 – 0.0224 in.)
0.58 – 0.62 mm
0.80 mm (0.0314 in.)
(0.0228 – 0.0244 in.)
0.63 – 0.67 mm
0.85 mm (0.0334 in.)
(0.0248 – 0.0263 in.)
0.68 – 0.72 mm
0.90 mm (0.0354 in.)
(0.0267 – 0.0283 in.)
5B-59 Manual Transmission/Transaxle: D13A Model

NOTE 17) Also confirm continuity of back up light switch with

Insert 0.2 mm (0.008 in.) feeler to know gears in reverse position using ohmmeter.
whether or not a shim fulfills specification
quickly. Transaxle Right Case Disassembly and
Reassembly
AENBL80A5226016

Disassembly
1) Remove differential side bearing outer race (1) using
brass bar (2), if necessary.

I9P60A521048-02

12) Place left case plate (2) inserting its end in groove of I9P60A522034-01

shift guide shaft (4), and then tighten new left case 2) Remove input shaft oil seal by using special tool, if
plate bolts (1) to specified torque. necessary.

NOTE Special tool

(A): 09913M75830
After tightening bolts, make sure that
countershaft (3) can be rotated by hand with
feeling certain load.

Tightening torque
Left case plate bolt (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft) (A)

1, (a)

I9P60A522035-01

3) Pull out countershaft right bearing outer race by

1, (a) using special tools, if necessary.
Special tool
5
(A): 09930M30104
(B): 09941M64511
3
(A)

(B)
1, (a)
I9P60A522033-02

5. Input shaft

13) Install input shaft 5th gear and countershaft 5th gear.
)(Page 5B-52)
14) Install gear shift & select shaft assembly. )(Page
5B-49)
I5RW0A520027-01
15) Install back up light switch. )(Page 5B-47) 4) Remove differential side oil seal from transaxle right
16) Check input shaft for rotation in each gear position. case, if necessary. )(Page 5B-46)
 Manual Transmission/Transaxle: D13A Model 5B-60

Reassembly Transaxle Left Case Disassembly and

1) Install input shaft oil seal facing its spring side Reassembly
AENBL80A5226017
upward until it becomes flush with case surface
using special tool and hammer. Apply grease to oil
Disassembly
seal lip.
1) Remove oil gutter (1), if necessary.
: Grease 99000–25011 (SUZUKI Super Grease A)
Special tool
(A): 09913M75830
1

(A)

I9P60A522036-01

2) Install countershaft right bearing outer race (1) by

using special tools and hammer.
I9P60A522039-02
Special tool
(A): 09913M75821 2) Remove differential side oil seal referring to
(B): 09924M84510M004 “Differential Side Oil Seal Replacement”: D13A
Model (Page 5B-46).
3) Remove differential side bearing outer race (1) using
special tools, and then remove shim.
(A)
Special tool
(A): 09942M15511
(B): 09944M96011
(B)
(A)

1
I9P60A522037-01 (B)

3) Install differential side bearing outer race by using

special tool and hammer.
Special tool
(A): 09924M74510
(B): 09925M14520 1
I9P60A522040-01

Reassembly
(A) 1) If oil gutter has been removed, tighten new oil gutter
bolt to specified torque.
Tightening torque
(B)
Oil gutter bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

I9P60A522038-01

4) Install differential side oil seal, if removed. )(Page

5B-46)
5B-61 Manual Transmission/Transaxle: D13A Model

Available shim thickness

Calculated shim
Select shim
thickness
(a)
0.800 – 0.839 mm
1.00 mm (0.0394 in.)
(0.03149 – 0.03303 in.)
0.840 – 0.879 mm
1.04 mm (0.0409 in.)
(0.03307 – 0.03461 in.)
0.880 – 0.919 mm
1.08 mm (0.0425 in.)
(0.03465 – 0.03618 in.)
0.920 – 0.959 mm
1.12 mm (0.0441 in.)
(0.03622 – 0.03776 in.)
0.960 – 0.999 mm
1.16 mm (0.0457 in.)
(0.03780 – 0.03933 in.)
1.000 – 1.039 mm
1.20 mm (0.0472 in.)
(0.03937 – 0.04091 in.)
1.040 – 1.079 mm
1.24 mm (0.0488 in.)
(0.04094 – 0.04248 in.)
I9P60A522041-01 1.080 – 1.119 mm
1.28 mm (0.0504 in.)
2) Select differential side shim as follows. (0.04252 – 0.04406 in.)
a) Keep pressing outer race (4) with the power of 1.120 – 1.159 mm
1.32 mm (0.0520 in.)
35 N (3.6 kgf, 7.9 lbf) by hand and turn (0.04409 – 0.04563 in.)
differential case 10 times or more. 1.160 – 1.199 mm
1.36 mm (0.0535 in.)
(0.04567 – 0.04720 in.)
b) Measure distance “a” of differential assembly (1).
1.200 – 1.239 mm
c) Measure depth “b” of left case (2) and “c” of right 1.40 mm (0.0551 in.)
(0.04724 – 0.04878 in.)
case (3). 1.240 – 1.279 mm
1.44 mm (0.0567 in.)
d) Calculate shim thickness by formula below. (0.04882 – 0.05035 in.)
Shim thickness = Depth “b” + Depth “c” – Distance “a” 1.280 – 1.319 mm
1.48 mm (0.0583 in.)
(0.05039 – 0.05193 in.)
1.320 – 1.359 mm
1.52 mm (0.0598 in.)
(0.05197 – 0.05350 in.)
1.360 – 1.399 mm
1.56 mm (0.0614 in.)
(0.05354 – 0.05508 in.)
1.400 – 1.439 mm
1.60 mm (0.0630 in.)
(0.05512 – 0.05665 in.)
1.440 – 1.479 mm
1.64 mm (0.0646 in.)
(0.05669 – 0.05823 in.)
1.480 – 1.529 mm
1.68 mm (0.0661 in.)
(0.05827 – 0.06020 in.)

4) Put shim, and then install differential side bearing

outer race using special tools.
Special tool
(A): 09924M74510
(B): 09925M14520

(A)
(B)

I9P60A522042-01

[A]: Press 35 N (3.5 kgf, 7.9 lbf)

I5RW0A520032-01
3) Select shim closest to calculated shim thickness
from the following available sizes. 5) Install oil seal. )(Page 5B-46)

Input Shaft and Countershaft Components
1. Input shaft
2. Oil seal
: Apply grease 99000-25011 to oil seal lip.
3. Input shaft right bearing
4. Input shaft 3rd gear
5. Needle bearing
6. High speed synchronizer ring
7. High speed synchronizer spring
8. High speed synchronizer sleeve & hub
9. High speed synchronizer key
10. Circlip
11. Input shaft 4th gear
Input Shaft Disassembly and Reassembly
AENBL80A5226019
Disassembly
1) Remove input shaft right bearing (2) from input shaft
(1) using bearing puller (3) and hydraulic press.
Manual Transmission/Transaxle: D13A Model 5B-62
12. Input shaft left bearing
13. Circlip
14. 5th gear spacer
15. Countershaft right bearing
16. Countershaft
17. Countershaft 1st gear
18. Countershaft left bearing
19. Low speed synchronizer spring
20. Low speed synchronizer sleeve & hub
21. Low speed synchronizer key
22. 2nd gear synchronizer outer ring
AENBL80A5226018
I6RS0E520008-01
23. 2nd gear synchronizer center cone
24. 2nd gear synchronizer inner ring
25. Circlip
26. Countershaft 2nd gear
27. Countershaft 3rd gear
28. 3rd & 4th gear spacer
29. Countershaft 4th gear
: Do not reuse.
: Apply transaxle oil.
5B-63 Manual Transmission/Transaxle: D13A Model

I2RH01520097-01

1. Input shaft
I4RH01520029-01

2) Remove 5th gear spacer (2), left bearing (3) and 4th 6) Remove 3rd gear needle bearing from input shaft.
gear (4) all at once using puller (5) and hydraulic
press. 7) Disassemble synchronizer sleeve & hub assembly.

! CAUTION Reassembly
To avoid gear teeth damage, support 4th gear 1) Clean all components thoroughly, inspect them for
at flat side of bearing puller. any abnormality and replace with new ones if
necessary.
2) Check clearance “a” between synchronizer ring (2)
and gear (1), key slot width “b” in synchronizer ring
and replace with new one, if necessary. Also, check
gear teeth for damage.
Clearance “a” between synchronizer ring and
gear
Standard: 1.0 – 1.4 mm (0.040 – 0.055 in.)
Service limit: 0.5 mm (0.020 in.)
I3RH0A520018-01 Key slot width “b”
1. Input shaft Standard: 10.0 – 10.2 mm (0.394 – 0.402 in.)
Limit: 10.45 mm (0.4114 in.)
3) Remove 4th gear needle bearing and high speed
synchronizer ring.
4) Using snap ring pliers (2), remove circlip (1).

I7RW01520007-01

5) Remove high speed synchronizer sleeve & hub

assembly (2) together with 3rd gear (3) by using
puller (4) and hydraulic press.

! CAUTION I5JB0A520054-01

To avoid gear teeth damage, support 3rd gear 3) To ensure lubrication of input shaft (1), blow air to oil
at flat side of bearing puller. holes (2) as shown in figure and make sure that they
are free from any obstruction.
 Manual Transmission/Transaxle: D13A Model 5B-64

I2RH01520049-01

4) Fit high speed synchronizer sleeve (4) to hub (3), I3RH0A520019-01

insert 3 keys (2) in it and then set springs (1) at
specified position as shown in figure.
NOTE
• Be sure to assemble sleeve and hub in
correct direction. (No direction is specified
to each key.)
• High speed synchronizer sleeve, hub, keys
and springs are smaller in size than low
speed ones.
Synchronizer spring installation position
“a” = “b”
[C]
6) Install 3rd gear needle bearing (4), apply oil to it,
then install 3rd gear (1) and synchronizer ring (2).
7) Install high speed sleeve & hub assembly (3) using
special tool and hydraulic press.
NOTE
• Make sure that synchronizer ring key slots
are aligned with keys (5) in sleeve & hub
assembly.
• Check free rotation of 3rd gear after press-
fitting sleeve & hub assembly.
Special tool
(A): 09913M84510

[B]

[C]
3 [A]

(A)

[C]

[A]

I9P60A522049-02

[A]: 4th gear side

[B]: Short flange side
[C]: Projecting end 4 [B] 2
I9P60A522051-01

5) Install right bearing (1) to input shaft (2) using special [A]: 3rd gear side
tool and hydraulic press. [B]: Key way
[C]: Long flange
Special tool
(A): 09913M80113 8) Install new circlip (1) to groove securely.
9) Install needle bearing (2), apply oil to it and then
install synchronizer ring (3) and 4th gear (4).
5B-65 Manual Transmission/Transaxle: D13A Model

I2RH01520054-01
I2RH01520052-01
1. Countershaft
5. Input shaft

2) Apply puller (5) to 2nd gear (4), and remove 3rd &
10) Press-fit left bearing (2) by using special tool and 4th gear spacer (2) and 3rd gear (3) together with
hydraulic press. 2nd gear by using hydraulic press. Needle bearing
Special tool would come out with 2nd gear.
(A): 09913M80113 ! CAUTION
11) Using the same special tool at step 10), install 5th To avoid gear teeth damage, be sure to
gear spacer (1). support 2nd gear at flat side of bearing puller.
! CAUTION
To prevent 5th gear spacer (1) from being
distorted by excessive compression, do not
press-fit it with left bearing (2) at once.

I2RH01520055-01

1. Countershaft

3) Remove 2nd synchronizer outer ring, center cone

and inner ring.
4) Using snap ring pliers (3), remove circlip (1).

I3RH0A520020-01

Countershaft Disassembly and Reassembly

AENBL80A5226020

Disassembly
1) Remove left bearing cone (2) with 4th gear (3) by
using puller (4) and hydraulic press.

! CAUTION
I7RW01520008-01
To avoid gear teeth damage, support 4th gear
(3) at flat side of puller. 2. Low speed synchronizer sleeve

5) Apply puller (3) to 1st gear (2) and remove low

speed synchronizer sleeve & hub assembly (1) with
1st gear by using hydraulic press.
 Manual Transmission/Transaxle: D13A Model 5B-66

! CAUTION Difference between synchronizer outer ring and

inner ring (1st and 2nd)
To avoid gear teeth damage, support 1st gear Standard “b”: 0.95 – 1.25 mm (0.0374 – 0.0492 in.)
at flat side of bearing puller. Service limit “b”: 0.5 mm (0.0196 in.)

I2RH01520057-01

6) Disassemble synchronizer sleeve & hub assembly. I2RH01520059-01

7) Remove 1st gear needle bearing from shaft. 3) To ensure lubrication of countershaft (1), blow air
8) In order to remove right bearing (1) from into oil holes (2) as shown in figure and make sure
countershaft, grind with a grinder (2) one part “a” of that they are free from any obstruction.
right bearing (1) as illustrated till it becomes thin.

! CAUTION
Be careful not to grind countershaft (3).

I2RH01520060-01

4) Fit low speed synchronizer sleeve (4) to hub (3),

2
insert 3 keys (2) in it and then set springs (1) at
3
specified position as shown in figure.
1 “a” NOTE
3
1
• Be sure to assemble sleeve and hub in
correct direction. (No direction is specified
I5RW0A520035-01
to each key.)
9) Break right bearing (2) at thin point with a chisel (1) • Low speed synchronizer keys and springs
to remove it. are larger than high speed ones in size.

Synchronizer spring installation position

“a” = “b”
1

2
I5RW0A520036-01

Reassembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new one if
necessary.
2) Put the synchronizer outer ring (1), inner ring (3) and
center cone (2) together, and then measure step
difference between outer ring and inner ring and
replace with new one, if necessary. Also, check gear
teeth for damage.
5B-67 Manual Transmission/Transaxle: D13A Model

NOTE
• Support shaft with special tool as shown in
figure so that retainer of bearing cone will
be free from compression.
• Make sure that synchronizer ring key slots
(8) are aligned with keys (5) while press-
fitting sleeve & hub assembly.
• Check free rotation of 1st gear (3) after
press-fitting sleeve & hub assembly.

Special tool
(A): 09923M78210
(B): 09913M85210
(C): 09940M54910
(D): 09924M07710

I7V20A522044-01

[A]: 1st gear side

B

5) Install right bearing cone (1) to countershaft (2) by

using special tools and hydraulic press.
Special tool
(A): 09913M76010
(B): 09924M07720

(A)

(B)
1
IBP80A522003-01

[A]: Section B – B
2
B: 1st gear side
C: Short flange

I5RW0A520038-01
9) Install new circlip (1) to groove securely.
6) Install needle bearing (4), apply oil to it, then install
10) Install needle bearing (2) and apply oil to needle
1st gear (3).
bearing.
7) Install synchronizer outer ring (2), center cone (6)
11) Install 2nd gear (6) with synchronizer outer ring (3),
and inner ring (7) together as shown in figure.
center cone (4) and inner ring (5) as shown in figure.
8) Install low speed sleeve & hub assembly (1) by using
special tools and hydraulic press.
 Manual Transmission/Transaxle: D13A Model 5B-68

13) Press-fit 4th gear (2) by using the same procedure

as step 11).
14) Install left bearing cone (1) by using special tool and
hydraulic press.

NOTE
For protection of bearing cone (3), be sure to
support shaft with special tool as shown in
figure.

Special tool
(A): 09923M78210
(B): 09913M80113

I5RW0A520040-01

[A]: Section A – A

12) Press-fit 3rd gear (2) and spacer (1) by using special
tools and hydraulic press.

NOTE
It is recommended to press-fit spacer and 3rd I2RH01520066-01

gear first, and then 4th gear later separately

so that countershaft will not be compressed
excessively.

Special tool
(A): 09923M78210
(B): 09913M85210

I4RH01520036-01

3. 2nd gear
5B-69 Manual Transmission/Transaxle: D13A Model

Gear Shift Shaft Components

AENBL80A5226021

7 (a)
6
8
9 (b)

3
1

10
5

I9P60A522043-01

1. Low speed gear shift shaft
2. High speed gear shift shaft
3. 5th & reverse gear shift shaft
4. 5th & reverse gear shift guide shaft
5. Reverse gear shift arm
6. 5th gear shift fork : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
7. Reverse gear shift lever bolt : 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft)
8. Reverse gear shift lever : Do not reuse.
9. 5th gear shift fork bolt
10. 5th & reverse gear shift yoke

5th and Reverse Gear Shift Shaft Disassembly

and Reassembly
AENBL80A5226022
Disassembly (A)
Disassemble component parts by using special tool and
hammer.
Special tool
(A): 09922M85811

Reassembly
Reverse disassembly procedure noting the following
point.

NOTE
I9P60A522044-01
Install 2 steel balls (3) in reverse gear shift
2. Spring 6. 5th & reverse gear shift yoke
arm (1) without fail.
4. Spring pin 7. 5th & reverse gear shift guide shaft
5. 5th & reverse gear shift shaft

Gear Shift Shaft and Fork Inspection

AENBL80A5226023
1) Using feeler gauge, check clearance between fork
(1) and sleeve (2) and replace those parts if it
exceeds specified value.
Clearance “a” between fork and sleeve
Service limit: 1.0 mm (0.039 in.)
 Manual Transmission/Transaxle: D13A Model 5B-70

2) Insert each gear shift shaft into case and check that
it moves smoothly. If it doesn’t, correct by using
oilstone, reamer or the like.

I2RH01520068-01

Differential Components
AENBL80A5226024

1 2 3
4

8 (a)
2
10
1

3 9

4
5 7

11

5
IBP80A522005-01

1. Differential pinion washer 6. Differential case 11. Speed sensor ring

2. Differential pinion 7. Final gear : 90 N⋅m (9.2 kgf-m, 66.5 lbf-ft)
3. Differential side gear 8. Final gear bolt : Do not reuse.
4. Side gear washer 9. Differential pinion shaft : Apply transaxle oil.

5. Differential side bearing 10. Differential pinion shaft pin

Differential Disassembly and Reassembly

AENBL80A5226025

Disassembly
(A)
1) Remove left bearing (1) using special tool. (B)
Special tool 1
(A): 09913M65135
(B): 09913M85230

I6RS0E520012-01

2) Remove right bearing in the same manner as step

1).
5B-71 Manual Transmission/Transaxle: D13A Model

3) Support differential case (1) with soft jawed vise.

4) Remove final gear bolts and remove final gear. (A)
5) Remove differential pinion shaft pin by using special [A]
tool and hammer, and then disassemble
components parts. (B)

Special tool
(A): 09922M85811

[B] (A)

(B)

I6RS0E520013-01

2. Differential side gear

(C)
I7V20A522045-01
Reassembly
2) Install new differential pinion shaft pin from right side
1) Install differential pinion, side gear and pinion shaft till the depth from differential case surface is about
to differential case, and measure backlash and thrust 1.2 mm (0.047 in.).
play of differential side gear using special tools as
3) Press-fit left bearing (1) by using special tool and
follows.
hydraulic press.
If measured value is out of specification, select
suitable side gear washer and check again. Special tool
(A): 09951M16080
Special tool
(A): 09900M20607
(B): 09900M20701
(C): 09952M06010
a) Differential side gear backlash [A]
• Hold differential assembly with soft jawed vise
and apply measuring tip of dial gauge to side
gear as shown in figure.
• Fixing differential pinion, turn side gear back
and forth and read dial gauge.
Differential side gear backlash
0.10 – 0.15 mm (0.0039 – 0.0059 in.)
b) Differential side gear thrust play [B]
• Hold differential assembly with soft jawed vise
and apply measuring tip of dial gauge to side
gear as shown in figure. I2RH01520074-01

• Move side gear up and down by hand and 2. Differential case

read dial gauge.
4) Press-fit right bearing (1) by using special tools and
Differential side gear thrust play
hydraulic press.
0.03 – 0.30 mm (0.001 – 0.012 in.)
Special tool
(A): 09925M15410
(B): 09940M54910
(C): 09913M85230
 Manual Transmission/Transaxle: D13A Model 5B-72

! CAUTION
Be sure to use new bolt with pre-coated
adhesive. Otherwise, bolt may loosen.

Tightening torque
Final gear bolt (a): 90 N·m (9.2 kgf-m, 66.5 lbf-ft)

I6RS0E520038-01

2. Differential case
3. Differential side left bearing

I5RW0A520049-01
5) Hold differential assembly with soft jawed vise (3),
install final gear (2) and then tighten new final gear
bolts (1).

Specifications
Tightening Torque Specifications
AENBL80A5227001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Transaxle oil level / filler plug 21 2.1 15.5 )/)
Transaxle oil drain plug 21 2.1 15.5 )
Back up light switch 19 1.9 14.0 )
Gear shift guide case No.1 bolt 23 2.3 17.0 )/)
Gear shift guide case No.2 bolt 23 2.3 17.0 )
Gear shift interlock bolt 23 2.3 17.0 )
5th to reverse interlock guide bolt 23 2.3 17.0 )
Countershaft nut 100 10.2 74.0 )
5th gear shift fork bolt 10 1.0 7.5 )
Side cover bolt 10 1.0 7.5 )
Reverse gear shift lever bolt 23 2.3 17.0 )
Transaxle case bolt 23 2.3 17.0 )
Reverse gear shaft bolt 23 2.3 17.0 )
Left case plate bolt 23 2.3 17.0 )/)
Oil gutter bolt 10 1.0 7.5 )
Final gear bolt 90 9.2 66.5 )

NOTE
The tightening torque(s) also specified in:
“Manual Transaxle Unit Components”: D13A Model
“Gear Shift and Select Shaft Assembly Components”: D13A Model
“Manual Transaxle Assembly Components”: D13A Model
“Gear Shift Shaft Components”: D13A Model
“Differential Components”: D13A Model

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
5B-73 Manual Transmission/Transaxle: D13A Model

Special Tools and Equipment

Recommended Service Material
AENBL80A5228001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 )/)/)
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 )/)/)/)/)/)

NOTE
Required service material(s) also described in:
“Manual Transaxle Assembly Components”: D13A Model
“Input Shaft and Countershaft Components”: D13A Model
“Differential Components”: D13A Model

Special Tool
AENBL80A5228002
09900M20607 09900M20701
Dial gauge Magnetic stand
) )

09912M34510 09913M50121
Case separator Oil seal remover
) )/)

09913M65135 09913M70123
Bearing puller Bearing installer
) )/)

09913M75821 09913M75830
Bearing installer attachment Steering pinion bush
installer
) )/)

09913M76010 09913M80113
Bearing installer Bearing installer
) )/)/)
 Manual Transmission/Transaxle: D13A Model 5B-74

09913M84510 09913M85210
Bearing installer Bearing installer
) )/)

09913M85230 09921M96510
Bearing remover tool Oil pan seal cutter
)/) )

09922M85811 09923M78210
Spring pin remover (4.5 mm) Bearing installer
)/) )/)/)

09924M07710 09924M07720
Synchronizer hub installer Synchronizer hub installer
) )

09924M74510 09924M84510M004
Bearing and oil seal handle Bearing installer attachment
)/)/) )

09925M14520 09925M15410
Bearing and oil seal installer Oil seal installer
(80 x 50 mm)
)/) )

09927M76060 09930M30104
Gear holder Sliding shaft
)/) )

09940M54910 09941M64511
Front fork oil seal install Bearing and oil seal remover
driver (30 mm min.)
)/) )
5B-75 Manual Transmission/Transaxle: D13A Model

09942M15511 09944M88220
Sliding hammer Oil seal installer
) )

09944M96011 09951M16080
Bearing outer race remover Bearing installer
) )

09951M18211 09952M06010
Oil seal remover & installer Dial gauge plate No.1
No. 2
) )
5C-1 Clutch: K14B Model

Clutch
Transmission / Transaxle

K14B Model
General Description
Clutch Construction
AENBL80A5311001
The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type,
which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries diaphragm spring in such a way that the peripheral edge part
of the spring pushes on the pressure plate against flywheel (with the disc in between), when the clutch release bearing
(incorporation in clutch operating cylinder) is held back. This is the engaged condition of the clutch.
Depressing the clutch pedal causes the release bearing (incorporation in clutch operating cylinder) to advance and
pushes on the tips of the tapered fingers of the diaphragm spring. When this happens, diaphragm spring pulls the
pressure plate away from flywheel, thereby interrupting the flow of drive from flywheel through clutch disc to transaxle
input shaft. Clutch fluid is supplied from brake fluid reservoir. Clutch fluid level can be checked by brake fluid level of
brake fluid reservoir.

IAP70A530001-01

1. Crankshaft 3. Clutch disc 5. Clutch cover 7. Operating cylinder assembly

2. Flywheel 4. Pressure plate 6. Diaphragm spring 8. Input shaft

Diagnostic Information and Procedures
Clutch System Symptom Diagnosis
Condition Possible cause
Slipping Improper clutch pedal free travel
Worn or oily clutch disc facing
Warped disc, pressure plate or flywheel • Replace clutch disc, cover or flywheel.
surface
Weakened diaphragm spring
Master cylinder piston or seal cup not Replace clutch master cylinder. )(Page 5C-6)
returning
Dragging clutch Improper clutch pedal free travel
Weakened diaphragm spring or worn
spring tip
Rusted input shaft spline
Damaged or worn spline of transaxle
input shaft
Excessively wobbly clutch disc
Clutch facings broken or dirty with oil Replace clutch disc. )(Page 5C-9)
Fluid leakage
Clutch vibration Glazed (glass-like) clutch facings
Clutch facings dirty with oil
Release bearing does not slide
smoothly
Wobbly clutch disc or poor facing
contact
Weakened torsion springs in clutch disc Replace clutch disc. )(Page 5C-9)
Clutch disc rivets loose
Distorted pressure plate or flywheel
surface
Weakened engine mounting or loosened Replace engine mounting or retighten engine
engine mounting bolt(s) and/or nut(s)
Noisy clutch Worn or broken release bearing
Input shaft right bearing worn down
Excessive rattle of clutch disc hub
Cracked clutch disc
Pressure plate and diaphragm spring
rattling
Clutch: K14B Model 5C-2
AENBL80A5314001
Correction / Reference Item
• Replace clutch pedal arm and/or clutch
master cylinder.
– Clutch pedal arm: )(Page 5C-9)
– Clutch master cylinder: )(Page 5C-6)
Replace clutch disc. )(Page 5C-9)
– Clutch disc and cover: )(Page 5C-9)
– Flywheel: “Flywheel Removal and
Installation”: K14B in Section 1D (Page
1D-25)
Replace clutch cover. )(Page 5C-9)
• Replace clutch pedal arm and/or clutch
master cylinder.
– Clutch pedal arm: )(Page 5C-9)
– Clutch master cylinder: )(Page 5C-6)
Replace clutch cover. )(Page 5C-9)
Lubricate input shaft spline.
Replace input shaft. )(Page 5B-28)
Replace clutch disc. )(Page 5C-9)
Repair or replace clutch system.
Repair or replace clutch disc. )(Page 5C-9)
Replace clutch disc. )(Page 5C-9)
Replace clutch operating cylinder assembly.
)(Page 5C-7)
Replace clutch disc. )(Page 5C-9)
Replace clutch disc. )(Page 5C-9)
• Replace clutch cover or flywheel.
– Clutch disc and cover: )(Page 5C-9)
– Flywheel: “Flywheel Removal and
Installation”: K14B in Section 1D (Page
1D-25)
mounting bolts and/or nuts. “Engine Mounting
Components”: K14B in Section 1D (Page 1D-
18)
Replace clutch operating cylinder assembly.
)(Page 5C-7)
Replace input shaft right bearing. )(Page 5B-
28)
Replace clutch disc. )(Page 5C-9)
Replace clutch disc. )(Page 5C-9)
Replace clutch cover. )(Page 5C-9)
5C-3 Clutch: K14B Model

Condition Possible cause Correction / Reference Item

Grabbing clutch
Clutch disc facings soaked with oil
Clutch disc facings excessively worn
Rivet heads protrude from clutch disc
facing surface
Weakened torsion springs
Replace clutch disc. )(Page 5C-9)
Replace clutch disc. )(Page 5C-9)
Replace clutch disc. )(Page 5C-9)
Replace clutch disc. )(Page 5C-9)

Repair Instructions
CPP Switch Removal and Installation
AENBL80A5316001
Removal
1) Disconnect connector of CPP switch (1) with ignition
“OFF”.
2) Remove CPP switch (1) from clutch pedal bracket.

(a)
(b)
IBP80A532007-01

Tightening torque
CPP switch lock nut (a): 7.5 N·m (0.76 kgf-m, 5.5 lbf-
ft)
3) Connect connector to CPP switch securely.

CPP Switch Inspection and Adjustment

AENBL80A5316002
Inspection
Check for resistance between terminals under each
condition below. If check result is not satisfactory,
1
replace switch.
CPP switch specification
When switch shaft is pushed [a]: No continuity
When switch shaft is free [b]: Continuity

IBP80A531022-01

Installation
1) Install CPP switch to clutch pedal bracket.
2) Maintain the clearance between end of thread part of
switch and pedal stay as per specification with clutch
pedal pulled up and hold. Tighten the switch to IAP70A530002-02

specified torque.
Gap between Switch thread top and pedal stay
“a”: 1.4 to 1.9 mm (0.055 to 0.074 in.)
Clutch Pedal Inspection
AENBL80A5316005
Clutch Pedal Height
Measure distance between free position (1) and fully
depressed position (2) on clutch pedal shown by “a” in
figure. If clutch pedal height is out of specification,
replace pedal arm and/or clutch master cylinder (3).
 Clutch: K14B Model 5C-4

Clutch pedal height Clutch Release Margin

“a”: 130 - 140 mm (5.11 - 5.51 in.) 1) Apply parking brake fully and block wheels.
2) Start engine and keep engine at idle in neutral
position.
3) Without clutch pedal (1) depressed, slightly push the
shift lever to reverse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
3
1
4) While listening to gear contact noise, slowly depress
clutch pedal (1) and stop it when gear contact noise
died (release point).
2
5) Measure distance between release point (4) and full
stroke point (5) on clutch pedal (1) shown by “c” in
“a”
the figure.
If “c” is not within specification, air may be trapped in
clutch system. Air bleed clutch fluid system. )(Page
5C-4)
Upon completion of above inspection, start engine
I7V20A532003-02 and check clutch for proper operation.
Clutch release margin
Cylinder Push Rod Play
“c”: 25 – 40 mm (0.98 – 1.57 in.)
Press clutch pedal (1) gradually with finger, stop when
slight increase of resistance is felt and measure how
much pedal has moved (shown by “a” in figure).
If “a” is not within specification, replace master cylinder
(3) or pedal arm (2).
Push rod play
“a”: Max. 2 mm (0.08 in.)
3
2

4 1

3 2 “b”
5 “c”

1
I7V20A532005-01

“a”
Clutch Fluid Level Inspection
AENBL80A5316006
1) Check clutch system for crack, damage and fluid
leakage.
If any fault is found, repair or replace faulty part.
I7V20A532004-01
2) Check fluid level. “Brake Fluid Level Inspection” in
Clutch Pedal Free Travel Section 4A (Page 4A-4)
Depress clutch pedal (1), stop the moment clutch
resistance is felt, and measure how much pedal has Air Bleeding of Clutch System
AENBL80A5316007
moved (shown by “b” in figure).
If “b” is not within specification, check pedal arm (2) and
master cylinder (3) and replace defective part.
Clutch pedal free travel “b”
: 5 – 7 mm (0.20 – 0.27 in.)
5C-5 Clutch: K14B Model

! CAUTION
1
• Brake fluid (Clutch fluid) is extremely
damaging to paint. If fluid should
accidentally touch painted surface,
immediately wipe fluid from paint and
clean painted surface. 2

• When operating the clutch pedal for air

bleeding, after releasing the clutch pedal,
be sure to wait 1 second or more before IAP70A530004-01

depressing it again. Otherwise, the oil seal
of operating cylinder will be damaged,
resulting in oil leakage.
Bleeding operation is necessary to remove air whenever
it entered hydraulic clutch system.
1) Fill master cylinder reservoir with brake fluid and
keep at least one-half full of fluid during bleeding
operation.
Clutch fluid specification
: Refer to reservoir cap
2) Remove bleeder plug cap. Attach a vinyl tube (1) to
bleeder plug, and insert the other end into container
(2).
10) Check clutch pedal for operation. If spongy condition
3) Depress clutch pedal several times, and then while
holding it depressed, loosen bleeder plug about one-
third to one-half turn.
4) When fluid pressure in cylinder is almost depleted,
retighten bleeder plug.
5) Repeat this operation until there are no more air
bubbles in hydraulic line.
6) When bubbles stop, depress and hold clutch pedal,
and tighten bleeder plug to specified torque.
Tightening torque
Clutch bleeder plug: 5.0 N·m (0.51 kgf-m, 4.0 lbf-
ft)
7) Attach bleeder plug cap.
8) After completing bleeding operation, apply fluid
pressure to pipe line and check for leakage.
9) Replenish master cylinder reservoir with fluid up to
specified level.
is felt, repeat entire procedure of bleeding.

Clutch Fluid Pipe and Hose Components

AENBL80A5316008

Si

3 1

4
6

IBP80A532001-01
 Clutch: K14B Model 5C-6

1. Clutch master cylinder 4. Brake master cylinder reservoir 7. Clutch fluid hose
: Apply grease 99000-25100 to push rod tip.
2. Clutch fluid pipe 5. Clutch operating cylinder assembly 8. Clutch pipe joint
3. Clutch reservoir hose 6. Clamp

Clutch Fluid Pipe and Hose Removal and • After installation, check clutch pedal free travel.
Installation )(Page 5C-3)
AENBL80A5316009
• After installation, bleed air from clutch system.
)(Page 5C-4)
Removal
• Check fluid leakage.
! CAUTION • Add fluid to “MAX” level of reservoir.
Do not allow fluid to get on painted surface. It
may cause painted surface damage. Clutch Fluid Pipe and Hose Inspection
AENBL80A5316010

1) Remove dust and dirt from each joint of pipe to be Check clutch fluid pipe and hose for damage, abrasions
disconnected and clean around brake master and leaks. If any defect is found replace clutch fluid pipe
cylinder reservoir cap. and hose.
2) Remove fluid from brake master cylinder reservoir
with syringe or such.
Clutch Master Cylinder Removal and
Installation
3) Pull out clip (1) at clutch master cylinder (3) and pull AENBL80A5316011
out clip (5) at fluid pipe joint (4), to disconnect clutch Removal
fluid pipe (2) and hose (6). 1) Clean around brake master cylinder reservoir cap
and remove fluid from brake master cylinder
reservoir with syringe or such.
2) Disconnect clutch fluid pipe from clutch master
cylinder. )(Page 5C-6)
3
3) Disconnect clutch reservoir hose (2).
1
2 2

2 IBP80A532003-01
5 4) Remove push rod (4) from clutch pedal (3).
5) Remove clutch master cylinder nuts (5), and then
6 remove clutch master cylinder (6).
7

IBP80A532002-01

4) Pull out clamp (6) of damper (7) and then disconnect

damper (7) from clutch fluid pipe (2).

Installation
Reverse removal procedure, noting the following points.

! CAUTION

• Do not allow fluid to get on painted

surface.
• Do not allow pipe to contact hard against
vehicle body or other parts.

• Install each clip securely.

5C-7 Clutch: K14B Model

! CAUTION
6
• Do not allow fluid to get on painted
surfaces. It may cause painted surface
damage.
5 4
• Do not disassemble clutch operating
cylinder assembly.

5 Removal
1) Clean around brake master cylinder reservoir cap
and remove fluid from brake master cylinder
3 reservoir with syringe or such.
2) Dismount transaxle assembly. )(Page 5B-11)
3) Remove clip (1), to disconnect clutch pipe joint (2).
4) Loosen clutch fluid pipe flare nut (3) of clutch
IBP80A532004-01 operating cylinder assembly (4).
5) Remove clutch pipe joint sleeve (5) from transaxle,
Installation and then remove clutch fluid pipe (6).
Reverse removal procedure noting the following points.
6) Remove clutch operating cylinder assembly from
• Apply grease to push rod tip. transaxle.
“A”: Grease 99000–25100 (SUZUKI Silicone
1
Grease)
2
• Tighten clutch master cylinder nuts (1) to specified
torque.
Tightening torque
Clutch master cylinder nut (a): 13 N·m (1.3 kgf-m,
5
9.5 lbf-ft)

4 3
1, (a)
6

1, (a)

“A”

IAP70A530009-01

I9P60A531013-01 Installation
1) Install clutch operating cylinder assembly (2) to
Clutch Master Cylinder Inspection transaxle. Tighten clutch operating cylinder
AENBL80A5316012
Check clutch master cylinder for damage and leak. assembly bolts to specified torque.
Replace clutch master cylinder if defective. Tightening torque
Clutch operating cylinder assembly bolt (a): 10
Clutch Operating Cylinder Assembly Removal N·m (1.0 kgf-m, 7.5 lbf-ft)
and Installation
AENBL80A5316013 2) Connect clutch fluid pipe (4) to clutch operating
cylinder assembly temporarily.
3) Install clutch pipe joint sleeve (3) to transaxle
securely and then tighten clutch fluid pipe flare nut
(1) to specified torque.
 Clutch: K14B Model 5C-8

Tightening torque
Clutch fluid pipe flare nut (b): 16 N·m (1.6 kgf-
m, 12.0 lbf-ft)
4) Connect clutch pipe joint (5), and install clip (6).

2 1, (b)

(a)

IAP70A530010-01

5) Remount transaxle assembly. )(Page 5B-11)

6) Bleed air from clutch system and check clutch pedal
free travel.
• Air bleeding of clutch system: )(Page 5C-4)
• Clutch pedal free travel: )(Page 5C-3)

Clutch Operating Cylinder Assembly Inspection

AENBL80A5316014
NOTE
Clutch operating cylinder is equipped with
grease-filled sealed bearing. Do not wash it
with cleaning solvent.

Check clutch fluid leakage, spring for damage and

bearing for smooth rotation. If malfunction is found,
replace clutch operating cylinder assembly.
Clutch Pedal Assembly Components
AENBL80A5316015
5C-9 Clutch: K14B Model

1
b (a)
a (a)

(b)
(c)

a (a)
2 E

2 E 4
7 E

IBP80A532006-01

1. Clutch pedal bracket assembly 7. Clutch pedal spring

: Apply grease 99000-25050 to inside of spring.
2. Pedal boss bushing 8. CPP switch
: Apply grease 99000-25050 to all surface of bushing.
3. Pedal shaft spacer : Tightening order: “a” → “b”
4. Clutch pedal : 13 N⋅m (1.3 kgf-m, 9.5 lbf-ft)
5. Pedal pad : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
6. Clutch pedal stop cushion : 7.5 N⋅m (0.76 kgf-m, 5.5 lbf-ft)

Clutch Pedal Assembly Removal and Clutch Cover and Clutch Disc Components
AENBL80A5316017
Installation
AENBL80A5316016
Removal 3 (a)

1) Remove push rod from clutch pedal. )(Page 5C-6)

2) Disconnect CPP switch connector, then remove CPP
switch from clutch pedal assembly, if necessary.
• CPP switch: )(Page 5C-3)
3) Remove clutch pedal assembly from vehicle body. 1

Installation
Reverse removal procedure, noting the following points. 2
I9P60A532007-01
• Tighten each bolt and nut to specified torques.
1. Clutch cover
)(Page 5C-8) 2. Clutch disc
• Apply grease to push rod tip. 3. Clutch cover bolt
: For tightening order, refer to “Clutch Cover and Clutch Disc
: Grease 99000–25100 (SUZUKI Silicone Grease) Removal and Installation”: K14B Model (Page 5C-9).
: 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
• If additional lubrication is required, apply grease to
specified position. )(Page 5C-8)
Clutch Cover and Clutch Disc Removal and
: Grease 99000–25050 (SUZUKI Super Grease E) Installation
AENBL80A5316018
 Clutch: K14B Model 5C-10

Removal
4, “4”, (a)
1) Dismount manual transaxle. )(Page 5B-11)
2) Hold flywheel with special tool and remove clutch 3, “2”, (b)
cover bolts (1), clutch cover (2) and clutch disc.
1
Special tool
(A): 09924M17811 3, “1”, (b)
(B)

1
4, “5”, (a)
2

(A)

4, “6”, (a)

1 3, “3”, (b)
I9P60A531019-02
1
I9P60A531018-01 4) Slightly apply grease to input shaft (1), then join
manual transaxle with engine. )(Page 5B-11)
Installation
“A”: Grease 99000–25210 (SUZUKI Super
NOTE Grease I)
Before assembling, make sure that flywheel
surface and pressure plate surface have
been cleaned and dried thoroughly.

1) Hold flywheel with special tool (A).

Special tool
(A): 09924M17811
1
2) Align clutch disc with crankshaft center using special
tool (B) and install clutch cover (1).
“A”
I6RS0E530018-01
Special tool
(B): 09923M36320
Clutch Cover and Clutch Disc Inspection
3) Install and tighten clutch cover bolts using the AENBL80A5316019
following procedure:
Clutch Disc
a) Tighten 3 bolts (3) by hand in numerical order
Measure depth of rivet head depression, i.e. distance
(“1” – “3”).
between rivet head and facing surface.
b) Tighten other 3 bolts (4) evenly and gradually to If depression is found to have reached service limit at
5.0 N⋅m (0.51 kgf-m, 4.0 lbf-ft) in numerical order any of rivet holes (2), replace clutch disc (1).
(“4” – “6”).
Rivet head depth
c) Fully tighten all bolts (3), (4) evenly and gradually
Standard: 1.15 – 1.75 mm (0.0453 – 0.0689 in.)
to specified torque in numerical order (“1” – “6”)
Limit: 0.5 mm (0.02 in.)
starting from bolt nearby strut plate rivet (2).

NOTE
While tightening clutch cover bolts, make
sure that clutch disc spline is centered by
pressing special tool to clutch disc.

Tightening torque
Clutch cover bolt* (a): 5.0 N⋅m → 23 N⋅m (0.51
kgf-m → 2.3 kgf-m, 4.0 lbf-ft → 17.0 lbf-ft)
Clutch cover bolt* (b): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)
I4RS0A530019-01
5C-11 Clutch: K14B Model

Clutch Cover Installation

1) Install input shaft bearing to flywheel (1) using
! CAUTION
special tool.
Do not disassemble clutch cover into
Special tool
diaphragm spring and pressure plate.
(A): 09925M98210
If abnormality is found, replace clutch cover.

Check clutch cover as follows.

1) Check diaphragm spring (1) for abnormal wear or
damage.
2) Inspect pressure plate (2) for wear or heat spots.
If any defect is found, replace clutch cover.

I4RS0A530016-01

Input Shaft Bearing Inspection

AENBL80A5316021
Check input shaft bearing (1) for smooth rotation.
If any defect is found, replace input shaft bearing.

I3RM0A530015-01

Input Shaft Bearing Removal and Installation

AENBL80A5316020 1
Removal
1) Pull out input shaft bearing (1) from flywheel (2)
using special tool.
Special tool
(A): 09921M26020
(B): 09930M30104

IAP70A530012-01

I2RH01530023-01

Specifications
Tightening Torque Specifications
AENBL80A5317001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
CPP switch lock nut 7.5 0.76 5.5 )
Clutch bleeder plug 5.0 0.51 4.0 )
 Clutch: K14B Model 5C-12

Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Clutch master cylinder nut 13 1.3 9.5 )
Clutch operating cylinder assembly bolt 10 1.0 7.5 )
Clutch fluid pipe flare nut 16 1.6 12.0 )
Clutch cover bolt* 5.0 N⋅m → 23 N⋅m (0.51 kgf-m → 2.3 kgf- )
m, 4.0 lbf-ft → 17.0 lbf-ft)
Clutch cover bolt* 23 2.3 17.0 )

NOTE
The tightening torque(s) also specified in:
“Clutch Pedal Assembly Components”: K14B Model
“Clutch Cover and Clutch Disc Components”: K14B Model

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fastener Caution” in Section 00 (Page 00-
5).
5C-13 Clutch: K14B Model

Special Tools and Equipment

Recommended Service Material
AENBL80A5318001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease E P/No.: 99000–25050 )
SUZUKI Silicone Grease P/No.: 99000–25100 )/)
SUZUKI Super Grease I P/No.: 99000–25210 )

NOTE
Required service material(s) also described in:
“Clutch Fluid Pipe and Hose Components”: K14B Model
“Clutch Pedal Assembly Components”: K14B Model

Special Tool
AENBL80A5318002
09921M26020 09923M36320
Bearing remover Clutch center guide (15 mm)
) )

09924M17811 09925M98210
Flywheel holder Input shaft bearing installer
)/) )

09930M30104
Sliding shaft
)
 Clutch: D13A Model 5C-14

D13A Model
General Description
Clutch (Hydraulic Type) Construction
AENBL80A5321001
The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type,
which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the peripheral edge
part of the spring pushes on the pressure plate against the flywheel (with the disc in between), when the clutch release
bearing (incorporated in clutch operating cylinder) is held back. This is the engaged condition of the clutch.
Depressing the clutch pedal causes the release bearing (incorporated in clutch operating cylinder) to advance and
pushes on the tips of the tapered fingers of the diaphragm spring. When this happens, the drive straps pull the
pressure plate away from the flywheel, thereby interrupting the flow of drive from flywheel through clutch disc to
transaxle input shaft. Clutch fluid is supplied from brake fluid reservoir. Clutch fluid level can be checked by brake fluid
level of brake fluid reservoir.

I6RS0E530001-01

1. Crankshaft 4. Pressure plate 7. Operating cylinder assembly

2. Flywheel 5. Clutch cover 8. Input shaft
3. Clutch disc 6. Diaphragm spring
5C-15 Clutch: D13A Model
Diagnostic Information and Procedures
Clutch System Symptom Diagnosis
Condition Possible cause
Slipping Improper clutch pedal free travel
Worn or oily clutch disc facing
Warped disc, pressure plate or flywheel Replace clutch disc, cover or flywheel.
surface
Weakened diaphragm spring
Master cylinder piston or seal cup not Replace clutch master cylinder. )(Page 5C-
returning
Dragging clutch Improper clutch pedal free travel
Weakened diaphragm spring or worn
spring tip
Rusted input shaft spline
Damaged or worn spline of transaxle
input shaft
Excessively wobbly clutch disc
Clutch facings broken or dirty with oil Replace clutch disc. )(Page 5C-21)
Fluid leakage
Clutch vibration Glazed (glass-like) clutch facings
Clutch facings dirty with oil
Release bearing does not slide
smoothly
Wobbly clutch disc or poor facing
contact
Weakened torsion springs in clutch disc Replace clutch disc. )(Page 5C-21)
Clutch disc rivets loose
Distorted pressure plate or flywheel
surface
Weakened engine mounting or loosened Replace engine mounting or retighten engine
engine mounting bolt(s) / nut(s)
Noisy clutch Worn or broken release bearing
Excessive rattle of clutch disc hub
Cracked clutch disc
Pressure plate and diaphragm spring
rattling
Grabbing clutch Clutch disc facings soaked with oil
Clutch disc facings excessively worn
Rivet heads protrude from clutch disc
facing surface
Weakened torsion springs
AENBL80A5324001
Correction / Reference Item
Replace clutch pedal arm and/or clutch master
cylinder.
- Clutch pedal arm: )(Page 5C-20)
- Clutch master cylinder: )(Page 5C-18)
Replace clutch disc. )(Page 5C-21)
- Clutch disc and cover: )(Page 5C-21)
- Flywheel: “Timing Chain Cover and Timing
Chain Removal and Installation”: D13A in
Section 1D (Page 1D-82)
Replace clutch cover. )(Page 5C-21)
18)
Replace clutch pedal arm and/or clutch master
cylinder.
- Clutch pedal arm: )(Page 5C-20)
- Clutch master cylinder: )(Page 5C-18)
Replace clutch cover. )(Page 5C-21)
Lubricate input shaft spline.
Replace input shaft. “Input Shaft Disassembly
and Reassembly”: D13A Model in Section 5B
(Page 5B-62)
Replace clutch disc. )(Page 5C-21)
Repair or replace clutch system.
Repair or replace clutch disc. )(Page 5C-21)
Replace clutch disc. )(Page 5C-21)
Replace clutch operating cylinder assembly.
)(Page 5C-18)
Replace clutch disc. )(Page 5C-21)
Replace clutch disc. )(Page 5C-21)
Replace clutch cover or flywheel.
- Clutch disc and cover: )(Page 5C-21)
- Flywheel: “Timing Chain Cover and Timing
Chain Removal and Installation”: D13A in
Section 1D (Page 1D-82)
mounting bolts / nuts. “Engine Mounting
Components”: D13A in Section 1D (Page 1D-
77)
Replace clutch operating cylinder assembly.
)(Page 5C-18)
Replace clutch disc. )(Page 5C-21)
Replace clutch disc. )(Page 5C-21)
Replace clutch cover. )(Page 5C-21)
Replace clutch disc. )(Page 5C-21)
Replace clutch disc. )(Page 5C-21)
Replace clutch disc. )(Page 5C-21)
Replace clutch disc. )(Page 5C-21)
 Clutch: D13A Model 5C-16

Repair Instructions
Clutch Pedal Position (CPP) Switch Removal Clutch Pedal Position (CPP) Switch Inspection
AENBL80A5326002
and Installation Refer to “CPP Switch Inspection and Adjustment”: K14B
AENBL80A5326001
Refer to “CPP Switch Removal and Installation”: K14B Model (Page 5C-3)
Model (Page 5C-3)

Clutch Pedal Inspection

AENBL80A5326003
Clutch Pedal Height
Measure distance between free position (1) and fully
depressed position (2) on clutch pedal which is shown
by “a” in figure. If clutch pedal height is out of
specification, replace pedal arm and/or clutch master
cylinder (3).
Clutch pedal height 3 2
“a”: 130 - 140 mm (5.11 - 5.51 in.)

“a”

3
1

I7V20A532004-01

2
Clutch Pedal Free Travel
Depress clutch pedal (1), stop the moment clutch
“a” resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by “b” in
the figure.
If “b” is not within specification, check pedal arm (2) and
master cylinder (3) and replace defective part.
I7V20A532003-02
Clutch pedal free travel
Cylinder Push Rod Play “b”: 2 – 8 mm (0.08 – 0.31 in.)
Press clutch pedal (1) gradually with finger, stop when
slight increase of resistance is felt and measure how Clutch Release Margin
much pedal has moved (push rod play) as represented 1) Pull up parking brake fully and block wheels.
by “a” as shown.
2) Start engine and keep engine at idle with neutral
If “a” is not within specification, replace master cylinder
gear position.
(3) or pedal arm (2).
3) Without clutch pedal (1) depressed, slightly push the
Push rod play shift lever to reverse position until transaxle emits
“a”: Max. 2mm (0.08 in.) gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress
clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full
stroke point (5) on clutch pedal (1) which is shown by
“c” in the figure.
If “c” is not within specification, it is possible that air
is trapped in this system. If suspected so, bleed air.
)(Page 5C-16)
Upon completion of above inspection, start engine
and check clutch for proper operation.
5C-17 Clutch: D13A Model

Clutch release margin

“c”: 25 – 55 mm (0.98 – 2.17 in.)

3
2

4 1

“b”
5 “c”

I7V20A532005-01

Clutch Fluid Level Inspection

AENBL80A5326004
1) Check clutch system for crack, damage and fluid
leakage.
If any faulty is found, repair or replace.
2) Check fluid level“Brake Fluid Level Inspection” in
Section 4A (Page 4A-4).
Clutch fluid specification
: Refer to Brake fluid reservoir cap

Air Bleeding of Clutch System

AENBL80A5326005 I7V20A532006-01

! CAUTION

• Brake fluid (Clutch fluid) is extremely

damaging to paint. If fluid should
accidentally touch painted surface,
immediately wipe fluid from paint and
clean painted surface.
• When operating the pedal stroke for air
bleeding of clutch system, after releasing
the clutch pedal, be sure to wait 1 second
or more before depressing it again.
Otherwise, the oil seal of operating
cylinder will be damaged, resulting in oil
leakage.

Bleed air from clutch system.

Refer to “Air Bleeding of Brake System” in Section 4A
(Page 4A-5)
 Clutch: D13A Model 5C-18

Clutch Fluid Pipe and Hose Components

AENBL80A5326006

Si

3 1

4
6

IBP80A532001-01

1. Clutch master cylinder 4. Brake master cylinder reservoir 7. Clutch fluid damper
Apply grease 99000-25100 to push rod tip.
2. Clutch fluid pipe 5. Operating cylinder 8. Clutch pipe joint
3. Clutch reservoir hose 6. Clamp

Clutch Fluid Pipe Removal and Installation

AENBL80A5326007
! CAUTION
Do not allow fluid to get on painted surface. It may cause painted surface damage.

Removal
1) Remove dust and dirt from each joint of pipe to be
disconnected and clean around brake master
cylinder reservoir cap.
2) Take out fluid from brake master cylinder reservoir 3

with syringe or such. 1

3) Pull out clamp (1) of clutch master cylinder (3) and 2
pull out clamp (5) of fluid pipe joint (4), and then
disconnect clutch fluid pipe (2).
4) Pull out clamp (6) of damper (7) and then disconnect
4
damper (7) from clutch fluid pipe (2).

6
7

IBP80A532002-01
5C-19 Clutch: D13A Model

Installation • After installation, check clutch pedal free travel.

Reverse removal procedure for installation noting the )(Page 5C-15)
following. • After installation, bleed air from clutch system.
)(Page 5C-16)
! CAUTION
• Check fluid leakage.
• Do not allow fluid to get on painted • Add fluid to MAX level of reservoir.
surface.
• Do not allow pipe to contact hard against Clutch Fluid Pipe Inspection
vehicle body or other parts. AENBL80A5326008
Check pipe for damage, dirt and leak. Replace if check
• Install each clamp securely. result is not satisfactory.

Clutch Master Cylinder Removal and Installation

AENBL80A5326009
Removal “A”: Grease 99000–25100 (SUZUKI Silicone
1) Clean around brake master cylinder reservoir cap Grease)
and take out fluid from brake master cylinder
reservoir with syringe or such.
2) Disconnect clutch fluid pipe from clutch master
cylinder (1). )(Page 5C-17)
3) Disconnect clutch reservoir hose (2). 1, (a)

1, (a)
1
“A”

IBP80A532003-01
IBP80A532005-01
4) Remove push rod (4) from clutch pedal (3). • Tighten clutch master cylinder nuts (1) to specified
5) Remove clutch master cylinder nuts (5) and then torque.
remove clutch master cylinder (6).
Tightening torque
Clutch master cylinder nut (a): 13 N·m (1.3 kgf-m,
6 9.58 lbf-ft)

Clutch Operating Cylinder Assembly Removal

5 4
and Installation
AENBL80A5326010
! CAUTION

5 • Do not allow fluid to get on painted

surfaces. It may cause painted surface
damage.
3 • Do not disassemble clutch operating
cylinder assembly.

Removal
1) Clean around brake master cylinder reservoir cap
IBP80A532004-01
and take out fluid from brake master cylinder
Installation reservoir with syringe or such.
Reverse removal procedure for installation noting the 2) Dismount transaxle assembly. “Manual Transaxle
following. Assembly Disassembly and Reassembly”: D13A
• Apply grease to push rod tip. Model in Section 5B (Page 5B-55)

3) Loosen clutch fluid pipe flare nut (1) of clutch
operating cylinder assembly (2).
4) Remove clutch pipe joint sleeve (3) from transaxle,
and then remove clutch fluid pipe (4).
5) Remove clutch operating cylinder assembly from
transaxle.
3
2
I5RW0A530008-01
Installation
1) Install clutch operating cylinder assembly (2) to
transaxle. Tighten new mounting bolts to specified
torque.
Tightening torque
Clutch operating cylinder assembly mounting
bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
Clutch Operating Cylinder Assembly Inspection
Check clutch fluid leakage, spring for damage and bearing for smooth rotation. If malfunction is found, replace clutch
operating cylinder assembly.
Clutch: D13A Model 5C-20
2) Connect clutch fluid pipe (4) to clutch operating
cylinder assembly temporarily.
3) Install clutch pipe joint sleeve (3) to transaxle
securely and then tighten clutch fluid pipe flare nut
(1) to specified torque.
Tightening torque
Clutch fluid pipe flare nut (b): 16 N·m (1.6 kgf-
m, 12.0 lbf-ft)
1, (b)
(a)
2
I5RW0A530009-01
4) Remount transaxle assembly. “Manual Transaxle
Assembly Disassembly and Reassembly”: D13A
Model in Section 5B (Page 5B-55)
5) Bleed air from clutch system and check clutch pedal
free travel.
- Bleed air clutch system: )(Page 5C-16)
- Clutch pedal free travel: )(Page 5C-15)
AENBL80A5326011
5C-21 Clutch: D13A Model

Clutch Pedal Assembly Components

AENBL80A5326012

1
b (a)
a (a)

(b)
(c)

a (a)
2 E

2 E 4
7 E

IBP80A532006-01

1. Clutch pedal bracket 5. Clutch pedal pad : 13 N⋅m (1.3 kgf-m, 9.58 lbf-ft)
2. Pedal bush 6. Cushion : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
: Apply grease to inside of spring.
3. Clutch pedal shaft spacer 7. Spring : 7.5 N⋅m (.76 kgf-m, 5.5 lbf-ft)
: Apply grease to inside of spring.
4. Clutch pedal 8. CPP Switch a, b: Tightening order: a → b

Clutch Pedal Assembly Removal and Installation

AENBL80A5326013
Removal
1) Remove push rod from clutch pedal.
2) Disconnect CPP switch connector, and then remove
CPP switch from clutch pedal assembly, if
necessary.
3) Remove clutch pedal assembly from vehicle body.

Installation
Reverse removal procedure for installation noting the
following.
• Tighten each bolts and nuts to specified torque.
)(Page 5C-20)
• Apply grease to push rod tip.
: Grease 99000–25100 (SUZUKI Silicone Grease)
 Clutch: D13A Model 5C-22

Clutch Cover and Clutch Disc Components

AENBL80A5326014

(a)

2
I7V20A532012-01

1. Clutch cover : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)

2. Clutch disc

Clutch Cover and Clutch Disc Removal and c) Fully tighten all bolts (3), (4) evenly and gradually
Installation to specified torque in numerical order (“1” – “6”)
AENBL80A5326015 starting from bolt nearby strut plate rivet (2).

Removal NOTE
1) Dismount manual transaxle. “Manual Transaxle While tightening clutch cover bolts, that the
Assembly Disassembly and Reassembly”: D13A clutch disc spline is centered.
Model in Section 5B (Page 5B-55)
2) Hold flywheel with special tool and remove clutch Special tool
cover (1) and clutch disc. (A): 09924M17811
(B): 09923M36320 m
Special tool
(A): 09924M17811 Tightening torque
Clutch cover bolt (a): 5 N⋅m → 23 N⋅m (0.51 kgf-m
→ 2.3 kgf-m, 4.0 lbf-ft → 17.0 lbf-ft)
Clutch cover bolt (b): 23 N⋅m (2.3 kgf-m, 17.0 lbf-
ft)

4, “4”, (a)

3, “2”, (b)
1

3, “1”, (b)
(B)
I7V20A532013-01

4, “5”, (a)
Installation 2

NOTE (A)
Before assembling, make sure that flywheel
surface and pressure plate surface have
been cleaned and dried thoroughly.
4, “6”, (a)
1) Hold flywheel with special tool (A).
2) Align clutch disc with crankshaft center using special 3, “3”, (b)
I9P60A531019-02
tool (B) and install clutch cover (1).
3) Install and tighten clutch cover bolts using the 4) Slightly apply grease to input shaft (1), then join
following procedure: manual transaxle with engine. “Manual Transaxle
Unit Dismounting and Remounting”: D13A Model in
a) Tighten 3 bolts (3) by hand. Section 5B (Page 5B-48)
b) Tighten other bolts (4) evenly and gradually to
5.0 N⋅m (0.51 kgf-m, 4.0 lbf-ft). “A”: Grease 99000–25210 (SUZUKI Super
Grease I)
5C-23 Clutch: D13A Model

NOTE
When inserting transaxle input shaft to clutch
disc, turn crankshaft little by little to match
the splines.

I7V20A532014-01

Clutch Cover

! CAUTION
I4RS0A530018-01
Do not disassemble clutch cover into
diaphragm spring and pressure plate.
Clutch Cover and Clutch Disc Inspection If found malfunction condition, replace clutch
AENBL80A5326016
cover.
Clutch Disc
Measure depth of rivet head depression, i.e. distance Check clutch cover for the following.
between rivet head and facing surface as shown in • Check diaphragm spring (1) for abnormal wear or
figure. damage.
If depression is found to have reached service limit at • Inspect pressure plate (2) for wear or heat spots.
any of rivet holes (2), replace clutch disc (1).
Rivet head depth
Limit: 0.2 mm (0.007 in.)

I3RM0A530015-01

Specifications
Tightening Torque Specifications
AENBL80A5327001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Clutch master cylinder nut 13 1.3 9.58 )
Clutch operating cylinder assembly mounting )
10 1.0 7.5
bolt
Clutch fluid pipe flare nut 16 1.6 12.0 )

NOTE
The tightening torque(s) also specified in:
“Clutch Pedal Assembly Components”: D13A Model
“Clutch Cover and Clutch Disc Components”: D13A Model

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fastener Caution” in Section 00 (Page 00-
5).
 Clutch: D13A Model 5C-24

Special Tools and Equipment

Recommended Service Material
AENBL80A5328001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Silicone Grease P/No.: 99000–25100 )/)
SUZUKI Super Grease I P/No.: 99000–25210 )

NOTE
Required service material(s) also described in:
“Clutch Fluid Pipe and Hose Components”: D13A Model
“Clutch Pedal Assembly Components”: D13A Model

Special Tool
AENBL80A5328002
09923M36320 09924M17811
Clutch center guide (15 mm) Flywheel holder
) )/)

Section 6
Steering
CONTENTS
Precautions .................................................6-1
Precautions............................................................. 6-1
Precautions for Steering ....................................... 6-1
Steering System Note ........................................... 6-1
Power Assisted Steering System........... 6C-1
Precautions for Diagnosing Trouble...................... 6-1
Steering General Diagnosis.................... 6A-1
Precautions...........................................................6A-1
Precautions for Steering General Diagnosis ....... 6A-1
Diagnostic Information and Procedures............6A-1
Steering Symptom Diagnosis.............................. 6A-1
Steering System Inspection ................................ 6A-2
Steering Wheel and Column................... 6B-1
General Description .............................................6B-1
Steering Wheel and Column Construction .......... 6B-1
Diagnostic Information and Procedures............6B-1
Checking Steering Column for Accident
Damage ............................................................ 6B-1
Repair Instructions ..............................................6B-1
Steering Wheel and Column Components.......... 6B-1
Steering Wheel Removal and Installation ........... 6B-3
Contact Coil Assembly Removal and
Installation (With Air Bag) ................................. 6B-5
Centering of Contact Coil Assembly (With Air
Bag) .................................................................. 6B-6
Contact Coil Assembly Inspection (With Air
Bag) .................................................................. 6B-6
Cancel Cam Removal and Installation
(Without Air Bag)............................................... 6B-6
Cancel Cam Inspection (Without Air Bag)........... 6B-7
Steering Column Removal and Installation ......... 6B-7
Steering Shaft Joint On-Vehicle Inspection ........ 6B-9
Steering Column Inspection ................................ 6B-9
Steering Column Lower Shaft Inspection.......... 6B-10
Steering Lock Removal and Installation............ 6B-10
Steering Lock Disassembly and Reassembly ... 6B-11
Steering Lock Inspection................................... 6B-12
Ignition Switch Removal and Installation........... 6B-12
Ignition Switch Inspection ................................. 6B-12
Steering Lower Shaft Removal and
Installation....................................................... 6B-13
Specifications.....................................................6B-14
Tightening Torque Specifications...................... 6B-14
Table of Contents 6- i
Special Tools and Equipment ...........................6B-14
Special Tool ......................................................6B-14
General Description .............................................6C-1
P/S System Description ......................................6C-1
Description of EPS System Component
Function ............................................................6C-1
OBD System Description ....................................6C-1
Schematic and Routing Diagram ........................6C-2
P/S System Diagram...........................................6C-2
Component Location ...........................................6C-3
Power Steering Control System Component
Location.............................................................6C-3
Diagnostic Information and Procedures ............6C-4
P/S System Check ..............................................6C-4
“P/S” Warning Light Check..................................6C-6
DTC Check..........................................................6C-6
6
DTC Clearance ...................................................6C-6
DTC Table...........................................................6C-7
Fail-Safe Table....................................................6C-8
Scan Tool Data ...................................................6C-9
Visual Inspection ...............................................6C-10
P/S System Symptom Diagnosis ......................6C-10
“P/S” Warning Light Does Not Come ON with
Ignition “ON” before Engine Starts ..................6C-11
“P/S” Warning Light Remains ON Steady after
Engine Starts...................................................6C-12
DTC C1111 / C1113 / C1115 / C1116 ..............6C-12
DTC C1141 / C1142 / C1143 / C1145 ..............6C-14
DTC C1153 / C1155..........................................6C-15
DTC C1160 .......................................................6C-16
DTC C1161 / C1162..........................................6C-16
DTC U0073 .......................................................6C-17
DTC U0100 .......................................................6C-17
DTC U0155 .......................................................6C-17
P/S Control Module Power Supply and
Ground Circuit Check......................................6C-17
Inspection of P/S Control Module and Its
Circuits ............................................................6C-18
Steering Wheel Play Check ..............................6C-22
Steering Force Check .......................................6C-22
Repair Instructions ............................................6C-23
Steering Gear Case Assembly Components ....6C-23
Tie-Rod End Boot On-Vehicle Inspection .........6C-23
6-ii Table of Contents
Tie-Rod End Removal and Installation..............6C-24
Tie-Rod End Inspection.....................................6C-25
Steering Gear Case Assembly Removal and
Installation .......................................................6C-25
Steering Gear Case Bushing Removal and
Installation .......................................................6C-26
Steering Rack Boot Inspection..........................6C-26
Tie-Rod / Rack Boot Removal and Installation ..6C-27
Pinion Shaft Rotation Torque Inspection...........6C-28
Pinion Shaft Rotation Torque Adjustment .........6C-28
P/S Control Module Removal and Installation...6C-29
Torque Sensor Inspection .................................6C-29
P/S Motor Inspection.........................................6C-30
Specifications .....................................................6C-31
Tightening Torque Specifications......................6C-31
Special Tools and Equipment ...........................6C-31
Recommended Service Material .......................6C-31
Special Tool ......................................................6C-31
 Precautions: 6-1

Precautions
Steering

Precautions
Precautions for Steering
AENBL80A6000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Fastener Caution
Refer to “Fastener Caution” in Section 00 (Page 00-5).

Air Bag Warning

Refer to “Air Bag Warning” in Section 00 (Page 00-5).

Precautions for Vehicle Equipped with Supplemental Restraint (Air Bag) System
Refer to “Precautions for Vehicles Equipped with Supplemental Restraint (Air Bag) System” in Section 00 (Page 00-6).

Reassembling Note for Wiring Harness

Be sure to observe the Wiring Diagram Manual whenever installing wiring whenever installing wiring harness.
Otherwise, electrical trouble may occur.

Precautions for CAN Communication System

Refer to “Precautions for CAN Communication System” in Section 00 (Page 00-8).

Steering System Note

AENBL80A6000002
NOTE
All steering gear fasteners are important attaching parts in that they could affect the performance of
critical parts and systems, and/or could result in major repair expense. They must be replaced with
those of the same part number or equivalent if replacement becomes necessary. Do not use a
substitute part of lesser quality. Torque values must be observed as specified during reassembly to
assure proper retention of these parts.

Precautions for Diagnosing Trouble

AENBL80A6000003
! WARNING
Road test should be carried out by 2 persons, a driver and a tester. Select a safe place where there is
neither any traffic nor the possibility of any traffic accident. Be very careful during testing to avoid
accidents.

• Before using scan tool, read its “Operator’s (Instruction) Manual” to know how to use it.
• Be sure to clear all DTCs after completing troubleshooting.
• Be sure to clear DTC after repair working. )(Page 6C-7)
6A-1 Steering General Diagnosis:
Steering General Diagnosis
Steering
Precautions
Precautions for Steering General Diagnosis
Since the problems in steering involve several systems, such possibilities should be fully considered when diagnosing
a complaint. To avoid being misled by an unclear symptom, always perform the road test first. Proceed with the
following preliminary inspection and correct defects if any.
1) Inspect tires for proper pressure and uneven wear.
2) Hoist vehicle and inspect steering system for loose or damaged parts.
3) Spin front wheels. Inspect for out-of-round tires, out-of-balance tires, bent rims, loose and/or rough wheel
bearings.
Diagnostic Information and Procedures
Steering Symptom Diagnosis
Condition Possible cause
Hard steering Insufficient tire pressure
Malfunction of power steering system
Binding tie-rod end ball joint
Binding suspension arm ball joint
Disturbed front wheel alignment
Binding steering column
Improper tooth contact between rack
and pinion
Too much play in steering Worn wheel bearings
Loose steering gear case bolt
Faulty steering gear case assembly
Worn joint of steering column
Worn tie-rod end or tie-rod ball joint
Worn suspension arm joint
Improper tooth contact between rack
and pinion
AENBL80A6100001
AENBL80A6104001
Correction / Reference Item
Adjust tire pressure.
Check and correct. )(Page 6C-4)
Replace tie-rod end. )(Page 6C-24)
Replace suspension arm. )(Page 2B-8)
Check and adjust front wheel alignment.
)(Page 2B-1)
Replace steering column. )(Page 6B-8)
Check rack and pinion shaft rotation torque.
)(Page 6C-28)
If defective, replace steering gear case
assembly. )(Page 6C-25)
Replace wheel bearing. )(Page 3A-14)
Tighten steering gear case bolt. )(Page 6C-
25)
Replace steering gear case assembly. )(Page
6C-25)
Replace steering column assembly. )(Page
6B-8)
Replace tie-rod end or tie-rod. Refer to “Tie-
Rod End Removal and Installation” in Section
6C (Page 6C-24) or “Tie-Rod / Rack Boot
Removal and Installation” in Section 6C (Page
6C-27).
Replace suspension arm. )(Page 2B-8)
Check rack and pinion shaft rotation torque.
)(Page 6C-28)
If defective, replace steering gear case
assembly. )(Page 6C-25)

Condition Possible cause
Poor return ability Binding tie-rod end ball joint
Binding suspension arm joint
Binding steering column
Disturbed front wheel alignment
Faulty steering gear case assembly
Insufficient tire pressure
Improper tooth contact between rack
and pinion
Steering noise (Rattle or Loose steering gear case bolt
chuckle)
Improper tooth contact between rack
and pinion
Faulty steering gear case assembly
Broken or damaged wheel bearing(s)
Worn tie-rod end or tie-rod inside ball
joint
Wander or poor steering Mismatched tire or uneven tire pressure
stability Loose suspension arm joint and tie-rod
end
Faulty front strut assembly or mounting
Loose stabilizer bar
Broken or sagging coil spring
Faulty front strut assembly (shock
absorber)
Improper tooth contact between rack
and pinion
Disturbed front wheel alignment
Faulty steering gear case assembly
Erratic steering when Worn wheel bearing(s)
braking Broken or sagging coil spring
Faulty front strut assembly (shock
absorber)
Uneven tire pressure
Disturbed front wheel alignment
Brakes not working in unison
Front brake disc stained with brake fluid
Warped brake disc
Badly worn brake pad
Steering General Diagnosis: 6A-2
Correction / Reference Item
Replace tie-rod end. )(Page 6C-24)
Replace suspension arm. )(Page 2B-8)
Replace steering column. )(Page 6B-8)
Check and adjust front wheel alignment.
)(Page 2B-1)
Replace steering gear case assembly. )(Page
6C-25)
Adjust tire pressure.
Check rack and pinion shaft rotation torque.
)(Page 6C-28)
If defective, replace steering gear case
assembly. )(Page 6C-25)
Tighten steering gear case bolt. )(Page 6C-
25)
Check rack and pinion shaft rotation torque.
)(Page 6C-28)
If defective, replace steering gear case
assembly. )(Page 6C-25)
Replace steering gear case assembly. )(Page
6C-25)
Replace wheel bearing(s). )(Page 3A-14)
Replace tie-rod end or tie-rod. Refer to “Tie-
Rod End Removal and Installation” in Section
6C (Page 6C-24) or “Tie-Rod / Rack Boot
Removal and Installation” in Section 6C (Page
6C-27).
Replace or adjust tire pressure. )(Page 2D-2)
Replace suspension arm or tie-rod end. Refer
to “Suspension Arm Removal and Installation”
in Section 2B (Page 2B-8) or “Tie-Rod End
Removal and Installation” in Section 6C (Page
6C-24).
Replace front strut assembly or repair
mounting. )(Page 2B-4)
Tighten or replace stabilizer bar or bushing.
)(Page 2B-12)
Replace coil spring. )(Page 2B-6)
Replace front strut assembly (shock absorber).
)(Page 2B-4)
Check rack and pinion shaft rotation torque.
)(Page 6C-28)
If defective, replace steering gear case
assembly. )(Page 6C-25)
Check and adjust front wheel alignment.
)(Page 2B-1)
Replace steering gear case assembly. )(Page
6C-25)
Replace wheel bearing(s). )(Page 3A-14)
Replace coil spring. )(Page 2B-6)
Replace front strut assembly (shock absorber).
)(Page 2B-4)
Adjust tire pressure.
Check and adjust front wheel alignment.
)(Page 2B-1)
Check and repair brake system. )(Page 4A-1)
Repair or replace disc. )(Page 4B-6)
Replace front brake disc. )(Page 4B-6)
Replace front brake pad. )(Page 4B-6)
6A-3 Steering General Diagnosis:

Steering System Inspection

AENBL80A6104002
Check steering system referring to the following items.
Inspection Item Referring section
Steering wheel Play, rattle “Steering Wheel Play Check” in Section 6C (Page 6C-22)
Tie-rod end Looseness and damage “Tie-Rod End Inspection” in Section 6C (Page 6C-25)
Wheel alignment “Front Wheel Alignment Inspection and Adjustment” in
Section 2B (Page 2B-1)
Tie-rod end boot Damage “Tie-Rod End Boot On-Vehicle Inspection” in Section 6C
(Page 6C-24)
Steering rack boot Damage “Steering Rack Boot Inspection” in Section 6C (Page 6C-
26)
Steering shaft joint Rattle and damage “Steering Shaft Joint On-Vehicle Inspection” in Section 6B
(Page 6B-9)
P/S system Operation “P/S System Check” in Section 6C (Page 6C-4)
 Steering Wheel and Column: 6B-1

Steering Wheel and Column

Steering

General Description
Steering Wheel and Column Construction
AENBL80A6201001
• The steering column is of a collapsible tube type. The column contracts in the event of a heavy frontal collision to
absorb impact energy and thus helps reduce injuries to the driver. The steering column also has the following
features:
– The steering column is provided with a tilt adjustment mechanism. This mechanism allows step-less adjustment
of the whole steering column in up-and-down directions.
– The steering column incorporates a steering lock to help prevent theft. The ignition switch is installed on the
steering column together with the steering lock.
When servicing the steering column, it is important that only the specified fasteners are used and they are tightened
exactly to the specified torques to keep the collapsible steering column and other features fully workable. It is also
important to carefully handle the steering column during and after its removal from the vehicle, such as avoiding
hammering the end of the steering shaft, leaning the removed steering column assembly against the wall or any other
object, or dropping the assembly. These precautions should be observed to prevent the capsules that keep the
designed length and position of the steering column from being loosened.
• For vehicle with air bags, the steering wheel has the driver air bag (inflator) module of the supplemental restraint (air
bag) system installed at the center. During service operations on the steering wheel, the air bag (inflator) module
should be handled carefully while observing all instructions in “Precautions for Air Bag System Service” in Section
8B (Page 8B-1) to prevent accidental deployment.

Diagnostic Information and Procedures

Checking Steering Column for Accident Refer to “Steering Column Inspection” (Page 6B-9).
Damage
AENBL80A6204001

Repair Instructions
Steering Wheel and Column Components
AENBL80A6206001
! WARNING
Be sure to remove and install driver air bag (inflator) module according to procedure described in
“Driver Air Bag (Inflator) Module Removal and Installation” in Section 8B (Page 8B-63).

! CAUTION
When installing steering wheel, be sure to center the contact coil assembly. )(Page 6B-6)
6B-2 Steering Wheel and Column:

[B] 7

3
(e)

(e)
18

(a)
2

13 (b)
8 9

12 (b)

10

[A]
3
11 (c)
17

(d) 14
6

15

(a)
1 16

(d)

IBP80A620001-02

[A]: With air bag
[B]: Without air bag
1. Driver air bag (inflator) module
2. Steering wheel pad
3. Steering wheel
4. Steering column upper cover
5. Steering column lower cover
6. Contact coil assembly
: Be sure to perform centering.
)(Page 6B-6)
7. Cancel cam
8. Steering column 17. Steering joint cover
9. Steering lower shaft 18. Steering column reinforcement
10. Steering column assembly : 33 N⋅m (3.4 kgf-m, 24.5 lbf-ft)
11. Steering column mounting nut : 35 N⋅m (3.6 kgf-m, 26.0 lbf-ft)
: For installation, refer to “Steering Column Removal
and Installation” (Page 6B-8)
12. Steering column joint bolt : 14 N⋅m (1.4 kgf-m, 10.5 lbf-ft)
: For installation, refer to “Steering Lower Shaft
Removal and Installation” (Page 6B-13).
13. Steering lower shaft joint bolt : 9.0 N⋅m (0.92 kgf-m, 7.0 lbf-ft)
: For installation, refer to “Steering Lower Shaft
Removal and Installation” (Page 6B-13).
14. Ignition switch : 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)
15. Steering lock : Do not reuse.
16. Ignition switch cylinder

Steering Wheel Removal and Installation
AENBL80A6206002
! WARNING
For handling of removed driver air bag
(inflator) module, refer to “Precautions for
Handling and Storage of Air Bag System
Components” in Section 8B (Page 8B-1).
! CAUTION
• Do not turn the rotor of the contact coil
more than about two and a half turns
clockwise or counterclockwise from the
center position with steering wheel
removed, otherwise the coil will break.
(with air bag)
• Be careful not to damage and give
excessive shock to steering column.
With Air Bag
Removal
1) Park vehicle on a level surface, apply parking brake,
set steering wheel in straight-ahead position and set
ignition “OFF”.
2) Disconnect negative (–) cable at battery.
3) Disable air bag system. )(Page 8B-61)
4) Remove driver air bag (inflator) module from
steering wheel. )(Page 8B-64)
5) Disconnect steering switch connector.
6) Remove steering shaft nut and then make alignment
marks (1) across steering wheel and shaft for correct
reinstallation.
I4RS0A620005-01
7) Remove steering wheel using special tool.
Special tool
(A): 09944M36011
Steering Wheel and Column: 6B-3
(A)
I9P60A620002-01
Installation
! CAUTION
Performing Steps 1), 2) and 3) below is
indispensable for installation of steering
wheel. Neglecting these steps will cause
damage to rotation part of contact coil when
steering is turned.
1) Check that vehicle's front wheels are at straight-
ahead position.
2) If contact coil is turned after removing steering
wheel, center contact coil assembly. )(Page 6B-6)
3) Install steering wheel to steering shaft with 2 grooves
(1) in contact coil assembly fitted on 2 lugs (2) on
back side of steering wheel aligning matchmarks (3)
on steering wheel and steering shaft.
4) Tighten steering shaft nut (4) to specified torque.
Tightening torque
Steering shaft nut (a): 33 N·m (3.4 kgf-m, 24.5
lbf-ft)
3
4,(a)
1
IAP70P620003-01
5) Connect steering switch connector.
6) Install driver air bag (inflator) module to steering
wheel. )(Page 8B-63)
7) Connect negative (–) cable at battery.
8) Enable air bag system. )(Page 8B-61)
6B-4 Steering Wheel and Column:

Without Air Bag

Removal
1) Park vehicle on a level surface, apply parking brake,
set steering wheel in straight-ahead position and set
ignition “OFF”.
2) Disconnect negative (–) cable at battery.
3) Remove steering wheel pad.
4) Remove screws (1) from steering wheel.
(A)
5) Disconnect horn connector (2).
I9P60A620002-01
6) Remove steering wheel pad base (3).
Installation
2
1) Check that vehicle's front wheels are at straight-
ahead position.
2) Install steering wheel to steering shaft with 2 lugs (1)
in cancel cam fitted on 2 grooves (2) on back side of
steering wheel aligning matchmarks (3) on steering
wheel and steering shaft.
3) Tighten steering shaft nut (4) to specified torque.
1
1
Tightening torque
3 Steering shaft nut (a): 33 N·m (3.4 kgf-m, 24.5
lbf-ft)
IBP80A620002-01

7) For diesel model, remove screws (1), then remove 3

steering wheel damper (2).

1 4,(a)

1
2 IBP80A620005-01

4) For diesel model, install steering wheel damper (2),

then tighten screws (1).
IBP80A620003-01

8) Remove steering shaft nut and then make alignment 1

marks (1) across steering wheel and shaft for correct
reinstallation.

IBP80A620003-01

5) Connect horn connector (2).

I4RS0A620005-01
6) Install steering wheel pad base (3), then tighten
9) Remove steering wheel using special tool. screws (1).
Special tool
(A): 09944M36011
 Steering Wheel and Column: 6B-5

“2”
1
1
1
“1”
2
3
I8C50A620009-01
IBP80A620002-01
3: Contact coil assembly
7) Install steering wheel pad.
8) Connect negative (–) cable at battery. 5) Disconnect horn connector (1).

Contact Coil Assembly Removal and

Installation (With Air Bag)
AENBL80A6206003

! CAUTION
Do not turn the rotor of the contact coil more
1
than about two and a half turns clockwise or
counterclockwise from the center position
with steering wheel removed, otherwise the
coil will break.
I8C50A620010-01
Removal
6) Release claws (2) and remove contact coil assembly
1) Remove steering wheel from steering column. (1).
)(Page 6B-3)
2) Remove screw (1), then detach steering column 2
lower cover (2). 1

3) Remove tapping screws (3), then detach steering

column upper cover (4).

4
3

IBP80A620006-01

Installation
1) Check that vehicle’s front wheels are at straight-
ahead position.
2
2) Install contact coil assembly (1) to steering column
1 securely.
I9P60A620004-02

4) Disconnect contact coil assembly connector (1) as

follows.
a) Release locking slider (2) by sliding it in arrow
direction “1”.
b) After unlocked, disconnect contact coil assembly
connector by pulling it in arrow direction “2”.
6B-6 Steering Wheel and Column:

NOTE
4
New contact coil assembly is supplied with 3
contact coil set and held at its center position
with a lock pin (2). Remove this lock pin after
installing contact coil assembly to steering
column.

1
I9P60A620004-02

6) Install steering wheel to steering column. )(Page

I9P60A620008-01 6B-3)
3) Connect contact coil assembly connector (1) and
horn connector (2) to contact coil assembly (3) Centering of Contact Coil Assembly (With Air
securely. )(Page 6B-6) Bag)
AENBL80A6206004
NOTE 1) Remove steering wheel.)(Page 6B-3)
Make sure to lock contact coil assembly 2) Confirm that ignition is “OFF”.
connector. 3) Turn contact coil assembly fully counterclockwise.

! CAUTION
Turning the assembly with excessive force
3 will break coil. Turn rotation part (2) with a
light force while holding bottom of connector
(1).

1
1

IBP80A620007-01

4) Install steering column upper cover (4) with tapping

screws (3).
5) Install steering column lower cover (2) with screw
(1).

! CAUTION
2
To prevent damage to each lead wire when IBP80A620008-01
installing covers, be careful not to pinch lead 4) From the position of Step 3), turn contact coil
wire between covers. assembly clockwise to place connector at top
position within one rotation.
5) Turn rotation part (2) two turns clockwise to place
connector (1) at top position. Check that triangle
mark (4) on rotation part is aligned with that on
stationary part (3) as shown in figure.
 Steering Wheel and Column: 6B-7

1 2
3

1
4 2
IBP80A620010-01
3
IBP80A620009-01
Installation
1) Check that vehicle’s front wheels are at straight-
Contact Coil Assembly Inspection (With Air
ahead position.
Bag)
AENBL80A6206005 2) Install cancel cam to steering column securely.
1) Remove contact coil assembly referring to “Contact 3) Connect horn connector to cancel cam.
Coil Assembly Removal and Installation (With Air 4) Install steering column upper cover (4) with tapping
Bag)” (Page 6B-5). screws (3).
2) Inspect contact coil assembly referring to “Contact 5) Install steering column lower cover (2) with screw
Coil and Its Circuit Check” in Section 8B (Page 8B- (1).
56).
! CAUTION
Cancel Cam Removal and Installation (Without To prevent damage to each lead wire when
Air Bag) installing covers, be careful not to pinch lead
AENBL80A6206006
Removal wire between covers.
1) Remove steering wheel from steering column.
)(Page 6B-3)
4
2) Remove screw (1), then detach steering column 3
lower cover (2).
3) Remove tapping screws (3), then detach steering
column upper cover (4).

4
3

1
I9P60A620004-02

6) Install steering wheel to steering column. )(Page

6B-3)
2
Cancel Cam Inspection (Without Air Bag)
1 AENBL80A6206007
I9P60A620004-02 • Inspect cancel cam (1) for any signs of scorching,
4) Disconnect horn connector (1). melting, wear or damage. Replace cancel cam if
5) Release claws (2) and remove cancel cam (3). defective.
• Check for continuity between cancel cam terminal (2)
and contact horn (3) as shown.
If no continuity, replace cancel cam.
6B-8 Steering Wheel and Column:

8) Disconnect P/S control module connector (2).

2
3
2

IBP80A620011-01
1

Steering Column Removal and Installation

AENBL80A6206008

! WARNING
IAP70P620007-01
For handling of removed air bag (inflator)
9) Remove driver side foot duct from HVAC unit.
module, refer to “Precautions for Handling
and Storage of Air Bag System Components” 10) Detach steering column harness clamps (1).
in Section 8B (Page 8B-1). 11) Disconnect P/S control module connector (2).
12) Disconnect both key switch connector (3) and
! CAUTION ignition switch connector (4).
13) Remove steering column mounting nuts (5) and
• Steering column is designed to absorb reinforcement nut (6).
impact by deforming itself. Be sure to take
the following in mind when handling
removed steering column.
1
– Dropping steering column assembly on
its end could collapse steering shaft or 4 3
loosen capsules that maintain original
column length.
1
– Leaning steering column assembly on
wall or anything other could cause it to 5
bend or be deformed.
5
• Any of the damage could impair the
column’s collapsible arrangement. 1

• Steering column mounting nuts should not

be loosened with steering shaft joint upper
side bolt tightened as this could cause 6
damage to shaft joint bearing.
2
Removal IBP80A620012-01
1) Remove the following part. 14) Remove steering column.
• With air bag: Contact coil )(Page 6B-5)
• Without air bag: Cancel cam )(Page 6B-7) Installation
2) Remove immobilizer control module from steering ! CAUTION
lock. )(Page 10C-13)
Be sure to install steering lower shaft after
3) Remove lighting switch and wiper switch.
tightening steering column mounting nuts. If
• Lighting switch: )(Page 9B-8) steering lower shaft is installed before
• Wiper switch: )(Page 9D-6) tightening the nuts, steering shaft joint of
4) Remove steering column hole cover. )(Page 9C-10) steering column may be damaged.
5) Remove steering joint cover. )(Page 6B-1)
1) Check that vehicle’s front wheels are at straight-
6) Remove steering lower shaft. )(Page 6B-13) ahead position.
7) Remove combination meter cluster panel (1).
)(Page 9C-10)
 Steering Wheel and Column: 6B-9

2) Install steering column. Then tighten steering column • Lighting switch: )(Page 9B-8)
lower nuts (1) and then steering column upper nuts • Wiper switch: )(Page 9D-6)
(2) to specified torque.
13) Install immobilizer control module to steering lock.
3) Install reinforce nut (3) to specified torque. )(Page 10C-13)
NOTE 14) Install the following part.
• With air bag: Contact coil )(Page 6B-5)
• When installing, make sure that clearance
“a” between bolt (4) and bracket (5) should • Without air bag: Cancel cam )(Page 6B-7)
be 0 (zero). 15) Install steering column hole cover. )(Page 9C-10)
• After installing tilt steering column, make
sure that steering column moves upwards Steering Shaft Joint On-Vehicle Inspection
AENBL80A6206009
and downwards smoothly and stops when
Check steering shaft joint for wear and damage. Replace
tilt lever is fixed.
steering column assembly with new one if defective.
Tightening torque
Steering column mounting lower nut (a): 14 N·m
(1.4 kgf-m, 10.5 lbf-ft)
Steering column mounting upper nut (b): 14 N·m
(1.4 kgf-m, 10.5 lbf-ft)
Steering column reinforce nut (C): 5.5 N·m (0.56
kgf-m, 4.0 lbf-ft)
4) Connect both key switch connector (6) and ignition
switch connector (7).
5) Connect P/S control module connector (8).
6) Attach steering column harness clamps (9) in place.
IAP70P620019-01

9 Steering Column Inspection

AENBL80A6206010
6
7
NOTE

2, (b)
Steering column assembly should be
9
inspected if vehicle was involved in accident
2, (b) and steering column assembly was exposed
to impact or air bag deployed.
9
1, (a)
Perform the following checks if damage to steering
column assembly is suspected. If check result is not OK,
1, (a) replace steering column assembly with new one.
• Check that two capsules (1) are attached to steering
3, (c) column bracket securely.

8 1
5

“a” “a”

4
IBP80A620013-01
I9P60A620019-01
7) Install driver side foot duct to HVAC unit.
• Check steering column assembly for looseness in
8) Connect P/S control module connector. direction of arrows [a] and [b] in figure.
9) Install combination meter cluster panel. )(Page 9C-
10)
10) Install steering lower shaft. )(Page 6B-13)
11) Install steering joint cover. )(Page 6B-1)
12) Install lighting switch and wiper switch.
6B-10 Steering Wheel and Column:

• Check steering lower shaft for smooth rotation.

Steering Lock Removal and Installation

AENBL80A6206012

Removal
[a]
! WARNING
[b]
The steering lock uses magnesium parts.
Never perform drilling, cutting, filing or other
work which produces sparks on the steering
lock. The magnesium powder is highly
I9P60A620020-02
flammable and the sparks may ignite the
• Check that distances “a” and “b” shown in figure are magnesium powder, causing a fire.
as specified.
Power steering column length ! CAUTION
“a”: 465 mm (18.3 in.)
“b”: 118.6 ± 1.5 mm (4.7 ± 0.059 in.) Take the following precautions when
removing and installing the steering column
“a” and steering lock.
• Be careful not to damage or apply heavy
impact.
• If dust, dirt, oil or water enters in the
steering column or steering lock, it may
causes malfunction. Keep the steering
column and lock away from such
contaminations.

1) Remove steering column. )(Page 6B-8)

2) Hold steering column using soft jawed vise.
“b”
3) Loosen steering lock bolts (2) using chisel, then
remove steering lock (3) from steering column (1).

3
1

I9P60A620021-01

Steering Column Lower Shaft Inspection

AENBL80A6206011 2
I8C50A620020-01
• Adjust distance “a” between yoke centers of steering
lower shaft bearing to 259 mm (10.19 in.). Installation
• Then check that steering lower shaft retracts by 25
mm (0.98 in.) and extends by 5 mm (0.20 in.) from ! CAUTION
distance “a”.
• If steering lock bolts (2) are loosened using
chisel, replace steering column (1) with
[a] [b]
new one. Also, do not expose new steering
column to any shock.
• If steering lock (3) is replaced, check
steering column and torque sensor after
installation.
1
“a” – Steering column: )(Page 6B-9)
I9P60A620025-01 – Torque sensor: )(Page 6C-29)
[a]: Retracts by 25 mm (0.98 in.) 1. Yoke
[b]: Extends by 5 mm (0.20 in.)
 Steering Wheel and Column: 6B-11

• Do not reuse steering lock bolts. Steering

lock cannot be installed on steering
column securely if these bolts are reused.

3
1
IBP80A620015-02

5) Install steering column. )(Page 6B-8)

6) Set ignition to “ACC” or “ON” and check that steering
shaft rotates smoothly. Then set ignition to “LOCK”
(OFF) (and pull out key) and check that steering
2
I8C50A620020-01 wheel is locked.
7) If ignition switch cylinder has been replaced, register
1) Align oblong hole (2) in steering shaft (3) with center ignition key transponder code in BCM after
of hole (1) in steering column. completing installation. )(Page 10B-26)
2) Turn ignition key to “LOCK” position and pull it out,
then align lug of steering lock with hole in steering Steering Lock Disassembly and Reassembly
AENBL80A6206013
shaft.
NOTE
• Ignition switch and ignition switch cylinder
can be replaced without removing steering
lock.
• When removing steering lock, refer to
“Steering Lock Removal and Installation”
(Page 6B-10).
3

2
Disassembly
1
1) Remove ignition switch (1). )(Page 6B-12)
2) Turn ignition key to “ACC”, then push lock button (4)
on ignition switch cylinder using a rod (2) of about 2
mm (0.08 in) in diameter inserted through hole (3).
3) Pull out ignition switch cylinder (5) from steering lock
(6).
I9P60A620029-01
1
3) Install steering lock to steering shaft with key
6
cylinder (1) toward steering wheel.

1
3

5
I9P60A620032-02

IBP80A620014-01

4) Tighten new steering lock bolts (1) until head of each

bolt is broken off.
6B-12 Steering Wheel and Column:

Reassembly 4) Disconnect connector (1) from ignition switch (2).

Reverse removal procedure, noting the following points. 5) Remove screws (4), then remove ignition switch
• Turn ignition key to “ACC”, then insert ignition switch from steering lock (3).
cylinder into steering lock securely.
3
• If ignition switch cylinder has been replaced, register
ignition key transponder code in BCM after completing 2

installation. )(Page 10B-26) 4 2

3
Steering Lock Inspection
AENBL80A6206014 1
NOTE
Steering lock can be inspected on vehicle.

Disconnect connector from steering lock (2).

Check for continuity between terminals “1” and “2” of
steering lock connector (1). If check result is not as I9P60A620036-05

specified, replace steering lock.

Installation
2 Reverse removal procedure.

Ignition Switch Inspection

AENBL80A6206016
1
• Check for continuity between terminals at each switch
position. If check result is not as specified, replace
ignition switch.

2 1 3 2 1

I9P60A620033-05 6 5 4
Steering lock switch continuity

[A]
1 2
[B]

[C]

[D] I9P60A620037-04
I9P60A620034-02
Ignition switch continuity
[A]: Terminal [C]: Key inserted
[B]: Condition [D]: Key pulled out
Terminal
1 2 3 4 5 6
Position
Ignition Switch Removal and Installation
AENBL80A6206015 LOCK

ACC
Removal
ON
1) Disconnect negative (–) cable at battery.
2) Remove steering column upper cover and lower
cover. START

• With air bag: )(Page 6B-5) I9P60A620038-01

• Without air bag: )(Page 6B-7)

3) Confirm that ignition key is removed.
 Steering Wheel and Column: 6B-13

Steering Lower Shaft Removal and Installation Installation

AENBL80A6206017
! CAUTION
Never turn steering wheel while steering
lower shaft is removed.
If it is turned and contact coil assembly gets
out of centered position, the assembly must
be centered again. Also, turning steering
wheel more than about two and a half turns
will break contact coil assembly. (with air
bag)
Removal
1) Turn steering wheel so that vehicle’s front wheels
are at straight-ahead position.
2) Set ignition “LOCK” and remove key.
3) Remove steering joint cover. )(Page 6B-1)
4) Make matchmarks (1) on the following parts for
correct reinstallation.
• Steering lower shaft (2) and shaft joint of steering
column (3)
• Steering lower shaft (2) and pinion shaft (4)
5) Remove steering lower shaft joint bolts (5) and
steering column joint bolt (6).
6) Remove steering lower shaft.
! CAUTION
First insert steering lower shaft into the joint
on the steering column side and then fit the
joint on the other end onto pinion shaft;
otherwise joints of steering lower shaft will
be damaged.
1) Check that vehicle’s front wheels are at straight-
ahead position.
2) Align flat part “a” on steering lower shaft (1) with bolt
hole “b” of steering shaft joint (2) of steering column
as shown. Then insert steering lower shaft into shaft
joint of steering column while aligning matchmarks
(3).
3) Fit joint part of steering lower shaft (1) onto pinion
shaft (4) while aligning matchmarks (5).
4) Tighten steering lower shaft joint bolt and steering
column joint bolt to specified torque in numerical
order (“1” through “2”) as indicated in figure.
Tightening torque
Steering lower shaft joint bolt (a): 35 N·m (3.6
kgf-m, 26.0 lbf-ft)
Steering column joint bolt (b): 35 N·m (3.6 kgf-
m, 26.0 lbf-ft)

3 2

“2”, (b) “b”

6

1
3 “a”
2
1

1
1
4 5
5
IBP80A620016-01
4 “1”, (a)

IBP80A620017-01

5) Install steering joint cover. )(Page 6B-1)

6B-14 Steering Wheel and Column:

Specifications
Tightening Torque Specifications
AENBL80A6207001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Steering shaft nut 33 3.4 24.5 )/)
Steering column mounting lower nut 14 1.4 10.5 )
Steering column mounting upper nut 14 1.4 10.5 )
Steering column reinforce nut 5.5 0.56 4.0 )
Steering lower shaft joint bolt 35 3.6 26.0 )
Steering column joint bolt 35 3.6 26.0 )

NOTE
The tightening torque(s) also specified in:
“Steering Wheel and Column Components”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Special Tool
AENBL80A6208001
09944M36011
Steering wheel remover
)/)
 Power Assisted Steering System: 6C-1

Power Assisted Steering System

Steering

General Description
P/S System Description
AENBL80A6301001
Power steering system employs an electronic power steering (EPS) system that is of a column assist type.
EPS system consists of P/S control module and steering column assembly (includes P/S motor and torque sensor).
The controllability of assisting steering force is optimized in all vehicle speed ranges.
For location of EPS system components, refer to “Power Steering Control System Component Location” (Page 6C-3).

Description of EPS System Component Function

AENBL80A6301002
EPS system components Function
Steering column Torque sensor Using two circuits (i.e. main and sub circuits), torque sensor outputs
assembly voltages proportional to steering input torque and direction to P/S
control module.
P/S motor P/S motor produces steering assist torques that correspond to
electric current from P/S control module.
P/S control module • P/S control module controls P/S motor drive current by
determining its amount and direction of assistance based on
voltage signal from torque sensor and vehicle speed and other
data it receives via CAN communication.
• P/S control module judges whether engine is running or not by
using engine speed signal from CAN communication.
“P/S” warning light “P/S” warning light comes on when P/S system is abnormal.

OBD System Description

AENBL80A6301003
The P/S control module has an on-board self-diagnostic function which detects a malfunction in this system. Be sure
to have full understanding of “OBD System Description” (Page 6C-1) and each item in “Precautions for Diagnosing
Trouble” in Section 6 (Page 6-1), before executing diagnosis according to “P/S System Check” (Page 6C-4).
The P/S control module performs the on-board diagnosis (self-diagnosis) on the system and operates the “P/S”
warning light (1) as follows.
• The “P/S” warning light turns on when the ignition is “ON” (but the engine at stop) regardless of the condition of the
P/S control system. This is only to check if the “P/S” warning light is operated properly.
• When the engine is started, the on-board self diagnosis is performed and the “P/S” warning light turns off if no
trouble is found.
• When the P/S control module detects a trouble, the “P/S” warning light comes on to warn the driver of the trouble. At
the same time, a DTC is stored in the module.

[A] [B]

1
1

IBP80A630001-01

[A]: Without tachometer [B]: With tachometer

6C-2 Power Assisted Steering System:

Schematic and Routing Diagram

P/S System Diagram
AENBL80A6302001

1
5
11
15 GRN E13-1
12 19 5V

RED WHT 4

6
RED WHT
E12-1 RED
BLK E13-2
M
23 19 E12-2 BLK

RED WHT
7

8
RED WHT
E11-5 GRN
RED RED G50-5
18 19
WHT WHT G50-6
9
13 E11-7 YEL
14 2
16 LT GRN/BLK G50-3
17 5V

RED RED G50-4

24 E11-8 RED
21 19 3
RED/BLK WHT WHT G50-7
22 10
5V

E11-1 WHT

E11-3 BLK

E11-2 BLU
RED/BLK WHT/BLK
20

IBP80A630002-02

1. P/S control module 9. Torque sensor (sub) circuit 17. Combination meter
2. CPU 10. Torque sensor amplifier 18. BCM
3. 9 V regulator 11. “P/S” fuse 19. CAN driver
4. Fail-safe FET 12. ECM 20. DLC
5. Individual circuit fuse box No. 1 13. J/B 21. Meter driver
6. P/S motor 14. “IG1 SIG” fuse 22. “P/S” warning light
7. Torque sensor 15. Continuous power supply 23. ABS control module
8. Torque sensor (main) circuit 16. Ignition power supply 24. “MTR” fuse

Terminal Arrangement of P/S Control Module Connector (Viewed from Harness Side)

[A] E13 [A] G50 [A] E11 [A] E12

[a] 1 1
3 2 1 4 3 2 1
1
2 8 7 6 5 4 8 7 6 5 2

I9P60A630039-01
 Power Assisted Steering System: 6C-3

[A]: P/S control module connector (View: [a]) 1. P/S control module

NOTE
For circuit name and terminal voltage, refer to“Inspection of P/S Control Module and Its Circuits”
(Page 6C-18).

Component Location
Power Steering Control System Component Location
AENBL80A6303001

[C]
[C]

10
11

[D]
[D]

4
8 [A]

8 [B]
1 10
6

7 [A]

2 3

[B]

9 11

2 3

IBL80A630001-02

[A]: Diesel model 2. “P/S” fuse 7. Steering gear case assembly

[B]: Petrol model 3. Individual circuit fuse box No.1 8. ECM
[C]: Without tachometer 4. P/S motor 9. J/B
[D]: With tachometer 5. P/S control module 10. Combination meter
1. “P/S” warning light 6. Steering column assembly (including P/S motor and 11. “IG1 SIG” fuse
torque sensor)
6C-4 Power Assisted Steering System:

Diagnostic Information and Procedures

P/S System Check
AENBL80A6304001
! WARNING
Carry out test drive in light traffic area to prevent an accident.

Refer to the following items for the details of each step.

Step Action Yes No
1 Customer complaint analysis )(Page 6C-5) Go to Step 2. Perform customer
1) Perform customer complaint analysis. complaint analysis.

Was customer complaint analysis performed?

2 DTC check, record and clearance )(Page 6C-5) Print DTC or write it Go to Step 4.
1) Check for DTC (including pending DTC). down and clear it by
referring to “DTC
Is there any DTC? Clearance” (Page 6C-
7), then go to Step 3.
3 Visual inspection )(Page 6C-5) Repair or replace Go to Step 5.
1) Perform visual inspection. )(Page 6C-10) malfunction part, go to
Step 11.
Is there any faulty condition?
4 Visual inspection )(Page 6C-5) Repair or replace Go to Step 8.
1) Perform visual inspection. )(Page 6C-10) malfunction part, go to
Step 11.
Is there any faulty condition?
5 Trouble symptom confirmation )(Page 6C-5) Go to Step 6. Go to Step 7.
1) Confirm trouble symptom.

Is trouble symptom identified?

6 Rechecking and record of DTC )(Page 6C-5) Go to Step 9. Go to Step 8.
1) Recheck for DTC. )(Page 6C-6)

Is there any DTC(s)?

7 Rechecking and record of DTC )(Page 6C-5) Go to Step 9. Go to Step 10.
1) Recheck for DTC. )(Page 6C-6)

Is there any DTC(s)?

8 Steering symptom diagnosis and P/S system symptom Go to Step 11. Check and repair
diagnosis )(Page 6C-5) malfunction part(s), then
1) Check and repair. go to Step 11.
- Steering symptom diagnosis: )(Page 6A-1)
- P/S system symptom diagnosis: )(Page 6C-10)

Are check and repair complete?

9 Troubleshooting for DTC )(Page 6C-6) Go to Step 11. Check and repair
1) Check and repair. malfunction part(s), then
go to Step 11.
Are check and repair complete?
10 Intermittent problems check )(Page 6C-6) Repair or replace Go to Step 11.
1) Check for intermittent problems. malfunction part(s), go
to Step 11.
Is there any faulty condition?
11 Final confirmation test )(Page 6C-6) Go to Step 6. End.
1) Clear DTC if any.
2) Perform final confirmation test.

Is there any problem symptom, DTC or abnormal condition?

 Power Assisted Steering System: 6C-5

Step 1: Customer Complaint Analysis

Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose,
use of such an inspection form as the following one will facilitate collecting information to the point required for proper
analysis and diagnosis. Check if the problem described in “Customer questionnaire” occurs actually in the vehicle if
necessary.
(This step should be performed with the customer if possible.)

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

Customer problem inspection form (Example)

of Registration:

Symptoms

i
and ignition “ON”
other
During driving: accelerating/decelerating/stopping/
turning/running at constant speed/

paved/rough/snow-covered
/other
Tire chain:
fair/cloudy/rainy/snowy/other
°C °F
normal code/malfunction code ( )
normal code/malfunction code ( )
I9P60A630038-01

Step 2: DTC Check, Record and Clearance
Check DTC (current and pending DTC) refer to “DTC
Check” (Page 6C-6).
If DTC is indicated, print or write down the DTC and then
clear the DTC referring to “DTC Clearance” (Page 6C-7).
Step 3 and 4: Visual Inspection
Visually check “P/S” warning light for proper operation,
connectors for proper condition and each part condition
referring to “Visual Inspection” (Page 6C-10).
Step 5: Trouble Symptom Confirmation
Based on “Step 1: Customer Complaint Analysis” (Page
6C-5) and “Step 2: DTC Check, Record and Clearance”
(Page 6C-5), confirm trouble symptoms. Also, reconfirm
trouble symptoms by performing test drive and turning
steering wheel fully to right and left with vehicle stopped.
Step 6 and 7: Rechecking and Record of DTC
Refer to “DTC Check” (Page 6C-6) for checking
procedure.

Step 8: Steering Symptom Diagnosis and P/S

System Symptom Diagnosis
Perform basic steering system check first. )(Page 6A-1)
When the end of the flow has been reached, check the
parts of the system suspected as a possible cause
6C-6 Power Assisted Steering System:

referring to “P/S System Symptom Diagnosis” (Page 6C-

10) and based on symptoms appearing on the vehicle [A]

(symptoms obtained through steps of customer

complaint analysis, trouble symptom confirmation and/or
basic P/S system check). Repair or replace faulty parts.

Step 9: Troubleshooting for DTC

Perform applicable DTC troubleshooting and repair or
replace faulty parts.

Step 10: Intermittent Problems Check 1

Check parts where an intermittent trouble is easy to
occur (e.g., wire harness, connector, etc.), referring to
“Intermittent Connection and Poor Contact Inspection” in [B]
Section 00 (Page 00-11) and related circuit of DTC
recorded in Step 2.

Step 11: Final Confirmation Test

Confirm that the problem symptom has disappeared and
the P/S system is free from any abnormal conditions. If
what has been repaired is related to the DTC, clear the
DTC once, perform DTC confirmation procedure and
1
confirm that no DTC is indicated.

IBP80A630004-01
“P/S” Warning Light Check
AENBL80A6304002 [A]: Without tachometer
1) When ignition is “ON” (without engine running), [B]: With tachometer
check if the “P/S” warning light (1) comes on. If the
light does not come on, go to ““P/S” Warning Light DTC Check
Does Not Come ON with Ignition “ON” before Engine AENBL80A6304003
Starts” (Page 6C-11) of the diagnostic flows. 1) Set ignition “OFF”.
2) Start engine and check if the “P/S” warning light 2) Connect SUZUKI scan tool to DLC (1) located
turns OFF. If light remains ON and no DTC is stored around bottom of instrument panel on driver’s seat
in P/S control module, go to ““P/S” Warning Light side.
Remains ON Steady after Engine Starts” (Page 6C-
Special tool
12) for troubleshooting.
(A): SUZUKI scan tool (SUZUKI-SDT)

(A)

IAP70P450005-01

3) Start engine.
4) Read DTC according to the instructions displayed on
SUZUKI scan tool. For further details, refer to
operator’s manual for SUZUKI scan tool.
 Power Assisted Steering System: 6C-7

NOTE
If communication between SUZUKI scan tool
and P/S control module is not possible,
check the following points for recovery.
• SUZUKI scan tool and communication
cable
• DLC power circuit and ground circuit (A)

• CAN communication system malfunction

(Control Module Communication Bus “Off” 1
is detected in any control module)

5) Set ignition to “OFF” and disconnect SUZUKI scan

tool from DLC.

DTC Clearance IAP70P450005-01

AENBL80A6304004
3) Set ignition “ON”.
1) Confirm that ignition is in “OFF”.
4) Clear DTC according to instructions displayed on
2) Connect SUZUKI scan tool to DLC (1) located
SUZUKI scan tool. For further details, refer to
around bottom of instrument panel on driver’s seat
operator’s manual for SUZUKI scan tool.
side.
5) When ignition is “OFF”, disconnect SUZUKI scan
Special tool tool from DLC after completing clearance.
(A): SUZUKI scan tool (SUZUKI-SDT)

DTC Table
AENBL80A6304005
! CAUTION
Be sure to perform the “P/S System Check” (Page 6C-4) before starting troubleshooting
corresponding to each DTC.

NOTE
*D/C (Driving Cycle) is a duration from an engine start-up to the following engine shutoff.
• 1 D/C: When a malfunction is detected in 1st driving cycle, DTC is detected as current DTC.

“P/S”
DTC DTC name DTC detecting condition *D/C warning
light
Voltage of torque sensor signal (main) circuit is
C1111 Torque Sensor (Main) higher than specified value (4.5 V) or lower than
1 Light up
)(Page 6C-13) Circuit Malfunction specified value (0.5 V) for more than specified
time.
Voltage difference between torque sensor signal
C1113 Torque Sensor (Main and (main) circuit and torque sensor signal (sub)
1 Light up
)(Page 6C-13) Sub) Signal Difference circuit remains too large for more than specified
time.
Voltage of torque sensor signal (sub) circuit is
C1115 Torque Sensor (Sub) Circuit higher than specified value (4.5 V) or lower than
1 Light up
)(Page 6C-13) Malfunction specified value (0.5 V) for more than specified
time.
Torque Sensor Power Reference power supply voltage (9 V) for torque
C1116
Supply (9 V) Circuit sensor circuit is lower than specified lower limit 1 Light up
)(Page 6C-13)
Malfunction (7.0 V) for more than specified time.
Voltage of P/S motor output circuit terminals is
C1141 P/S Motor Circuit Voltage higher than upper limit (8.5 V) or lower than
1 Light up
)(Page 6C-14) Malfunction specified lower limit (0.2 V) for more than
specified time.
C1142 P/S Motor Circuit Current Measured motor drive current is bigger than target
1 Light up
)(Page 6C-14) Malfunction 1 value by 10 A or more.
6C-8 Power Assisted Steering System:

“P/S”
DTC DTC name DTC detecting condition *D/C warning
light
C1143 P/S Motor Circuit Current
Measured motor drive current is more than 65 A. 1 Light up
)(Page 6C-14) too Big
Measured motor drive current is less than 2 A
continuously for more than 5 seconds even
though target motor drive current is more than 4 A.
C1145 P/S Motor Circuit Current 1 Light up
Measured motor drive current is less than 0.8 A
)(Page 6C-14) Malfunction 2
and motor control duty is more than 90% for total 1
second even though target motor drive current is
less than 8 A.
Measured voltage of fail-safe FET power supply is
C1153 Power Supply Voltage too
lower than 9 V even if engine speed is more than 1 Light up
)(Page 6C-15) Low
600 rpm and commanded fail-safe FET is ON.
P/S Control Module Internal
C1155
Failure / Power Supply P/S control module is internally faulty. 1 Light up
)(Page 6C-15)
Voltage too High
C1160
Assist Map Signal Failure Assist map data is not set in P/S control module. 1 Light up
)(Page 6C-16)
C1161 CAN Invalid Data from
Invalid data is received from ECM. 1 Off
)(Page 6C-16) Vehicle Speed
C1162 CAN Invalid Data from
Invalid data is received from ECM. 1 Light up
)(Page 6C-16) Engine Speed
U0073 Control Module Transmitting and receiving error of P/S control
1 Off
)(Page 6C-17) Communication Bus Off module for specified time continuously.
U0100 Lost Communication With CAN communication data from ECM cannot be
1 Light up
)(Page 6C-17) ECM received.
Lost Communication With
U0155 CAN communication data cannot be received from
Instrument Panel Cluster 1 Light up
)(Page 6C-17) combination meter.
(IPC) Control Module

Fail-Safe Table
AENBL80A6304006
When any of the following DTCs is detected, P/S control module enters fail-safe mode as long as malfunction
continues to exist but that mode is cancelled when following cancel conditions are met after that.
DTC Fail-safe operation Fail-safe operation cancel condition
C1111
C1113
C1115
C1116
P/S motor and fail-safe FET turned off. Ignition is set to “OFF”.
C1141
C1142
C1143
C1145
C1153 P/S motor turned off.
Recovery from malfunction or setting ignition to
P/S motor turned off or P/S motor and fail-safe
C1155 “OFF”.
FET turned off.
C1160 Default assist map is applied. Setting of correct assist map.
C1161 Assist value is decreased to minimum.
C1162 Assist is stopped.
Normal data is received or set ignition “OFF”.
Assist is stopped or assist value is decreased
U0100
to minimum.
 Power Assisted Steering System: 6C-9

Scan Tool Data

AENBL80A6304007

NOTE
• If communication between SUZUKI scan tool and P/S control module is not possible, check the
following points for recovery.
– SUZUKI scan tool and communication cable
– DLC power circuit and ground circuit
– CAN communication system malfunction (Control Module Communication Bus “Off” is detected
in any control module)
• *1: Turn steering wheel fully after stopping and hold it with force applied.
• *2: The voltage and current of motor decrease gradually after few seconds when steering wheel is
turned.

Normal condition /
Scan tool data Vehicle condition
reference value
Battery Voltage Approx. 12 – 14 V Set ignition “ON”
Sensor Power Supply Approx. 8 – 10 V Set ignition “ON”
Approx. – 0.8 – 0.8 N⋅m Steering wheel at neutral
Approx. 10.00 – 14.00 N⋅m Vehicle stopped and steering wheel turned fully to right
Sensor (Main) Torque
Approx. –10.00 – –14.00
Vehicle stopped and steering wheel turned fully to left
N⋅m
Approx. –0.8 – 0.8 N⋅m Steering wheel at neutral
Approx. –10.00 – –14.00
Sensor (Sub) Torque Vehicle stopped and steering wheel turned fully to right
N⋅m
Approx. 10.00 – 14.00 N⋅m Vehicle stopped and steering wheel turned fully to left
Approx. –0.8 – 0.8 N⋅m Steering wheel at neutral
Control Torque Approx. 7 N⋅m Vehicle stopped and steering wheel turned fully to right
Approx. –7 N⋅m Vehicle stopped and steering wheel turned fully to left
0.0 A Steering wheel at neutral
Engine running at idle speed
Target Motor Current Vehicle stopped and steering wheel turned fully to right *1, *2
Approx. 45 – 60 A
Engine running at idle speed
Vehicle stopped and steering wheel turned fully to left *1, *2
0.0 A Steering wheel at neutral
Engine running at idle speed
Measured MOT Current Vehicle stopped and steering wheel turned fully to right *1, *2
Approx. 45 – 60 A
Engine running at idle speed
Vehicle stopped and steering wheel turned fully to left *1, *2
Drive vehicle at 40 km/h using chassis dynamometer or while
Vehicle Speed Approx. 40 km/h
checking speedometer
0 rpm Set ignition “ON”
Engine Speed
Specified idle speed Engine running at idle speed after warming up
ON Set ignition “ON”
IGN Switch Status
OFF Other than above condition
ON Current flowing to P/S control module power supply
System Power Status
OFF Other than above condition
ON Voltage is output from P/S control module to torque sensor
Torque Sensor Status
OFF Other than above condition
ON Power steering system operates normally
Fail Safe FET Status
OFF Performing fail-safe operation
Approx. 0.8 V Steering wheel at neutral
Motor Drive Voltage (+) Approx. 5 – 12 V Vehicle stopped and steering wheel turned fully to right *1, *2
Approx. 0 V Vehicle stopped and steering wheel turned fully to left *1, *2
Approx. 0.8 V Steering wheel at neutral
Motor Drive Voltage (–) Approx. 0 V Vehicle stopped and steering wheel turned fully to right *1, *2
Approx. 5 – 12 V Vehicle stopped and steering wheel turned fully to left *1, *2
6C-10 Power Assisted Steering System:

Visual Inspection
AENBL80A6304008
Visually check the following parts and system.
Inspection Item Referring section
Battery “Battery Inspection”: K14B in Section 1J (Page 1J-3) or “Battery
Level, leakage
Inspection”: D13A in Section 1J (Page 1J-17)
Connectors of electric wire “Intermittent Connection and Poor Contact Inspection” in Section
Disconnection, friction
harness 00 (Page 00-11)
Fuses Blowout
“P/S” warning light Operation ““P/S” Warning Light Check” (Page 6C-6)
Other parts that can be checked visually

P/S System Symptom Diagnosis

AENBL80A6304009
This section describes trouble diagnosis of the P/S system parts whose trouble is not indicated by SUZUKI scan tool.
When no malfunction is indicated by the SUZUKI scan tool and steering basic parts as described in “Steering
Symptom Diagnosis” in Section 6A (Page 6A-1) are all in good condition, check the following power steering system
parts which may be possible causes for each trouble symptom of steering.

NOTE
Perform “Steering Force Check” (Page 6C-22) / “Front Wheel Alignment Inspection and Adjustment” in
Section 2B (Page 2B-1) before diagnosis.

Condition Possible cause Correction / Reference Item

Steering wheel feels Steering wheel installed improperly
heavy Poor performance of torque sensor
Poor performance of P/S motor
Steering gear case assembly
malfunction
Vehicle speed faulty data through CAN
communication
Steering wheel feels Steering gear case assembly
heavy momentarily when malfunction
turning it to the left or
right
Poor recovery from turns Poor performance of torque sensor
Steering gear case assembly
malfunction
Vehicle pulls to one side Poor performance of torque sensor
during straight driving Steering gear case assembly
malfunction
Abnormal noise P/S motor (built in steering column
assembly) malfunction
Install steering wheel correctly. )(Page 6B-3)
Check torque sensor. )(Page 6C-29)
Check motor. )(Page 6C-30)
Replace steering gear case assembly. )(Page
6C-25)
Check vehicle speed data. )(Page 6C-9)
Replace steering gear case assembly. )(Page
6C-25)
Check torque sensor. )(Page 6C-29)
Replace steering gear case assembly. )(Page
6C-25)
Check torque sensor. )(Page 6C-29)
Replace steering gear case assembly. )(Page
6C-25)
Replace steering column. )(Page 6B-8)
 Power Assisted Steering System: 6C-11

“P/S” Warning Light Does Not Come ON with Ignition “ON” before Engine Starts
AENBL80A6304010
Circuit Diagram

2 4

3
1 LT GRN/BLK G50-3
6
5V
11
RED/BLK G240-3 G240-9 WHT G50-7
10 9 8
5
A1
G240-21 RED G50-4
WHT G50-6
GRY G240-5 7
RED G50-5
A2 BLK E13-2

[A] [B] [C]

[a] 1 12 11 10 9 8 7 6 5 4 3 2 1
3 2 1
2 24 23 22 21 20 19 18 17 16 15 14 13
8 7 6 5 4

IBP80A630005-01

[A]: P/S control module connector “E13” (View: [a]) 2. J/B 8. CAN driver
[B]: P/S control module connector “G50” (View: [a]) 3. “IG1 SIG” fuse 9. Meter driver
[C]: Combination meter connector (View: [a]) 4. P/S control module 10. “P/S” warning light
A1: Combination meter power supply circuit 5. CPU 11. “MTR” fuse
A2: Combination meter ground circuit 6. Combination meter
1. Ignition power supply 7. To other control module

Troubleshooting
Step Action Yes No
1 Warning light check Go to Step 2. Go to Step 4.
1) Set ignition switch to ON position.

Do other warning lights come ON?

2 DTC check Go to “CAN DTC (Lost Go to Step 3.
1) Connect scan tool to DLC with ignition “OFF”. Communication and
Communication Bus
2) When ignition is “ON”, check DTC.
Off) Table”: K14B Model
Is there DTC U0073 or DTC U0155? in Section 10H (Page
10H-6) or “CAN DTC
(Lost Communication
and Communication
Bus Off) Table”: D13A
Model in Section 10H
(Page 10H-25)”.
3 Combination meter check Replace P/S control End.
1) Replace combination meter. )(Page 9C-9) module. )(Page 6C-29)
2) Set ignition “ON”.

Does P/S warning light stay OFF?

4 Fuse check Go to Step 5. Replace fuse and check
for short circuit to
Is Circuit fuse for combination meter in good condition? ground.
6C-12 Power Assisted Steering System:

Step Action Yes No

5 Combination meter power supply circuit check Replace combination Go to Step 6.
1) Remove combination meter with ignition “OFF”. meter and recheck
warning light operation.
2) Check for proper connection to combination meter
)(Page 9C-9)
connector.
3) If OK, when ignition is “ON”, measure voltage between
“G240-3” and “G240-5” terminals.

Is it 10 – 14 V?
6 Combination meter ground circuit check Repair “A1” circuit. Repair “A2” circuit.
1) Set ignition “OFF”.
2) Measure resistance between “G240-5” terminal and
ground.

Is it 1 Ω or less?

“P/S” Warning Light Remains ON Steady after Engine Starts

AENBL80A6304011
Circuit Diagram

2 4

3
1 LT GRN/BLK G50-3
6
5V
11
RED/BLK G240-3 G240-9 WHT G50-7
10 9 8
5
A1
G240-21 RED G50-4
WHT G50-6
GRY G240-5 7
RED G50-5
A2 BLK E13-2

[A] [B] [C]

[a] 1 12 11 10 9 8 7 6 5 4 3 2 1
3 2 1
2 24 23 22 21 20 19 18 17 16 15 14 13
8 7 6 5 4

IBP80A630006-01

[A]: P/S control module connector “E13” (View: [a]) 2. J/B 8. CAN driver
[B]: P/S control module connector “G50” (View: [a]) 3. “IG1 SIG” fuse 9. Meter driver
[C]: Combination meter connector (View: [a]) 4. P/S control module 10. “P/S” warning light
A1: Combination meter power supply circuit 5. CPU 11. “MTR” fuse
A2: Combination meter ground circuit 6. Combination meter
1. Ignition power supply 7. To other control module

Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Go to Step 2.
1) Start engine and recheck DTC of P/S control module. for applicable DTC.

Is there any DTC(s)?

2 Combination meter check Replace P/S control End.
1) Replace combination meter. )(Page 9C-9) module. )(Page 6C-29)
2) Set ignition “ON”.

Does P/S warning light stay ON?

 Power Assisted Steering System: 6C-13

DTC C1111 / C1113 / C1115 / C1116

AENBL80A6304012
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1111: Torque Sensor (Main) Circuit Malfunction • Torque sensor (steering column assembly)
Voltage of torque sensor signal (main) circuit is higher than specified • P/S control module
value (4.5 V) or lower than specified value (0.5 V) for more than
specified time.
C1113: Torque Sensor (Main and Sub) Signal Difference
Voltage difference between torque sensor signal (main) circuit and
torque sensor signal (sub) circuit remains too large for more than
specified time.
C1115: Torque Sensor (Sub) Circuit Malfunction
Voltage of torque sensor signal (sub) circuit is higher than specified
value (4.5 V) or lower than specified value (0.5 V) for more than
specified time.
C1116: Torque Sensor Power Supply (9 V) Circuit Malfunction
Reference power supply voltage (9 V) for torque sensor circuit is lower
than specified lower limit (7.0 V) for more than specified time.

Circuit Diagram

1 3
A1
5V

E11-5 GRN

[a]
A2

E11-7 YEL
5V A3

[A]
E11-8 RED
2 5

4 4 3 2 1
5V
8 7 6 5

E11-1 WHT

E11-3 BLK

E11-2 BLU

I9P60A630008-03

[A]: Torque sensor connector “E11” (View [a]) A3: 9 V reference power supply for 3. Torque sensor
torque sensor circuit
A1: Torque sensor signal (main) circuit 1. P/S control module 4. Torque sensor amplifier
A2: Torque sensor signal (sub) circuit 2. CPU 5. 9 V regulator

DTC Confirmation Procedure

Upon completion of initial check, turn steering wheel in both directions (fully turn when stopped and turn while driving).

Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-4).
2 Torque sensor circuit wire check Go to Step 3. Replace torque sensor
1) Visually check circuit between torque sensor connector (steering column
and torque sensor for open circuit and short to ground. assembly)

Are they in good condition?

6C-14 Power Assisted Steering System:

Step Action Yes No

3 Torque sensor power supply circuit voltage check Go to Step 4. Replace P/S control
1) With ignition “ON”, measure voltage between P/S control module. )(Page 6C-29)
module (torque sensor) connector terminal and ground.
• Between P/S control module (torque sensor)
connector terminal “E11-8” and ground is about 9 V.
• Between P/S control module (torque sensor)
connector terminal “E11-1” and ground is about 3.3 V.

Are measured voltage correct?

4 Torque sensor ground circuit check Go to Step 5. Replace P/S control
1) Measure voltage between P/S control module (torque module. )(Page 6C-29)
sensor) connector terminals “E11-1” and “E11-3”.

Is voltage about 3.3 V?

5 Torque sensor check Replace P/S control Replace torque sensor
1) Check torque sensor. )(Page 6C-29) module. )(Page 6C-29) (steering column
assembly).
Is circuit in good condition?

DTC C1141 / C1142 / C1143 / C1145

AENBL80A6304013
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1141: P/S Motor Circuit Voltage Malfunction • P/S control module
Voltage of P/S motor output circuit terminals is higher than upper limit • P/S motor (steering column assembly)
(8.5 V) or lower than specified lower limit (0.2 V) for more than
specified time.
C1142: P/S Motor Circuit Current Malfunction 1
Measured motor drive current is bigger than target value by 10 A or
more.
C1143: P/S Motor Circuit Current too Big
Measured motor drive current is more than 65 A.
C1145: P/S Motor Circuit Current Malfunction 2
• Measured motor drive current is less than 2 A continuously for more
than 5 seconds even though target motor drive current is more than
4 A.
• Measured motor drive current is less than 0.8 A and motor control
duty is more than 90% for total 1 second even though target motor
drive current is less than 8 A.

Circuit Diagram

1
5V

12V
[a]

A1 3

E12-1 RED
2 [A]
M
E12-2 BLK
1
A1
2

I9P60A630009-03
 Power Assisted Steering System: 6C-15

[A]: “P/S motor connector “E12” (View [a]) 1. P/S control module 3. P/S motor
A1: P/S motor output circuit 2. CPU

DTC Confirmation Procedure

1) Start engine.
2) Turn steering wheel fully in both direction.

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-4).
2 P/S motor drive circuit wire check Go to Step 3 Replace P/S motor
1) Disconnect P/S motor connector “E12”. (steering column
assembly).
2) Check “P/S motor output circuit (A1)” wires for open
circuit and short to ground.

Is circuit in good condition?

3 P/S motor circuit check Replace P/S control Replace P/S motor
1) Check P/S motor. )(Page 6C-30) module. )(Page 6C-29) (steering column
assembly).
Is circuit in good condition?

DTC C1153 / C1155

AENBL80A6304014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1153: Power Supply Voltage too Low • Charging system
Measured voltage of fail-safe FET power supply is lower than 9 V even • P/S control module
if engine speed is more than 600 rpm and commanded fail-safe FET is
ON.
C1155: P/S Control Module Internal Failure / Power Supply
Voltage too High
P/S control module is internally faulty.

Circuit Diagram

4 1

5
6 GRN E13-1 [a]
5V
A1
3

2 [A]

A2
1
BLK E13-2 2

IBP80A630021-01

[A]: P/S control module connector “E13” (View [a]) 1. P/S control module 4. Individual circuit fuse box No.1
A1: P/S control module power supply circuit 2. CPU 5. “P/S” fuse
A2: P/S control module ground circuit 3. Fail-safe FET 6. Continuous power supply
6C-16 Power Assisted Steering System:

DTC Confirmation Procedure

Run engine at idle speed for more than 5 seconds.

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-4).
2 P/S control module power supply and ground check Go to Step 3. Repair A1 circuit and A2
1) Check A1 circuit and A2 circuit. )(Page 6C-17) circuit.

Are they in good condition?

3 P/S control module power supply voltage check Replace P/S control Check charging system.
1) Measure battery voltage with engine running at 3000 module and recheck “Charging System
rpm. DTC. )(Page 6C-29) Specifications”: K14B in
Section 1J (Page 1J-14)
Is voltage between 9 V and 15 V? or )(Page 1J-29)

DTC C1160
AENBL80A6304015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1160: Assist Map Signal Failure • P/S control module
Assist map data is not set in P/S control module.

DTC Confirmation Procedure

1) Set ignition “ON”.
2) Set ignition “OFF”.
3) Set ignition “ON”.

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Substitute a known- Go to “P/S System
good P/S control Check” (Page 6C-4).
module and recheck
DTC. )(Page 6C-29)

DTC C1161 / C1162

AENBL80A6304016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C1161: CAN Invalid Data from Vehicle Speed • CAN communication circuit
Invalid data is received from ECM. • ECM
C1162: CAN Invalid Data from Engine Speed
• P/S control module
Invalid data is received from ECM.

DTC Confirmation Procedure

DTC C1161
• Refer to Confirmation Procedure for DTC P0500 Vehicle Speed Sensor “A”. “DTC P0500”: K14B in Section 1A
(Page 1A-87) / )(Page 1A-209)

DTC C1162
• Refer to Confirmation Procedure for DTC P0335 Crankshaft Position Sensor “A”. )(Page 1A-72) / )(Page 1A-198)

DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” (Page 6C-4).
 Power Assisted Steering System: 6C-17

Step Action Yes No

2 DTC Check Go to troubleshooting Substitute a known-
1) Check DTC for ECM. )(Page 6C-6) for applicable DTC. good P/S control
(ECM-related faulty) module and recheck
Is there any DTC(s) detected? )(Page 1A-19) or DTC. )(Page 6C-29)
)(Page 1A-135)

DTC U0073
AENBL80A6304017
Refer to “CAN DTC (Lost Communication and Communication Bus Off) Table”: K14B Model in Section 10H (Page
10H-6) or “CAN DTC (Lost Communication and Communication Bus Off) Table”: D13A Model in Section 10H (Page
10H-25).

DTC U0100
AENBL80A6304018
Refer to “CAN DTC (Lost Communication and Communication Bus Off) Table”: K14B Model in Section 10H (Page
10H-6) or “CAN DTC (Lost Communication and Communication Bus Off) Table”: D13A Model in Section 10H (Page
10H-25).

DTC U0155
AENBL80A6304019
Refer to “CAN DTC (Lost Communication and Communication Bus Off) Table”: K14B Model in Section 10H (Page
10H-6) or “CAN DTC (Lost Communication and Communication Bus Off) Table”: D13A Model in Section 10H (Page
10H-25).

P/S Control Module Power Supply and Ground Circuit Check

AENBL80A6304020
Circuit Diagram

5 A1 7
6
2 GRN E13-1
5V

3 A2 8
4
1 LT GRN/BLK G50-3 9

A3

BLK E13-2

[A] [B]
[a]

1 3 2 1
2 8 7 6 5 4
IBP80A630022-01

[A]: P/S control module connector “E13” (View: [a]) 1. Ignition power supply 6. “P/S” fuse
[B]: P/S control module connector “G50” (View: [a]) 2. Continuous power supply 7. P/S control module
A1: P/S control module power supply circuit 3. J/B 8. Fail-safe FET
A2: IG1 power supply circuit 4. “IG1 SIG” fuse 9. CPU
A3: P/S control module ground circuit 5. Individual circuit fuse box No.1
6C-18 Power Assisted Steering System:

Step Action Yes No

1 Circuit fuse check Go to Step 2. Replace fuse(s) and
1) Confirm that ignition is in “OFF”. check for short to
ground in circuits
2) Disconnect “E13” and “G50” connectors.
connected to fuse(s).
3) Check for proper connection to “G50-3” and “E13-1”
terminals.
4) If connections are OK, check “P/S” fuse and “IG1 SIG”
fuse for blowing.

Are they in good condition?

2 P/S control module power supply circuit check Go to Step 3. “A1” circuit is open.
1) Check voltage between “E13-1” terminal and ground.

Is voltage 10 – 14 V?
3 IG1 power supply circuit check Go to Step 4. “A2” circuit is open.
1) Set ignition “ON”.
2) Check voltage between “G50-3” terminal and ground.

Is voltage 10 – 14 V?
4 P/S control module ground circuit check End. “A3” circuit is open or
1) Set ignition “OFF”. too high in resistance.
2) Check resistance between “E13-2” terminal and ground.

Is resistance 1 Ω or less?

Inspection of P/S Control Module and Its Circuits

AENBL80A6304021
P/S control module (1) and its circuits can be checked at P/S control module wiring connectors (2) by measuring
voltage and resistance.

! CAUTION

• P/S control module must be checked only through its connector. It is strictly prohibited to connect
tester to the P/S control module with connectors disconnected from the P/S control module.
• Make sure to observe instructions for checking electrical system. )(Page 00-9)
 Power Assisted Steering System: 6C-19

[C] [A] [B]

1 1
4 3 2 1
2 2 8 7 6 5

2 2

[D]

3 2 1 [a]
1
8 7 6 5 4

IBP80A630007-01

[A]: P/S motor connector “E12” (View: [a]) [C]: P/S control module connector “E13” (View: [a])
[B]: Torque sensor connector “E11” (View: [a]) [D]: P/S control module connector “G50” (View: [a])

Voltage Check
1) Remove combination meter cluster panel. )(Page 9C-9)
2) Check for voltage at each terminal with connectors connected to the P/S control module.

NOTE
As each terminal voltage is affected by the battery voltage, confirm if the battery voltage is 11 V or
more when ignition is “ON”.

“E13” connector
Terminal Circuit Wire color Normal voltage Condition
Main power supply for P/S
1 GRN Approx. 12 V Ignition in any position/mode.
control module
Ground for P/S control
2 BLK 0V Ignition in any position/mode.
module

“G50” connector
Terminal Circuit Wire color Normal voltage Condition
IG1 power supply for P/S
3 LT GRN/BLK Approx. 12 V Ignition “ON”.
control module
CAN (HI2) communication Refer to “CAN Communication Signal” (Page 6C-20).
4 RED
circuit
CAN (HI1) communication
5 RED Refer to “CAN Communication Signal” (Page 6C-20).
circuit
CAN (LO1) communication
6 WHT Refer to “CAN Communication Signal” (Page 6C-20).
circuit
CAN (LO2) communication
7 WHT Refer to “CAN Communication Signal” (Page 6C-20).
circuit
6C-20 Power Assisted Steering System:

“E11” connector
Terminal Circuit Wire color Normal voltage Condition
3 V reference power supply
1 WHT Approx. 3.3 V Ignition “ON”.
for torque sensor
2 Shield ground circuit BLU 0V Ignition in any position/mode.
3 Ground for torque sensor BLK 0V Ignition in any position/mode.
Approx. 2.5 V Steering wheel at neutral
Vehicle in stopped and steering
Approx. 3.9 V
5 Torque sensor signal (Main) GRN wheel turned fully to right *1
Vehicle in stopped and steering
Approx. 1.2 V
wheel turned fully to left *1
Approx. 2.5 V Steering wheel at neutral
Vehicle in stopped and steering
Approx. 1.2 V
7 Torque sensor signal (Sub) YEL wheel turned fully to right *1
Vehicle in stopped and steering
Approx. 3.9 V
wheel turned fully to left *1
9 V reference power supply
8 RED Approx. 9 V Ignition “ON”.
for torque sensor

“E12” connector
Terminal Circuit Wire color Normal voltage Condition
Refer to “P/S Motor signal No.1” (Page 6C-21) / “P/S Motor
1 P/S motor output RED Signal No.2” (Page 6C-21) / “P/S Motor Signal No.3” (Page
6C-21)
Refer to “P/S Motor signal No.1” (Page 6C-21) / “P/S Motor
2 P/S motor output BLK Signal No.2” (Page 6C-21) / “P/S Motor Signal No.3” (Page
6C-21)

NOTE
*1: Turn steering wheel fully after stopping and hold it with force applied.

Reference waveform • Waveforms may vary with measurement

Shown below is typical waveform display provided by condition and vehicle specifications.
oscilloscope.

NOTE CAN Communication Signal

Channel Probe Terminal No.
• Display includes the following types of CH1 + G50-5
data: G50-4
– Ground
CH2 + G50-6
G50-7
– —

I8T401111066-01

[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel

[B]: Ground level of each channel [D]: TIME/DIV
 Power Assisted Steering System: 6C-21

Measurement condition
• Ignition: ON

IAW101630008-01

[a]: CH1 1. CAN communication signal

[b]: CH2

P/S Motor signal No.1

Measurement condition
• Engine is idling and steering wheel is in the center
position.
Channel Probe Terminal No.
CH1 + E12-1
– Ground
CH2 + E12-2 I8C50B630013-01
– —
[A]: Steering wheel is turned right turning speed of 90° /sec.
[B]: Steering wheel is turned left turning speed of 90° /sec.
[C]: 12 V ON
[D]: GND ON
[E]: 1 duty cycle
1. Motor output signal 1
2. Motor output signal 2

P/S Motor Signal No.3

Measurement condition
• Engine is idling and steering wheel is kept fully turned
to left or right until it stops
Channel Probe Terminal No.
CH1 + E12-1
I8C50B630012-01
– Ground
1. Motor output signal 1 2. Motor output signal 2 CH2 + E12-2
– —
P/S Motor Signal No.2
Measurement condition
• Engine is idling and steering wheel is turned to left or
right at turning speed of 90° /sec.
Channel Probe Terminal No.
CH1 + E12-1
– Ground
CH2 + E12-2
– —
6C-22 Power Assisted Steering System:

“a”

I8C50A630015-02

Steering Force Check

AENBL80A6304023
1) Place vehicle on level road and set steering wheel at
straight-ahead position.
2) Check that tire inflation pressure is as specified
referring to the tire placard.
3) Start engine.
4) With engine idling, measure steering force using
spring balance (1).
Steering force
: 34 N (3.5 kgf, 7.6 lbf)

I8C50B630014-01

[A]: Engine is idling and steering wheel is kept fully turned to left until it
stops
[B]: Engine is idling and steering wheel is kept fully turned to right until
it stops
[C]: 12 V ON
[D]: GND ON
1. Motor output signal 1
2. Motor output signal 2 1
I8C50A630016-01

Steering Wheel Play Check

AENBL80A6304022
• Check steering wheel for looseness or rattle by
moving it in axial and lateral directions.
If check result is not OK, repair or replace steering
wheel.
• Check steering wheel for play, holding vehicle in
straight-ahead position on the ground with engine
stopped.
If steering wheel play is not within specification,
inspect following components and replace any of
them if found defective.
– Tie-rod end and tie-rod ball joint for wear.
– Suspension arm joint for wear
– Steering shaft joint for wear
– Steering pinion or rack gear for wear or breakage
– Each part for looseness
Steering wheel play “a”
: 0 – 30 mm (0 – 1.2 in.)
 Power Assisted Steering System: 6C-23

Repair Instructions
Steering Gear Case Assembly Components
AENBL80A6306001

(c)

(c)

10
7

12

7
11
1

9 (a)

(a)

8
4

5
E

3 (b)

E 2

4 2
[a]
3 (b)
11
(a)

5
6
8

9 (a)
IBP80A630008-01

[a]: Forward 6. Rack boot clip 12: Steering gear cover

1. Steering gear case 7. Steering gear case bushing : 45 N⋅m (4.6 kgf-m, 33.5 lbf-ft)
2. Tie-rod lock washer 8. Tie-rod end : 85 N⋅m (8.7 kgf-m, 63.0 lbf-ft)
: For removing and installing procedure of
tie-rod lock washer, refer to “Tie-Rod / Rack
Boot Removal and Installation” (Page 6C-
27).
3. Tie-rod 9. Tie-rod end nut : 80 N⋅m (8.2 kgf-m, 59.0 lbf-ft)
: For tightening procedure of tie-rod
end nut, refer to “Tie-Rod End
Removal and Installation” (Page 6C-
24).
4. Band 10. Steering gear case packing : Do not reuse.
5. Rack boot 11. Cotter pin : Apply grease 99000-25050 to tie-rod and
: For removing and installing procedure rack boot, refer to “Tie-Rod / Rack Boot
of cotter pin, refer to “Tie-Rod End Removal and Installation” (Page 6C-27).
Removal and Installation” (Page 6C-
24).
6C-24 Power Assisted Steering System:

Tie-Rod End Boot On-Vehicle Inspection

AENBL80A6306002
Check boot for crack and damage.
Replace tie-rod end with boot if boot is defective.
(A)

I9P60A630016-01

4) To facilitate adjustment after installation, make mark

(1) of tie-rod end lock nut (2) position on tie-rod end
thread. Then, loosen lock nut and remove tie-rod
end (3) from tie-rod (4).

IBP80A630010-01

Tie-Rod End Removal and Installation

AENBL80A6306003

Removal
2
1) Hoist vehicle, and then remove front wheel. )(Page 3
2D-2) 4
2) Remove cotter pin (2), and tie-rod end nut (1) from
1
tie-rod end. I9P60A630017-02

Installation
1) Install tie-rod end lock nut (2) and tie-rod end (3) to
tie-rod (4). Align lock nut with mark (1) on tie-rod
thread.

1 2
3
4
IBP80A630011-01
1
3) Disconnect tie-rod end (1) from steering knuckle (2)
I9P60A630017-02
using special tool.
2) Connect tie-rod end to steering knuckle. Tighten tie-
Special tool rod end nut (1) to specified torque.
(A): 09913M65210
Tightening torque
Tie-rod end nut (a): 45 N·m (4.6 kgf-m, 33.5 lbf-ft)
3) Install new cotter pin (2) and bend it.
 Power Assisted Steering System: 6C-25

NOTE
• After tightening tie-rod end nut to specified
torque, align a cotter pin slot in nut with
hole in tie-rod end by giving minimum
tightening turn to nut (maximum rotation
angle 60°).
• Insert cotter pin fully as shown in figure
(With longer arm downward). After
inserting cotter pin, bend cotter pin as
shown in figure.
! CAUTION
• Be sure to set front wheels (tires) in
straight-ahead direction and lock steering
wheel before performing the following
steps; otherwise, contact coil of air bag
system may get damaged. (air bag model)
• Steering gear case bolts are pre-coated
with friction stabilizer. Do not reuse
steering gear case bolts, otherwise bolts
may loosen.

Removal
1) Remove front suspension frame with steering gear
case assembly. )(Page 2B-12)
2) Remove steering gear case cover (1) after detaching
1, (a)
its claws (3) from gear case.
3) Remove steering gear case bolts (4), then remove
2 steering gear case assembly (2) from front
suspension frame.

1,(a)
3 2

IBP80A630020-01
1
4) Install front wheel. )(Page 2D-2) 2
5) Inspect for toe. )(Page 2B-1)
6) After confirming that toe is as specified, tighten tie-
rod end lock nut to specified torque.
Tightening torque
Tie-rod end lock nut: 45 N·m (4.6 kgf-m, 33.5 lbf-
ft) 4
IAP70P630010-02

Tie-Rod End Inspection Installation

AENBL80A6306004
• Inspect for play in tie-rod end ball joint.
• Inspect for play in tie-rod ball joint.
If result of either inspection is not OK, replace with
new one(s).
1) Mount steering gear case assembly (1) to front
suspension frame.
2) Install new steering gear case bolts (2) to specified
torque.

! CAUTION
Do not reuse steering gear case bolt pre-
coated with adhesive.

Tightening torque
Steering gear case bolt (a): 80 N·m (8.2 kgf-m,
I9P60A630019-01 59.0 lbf-ft)
3) Align matchmarks (4) in steering gear case and
Steering Gear Case Assembly Removal and steering gear cover (3), then install cover.
Installation
AENBL80A6306005
6C-26 Power Assisted Steering System:

3 2

(B)

1 1

3 (A)
1
IBP80A630015-01

Installation
1) Press-fit new steering gear case bushing (1) using
special tools and hydraulic press (2).

2, (a) ! CAUTION
IBP80A630013-01
Do not reuse bushing.
4) Install front suspension frame with steering gear
case assembly. )(Page 2B-12)
NOTE
Steering Gear Case Bushing Removal and Before installing bushing, apply soapy water
Installation on its circumference to facilitate installation.
AENBL80A6306006
Special tool
! CAUTION (A): 09943M76310
When replacing steering gear case bushing, (B): 09943M88211
also replace bushing on the other side as
well.
2

Removal
1) Remove steering gear case assembly. )(Page 6C- (B)
25)
1
2) Cut off flange (rubber) part (1) of each steering gear
case bushing using knife.

(A)

IBP80A630015-01

2) Press-fit steering gear case bushing (1) so that

dimensions “a” and “b” in figure become equal.
1

IBP80A630014-01

3) Push out steering gear case bushing (1) using

hydraulic press (2) and special tools.
“a” “b”
Special tool
I7V10A220012-01
(A): 09943M76310
(B): 09943M88211 3) Install steering gear case assembly. )(Page 6C-25)

Steering Rack Boot Inspection

AENBL80A6306007
Check the rack boot for the following points. Repair or
replace rack boot if defective.
 Power Assisted Steering System: 6C-27

• Check rack boot (3) for deformation, deterioration or

crack.
• Check rack boot clip (1) and band (2) for fitting.

1,(a)

2
3

3 IAP70P630017-01

2) Bend lock washer (1) at 2 places as shown in figure.

1
IAP70P630015-02

Tie-Rod / Rack Boot Removal and Installation

AENBL80A6306008
1

Removal
1) Remove steering gear case assembly. )(Page 6C-
25)
2) Remove tie-rod end. )(Page 6C-24)
3) Remove band (2) and rack boot clip (1).
4) Remove rack boot (3) from tie-rod. IAP70P630018-01

3) Apply grease to section “A” of tie-rod indicated in

figure. Position rack boot properly in grooves of gear
case and tie-rod.
2 After this, check that rack boot is free from twist and
dent.
“A”: Grease 99000–25050 (SUZUKI Super
Grease E)

1
IAP70P630015-02

5) Unbend bent parts (4) of tie-rod lock washer (1).

6) Remove tie-rod (3) from rack (2) as shown. “A”
I9P60A630030-01

2 4) Fasten new band (1) using special tool, and install

rack boot clip (2)
3
Special tool
(A): 09943M55010

4 1

1
2
IAP70P630016-02 (A)

Installation
1) Install tie-rod (1) and new tie-rod lock washer (3) to
rack (2), and then tighten tie-rod to specified torque. IAP70P630019-02

5) Install tie-rod end. )(Page 6C-24)

Tightening torque
Tie-rod (a): 85 N·m (8.7 kgf-m, 63.0 lbf-ft) 6) Install steering gear case assembly. )(Page 6C-25)
6C-28 Power Assisted Steering System:

Pinion Shaft Rotation Torque Inspection 5) Apply sealant “A” to rack damper screw and then
AENBL80A6306009 tighten it using special tool.
1) Remove steering gear case assembly. )(Page 6C-
25) “A”: Sealant 99000–31310 (Three Bond TB
1141G)
2) Remove rack boots. )(Page 6C-27)
3) Check pinion shaft rotation torque with rack position Tightening torque
centered using special tool. Rack damper screw (a): 15 N·m (1.5 kgf-m, 11.0
Also check that rack as a whole moves smoothly. lbf-ft)
If check result is not as specified, adjust pinion shaft
rotation torque.
Special tool
(A): 09944M16810
Rotation torque specification
1.20 – 1.75 N⋅m (0.12 – 0.18 kgf-m, 1.0 – 1.5 lbf-ft)

1
(A)

(A) 2,(a),“A”

(B)
IBP80A630017-01

6) Tighten or loosen rack damper screw so as to adjust

IAP70P630021-02
Pinion Shaft Rotation Torque Adjustment
AENBL80A6306010
! CAUTION
• Perform pinion shaft rotation torque
adjustment with rack stroke position is
centered (steering wheel is at straight-
ahead position).
• Do not remove rack damper screw lock nut
and rack damper screw so as to prevent
damage to rack damper screw lock nut and
rack damper screw.
• Rack damper screw and rack damper
screw lock nut are not individually
supplied as spare parts. Be careful not to
damage or lose them.
1) Remove steering gear case assembly. )(Page 6C-
25)
2) Remove rack boots. )(Page 6C-27)
3) Using special tool, loosen rack damper screw lock
nut (1).
Special tool
(A): 09941M75410
4) Using special tool, loosen rack damper screw (2).
Special tool
(A): 09941M75420
pinion rotation torque to specification using special
tool. )(Page 6C-28)
7) Using special tools, tighten rack damper screw lock
nut (1) while holding rack damper screw (2).
Special tool
(A): 09941M75410
(B): 09941M75420
Tightening torque
Rack damper screw lock nut (a): 70 N·m (7.1
kgf-m, 52.0 lbf-ft)
NOTE
When tightening rack damper screw lock nut
with torque wrench connected to arm portion
of special tool, reading value is smaller than
the nut torque. Reading value should be
calculated using the formula below.
Formula for reading value of torque wrench.
M = T X L / (L + “a”)
• M: Reading value using extension special tool
• T: Specified torque
• L: Torque wrench length
• “a”: Dimension of special tool
 Power Assisted Steering System: 6C-29

Installation
Reverse removal procedure, noting the following points.
• Tighten P/S control module bolts to the specified
torque.
Tightening torque
P/S control module mounting bolt (a): 5.0 N·m (
0.51 kgf-m, 4.0 lbf-ft)

L
1,(a)
(A) (a)

(a)
“a” (B)

IBP80A630018-01

“a”: 60 mm (2.36 in)

8) Recheck pinion rotation torque is as specified.

)(Page 6C-28)
9) Install rack boots. )(Page 6C-27)
10) Install steering gear case assembly. )(Page 6C-25)
IAP70P630024-01

P/S Control Module Removal and Installation • Install brake pedal assembly. )(Page 4A-7)
AENBL80A6306011
Removal
Torque Sensor Inspection
1) Disconnect negative (–) cable at battery. AENBL80A6306012

2) Remove combination meter cluster panel. )(Page Using SUZUKI Scan Tool
9C-9) 1) Connect SUZUKI scan tool to DLC (1) located
3) Remove brake pedal assembly. )(Page 4A-7) around bottom of instrument panel on driver’s seat
side.
4) Disconnect connectors (1) from P/S control module
(2). Special tool
5) Remove P/S control module bolts (3) from steering (A): SUZUKI scan tool (SUZUKI-SDT)
support member.

1 3

1
(A)

IAP70P450005-01

2) With ignition “ON”, check “Sensor (Main) Torque”

and “Sensor (Sub) Torque” in “Data list” mode on
SUZUKI scan tool.
IAP70P630023-01
Sensor torque
6) Remove P/S control module. Main: Approx. –0.8 – 0.8 N⋅m
6C-30 Power Assisted Steering System:

Sub: Approx. –0.8 – 0.8 N⋅m If check result is not as specified, replace steering
column assembly.
3) If check result is not as specified, remove steering
wheel and steering lower shaft. Motor circuit resistance
• Steering wheel: )(Page 6B-3) Between “1” and “2” Approx. 1 Ω
• Steering lower shaft: )(Page 6B-13)
3) Check continuity between terminal “1” of “E12”
4) With ignition “ON”, check “Sensor (Main) Torque” connector and ground.
and “Sensor (Sub) Torque” in “Data list” mode on If check result is not as specified, replace steering
SUZUKI scan tool. column assembly.
If check result is not as specified, replace torque
sensor (steering column assembly). Motor circuit resistance
“1” and ground No continuity
Sensor torque
Main: Approx. –0.8 – 0.8 N⋅m
Sub: Approx. –0.8 – 0.8 N⋅m
1
Using Voltmeter
1) Remove steering column hole cover and steering
1
lower shaft. 2
• steering column hole cover: )(Page 9C-9)
• Steering lower shaft: )(Page 6B-13) [a]

2) With ignition “ON”, measure voltage between I9P60A630036-01

terminals “3” – “5” and “3” – “7” at “E11” connector
1. “E12” connector (View: [a])
(1) connected to P/S control module (2). If check
result is not as specified, replace steering column.
4) Hoist vehicle.
Torque sensor voltage 5) With ignition “OFF”, connect “E12” connector (1) to
“3” and “5”: Approx. 2.5 V P/S control module (2).
“3” and “7”: Approx. 2.5 V
6) Using ammeter (3), check that P/S motor current
with engine idling is as indicated below. If check
result is not as specified, check P/S control module.
)(Page 6C-18)
4 3 2 1
8 7 6 5
If check result is as specified, replace steering
column assembly.
2
Motor current at hoisted vehicle
When
1 When
steering
When steering
wheel is
steering wheel is kept
turned left or
Condition wheel is at fully turned
right at
straight left or right
turning
position: [A] until it stops:
speed of 90° /
[C]
sec.: [B]
Motor Approx. Approx.
Approx. 0 A
current 3.0 – 4.2 A 45 – 60 A

IAP70P630025-01

P/S Motor Inspection

AENBL80A6306013
1) With ignition “OFF”, disconnect “E12” connector (1)
from P/S control module.
2) Check resistance between terminals “1” and “2” of
“E12” connector (1).
 Power Assisted Steering System: 6C-31

[A] [A]

[C]

2
3
1 A
1

I8C50A630034-01

Specifications
Tightening Torque Specifications
AENBL80A6307001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Tie-rod end nut 45 4.6 33.5 )
Tie-rod end lock nut 45 4.6 33.5 )
Steering gear case bolt 80 8.2 59.0 )
Tie-rod 85 8.7 63.0 )
Rack damper screw 15 1.5 11.0 )
Rack damper screw lock nut 70 7.1 52.0 )
P/S control module mounting bolt 5.0 0.51 4.0 )

NOTE
The tightening torque(s) also specified in:
“Steering Gear Case Assembly Components”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Recommended Service Material
AENBL80A6308001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease E P/No.: 99000–25050 )
Sealant Three Bond TB 1141G P/No.: 99000–31310 )
6C-32 Power Assisted Steering System:

NOTE
Required service material(s) also described in:
“Steering Gear Case Assembly Components”:

Special Tool
AENBL80A6308002
09913M65210 09941M75410
Tie-rod end remover Lock nut wrench outer
) )/)

09941M75420 09943M55010
Lock nut wrench inner Boot clamp pliers
)/) )

09943M76310 09943M88211
Bush remover Pinion bearing installer
)/) )/)

09944M16810 SUZUKI scan tool (SUZUKI- 6

SDT)
Pinion torque checking — 1 2
socket
4
) This kit includes following 3
items. 1. SUZUKI-SDT 2. 5
DLC cable 3. USB cable 4.
AC/DC power supply 5.
Voltage meter probe 6.
Storage case) / ) / )

Section 7
HVAC
CONTENTS
Precautions .................................................7-1
Precautions............................................................. 7-1
Precautions for HVAC ........................................... 7-1
A/C System Caution.............................................. 7-1
Precautions for Servicing A/C System .................. 7-1
HVAC System........................................... 7B-1
Single A/C Type.......................................................7B-1
General Description .............................................7B-1
HVAC System Description .................................. 7B-1
Sub-Cool A/C System Description ...................... 7B-3
A/C Operation Description at ECM (Petrol
Model) ............................................................... 7B-3
A/C Operation Description at ECM (Diesel
Model) ............................................................... 7B-5
Schematic and Routing Diagram........................7B-6
Manual A/C Electronic Control Input / Output
Block Diagram................................................... 7B-6
Manual A/C System Circuit Diagram................... 7B-7
Component Location ...........................................7B-9
Manual A/C Control System Component
Location ............................................................ 7B-9
Diagnostic Information and Procedures............7B-9
A/C System Performance Inspection .................. 7B-9
Trouble Diagnosis for Abnormal Pressure ........ 7B-15
A/C System Symptom Diagnosis ...................... 7B-18
Abnormal Noise Symptom Diagnosis of
HVAC System ................................................. 7B-20
Visual Inspection ............................................... 7B-22
Inspection of HVAC Control Unit and Its
Circuit.............................................................. 7B-22
A/C System Inspection at ECM......................... 7B-23
Repair Instructions ............................................7B-23
Operation Procedure for Refrigerant Charge .... 7B-23
A/C System Major Components........................ 7B-30
Radiator Cooling Fan Removal and
Installation....................................................... 7B-31
Radiator Cooling Fan Inspection....................... 7B-31
Condenser Assembly On-Vehicle Inspection.... 7B-31
Condenser Assembly Removal and
Installation....................................................... 7B-31
HVAC Unit Components ................................... 7B-32
HVAC Unit Removal and Installation ................ 7B-33
Blower Motor Removal and Installation............. 7B-33
Table of Contents 7- i
Blower Motor Inspection....................................7B-33
Blower Motor Resistor Removal and
Installation .......................................................7B-34
Blower Motor Resistor Inspection .....................7B-34
Evaporator Inspection .......................................7B-35
Evaporator Temperature Sensor Removal
and Installation (If Equipped) ..........................7B-35
Evaporator Temperature Sensor Inspection
(If Equipped)....................................................7B-35
Expansion Valve Removal and Installation .......7B-36
Expansion Valve Inspection ..............................7B-36
HVAC Control Unit Components.......................7B-36
HVAC Control Unit Removal and Installation....7B-36
Blower Speed Selector Inspection ....................7B-38
A/C Refrigerant Pressure Sensor and Its
Circuit Inspection.............................................7B-38
A/C Refrigerant Pressure Sensor Removal
and Installation ................................................7B-39
Air Intake Switch Inspection ..............................7B-40
Air Intake Control Actuator Removal and
Installation .......................................................7B-40
Air Intake Control Actuator Inspection...............7B-41
Actuator Linkage Inspection..............................7B-41 7
Center Ventilation Louver Removal and
Installation .......................................................7B-41
Side Ventilation Louver Removal and
Installation .......................................................7B-42
A/C Switch Inspection .......................................7B-42
HVAC System Relay Inspection........................7B-43
A/C Compressor Drive Belt Inspection and
Adjustment ......................................................7B-43
A/C Compressor Drive Belt Removal and
Installation .......................................................7B-43
A/C Compressor Assembly Removal and
Installation .......................................................7B-44
A/C Compressor Assembly Components
(Petrol Model)..................................................7B-45
A/C Compressor Assembly Components
(Diesel Model) .................................................7B-46
Magnet Clutch Inspection..................................7B-46
Magnet Clutch Removal and Installation...........7B-46
Relief Valve Inspection......................................7B-48
Relief Valve Removal and Installation (Petrol
Model) .............................................................7B-48
Specifications.....................................................7B-48
7-ii Table of Contents
Tightening Torque Specifications...................... 7B-48
Special Tools and Equipment ...........................7B-49
Recommended Service Material ....................... 7B-49
Special Tool ...................................................... 7B-49
Dual A/C Type ........................................................7B-50
General Description ...........................................7B-50
HVAC System Description ................................ 7B-50
Sub-Cool A/C System Description .................... 7B-52
A/C Operation Description at ECM (Petrol
Model) ............................................................. 7B-52
A/C Operation Description at ECM (Diesel
Model) ............................................................. 7B-53
Schematic and Routing Diagram......................7B-54
Manual A/C Electronic Control Input / Output
Block Diagram................................................. 7B-54
Manual A/C System Circuit Diagram................. 7B-55
Component Location .........................................7B-57
Manual A/C Control System Component
Location .......................................................... 7B-57
Diagnostic Information and Procedures..........7B-58
A/C System Performance Inspection ................ 7B-58
Trouble Diagnosis for Abnormal Pressure ........ 7B-64
A/C System Symptom Diagnosis ...................... 7B-67
Abnormal Noise Symptom Diagnosis of
HVAC System ................................................. 7B-68
Visual Inspection ............................................... 7B-68
Inspection of HVAC Control Unit and Its
Circuit .............................................................. 7B-68
A/C System Inspection at ECM......................... 7B-69
Repair Instructions ............................................7B-69
Operation Procedure for Refrigerant Charge .... 7B-69
A/C System Major Components........................ 7B-79
Radiator Cooling Fan Removal and
Installation ....................................................... 7B-83
Radiator Cooling Fan Inspection....................... 7B-83
Condenser Assembly On-Vehicle Inspection.... 7B-83
Condenser Assembly Removal and
Installation ....................................................... 7B-83
HVAC Unit Components ................................... 7B-84
HVAC Unit Removal and Installation ................ 7B-84
Blower Motor Removal and Installation............. 7B-84
Blower Motor Inspection.................................... 7B-84
Blower Motor Resistor Removal and
Installation ....................................................... 7B-84
Blower Motor Resistor Inspection ..................... 7B-84
Evaporator Inspection ....................................... 7B-84
Evaporator Temperature Sensor Removal
and Installation (If Equipped) .......................... 7B-84
Evaporator Temperature Sensor Inspection
(If Equipped)....................................................7B-84
Expansion Valve Removal and Installation .......7B-84
Expansion Valve Inspection ..............................7B-85
HVAC Control Unit Components .......................7B-85
HVAC Control Unit Removal and Installation....7B-85
Blower Speed Selector Inspection ....................7B-86
A/C Refrigerant Pressure Sensor and Its
Circuit Inspection.............................................7B-86
A/C Refrigerant Pressure Sensor Removal
and Installation ................................................7B-86
Air Intake Switch Inspection ..............................7B-86
Air Intake Control Actuator Removal and
Installation .......................................................7B-87
Air Intake Control Actuator Inspection...............7B-87
Actuator Linkage Inspection..............................7B-87
Center Ventilation Louver Removal and
Installation .......................................................7B-87
Side Ventilation Louver Removal and
Installation .......................................................7B-87
A/C Switch Inspection .......................................7B-87
Rear Defogger Switch Inspection (If
Equipped)........................................................7B-87
Rear Cooling Unit Removal and Installation .....7B-88
Rear Cooling Unit Inspection ............................7B-89
Rear Blower Speed Selector Removal and
Installation .......................................................7B-90
Rear Blower Speed Selector Inspection ...........7B-91
Rear Ventilation Louver Removal and
Installation .......................................................7B-91
HVAC System Relay Inspection........................7B-92
A/C Compressor Drive Belt Inspection and
Adjustment ......................................................7B-92
A/C Compressor Drive Belt Removal and
Installation .......................................................7B-92
A/C Compressor Assembly Removal and
Installation .......................................................7B-92
A/C Compressor Assembly Components..........7B-92
Magnet Clutch Inspection..................................7B-92
Magnet Clutch Removal and Installation...........7B-92
Relief Valve Inspection......................................7B-93
Relief Valve Removal and Installation (Petrol
Model) .............................................................7B-93
Specifications .....................................................7B-93
Tightening Torque Specifications......................7B-93
Special Tools and Equipment ...........................7B-93
Recommended Service Material .......................7B-93
Special Tool ......................................................7B-93
 Precautions: 7-1

Precautions
HVAC

Precautions
Precautions for HVAC
AENBL80A7000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precaution for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Fastener Caution
Refer to “Fastener Caution” in Section 00 (Page 00-5).

Air Bag Warning

Refer to “Air Bag Warning” in Section 00 (Page 00-5).

Reassembling Note for Wiring Harness

Be sure to observe the Wiring Diagram Manual whenever installing wiring whenever installing wiring harness.
Otherwise, electrical trouble may occur.

Precautions for CAN Communication System

Refer to “Precautions for CAN Communication System” in Section 00 (Page 00-8).

Precautions for Ignition Mode

Refer to “Ignition Modes and Ignition Switch Positions” in Section 0A (Page 0A-5).

A/C System Caution

AENBL80A7000002
! CAUTION
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of an incorrect material or part will result in leakage of refrigerant, damage to parts or other faulty
condition.

Precautions for Servicing A/C System

AENBL80A7000003
Handling HFC-134a (R-134a) Refrigerant and Specified Compressor Oil

! WARNING

• Handle the HFC-134a (R-134a) refrigerant with care as follows. If not, it may cause severe injury
such as blindness and frostbite.
– Avoid contact with skin and eyes by wearing safety glasses and gloves. In case of contact with
skin or eyes, get medical attention.
– Keep away from fire. High temperature may cause toxic gas. Therefore, take care of much room
ventilation.
– The temperature above 40 °C (104 °F) in the refrigerant container may cause explosion.
7-2 Precautions:

! CAUTION

• Do not expose bright metals to liquid refrigerant. Refrigerant combined with moisture is corrosive
and tarnishes the surfaces of bright metals including chrome.
• Do not discharge the refrigerant into atmosphere.
• The specified compressor oil for use with the refrigerant is highly hygroscopic.
Keep internal parts of the A/C system free from moisture and dirt. When disconnecting any line from
the system, install a blind plug or cap to the fitting immediately.
• If pipes or hoses are replaced, replenish the system with the compressor oil to the specified amount
from the A/C compressor suction side.
– Single A/C type: Refer to “Replenishing Compressor Oil” in “Operation Procedure for Refrigerant
Charge”: Single A/C Type in Section 7B (Page 7B-24).
– Dual A/C type: Refer to “Replenishing Compressor Oil” in “Operation Procedure for Refrigerant
Charge”: Dual A/C Type in Section 7B (Page 7B-69).

Handling A/C Cycle Parts and Tooling

! CAUTION

• When connecting hoses and pipes, apply a few drops of compressor oil to O-ring.
• Replace O-rings with new ones whenever hoses, pipes and after parts are disconnected.
• Route drain hose so as to avoid any contact of drainage with vehicle components.
• If pipes or hoses are replaced, replenish the system with the compressor oil to the specified amount
from the A/C compressor suction side.
– Single A/C type: Refer to “Replenishing Compressor Oil” in “Operation Procedure for Refrigerant
Charge”: Single A/C Type in Section 7B (Page 7B-24).
– Dual A/C type: Refer to “Replenishing Compressor Oil” in “Operation Procedure for Refrigerant
Charge”: Dual A/C Type in Section 7B (Page 7B-69).
• When handling recovery and recycling equipment, be sure to follow the instruction manual for the
equipment.

NOTE
Check local governmental regulations regarding working with refrigerator systems and its tooling.

Refrigerant Recovery
When discharging refrigerant out of A/C system, always recover it using refrigerant recovery and recycling equipment
because discharging HFC-134a (R-134a) refrigerant into atmosphere would cause adverse effect to environment.
• Single A/C type: Refer to “Recovery” in “Operation Procedure for Refrigerant Charge”: Single A/C Type in Section
7B (Page 7B-24).
• Dual A/C type: Refer to “Recovery” in “Operation Procedure for Refrigerant Charge”: Dual A/C Type in Section 7B
(Page 7B-69).

Refrigerant Charge
After performing compressor oil replenishment and evacuation, charge a proper amount of refrigerant to A/C system.
• Single A/C type: Refer to “Charge” in “Operation Procedure for Refrigerant Charge”: Single A/C Type in Section 7B
(Page 7B-24).
• Dual A/C type: Refer to “Charge” in “Operation Procedure for Refrigerant Charge”: Dual A/C Type in Section 7B
(Page 7B-69).
 HVAC System: Single A/C Type 7B-1

HVAC System
HVAC

Single A/C Type

General Description
HVAC System Description
AENBL80A7211001
• This HVAC system is of a manually controlled air conditioning type.
• Settings of airflow mode and temperature are possible using air flow selector and temperature selector respectively.
When these selectors are set in desired positions, the corresponding cables move air flow control door and
temperature control door accordingly.
• There are two other selectors: air intake selector and blower speed selector.
• Air inlet mode can be switched between recirculated air mode and fresh air mode by air intake selector. When the
desired mode is selected, the air intake actuator moves the air intake door to the corresponding position.
• Air flow rate can be adjusted by blower speed selector. Four positions are available: LO, ML, MH and HI.
• A/C switch turns on and off the A/C system. Signal from the A/C switch is transmitted to ECM via BCM through CAN
communication system. The ECM circuits related to the A/C system controls A/C compressor relay and radiator
(condenser) cooling fan relay according to the signal. Refer to “A/C Operation Description at ECM (Petrol Model)”:
Single A/C Type (Page 7B-3) or “A/C Operation Description at ECM (Diesel Model)”: Single A/C Type (Page 7B-5)
for details.
• In Petrol model, the ECM circuits related to the A/C system also controls evaporator temperature depending on the
data from evaporator temperature sensor. Refer to “A/C Operation Description at ECM (Petrol Model)”: Single A/C
Type (Page 7B-3) for details. In Diesel model, A/C compressor can adjust the flow rate of refrigerant, monitoring the
A/C refrigerant pressure mechanically. This also helps to keep the evaporator temperature at an optimum level.
• The A/C system uses an A/C refrigerant pressure sensor that is capable of detecting linear changes in refrigerant
pressure.
• HVAC unit incorporates blower motor unit, heater core unit and evaporator unit.
• Each side ventilator has a shutter mechanism.
• The condenser is of a sub-cool type. It is integral with the receiver/dryer and mounted on the vehicle body in a
floating manner.
• For the electronic control system components location, refer to “Manual A/C Control System Component Location”:
Single A/C Type (Page 7B-9).
For the A/C system components location, refer to “A/C System Major Components”: Single A/C Type (Page 7B-29).
For the A/C electrical control input / output diagram, refer to “Manual A/C Electronic Control Input / Output Block
Diagram”: Single A/C Type (Page 7B-6).
7B-2 HVAC System: Single A/C Type

HVAC System Construction

9
12

10
13 13

9
23 22

19
1

20

21

14
15

18 11 11
17
16

8
6

4
2
7
5
: [A]
3
: [B]

: [C]

IBL80A721001-01

[A]: Air flow 5. Discharge hose 12. Defroster air 19. Air flow control door
[B]: Refrigerant flow 6. Suction hose 13. Demister air 20. Heater core
[C]: Engine coolant flow 7. Liquid pipe 14. Fresh air 21. Engine
1. HVAC unit 8. Expansion valve 15. Recirculation air 22. Radiator
2. A/C compressor 9. Side ventilation air 16. Evaporator 23. Reservoir
3. Condenser assembly 10. Center ventilation air 17. Air intake door
4. Receiver/dryer 11. Front foot air 18. Temperature control door

Sub-Cool A/C System Description

AENBL80A7211002
In the sub-cool A/C system (condenser integrated with receiver/dryer), the inside of the condenser is divided into the
condensation part and the sub-cooler part, and the receiver/dryer is located between these. In the receiver/dryer, the
refrigerant is separated into vapor refrigerant and liquid refrigerant. Only the liquid refrigerant is delivered to the sub-
cooler part of the condenser. The refrigerant is supercooled by the sub-cooler part of the condenser.
 HVAC System: Single A/C Type 7B-3

: [A]
3 : [B]
: [C]

1
2

IBP80A721075-01

[A]: Liquid 1. A/C compressor 4. Expansion valve 7. Sub-cooler part

[B]: Vapor 2. Condenser 5. Evaporator
[C]: Superheated vapor 3. Receiver/dryer 6. Condensation part

A/C Operation Description at ECM (Petrol Model)

AENBL80A7211003
Upon receiving A/C switch ON signal from HVAC control unit, ECM controls A/C compressor relay and radiator
(condenser) cooling fan relay as described in the following table.
The A/C switch ON signal is sent from the HVAC control unit to BCM. Then it is transmitted to ECM as A/C request
signal through CAN. For CAN communication system, refer to “Communication System Description”: K14B Model in
Section 10H (Page 10H-1).
7B-4 HVAC System: Single A/C Type

Input sensor
Control item Description
(or signal)
A/C compressor Evaporator Evaporator ECM controls A/C compressor by turning A/C compressor relay
relay control temperature temperature ON/OFF according to request signal from BCM. BCM sends the
control sensor signal based on the signal from evaporator temperature sensor to
prevent evaporator from being frozen.
Control during ECM stops A/C compressor by turning A/C compressor relay OFF
low engine according to signal from CKP sensor (engine rpm) so as to
speed prevent engine from stalling while engine speed is low.
Control during ECM stops A/C compressor by turning A/C compressor relay OFF
high engine according to signal from CKP sensor (engine rpm) so as to
CKP sensor
speed prevent A/C compressor from over-revolution while engine speed
(engine rpm)
is high.
Control at ECM stops A/C compressor temporarily by turning A/C
engine start compressor relay OFF according to signals from CKP sensor
(engine rpm) and others so as to ensure stable engine idling
speed immediately after engine start.
Control at A/C refrigerant • ECM stops A/C compressor by turning A/C compressor relay
abnormal pressure sensor OFF according to signal from A/C refrigerant pressure sensor
refrigerant so as to protect system when refrigerant pressure is abnormal.
pressure • ECM stops A/C compressor by turning A/C compressor relay
OFF when A/C refrigerant pressure sensor malfunctions.
Control during Accelerator • ECM stops A/C compressor temporarily by turning A/C
acceleration pedal position compressor relay OFF according to signal from accelerator
sensor and VSS pedal position sensor so as to ensure acceleration while
accelerator pedal is fully depressed regardless of vehicle
speed.
• ECM stops A/C compressor temporarily by turning A/C
compressor relay OFF according to signal from throttle position
sensor so as to ensure acceleration when accelerator pedal is
depressed more than specification while vehicle speed is low.
Control at high ECT sensor • ECM stops A/C compressor by turning A/C compressor relay
engine coolant OFF according to signal from ECT sensor so as to prevent
temperature overheating when engine coolant temperature is higher than
specified level.
• ECM stops A/C compressor by turning A/C compressor relay
OFF when ECT sensor malfunctions.
Radiator (condenser) cooling fan A/C refrigerant ECM drives radiator cooling fan under following conditions by
relay control pressure sensor turning radiator cooling fan relay ON according to signals from A/
and VSS C refrigerant pressure sensor and VSS when A/C compressor
relay is ON.
• Vehicle speed is less than specified range
• Vehicle speed is more than specified range and refrigerant
pressure more than specified range
• VSS malfunction is not detected
 HVAC System: Single A/C Type 7B-5

A/C Operation Description at ECM (Diesel Model)

AENBL80A7211004
Upon receiving A/C switch ON signal from HVAC control unit, ECM controls A/C compressor relay and radiator
(condenser) cooling fan relay as described in the following table.
The A/C switch ON signal is sent from the HVAC control unit to BCM. Then it is transmitted to ECM as A/C request
signal through CAN. For CAN communication system, refer to “Communication System Description”: D13A Model in
Section 10H (Page 10H-20).
Input sensor
Control item Description
(or signal)
A/C compressor Control during CKP sensor ECM stops A/C compressor by turning A/C compressor relay OFF
relay control low engine (engine rpm) according to signal from CKP sensor (engine rpm) so as to
speed prevent engine from stalling while engine speed is low.
Control during ECM stops A/C compressor by turning A/C compressor relay OFF
high engine according to signal from CKP sensor (engine rpm) so as to
speed prevent A/C compressor from over-revolution while engine speed
is high.
Control at A/C refrigerant • ECM stops A/C compressor by turning A/C compressor relay
abnormal pressure sensor OFF according to signal from A/C refrigerant pressure sensor
refrigerant so as to protect system when refrigerant pressure is abnormal.
pressure • ECM stops A/C compressor by turning A/C compressor relay
OFF when A/C refrigerant pressure sensor malfunctions.
Control during Accelerator • ECM stops A/C compressor temporarily by turning A/C
acceleration pedal position compressor relay OFF according to signal from accelerator
sensor and VSS pedal position sensor so as to ensure acceleration while
accelerator pedal is fully depressed regardless of vehicle
speed.
• ECM stops A/C compressor temporarily by turning A/C
compressor relay OFF according to signal from throttle position
sensor so as to ensure acceleration when accelerator pedal is
depressed more than specification while vehicle speed is low.
Control at high ECT sensor • ECM stops A/C compressor by turning A/C compressor relay
engine coolant OFF according to signal from ECT sensor so as to prevent
temperature overheating when engine coolant temperature is higher than
specified level.
• ECM stops A/C compressor by turning A/C compressor relay
OFF when ECT sensor malfunctions.
Radiator (condenser) cooling fan A/C refrigerant ECM drives radiator cooling fan in low or high speed mode by
relay control pressure sensor turning radiator cooling fan relays No.1, No.2 and No.3 ON/OFF
according to signal from A/C refrigerant pressure sensor.
7B-6 HVAC System: Single A/C Type

Schematic and Routing Diagram

Manual A/C Electronic Control Input / Output Block Diagram
AENBL80A7212001

Input sensor (or signal) Electronic control Output actuator (or signal)

ECM (A/C control area)

A/C refrigerant
pressure sensor A/C Compressor relay
A/C compressor relay
control
[A] Throttle position sensor
A/C compressor
Accelerator pedal
position sensor
Radiator (condenser)
Radiator cooling fan relay
ECT sensor cooling fan relay control

CKP sensor Radiator cooling fan motor

VSS

[A]
Evaporator temperature
sensor

BCM

HVAC control unit

A/C switch Blower motor

Blower speed selector Blower motor resistor

Air intake switch Air intake control actuator

CAN communication
IBL80A721002-01

[A]: For petrol model

 HVAC System: Single A/C Type 7B-7

Manual A/C System Circuit Diagram

AENBL80A7212002
Petrol Model

1
8
RED/WHT WHT G155-6
BLK BLK/WHT YEL G155-7
G155-1 BLK
9
BLU/WHT G155-3
RED/WHT BLK 2
15
BLU BLK/YEL RED G155-2
10 LT GRN G155-5
11 3
G154-1 G154-7 GRN/RED
4
RED/WHT G154-11
12
5
BLU G154-5 6
G154-12 GRY
GRN/YEL G154-6
13
RED/YEL G154-9
WHT/BLK
7
14 RED/BLK G154-3 BEG
16
17

19 20 18
BLU/WHT E01-48
BLU/YEL WHT
GRY E01-37
BLK/RED E01-55
BLK/RED E01-56
21
27
BLK/YEL BRN/WHT E01-54
BLK/YEL
E01- 1 RED
18
22 E01- 2 WHT
LT GRN E01-42
GRY BLU 26
E01-30 GRY/RED
23
E01-35 RED/GRN
BLU/BLK 25 BLK
E01-14 BLU/RED
BLU
24
BLU
C01-50 BLK
BLU/WHT
C01-51 BLK
C01-53 BLK
GRN E01-41

IBL80A721003-01

1. HVAC control unit
2. Blower speed selector
3. A/C switch
4. “A/C” indicator light
5. “REC” indicator light
6. Air intake switch
7. Illumination light
8. Fan relay 15. BCM 22. Radiator cooling fan relay No.1
9. Heater relay 16. Evaporator temperature sensor 23. Radiator cooling fan relay No.2
10. Blower motor 17. ECM 24. Radiator cooling fan relay No.3
11. Blower motor resistor 18. CAN driver 25. Radiator cooling fan motor
12. Air intake control actuator 19. A/C compressor relay 26. A/C refrigerant pressure sensor
13. Lighting switch 20. A/C compressor 27. Ignition switch
14. Combination meter 21. Main relay
7B-8 HVAC System: Single A/C Type

Diesel Model

1
8
RED/WHT WHT G155-6
BLK BLK/WHT YEL G155-7
G155-1 BLK
9
BLU/WHT G155-3
RED/WHT BLK 2
15
BLU BLK/YEL RED G155-2
10 LT GRN G155-5
11 3
G154-1 G154-7 GRN/RED
4
RED/WHT G154-11
12
5
BLU G154-5 6
G154-12 GRY
GRN/YEL G154-6
13
RED/YEL G154-9
7
14 RED/BLK G154-3

16
BLK
18 19 17
BLU/YEL WHT
GRY E01-79
20
LT GRN/RED E01-7
GRY BLU E01- 64 RED
26 17
21 E01- 40 WHT
BLU/BLK 23 BLK

25
BLU/WHT E01-37 GRY/RED
22
E01-87 RED/GRN
GRN E01-8 E01-10 BLU/RED
BLK/RED E01-4
BLU BLK/RED E01-5
24
BLK/YEL BLK/RED BLK/RED E01-6
YEL/GRN BRN/WHT E01-80

E01-1 BRN
E01-2 BRN
E01-3 BRN

IBL80A721004-03

1. HVAC control unit
2. Blower speed selector
3. A/C switch
4. “A/C” indicator light
5. “REC” indicator light
6. Air intake switch
7. Illumination light
8. Fan relay 15. BCM 22. Radiator cooling fan relay No.3
9. Heater relay 16. ECM 23. Radiator cooling fan motor
10. Blower motor 17. CAN driver 24. Main relay
11. Blower motor resistor 18. A/C compressor relay 25. A/C refrigerant pressure sensor
12. Air intake control actuator 19. A/C compressor 26. Ignition switch
13. Lighting switch 20. Radiator cooling fan relay No.1
14. Combination meter 21. Radiator cooling fan relay No.2
 HVAC System: Single A/C Type 7B-9

Component Location
Manual A/C Control System Component Location
AENBL80A7213001

7 15
8

14 12 17 16

11
22
6
10

[A] 19 20 21 2 18

[B]

13

[B] 19 20 21 2 18

[A]

5
1

4
1
3
IBL80A721006-02

[A]: Petrol model 7. Evaporator temperature sensor (If equipped) 15. Blower speed selector
[B]: Diesel model 8. Air intake control actuator 16. Air flow selector
1. A/C refrigerant pressure sensor 9. Blower motor 17. A/C switch
2. A/C compressor relay 10. Blower motor resistor 18. Radiator cooling fan relay No.1
3. A/C compressor 11. HVAC control unit 19. Radiator cooling fan relay No.2
4. ECM 12. Air intake switch 20. Radiator cooling fan relay No.3
5. Radiator cooling fan motor 13. HVAC unit 21. Main relay
6. Fan relay 14. Temperature selector 22. Heater relay

Diagnostic Information and Procedures

A/C System Performance Inspection • Vehicle is put indoors.
AENBL80A7214001
• Ambient temperature is within 25 – 45 °C (77 –
1) Confirm that vehicle and environmental conditions
113 °F).
are as follows.
7B-10 HVAC System: Single A/C Type

• Relative humidity is within 30 – 70%. 4) Warm up engine to normal operating temperature

• There is no wind indoors. and keep it at specified idle speed.
• HVAC unit is normal. 5) Turn A/C switch ON, then set blower speed selector
to maximum speed position, temperature selector to
• Blower motor is normal.
maximum cold position, air flow selector to face
• There is no air leakage from air ducts. position, air intake switch to recirculation mode and
• Condenser fins are clean. side ventilation louvers to open position. (Confirm
• Battery voltage is about 12 V or more (battery in that A/C compressor and radiator cooling fan are
good condition). working.)
• Radiator cooling fan operates normally. 6) Wait for ten minutes to stabilize A/C operation.
2) Make sure that high pressure valve (1) and low 7) Open all door windows, front doors and hood.
pressure valve (2) of manifold gauge (A) are firmly 8) With about 20 mm (0.8 in.) of dry bulb thermometer
closed. (1) put right in front of center ventilation louver and a
wet and dry bulb thermometer (2) near air inlet of
Special tool
HVAC unit.
(A): 09990–06020
3) Connect high pressure charging hose (3) to high 1
pressure service valve (5) on vehicle and low
pressure charging hose (4) to low pressure service
valve (6).

(A)
2
1

3
4

2
IBP80A721081-01
5

IBL80A721007-01

9) Check for each pressure of low side and high side if it is within shaded range of graph. If each gauge reading is out
of specified pressure, correct defective part referring to the following table.
When diagnosing troubles of abnormal pressure on the low side and high side for each pressure more specifically,
refer to “Trouble Diagnosis for Abnormal Pressure”: Single A/C Type (Page 7B-14).

NOTE
Pressure registered on gauge varies with ambient temperature. Therefore, use the graphs when
determining if pressures are normal or not.

Low side and high side pressure example, gauges should read as follows when ambient temperature is 30
°C (86 °F)
Petrol model Diesel model
Pressure on high pressure gauge (HI) 1220 – 1540 kPa (12.4 – 15.7 kgf/ 1320 – 1650 kPa (13.5 – 16.8 kgf/
cm2) cm2)
Pressure on low pressure gauge (LO) 240 – 350 kPa (2.4 – 3.6 kgf/cm2) 210 – 290 kPa (2.1 – 3.0 kgf/cm2)
 HVAC System: Single A/C Type 7B-11

[A]
psi kPa kgf/cm 2
327.1 2300 23
312.9 2200 22 70
298.7 2100 21
284.4 2000 20
270.2 1900 19
256.0 1800 18 “H” 30
241.7 1700 17
227.5 1600 16 [G]
213.3 1500 15
199.1 1400 14
184.9 1300 13
“I ”
[C] 170.6 1200 12 [F ]
151.4 1100 11
142.2 1000 10
128.0 900 9
113.8 800 8
99.5 700 7
85.3 600 6 70
71.1 500 5 “J ”
56.9 400 4
[G] 30
[D] 42.7 300 3
28.4 200 2 “K”
14.2 100 1
0
25 30 35 40 45 [E ]
77 86 95 104 113

[B]
psi kPa kgf/cm 2
362.6 2500 25 70
348.1 2400 24
327.1 2300 23
312.9 2200 22
298.7 2100 21
284.4 2000 20
270.2 1900 19 30
256.0 1800 18 “H”
[G]
241.7 1700 17
227.5 1600 16
213.3 1500 15
199.1 1400 14
184.9 1300 13
“I ”
[C] 170.6 1200 12 [F ]
151.4 1100 11
142.2 1000 10
128.0 900 9
113.8 800 8
99.5 700 7
85.3 600 6
71.1 500 5 “J ”
70
56.9 400 4
[D] 42.7 300 3 [G] 30
28.4 200 2
14.2 100 1 “K”
0
25 30 35 40 45 [E ]
77 86 95 104 113
IBL80A721034-01

[A]: Petrol model [C]: Pressure of high pressure gauge [E]: Ambient temperature [G]: Acceptable range
[B]: Diesel model [D]: Pressure of low pressure gauge [F]: Humidity
7B-12 HVAC System: Single A/C Type

High pressure gauge

Condition Possible cause Correction
Pressure is higher than Refrigerant overcharged Recharge.
acceptable range Expansion valve frozen or clogged Check expansion valve.
(“H” area) Clogged refrigerant passage of high pressure side Clean or replace.
Radiator cooling fan malfunction (Insufficient Check radiator cooling fan.
cooling of condenser)
Dirty or bent condenser fins (Insufficient cooling of Clean or repair.
condenser)
A/C compressor malfunction (Insufficient oil etc.) Check A/C compressor.
Engine overheat Check engine cooling system.
- Petrol model: )(Page 1F-4)
- Diesel model: )(Page 1F-18)
Pressure is lower than Insufficient refrigerant (Insufficient charge or Check for leakage, repair if necessary
acceptable range leakage) and recharge.
(“I” area) Expansion valve malfunction (valve opens too Check expansion valve.
wide)
A/C compressor malfunction (Insufficient Check A/C compressor.
compression)

Low pressure gauge

Condition Possible cause Correction
Pressure is higher than Expansion valve malfunction (valve opens too Check expansion valve.
acceptable range wide)
(“J” area) A/C compressor malfunction (Insufficient Check A/C compressor.
compression)
Pressure is lower than Insufficient refrigerant (Insufficient charge or Check for leakage, repair if necessary
acceptable range leakage) and recharge.
(“K” area) Expansion valve malfunction (valve opens too Check expansion valve.
narrow)
Clogged refrigerant passage (crashed pipe) Repair or replace.

10) Check correlation between inlet port temperature-and-outlet port temperature using the following graph. For
example, if temperature near air inlet of HVAC unit is 35 °C (95 °F) and the one at air outlet of center ventilation
louver is 18 °C (64.4 °F), their crossing point is within acceptable range as shown in the graph. In this case,
cooling performance is satisfactory and proper.
11) If crossing point is out of acceptable range, diagnose trouble referring to the following table.
 HVAC System: Single A/C Type 7B-13

[A ]
[C ] [E ]

104 40
102 39
70

100 38
99 37
97 36
95 35
93 34
91 33
90 32
88 31
86 30
84 29
82 28
81 27
79 26
77 25 “H”
75 24 30
73 23
72 22
70 21 [F ]
68 20
66 19 [G]
64 18
63 17
61 16
59 15
57 14
55 13
“I”
54 12
52 11
50 10
48 9
46 8
25 30 35 40 45 [D ]
77 86 95 104 113
IBL80A721035-01
7B-14 HVAC System: Single A/C Type

[B]
[C ] [E ]

104 40
102 39
70
100 38
99 37
97 36
95 35
93 34
91 33
90 32
88 31
86 30
84 29
82 28
81 27
79 26
77 25 “H”
75 24 30
73 23
72 22
70 21 [F ]
68 20
66 19 [G]
64 18
63 17
61 16
59 15
57 14
55 13
“I”
54 12
52 11
50 10
48 9
46 8
25 30 35 40 45 [D ]
77 86 95 104 113
IBL80A721036-01

[A]: Petrol model [D]: Temperature near air inlet of HVAC unit [G]: Crossing point
[B]: Diesel model [E]: Humidity
[C]: Temperature at outlet of center ventilation louver [F]: Acceptable range

Thermometer at center ventilation louver

Condition Possible cause Correction
Crossing point is higher Insufficient or excessive charge of refrigerant Check refrigerant pressure.
than acceptable range Dirty or bent evaporator fins Clean or repair.
(“H” area) Air leakage from cooling (heater) unit or air duct Repair or replace.
Malfunctioning, switch over function of door in Repair or replace.
cooling (heater) unit
A/C compressor malfunction Check A/C compressor.
Crossing point is lower Insufficient air volume from center ventilation Check blower motor and fan.
than acceptable range (“I” louver (Heater blower malfunction)
area) A/C compressor malfunction Check A/C compressor.

Trouble Diagnosis for Abnormal Pressure

AENBL80A7214002
 HVAC System: Single A/C Type 7B-15

Petrol Model

NOTE
Normal pressure values for high pressure gauge (HI) and low pressure gauge (LO) in the following
table are those measured when the ambient temperature is about 30 °C (86 °F). As normal pressure
values for both gauges vary depending on the ambient temperature, be sure to perform the following
steps before starting diagnosis of troubles.
1. Measure the ambient temperature and using that temperature, read the normal high and low
pressure values from the graph given in Step 10) of “A/C System Performance Inspection”: Single
A/C Type (Page 7B-9).
2. Use these values in place of the normal pressure values in the following table.

Condition
Manifold gauge kPa (kgf/cm2) (psi) Possible cause Correction
Detail
LO HI
240 – 350 1220 – 1540 Normal condition
(2.4 – 3.6) (12.4 – 15.7) — —
(34.8 – 50.8) (177.0 – 223.4)
Negative pressure 500 – 600 LO gauge reads Dust particles Replace expansion
(5.1 – 6.1) negative pressure, while accumulate or water valve.
(72.5 – 87.0) HI gauge reads droplets are frozen Replace condenser
extremely low pressure. inside expansion assembly.
Presence of frost around valve, preventing Evacuate A/C system
tubing to and from refrigerant from and recharge system
condenser assembly flowing. with fresh refrigerant.
and expansion valve.
Normal: Normal: During A/C operation, Expansion valve is Replace expansion
240 – 350 1220 – 1540 LO gauge sometimes frozen due to moisture valve.
(2.4 – 3.6) (12.4 – 15.7) indicates negative in system, temporarily Replace condenser
(34.8 – 50.8) (177.0 – 223.4) pressure, and shutting off assembly.
↑↓ ↑↓ sometimes normal refrigeration cycle. Evacuate A/C system
Abnormal: Abnormal: pressure. Also HI gauge and recharge system
Negative 700 – 1000 reading fluctuates with fresh refrigerant.
pressure (7.1 – 10.2) between abnormal and
(102 – 145) normal pressures.
50 – 150 700 – 1000 Both LO and HI gauge Insufficient refrigerant Using leak detector,
(0.5 – 1.5) (7.1 – 10.2) indicate low readings. in system check for leaks and
(7.25 – 21.8) (102 – 145) (Refrigerant leaking). repair if necessary.
Output air is slightly cold.
Recharge system with
refrigerant to specified
amount.
If pressure readings is
almost 0 when
manifold gauges are
attached, check for
any leaks, repair them,
and evacuate system.
400 – 600 Pressure on LO gauge is Internal leak in A/C Inspect A/C
(4.1 – 6.1) high. compressor. compressor and repair
(58.0 – 87.0) Pressure on HI gauge is or replace if
low. necessary.
Both pressures become
equal right after A/C is
turned OFF.
7B-16 HVAC System: Single A/C Type

Condition
Manifold gauge kPa (kgf/cm2) (psi) Possible cause Correction
Detail
LO HI
400 – 450 2000 – 2500 High pressure readings Overcharged A/C Adjust refrigerant to
(4.1 – 4.6) (20.4 – 25.5) on both LO and HI system. specified amount.
(58.0 – 65.3) (290 – 363) gauges. Faulty condenser Clean condenser.
cooling operation.
Faulty radiator cooling Inspect and repair
fan operation. radiator cooling fan.
High pressure reading Presence of air in A/C Replace condenser.
on both LO and HI system Inspect quantity of
gauges. (Improperly compressor oil and
Low pressure tubing is evacuated). presence of
not cold when touched. contaminants in oil.
Evacuate system and
recharge system with
fresh refrigerant.
450 – 550 High pressure reading Faulty expansion Replace expansion
(4.6 – 5.6) on both LO and HI valve. valve.
(65.3 – 79.8) gauges. Refrigerant flow is not
Large amount of frost or regulated properly.
dew on low pressure
tubing.

Diesel Model

NOTE
Normal pressure values for pressure gauge (HI) and low pressure gauge (LO) in the following table are
those measured when the ambient temperature is about 30 °C (86 °F). As normal pressure values for
both gauges vary depending on the ambient temperature, be sure to perform the following steps
before starting diagnosis of troubles.
1. Measure the ambient temperature and using that temperature, read the normal high and low
pressure values from the graph given in Step 10) of “A/C System Performance Inspection”: Single
A/C Type (Page 7B-9).
2. Use these values in place of the normal pressure values in the following table.

Condition
Manifold gauge kPa (kgf/cm2) (psi) Possible cause Correction
Detail
LO HI
210 – 290 1320 – 1650 Normal condition
(2.1 – 3.0) (13.5 – 16.8) — —
(30.5 – 42.1) (191.4 – 239.3)
Negative pressure 500 – 600 LO gauge reads Dust particles Replace expansion
(5.1 – 6.1) negative pressure, while accumulate or water valve.
(72.5 – 87.0) HI gauge reads droplets are frozen Replace condenser
extremely low pressure. inside expansion assembly.
Presence of frost around valve, preventing Evacuate A/C system
tubing to and from refrigerant from and recharge system
condenser assembly flowing. with fresh refrigerant.
and expansion valve.
Normal: Normal: During A/C operation, Expansion valve is Replace expansion
210 – 290 1320 – 1650 LO gauge sometimes frozen due to moisture valve.
(2.1 – 3.0) (13.5 – 16.8) indicates negative in system, temporarily Replace condenser
(30.5 – 42.1) (191.4 – 239.3) pressure, and shutting off assembly.
↑↓ ↑↓ sometimes normal refrigeration cycle. Evacuate A/C system
Abnormal: Abnormal: pressure. Also HI gauge and recharge system
Negative 700 – 1000 reading fluctuates with fresh refrigerant.
pressure (7.1 – 10.2) between abnormal and
(102 – 145) normal pressures.
 HVAC System: Single A/C Type 7B-17

Condition
Manifold gauge kPa (kgf/cm2) (psi) Possible cause Correction
Detail
LO HI
50 – 150 700 – 1000 Both LO and HI gauge Insufficient refrigerant Using leak detector,
(0.5 – 1.5) (7.1 – 10.2) indicate low readings. in system check for leaks and
(7.25 – 21.8) (102 – 145) Output air is slightly cold. (Refrigerant leaking). repair if necessary.
Recharge system with
refrigerant to specified
amount.
If pressure readings
are almost 0 when
manifold gauges are
attached, check for
any leaks, repair them,
and evacuate system.
400 – 600 Pressure on LO gauge is Internal leak in A/C Inspect A/C
(4.1 – 6.1) high. compressor. compressor and repair
(58.0 – 87.0) Pressure on HI gauge is or replace if
low. necessary.
Both pressures become
equal right after A/C is
turned OFF.
400 – 450 2000 – 2500 High pressure readings Overcharged A/C Adjust refrigerant to
(4.1 – 4.6) (20.4 – 25.5) on both LO and HI system. specified amount.
(58.0 – 65.3) (290 – 363) gauges. Faulty condenser Clean condenser.
cooling operation.
Faulty radiator cooling Inspect and repair
fan operation. radiator cooling fan.
High pressure reading Presence of air in A/C Replace condenser.
on both LO and HI system Inspect quantity of
gauge. (Improperly compressor oil and
Low pressure tubing is evacuated). presence of
not cold when touched. contaminants in oil.
Evacuate system and
recharge system with
fresh refrigerant.
450 – 550 High pressure reading Faulty expansion Replace expansion
(4.6 – 5.6) on both LO and HI valve. valve.
(65.3 – 79.8) gauge. Refrigerant flow is not
Large amount of frost or regulated properly.
dew on low pressure
tubing.

A/C System Symptom Diagnosis

AENBL80A7214003

Condition Possible cause Correction / Reference Item

Blower motor does not Blown fuse Check related fuses, and then check for short
operate circuit to ground.
Faulty fan relay Check fan relay. )(Page 7B-41)
Faulty heater relay Check heater relay. )(Page 7B-41)
Faulty blower motor resistor Check blower motor resistor. )(Page 7B-33)
Faulty blower speed selector Check blower speed selector. )(Page 7B-37)
Faulty wiring or grounding Repair or replace wiring as necessary.
Faulty blower motor Check blower motor. )(Page 7B-33)
Foreign material is present Remove foreign material.
7B-18 HVAC System: Single A/C Type
Condition Possible cause
Air outlet ports do not Broken or bent air flow control cable
change or do not agree Faulty air flow selector
with air flow selector’s Incorrect installation of air flow control
position even if air flow cable
selector is changed Broken air flow control door assembly
Leaky or clogged air ducts
Air intake door does not Blown fuse
change even if air intake
mode is changed Broken air intake door
Faulty air intake control actuator
Faulty air intake switch
Faulty wiring or grounding
Warm air does not come Broken or bent temperature control
out or insufficient heating cable
(Faulty temperature Faulty temperature selector
control) Incorrect installation of temperature Check position of cable and adjust it if
control cable
Broken temperature control door
assembly
Clogged air ducts
Leaky or clogged heater core
Leaky or clogged heater hoses
Faulty ECT Sensor
No cool air comes out (A/ No refrigerant
C compressor does not
operate) Blown fuse
Faulty A/C switch
Faulty blower speed selector
Faulty evaporator temperature sensor (If Check evaporator temperature sensor.
equipped)
Faulty A/C refrigerant pressure sensor Check A/C refrigerant pressure sensor.
Faulty wiring or grounding
Faulty ECM and its circuit
Faulty magnet clutch
Loose or broken A/C compressor drive Check A/C compressor drive belt. )(Page 7B-
belt (petrol model)
Loose or broken accessory drive belt
(diesel model)
Faulty A/C compressor
Faulty A/C compressor relay
Faulty BCM
Correction / Reference Item
Check air flow control cable.
Check air flow selector.
Check position of cable and adjust it if
necessary.
Repair air flow control door assembly.
Repair air ducts.
Check related fuses, and then check for short
circuit to ground.
Repair air intake door.
Check air intake control actuator. )(Page 7B-
40)
Check air intake switch. )(Page 7B-39)
Repair or replace wiring as necessary.
Check temperature control cable.
Check temperature selector.
necessary.
Repair or replace temperature control door
assembly.
Repair air ducts.
Replace heater core.
Replace heater hoses.
Check ECT sensor.
- Petrol model: )(Page 1C-6)
- Diesel model: )(Page 1C-21)
Perform refrigerant recovery, evacuation and
charge. )(Page 7B-23)
Check related fuses, and then check for short
circuit to ground.
Check A/C switch. )(Page 7B-41)
Check blower speed selector. )(Page 7B-37)
)(Page 7B-34)
)(Page 7B-37)
Repair or replace wiring as necessary.
Check ECM.
- Petrol model: “Inspection of ECM and Its
Circuits”: K14B in Section 1A (Page 1A-109)
- Diesel model: “Inspection of ECM and Its
Circuits”: D13A in Section 1A (Page 1A-272)
Check magnet clutch. )(Page 7B-44)
42)
Check accessory drive belt. )(Page 1J-20)
Check A/C compressor.
Check A/C compressor relay. )(Page 7B-41)
Check BCM. “Body Electrical Control System
Check” in Section 10B (Page 10B-7)

Condition Possible cause
No cool air comes out Blown fuse
(radiator cooling fan
motor does not operate) Faulty wiring or grounding
Faulty radiator cooling fan relay
Faulty radiator cooling fan motor
ECM faulty
Cool air does not come Insufficient or excessive charge of
out or insufficient cooling refrigerant
(A/C compressor in Clogged condenser
normal operation) Clogged or frosted evaporator
Faulty evaporator temperature sensor (if Check evaporator temperature sensor.
equipped)
Faulty expansion valve
Loose or broken A/C compressor drive Check A/C compressor drive belt. )(Page 7B-
belt (petrol model)
Loose or broken accessory drive belt
(diesel model)
Faulty magnet clutch
Faulty A/C compressor
Air in A/C system
Air leaking from HVAC unit or air duct
Faulty heater and ventilation system
Faulty blower motor
Excessive compressor oil in A/C system Drain excessive compressor oil from A/C
Cool air does not come Faulty wiring connection
out intermittently Faulty evaporator temperature sensor (If Check evaporator temperature sensor.
equipped)
Faulty expansion valve
Excessive moisture in A/C system
Faulty magnet clutch
Excessive amount of refrigerant
Cool air comes out only at Clogged condenser
high speed Insufficient charge of refrigerant
Air in A/C system
Loose A/C compressor drive belt (petrol Check A/C compressor drive belt. )(Page 7B-
model)
Loose or broken accessory drive belt
(diesel model)
Faulty A/C compressor
Cool air does not come Excessive amount of refrigerant
out only at high speed Frosted evaporator
HVAC System: Single A/C Type 7B-19
Correction / Reference Item
Check related fuses, and then check for short
circuit to ground.
Repair or replace wiring as necessary.
Check radiator cooling fan relay. )(Page 10B-
28)
Check radiator cooling fan motor.
- Petrol model: )(Page 1F-11)
- Diesel model: )(Page 1F-23)
Check ECM. )(Page 7B-23)
Check amount of refrigerant and system for
leaks.
Check condenser. )(Page 7B-30)
Check evaporator and evaporator temperature
sensor (If equipped).
- Evaporator: )(Page 7B-34)
- Evaporator temperature sensor: )(Page 7B-
34)
)(Page 7B-34)
Check expansion valve. )(Page 7B-35)
42)
Check accessory drive belt. )(Page 1J-20)
Check magnet clutch. )(Page 7B-44)
Check A/C compressor.
Replace condenser, and then perform
evacuation and refrigerant charge. )(Page
7B-23)
Repair HVAC unit or air duct as necessary.
Check HVAC unit.
Check blower motor. )(Page 7B-33)
system circuit and A/C compressor.
Repair or replace wiring as necessary.
)(Page 7B-34)
Check expansion valve. )(Page 7B-35)
Replace condenser, and then perform
evacuation and charge. )(Page 7B-23)
Check magnet clutch. )(Page 7B-44)
Check the amount of refrigerant.
Check condenser. )(Page 7B-30)
Check amount of refrigerant and system for
leaks.
Replace condenser, and then perform
evacuation and refrigerant charge. )(Page
7B-23)
42)
Check accessory drive belt. )(Page 1J-20)
Check A/C compressor.
Check amount of refrigerant.
Check evaporator and evaporator temperature
sensor (If equipped).
- Evaporator: )(Page 7B-34)
- Evaporator temperature sensor: )(Page 7B-
34)
7B-20 HVAC System: Single A/C Type

Condition Possible cause Correction / Reference Item

Insufficient cool air flow Clogged or frosted evaporator
Air leaking from HVAC unit or air duct
Faulty blower motor
Faulty wiring or grounding
Check evaporator and evaporator temperature
sensor (If equipped).
- Evaporator: )(Page 7B-34)
- Evaporator temperature sensor: )(Page 7B-
34)
Repair HVAC unit or air duct as necessary.
Check blower motor. )(Page 7B-33)
Repair or replace wiring as necessary.

Abnormal Noise Symptom Diagnosis of HVAC System

AENBL80A7214004
Abnormal Noise from Compressor
Condition Possible cause Correction / Reference Item
During A/C compressor Inadequate clearance in scroll area Replace A/C compressor. )(Page 7B-42)
operation, a rumbling
noise is heard as to
engine speed increases
Loud noise is heard at Loose or faulty A/C compressor drive Check A/C compressor drive belt. “A/C
certain rpm, irrespective belt (petrol model) Compressor Drive Belt Inspection and
of greatness of speed in Adjustment”: Single A/C Type (Page 7B-42)
Loose or faulty accessory drive belt Check accessory drive belt. )(Page 1J-20)
(diesel model)
Loose A/C compressor mounting bolts Retighten mounting bolts. )(Page 7B-42)
Loud rattle is heard at low Loose armature plate bolt or nut Retighten armature plate bolt or nut. “Magnet
engine rpm Clutch Removal and Installation”: Single A/C
Type (Page 7B-45)
Replace A/C compressor if it has been
operated in rattling condition for a long time.

Abnormal Noise from Magnetic Clutch

Condition Possible cause Correction / Reference Item
Rumbling noise is heard Worn or damaged bearings Replace magnet clutch assembly. “Magnet
when A/C compressor is Clutch Removal and Installation”: Single A/C
not in operation Type (Page 7B-45)
Chattering noise is heard Faulty magnet clutch clearance Adjust magnet clutch clearance. “Magnet
when A/C compressor is (excessive clearance) Clutch Removal and Installation”: Single A/C
in operation Type (Page 7B-45)
Worn magnet clutch friction surface Replace magnet clutch assembly. “Magnet
Clutch Removal and Installation”: Single A/C
Type (Page 7B-45)
Compressor oil leaked from shaft seal, Replace A/C compressor. )(Page 7B-42)
contaminating friction surface

Abnormal Noise from Tubing

Condition Possible cause Correction / Reference Item
Droning noise is heard Faulty tubing clamps Reposition clamps or increase number of
from inside of the vehicle, clamps.
but not particularly Resonance caused by pulsation from Attach a silencer to tubing, or modify its
noticeable in engine variations in refrigerant pressure position and length.
compartment

Abnormal Noise from Condenser Assembly

Condition Possible cause Correction / Reference Item
Considerable vibration in Resonance from condenser assembly Firmly insert a silencer between condenser
condenser assembly bracket and body assembly bracket and body.
 HVAC System: Single A/C Type 7B-21

Abnormal Noise from Crankshaft Pulley

Condition Possible cause Correction / Reference Item
Large rattling noise is Loosen crankshaft pulley bolt Retighten bolt.
heard at idle or sudden - Petrol model: )(Page 1D-21)
acceleration - Diesel model: )(Page 1D-82)

Abnormal Noise from Tension Pulley

Condition Possible cause Correction / Reference Item
Clattering noise is heard Worn or damaged bearing Replace tension pulley.
from pulley
Pulley cranks upon Cracked or loose bracket Replace or retighten bracket.
contact

Abnormal Noise from Evaporator

Condition Possible cause Correction / Reference Item
Whistling sound is heard Depending on the combination of the Slightly decreasing amount of refrigerant may
from evaporator interior / exterior temperatures, engine stop this noise.
rpm and refrigerant pressure, the Inspect expansion valve and replace if faulty.
refrigerant flowing out of the expansion
valve may generate whistling sound.

Abnormal Noise from Blower Motor

Condition Possible cause Correction / Reference Item
Blower motor emits a Worn or damaged motor brushes or Replace blower motor. )(Page 7B-32)
chirping sound in commutator
proportion to its speed of
rotation
Fluttering noise or large Leaves or other debris introduced from Remove debris and make sure that screen at
droning noise is heard fresh air inlet to blower motor fresh air inlet is intact.
from blower motor

Visual Inspection
AENBL80A7214008
Check visually the following parts and systems.
Inspection item Correction
• Battery Fluid level and corrosion of Petrol model: “Battery Description”: K14B
terminals in Section 1J (Page 1J-1)
Diesel model: “Battery Description”: D13A
in Section 1J (Page 1J-15)
• Connectors of electric wire harness Disconnection and friction “Intermittent Connection and Poor Contact
Inspection” in Section 00 (Page 00-11)
• Fuses Blowout “Intermittent Connection and Poor Contact
Inspection” in Section 00 (Page 00-11)
• Parts Installation and damage —
• Other parts that can be checked visually

Inspection of HVAC Control Unit and Its Circuit

AENBL80A7214006
HVAC control unit and its circuits can be checked at HVAC control unit wiring connectors by measuring voltage.

! CAUTION
HVAC control unit can be checked only through connectors. It is strictly prohibited to connect
voltmeter to HVAC control unit with connectors disconnected from it.

Voltage Check
1) Remove HVAC control unit. )(Page 7B-32)
2) Connect G154 connector and G155 connector.
3) Check voltage at each terminal.
7B-22 HVAC System: Single A/C Type

NOTE
As each terminal voltage is affected by the battery voltage, confirm that battery voltage is 11 V or more
with ignition “ON”.

2
G154
1
G155
3 2 1
[a] 6 5 4 3 2 1
7 6 5 4
12 11 10 9 8 7
IBL80A721008-01

1. HVAC control unit 2. HVAC control unit connector (View: [a])

Normal
Terminal Wire Color Circuit Condition
Voltage
A/C switch at OFF or A/C switch at
0–1V ON and blower speed selector is at
G154-1 LT GRN Ground for A/C switch any position other than OFF
A/C switch at ON and blower speed
10 – 14 V
selector at OFF
G154-2 — — — —
G154-3 RED/BLK Ground for illumination Below 0.5 V —
Air intake switch in “REC” position or
Air intake control actuator 0–1V air intake control actuator operating
G154-5 BLU
(Recirculation air) from “FRE” to “REC”
10 – 14 V Air intake switch in “FRE” position
Air intake switch in “FRE” position or
Air intake control actuator 0–1V air intake control actuator operating
G154-6 GRN/YEL
(Fresh air) from “REC” to “FRE”
10 – 14 V Air intake switch in “REC” position
A/C switch at ON and blower speed
0–1V selector is at any position other than
G154-7 GRN/RED A/C switch signal
OFF position
10 – 14 V A/C switch at OFF
G154-8 — — — —
0–1V Lighting switch in OFF position
G154-9 RED/YEL Illumination switch
10 – 14 V Lighting switch in ON position
0–1V Ignition “OFF”
G154-11 RED/WHT Power supply
10 – 14 V Ignition “ON”
G154-12 GRY Ground for HVAC control unit Below 0.5 V —
Ground for blower speed
G155-1 BLK Below 0.5 V —
selector
10 – 14 V Blower speed selector in OFF position
G155-2 RED Blower speed selector (1st)
0–1V Other than above condition
10 – 14 V Blower speed selector in OFF position
Approx 6 V Blower speed selector in 1st position
G155-3 BLU/WHT Blower speed selector (2nd)
Blower speed selector between 2nd
0–1V
and 4th positions
A/C switch OFF or A/C switch ON and
0–1V blower speed selector is at any
G155-5 LT GRN Ground for A/C switch position other than OFF position
A/C switch ON and blower speed
10 – 14 V
selector OFF position
Blower speed selector is at any
10 – 14 V
G155-6 WHT Blower speed selector (4th) position other than 4th position
0–1V Blower speed selector in 4th position
 HVAC System: Single A/C Type 7B-23

Normal
Terminal Wire Color Circuit Condition
Voltage
10 – 14 V Blower speed selector in OFF position
Approx 6 V Blower speed selector in 1st position
G155-7 YEL Blower speed selector (3rd) Approx 3 V Blower speed selector in 2nd position
Blower speed selector become 3rd
0–1V
and 4th positions

A/C System Inspection at ECM

AENBL80A7214007
Check the voltage related to A/C system at ECM terminals.
- Petrol model: )(Page 1A-109)
- Diesel model: )(Page 1A-272)

Repair Instructions
Operation Procedure for Refrigerant Charge
AENBL80A7216001
! WARNING

• Handle the HFC-134a (R-134a) refrigerant with care as follows. If not, it may cause severe injury
such as blindness and frostbite.
– Avoid contact with skin and eyes by wearing safety glasses and gloves. In case of contact with
skin or eyes, get medical attention.
– Keep away from fire. High temperature may cause toxic gas. Therefore, take care of much room
ventilation.
– The temperature above 40 °C (104 °F) in the refrigerant container may cause explosion.

! CAUTION

• Do not expose bright metals to liquid refrigerant. Refrigerant combined with moisture is corrosive
and tarnishes the surfaces of bright metals including chrome.
• The specified compressor oil for use with the refrigerant is highly hygroscopic. Keep internal parts
of A/C system free from moisture and dirt. When disconnecting any line from the system, install a
blind plug or cap to the fitting immediately.
• Do not discharge the refrigerant into atmosphere.
• When handling recovery and recycling equipment, be sure to follow the instruction manual for the
equipment.
7B-24 HVAC System: Single A/C Type

NOTE
Check local governmental regulations regarding working with refrigerator systems and its tooling.

Start evacuation.
15 minutes (below -100 kPa)
Stop evacuation. Inspect and repair connections.
Wait for 10 minutes
If gauge shows
Check A/C system for abnormal conditions
pressure tightness.

Recharge A/C system with Recharge system with 400 20 g (14.1 0.7 oz) g
refrigerant. of refrigerant.

Check A/C system for refrigerant

leaks and amount of refrigerant
charged.

Performance test
IBP80A721084-01

Recovery Replenishing Compressor Oil

When discharging refrigerant out of A/C system, always It is necessary to replenish A/C compressor with
recover it using refrigerant recovery and recycling compressor oil to specified amount from A/C
equipment because discharging refrigerant HFC-134a compressor suction side hole (1) before evacuating
(R-134a) into atmosphere would cause adverse effect to system and charging it with refrigerant.
environment.
[A]
NOTE
1
• After recovering refrigerant from system,
the amount of removed compressor oil
must be measured to determine the
amount of compressor oil for
replenishment.
• When handling recovery and recycling
equipment, be sure to follow the
1
instruction manual for the equipment.
[B]

IBL80A721010-01

[A]: Petrol model [B]: Diesel model

When charging refrigerant only

When charging refrigerant without replacing any
component, replenish A/C compressor with compressor
oil of the same amount measured when recovering
refrigerant (if not measured, add 10 cm3 (10 ml, 0.33
US.oz, 0.35 Imp.oz) of oil).
IBL80A721009-01

When replacing A/C compressor Be sure to use specified compressor oil or an

equivalent compressor oil.
! CAUTION
 HVAC System: Single A/C Type 7B-25

Compressor oil is sealed in each new A/C compressor Condenser (with receiver/dryer): 35 cm3 (35 ml, 1.18
by the amount required for A/C system. Therefore, when US.oz, 1.23 Imp.oz)
using a new A/C compressor, drain the calculated Hoses: 10 cm3 (10 ml, 0.34 US.oz, 0.35 Imp.oz) each
amount of oil from it. Pipes: 10 cm3 (10 ml, 0.34 US.oz, 0.35 Imp.oz) each
“C” = “A” – “B”
“C”: Amount of oil to be drained Evacuation
“A”: Amount of oil in a new A/C compressor
“B”: Amount of oil in removed A/C compressor ! CAUTION
Do not evacuate A/C system before
NOTE
recovering refrigerant.
A/C compressor assembly supplied from
factory is filled up with the following amount NOTE
of oil.
If A/C system circuit is opened (exposed) to
Petrol Model: Compressor oil 95590–58D30 atmosphere, system must be evacuated
(Compressor oil (ND-OIL8)) using a vacuum pump. The A/C system
Diesel Model: Compressor oil 99000–990C5–00A should be fitted with manifold gauge set, and
(Compressor oil (SP10)) should be evacuated for approximately 15
minutes.
Amount of oil in A/C compressor
Petrol model: 1) Connect high pressure charging hose (1) and low
60 – 70 cm3 (60 – 70 ml, 2.03 – 2.37 US.oz, 2.11 – 2.46 pressure charging hose (2) of special tool (manifold
Imp.oz) gauge set) as follows:
Diesel model: High pressure charging hose → High pressure
105 – 135 cm3 (105 – 135 ml, 3.55 – 4.56 US.oz, 3.70 – charging valve (3) on discharge hose
4.75 Imp.oz) Low pressure charging hose → Low pressure
charging valve (4) on suction pipe
1 2
Special tool
(A): 09990–06020
2) Attach center charging hose (5) of manifold gauge
set to vacuum pump (6).
3) Operate vacuum pump, and then open discharge
side valve (HI) (7) of manifold gauge set.
If there is no blockage in the system, there will be an
indication on high pressure gauge (8).
When this occurs, open the other side valve (LO) (9)
"C" of the gauge set.
"A"
"B" 4) Approximately 10 minutes later, low pressure gauge
(10) should show a vacuum lower than –100 kPa
I7V20A720017-01
(–1.0 kgf/cm2, –760 mmHg, –14.7 psi), indicating
that no leakage exists.
1. New A/C compressor
2. Removed A/C compressor NOTE

When replacing other parts
Replenish A/C compressor with the following amount of
oil.
Petrol model
Amount of compressor oil to be replenished
Evaporator: 25 cm3 (25 ml, 0.85 US.oz, 0.88 Imp.oz)
Condenser (with receiver/dryer): 20 cm3 (20 ml, 0.68
US.oz, 0.70 Imp.oz)
Hoses: 5 cm3 (5 ml, 0.17 US.oz, 0.18 Imp.oz) each
Pipes: 5 cm3 (5 ml, 0.17 US.oz, 0.18 Imp.oz) each
Diesel model
Amount of compressor oil to be replenished
Evaporator: 25 cm3 (25 ml, 0.85 US.oz, 0.88 Imp.oz)
• If the system does not show a vacuum
below –100 kPa (–1.0 kgf/cm2, –760 mmHg,
–14.7 psi), close both valves, stop vacuum
pump and watch change in reading of low
pressure gauge.
• Increase in gauge reading suggests of
leakage. In this case, repair the system
before continuing its evacuation.
• If the gauge shows a stable reading
(suggesting no leakage), continue
evacuation.
5) Evacuation should be carried out for a total of at
least 15 minutes.
7B-26 HVAC System: Single A/C Type

6) Continue evacuation until low pressure gauge Charge

indicates a vacuum less than –100 kPa (–1.0 kgf/
cm2, –760 mmHg, –14.7 psi), and then close both ! CAUTION
valves.
• Because the sight glass is not used for this
7) Stop vacuum pump. Disconnect center charging A/C system, do not perform any additional
hose from pump inlet. Now, the system is ready for charge to the A/C system. To charge the
charging refrigerant. system with proper amount of refrigerant,
recover the refrigerant and evacuate the A/
(A)
10 5 C system first. Then charge A/C system
8
with proper amount of refrigerant.
7
9 • Always charge the A/C system through the
6 low pressure side after the initial charge is
2 performed from the high pressure side
with the engine stopped.
1
• Never charge the A/C system through the
high pressure side with engine running.
• Do not charge the A/C system while A/C
compressor is hot.
3 • When installing tap valve to refrigerant
container to make a hole there through,
4 carefully follow directions given by
manufacturer.
• A pressure gauge should always be used
before and during refrigerant charge.
• The refrigerant container should be
emptied of refrigerant when discarding it.
IBL80A721011-01
• The refrigerant container should not be
heated to 40 °C (104 °F) or over.
Checking A/C System for Pressure Leaks • Refrigerant container should not be turned
After completing the evacuation, close manifold gauge upside down during refrigerant charge.
high pressure valve and low pressure valve and wait for Doing so causes liquid refrigerant to enter
10 minutes. Verify that low pressure gauge reading has A/C compressor, causing troubles, such as
not changed. compression of liquid refrigerant.
! CAUTION
NOTE
If the gauge reading changes closer to “0”, The A/C system contains HFC-134a (R-134a).
there is a leak somewhere. Inspect the tubing Described here is a method for charging the
connections and make necessary A/C system with refrigerant from the
corrections. Evacuate system again and refrigerant service container.
make sure that there are no leaks. When charging the system with the
refrigerant recovered using the refrigerant
recycling equipment, follow the procedure
described in the equipment manufacturer’s
instruction manual.

Perform initial charge through high pressure side with

the engine stopped.
Next, charge the system with refrigerant as follows from
low pressure side with engine running.
1) Check if hoses are routed properly after evacuating
system.
2) Connect low charging hose (1) and high charging
hose (2) of manifold gauge set (3) in position. Then,
open refrigerant container valve (4) to purge
charging line.
 HVAC System: Single A/C Type 7B-27

3) Open high pressure side valve (5) to charge system

with refrigerant.
4) After a while, open low pressure side valve (6) and
close high pressure side valve.

! WARNING
Make sure that high pressure side valve is
closed securely. Failure to do so may cause
explosion of refrigerant container because
high pressure refrigerant way flow back into
the container. I2RH01720018-01

c) Purge any air from center charging hose.

5) Start engine and keep engine speed at 1500 r/min,
When using refrigerant container tap valve, use
then operate A/C system.
the following procedure to purge air.
6) Charge A/C system with vapor refrigerant. At this
i) Fully tighten refrigerant container tap valve
time, refrigerant container should be held upright.
(1), and then loosen (open) plate nut (2)
3
slightly.
4 ii) Open low pressure side valve (3) of manifold
5 gauge set (4) a little.
6
iii) As soon as refrigerant comes out with a
“hiss” through a clearance between
1 refrigerant container and tap valve, tighten
2 plate nut as well as low pressure side valve.
iv) Turn handle of tap valve clockwise so that its
needle is screwed into the new container to
make a hole for refrigerant flow.

IBL80A721012-01

7) When refrigerant container (1) is emptied, use the

following procedure to replace it with a new
refrigerant container.
a) Close low pressure valve.
b) Replace empty container with a refrigerant
container which has been charged with
refrigerant. When using refrigerant container tap
valve (2), use the following procedure for
replacement.
i) Turn handle of tap valve counterclockwise to
retract needle (3), then remove refrigerant
container tap valve by loosening its plate nut
(4).
ii) Install refrigerant container tap valve to new
refrigerant container.
I2RH01720019-01
8) After the system has been charged with specified
amount of refrigerant or when low pressure gauge
(1) and high pressure gauge (2) have indicated the
following specified values, close low pressure side
valve (3) on manifold gauge set (4).
Specified amount of refrigerant
400 ± 20 g (14.1 ± 0.7 oz)
Low pressure side and high pressure side
example (Petrol model)
Gauges should read as follows when ambient
temperature is 30 °C (86 °F).
Pressure 1220 – 1540 kPa
on high pressure gauge (12.4 – 15.7 kgf/cm2)
(177.0 – 223.4 psi)
7B-28 HVAC System: Single A/C Type

Pressure 240 – 350 kPa 2) Close refrigerant container valve.

on low pressure gauge (2.4 – 3.6 kgf/cm2) 3) Stop engine.
(34.8 – 50.8 psi) 4) Using shop rag, remove charging hoses from service
valves. This operation must be performed quickly.
Low pressures side and high pressure side
example (Diesel model) 5) Put caps on service valves.
Gauges should read as follows when ambient
Check A/C System for Refrigerant Leaks
temperature is 30 °C (86 °F).
Whenever a refrigerant leak is suspected in the system
Pressure 1320 – 1650 kPa
or any service operation has been performed which may
on high pressure gauge (13.5 – 16.8 kgf/cm2)
result in malfunction of lines and connections, it is
(191.4 – 239.3 psi)
important to perform check for leaks.
Pressure 210 – 290 kPa
Common sense should be used during refrigerant leak
on low pressure gauge (2.1 – 3.0 kgf/cm2)
test, since the need and extent of any such test will, in
(30.5 – 42.1 psi)
general, depend upon the nature of a complaint and the
type of a service performed on the system.
4
Liquid leak detector
1 2
3 ! WARNING

• To prevent explosions and fires, make sure

that there are no flammables in the vicinity.
• When the refrigerant is exposed to fire, it
turns into a poisonous gas (phosgene). Do
not inhale this gas.

There are a number of fittings and places throughout the

A/C system where liquid leak detector solution may be
used to pinpoint refrigerant leaks.
By applying the solution to the area in question with a
swab, bubbles will form within seconds if there is a leak.
For connections in such confined areas, as those around
evaporator and condenser, electronic (refrigerant) leak
detector is more practical for determining leaks.
Special tool
IBL80A721014-01 (A): 09990–86012

Removal of Manifold Gauge Set

! WARNING
(A)
Be careful not to get injured by refrigerant
from high pressure side especially in your
eyes and skin.

For A/C system charged with specified amount of

refrigerant, remove manifold gauge set as follows: I5RW0A721054-01
1) Close low pressure side valve of manifold gauge set.
(High pressure side valve has already been closed
during charging process.)
 HVAC System: Single A/C Type 7B-29

A/C System Major Components

AENBL80A7216002

[A] [B]

13
7
OIL

11

OIL
11

6 6

a
10

OIL
11
a
7
OIL

11
OIL

11

OIL
11
2 2

5 5

b
OIL

11 a
8
OIL

11

12 (a)
OIL

11

IBL80A721015-01

[A]: Petrol model 5. A/C compressor mounting bolt 11. O-ring

: For tightening procedure, refer to “A/C Compressor Assembly : Apply compressor oil.
Removal and Installation”: Single A/C Type (Page 7B-42)
[B]: Diesel model 6. Discharge hose 12. A/C refrigerant pressure sensor
1. HVAC unit 7. Suction hose 13. Suction pipe
7B-30 HVAC System: Single A/C Type

2. A/C compressor 8. Liquid pipe : 11 N⋅m (1.1 kgf-m, 8.5 lbf-ft)

3. Condenser with receiver/dryer 9. Expansion valve : Do not reuse.
4. Radiator cooling fan motor 10. Tension pulley

Radiator Cooling Fan Removal and Installation 3) Remove upper side horn (1).
AENBL80A7216003
Refer to )(Page 1F-12) or “Radiator Cooling Fan 4) Remove discharge hose bolt (2) and liquid pipe bolt
Assembly Removal and Installation”: D13A in Section 1F (3).
(Page 1F-24) 5) Disconnect discharge hose (4) and liquid pipe (5)
from condenser assembly (6).
Radiator Cooling Fan Inspection 6) Remove condenser assembly mounting bolts (7).
AENBL80A7216004
Refer to )(Page 1F-11)or “Radiator Cooling Fan 7) Remove condenser assembly from radiator.
Assembly On-Vehicle Inspection”: D13A in Section 1F
7
(Page 1F-23) 1
7

Condenser Assembly On-Vehicle Inspection

AENBL80A7216005
Check the followings. 4
• Condenser fins 2
If clogged, wash condenser with water and dry it with
compressed air. 3
• Condenser fins for leakage and breakage
If any defects are found, repair or replace condenser.
• Condenser fittings for leakage.
If any defects are found, repair or replace condenser. 5

Condenser Assembly Removal and Installation
AENBL80A7216006
! CAUTION
Do not damage condenser fins. If condenser
fin is bent, straighten it using flat-bladed
screwdriver or pliers.
Removal
1) Recover refrigerant from A/C system referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”: Single A/C Type (Page 7B-23).
NOTE
The amount of removed compressor oil must
be measured to determine how much
compressor oil is required for replenishment.
2) Remove front bumper. )(Page 9H-1)
6
IBL80A721016-01
Installation
Reverse removal procedure, noting the following points.
• Apply compressor oil to new O-ring of discharge hose
and liquid pipe.
Petrol Model: Compressor oil 95590–58D30
(Compressor oil (ND-OIL8))
Diesel Model: Compressor oil 99000–990C5–00A
(Compressor oil (SP10))
• Replenish A/C compressor with compressor oil to
specified amount from A/C compressor suction side
referring to “Replenishing Compressor Oil” in
“Operation Procedure for Refrigerant Charge”: Single
A/C Type (Page 7B-23).
• Evacuate and charge A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”: Single A/C Type (Page 7B-
23).
 HVAC System: Single A/C Type 7B-31

HVAC Unit Components

AENBL80A7216007

3
1

20
5

7
18 4

(a)

15

15
2
15
7
8

9 14
8

10
OIL

13 21
17
14

11
20
16
6

19 22

12

IBL80A721017-01

1. Fresh air inlet duct
2. Blower upper case
3. Air intake control actuator
4. Cover
5. Heater unit upper case
8. Temperature control door 15. Airflow control lever 22. Drain hose
assembly
9. Blower motor resistor 16. Evaporator : 3.5 N⋅m (0.36 kgf-m, 2.5 lbf-ft)
10. Blower lower case 17. O-ring : Do not reuse.
: Apply compressor oil
11. Blower motor 18. Expansion valve
12. Heater unit lower case 19. Evaporator temperature sensor
(If equipped)
7B-32 HVAC System: Single A/C Type

6. Foot duct 13. Heater core 20. Packing

7. Airflow control door 14. Temperature control lever 21. Cable lock clamp
assembly

HVAC Unit Removal and Installation NOTE

AENBL80A7216008
When removing HVAC unit, be careful not to
Removal spill engine coolant and compressor oil on
vehicle floor.
1) Recover refrigerant from A/C system using recovery
and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge”: 1
Single A/C Type (Page 7B-23).
2) Disconnect negative (–) cable at battery.
3) Disable air bag system (if equipped). )(Page 8B-61)
4) Drain engine coolant.
- Petrol model: )(Page 1F-9)
2
- Diesel model: “Cooling System Draining”: D13A in
Section 1F (Page 1F-22)
Then disconnect heater hoses from HVAC unit.
5) Remove cowl top garnish from vehicle body “Cowl
Top Garnish Removal and Installation” in Section 9H
(Page 9H-3).
6) Diesel model: Remove battery. )(Page 1J-19)
7) Loosen bolt (1), then remove liquid pipe and suction
2
hose from expansion valve (2). IBL80A721018-01

Installation
1 Reverse removal procedure, noting the following points.
• Replenish A/C compressor with compressor oil to
specified amount from A/C compressor suction side
referring to “Replenishing Compressor Oil” in
“Operation Procedure for Refrigerant Charge”: Single
A/C Type (Page 7B-23).
2 • Install padding (1) to installation hole uniformly.
I7V20A720023-01

8) Remove instrument panel from vehicle body.

)(Page 9C-9)
9) Remove HVAC unit (1) from vehicle body by
1
removing nuts (2).

IBP80A721094-01

• Refill cooling system with coolant.

- Petrol model: )(Page 1F-10)
- Diesel model: )(Page 1F-22)
• Adjust control cables. )(Page 7B-35)
• Enable air bag system (if equipped). )(Page 8B-61)
• Evacuate and charge the A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”: Single A/C Type (Page 7B-
23).

Blower Motor Removal and Installation

AENBL80A7216009
Removal
1) Disconnect negative (–) cable at battery.
 HVAC System: Single A/C Type 7B-33

2) Disconnect connector (1) from blower motor (2)

3) Remove blower motor from HVAC unit by removing
screws (3)

3
3

1 IBP80A721043-01

2
Blower Motor Resistor Removal and Installation
3 AENBL80A7216011
IBL80A721019-01 Removal
1) Disconnect negative (–) cable at battery.
Installation
Reverse removal procedure. 2) Remove glove box from instrument panel.
3) Remove foot duct (1) from HVAC unit.
Blower Motor Inspection
AENBL80A7216010 1
• Check for continuity between two terminals as shown.
If there is no continuity, replace blower motor.

IBP80A721048-01
IBL80A721020-01
• Check for operation and current
4) Remove connector (1) from blower motor resistor
a. Put blower motor (1) in a soft-jawed vise.
(2), and then remove blower motor resistor from
b. Connect battery to blower motor as shown. HVAC unit by removing screws (3).
c. Check if blower motor operates smoothly without
noise.
d. Check if ammeter indicates the specified current. 1
If measured current is out of specification, replace
blower motor. 3

Blower motor specified current at 13.5 V

19.5 A maximum at 20 – 25°C (68 – 77°F)

2 3
IBP80A721046-01

Installation
Reverse removal procedure.

Blower Motor Resistor Inspection

AENBL80A7216012
7B-34 HVAC System: Single A/C Type

Measure each terminal-to-terminal resistance. If

measured resistance is out of specification, replace
blower motor resistor.
Blower motor resistor resistance
“H” – “MH”: Approximately 0.5 Ω at 20 – 25°C (68
–77°F)
“MH” – “ML”: Approximately 1.0 Ω at 20 – 25°C (68
1
–77°F)
“ML” – “L”: Approximately 2.4 Ω at 20 – 25°C (68
–77°F)

MH
L 3

4 2 6
5
IBP80A721096-01

3. 50 ± 2 mm (1.9 ± 0.08 in)

4. Sensor part fixed to 10th fin from the left
5. Holding part fixed to 12th fin from the left
H 6. Pipe fitting
ML
IBP80A721047-01

Evaporator Temperature Sensor Inspection (If

Evaporator Inspection Equipped)
AENBL80A7216013 AENBL80A7216015
Check the following: Check resistance between terminals of evaporator
• Evaporator fins for clogging. temperature sensor (1).
If clogged, wash evaporator fins with water, and then If check result is not as specified, replace evaporator
dry it with compressed air. temperature sensor.
• Evaporator fins for leakage and breakage Evaporator temperature sensor resistance
If evaporator fins are leaky or broken, repair or 0 °C (32 °F): 6.5 – 6.9 kΩ
replace evaporator. 25 °C (77 °F): 1.9 – 2.3 kΩ
• Evaporator fittings for leakage
If evaporator fittings are leaky, repair or replace
evaporator.

Evaporator Temperature Sensor Removal and

Installation (If Equipped)
AENBL80A7216014
Removal 1
k 10
1) Remove HVAC unit from vehicle body. )(Page 7B-
32) 9

2) Remove evaporator temperature sensor (1) from 8

evaporator (2) by disassembling HVAC unit. 7

[A] 5

3
1
2
2
1

I7RW01721018-01 0 5 10 15 20 25 30 (°C)
32 41 50 59 68 77 86 (°F)
[B]
Installation I9P60A722044-03
Reverse removal procedure, noting the following point.
[A]: Resistance
• Install evaporator temperature sensor (1) onto [B]: Temperature
evaporator (2) as shown.
 HVAC System: Single A/C Type 7B-35

Expansion Valve Removal and Installation Installation

AENBL80A7216016
Removal
1) Recover refrigerant from the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”: Single A/C Type (Page 7B-23).
2) Loosen bolt (1), then remove liquid pipe and suction
hose (pipe) from expansion valve (2).
3) Loosen bolts (3) and remove expansion valve.
1
3 • Evacuate and charge the A/C system referring to
Reverse removal procedure, noting the following points.
• Apply compressor oil to O-ring of expansion valve and
pipes.
Petrol Model: Compressor oil 95590–58D30
(Compressor oil (ND-OIL8))
Diesel Model: Compressor oil 99000–990C5–00A
(Compressor oil (SP10))
• Tighten expansion valve bolts to specified torque.
Tightening torque
Expansion valve bolt: 3.5 N·m (0.36 kgf-m, 2.5 lbf-
ft)
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”: Single A/C Type (Page 7B-
23).

2
2 Expansion Valve Inspection
AENBL80A7216017
I4RS0A720028-01 Refer to “A/C System Performance Inspection”: Single
A/C Type (Page 7B-9).

HVAC Control Unit Components

AENBL80A7216018

4
3
IBL80A721021-02

1. HVAC control body 3. Air flow selector 5. Temperature selector

assembly
2. HVAC control panel 4. Blower speed selector

HVAC Control Unit Removal and Installation 6) Remove center side covers. )(Page 9C-9)
AENBL80A7216019
7) Disconnect temperature control cable (1) and airflow
Removal control cable (2) from HVAC unit.
1) Disconnect negative (–) cable at battery.
2) Remove instrument panel center upper garnish and
combination meter cluster panel. )(Page 9C-9)
3) Remove radio hole cover. )(Page 9O-5)
4) Remove air bag cover. )(Page 9C-9)
5) Remove floor console front box. )(Page 9H-9)
7B-36 HVAC System: Single A/C Type

2 4

1 3

IBP80A721098-01

8) Remove connectors (2) from HVAC control unit.

9) Remove HVAC control unit (1) from instrument
panel.

NOTE
Use rag to protect HVAC control unit and
instrument panel from damage.
2 1
IBP80A721100-01

1 b. Move temperature control lever (1) and airflow

control plate (2) fully to the direction of arrow.

2
IBP80A721099-01

Installation
Reverse removal procedure noting the following points.
• Connect temperature control cable (3) and air flow
control cable (4) of HVAC control unit to
corresponding links of HVAC unit as follows:
a. Set airflow selector (1) to “VENT” position and
temperature selector (2) to “MAX COOL” position. 2

IBP80A721101-01

c. Fix temperature control inner cable (1) to pin of

temperature control lever and air flow control inner
cable (2) to pin of airflow control plate, and then fix
each outer cable (3) to each cable lock clamp (4).
 HVAC System: Single A/C Type 7B-37

Blower speed selector continuity

Terminal
1 5 2 3 7 6
Position

3 OFF

1
1
4 2

3 2 1

7 6 5 4

2
3
4

IBP80A721102-01
6
1
NOTE 7

3
After installing control cables, make sure that
2
control lever and plate move smoothly and
stop at proper position. 5

IBP80A721104-01
• Make sure that airflow outlet changes correctly as
airflow selector is changed.
A/C Refrigerant Pressure Sensor and Its Circuit
• Make sure that outlet temperature changes correctly Inspection
as temperature selector is changed. AENBL80A7216021

Blower Speed Selector Inspection Using SUZUKI Scan Tool (Petrol Model)
AENBL80A7216020 1) Connect manifold gauge set to charging valves.
Check blower speed selector for terminal-to-terminal
continuity. If check result is not as specified, replace Special tool
HVAC control unit. : 09990–06020
2) Connect scan tool to DLC and display “Refrigerant
Pressure” in “Data list” mode on SUZUKI scan tool.
3) When A/C switch is at OFF, compare pressure [B] of
high pressure gauge and pressure [A] displayed on
SUZUKI scan tool.
Special tool
: SUZUKI scan tool (SUZUKI-SDT)
4) Start engine and operate A/C system.
5) Check that the relation between pressure [B] and
pressure [A] shows such characteristic as shown.
If check result is not as specified, replace A/C
refrigerant pressure sensor.
7B-38 HVAC System: Single A/C Type

(kPa) (V)
3,409
4.986

2,764
4.034

1,938
[A] 3.0

1,203
2.0
0,407

0.744
0.5 1.0 1.5 2.0 2.5 3.0 3.5 (MPa)
0 0.28 1.0 2.0 2.7 3.0 3.4 (MPa)
[B] I9P60A722041-01
IAW101720060-03

Not Using SUZUKI Scan Tool A/C Refrigerant Pressure Sensor Removal and
Installation
1) Disconnect A/C refrigerant pressure sensor AENBL80A7216022
connector. ! CAUTION
2) Set ignition “ON”.
When tightening or loosening a fitting, use
3) Check that voltage between “GRY/RED” wire two wrenches, one for turning and the other
terminal and “BLU/RED” wire terminal of A/C for support.
refrigerant pressure sensor connector is 4.75 V to
5.25 V. Removal
If check result is not as specified, check A/C
1) Recover refrigerant from the A/C system using
refrigerant pressure sensor circuit.
recovery and recycling equipment referring to
4) Connect A/C refrigerant pressure sensor connector “Recovery” in “Operation Procedure for Refrigerant
with ignition “OFF”. Charge”: Single A/C Type (Page 7B-23).
5) Connect manifold gauge set to charging valves. 2) Disconnect negative (–) cable at battery.
Special tool 3) Disconnect A/C refrigerant pressure sensor
: 09990–06020 connector (1).
6) Check A/C refrigerant pressure sensor voltage of 4) Remove A/C refrigerant pressure sensor (2) from
ECM connector. liquid pipe (3).
- Petrol model: “Inspection of ECM and Its Circuits”:
K14B in Section 1A (Page 1A-109)
- Diesel model: )(Page 1A-272)
If voltage is not as specified, replace A/C refrigerant
pressure sensor.
A/C refrigerant pressure sensor voltage
specifications (A/C refrigerant pressure measured
by manifold gauge)
0.28 MPa (2.80 kgf-cm2, 39.82 psi): 0.744 V
2.70 MPa (27.0 kgf-cm2, 384.03 psi): 4.034 V 3
2
3.40 MPa (34.0 kgf-cm2, 483.59 psi): 4.986 V
1
IBL80A721022-01

Installation
Reverse removal procedure, noting the following points.
• Apply compressor oil to new O-ring of A/C refrigerant
pressure sensor.
Petrol Model: Compressor oil 95590–58D30
(Compressor oil (ND-OIL8))
Diesel Model: Compressor oil 99000–990C5–00A
(Compressor oil (SP10))
 HVAC System: Single A/C Type 7B-39

• Tighten A/C refrigerant pressure sensor to specified

torque. Air intake switch continuity
Tightening torque Terminal
A/C refrigerant pressure sensor (a): 11 N·m (1.1 5 6 11 12
Position
kgf-m, 8.5 lbf-ft)
FRE

REC

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

(a)
IBL80A721023-01

• Evacuate and charge A/C system referring to

“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”: Single A/C Type (Page 7B-
23).

Air Intake Switch Inspection

AENBL80A7216023
Check air intake switch for terminal-to-terminal
continuity. If check result is not as specified, replace 11

HVAC control unit. 5

12
6
NOTE IBP80A721107-01

To perform measurement with air intake

selector in “REC” position, use diode range Air Intake Control Actuator Removal and
of circuit tester. Installation
AENBL80A7216024

Removal
1) Disconnect negative (–) cable at battery.
2) Remove glove box.
3) Disconnect air intake control actuator connector (3).
4) Remove screws (1).
5) Remove air intake control actuator (2) from HVAC
unit.

1
3

2
IBP80A721108-01

Installation
Reverse removal procedure, noting the following point.
7B-40 HVAC System: Single A/C Type

• Be sure to insert linkage pin (1) into groove (2) of air

intake control actuator.
7 6 5 4 3 2 1
1
[a]

“a” 3
2

[b]
IBP80A721109-01 [c]
“b”

Air Intake Control Actuator Inspection

AENBL80A7216025
1) Check stop position of arm when battery voltage is
applied to the terminals in air intake control actuator [a]
connector (1) as follows. 1
3 [c]
2) If check result is not OK, replace air intake control 3 -
actuator.
[b]
5
1

7 6 5 4 3 2 1 7 +

IBL80A721024-01

“a” 120° 2. Air intake control actuator

[B] “b” 240° 3. Arm rotation direction
[C]
1 3 5 7

REC [a] Actuator Linkage Inspection

AENBL80A7216026
HALF REC [b] • Check that each actuator linkage operates smoothly.
FRE [c] • Check actuator rod for bend.
IBP80A721110-01
• Check each actuator linkage for breakage.
[B] Terminal [C] Arm stop position
• Make sure that there is not any obstruction in
operating range of actuator linkage.
If check result is not OK, repair or replace faulty
part(s).

Center Ventilation Louver Removal and

Installation
AENBL80A7216027
Removal
1) Disconnect negative (–) cable at battery.
2) Remove center ventilation louver from instrument
panel. )(Page 9C-9)
3) Release tabs (2) and then remove center ventilation
louver (1).

NOTE
Center ventilation louver is fitted to
instrument panel center upper garnish and
hazard switch with twelve clips. When
removing louver from instrument panel
center upper garnish, be careful not to break
these clips.
 HVAC System: Single A/C Type 7B-41

Installation
1 Reverse removal procedure.

A/C Switch Inspection

AENBL80A7216029
Check A/C switch for terminal-to-terminal continuity. If
check result is not as specified, replace HVAC control
unit.

NOTE
To perform measurement with A/C switch to
“ON”, use diode range of circuit tester.
:2
IBP80A721112-01 A/C switch continuity

Installation Terminal
Reverse removal procedure. 1 7 11
Position

OFF
Side Ventilation Louver Removal and
Installation ON
AENBL80A7216028
Removal
I9P60A722020-06
1) Disconnect negative (–) cable at battery.
2) Driver side: Remove combination meter cluster
panel from instrument panel. )(Page 9C-9)
Passenger side: Remove passenger air bag door.
)(Page 9C-9) 6 5 4 3 2 1

3) Remove side ventilation louver from instrument 12 11 10 9 8 7

panel. )(Page 9C-9)
4) Release tabs (1) and then separate side demister
nozzle (2) from instrument panel side garnish (3).
5) Release tabs (4) and then separate side ventilation
louver (5) from instrument panel side garnish (3).

NOTE
Side demister nozzle and side ventilation
louver are fitted to instrument panel side
garnish with six clips.
When removing nozzle and louver from 1
instrument panel side garnish, be careful not 11 7
to break them.
I9P60A722049-04

HVAC System Relay Inspection

AENBL80A7216030
1 A/C Compressor Relay
2
Refer to “Control Relay Inspection” in Section 10B (Page
10B-28).

Fan Relay
5 Refer to “Control Relay Inspection” in Section 10B (Page
10B-28).

4
Heater Relay
3 Refer to “Control Relay Inspection” in Section 10B (Page
10B-28).

IBP80A721113-01
7B-42 HVAC System: Single A/C Type

A/C Compressor Drive Belt Inspection and

Adjustment 2
AENBL80A7216031 1
Petrol Model
Inspection
• Check A/C compressor drive belt (1) for wear, cracks,
deformation and contamination. If any defect is found,
replace the belt with new one. )(Page 7B-42)
• Check A/C compressor drive belt tension by
3
measuring how much it deflects when pushed at
intermediate point between magnet clutch pulley (2)
and crankshaft pulley (3) with about 100 N (10 kg)
force after rotating crankshaft pulley 360°. If belt
tension is out of specification, adjust belt tension I9P60A722023-08

referring to “Adjustment”.
Diesel Model
A/C compressor drive belt tension “a” For inspection and adjustment, refer to “Accessory Drive
: 7 – 8 mm (0.28 – 0.31 in.) / 100 N (10 kgf or 22 lb) Belt Tension Inspection”: D13A in Section 1J (Page 1J-
20).
NOTE
When replacing drive belt, adjust drive belt A/C Compressor Drive Belt Removal and
tension to the following specifications.
Installation
AENBL80A7216032
New A/C compressor drive belt tension “a” Petrol Model
: 7 – 8 mm (0.28 – 0.31 in.) /100 N (10 kgf or 22 lb) Removal
1) Loosen tension pulley bolt (1).
2) Loosen belt tension by loosening tension pulley
adjusting bolt (2).
3) Remove A/C compressor drive belt (3).
1

2
1
2

“a”
3
IBP80A721114-01

3
Adjustment
1) Loosen tension pulley bolt (1).
2) Adjust belt tension by tightening or loosening tension
pulley adjusting bolt (2). I9P60A722023-08

3) Tighten tension pulley bolt (1).

4) Rotate the crankshaft pulley 360°, and then recheck Installation
drive belt (3) tension. Reverse removal procedure noting the following point.
• Adjust belt tension. )(Page 7B-42)

Diesel Model
For removal and installation, refer to “Accessory Drive
Belt Tensioner Removal and Installation”: D13A in
Section 1J (Page 1J-20).

A/C Compressor Assembly Removal and

Installation
AENBL80A7216033
Removal
1) Run engine at idle speed with A/C ON for 10
minutes.
 HVAC System: Single A/C Type 7B-43

2) Stop engine. Installation

3) Disconnect negative (–) cable at battery.
4) Recover refrigerant from A/C system using recovery
and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge”:
Single A/C Type (Page 7B-23).
5) Remove right side engine undercover.
6) Petrol Model: Remove A/C compressor drive belt.
)(Page 7B-42)
Diesel Model: Remove accessory drive belt. )(Page
1J-20)
7) Disconnect magnet clutch lead wire connector.
8) Disconnect discharge hose (1) and suction hose (2)
from A/C compressor (3).
NOTE
Cap open fittings immediately to keep
moisture out of the system.
Reverse removal procedure, noting the following points.
• If A/C compressor is replaced, pour new compressor
oil referring to “Replenishing Compressor Oil” in
“Operation Procedure for Refrigerant Charge”: Single
A/C Type (Page 7B-23).
• Apply compressor oil to new O-ring of discharge hose
and liquid pipe.
Petrol Model: Compressor oil 95590–58D30
(Compressor oil (ND-OIL8))
Diesel Model: Compressor oil 99000–990C5–00A
(Compressor oil (SP10))
• Tighten A/C compressor mounting bolts in numerical
order (“1” through “3”) as shown in the figure.
[A]

9) Remove A/C compressor mounting bolts (4), and

then remove A/C compressor (3) from its bracket.

[A]
2 1 3

"2" "3"
"1"

[B]

4
4

[B]
4

"2" "1" "3"

IBL80A721026-01

[A]: Petrol model [B]: Diesel model

• Evacuate and charge A/C system referring to

“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”: Single A/C Type (Page 7B-
23).
3 4 2 1 4
IBL80A721025-01 • Petrol Model: Adjust drive belt tension. )(Page 7B-
[A]: Petrol model
42)
[B]: Diesel model Diesel Model: Adjust accessory drive belt. )(Page
1J-20)

A/C Compressor Assembly Components (Petrol Model)

AENBL80A7216034
7B-44 HVAC System: Single A/C Type

6 (b)

OIL
5

(a)

IBL80A721027-01

1. Clutch set 4. A/C compressor : 20 N⋅m (2.0 kgf-m, 15.0 lbf-ft)

2. Clip set 5. O-ring : 13 N⋅m (1.3 kgf-m, 10.0 lbf-ft)
: Apply compressor oil
3. Screw 6. Relief valve : Do not reuse.

A/C Compressor Assembly Components (Diesel Model)

AENBL80A7216041
! CAUTION
Do not disassemble A/C compressor assembly. If any repair is required on A/C compressor, replace it
as assembly.

Magnet Clutch Inspection

AENBL80A7216035 [A]
• Check armature plate for wear and magnet clutch
pulley for oil soak respectively.
• Check magnet clutch pulley bearing for noise, wear
and grease leakage.
• Measure magnet clutch coil at 20 °C (68 °F). If the
measured resistance is out of specification, replace
magnet clutch assembly.
Magnet clutch coil resistance
Petrol model: Approximately 3.9 – 4.3 Ω (at 20 °C
(68 °F)) [B]
Diesel model: Approximately 3.55 Ω – 3.75 Ω (at 20
°C (68 °F))

IBL80A721028-01

[A]: Petrol model

[B]: Diesel model
 HVAC System: Single A/C Type 7B-45

Magnet Clutch Removal and Installation

AENBL80A7216036 2
Petrol Model
Removal
1) Remove A/C compressor from vehicle. )(Page 7B-
42) 3
2) Fix armature plate (2) with special tool and remove
armature plate bolt (1).
Special tool
(A): 09991–06310
1
3) Remove armature plate (2).

I8C50B720053-01
2
Installation
(A)
1) Install magnet clutch coil (2) by fitting protrusion (3)
of magnet clutch coil onto hole (4) of A/C
compressor.
2) Install new circlip (1) directing the plane side
I8C50B720051-01
downward by using snap ring pliers.
4) Remove shims (1) from shaft. 1
5) Remove circlip (2) by using snap ring pliers.
6) Remove magnet clutch pulley (3) by using puller.
2
1
1

3
3

I8C50B720054-01

I8C50B720052-01
3) Press-fit magnet clutch pulley (1) by using special
tool and hydraulic press.
7) Remove circlip (2) by using snap ring pliers.
8) Remove magnet clutch lead wire clamp (1). Special tool
(A): 09913–84510
9) Remove magnet clutch coil (3) from A/C
compressor. (A)

IBL80A721029-01

4) Install new circlip (2) directing the plane side

downward by using snap ring pliers.
7B-46 HVAC System: Single A/C Type

Standard clearance between armature plate

and magnet clutch pulley “a”:
0.3 – 0.6 mm (0.0118 – 0.0236 in.)
2
2
1 4

“a”
1

IBL80A721030-01

5) Install same amount of removing shims.

6) Tighten armature plate bolt (1) to specified torque.
Tightening torque I8C50B720057-02

Armature plate bolt (a): 20 N·m (2.0 kgf-m, 15

lbf-ft) Relief Valve Inspection
AENBL80A7216039
Special tool Check relief valve for refrigerant leakage using special
(A): 09991–06310 tool.
If there is refrigerant leakage, replace relief valve (petrol
1, (a) model) or replace A/C compressor assembly (diesel
model).
Special tool
(C) : 09990–86012
(A)

[A]

(C)

I8C50B720056-01

7) Adjust clearance between armature plate (1) and

magnet clutch pulley (2) by putting shim(s) on A/C
compressor shaft. To measure the clearance,
perform the following steps.
a) Put A/C compressor in a vise (3).
b) Set dial gauge (4) on armature plate, and then
[B]
adjust its pointer at 0.
(C)
c) Connect battery positive terminal (+) to magnet
clutch coil lead wire.
d) Connect battery negative terminal (–) to A/C
compressor body assembly. (At this point,
armature plate and magnet clutch pulley are kept
in contact.)
e) Disconnect battery negative terminal (–) from A/
C compressor body assembly. (At this point,
IBL80A721031-01
armature plate and magnet clutch pulley are not
in contact.) [A]: Petrol model
[B]: Diesel model
f) Read stroke of armature plate from dial gauge by
performing step d) and e) repeatedly. (Stroke of
armature plate is clearance between armature Relief Valve Removal and Installation (Petrol
plate and magnet clutch pulley.) Model)
AENBL80A7216040
 HVAC System: Single A/C Type 7B-47

Removal • Apply compressor oil to O-ring.

1) Recover refrigerant from the A/C system using
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”: Single A/C Type (Page 7B-23).
2) Remove relief valve (1) from A/C compressor (2).
1
: Compressor oil 95590–58D30 (Compressor oil
(ND-OIL8))
• Tighten relief valve to the specified torque.
Tightening torque
Relief valve (a): 13 N·m (1.3 kgf-m, 10.0 lbf-ft)
(a)

IBL80A721033-01

IBL80A721032-01
Installation • Evacuate and charge the A/C system referring to
Reverse removal procedure, noting the following points. “Evacuation” and “Charge” in “Operation Procedure
• Use new O-ring. for Refrigerant Charge”: Single A/C Type (Page 7B-
23).

Specifications
Tightening Torque Specifications
AENBL80A7217001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Expansion valve bolt 3.5 0.36 2.5 )
A/C refrigerant pressure sensor 11 1.1 8.5 )
Armature plate bolt 20 2.0 15 )
Relief valve 13 1.3 10.0 )

NOTE
The tightening torque(s) also specified in:
“A/C System Major Components”: Single A/C Type
“HVAC Unit Components”: Single A/C Type
“A/C Compressor Assembly Components (Petrol Model)”: Single A/C Type

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Recommended Service Material
AENBL80A7218001
Material SUZUKI recommended product or Specification Note
Compressor oil Compressor oil (ND-OIL8) P/No.: 95590–58D30 )/)/)/)/)/)
Compressor oil (SP10) P/No.: )/)/)/)/)
99000–990C5–00A
7B-48 HVAC System: Single A/C Type

NOTE
Required service material(s) also described in:
“A/C System Major Components”: Single A/C Type
“HVAC Unit Components”: Single A/C Type
“A/C Compressor Assembly Components (Petrol Model)”: Single A/C Type

Special Tool
09913–84510
Bearing installer
) 1. Manifold gauge 2.
09990–86012
Gas leak detector
This kit includes following
items. 1. Gas leak detector,
2. Instruction manual, 3.
Filter, 4. Sensor, 5. Dry-cell
battery (size D)) / )
AENBL80A7218002
09990–06020
Manifold gauge set (R134a)
Charging hoses 3. Quick
connector 4. Refrigerant
container tap valve 5.
Refrigerant container T joint
6. Packing sets 7. Case) /
)/)/)
09991–06310
2 Armature plate holder
1
)/)
5
3 4

SUZUKI scan tool (SUZUKI- 6

SDT)
— 1 2
This kit includes following
4
items. 1. SUZUKI-SDT 2. 3
DLC cable 3. USB cable 4. 5
AC/DC power supply 5.
Voltage meter probe 6.
Storage case)
 HVAC System: Dual A/C Type 7B-49

Dual A/C Type

General Description
HVAC System Description
AENBL80A7221001
• This HVAC system is of a manually controlled air conditioning type.
• Settings of airflow mode and temperature are possible using air flow selector and temperature selector respectively.
When these selectors are set in desired positions, the corresponding cables move air flow control door and
temperature control door accordingly.
• There are two other selectors: air intake selector and blower speed selector.
• Air inlet mode can be switched between recirculated air mode and fresh air mode by air intake selector. When the
desired mode is selected, the air intake actuator moves the air intake door to the corresponding position.
• Air flow rate can be adjusted by blower speed selector. Four positions are available: LO, ML, MH and HI.
• A/C switch turns on and off the A/C system. Signal from the A/C switch is transmitted to ECM via BCM through CAN
communication system. The ECM circuits related to the A/C system controls A/C compressor relay and radiator
(condenser) cooling fan relay according to the signal. Refer to “A/C Operation Description at ECM (Petrol Model)”:
Dual A/C Type (Page 7B-51) or “A/C Operation Description at ECM (Diesel Model)”: Dual A/C Type (Page 7B-51)
for details.
• In Petrol model, the ECM circuits related to the A/C system also controls evaporator temperature depending on the
data from evaporator temperature sensor. Refer to “A/C Operation Description at ECM (Petrol Model)”: Dual A/C
Type (Page 7B-51) for details. In Diesel model, A/C compressor can adjust the flow rate of refrigerant, monitoring
the A/C refrigerant pressure mechanically. This also helps to keep the evaporator temperature at an optimum level.
• The A/C system uses an A/C refrigerant pressure sensor that is capable of detecting linear changes in refrigerant
pressure.
• HVAC unit incorporates blower motor unit, heater core unit and evaporator unit.
• Each side ventilator has a shutter mechanism.
• The condenser is of a sub-cool type. It is integral with the receiver/dryer and mounted on the vehicle body in a
floating manner.
• Rear defogger switch is located on the HVAC control unit.
• Rear cooling unit incorporates rear blower motor unit, rear blower motor resistor, rear expansion valve and rear
evaporator unit.
• When A/C system is ON and rear blower speed selector is turned ON, cool air comes out from rear ventilation
louver.
• Rear air flow rate can be adjusted by rear blower speed selector. Three positions are available: L, M and H.
• For the electronic control system components location, refer to “Manual A/C Control System Component Location”:
Dual A/C Type (Page 7B-55).
For the A/C system components location, refer to “A/C System Major Components”: Dual A/C Type (Page 7B-75).
For the A/C electrical control input / output diagram, refer to “Manual A/C Electronic Control Input / Output Block
Diagram”: Dual A/C Type (Page 7B-52).
7B-50 HVAC System: Dual A/C Type

HVAC System Construction

9
12

10
13 13

9
23 22

19
1

20

21

14
15

18 11 11
17
16

25
8
26 27

6
4
2
7
5
24
: [A]
3
: [B]

: [C]

IBL80A722001-01

[A]: Air flow 6. Suction hose 14. Fresh air 22. Radiator
[B]: Refrigerant flow 7. Liquid pipe 15. Recirculation air 23. Reservoir
[C]: Engine coolant flow 8. Expansion valve 16. Evaporator 24. Room air
1. HVAC unit 9. Side ventilation air 17. Air intake door 25. Rear ventilation air
2. A/C compressor 10. Center ventilation air 18. Temperature control door 26. Rear expansion valve
3. Condenser assembly 11. Front foot air 19. Air flow control door 27. Rear evaporator
4. Receiver/dryer 12. Defroster air 20. Heater core
5. Discharge hose 13. Demister air 21. Engine

Sub-Cool A/C System Description

AENBL80A7221002
In the sub-cool A/C system (condenser integrated with receiver/dryer), the inside of the condenser is divided into the
condensation part and the sub-cooler part, and the receiver/dryer is located between these. In the receiver/dryer, the
refrigerant is separated into vapor refrigerant and liquid refrigerant. Only the liquid refrigerant is delivered to the sub-
cooler part of the condenser. The refrigerant is supercooled by the sub-cooler part of the condenser.
 HVAC System: Dual A/C Type 7B-51

8
5

: [A]
3 : [B]
: [C]

1
2

IBL80A722002-01

[A]: Liquid 1. A/C compressor 4. Expansion valve 7. Sub-cooler part

[B]: Vapor 2. Condenser 5. Evaporator 8. Rear expansion valve
[C]: Superheated vapor 3. Receiver/dryer 6. Condensation part 9. Rear evaporator

A/C Operation Description at ECM (Petrol Model)

AENBL80A7221003
Refer to “A/C Operation Description at ECM (Petrol Model)”: Single A/C Type (Page 7B-3).

A/C Operation Description at ECM (Diesel Model)

AENBL80A7221004
Refer to “A/C Operation Description at ECM (Diesel Model)”: Single A/C Type (Page 7B-5).
7B-52 HVAC System: Dual A/C Type

Schematic and Routing Diagram

Manual A/C Electronic Control Input / Output Block Diagram
AENBL80A7222001

Input sensor (or signal) Electronic control Output actuator (or signal)

ECM (A/C control area)

A/C refrigerant
pressure sensor A/C Compressor relay
A/C compressor relay
control
[A] Throttle position sensor
A/C compressor
Accelerator pedal
position sensor
Radiator (condenser)
Radiator cooling fan relay
ECT sensor cooling fan relay control

CKP sensor Radiator cooling fan motor

VSS

[A]
Evaporator temperature
sensor

BCM

HVAC control unit

Blower motor
A/C switch

Blower speed selector Blower motor resistor

Air intake switch Air intake control actuator

Rear blower speed selector Rear blower motor resistor

CAN communication Rear blower motor

IBL80A722003-01

[A]: For petrol model

 HVAC System: Dual A/C Type 7B-53

Manual A/C System Circuit Diagram

AENBL80A7222003
Petrol Model

1
11
RED/WHT BLK BLK/WHT G155-6
BLU BLK/YEL YEL G155-7
G155-1 BLK
16 13 BLU/WHT G155-3
2
RED/WHT 24
RED G155-2
15 14
LT GRN G155-5
17 12 3
G154-1 G154-7 GRN/RED
4
RED/WHT G154-11
18 WHT/BLK
5
6 BEG
19 BLU G154-5
25
21 GRN/YEL G154-6
20 7
WHT BLK/RED G154-2 G154-12 GRY

22 8
RED/YEL G154-9
9 G154-8 BRN
23 RED/BLK G154-3

BLK/YEL
26

28 29 27
BLU/WHT E01-48
BLU/YEL WHT
GRY E01-37
BLK/RED E01-55
BLK/RED E01-56
30
10 35
BLK/YEL BRN/WHT E01-54
BLK/YEL 27
E01- 1 RED
27
31 E01- 2 WHT
LT GRN E01-42
GRY BLU 36
E01-30 GRY/RED
32
E01-35 RED/GRN
BLU/BLK 34 BLK
E01-14 BLU/RED
BLU
33
BLU
C01-50 BLK
BLU/WHT
C01-51 BLK
C01-53 BLK
GRN E01-41

IBL80A722004-02

1. HVAC control unit 10. Ignition switch 19. Rear defogger (if equipped) 28. A/C compressor relay
2. Blower speed selector 11. Heater relay 20. “RR DEF” fuse (if equipped) 29. A/C compressor
3. A/C switch 12. Blower motor resistor 21. Rear defogger relay (if equipped) 30. Main relay
4. “A/C” indicator light 13. Blower motor 22. Lighting switch 31. Radiator cooling fan relay No.1
5. “REC” indicator light 14. “RR A/C” fuse 23. Combination meter 32. Radiator cooling fan relay No.2
6. Air intake switch 15. Rear blower motor 24. BCM 33. Radiator cooling fan relay No.3
7. Rear defogger indicator (if equipped) 16. Rear blower motor resistor 25. Evaporator temperature sensor 34. Radiator cooling fan motor
8. Rear defogger switch (if equipped) 17. Rear blower speed selector 26. ECM 35. ABS control module (if equipped)
9. Illumination light 18. Air intake control actuator 27. CAN driver 36. A/C refrigerant pressure sensor
7B-54 HVAC System: Dual A/C Type

Diesel Model

1
11
RED/WHT BLK BLK/WHT G155-6
BLU BLK/YEL YEL G155-7
16 G155-1 BLK
13 BLU/WHT G155-3
RED/WHT 2
24
15 14 RED G155-2

17 LT GRN G155-5
12 3
G154-1 G154-7 GRN/RED
4
RED/WHT G154-11
18
5
BLU G154-5 6
19
21 GRN/YEL G154-6
20 7
WHT BLK/RED G154-2 G154-12 GRY

22 8
RED/YEL G154-9
9 G154-8 BRN
23 RED/BLK G154-3

BLK/YEL
25
BLK
27 28 26
BLU/YEL WHT
GRY E01-79
34
29
LT GRN/RED E01-7 26
GRY BLU E01- 64 RED
10 26
30 E01- 40 WHT
BLU/BLK 32 BLK

35
BLU/WHT E01-37 GRY/RED
31
E01-87 RED/GRN
GRN E01-8 E01-10 BLU/RED
BLK/RED E01-4
BLU BLK/RED E01-5
33
BLK/YEL BLK/RED BLK/RED E01-6
YEL/GRN BRN/WHT E01-80

E01-1 BRN
E01-2 BRN
E01-3 BRN

IBL80A722005-02

1. HVAC control unit 10. Ignition switch 19. Rear defogger (if equipped) 28. A/C compressor
2. Blower speed selector 11. Heater relay 20. “RR DEF” fuse (if equipped) 29. Radiator cooling fan relay No.1
3. A/C switch 12. Blower motor resistor 21. Rear defogger relay (if equipped) 30. Radiator cooling fan relay No.2
4. “A/C” indicator light 13. Blower motor 22. Lighting switch 31. Radiator cooling fan relay No.3
5. “REC” indicator light 14. “RR A/C” fuse 23. Combination meter 32. Radiator cooling fan motor
6. Air intake switch 15. Rear blower motor 24. BCM 33. Main relay
7. Rear defogger indicator (if equipped) 16. Rear blower motor resistor 25. ECM 34. ABS control module (if equipped)
8. Rear defogger switch (if equipped) 17. Rear blower speed selector 26. CAN driver 35. A/C refrigerant pressure sensor
9. Illumination light 18. Air intake control actuator 27. A/C compressor relay
 HVAC System: Dual A/C Type 7B-55

Component Location
Manual A/C Control System Component Location
AENBL80A7223001

3 6
1

5 7 8 9 10

2
12
11

13

14 15 [B] [A] 17 18 19 20 21

16 [B]
17 18 19 20 21

23

[A]

22

16

24 26
25
IBL80A722007-02
7B-56 HVAC System: Dual A/C Type

[A]: Petrol model
[B]: Diesel model
1. Air intake control actuator
2. Blower motor resistor
3. Evaporator temperature sensor (if
equipped)
4. HVAC control unit
5. Temperature selector
6. Blower speed selector
7. Air intake switch
8. A/C switch
9. Rear defogger switch (if equipped)
10. Air flow selector
11. Blower motor
12. Heater relay
13. Rear defogger relay (if equipped)
14. Rear blower speed selector
15. “RR A/C” fuse
16. ECM
17. Radiator cooling fan relay No.2
18. Radiator cooling fan relay No.3
19. Main relay
20. A/C compressor relay
21. Radiator cooling fan relay No.1
22. HVAC unit
23. Rear cooling unit
24. A/C refrigerant pressure sensor
25. A/C compressor
26. Radiator cooling fan motor

Diagnostic Information and Procedures

A/C System Performance Inspection
AENBL80A7224001
(A)
1) Confirm that vehicle and environmental conditions 2
1
are as follows.
3
• Vehicle is put indoors.
4
• Ambient temperature is within 25 – 45 °C (77 –
113 °F).
• Relative humidity is within 30 – 70%.
• There is no wind indoors.
• HVAC unit is normal. 5

• Blower motor is normal.

6
• There is no air leakage from air ducts.
• Condenser fins are clean.
• Battery voltage is about 12 V or more (battery in
good condition).
• Radiator cooling fan operates normally.
2) Make sure that high pressure valve (1) and low IBL80A722008-01

pressure valve (2) of manifold gauge (A) are firmly

closed.
Special tool
(A): 09990–06020
3) Connect high pressure charging hose (3) to high
pressure service valve (5) on vehicle and low
pressure charging hose (4) to low pressure service
valve (6).
 HVAC System: Dual A/C Type 7B-57

4) Warm up engine to normal operating temperature

and keep it at specified idle speed. 1

5) Turn A/C switch ON, then set blower speed selector

to maximum speed position, rear blower speed
selector to maximum speed position, temperature
selector to maximum cold position, air flow selector
to face position, air intake switch to recirculation
mode and side ventilation louvers to open position.
(Confirm that A/C compressor and radiator cooling
fan are working.)
6) Wait for ten minutes to stabilize A/C operation.
7) Open all door windows, front doors and hood.
8) With about 20 mm (0.8 in.) of dry bulb thermometer 2
(1) put right in front of center ventilation louver or
rear ventilation louver and a wet and dry bulb
thermometer (2) near air inlet of HVAC unit or rear
cooling unit.
1

IBL80A722009-03

9) Check for each pressure of low side and high side if it is within shaded range of graph. If each gauge reading is out
of specified pressure, correct defective part referring to the following table.
When diagnosing troubles of abnormal pressure on the low side and high side for each pressure more specifically,
refer to “Trouble Diagnosis for Abnormal Pressure”: Dual A/C Type (Page 7B-61).

NOTE
Pressure registered on gauge varies with ambient temperature. Therefore, use the graphs when
determining if pressures are normal or not.

Low side and high side pressure example, gauges should read as follows when ambient temperature is 30
°C (86 °F)
Petrol model Diesel model
Pressure on high pressure gauge (HI) 1220 – 1510 kPa (12.4 – 15.4 kgf/ 1300 – 1580 kPa (13.3 – 16.1 kgf/
cm2) cm2)
Pressure on low pressure gauge (LO) 260 – 370 kPa (2.7 – 3.8 kgf/cm2) 240 – 330 kPa (2.4 – 3.4 kgf/cm2)
7B-58 HVAC System: Dual A/C Type

[A]
psi kPa kgf/cm 2
362.6 2500 25
348.1 2400 24 70
327.1 2300 23
312.9 2200 22
298.7 2100 21
284.4 2000 20 30
270.2 1900 19
256.0 1800 18 “H”
[G]
241.7 1700 17
227.5 1600 16
213.3 1500 15
199.1 1400 14
184.9 1300 13
“I ”
[C] 170.6 1200 12 [F ]
151.4 1100 11
142.2 1000 10
128.0 900 9
113.8 800 8
99.5 700 7
85.3 600 6 70
71.1 500 5 “J ”
56.9 400 4 [G]
30
[D] 42.7 300 3
28.4 200 2
14.2 100 1 “K”
0
25 30 35 40 45 [E ]
77 86 95 104 113

[B]
psi kPa kgf/cm 2
362.6 2500 25
348.1 2400 24
327.1 2300 23
70
312.9 2200 22
298.7 2100 21
284.4 2000 20
270.2 1900 19 30
256.0 1800 18 “H”
241.7 1700 17 [G]
227.5 1600 16
213.3 1500 15
199.1 1400 14
184.9 1300 13
“I ”
[C] 170.6 1200 12 [F ]
151.4 1100 11
142.2 1000 10
128.0 900 9
113.8 800 8
99.5 700 7
85.3 600 6
70
71.1 500 5 “J ”
56.9 400 4
[G] 30
[D] 42.7 300 3
28.4 200 2
14.2 100 1 “K”
0
25 30 35 40 45 [E ]
77 86 95 104 113
IBL80A722038-01

[A]: Petrol model [C]: Pressure of high pressure gauge [E]: Ambient temperature [G]: Acceptable range
[B]: Diesel model [D]: Pressure of low pressure gauge [F]: Humidity
 HVAC System: Dual A/C Type 7B-59

High pressure gauge

Condition Possible cause Correction
Pressure is higher than Refrigerant overcharged Recharge.
acceptable range Expansion valve frozen or clogged Check expansion valve.
(“H” area) Clogged refrigerant passage of high pressure side Clean or replace.
Radiator cooling fan malfunction (Insufficient Check radiator cooling fan.
cooling of condenser)
Dirty or bent condenser fins (Insufficient cooling of Clean or repair.
condenser)
A/C compressor malfunction (Insufficient oil etc.) Check A/C compressor.
Engine overheat Check engine cooling system.
- Petrol model: )(Page 1F-4)
- Diesel model: )(Page 1F-18)
Pressure is lower than Insufficient refrigerant (Insufficient charge or Check for leakage, repair if necessary
acceptable range leakage) and recharge.
(“I” area) Expansion valve malfunction (valve opens too Check expansion valve.
wide)
A/C compressor malfunction (Insufficient Check A/C compressor.
compression)

Low pressure gauge

Condition Possible cause Correction
Pressure is higher than Expansion valve malfunction (valve opens too Check expansion valve.
acceptable range wide)
(“J” area) A/C compressor malfunction (Insufficient Check A/C compressor.
compression)
Pressure is lower than Insufficient refrigerant (Insufficient charge or Check for leakage, repair if necessary
acceptable range leakage) and recharge.
(“K” area) Expansion valve malfunction (valve opens too Check expansion valve.
narrow)
Clogged refrigerant passage (crashed pipe) Repair or replace.

10) Check correlation between inlet port temperature-and-outlet port temperature using the following graph. For
example, if temperature near air inlet of HVAC unit or rear cooling unit is 35 °C (95 °F) and the one at air outlet of
center or rear ventilation louver is 23 °C (73 °F), their crossing point is within acceptable range as shown in the
graph. In this case, cooling performance is satisfactory and proper.
11) If crossing point is out of acceptable range, diagnose trouble referring to the following table.
7B-60 HVAC System: Dual A/C Type

Outlet temperature of center ventilation louver

[A] [B]
[C ] [E ] [C ] [E ]

99 37 99 37
97 36 70 97 36 70
95 35 95 35
93 34 93 34
91 33 91 33
90 32 90 32
88 31 88 31
86 30 86 30
84 29 84 29
82 28 82 28
81 27 81 27
79 26 79 26
77 25 “H” 77 25 “H”
75 24 [G] 75 24 [G]
73 23 30 73 23
72 22 72 22 30
70 21 70 21
68 20 68 20
66 19 66 19
[F ] [F ]
64 18 64 18
63 17 63 17
61 16 61 16
59 15 59 15
57 14 57 14
55 13 55 13
“I” “I”
54 12 54 12
52 11 52 11
50 10 50 10
48 9 48 9
46 8 46 8
25 30 35 40 45 25 30 35 40 45
77 86 95 104 113 77 86 95 104 113
[D ] [D ]
IBL80A722039-01

[A]: Petrol model [D]: Temperature near air inlet of HVAC unit [G]: Crossing point
[B]: Diesel model [E]: Humidity
[C]: Temperature at outlet of center ventilation louver [F]: Acceptable range
 HVAC System: Dual A/C Type 7B-61

Outlet temperature of rear ventilation louver

[A] [B]
[C ] [E ] [C ] [E ]

104 40 104 40 70
70
102 39 102 39
100 38 100 38
99 37 99 37
97 36 97 36
95 35 95 35
93 34 “H” 93 34 “H”
91 33 91 33
90 32 90 32
88 31 88 31
86 30 86 30
84 29 84 29 30
82 28 82 28
81 27 81 27
79 26 [F ] 79 26 [F ]
77 25 77 25
75 24 [G] 75 24 [G]
73 23 73 23
72 22 30 72 22
70 21 70 21
68 20 68 20
66 19 66 19
64 18 64 18
63 17 “I” 63 17 “I”
61 16 61 16
59 15 59 15
57 14 57 14
55 13 55 13
54 12 54 12
52 11 52 11
50 10 50 10
48 9 48 9
46 8 46 8
25 30 35 40 45 25 30 35 40 45
77 86 95 104 113 77 86 95 104 113
[D ] [D ]
IBL80A722040-01

[A]: Petrol model [D]: Temperature near air inlet of rear cooling unit [G]: Crossing point
[B]: Diesel model [E]: Humidity
[C]: Temperature at outlet of rear ventilation louver [F]: Acceptable range

Thermometer at center or rear ventilation louver

Condition Possible cause Correction
Crossing point is higher Insufficient or excessive charge of refrigerant Check refrigerant pressure.
than acceptable range Dirty or bent evaporator fins Clean or repair.
(“H” area) Air leakage from cooling (heater) unit or air duct Repair or replace.
Malfunctioning, switch over function of door in Repair or replace.
cooling (heater) unit
A/C compressor malfunction Check A/C compressor.
Crossing point is lower Insufficient air volume from center or rear Check blower motor and fan.
than acceptable range (“I” ventilation louver (Heater blower malfunction)
area) A/C compressor malfunction Check A/C compressor.

Trouble Diagnosis for Abnormal Pressure

AENBL80A7224002
7B-62 HVAC System: Dual A/C Type

Petrol Model

NOTE
Normal pressure values for high pressure gauge (HI) and low pressure gauge (LO) in the following
table are those measured when the ambient temperature is about 30 °C (86 °F). As normal pressure
values for both gauges vary depending on the ambient temperature, be sure to perform the following
steps before starting diagnosis of troubles.
1. Measure the ambient temperature and using that temperature, read the normal high and low
pressure values from the graph given in Step 10) of “A/C System Performance Inspection”: Dual A/
C Type (Page 7B-56).
2. Use these values in place of the normal pressure values in the following table.

Condition
Manifold gauge kPa (kgf/cm2) (psi) Possible cause Correction
Detail
LO HI
260 – 370 1220 – 1510 Normal condition
(2.7 – 3.8) (12.4 – 15.4) — —
(37.7 – 53.7) (176.9 – 219.0)
Negative pressure 500 – 600 LO gauge reads Dust particles Replace expansion
(5.1 – 6.1) negative pressure, while accumulate or water valve.
(72.5 – 87.0) HI gauge reads droplets are frozen Replace condenser
extremely low pressure. inside expansion assembly.
Presence of frost around valve, preventing Evacuate A/C system
tubing to and from refrigerant from and recharge system
condenser assembly flowing. with fresh refrigerant.
and expansion valve.
Normal: Normal: During A/C operation, Expansion valve is Replace expansion
260 – 370 1220 – 1510 LO gauge sometimes frozen due to moisture valve.
(2.7 – 3.8) (12.4 – 15.4) indicates negative in system, temporarily Replace condenser
(37.7 – 53.7) (176.9 – 219.0) pressure, and shutting off assembly.
↑↓ ↑↓ sometimes normal refrigeration cycle. Evacuate A/C system
Abnormal: Abnormal: pressure. Also HI gauge and recharge system
Negative 700 – 1000 reading fluctuates with fresh refrigerant.
pressure (7.1 – 10.2) between abnormal and
(102 – 145) normal pressures.
50 – 150 700 – 1000 Both LO and HI gauge Insufficient refrigerant Using leak detector,
(0.5 – 1.5) (7.1 – 10.2) indicate low readings. in system check for leaks and
(7.25 – 21.8) (102 – 145) Output air is slightly cold. (Refrigerant leaking). repair if necessary.
Recharge system with
refrigerant to specified
amount.
If pressure readings is
almost 0 when
manifold gauges are
attached, check for
any leaks, repair them,
and evacuate system.
400 – 600 Pressure on LO gauge is Internal leak in A/C Inspect A/C
(4.1 – 6.1) high. compressor. compressor and repair
(58.0 – 87.0) Pressure on HI gauge is or replace if
low. necessary.
Both pressures become
equal right after A/C is
turned OFF.
 HVAC System: Dual A/C Type 7B-63

Condition
Manifold gauge kPa (kgf/cm2) (psi) Possible cause Correction
Detail
LO HI
400 – 450 2000 – 2500 High pressure readings Overcharged A/C Adjust refrigerant to
(4.1 – 4.6) (20.4 – 25.5) on both LO and HI system. specified amount.
(58.0 – 65.3) (290 – 363) gauges. Faulty condenser Clean condenser.
cooling operation.
Faulty radiator cooling Inspect and repair
fan operation. radiator cooling fan.
High pressure reading Presence of air in A/C Replace condenser.
on both LO and HI system Inspect quantity of
gauges. (Improperly compressor oil and
Low pressure tubing is evacuated). presence of
not cold when touched. contaminants in oil.
Evacuate system and
recharge system with
fresh refrigerant.
450 – 550 High pressure reading Faulty expansion Replace expansion
(4.6 – 5.6) on both LO and HI valve. valve.
(65.3 – 79.8) gauges. Refrigerant flow is not
Large amount of frost or regulated properly.
dew on low pressure
tubing.

Diesel Model

NOTE
Normal pressure values for pressure gauge (HI) and low pressure gauge (LO) in the following table are
those measured when the ambient temperature is about 30 °C (86 °F). As normal pressure values for
both gauges vary depending on the ambient temperature, be sure to perform the following steps
before starting diagnosis of troubles.
1. Measure the ambient temperature and using that temperature, read the normal high and low
pressure values from the graph given in Step 10) of “A/C System Performance Inspection”: Dual A/
C Type (Page 7B-56).
2. Use these values in place of the normal pressure values in the following table.

Condition
Manifold gauge kPa (kgf/cm2) (psi) Possible cause Correction
Detail
LO HI
240 – 330 1300 – 1580 Normal condition
(2.4 – 3.4) (13.3 – 16.1) — —
(34.8 – 47.9) (188.5 – 229.2)
Negative pressure 500 – 600 LO gauge reads Dust particles Replace expansion
(5.1 – 6.1) negative pressure, while accumulate or water valve.
(72.5 – 87.0) HI gauge reads droplets are frozen Replace condenser
extremely low pressure. inside expansion assembly.
Presence of frost around valve, preventing Evacuate A/C system
tubing to and from refrigerant from and recharge system
condenser assembly flowing. with fresh refrigerant.
and expansion valve.
Normal: Normal: During A/C operation, Expansion valve is Replace expansion
240 – 330 1300 – 1580 LO gauge sometimes frozen due to moisture valve.
(2.4 – 3.4) (13.3 – 16.1) indicates negative in system, temporarily Replace condenser
(34.8 – 47.9) (188.5 – 229.2) pressure, and shutting off assembly.
↑↓ ↑↓ sometimes normal refrigeration cycle. Evacuate A/C system
Abnormal: Abnormal: pressure. Also HI gauge and recharge system
Negative 700 – 1000 reading fluctuates with fresh refrigerant.
pressure (7.1 – 10.2) between abnormal and
(102 – 145) normal pressures.
7B-64 HVAC System: Dual A/C Type

Condition
Manifold gauge kPa (kgf/cm2) (psi) Possible cause Correction
Detail
LO HI
50 – 150 700 – 1000 Both LO and HI gauge Insufficient refrigerant Using leak detector,
(0.5 – 1.5) (7.1 – 10.2) indicate low readings. in system check for leaks and
(7.25 – 21.8) (102 – 145) Output air is slightly cold. (Refrigerant leaking). repair if necessary.
Recharge system with
refrigerant to specified
amount.
If pressure readings
are almost 0 when
manifold gauges are
attached, check for
any leaks, repair them,
and evacuate system.
400 – 600 Pressure on LO gauge is Internal leak in A/C Inspect A/C
(4.1 – 6.1) high. compressor. compressor and repair
(58.0 – 87.0) Pressure on HI gauge is or replace if
low. necessary.
Both pressures become
equal right after A/C is
turned OFF.
400 – 450 2000 – 2500 High pressure readings Overcharged A/C Adjust refrigerant to
(4.1 – 4.6) (20.4 – 25.5) on both LO and HI system. specified amount.
(58.0 – 65.3) (290 – 363) gauges. Faulty condenser Clean condenser.
cooling operation.
Faulty radiator cooling Inspect and repair
fan operation. radiator cooling fan.
High pressure reading Presence of air in A/C Replace condenser.
on both LO and HI system Inspect quantity of
gauge. (Improperly compressor oil and
Low pressure tubing is evacuated). presence of
not cold when touched. contaminants in oil.
Evacuate system and
recharge system with
fresh refrigerant.
450 – 550 High pressure reading Faulty expansion Replace expansion
(4.6 – 5.6) on both LO and HI valve. valve.
(65.3 – 79.8) gauge. Refrigerant flow is not
Large amount of frost or regulated properly.
dew on low pressure
tubing.

A/C System Symptom Diagnosis

AENBL80A7224003
Front (Main) A/C System
Refer to “A/C System Symptom Diagnosis”: Single A/C Type (Page 7B-17).

Rear A/C System

Condition Possible cause
Rear blower motor does Blown fuse
not operate
Faulty rear blower speed selector
Faulty wiring or grounding
Faulty rear blower motor resistor
Faulty rear blower motor
Foreign material is present
Correction / Reference Item
Check related fuses, and then check for short
circuit to ground.
Check rear blower speed selector. )(Page
7B-86)
Repair or replace wiring as necessary.
Check rear blower motor resistor. )(Page 7B-
85)
Check rear blower motor. )(Page 7B-85)
Remove foreign material.
 HVAC System: Dual A/C Type 7B-65

Condition Possible cause Correction / Reference Item

Cool air does not come Faulty rear expansion valve Check rear expansion valve. )(Page 7B-85)
out or insufficient cooling Clogged or frosted rear evaporator Repair or replace rear cooling unit as
necessary.
Cool air does not come Faulty wiring connection Repair or replace wiring as necessary.
out intermittently Faulty rear expansion valve Check rear expansion valve. )(Page 7B-85)
Cool air does not come Frosted rear evaporator Repair or replace rear cooling unit as
out only at high speed necessary.
Insufficient cool air flow Clogged or frosted rear evaporator Repair or replace rear cooling unit as
necessary.
Faulty rear blower motor Check rear blower motor. )(Page 7B-85)
Faulty wiring or grounding Repair or replace wiring as necessary.

Abnormal Noise Symptom Diagnosis of HVAC System

AENBL80A7224004
Refer to “Abnormal Noise Symptom Diagnosis of HVAC System”: Dual A/C Type (Page 7B-65).

Visual Inspection
AENBL80A7224018
Refer to “Visual Inspection”: Single A/C Type (Page 7B-21).

Inspection of HVAC Control Unit and Its Circuit

AENBL80A7224015
HVAC control unit and its circuits can be checked at HVAC control unit wiring connectors by measuring voltage.

! CAUTION
HVAC control unit can be checked only through connectors. It is strictly prohibited to connect
voltmeter to HVAC control unit with connectors disconnected from it.

Voltage Check
1) Remove HVAC control unit. )(Page 7B-79)
2) Connect G154 connector and G155 connector.
3) Check voltage at each terminal.

NOTE
As each terminal voltage is affected by the battery voltage, confirm that battery voltage is 11 V or more
with ignition “ON”.

2
G154
1
G155
3 2 1
[a] 6 5 4 3 2 1
7 6 5 4
12 11 10 9 8 7
IBL80A722010-01

1. HVAC control unit 2. HVAC control unit connector (View: [a])

Normal
Terminal Wire Color Circuit Condition
Voltage
A/C switch at OFF or A/C switch at
0–1V ON and blower speed selector is at
G154-1 LT GRN Ground for A/C switch any position other than OFF
A/C switch at ON and blower speed
10 – 14 V
selector at OFF
Rear defogger OFF (rear defogger
0–1V
Rear defogger indicator (if indicator OFF)
G154-2 BLK/RED
equipped) Rear defogger ON (rear defogger
10 – 14 V
indicator ON)
G154-3 RED/BLK Ground for illumination Below 0.5 V —
7B-66 HVAC System: Dual A/C Type

Normal
Terminal Wire Color Circuit Condition
Voltage
Air intake switch in “REC” position or
Air intake control actuator 0–1V air intake control actuator operating
G154-5 BLU
(Recirculation air) from “FRE” to “REC”
10 – 14 V Air intake switch in “FRE” position
Air intake switch in “FRE” position or
Air intake control actuator 0–1V air intake control actuator operating
G154-6 GRN/YEL
(Fresh air) from “REC” to “FRE”
10 – 14 V Air intake switch in “REC” position
A/C switch at ON and blower speed
0–1V selector is at any position other than
G154-7 GRN/RED A/C switch signal
OFF position
10 – 14 V A/C switch at OFF
Rear defogger switch signal (if Refer to “Inspection of BCM and Its Circuits” in Section
G154-8 BRN
equipped) 10B (Page 10B-19)
0–1V Lighting switch in OFF position
G154-9 RED/YEL Illumination switch
10 – 14 V Lighting switch in ON position
0–1V Ignition “OFF”
G154-11 RED/WHT Power supply
10 – 14 V Ignition “ON”
G154-12 GRY Ground for HVAC control unit Below 0.5 V —
Ground for blower speed
G155-1 BLK Below 0.5 V —
selector
10 – 14 V Blower speed selector in OFF position
G155-2 RED Blower speed selector (1st)
0–1V Other than above condition
10 – 14 V Blower speed selector in OFF position
Approx 6 V Blower speed selector in 1st position
G155-3 BLU/WHT Blower speed selector (2nd)
Blower speed selector between 2nd
0–1V
and 4th positions
A/C switch OFF or A/C switch ON and
0–1V blower speed selector is at any
G155-5 LT GRN Ground for A/C switch position other than OFF position
A/C switch ON and blower speed
10 – 14 V
selector OFF position
Blower speed selector is at any
10 – 14 V
G155-6 WHT Blower speed selector (4th) position other than 4th position
0–1V Blower speed selector in 4th position
10 – 14 V Blower speed selector in OFF position
Approx 6 V Blower speed selector in 1st position
G155-7 YEL Blower speed selector (3rd) Approx 3 V Blower speed selector in 2nd position
Blower speed selector become 3rd
0–1V
and 4th positions

A/C System Inspection at ECM

AENBL80A7224017
Refer to “A/C System Inspection at ECM”: Single A/C Type (Page 7B-23).

Repair Instructions
Operation Procedure for Refrigerant Charge
AENBL80A7226001
 HVAC System: Dual A/C Type 7B-67

! WARNING

• Handle the HFC-134a (R-134a) refrigerant with care as follows. If not, it may cause severe injury
such as blindness and frostbite.
– Avoid contact with skin and eyes by wearing safety glasses and gloves. In case of contact with
skin or eyes, get medical attention.
– Keep away from fire. High temperature may cause toxic gas. Therefore, take care of much room
ventilation.
– The temperature above 40 °C (104 °F) in the refrigerant container may cause explosion.

! CAUTION

• Do not expose bright metals to liquid refrigerant. Refrigerant combined with moisture is corrosive
and tarnishes the surfaces of bright metals including chrome.
• The specified compressor oil for use with the refrigerant is highly hygroscopic. Keep internal parts
of A/C system free from moisture and dirt. When disconnecting any line from the system, install a
blind plug or cap to the fitting immediately.
• Do not discharge the refrigerant into atmosphere.
• When handling recovery and recycling equipment, be sure to follow the instruction manual for the
equipment.

NOTE
Check local governmental regulations regarding working with refrigerator systems and its tooling.

Start evacuation.
15 minutes (below -100 kPa)
Stop evacuation. Inspect and repair connections.
Wait for 10 minutes
If gauge shows
Check A/C system for abnormal conditions
pressure tightness.

Recharge A/C system with Recharge system with 600 20 g (21.1 0.7 oz) g
refrigerant. of refrigerant.

Check A/C system for refrigerant

leaks and amount of refrigerant
charged.

Performance test
IBL80A722011-01

Recovery
When discharging refrigerant out of A/C system, always recover it using refrigerant recovery and recycling equipment
because discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to environment.
7B-68 HVAC System: Dual A/C Type

NOTE
• After recovering refrigerant from system, the amount of removed compressor oil must be measured
to determine the amount of compressor oil for replenishment.
• When handling recovery and recycling equipment, be sure to follow the instruction manual for the
equipment.

IBL80A722012-01

Replenishing Compressor Oil

It is necessary to replenish A/C compressor with compressor oil to specified amount from A/C compressor suction side
hole (1) before evacuating system and charging it with refrigerant.

[A]

1
1

[B]

IBL80A722014-01

[A]: Petrol model [B]: Diesel model

When charging refrigerant only

When charging refrigerant without replacing any component, replenish A/C compressor with compressor oil of the
same amount measured when recovering refrigerant (if not measured, add 10 cm3 (10 ml, 0.33 US.oz, 0.35 Imp.oz) of
oil).

When replacing A/C compressor

! CAUTION
Be sure to use specified compressor oil or an equivalent compressor oil.
 HVAC System: Dual A/C Type 7B-69

Compressor oil is sealed in each new A/C compressor by the amount required for A/C system. Therefore, when using
a new A/C compressor, drain the calculated amount of oil from it.
“C” = “A” – “B”
“C”: Amount of oil to be drained
“A”: Amount of oil in a new A/C compressor
“B”: Amount of oil in removed A/C compressor

NOTE
A/C compressor assembly supplied from factory is filled up with the following amount of oil.

Petrol model: Compressor oil 95590–58D30 (Compressor oil (ND-OIL8))

Diesel Model: Compressor oil 99000–990C5–00A (Compressor oil (SP10))
Amount of oil in A/C compressor
Petrol model:
120 – 135 cm3 (120 – 135 ml, 4.06 – 4.56 US.oz, 4.22 – 4.75 Imp.oz)
Diesel model:
205 – 235 cm3 (205 – 235 ml, 6.93 – 7.95 US.oz, 7.22 – 8.27 Imp.oz)

1 2

"C"
"A"
"B"

I7V20A720017-01

1. New A/C compressor

2. Removed A/C compressor

When replacing other parts

Replenish A/C compressor with the following amount of oil.
Petrol model
Amount of compressor oil to be replenished
Evaporator: 25 cm3 (25 ml, 0.85 US.oz, 0.88 Imp.oz)
Condenser (with receiver/dryer): 20 cm3 (20 ml, 0.68 US.oz, 0.70 Imp.oz)
Hoses: 5 cm3 (5 ml, 0.17 US.oz, 0.18 Imp.oz) each
Pipes: 5 cm3 (5 ml, 0.17 US.oz, 0.18 Imp.oz) each
Diesel model
Amount of compressor oil to be replenished
Evaporator: 25 cm3 (25 ml, 0.85 US.oz, 0.88 Imp.oz)
Condenser (with receiver/dryer): 35 cm3 (35 ml, 1.18 US.oz, 1.23 Imp.oz)
Hoses: 10 cm3 (10 ml, 0.34 US.oz, 0.35 Imp.oz) each
Pipes: 10 cm3 (10 ml, 0.34 US.oz, 0.35 Imp.oz) each

Evacuation

! CAUTION
Do not evacuate A/C system before recovering refrigerant.
7B-70 HVAC System: Dual A/C Type

NOTE
If A/C system circuit is opened (exposed) to atmosphere, system must be evacuated using a vacuum
pump. The A/C system should be fitted with manifold gauge set, and should be evacuated for
approximately 15 minutes.

1) Connect high pressure charging hose (1) and low pressure charging hose (2) of special tool (manifold gauge set)
as follows:
High pressure charging hose → High pressure charging valve (3) on discharge hose
Low pressure charging hose → Low pressure charging valve (4) on suction pipe
Special tool
(A): 09990–06020
2) Attach center charging hose (5) of manifold gauge set to vacuum pump (6).
3) Operate vacuum pump, and then open discharge side valve (HI) (7) of manifold gauge set.
If there is no blockage in the system, there will be an indication on high pressure gauge (8).
When this occurs, open the other side valve (LO) (9) of the gauge set.
4) Approximately 10 minutes later, low pressure gauge (10) should show a vacuum lower than –100 kPa (–1.0 kgf/
cm2, –760 mmHg, –14.7 psi), indicating that no leakage exists.

NOTE
• If the system does not show a vacuum below –100 kPa (–1.0 kgf/cm2, –760 mmHg, –14.7 psi), close
both valves, stop vacuum pump and watch change in reading of low pressure gauge.
• Increase in gauge reading suggests of leakage. In this case, repair the system before continuing its
evacuation.
• If the gauge shows a stable reading (suggesting no leakage), continue evacuation.

5) Evacuation should be carried out for a total of at least 15 minutes.

6) Continue evacuation until low pressure gauge indicates a vacuum less than –100 kPa (–1.0 kgf/cm2, –760 mmHg,
–14.7 psi), and then close both valves.
7) Stop vacuum pump. Disconnect center charging hose from pump inlet. Now, the system is ready for charging
refrigerant.

(A)
10 5
8

7
9
6

IBL80A722015-01

Checking A/C System for Pressure Leaks

After completing the evacuation, close manifold gauge high pressure valve and low pressure valve and wait for 10
minutes. Verify that low pressure gauge reading has not changed.
 HVAC System: Dual A/C Type 7B-71

! CAUTION
If the gauge reading changes closer to “0”, there is a leak somewhere. Inspect the tubing connections
and make necessary corrections. Evacuate system again and make sure that there are no leaks.

Charge

! CAUTION

• Because the sight glass is not used for this A/C system, do not perform any additional charge to the
A/C system. To charge the system with proper amount of refrigerant, recover the refrigerant and
evacuate the A/C system first. Then charge A/C system with proper amount of refrigerant.
• Always charge the A/C system through the low pressure side after the initial charge is performed
from the high pressure side with the engine stopped.
• Never charge the A/C system through the high pressure side with engine running.
• Do not charge the A/C system while A/C compressor is hot.
• When installing tap valve to refrigerant container to make a hole there through, carefully follow
directions given by manufacturer.
• A pressure gauge should always be used before and during refrigerant charge.
• The refrigerant container should be emptied of refrigerant when discarding it.
• The refrigerant container should not be heated to 40 °C (104 °F) or over.
• Refrigerant container should not be turned upside down during refrigerant charge. Doing so causes
liquid refrigerant to enter A/C compressor, causing troubles, such as compression of liquid
refrigerant.

NOTE
The A/C system contains HFC-134a (R-134a).
Described here is a method for charging the A/C system with refrigerant from the refrigerant service
container.
When charging the system with the refrigerant recovered using the refrigerant recycling equipment,
follow the procedure described in the equipment manufacturer’s instruction manual.

Perform initial charge through high pressure side with the engine stopped.
Next, charge the system with refrigerant as follows from low pressure side with engine running.
1) Check if hoses are routed properly after evacuating system.
2) Connect low charging hose (1) and high charging hose (2) of manifold gauge set (3) in position. Then, open
refrigerant container valve (4) to purge charging line.
3) Open high pressure side valve (5) to charge system with refrigerant.
4) After a while, open low pressure side valve (6) and close high pressure side valve.

! WARNING
Make sure that high pressure side valve is closed securely. Failure to do so may cause explosion of
refrigerant container because high pressure refrigerant way flow back into the container.

5) Start engine and keep engine speed at 1500 r/min, then operate front and rear A/C system.
6) Charge A/C system with vapor refrigerant. At this time, refrigerant container should be held upright.
7B-72 HVAC System: Dual A/C Type

3
4

5
6

IBL80A722016-01

7) When refrigerant container (1) is emptied, use the following procedure to replace it with a new refrigerant
container.
a) Close low pressure valve.
b) Replace empty container with a refrigerant container which has been charged with refrigerant. When using
refrigerant container tap valve (2), use the following procedure for replacement.
i) Turn handle of tap valve counterclockwise to retract needle (3), then remove refrigerant container tap valve
by loosening its plate nut (4).
ii) Install refrigerant container tap valve to new refrigerant container.

I2RH01720018-01

c) Purge any air from center charging hose.

When using refrigerant container tap valve, use the following procedure to purge air.
i) Fully tighten refrigerant container tap valve (1), and then loosen (open) plate nut (2) slightly.
ii) Open low pressure side valve (3) of manifold gauge set (4) a little.
iii) As soon as refrigerant comes out with a “hiss” through a clearance between refrigerant container and tap
valve, tighten plate nut as well as low pressure side valve.
iv) Turn handle of tap valve clockwise so that its needle is screwed into the new container to make a hole for
refrigerant flow.
 HVAC System: Dual A/C Type 7B-73

I2RH01720019-01

8) After the system has been charged with specified amount of refrigerant or when low pressure gauge (1) and high
pressure gauge (2) have indicated the following specified values, close low pressure side valve (3) on manifold
gauge set (4).
Specified amount of refrigerant
600 ± 20 g (21.1 ± 0.7 oz)
Low pressure side and high pressure side example (Petrol model)
Gauges should read as follows when ambient
temperature is 30 °C (86 °F).
Pressure 1220 – 1510 kPa
on high pressure gauge (12.4 – 15.4 kgf/cm2)
(176.9 – 219.0 psi)
Pressure 260 – 370 kPa
on low pressure gauge (2.7 – 3.8 kgf/cm2)
(37.7 – 53.7 psi)

Low pressures side and high pressure side example (Diesel model)
Gauges should read as follows when ambient
temperature is 30 °C (86 °F).
Pressure 1300 – 1580 kPa
on high pressure gauge (13.3 – 16.1 kgf/cm2)
(188.5 – 229.2 psi)
Pressure 240 – 330 kPa
on low pressure gauge (2.4 – 3.4 kgf/cm2)
(34.8 – 47.9 psi)
7B-74 HVAC System: Dual A/C Type

1 2
3

IBL80A722018-01

Removal of Manifold Gauge Set

! WARNING
Be careful not to get injured by refrigerant from high pressure side especially in your eyes and skin.

For A/C system charged with specified amount of refrigerant, remove manifold gauge set as follows:
1) Close low pressure side valve of manifold gauge set. (High pressure side valve has already been closed during
charging process.)
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service valves. This operation must be performed quickly.
5) Put caps on service valves.

Check A/C System for Refrigerant Leaks

Whenever a refrigerant leak is suspected in the system or any service operation has been performed which may result
in malfunction of lines and connections, it is important to perform check for leaks.
Common sense should be used during refrigerant leak test, since the need and extent of any such test will, in general,
depend upon the nature of a complaint and the type of a service performed on the system.

Liquid leak detector

! WARNING

• To prevent explosions and fires, make sure that there are no flammables in the vicinity.
• When the refrigerant is exposed to fire, it turns into a poisonous gas (phosgene). Do not inhale this
gas.

There are a number of fittings and places throughout the A/C system where liquid leak detector solution may be used
to pinpoint refrigerant leaks.
By applying the solution to the area in question with a swab, bubbles will form within seconds if there is a leak.
For connections in such confined areas, as those around evaporator and condenser, electronic (refrigerant) leak
detector is more practical for determining leaks.
Special tool
(A): 09990–86012
 HVAC System: Dual A/C Type 7B-75

(A)

I5RW0A721054-01

A/C System Major Components

AENBL80A7226002
7B-76 HVAC System: Dual A/C Type

Petrol model

OIL
22
OIL 24
22

(e)

25
(d) (d)

(d) 17
20
25
(d)

14
1

18

25 25

1
25
21

19

25

OIL
b 22
22 OIL

2
11 16 (c)
OIL

22

OIL
22
13 (b) 15

OIL
22
OIL

22
c
12

10

OIL
8 22

9
OIL

22 5
a

OIL

22
b 6
OIL

22

7
OIL

22 a
OIL

22

c
OIL

22
23 (a)
OIL

22

7 4

IBL80A722035-02
 HVAC System: Dual A/C Type 7B-77

1. HVAC unit 11. Suction pipe No.2 22. O-ring

: Apply compressor oil.
2. Expansion valve 12. Suction hose No.3 23. A/C refrigerant pressure sensor
3. Condenser with receiver/dryer 13. Suction pipe No.4 24. Rear cooling unit
14. Suction pipe No.5 25. Adhesive tape
: Before installing, bind suction pipe No.5
and drain hoses together with adhesive tape.
4. Radiator cooling fan motor 15. Liquid hose No.2 : 3.5 N⋅m (0.36 kgf-m, 2.5 lbf-ft)
5. A/C compressor 16. Liquid pipe No.3 : 33 N⋅m (3.4 kgf-m, 24.5 lbf-ft)
6. A/C compressor mounting bolt 17. Liquid pipe No.4 : 14 N⋅m (1.4 kgf-m, 10.5 lbf-ft)
: For tightening procedure, refer to “A/C : Before installing, bind liquid pipe No.4 and
Compressor Assembly Removal and Installation”: drain hoses together with adhesive tape.
Dual A/C Type (Page 7B-87).
7. Liquid pipe No.1 18. Drain hose (R) : 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft)
: Before installing, bind suction pipe No.5
and drain hoses together with adhesive tape.
8. Suction hose No.1 19. Lower drain hose (R) : 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)
: Before installing, bind suction pipe No.5
and drain hoses together with adhesive tape.
9. Tension pulley 20. Drain hose (L) : Do not reuse.
: Before installing, bind liquid pipe No.4 and
drain hoses together with adhesive tape.
10. Discharge hose 21. Lower drain hose (L)
: Before installing, bind liquid pipe No.4 and
drain hoses together with adhesive tape.
7B-78 HVAC System: Dual A/C Type

Diesel model

OIL
22
OIL 24
22

(e)

25
(d) (d)

(d) 17
20
25
(d)

14
1

18

25 25

1
25
21

19

25

OIL
b 22
22 OIL

2
11 16 (c)
OIL

22

OIL
22
13 (b) 15

OIL
22
9
OIL

22
c
12

OIL
22

8
OIL

22
10
5 a OIL

b 22
6
OIL

22

7
OIL

a
OIL

22 22

c
OIL

22
23 (a)
OIL

22

7 4

IBL80A722036-02
 HVAC System: Dual A/C Type 7B-79

1. HVAC unit 12. Suction hose No.3 23. A/C refrigerant pressure sensor
2. Expansion valve 13. Suction pipe No.4 24. Rear cooling unit
3. Condenser with receiver/dryer 14. Suction pipe No.5 25. Adhesive tape
: Before installing, bind suction pipe No.5 and
drain hoses together with adhesive tape.
4. Radiator cooling fan motor 15. Liquid hose No.2 : 3.5 N⋅m (0.36 kgf-m, 2.5 lbf-ft)
5. A/C compressor 16. Liquid pipe No.3 : 33 N⋅m (3.4 kgf-m, 24.5 lbf-ft)
6. A/C compressor mounting bolt 17. Liquid pipe No.4 : 14 N⋅m (1.4 kgf-m, 10.5 lbf-ft)
: For tightening procedure, refer to “A/C : Before installing, bind liquid pipe No.4 and
Compressor Assembly Removal and drain hoses together with adhesive tape.
Installation”: Dual A/C Type (Page 7B-
87).
7. Liquid pipe No.1 18. Drain hose (R) : 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft)
: Before installing, bind suction pipe No.5 and
drain hoses together with adhesive tape.
8. Suction hose 19. Lower drain hose (R) : 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)
: Before installing, bind suction pipe No.5 and
drain hoses together with adhesive tape.
9. Suction pipe No.1 20. Drain hose (L) : Do not reuse.
: Before installing, bind liquid pipe No.4 and
drain hoses together with adhesive tape.
10. Discharge hose 21. Lower drain hose (L)
: Before installing, bind liquid pipe No.4 and
drain hoses together with adhesive tape.
11. Suction pipe No.2 22. O-ring
: Apply compressor oil.

Radiator Cooling Fan Removal and Installation
AENBL80A7226003
Refer to “Radiator Cooling Fan Removal and
Installation”: Single A/C Type (Page 7B-30).
Radiator Cooling Fan Inspection
AENBL80A7226004
Refer to “Radiator Cooling Fan Inspection”: Single A/C
Type (Page 7B-30).
Condenser Assembly On-Vehicle Inspection
AENBL80A7226005
Refer to “Condenser Assembly On-Vehicle Inspection”:
Single A/C Type (Page 7B-30).
Condenser Assembly Removal and Installation
AENBL80A7226006
Removal and installation procedure are basically the
same as “Condenser Assembly Removal and
Installation”: Single A/C Type (Page 7B-30), however
note the following points.
• Replenish A/C compressor with compressor oil to
specified amount from A/C compressor suction side
referring to “Replenishing Compressor Oil” in
“Operation Procedure for Refrigerant Charge”: Dual
A/C Type (Page 7B-66).
• Evacuate and charge A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”: Dual A/C Type (Page 7B-66).
Removal and installation procedure are basically the
same as “HVAC Unit Removal and Installation”: Single
A/C Type (Page 7B-32), however note the following
points.
• Replenish A/C compressor with compressor oil to
specified amount from A/C compressor suction side
referring to “Replenishing Compressor Oil” in
“Operation Procedure for Refrigerant Charge”: Dual
A/C Type (Page 7B-66).
• Evacuate and charge the A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”: Dual A/C Type (Page 7B-66).
Blower Motor Removal and Installation
AENBL80A7226009
Refer to “Blower Motor Removal and Installation”: Single
A/C Type (Page 7B-32).
Blower Motor Inspection
AENBL80A7226010
• Check for continuity between two terminals as shown.
If there is no continuity, replace blower motor.

HVAC Unit Components

AENBL80A7226007
Refer to “HVAC Unit Components”: Single A/C Type
(Page 7B-31).
IBP80A721048-01
HVAC Unit Removal and Installation • Check for operation and current
AENBL80A7226008
a. Put blower motor (1) in a soft-jawed vise.
b. Connect battery to blower motor as shown.
7B-80 HVAC System: Dual A/C Type

c. Check if blower motor operates smoothly without

noise.
3
d. Check if ammeter indicates the specified current.
If measured current is out of specification, replace
blower motor.
Blower motor specified current at 12 V
16 A maximum at 20 – 25°C (68 – 77°F)

IBL80A722019-01

3. Expansion valve

3) Remove bolt (1), then remove liquid pipe and suction

hose (pipe) from expansion valve (2).
4) Loosen bolts (3) and remove expansion valve.
IBP80A721043-01

1
Blower Motor Resistor Removal and Installation 3
AENBL80A7226011
Refer to “Blower Motor Resistor Removal and
Installation”: Single A/C Type (Page 7B-33).

Blower Motor Resistor Inspection

AENBL80A7226012 2
2
Refer to “Blower Motor Resistor Inspection”: Single A/C
Type (Page 7B-33). I4RS0A720028-01

Installation
Evaporator Inspection
AENBL80A7226015 Reverse removal procedure, noting the following points.
Refer to “Evaporator Inspection”: Single A/C Type (Page • Apply compressor oil to O-ring of expansion valve and
7B-34). pipes.
Petrol Model: Compressor oil 95590–58D30
Evaporator Temperature Sensor Removal and (Compressor oil (ND-OIL8))
Installation (If Equipped) Diesel Model: Compressor oil 99000–990C5–00A
AENBL80A7226016
Refer to “Evaporator Temperature Sensor Removal and (Compressor oil (SP10))
Installation (If Equipped)”: Single A/C Type (Page 7B- • Tighten expansion valve bolts to specified torque.
34).
Tightening torque
Evaporator Temperature Sensor Inspection (If Expansion valve bolt: 3.5 N·m (0.36 kgf-m, 2.5 lbf-
ft)
Equipped)
AENBL80A7226017
• Evacuate and charge the A/C system referring to
Refer to “Evaporator Temperature Sensor Inspection (If
“Evacuation” and “Charge” in “Operation Procedure
Equipped)”: Single A/C Type (Page 7B-34).
for Refrigerant Charge”: Dual A/C Type (Page 7B-66).

Expansion Valve Removal and Installation

AENBL80A7226018 Expansion Valve Inspection
AENBL80A7226019
Refer to “A/C System Performance Inspection”: Dual A/
Removal
C Type (Page 7B-56).
1) Recover refrigerant from the A/C system with
recovery and recycling equipment referring to
HVAC Control Unit Components
“Recovery” in “Operation Procedure for Refrigerant AENBL80A7226020
Charge”: Dual A/C Type (Page 7B-66). Refer to “HVAC Control Unit Components”: Single A/C
2) Remove bolt (1), then disconnect suction hose (pipe) Type (Page 7B-35).
No.1 (2).
HVAC Control Unit Removal and Installation
AENBL80A7226021
 HVAC System: Dual A/C Type 7B-81

Removal
1) Disconnect negative (–) cable at battery. 4

2) Disable air bag system (if equipped). )(Page 8B-61)

3) Remove instrument panel center upper garnish and
combination meter cluster panel. )(Page 9C-9)
4) Remove audio unit. )(Page 9O-5)
5) Remove passenger air bag (inflator) module.
)(Page 8B-65)
6) Remove floor console front box. )(Page 9H-9) 3

7) Remove center side covers. )(Page 9C-9)

8) Disconnect temperature control cable (1) and airflow
control cable (2) from HVAC unit.

2 1
IBP80A721100-01

b. Move temperature control lever (1) and airflow

control plate (2) fully to the direction of arrow.
1

IBP80A721098-01

9) Disconnect connectors (2) from HVAC control unit.

10) Remove HVAC control unit (1) from instrument
panel. 1

NOTE
Use rag to protect HVAC control unit and
instrument panel from damage.

2
IBP80A721099-01

Installation IBP80A721101-01

Reverse removal procedure noting the following points.
• Connect temperature control cable (3) and air flow
control cable (4) of HVAC control unit to
corresponding links of HVAC unit as follows:
a. Set airflow selector (1) to “VENT” position and
temperature selector (2) to “MAX COOL” position.
c. Fix temperature control inner cable (1) to pin of
temperature control lever and air flow control inner
cable (2) to pin of airflow control plate, and then fix
each outer cable (3) to each cable lock clamp (4).
7B-82 HVAC System: Dual A/C Type
3 Installation
1 Refer to “Air Intake Control Actuator Removal and
4
2 Center Ventilation Louver Removal and
3 Installation
4 AENBL80A7226029
IBP80A721102-01
NOTE
After installing control cables, make sure
that control lever and plate move smoothly
and stop at proper position.
• Make sure that airflow outlet changes correctly as
airflow selector is changed.
• Make sure that outlet temperature changes correctly
as temperature selector is changed.
• Enable air bag system (if equipped). )(Page 8B-61)
Blower Speed Selector Inspection
AENBL80A7226022
Refer to “Blower Speed Selector Inspection”: Single A/C
Type (Page 7B-37).
A/C Refrigerant Pressure Sensor and Its Circuit
Inspection
AENBL80A7226023
Refer to “A/C Refrigerant Pressure Sensor and Its Circuit
Inspection”: Single A/C Type (Page 7B-37).
A/C Refrigerant Pressure Sensor Removal and
Installation
AENBL80A7226024
Removal and installation procedure are basically the
same as “A/C Refrigerant Pressure Sensor Removal
and Installation”: Single A/C Type (Page 7B-38),
however note the following point.
• Evacuate and charge A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”: Dual A/C Type (Page 7B-66).
Air Intake Switch Inspection
AENBL80A7226025
Refer to “Air Intake Switch Inspection”: Single A/C Type
(Page 7B-39).
Air Intake Control Actuator Removal and
AENBL80A7226026
Installation”: Single A/C Type (Page 7B-39).
Air Intake Control Actuator Inspection
AENBL80A7226027
Refer to “Air Intake Control Actuator Inspection”: Single
A/C Type (Page 7B-40).
Actuator Linkage Inspection
AENBL80A7226028
Refer to “Actuator Linkage Inspection”: Single A/C Type
(Page 7B-40).
Refer to “Center Ventilation Louver Removal and
Installation”: Single A/C Type (Page 7B-40).
Side Ventilation Louver Removal and
Installation
AENBL80A7226030
Removal
1) Disconnect negative (–) cable at battery.
2) Passenger side: Disable air bag system (if
equipped). )(Page 8B-61)
3) Driver side: Remove combination meter cluster
panel from instrument panel. )(Page 9C-9)
Passenger side: Remove passenger air bag (inflator)
module. )(Page 8B-65)
4) Remove side ventilation louver from instrument
panel. )(Page 9C-9)
5) Release tabs (1) and then separate side demister
nozzle (2) from instrument panel side garnish (3).
6) Release tabs (4) and then separate side ventilation
louver (5) from instrument panel side garnish (3).
NOTE
Side demister nozzle and side ventilation
louver are fitted to instrument panel side
garnish with six clips.
When removing nozzle and louver from
instrument panel side garnish, be careful not
to break them.
 HVAC System: Dual A/C Type 7B-83

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

4
3

IBP80A721113-01
8
Installation 2 12
Reverse removal procedure noting the following point.
• Enable air bag system (if equipped). )(Page 8B-61) IBL80A722021-01

A/C Switch Inspection Rear Cooling Unit Removal and Installation

AENBL80A7226034
Refer to “A/C Switch Inspection”: Single A/C Type (Page
7B-41).
Rear Defogger Switch Inspection (If Equipped)
AENBL80A7226048
Check rear defogger switch for terminal-to-terminal
continuity. If check result is not as specified, replace
HVAC control unit.
NOTE
To perform measurement with rear defogger
indicator, use diode range of circuit tester.
AENBL80A7226049
Removal
1) Recover refrigerant from the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”: Dual A/C Type (Page 7B-66).
2) Disconnect negative (–) cable at battery.
3) Remove rear ventilation louver garnish (1) by pulling
it and disconnect rear blower speed selector
connector.

Rear defogger switch continuity

Terminal
8 12 2
Position
1
OFF IBL80A722022-01

4) Remove head lining. )(Page 9H-7)

ON 5) Disconnect rear cooling unit connector.
6) Disconnect suction pipe No.5 (1), liquid pipe No.4 (2)
IBL80A722020-01
and drain hoses (3) from rear cooling unit.
7B-84 HVAC System: Dual A/C Type

[A]
[A]

[B]

[B]

3
IBL80A722024-01
IBL80A722023-01
[A]: Right side [B]: Left side
[A]: Right side [B]: Left side

7) Remove rear cooling unit (1). Installation

! CAUTION
Do not disassemble rear cooling unit. If any
repair is required on rear cooling unit,
replace it as assembly.
Reverse removal procedure, noting the following points.
• Apply compressor oil to new O-ring of suction pipe
No.5 and liquid pipe No.4.
Petrol model: Compressor oil 95590–58D30
(Compressor oil (ND-OIL8))
Diesel model: Compressor oil 99000–990C5–00A
(Compressor oil (SP10))
• Replenish A/C compressor with compressor oil to
specified amount from A/C compressor suction side
referring to “Replenishing Compressor Oil” in
“Operation Procedure for Refrigerant Charge”: Dual
A/C Type (Page 7B-66).
• Tighten rear cooling unit bolts to specified torque.
Tightening torque
Rear cooling unit bolt (a): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)
 HVAC System: Dual A/C Type 7B-85

Rear Blower Motor

[A] • Check resistance between terminal “2” of rear blower
speed selector connector and terminal “2” of rear
cooling unit connector as shown.
If there is no continuity, replace rear cooling unit.

(a)

(a)

(a)
1 2 1 2
3 4 1 2
[B]
[a] [a]

IBL80A722026-01

(a) 1. Rear blower speed selector connector (View: [a])

2. Rear cooling unit connector (View: [a])

• Check blower motor for operation and current.

a. Connect lead wire from battery positive (+)
(a) terminal to terminal “2” of rear cooling unit
IBL80A722025-01 connector. Connect lead wire from battery
negative (–) terminal to terminal “2” of rear blower
[A]: Right side [B]: Left side
speed selector connector.
• Tighten liquid pipe No.4 bolt to specified torque. b. Check if blower motor operates smoothly without
noise.
Tightening torque
c. Check that the ammeter indicates specified
Liquid pipe No.4 bolt (b): 5.5 N·m (0.56 kgf-m, 4.0
current when the voltage is applied for 1 min.
lbf-ft)
If check result is not as specified, replace rear
cooling unit.
Rear blower motor specified current at 13.5 V
3.3 A maximum at 20 – 25 °C (68 – 77 °F)

(b)
IBL80A722037-01

• Evacuate and charge the A/C system referring to

“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”: Dual A/C Type (Page 7B-66).

Rear Cooling Unit Inspection

AENBL80A7226050
7B-86 HVAC System: Dual A/C Type

Removal
1) Disconnect negative (–) cable at battery.
2) Remove rear ventilation louver garnish (1) by pulling
it and disconnect rear blower speed selector
connector.

1
IBL80A722029-01
1 2 1 2
3 4 2 3) Pull out rear blower speed selector knob (1), and
1
then remove rear blower speed selector (2) from rear
[a] [a] ventilation louver.
IBL80A722027-01
1
1. Rear blower speed selector connector (View: [a])
2. Rear cooling unit connector (View: [a])

Rear Blower Motor Resistor

1) Disconnect rear blower motor resistor connector.
2) Measure each terminal-to-terminal resistance.
If measured resistance is out of specification,
replace rear cooling unit.
Rear blower motor resistor resistance
“H” – “M”: Approximately 4.7 Ω at 20 – 25 °C (68
– 77 °F)
“M” – “L”: Approximately 4.3 Ω at 20 – 25 °C (68 2
IBL80A722030-01
– 77 °F)
Installation
Reverse removal procedure.

Rear Blower Speed Selector Inspection

AENBL80A7226052
Check rear blower speed selector for terminal-to-
terminal continuity.
If check result is not as specified, replace rear blower
speed selector.
Rear blower speed selector continuity

Terminal
3 4 1 2
Position

OFF
M
1
L H
2
IBL80A722028-01 3
IBL80A722031-01
Rear Expansion Valve Inspection
Refer to “A/C System Performance Inspection”: Dual A/
C Type (Page 7B-56).

Rear Blower Speed Selector Removal and

Installation
AENBL80A7226051
 HVAC System: Dual A/C Type 7B-87

1
1 2 2
3 4

3 IBL80A722034-01
4
1
2 HVAC System Relay Inspection
AENBL80A7226035
IBL80A722032-02 Refer to “HVAC System Relay Inspection”: Single A/C
Type (Page 7B-41).
Rear Ventilation Louver Removal and
Installation A/C Compressor Drive Belt Inspection and
AENBL80A7226053
Removal Adjustment
AENBL80A7226036
1) Disconnect negative (–) cable at battery. Refer to “A/C Compressor Drive Belt Inspection and
2) Remove rear ventilation louver garnish (1) by pulling Adjustment”: Single A/C Type (Page 7B-42).
it and disconnect rear blower speed selector
connector. A/C Compressor Drive Belt Removal and
Installation
AENBL80A7226037
Refer to “A/C Compressor Drive Belt Removal and
Installation”: Single A/C Type (Page 7B-42).

A/C Compressor Assembly Removal and

1 Removal and installation procedure are basically the
IBL80A722033-01
3) To remove rear ventilation louver, expand opening
between rear ventilation louver (1) and rear
ventilation louver garnish (2) using a flat-bladed
screwdriver (3) or the like, then push it out in
direction of arrow.
Installation
AENBL80A7226038
same as “A/C Compressor Assembly Removal and
Installation”: Single A/C Type (Page 7B-42), however
note the following points.
• If A/C compressor is replaced, pour new compressor
oil referring to “Replenishing Compressor Oil” in
“Operation Procedure for Refrigerant Charge”: Dual
A/C Type (Page 7B-66).
• Evacuate and charge A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”: Dual A/C Type (Page 7B-66).

A/C Compressor Assembly Components

AENBL80A7226039
Petrol model: Refer to “A/C Compressor Assembly
Components (Petrol Model)”: Single A/C Type (Page 7B-
43).
Diesel model: Refer to “A/C Compressor Assembly
Components (Diesel Model)”: Single A/C Type (Page
7B-44).
7B-88 HVAC System: Dual A/C Type

Magnet Clutch Inspection Relief Valve Removal and Installation (Petrol

AENBL80A7226040
Refer to “Magnet Clutch Inspection”: Single A/C Type
Model)
AENBL80A7226043
(Page 7B-44). Removal and installation procedure are basically the
same as “Relief Valve Removal and Installation (Petrol
Magnet Clutch Removal and Installation Model)”: Single A/C Type (Page 7B-46), however note
AENBL80A7226044 the following point.
Refer to “Magnet Clutch Removal and Installation”:
• Evacuate and charge the A/C system referring to
Single A/C Type (Page 7B-45).
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”: Dual A/C Type (Page 7B-66).
Relief Valve Inspection
AENBL80A7226042
Refer to “Relief Valve Inspection”: Single A/C Type
(Page 7B-46).

Specifications
Tightening Torque Specifications
AENBL80A7227001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Expansion valve bolt 3.5 0.36 2.5 )
Rear cooling unit bolt 10 1.0 7.5 )
Liquid pipe No.4 bolt 5.5 0.56 4.0 )

NOTE
The tightening torque(s) also specified in:
“A/C System Major Components”: Dual A/C Type

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Recommended Service Material
AENBL80A7228001
Material SUZUKI recommended product or Specification Note
Compressor oil Compressor oil (ND-OIL8) P/No.: 95590–58D30 )/)/)
Compressor oil (SP10) P/No.: )/)/)
99000–990C5–00A

NOTE
Required service material(s) also described in:
“A/C System Major Components”: Dual A/C Type

Special Tool
AENBL80A7228002
09990–06020 09990–86012
Manifold gauge set (R134a) Gas leak detector 2
1
1. Manifold gauge 2. This kit includes following
Charging hoses 3. Quick items. 1. Gas leak detector,
connector 4. Refrigerant 2. Instruction manual, 3. 5
container tap valve 5. Filter, 4. Sensor, 5. Dry-cell
Refrigerant container T joint battery (size D)) 3 4
6. Packing sets 7. Case) /
)

Section 8
Restraint
CONTENTS
Precautions .................................................8-1
Precautions............................................................. 8-1
Precautions for Restraint ...................................... 8-1
Seat Belts ................................................. 8A-1
Precautions...........................................................8A-1
Precautions for Service and Diagnosis of Seat
Belt.................................................................... 8A-1
General Description .............................................8A-2
Seat Belt Construction ........................................ 8A-2
Diagnostic Information and Procedures............8A-3
Repair and Inspection Required after
Accident ............................................................ 8A-3
Repair Instructions ..............................................8A-3
Front Seat Belt Components............................... 8A-3
Front Seat Belt Assembly Removal and
Installation......................................................... 8A-4
Front Seat Belt Assembly Inspection .................. 8A-6
Front Seat Belt Buckle Inspection ....................... 8A-8
2nd Row Seat Belt Components ......................... 8A-8
2nd Row Seat Belt Assembly Removal and
Installation......................................................... 8A-9
2nd Row Center Seat Belt Removal and
Installation....................................................... 8A-10
3rd Row Seat Belt Components........................ 8A-10
3rd Row Seat Belt Assembly Removal and
Installation....................................................... 8A-10
2nd Row and 3rd Row Rear Seat Belt
Assembly Inspection ....................................... 8A-11
2nd Row and 3rd Row Seat Belt Buckle
Inspection........................................................ 8A-11
Specifications.....................................................8A-12
Tightening Torque Specifications...................... 8A-12
Special Tools and Equipment ...........................8A-12
Special Tool ...................................................... 8A-12
Air Bag System ........................................ 8B-1
Precautions...........................................................8B-1
Precautions for Air Bag System Service ............. 8B-1
Precautions for Handling and Storage of Air
Bag System Components ................................. 8B-1
Precautions for Disposal of Air Bag and Seat
Belt Pretensioner .............................................. 8B-3
General Description .............................................8B-3
Table of Contents 8- i
Air Bag System Construction ..............................8B-3
Schematic and Routing Diagram ........................8B-4
Air Bag System Input / Output Diagram ..............8B-4
Air Bag System Circuit Diagram..........................8B-4
Component Location ...........................................8B-5
Air Bag System Component, Wiring and
Connector Location ...........................................8B-5
Diagnostic Information and Procedures ............8B-6
Air Bag Diagnostic System Check ......................8B-6
Visual Inspection .................................................8B-7
“AIR BAG” Warning Light Check.........................8B-7
Self Diagnosis Function ......................................8B-8
DTC Check..........................................................8B-8
DTC Clearance ...................................................8B-8
DTC Table...........................................................8B-9
Scan Tool Data .................................................8B-10
“AIR BAG” Warning Light Comes ON Steady ...8B-11
“AIR BAG” Warning Light Does Not Come ON ..8B-12
DTC B1011 .......................................................8B-13
DTC B1012 .......................................................8B-13
DTC B1013 .......................................................8B-14
DTC B1016 .......................................................8B-14
DTC B1017 .......................................................8B-16
DTC B1021 / B1026 ..........................................8B-16
DTC B1031 .......................................................8B-17
DTC B1032 .......................................................8B-19
DTC B1033 .......................................................8B-22 8
DTC B1034 .......................................................8B-24
DTC B1041 .......................................................8B-27
DTC B1042 .......................................................8B-31
DTC B1043 .......................................................8B-34
DTC B1044 .......................................................8B-36
DTC B1051 / B1055 ..........................................8B-38
DTC B1052 / B1056 ..........................................8B-41
DTC B1053 / B1057 ..........................................8B-43
DTC B1054 / B1058 ..........................................8B-45
DTC B1071 / B1072 ..........................................8B-48
DTC B1073 / B1074 ..........................................8B-49
DTC U0073 .......................................................8B-53
SDM Power Supply and Ground Circuit
Check ..............................................................8B-53
Contact Coil and Its Circuit Check ....................8B-55
Repair and Inspection Required after
Accident ..........................................................8B-58
Repair Instructions ............................................8B-60
8-ii Table of Contents
Disabling Air Bag System.................................. 8B-60
Enabling Air Bag System .................................. 8B-60
SDM Removal and Installation.......................... 8B-60
SDM Inspection................................................. 8B-61
Driver Air Bag (Inflator) Module Removal and
Installation ....................................................... 8B-62
Driver Air Bag (Inflator) Module Inspection ....... 8B-63
Passenger Air Bag (Inflator) Module Removal
and Installation ................................................ 8B-64
Passenger Air Bag (Inflator) Module
Inspection........................................................ 8B-65
Seat Belt Pretensioner Components................. 8B-65
Seat Belt Pretensioner Removal and
Installation ....................................................... 8B-65
Seat Belt Pretensioner Inspection.....................8B-65
Forward Impact Sensor Removal and
Installation .......................................................8B-66
Forward Impact Sensor Inspection ...................8B-66
Air Bag (Inflator) Module and Seat Belt
Pretensioner Disposal .....................................8B-67
Deployed Air Bag (Inflator) Module and
Activated Seat Belt Pretensioner Disposal......8B-72
Specifications .....................................................8B-73
Tightening Torque Specifications......................8B-73
Special Tools and Equipment ...........................8B-73
Use of Special Tools .........................................8B-73
Special Tool ......................................................8B-74
 Precautions: 8-1

Precautions
Restraint

Precautions
Precautions for Restraint
AENBL80A8000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Fastener Caution
Refer to “Fastener Caution” in Section 00 (Page 00-5).

Air Bag Warning

Refer to “Air Bag Warning” in Section 00 (Page 00-5).

Precautions for Vehicle Equipped with Supplemental Restraint (Air Bag) System
Refer to “Air Bag Warning” in Section 00 (Page 00-5).

Reassembling Note for Wiring Harness

Be sure to observe the Wiring Diagram Manual whenever installing wiring whenever installing wiring harness.
Otherwise, electrical trouble may occur.

Precautions for CAN Communication System

Refer to “Precautions for CAN Communication System” in Section 00 (Page 00-8).
8A-1 Seat Belts:
Seat Belts
Restraint
Precautions
Precautions for Service and Diagnosis of Seat
Belt
AENBL80A8100001
! WARNING
If replacing seat belt assembly is necessary,
replace buckle and seat belt assembly
together. This is essential to correct locking
of tongue plate in buckle. For this reason,
SUZUKI will supply spare buckle and seat
belt assembly only as a set.
! CAUTION
For vehicle with air bags, do not reuse the
seat belt pretensioner (retractor) that has
activated. Replace them with new front seat
belt assembly and buckle together as a set.
For checking procedure of the activation,
refer to “Repair and Inspection Required after
Accident” in Section 8B (Page 8B-58).
Before servicing or replacing seat belt assembly, refer to
the following precautionary items.
• Be sure to check if tongue plate and buckle are
normal.
• Keep sharp edges and damaging objects away from
webbing.
• Never bend or damage buckle and tongue plate.
• Do not bleach or dye webbing. (Use only mild soap
and lukewarm water to clean it.)
• When installing a seat belt anchor bolt, first tighten it
by hand to prevent cross-threading and then tighten to
the specified torque.
• Do not attempt any repair on seat belt assembly. If
any fault is found, replace the seat belt as an
assembly.
• Keep belts dry and clean at all times.
• Any defective part must be replaced with a new one.
• Replace seat belt assembly whose webbing is cut or
damaged.
• Do not put anything into trim panel opening which seat
belt webbing passes through.
• After an accident, whether the seat belt pretensioner
has been activated or not, be sure to perform checks
and repairs described on “Repair and Inspection
Required after Accident” in Section 8B (Page 8B-58).
 Seat Belts: 8A-2

General Description
Seat Belt Construction
AENBL80A8101001

3 10 5
1

13

15
2

9
14
11
12
8

15
IBL80A810001-01

1. Driver front seat belt assembly (with ELR)
2. Driver seat belt pretensioner (if equipped)
3. Passenger front seat belt assembly (with ELR)
4. Passenger seat belt pretensioner (if equipped)
5. Buckle for front seat belt
6. Right side 2nd row seat belt assembly
(with ELR)
7. Left side 2nd row seat belt assembly (with
ELR)
8. Buckle for 2nd row seat belt
9. Retractor for 2nd row seat belt
10. 2nd row center seat belt assembly
11. Buckle for 2nd row center seat belt
12. Right side 3rd row seat belt assembly
(with ELR)
13. Left side 3rd row seat belt assembly
(with ELR)
14. Buckle for 3rd row seat belt
15. Retractor for 3rd row seat belt

Seat Belt Assembly with ELR driver and passenger air bag (inflator) modules, when an
Seat belt assembly with emergency locking retractor impact at the front of vehicle exceeds the specified
(ELR) is designed so that it locks immediately to prevent value.
the webbing from being pulled out of the retractor any When servicing front seat belt assembly, be sure to
further when any of the following items are detected as observe all WARNINGs and CAUTIONs and
exceeding each set value: “Precautions for Air Bag System Service” in Section 8B
• Speed at which the webbing is pulled out of the (Page 8B-1).
retractor.
Seat Belt Reminder
• Acceleration or deceleration of vehicle speed.
When driver seat belt is unfastened, seat belt reminder
• Inclination. light located in combination meter flashes to warn the
driver.
Seat Belt Assembly with ELR and Pretensioner
The seat belt assembly with ELR and a pretensioner has
a pretensioner mechanism which operates in linkage
with the air bag in addition to the described ELR.
The pretensioner is incorporated in retractor and
controlled by SDM as one of air bag system
components. It will be activated at the same time as the
8A-3 Seat Belts:

Diagnostic Information and Procedures

Repair and Inspection Required after Accident
AENBL80A8104001
After an accident, whether the seat belt pretensioner has activated or not, be sure to perform checks and repairs
referring to “Repair and Inspection Required after Accident” in Section 8B (Page 8B-58).

Repair Instructions
Front Seat Belt Components
AENBL80A8106001
! WARNING
Tighten buckle to specified torque and then check that it can be moved backward and forward.
Otherwise, the front seat belt may not work properly and cause injury in case of a collision.

! CAUTION
The figure shows the driver’s seat belt. The tightening torque for the passenger’s seat belt bolts and
screw are the same.
 Seat Belts: 8A-4

[A]
6

“5” (a)

[B]

“1” (a)

“2” (a)
4

“4” (b)
“5” (a)

“3” (a)
2
“6” (a)

(a)

IBL80A810002-01

[A]: For vehicle without shoulder adjuster 4. Cover

[B]: For vehicle with shoulder adjuster 5. Center pillar upper trim
1. Shoulder adjuster 6. Anchor bracket
Tighten bolts in numerical order (“1” to “2”).
2. Seat belt assembly : 43 N⋅m (4.4 kgf-m, 32.0 lbf-ft)
Tighten bolts and screw in numerical order (“3” to “6”).
3. Buckle : 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)

Front Seat Belt Assembly Removal and

Installation
AENBL80A8106002
8A-5 Seat Belts:

! WARNING
Never attempt to disassemble or repair the
1
seat belt pretensioner. If any abnormality is
found, be sure to replace it with new one as
an assembly.
Be sure to read “Precautions for Service and
Diagnosis of Seat Belt” (Page 8A-1) before
starting to work and observe every 2
precaution during work. Neglecting them
may result in personal injury or inactivation
of the seat belt pretensioner when necessary.

Removal

NOTE
For vehicle with air bags, refer to “Repair and
Inspection Required after Accident” in 3
IBP80A810009-01
Section 8B (Page 8B-58) before replacing an
activated pretensioner. • Tighten bolts and screw of front seat belt assembly in
the numerical order to specified torque referring to the
1) Disconnect negative (–) cable at battery. following procedure. )(Page 8A-3)
2) For vehicle with air bags, disable air bag system. • Tighten seat belt bolt (1) using special tool to specified
)(Page 8B-60) torque.
3) Remove center pillar lower trim. )(Page 9H-6) Special tool
4) For vehicle with air bags, disconnect connector (1) (A): 09945–25710
from seat belt pretensioner (2) as shown in figure. Tightening torque
a) Release lock (3). Seat belt bolt (a): 43 N·m (4.4 kgf-m, 32.0 lbf-ft)
b) Disconnect connector (1).
! CAUTION
When using special tool (extension) with
3
torque wrench, the value indicated on the
“1”
torque wrench is smaller than the actually
applied torque. Use the following formula
and calculate the value to be indicated on the
“2”
1
torque wrench to correctly apply the
specified tightening torque.

2 Formula
M = T X L / (L +“a”)
• M: Torque wrench reading
• T: Specified torque
• L: Torque wrench length
1
• “a”: Special tool length
IBP80A810004-01

5) Turn over floor carpet.

6) Remove screw and bolts of front seat belt assembly.
7) Remove front seat belt assembly.

Installation
Reverse removal procedure, noting the following points.
• Check that pins (3) on body panel are inserted in long
holes (2) on retractor (1).
 Seat Belts: 8A-6

Front Seat Belt Assembly Inspection

L “a” AENBL80A8106003

! WARNING

• For vehicle without air bag, be sure to read

(A) “Precautions for Service and Diagnosis of
Seat Belt” (Page 8A-1), before starting to
work and observe every precaution during
work.
Neglecting them may result in personal
injury.
• For vehicle with air bags, pay attention to
the following points
– Never attempt to disassemble the seat
belt pretensioner. If any abnormality is
found, replace it with new one as seat
belt assembly.
(A) – Be sure to read “Precautions for Service
1, (a) and Diagnosis of Seat Belt” (Page 8A-1),
IBL80A810003-02
before starting to work and observe
“a”: 50 mm (1.97 in) every precaution during work.
Neglecting them may result in personal
• For vehicle with air bags, connect connector (2) to injury or inactivation of the seat belt
seat belt pretensioner (1) as follows. pretensioner when necessary.
a. Connect connector (2) to seat belt pretensioner – Never measure resistance of seat belt
with lock (3) released. pretensioner or disassemble it.
b. Press lock button (3) to lock connector securely. Otherwise, personal injury may result.

“2”

“1”
2

I9P60A810006-01

– When placing a live seat belt

2
pretensioner on a workbench or other
surface, do not lay it with its exhaust
IBP80A810005-01
hole side (1) facing down. Never place
anything above the exhaust hole nor
• For vehicle with air bags, enable air bag system.
stack seat belt pretensioners.
)(Page 8B-60)
Otherwise, personal injury may result.
8A-7 Seat Belts:

2
I9P60A810008-01
IBP80A810010-01
1. Webbing 2. Seat belt pretensioner

! CAUTION Front Seat Belt Buckle Inspection

For vehicle with air bags, carefully handle
seat belt pretensioner so as not to drop it or
give impact to it. If it was dropped, replace
with a new one even if there is no abnormal
appearance. Also replace with a new one if
any abnormality is found.
AENBL80A8106004
Belt Latch
• It should be securely locked when tongue plate (2) is
latched.
• Lock should be released by pressing release button
(3) when tongue plate (2) is latched to buckle (1).

Seat belts and attaching parts can affect the vital

components and systems of vehicle. 2
Therefore, they should be inspected carefully and
replaced with genuine parts only. 3

Webbing
• Check that webbing is not damaged.

Seat Belt Pretensioner 1

I8T201810005-01
1) Confirm the following points.
• Let the seat belt retract fully to confirm its easy Seat Belt Buckle Switch
retraction. 1) Disconnect seat belt buckle switch connector (1).
• Retractor should lock webbing when pulled 2) Check continuity between terminal 1 and 2 of seat
quickly. belt buckle switch connector.
• Retractor should lock webbing when tilted forward
and backward, and leftward and rightward.
2) Replace seat belt assembly with new one if any of
the following symptom is found.
• Pretensioner has activated.
• There is a crack in seat belt pretensioner
(retractor).
• Seat belt pretensioner (retractor) is damaged or a
strong impact (e.g. dropping) was applied to it.

1
1 2

IBP80A810011-01
 Seat Belts: 8A-8

Seat belt buckle switch continuity

Terminal
1 2
Seat belt status
Unlatched

Latched
I9P60A810010-01

2nd Row Seat Belt Components

AENBL80A8106005
NOTE
The figure shows left side 2nd row seat belt and 2nd row center seat belt. Right side 2nd row seat belt
is the same as the left side 2nd row seat belt.

“4” (b)

“2” (a)

(a)
(a) “1” (a)

3 “3” (a)

2
3 4
IBL80A810004-01

1. 2nd row seat belt assembly 4. Buckle for 2nd row center seat belt
Tighten bolts and screw in numerical order (“1” to “4”).
2. 2nd row center seat belt : 43 N⋅m (4.4 kgf-m, 32.0 lbf-ft)
3. Buckle for 2nd row seat belt : 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)

2nd Row Seat Belt Assembly Removal and Installation

Installation Reverse removal procedure, noting the following points.
AENBL80A8106006
• Check that pins (3) on body panel are inserted in long
Removal
holes (2) in retractor (1).
1) Remove rear quarter inner lower trim. )(Page 9H-6)
2) For removal of left side seat belt buckle, remove
reclining inside left cover.
3) For removal of right side seat belt buckle, remove
right side 2nd seat cushion assembly.
4) Remove screw and bolts and then remove 2nd row
seat belt assembly. )(Page 8A-8)
8A-9 Seat Belts:

I8C50A810008-01

1
2nd Row Center Seat Belt Removal and
2 Installation
3 AENBL80A8106007
Removal
IBL80A810005-01

• Tighten bolts and screw of 2nd row seat belt in 1) Remove right side 2nd row seat cushion assembly.
numerical order to specified torque. )(Page 8A-8) 2) Remove reclining inside right cover.
• Install anchor plate (1) without putting on bead (2) on 3) Remove bolts and then remove 2nd row center seat
floor paneling. belt assembly. )(Page 8A-8)

NOTE
This installing manner i.e. not putting the
anchor plate on the bead is applied to the
right side seat belt buckle.
Installation
Reverse removal procedure, noting the following points.
• Tighten bolts of 2nd row center seat belt to specified
torque. )(Page 8A-8)
• Install anchor plate without putting on bead on rear
right adjuster assembly.
 Seat Belts: 8A-10

3rd Row Seat Belt Components

AENBL80A8106010

“3” (a)

1
1

“2” (b)

“2” (b)
(a)

“1” (a)

“1” (a)

“4” (a)
2

“4” (a)

IBL80A810006-01

1. 3rd row seat belt assembly : 43 N⋅m (4.4 kgf-m, 32.0 lbf-ft)
Tighten bolts and screw in numerical order (“1” to “4”).
2. Buckle for 3rd row seat belt : 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)

3rd Row Seat Belt Assembly Removal and

Installation
AENBL80A8106011
1
Removal
1) Remove 3rd row seat.
2) Remove rear quarter inner lower trim. )(Page 9H-6)
3) Remove screw and bolts and then remove 3rd row 2 2
seat belt assembly. )(Page 8A-10)

Installation
Reverse removal procedure, noting the following points. 3
• Check that pins (3) on body panel are inserted in long
holes (2) in retractor (1).
IBL80A810007-01

• Tighten bolts and screw of 3rd row seat belt in

numerical order to specified torque. )(Page 8A-10)
• Install each anchor plate (1) without putting on bead
(2) on floor paneling.
8A-11 Seat Belts:

Retractor
• Retractor should lock webbing when pulled quickly.
• Retractor should lock webbing when tilted forward and
backward, and leftward and rightward.
1
1

2nd Row and 3rd Row Seat Belt Buckle

Inspection
AENBL80A8106009
2 Belt latch
2 Lock should be released by pressing release button (3)
when tongue plate (2) is latched to buckle (1).

IBL80A810008-01
2
2nd Row and 3rd Row Rear Seat Belt Assembly
Inspection 3
AENBL80A8106008
Seat belts and attaching parts can affect the vital
components and systems of vehicle.
Therefore, they should be inspected carefully and
replaced with genuine parts only.
1
I8T201810005-01
Webbing
Check that webbing is not damaged.

Specifications
Tightening Torque Specifications
AENBL80A8107001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Seat belt bolt 43 4.4 32.0 )

NOTE
The tightening torque(s) also specified in:
“Front Seat Belt Components”:
“2nd Row Seat Belt Components”:
“3rd Row Seat Belt Components”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Special Tool
AENBL80A8108001
09945–25710
Torque wrench adaptor
)
8B-1 Air Bag System:

Air Bag System

Restraint

Precautions
Precautions for Air Bag System Service
AENBL80A8200001
! WARNING
When performing service on or around air
bag system components or air bag wiring,
follow the procedures listed in “Disabling Air
Bag System” (Page 8B-60) to temporarily
disable the air bag system.
Failure to follow procedures could result in
possible air bag system activation, personal
injury or unneeded air bag system repairs.
• When storing air bag system components, select a
place where the ambient temperature is below 65 °C
(149 °F).
• When applying paint around the air bag system
related parts, be careful that the harness or connector
will not be exposed to the paint mist.
! CAUTION
• If abnormality is found in a live
(undeployed) air bag (inflator) module, be
sure to deploy it before disposing it.
• When connecting connectors with a
locking mechanism, be sure to lock them
firmly. Improper locking may cause the
connection detection pin to turn on the
“AIR BAG” warning light.
• When conducting continuity check of
wiring harness or removal check of
connectors, be sure to use the special tool
(A). Since terminals are chrome-plated to
improve the electric conductivity, the
direct contact of tester probe with
terminals may peel off the plating causing
a loss of reliability.

Special tool
Precautions for Handling and Storage of Air
(A): 09932–76010
Bag System Components
AENBL80A8200002
! WARNING

• Never attempt to insert foreign matter such

as flat-end screwdriver into the connector
of air bag (inflator) module or seat belt
pretensioner, as static electricity may
(A)
cause accidental deployment.
• Never attempt to disassemble the air bag
(inflator) module. If any abnormality is
(A)
found, replace it with new one as an
assembly.
I8T201821003-02

SDM

! CAUTION
Never use SDM which has detected a
condition that meets any of the deployment
conditions. Refer to “Air Bag Diagnostic
System Check” (Page 8B-7) when checking
SDM.

IAP70P821001-01
 Air Bag System: 8B-2

Live (Inactivated) Seat Belt Pretensioner

! WARNING

• Never carry a seat belt pretensioner by

holding the webbing.
• When placing a live seat belt pretensioner
on a workbench or other surface, do not
lay it with its exhaust hole side (1) facing
down. Never place anything above the
exhaust hole nor stack seat belt
pretensioners.

I9W10P821061-01

• If SDM installation part of floor is damaged, repair it

IBP80A820035-01
completely before reinstallation.
Otherwise, personal injury may result.
• All SDM and mounting bracket fasteners must be
carefully tightened to specification and the arrow on
Special care is necessary when handling and storing a
SDM must be pointed toward the front of the vehicle
live (inactivated) pretensioner. Accidental activation of
to ensure proper operation of the air bag system.
pretensioner will cause high pressure gas to blow off
from the exhaust hole and retract the webbing (1) quickly
Live (Undeployed) Air Bag (Inflator) Modules
into the retractor assembly (2). These actions may throw
Special care is necessary when handling and storing live
the pretensioner itself or objects around it in the air.
(undeployed) air bag (inflator) modules. Accidental
deployment of air bag (inflator) module could throw itself
or objects around it in the air.

2
I9P60A820003-01

Deployed Air Bag (Inflator) Module and Activated

Seat Belt Pretensioner
Refer to “Deployed Air Bag (Inflator) Module and
IBP80A820001-01 Activated Seat Belt Pretensioner Disposal” (Page 8B-
72).

Air Bag Wire Harness and Connector

Air bag wire harness includes in main harness (1),
instrument panel harness (2) and floor harness (3). Air
bag wire harness can be identified easily as the
connector side wire harness is covered with a yellow
protection tube or tape. Be careful when handling it.
• If damaged harness, connector or terminal is found on
an air bag wire harness, replace the harness.
8B-3 Air Bag System:

• When installing the air bag wire harness, be careful so

that it is not caught or does not interfere with other 2

parts.
• Make sure air bag system grounding point (4) is clean 3
and ground terminal is securely fastened for optimum
metal-to-metal contact. Poor grounding can cause
1
intermittent problems that are difficult to diagnose.

IBL80A820001-01

Precautions for Disposal of Air Bag and Seat

Belt Pretensioner
AENBL80A8200003
When disposal is necessary, be sure to deploy / activate
the air bag and seat belt pretensioner. )(Page 8B-66)

General Description
Air Bag System Construction
AENBL80A8201001
A 4-channel air bag system is employed in this model.
The 4-channel air bag system consists of the following
components.
• Driver and passenger air bag (inflator) modules
• Driver-side and passenger-side seat belt
pretensioners
• Forward impact sensor
• SDM
To supplement protection offered by seat belts, the air
bag system includes front air bags and seat belt
pretensioners for driver and passenger.
In the event of a frontal collision with an impact larger
than the preset level, the front air bag (inflator) modules,
which are stowed in the center of the steering wheel for IBP80A820002-02

the driver seat and under the top of instrument panel for
passenger seat, are deployed.
The seat belt pretensioners are activated whenever a
frontal impact exceeding the preset level is detected to
take up the sag in the seat belts.
1. Driver air bag 3. Seat belt pretensioner
2. Passenger air bag
The air bag system is designed to activate in severe
frontal collisions. It is not designed to activate in rear
impacts, side impacts, rollovers, or minor frontal
collisions, since it would offer no protection in these
types of accidents.

IBL80A820002-01
 Air Bag System: 8B-4

Schematic and Routing Diagram

Air Bag System Input / Output Diagram
AENBL80A8202001

INPUT SDM OUTPUT

Driver air bag

Battery voltage DC / DC converter Safing power driver
Front air
bag and
seat belt
Back up capacitor preten-
tioner Passenger air bag
deploy-
X-Y G sensor ment
(Longitudinal / driver Driver seat belt pretensioner
lateral acceleration)
Main CPU Passenger seat belt pretensioner
Forward impact sensor

BCM

Combination meter

IBP80A820005-01

Air Bag System Circuit Diagram

AENBL80A8202002

9
BEG BEG G11-10
11 G11-6 GRN/RED
PNK/BLK PNK/BLK G11-9
[E40] G11-5 GRN
[E382] [G334] [G347] [S172] [S121] 12

G11-19 BLU/RED BLU/RED

G11-18 YEL/RED YEL/RED

1 [G372] [G373] [G259] 13
2
RED/BLK L04-6 GRN/WHT
3 7 [G240] 5

8 L04-5 GRN/YEL
10 RED G11-13 [L283] 14
6 6
WHT G11-14 L04-7 BLU/WHT
GRY
L04-8 BLU/YEL
RED L04-18 [L285]
4 15
L1

L2
L3
L04-23 BLK
L4
: 16
L5
: 17

L6

IBL80A820003-02
8B-5 Air Bag System:

1. Ignition power supply 7. Combination meter 13. Passenger air bag (inflator) module
2. J/B 8. CPU (Combination meter) 14. Driver seat belt pretensioner
3. “MTR” fuse 9. Contact coil assembly 15. Passenger seat belt pretensioner
4. “A/B” fuse 10. “AIR BAG” warning light 16. Shorting bar
5. SDM 11. Forward impact sensor 17. Connection detection pin
6. CAN Driver 12. Driver air bag (inflator) module

Terminal arrangement of SDM connector

[A] [B]

[a] 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 9 10 11 12 13 14
17 18 19 20 21 22 23 15 16 17 18 19 20 21
IBL80A820004-01

[A]: SDM connector “L04” (View: [a]) [B]: SDM connector “G11” (View: [a])

“G11” connector
Terminal Circuit Terminal Circuit
G11-1 — G11-12 —
G11-2 — G11-13 CAN (Hi)
G11-3 — G11-14 CAN (Lo)
G11-4 — G11-15 —
G11-5 Driver air bag (inflator) module (–) G11-16 —
G11-6 Driver air bag (inflator) module (+) G11-17 —
G11-7 — G11-18 Passenger air bag (inflator) module (–)
G11-8 — G11-19 Passenger air bag (inflator) module (+)
G11-9 Forward impact sensor (–) G11-20 —
G11-10 Forward impact sensor (+) G11-21 —
G11-11 —

“L04” connector
Terminal Circuit Terminal Circuit
L04-1 — L04-13 —
L04-2 — L04-14 —
L04-3 — L04-15 —
L04-4 — L04-16 —
L04-5 Driver seat belt pretensioner (–) L04-17 —
L04-6 Driver seat belt pretensioner (+) L04-18 Power supply
L04-7 Passenger seat belt pretensioner (+) L04-19 —
L04-8 Passenger seat belt pretensioner (–) L04-20 —
L04-9 — L04-21 —
L04-10 — L04-22 —
L04-11 — L04-23 Ground
L04-12 —
 Air Bag System: 8B-6

Component Location
Air Bag System Component, Wiring and Connector Location
AENBL80A8203001

[a]
1

[A]
[A] [A] [A] 6
“G259”
“G373” “G372” “S121” 2
3 [A]
“G240”
7
[D]

[a]
[A] [A]
“L285” “E40”

[C]

[A]
“G347” [A]
“S172” [B]

[A]
“G334” [A]
[C]
4 “E382”

[A]
“L283”

[A] [A]
“L04” “G11”

8 5

IBL80A820005-02

[A]: Connector number 1. “AIR BAG” warning light 5. “A/B” fuse (in junction block)
[B]: Main harness 2. Driver air bag (inflator) module 6. Contact coil assembly
[C]: Floor harness 3. Passenger air bag (inflator) module 7. Forward impact sensor
[D]: Instrument panel harness 4. Retractor pretensioner 8. SDM
8B-7 Air Bag System:

Diagnostic Information and Procedures

Air Bag Diagnostic System Check
AENBL80A8204001
Refer to “Precautions for Air Bag System Service” (Page 8B-1) and check air bag system according to the following
procedure.

Air Bag Diagnostic System Check Flow

Step Action Yes No
1 DTC check Go to applicable DTC Go to Step 2.
1) Check DTC referring to “DTC Check” (Page 8B-8). diagnosis flow, and go
to Step 5.
NOTE
If communication between SUZUKI scan tool and
vehicle cannot be established, perform “DLC and
Its Communication Check (No Communication to
SDM)”.

2) Clear DTC referring to “DTC Clearance” (Page 8B-8).

Is there any DTC(s) when rechecking?

2 Visual inspection Repair faulty part or Go to Step 3.
1) Perform visual inspection referring to “Visual Inspection” replace it, and go to
(Page 8B-7). Step 5.

Is there any faulty condition?

3 Impact sign check Inspect faulty Go to Step 4.
1) Check vehicle for evidence of impact. connections and
replace them according
Are there any signs of impact? to “Repair and
Inspection Required
after Accident” (Page
8B-58), and go to Step
5.
4 Intermittent problem check Repair faulty part or Go to Step 5.
1) Check intermittent problems referring to “Intermittent replace it, and go to
Connection and Poor Contact Inspection” in Section 00 Step 5.
(Page 00-11).

Is there any faulty condition?

5 Final confirmation test Return to Step 1. End.
1) Confirm that problematic symptom has gone and air bag
system is free from any abnormal conditions. If what has
been repaired is related to DTC, clear DTC once, check
that no DTC is indicated.

Does malfunction recur?

Visual Inspection
AENBL80A8204002
Visually check the following parts and system.
Inspection Item Reference
Battery Level, leakage “Battery Description”: K14B in Section 1J (Page 1J-1) /
“Battery Description”: D13A in Section 1J (Page 1J-15)
Connectors of electric wire Disconnection, friction “Intermittent Connection and Poor Contact Inspection” in
harness Section 00 (Page 00-11)
Fuses Burning “Air Bag System Component, Wiring and Connector
Air bag system component Installation, damage Location” (Page 8B-6)
Other parts that can be checked visually

“AIR BAG” Warning Light Check
AENBL80A8204003
1) Set ignition “ON”.
2) Make sure that “AIR BAG” warning light (1) is on for
6 seconds. If “AIR BAG” warning light is not on, refer
to ““AIR BAG” Warning Light Does Not Come ON”
(Page 8B-11). If “AIR BAG” warning light is kept on
and no DTC is detected in SDM, refer to ““AIR BAG”
Warning Light Comes ON Steady” (Page 8B-10).
IBL80A820006-01
Self Diagnosis Function
AENBL80A8204004
SDM also has self-diagnosis function that memorizes
DTC when an error is detected. After understanding the
following descriptions, perform troubleshooting referring
to “Air Bag Diagnostic System Check” (Page 8B-7) when
an error is detected.
• SDM always monitors system while ignition is “ON”. If
an error is detected, it notifies driver of error by turning
on “AIR BAG” warning light (1) and detected error is
stored in SDM memory as DTC.
• “AIR BAG” warning light turns on for about 6 seconds
when ignition to “ON” to indicate that it is operating
properly and turns off if no error is found in air bag
system.
IBL80A820006-01
Air Bag System: 8B-8
DTC Check
AENBL80A8204005
1) Confirm that ignition is in “OFF”.
2) Connect SUZUKI scan tool to DLC (1) located on
underside of instrument panel at driver’s seat side.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
(A)
IAP70P722007-01
3) Set ignition “ON”. Read DTC according to
instructions displayed on SUZUKI scan tool and print
it or write it down. Refer to SUZUKI scan tool
operators manual for further details.
4) Set ignition “OFF”, and disconnect SUZUKI scan tool
from DLC.
DTC Clearance
AENBL80A8204006
1) Confirm that ignition is in “OFF”.
2) Connect SUZUKI scan tool to DLC (1) located on
underside of instrument panel at driver’s seat side.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
(A)
IAP70P722007-01
3) Set ignition “ON”.
4) Clear DTC according to instructions displayed on
SUZUKI scan tool. Refer to SUZUKI scan tool
operator’s manual for further details.
8B-9 Air Bag System:

5) Perform “DTC Check” (Page 8B-8) and confirm that NOTE

normal DTC (NO CODES) is displayed and not If DTC B1013, B1021 or DTC B1026 is stored
malfunction DTC after completing clearance. in SDM, it is not possible to clear the DTC.
6) Set ignition “OFF”, and disconnect SUZUKI scan tool
from DLC.

DTC Table
AENBL80A8204007
DTC DTC name DTC detecting condition
— Normal —
B1011 )(Page 8B-
SDM Wrong Assembly SDM has inconsistent ID code.
12)
B1012 )(Page 8B-
Intermittent Connection of SDM Connector Faulty connection of SDM connector.
13)
B1013 )(Page 8B- Malfunctioned SDM internal circuit, G sensor,
SDM Internal Failure
13) memory or CPU.
B1016 )(Page 8B- Power supply voltage is more than specified
Power Source Voltage too High
14) range.
B1017 )(Page 8B- Power supply voltage is less than specified
Power Source Voltage too Low
15) range.
B1021 )(Page 8B- Deployment of front air bag has been recorded
Front Air Bag Deployment Record
16) in SDM.
B1026 )(Page 8B- Activation of seat belt pretensioner has been
Seat Belt Pretensioner Activation Record
16) recorded in SDM.
B1031 )(Page 8B- Driver air bag (inflator) module circuit resistance
Driver Air Bag Circuit High Resistance
17) is more than specified range.
B1032 )(Page 8B- Driver air bag (inflator) module circuit resistance
Driver Air Bag Circuit Low Resistance
19) is less than specified range.
B1033 )(Page 8B- Driver air bag (inflator) module circuit has been
Driver Air Bag Circuit Shorted to Ground
22) shorted to ground.
B1034 )(Page 8B- Driver Air Bag Circuit Shorted to Power Driver air bag (inflator) module circuit has been
24) Supply shorted to power supply.
B1041 )(Page 8B- Passenger air bag (inflator) module circuit
Passenger Air Bag Circuit High Resistance
27) resistance is more than specified range.
B1042 )(Page 8B- Passenger air bag (inflator) module circuit
Passenger Air Bag Circuit Low Resistance
31) resistance is less than specified range.
B1043 )(Page 8B- Passenger Air Bag Circuit Shorted to Passenger air bag (inflator) module circuit has
34) Ground been shorted to ground.
B1044 )(Page 8B- Passenger Air Bag Circuit Shorted to Power Passenger air bag (inflator) module circuit has
36) Supply been shorted to power supply.
B1051 )(Page 8B- Driver Seat Belt Pretensioner Circuit High Driver seat belt pretensioner circuit resistance is
38) Resistance more than specified range.
B1052 )(Page 8B- Driver Seat Belt Pretensioner Circuit Low Driver seat belt pretensioner circuit resistance is
41) Resistance less than specified range.
B1053 )(Page 8B- Driver Seat Belt Pretensioner Circuit Shorted Driver seat belt pretensioner circuit has been
43) to Ground shorted to ground.
B1054 )(Page 8B- Driver Seat Belt Pretensioner Circuit Shorted Driver seat belt pretensioner circuit has been
45) to Power Supply shorted to power supply.
B1055 )(Page 8B- Passenger Seat Belt Pretensioner Circuit Passenger seat belt pretensioner circuit
38) High Resistance resistance is more than specified range.
B1056 )(Page 8B- Passenger Seat Belt Pretensioner Circuit Passenger seat belt pretensioner circuit
41) Low Resistance resistance is less than specified range.
B1057 )(Page 8B- Passenger Seat Belt Pretensioner Circuit Passenger seat belt pretensioner circuit has
43) Shorted to Ground been shorted to ground.
B1058 )(Page 8B- Passenger Seat Belt Pretensioner Circuit Passenger seat belt pretensioner circuit has
45) Shorted to Power Supply been shorted to power supply.
B1071 )(Page 8B- Driver Forward Impact Sensor Forward impact sensor has communicated with
48) Communication Data Inconsistent no response or inconsistent ID code.
B1072 )(Page 8B- Driver Forward Impact Sensor Forward impact sensor has communicated with
48) Communication Data Invalid invalid data.
 Air Bag System: 8B-10

DTC DTC name DTC detecting condition

B1073 )(Page 8B- Driver Forward Impact Sensor Circuit Forward impact sensor circuit has been shorted
49) Shorted to Ground to ground.
B1074 )(Page 8B- Forward impact sensor circuit has been shorted
Driver Forward Impact Sensor Circuit Open
49) to power supply or opened.
U0073 )(Page 8B- Transmitting and receiving error of SDM for
Control Module Communication Bus Off
53) specified time continuously.

Scan Tool Data Backup Volt (V)

AENBL80A8204008 This parameter indicates capacity of backup capacitor
Data list of SDM
installed to maintain ignition current (as much as
Normal Condition /
Scan Tool Data possible) even when power supply to SDM that ignites
Reference Value
inflator is shut off.
System ID 4ch
Driv A/B Ini Res (Driver air bag initiator resistance)
Battery Voltage 10 – 14 V
(ohm)
Backup Volt 27.0 – 33.0 V
This parameter indicates resistance of driver air bag
Driv A/B Ini Res 1.0 – 4.5 ohm
initiator circuit.
Pass A/B Ini Res 1.0 – 3.8 ohm
Driv Preten Ini Res 1.0 – 3.8 ohm
Pass A/B Ini Res (Passenger air bag initiator
Pass Preten Ini Res 1.0 – 3.8 ohm
resistance) (ohm)
This parameter indicates resistance of passenger air bag
Scan Tool Data Definition
initiator circuit.
System ID (4ch)
This parameter indicates number of initiator circuits. Driv Preten Ini Res (Driver pretensioner initiator
resistance) (ohm)
Battery Voltage (V) This parameter indicates resistance of driver seat belt
Power supply voltage is an analog input signal read by pretensioner initiator circuit.
SDM.

“AIR BAG” Warning Light Comes ON Steady

AENBL80A8204009
Circuit Diagram

3 6 2
4
1 RED/BLK G240-3 7
GRY G240-5
G240-24 RED G11-13
8 8
G240-12 WHT G11-14

5
RED L04-18

BLK L04-23

[A] [B] [C]

[a] 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 9 10 11 12 13 14 15 16

15 16 17 18 19 20 21 17 18 19 20 21 22 23
IBP80A820008-01

[A]: Connector “G240” (view: [a]) 2. SDM 6. Combination meter

[B]: Connector “G11” (view: [a]) 3. J/B 7. CPU (Combination meter)
[C]: Connector “L04” (view: [a]) 4. “MTR” fuse 8. CAN driver
1. Ignition power supply 5. “A/B” fuse
8B-11 Air Bag System:

DTC Troubleshooting
Step Action Yes No
1 SDM connector check Go to Step 2. Connect connector
1) Check for proper connection to SDM connector. securely.

Is connection in good condition?

2 DTC Check Go to applicable DTC Go to Step 3.
1) Perform “DTC Check” (Page 8B-8). troubleshooting.

Is there any DTC(s)?

3 SDM power supply and ground circuit check Go to Step 4. Repair SDM power
1) Check SDM power supply circuit and ground circuit. supply and ground
)(Page 8B-53) circuit.

Are the circuits in good condition?

4 CAN communication circuit check Go to Step 5. Repair defective wire
1) Check CAN communication circuit between SDM and harness.
combination meter.

Is circuit in good condition?

5 Combination meter check Replace SDM and End.
1) Replace combination meter. )(Page 9C-9) recheck DTC. )(Page
8B-61)
2) Set ignition “ON”.

Does AIR BAG warning light stay on?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.

“AIR BAG” Warning Light Does Not Come ON

AENBL80A8204010
Circuit Diagram

3 6 2
4
1 RED/BLK G240-3 7
GRY G240-5
G240-24 RED G11-13
8 8
G240-12 WHT G11-14

5
RED L04-18

BLK L04-23

[A] [B] [C]

[a] 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 9 10 11 12 13 14 15 16

15 16 17 18 19 20 21 17 18 19 20 21 22 23
IBP80A820008-01
 Air Bag System: 8B-12

[A]: Connector “G240” (view: [a]) 2. SDM 6. Combination meter

[B]: Connector “G11” (view: [a]) 3. J/B 7. CPU (Combination meter)
[C]: Connector “L04” (view: [a]) 4. “MTR” fuse 8. CAN driver
1. Ignition power supply 5. “A/B” fuse

DTC Troubleshooting
Step Action Yes No
1 Warning light check Go to Step 2. Go to Step 3.
1) Set ignition “ON”.

Do other indicator lights come ON?

2 DTC check Go to “Troubleshooting Replace SDM and
1) Confirm that ignition is in “OFF”. for Communication Bus recheck DTC. )(Page
Off”:. 8B-61)
2) Connect scan tool to DLC.
3) Set ignition “ON”.
4) Check DTC. )(Page 8B-8)

Is DTC U0073 detected?

3 Fuse check Go to Step 4. Replace “MTR” fuse
and check for short
Is “MTR” fuse for combination meter in good condition? circuit to ground.
4 CAN communication circuit check Go to Step 5. Repair defective wire
1) Check CAN communication circuit between SDM and harness.
combination meter.

Is circuit in good condition?

5 Combination meter power supply circuit check Go to Step 6. Repair power supply
1) Confirm that ignition is in “OFF”. circuit for combination
meter.
2) Remove combination meter.
3) Check for proper connection to “RED/BLK” and “GRY”
wire of combination meter connector.
4) If OK, set ignition “ON” and measure voltage between
connector terminal “G240-3” and ground.
5) Measure voltage between “RED/BLK” wire and ground.

Is it 10 – 14 V?
6 Combination meter ground circuit check Replace combination “GRY” circuit open.
1) Measure resistance between “GRY” wire and ground. meter and recheck “AIR
BAG” warning light
Is resistance less than 1 Ω? operation. )(Page 9C-
9)

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been
corrected.

DTC B1011
AENBL80A8204011
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1011: SDM Wrong Assembly SDM
SDM has inconsistent ID code.
8B-13 Air Bag System:

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
2 Air bag system type check Replace SDM and Change SDM with the
1) Identify SDM’s channel number of air bag, judging from recheck DTC. )(Page one compatible with
SDM part number. 8B-61) vehicle air bag
specification.
2) Identify vehicle’s channel number of air bag, judging
from modules or pretensioners installed in vehicle.

Is SDM applicable to vehicle specification?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs referring to “DTC Clearance” (Page 8B-8), if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.

DTC B1012
AENBL80A8204012
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1012: Intermittent Connection of SDM Connector • SDM connector
Faulty connection of SDM connector. • SDM

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
2 SDM connector check Replace SDM with new Check intermittent
1) Check proper connection of SDM connector and one. )(Page 8B-61) trouble. )(Page 00-11)
“Connection detection pin” of SDM connector.

Is it in good condition?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.

DTC B1013
AENBL80A8204013
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1013: SDM Internal Failure SDM
Malfunctioned SDM internal circuit, G sensor, memory or CPU.

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
 Air Bag System: 8B-14

Step Action Yes No

2 DTC check Replace SDM and Check intermittent
1) Clear DTC. )(Page 8B-8) recheck DTC. )(Page trouble. )(Page 00-11)
8B-61)
2) Confirm that ignition is in “OFF”.
3) Set ignition “ON”.
4) Check DTC. )(Page 8B-8)

Is DTC B1013 still indicated?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.

DTC B1016
AENBL80A8204014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1016: Power Source Voltage too High • Charging system
Power supply voltage is more than specified range. • SDM

Circuit Diagram

5 3

2
1 RED L04-18

BLK L04-23

[A]

:4 [a] 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23
I9P60A820107-03

[A]: “L04” connector (view: [a]) 2. “A/B” fuse 4. Floor harness

1. Ignition power supply 3. SDM 5. J/B

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
8B-15 Air Bag System:

Step Action Yes No

2 SDM power voltage check Go to Step 3. Check charging system
1) Confirm that ignition is in “OFF”. and repair wiring.
)(Page 1J-5) / )(Page
2) Disconnect “L04” connector.
1J-18)
3) Start engine and set engine speed at 3,000 rpm or more.
4) Measure voltage between “L04-18” terminal and ground.
Special tool
(A): 09932–76010

[L04]

(A)

[L04]

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23
IAW101820120-01

Is voltage 15 V or less?
3 DTC check Replace SDM and Intermittent trouble.
1) Confirm that ignition is in “OFF”. recheck DTC. )(Page Check for intermittent
8B-61) trouble. )(Page 00-11)
2) Connect “L04” connector.
3) Set ignition “ON”.

Is DTC B1016 detected?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been
corrected.

DTC B1017
AENBL80A8204015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1017: Power Source Voltage too Low • Charging system
Power supply voltage is less than specified range. • SDM
 Air Bag System: 8B-16

Circuit Diagram

5 3

2
1 RED L04-18

BLK L04-23

[A]

:4 [a] 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23
I9P60A820107-03

[A]: “L04” connector (view: [a]) 2. “A/B” fuse 4. Floor harness

1. Ignition power supply 3. SDM 5. J/B

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
2 SDM power supply circuit and ground circuit check Go to Step 3. Repair or replace
1) Check SDM power supply circuit and ground circuit. defective part.

Is SDM power circuit and ground circuit in good condition?

)(Page 8B-53)
3 DTC check Replace SDM and Intermittent trouble.
1) Confirm that ignition is in “OFF”. recheck DTC. )(Page Check for intermittent
8B-61) trouble. )(Page 00-11)
2) Connect “L04” connector.
3) Set ignition “ON”.

Is DTC B1017 detected?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.

DTC B1021 / B1026

AENBL80A8204016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1021: Front Air Bag Deployment Record If this DTC has been recorded even though air
Deployment of front air bag has been recorded in SDM. bag or pretensioner has not been deployed
B1026: Seat Belt Pretensioner Activation Record • SDM
Activation of seat belt pretensioner has been recorded in SDM.
• Driver and/or Passenger air bag (inflator)
module
• Driver and/or Passenger seat belt pretensioner
• Those initiator circuits.
8B-17 Air Bag System:

NOTE
If DTC B1021 or DTC B1026 is stored in SDM, it is not possible to clear DTC.

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Replace SDM. )(Page Go to “Air Bag
8B-61) Diagnostic System
Check” (Page 8B-7).

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been
corrected.

DTC B1031
AENBL80A8204017
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1031: Driver Air Bag Circuit High Resistance • Driver air bag (inflator) module circuit
Driver air bag (inflator) module circuit resistance is more • Contact coil assembly
than specified range.
• Driver air bag (inflator) module
• SDM

Circuit Diagram

[S121] [S172] [G347]

A1
1 2

GRN/RED G11-6
A2

GRN G11-5

[A] [B] [C]

:4
[a] 1 2 1 2 3 4 5 6 7 8
:5 1 2
9 10 11 12 13 14
15 16 17 18 19 20 21
IBP80A820009-01

[A]: “S121” connector (view: [a]) A2. Driver air bag (inflator) module deployment signal 4. Shorting bar
ground circuit
[B]: “G347” connector (view: [a]) 1. Driver air bag (inflator) module 5. Instrument panel harness
[C]: “G11” connector (view: [a]) 2. Contact coil assembly
A1. Driver air bag (inflator) module deployment signal output circuit 3. SDM

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
 Air Bag System: 8B-18

Step Action Yes No

2 Driver air bag (inflator) module check Go to Step 3. Go to Step 4.
1) Confirm that ignition is in “OFF”.
2) Check for proper connection to “G347” connector.
3) Disconnect “G347” connector.
4) Connect “STEERING WHEEL” harness (1) of special
tools (A) and (B) to “G347” connector.
Special tool
(A): 09932–78340
(B): 09932–75010

[G347]

1
(A)
(B)
IBP80A820010-01

5) Set ignition “ON”.

6) Check DTC. )(Page 8B-8)

Is DTC B1031 detected?

8B-19 Air Bag System:

Step Action Yes No

3 Instrument panel harness circuit check Replace SDM with new Replace instrument
1) Set ignition “OFF”. one. )(Page 8B-61) panel harness.
2) Check for proper connection to “G11” connector.
3) Disconnect “G11” connector.
4) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
5) Check the following point.
• Resistance of “A1” and “A2” circuit: 1 Ω or less
Special tool
(A): 09932–76010

[G11] (A)

[G11] [G347]

1 2
1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
IBP80A820011-01

Are they in good condition?

4 Contact coil circuit check Replace driver air bag Replace contact coil
1) Check contact coil circuit. )(Page 8B-55) (inflator) module. assembly. )(Page 6B-
)(Page 8B-62) 5)
Is contact coil circuit in good condition?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.

DTC B1032
AENBL80A8204018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1032: Driver Air Bag Circuit Low Resistance • Driver air bag (inflator) module circuit
Driver air bag (inflator) module circuit resistance is less • Contact coil assembly
than specified range.
• Driver air bag (inflator) module
• SDM
 Air Bag System: 8B-20

Circuit Diagram

[S121] [S172] [G347]

A1
1 2

GRN/RED G11-6
A2

GRN G11-5

[A] [B] [C]

:4
[a] 1 2 1 2 3 4 5 6 7 8
:5 1 2
9 10 11 12 13 14
15 16 17 18 19 20 21
IBP80A820009-01

[A]: “S121” connector (view: [a]) A2. Driver air bag (inflator) module deployment signal 4. Shorting bar
ground circuit
[B]: “G347” connector (view: [a]) 1. Driver air bag (inflator) module 5. Instrument panel harness
[C]: “G11” connector (view: [a]) 2. Contact coil assembly
A1. Driver air bag (inflator) module deployment signal output circuit 3. SDM

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
8B-21 Air Bag System:

Step Action Yes No

2 Driver air bag (inflator) module check Go to Step 3. Go to Step 4.
1) Confirm that ignition is in “OFF”.
2) Disconnect “G347” connector.
3) Connect “STEERING WHEEL” harness (1) of special
tools (A) and (B) to “G347” connector.
Special tool
(A): 09932–78340
(B): 09932–75010

[G347]

1
(A)
(B)
IBP80A820010-01

4) Set ignition “ON”.

5) Check DTC. )(Page 8B-8)

Is DTC B1032 detected?

 Air Bag System: 8B-22

Step Action Yes No

3 Instrument panel harness circuit check Replace SDM and Replace instrument
1) Set ignition “OFF”. recheck DTC. )(Page panel harness.
8B-61)
2) Disconnect “G11” connector.
3) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
4) Check the following point.
• Resistance between “G11-5” and “G11-6” terminals:
infinity
Special tool
(A): 09932–76010

[G11] (A)

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
IAW10A820057-01

Are they in good condition?

4 Contact coil circuit check Replace driver air bag Replace contact coil
1) Check contact coil circuit. )(Page 8B-55) (inflator) module. assembly. )(Page 6B-
)(Page 8B-62) 5)
Is contact coil circuit in good condition?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.

DTC B1033
AENBL80A8204019
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1033: Driver Air Bag Circuit Shorted to Ground • Driver air bag (inflator) module circuit
Driver air bag (inflator) module circuit has been shorted to • Contact coil assembly
ground.
• SDM
8B-23 Air Bag System:

Circuit Diagram

[S121] [S172] [G347]

A1
1 2

GRN/RED G11-6
A2

GRN G11-5

[A] [B] [C]

:4
[a] 1 2 1 2 3 4 5 6 7 8
:5 1 2
9 10 11 12 13 14
15 16 17 18 19 20 21
IBP80A820009-01

[A]: “S121” connector (view: [a]) A2. Driver air bag (inflator) module deployment signal 4. Shorting bar
ground circuit
[B]: “G347” connector (view: [a]) 1. Driver air bag (inflator) module 5. Instrument panel harness
[C]: “G11” connector (view: [a]) 2. Contact coil assembly
A1. Driver air bag (inflator) module deployment signal output circuit 3. SDM

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
2 Instrument panel harness circuit check Go to Step 3. Replace instrument
1) Confirm that ignition is in “OFF”. panel harness.
2) Disconnect “G347” and “G11” connectors.
3) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
4) Check the following point.
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
Special tool
(A): 09932–76010

(A)
[G11]

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
IAW10A820052-02

Are they in good condition?

 Air Bag System: 8B-24

Step Action Yes No

3 Contact coil circuit check Replace SDM and Replace contact coil.
1) Connect “G347” connector. recheck DTC. )(Page )(Page 6B-5)
8B-61)
2) Remove driver air bag (inflator) module from steering
column. )(Page 8B-62)
3) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
4) Check the following point.
• Resistance between each of “A1” and “A2” circuit and
ground: infinity
Special tool
(A): 09932–76010

(A)
[G11]

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
IAW10A820052-02

Are they in good condition?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.

DTC B1034
AENBL80A8204020
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1034: Driver Air Bag Circuit Shorted to Power Supply • Driver air bag (inflator) module circuit
Driver air bag (inflator) module circuit has been shorted to power supply. • Contact coil assembly
• SDM
8B-25 Air Bag System:

Circuit Diagram

[S121] [S172] [G347]

A1
1 2

GRN/RED G11-6
A2

GRN G11-5

[A] [B] [C]

:4
[a] 1 2 1 2 3 4 5 6 7 8
:5 1 2
9 10 11 12 13 14
15 16 17 18 19 20 21
IBP80A820009-01

[A]: “S121” connector (view: [a]) A2. Driver air bag (inflator) module deployment signal 4. Shorting bar
ground circuit
[B]: “G347” connector (view: [a]) 1. Driver air bag (inflator) module 5. Instrument panel harness
[C]: “G11” connector (view: [a]) 2. Contact coil assembly
A1. Driver air bag (inflator) module deployment signal output circuit 3. SDM

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
2 Instrument panel harness circuit check Go to Step 3. Replace instrument
1) Confirm that ignition is in “OFF”. panel harness.
2) Disconnect “G347” and “G11” connectors.
3) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
4) Set ignition “ON”.
5) Check the following point.
• Voltage between each of “A1” and “A2” circuits and
ground: 0 V
Special tool
(A): 09932–76010

(A)
[G11]

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
IAW10A820053-02

Are they in good condition?

 Air Bag System: 8B-26

Step Action Yes No

3 Contact coil circuit check Replace SDM and Replace contact coil
1) Confirm that ignition is in “OFF”. recheck DTC. )(Page assembly. )(Page 6B-
8B-61) 5)
2) Connect “G347” connector.
3) Remove driver air bag (inflator) module from steering
column. )(Page 8B-62)
4) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
5) Set ignition “ON”.
6) Check the following point.
• Voltage between each of “A1” and “A2” circuits and
ground: 0 V
Special tool
(A): 09932–76010

(A)
[G11]

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
IAW10A820053-02

Are they in good condition?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.
8B-27 Air Bag System:

DTC B1041
AENBL80A8204021
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1041: Passenger Air Bag Circuit High Resistance • Passenger air bag (inflator) module circuit
Passenger air bag (inflator) module circuit resistance is • Passenger air bag (inflator) module
more than specified range.
• SDM

Circuit Diagram

[G259] [G373] [G372]

A1 A3
1

BLU/RED BLU/RED G11-19

A2 A4

YEL/RED YEL/RED G11-18

[A] [B] [C]

:3
[a] 1 2 1 2 3 4 5 6 7 8
:4
1 2 9 10 11 12 13 14
:5
15 16 17 18 19 20 21
I9P60A820020-07

[A]: “G259” connector (view: [a]) A2. Passenger air bag (inflator) module deployment 2. SDM
signal ground circuit
[B]: “G372” connector (view: [a]) A3. Passenger air bag (inflator) module deployment 3. Shorting bar
signal output circuit
[C]: “G11” connector (view: [a]) A4. Passenger air bag (inflator) module deployment 4. Instrument panel harness
signal ground circuit
A1. Passenger air bag (inflator) module deployment 1. Passenger air bag (inflator) module 5. Passenger air bag (inflator) module
signal output circuit harness

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
 Air Bag System: 8B-28

Step Action Yes No

2 Passenger air bag (inflator) module check Go to Step 3. Replace passenger air
1) Confirm that ignition is in “OFF”. bag (inflator) module.
)(Page 8B-63)
2) Check for proper connection to “G259” connector.
3) Disconnect “G259” connector.
4) Connect “STEERING WHEEL” harness (1) of special
tool (A), (B) and (C) to “G259” connector.
Special tool
(A): 09932–76010
(B): 09932–78310
(C): 09932–75010

(B)
[G259]

(A)

(C)
IBP80A820012-01

5) Set ignition “ON”.

6) Check DTC. )(Page 8B-8)

Is DTC B1041 detected?

8B-29 Air Bag System:

Step Action Yes No

3 Passenger air bag (inflator) module circuit check Replace SDM and Go to Step 4.
1) Set ignition “OFF”. recheck DTC. )(Page
8B-61)
2) Check for proper connection to “G11” connector.
3) Disconnect “G11” connector.
4) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
5) Check the following points.
• Resistance between “G11-19” and “G259-1”
terminals: 1 Ω or less
• Resistance between “G11-18” and “G259-2”
terminals: 1 Ω or less
Special tool
(A): 09932–76010

[G259] 1 2

(A)
[G11]

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
IAP70P821051-01

Are they in good condition?

 Air Bag System: 8B-30

Step Action Yes No

4 Instrument panel harness circuit check Replace passenger air Replace instrument
1) Check for proper connection to “G372” connector. bag (inflator) module panel harness.
harness.
2) Disconnect “G372” connector.
3) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
4) Check the following point.
• Resistance of “A3” and “A4” circuits: 1 Ω or less
Special tool
(A): 09932–76010

[G11] (A)

[G11] [G372]

1 2 3 4 5 6 7 8 1 2
9 10 11 12 13 14
15 16 17 18 19 20 21
I9P60A820023-03

Are they in good condition?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.
8B-31 Air Bag System:

DTC B1042
AENBL80A8204022
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1042: Passenger Air Bag Circuit Low Resistance • Passenger air bag (inflator) module circuit
Passenger air bag (inflator) module circuit resistance is • Passenger air bag (inflator) module
less than specified range.
• SDM

Circuit Diagram

[G259] [G373] [G372]

A1 A3
1

BLU/RED BLU/RED G11-19

A2 A4

YEL/RED YEL/RED G11-18

[A] [B] [C]

:3
[a] 1 2 1 2 3 4 5 6 7 8
:4
1 2 9 10 11 12 13 14
:5
15 16 17 18 19 20 21
I9P60A820020-07

[A]: “G259” connector (view: [a]) A2. Passenger air bag (inflator) module deployment 2. SDM
signal ground circuit
[B]: “G372” connector (view: [a]) A3. Passenger air bag (inflator) module deployment 3. Shorting bar
signal output circuit
[C]: “G11” connector (view: [a]) A4. Passenger air bag (inflator) module deployment 4. Instrument panel harness
signal ground circuit
A1. Passenger air bag (inflator) module deployment 1. Passenger air bag (inflator) module 5. Passenger air bag (inflator) module
signal output circuit harness

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
 Air Bag System: 8B-32

Step Action Yes No

2 Passenger air bag (inflator) module check Go to Step 3. Replace passenger air
1) Confirm that ignition is in “OFF”. bag (inflator) module.
)(Page 8B-63)
2) Disconnect “G259” connector.
3) Connect “STEERING WHEEL” harness (1) of special
tool (A), (B) and (C) to “G259” connector.
Special tool
(A): 09932–76010
(B): 09932–78310
(C): 09932–75010

(B)
[G259]

(A)

(C)
IBP80A820012-01

4) Set ignition “ON”.

5) Check DTC. )(Page 8B-8)

Is DTC B1042 detected?

8B-33 Air Bag System:

Step Action Yes No

3 Passenger air bag (inflator) module circuit check Replace SDM and Go to Step 4.
1) Set ignition “OFF”. recheck DTC. )(Page
8B-61)
2) Disconnect “G11” connector.
3) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
4) Check the following point.
• Resistance between “G11-18” and “G11-19”
terminals: infinity
Special tool
(A): 09932–76010

[G11] (A)

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
IAW10A820054-02

Are they in good condition?

4 Instrument panel harness circuit check Replace passenger air Replace instrument
1) Disconnect “G372” connector. bag (inflator) module panel harness.
harness.
2) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
3) Check the following point.
• Resistance between “G11-18” and “G11-19” terminal:
infinity
Special tool
(A): 09932–76010

[G11] (A)

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
IAW10A820054-02

Are they in good condition?

 Air Bag System: 8B-34

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.

DTC B1043
AENBL80A8204023
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1043: Passenger Air Bag Circuit Shorted to Ground • Passenger air bag (inflator) module circuit
Passenger air bag (inflator) module circuit has been • SDM
shorted to ground.

Circuit Diagram

[G259] [G373] [G372]

A1 A3
1

BLU/RED BLU/RED G11-19

A2 A4

YEL/RED YEL/RED G11-18

[A] [B] [C]

:3
[a] 1 2 1 2 3 4 5 6 7 8
:4
1 2 9 10 11 12 13 14
:5
15 16 17 18 19 20 21
I9P60A820020-07

[A]: “G259” connector (view: [a]) A2. Passenger air bag (inflator) module deployment 2. SDM
signal ground circuit
[B]: “G372” connector (view: [a]) A3. Passenger air bag (inflator) module deployment 3. Shorting bar
signal output circuit
[C]: “G11” connector (view: [a]) A4. Passenger air bag (inflator) module deployment 4. Instrument panel harness
signal ground circuit
A1. Passenger air bag (inflator) module deployment 1. Passenger air bag (inflator) module 5. Passenger air bag (inflator) module
signal output circuit harness

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
8B-35 Air Bag System:

Step Action Yes No

2 Passenger air bag (inflator) module circuit check Replace SDM and Go to Step 3.
1) Confirm that ignition is in “OFF”. recheck DTC. )(Page
8B-61)
2) Disconnect “G259” connector.
3) Disconnect “G11” connector.
4) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
5) Check the following point.
• Resistance between each of “A3” and “A4” circuits
and ground: infinity
Special tool
(A): 09932–76010

(A)
[G11]

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
IAW10A820018-02

Are they in good condition?

3 Instrument panel harness circuit check Replace passenger air Replace instrument
1) Disconnect “G372” connector. bag (inflator) module panel harness.
harness.
2) Release shorting bar in SDM connector using special
tool (A).
3) Check the following point.
• Resistance between each of “A3” and “A4” circuits
and ground: infinity
Special tool
(A): 09932–76010

(A)
[G11]

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
IAW10A820018-02

Are they in good condition?

 Air Bag System: 8B-36

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.

DTC B1044
AENBL80A8204024
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1044: Passenger Air Bag Circuit Shorted to Power Supply • Passenger air bag (inflator) module circuit
Passenger air bag (inflator) module circuit has been shorted to • SDM
power supply.

Circuit Diagram

[G259] [G373] [G372]

A1 A3
1

BLU/RED BLU/RED G11-19

A2 A4

YEL/RED YEL/RED G11-18

[A] [B] [C]

:3
[a] 1 2 1 2 3 4 5 6 7 8
:4
1 2 9 10 11 12 13 14
:5
15 16 17 18 19 20 21
I9P60A820020-07

[A]: “G259” connector (view: [a]) A2. Passenger air bag (inflator) module deployment 2. SDM
signal ground circuit
[B]: “G372” connector (view: [a]) A3. Passenger air bag (inflator) module deployment 3. Shorting bar
signal output circuit
[C]: “G11” connector (view: [a]) A4. Passenger air bag (inflator) module deployment 4. Instrument panel harness
signal ground circuit
A1. Passenger air bag (inflator) module deployment 1. Passenger air bag (inflator) module 5. Passenger air bag (inflator) module
signal output circuit harness

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
8B-37 Air Bag System:

Step Action Yes No

2 Passenger air bag (inflator) module circuit check Replace SDM and Go to Step 3.
1) Confirm that ignition is in “OFF”. recheck DTC. )(Page
8B-61)
2) Disconnect “G259” connector.
3) Disconnect “G11” connector.
4) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
5) Set ignition “ON”.
6) Check the following point.
• Voltage between each of “A3” and “A4” circuits and
ground: 0 V
Special tool
(A): 09932–76010

(A)
[G11]

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
IAW10A820019-02

Are they in good condition?

3 Instrument panel harness circuit check Replace passenger air Replace instrument
1) Confirm that ignition is in “OFF”. bag (inflator) module panel harness.
harness.
2) Disconnect “G372” connector.
3) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
4) Set ignition “ON”.
5) Check the following point.
• Voltage between each of “A3” and “A4” circuits and
ground: 0 V
Special tool
(A): 09932–76010

(A)
[G11]

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
IAW10A820019-02

Are they in good condition?

 Air Bag System: 8B-38

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been
corrected.

DTC B1051 / B1055

AENBL80A8204025
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1051: Driver Seat Belt Pretensioner Circuit High Resistance • Driver / passenger seat belt pretensioner circuit
Driver seat belt pretensioner circuit resistance is more than • Driver / passenger seat belt pretensioner
specified range.
• SDM
B1055: Passenger Seat Belt Pretensioner Circuit High
Resistance
Passenger seat belt pretensioner circuit resistance is more than
specified range.

Circuit Diagram

[L283] 3
1 A1

GRN/WHT L04-6
A2

GRN/YEL L04-5
[L285]
A3
2
BLU/WHT L04-7
A4

BLU/YEL L04-8

[A] [B]
:4
[a] 1 2 3 4 5 6 7 8
1 2
:5 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23
IBL80A820007-02

[A]: “L283” and “L285” connector (view: [a]) A3. Passenger seat belt pretensioner operation signal 3. SDM
output circuit
[B]: “L04” connector (view: [a]) A4. Passenger seat belt pretensioner operation signal 4. Shorting bar
ground circuit
A1. Driver seat belt pretensioner operation signal 1. Driver seat belt pretensioner 5. Floor harness
output circuit
A2. Driver seat belt pretensioner operation signal 2. Passenger seat belt pretensioner
ground circuit

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
8B-39 Air Bag System:

Step Action Yes No

2 Seat belt pretensioner check Go to Step 3. Replace seat belt
1) Confirm that ignition is in “OFF”. pretensioner. )(Page
8A-4)
2) Check for proper connection to “L283” or “L285”
connector.
3) Disconnect “L283” or “L285” connector.
4) Connect “STEERING WHEEL” harness (1) of special
tool (A), (B) and (C) to “L283” or “L285” connector.
Special tool
(A): 09932–76010
(B): 09932–78310
(C): 09932–75010

(C)
)A(

(B)

[L283 (L285)]

1
IBP80A820014-01

5) Set ignition “ON”.

6) Check DTC. )(Page 8B-8)

Is DTC B1051 or DTC B1055 indicated?

 Air Bag System: 8B-40

Step Action Yes No

3 Floor harness circuit check Replace SDM and Replace floor harness.
1) Set ignition “OFF”. recheck DTC. )(Page
8B-61)
2) Check for proper connection to “L04” connector.
3) Disconnect “L04” connector.
4) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
5) Check the following points.
• Resistance of “A1” and “A2” circuits (DTC B1051): 1 Ω
or less
• Resistance of “A3” and “A4” circuits (DTC B1055): 1 Ω
or less
Special tool
(A): 09932–76010

[L04] (A)

[L04]

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23

[L04] (A)

[L283(L285)]

1 2

IBL80A820008-01

Are they in good condition?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.
8B-41 Air Bag System:

DTC B1052 / B1056

AENBL80A8204026
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1052: Driver Seat Belt Pretensioner Circuit Low Resistance • Driver / passenger seat belt pretensioner circuit
Driver seat belt pretensioner circuit resistance is less than • Driver / passenger seat belt pretensioner
specified range.
• SDM
B1056: Passenger Seat Belt Pretensioner Circuit Low
Resistance
Passenger seat belt pretensioner circuit resistance is less than
specified range.

Circuit Diagram

[L283] 3
1 A1

GRN/WHT L04-6
A2

GRN/YEL L04-5
[L285]
A3
2
BLU/WHT L04-7
A4

BLU/YEL L04-8

[A] [B]
:4
[a] 1 2 3 4 5 6 7 8
1 2
:5 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23
IBL80A820007-02

[A]: “L283” and “L285” connector (view: [a]) A3. Passenger seat belt pretensioner operation signal 3. SDM
output circuit
[B]: “L04” connector (view: [a]) A4. Passenger seat belt pretensioner operation signal 4. Shorting bar
ground circuit
A1. Driver seat belt pretensioner operation signal 1. Driver seat belt pretensioner 5. Floor harness
output circuit
A2. Driver seat belt pretensioner operation signal 2. Passenger seat belt pretensioner
ground circuit

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
 Air Bag System: 8B-42

Step Action Yes No

2 Seat belt pretensioner check Go to Step 3. Replace seat belt
1) Confirm that ignition is in “OFF”. pretensioner. )(Page
8A-4)
2) Disconnect “L283” or “L285” connector.
3) Connect “STEERING WHEEL” harness (1) of special
tool (A), (B) and (C) to “L283” or “L285” connector.
Special tool
(A): 09932–76010
(B): 09932–78310
(C): 09932–75010

(C)
)A(

(B)

[L283 (L285)]

1
IBP80A820014-01

4) Set ignition “ON”.

5) Check DTC. )(Page 8B-8)

Is DTC B1052 or DTC B1056 indicated?

8B-43 Air Bag System:

Step Action Yes No

3 Floor harness circuit check Replace SDM and Replace floor harness.
1) Set ignition “OFF”. recheck DTC. )(Page
8B-61)
2) Disconnect “L04” connector.
3) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
4) Check the following points.
• Resistance between “L04-6” and “L04-5” terminals
(DTC B1052): infinity
• Resistance between “L04-7” and “L04-8” terminals
(DTC B1056): infinity
Special tool
(A): 09932–76010

[L04] (A)

[L04]

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23

[L04]

(A)

IBL80A820009-01

Are they in good condition?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.

DTC B1053 / B1057

AENBL80A8204027
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1053: Driver Seat Belt Pretensioner Circuit Shorted to Ground • Driver / passenger seat belt
Driver seat belt pretensioner circuit has been shorted to ground. pretensioner circuit
B1057: Passenger Seat Belt Pretensioner Circuit Shorted to Ground • SDM
Passenger seat belt pretensioner circuit has been shorted to ground.
 Air Bag System: 8B-44

Circuit Diagram

[L283] 3
1 A1

GRN/WHT L04-6
A2

GRN/YEL L04-5
[L285]
A3
2
BLU/WHT L04-7
A4

BLU/YEL L04-8

[A] [B]
:4
[a] 1 2 3 4 5 6 7 8
1 2
:5 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23
IBL80A820007-02

[A]: “L283” and “L285” connector (view: [a]) A3. Passenger seat belt pretensioner operation signal 3. SDM
output circuit
[B]: “L04” connector (view: [a]) A4. Passenger seat belt pretensioner operation signal 4. Shorting bar
ground circuit
A1. Driver seat belt pretensioner operation signal 1. Driver seat belt pretensioner 5. Floor harness
output circuit
A2. Driver seat belt pretensioner operation signal 2. Passenger seat belt pretensioner
ground circuit

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
8B-45 Air Bag System:

Step Action Yes No

2 Floor harness circuit check Replace SDM and Replace floor harness.
1) Confirm that ignition is in “OFF”. recheck DTC. )(Page
8B-61)
2) Disconnect “L283” or “L285” connector.
3) Disconnect “L04” connector.
4) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
5) Check the following points.
• Resistance between each of “A1” and “A2” circuits
and ground (DTC B1053): infinity
• Resistance between each of “A3” and “A4” circuits
and ground (DTC B1057): infinity
Special tool
(A): 09932–76010

[L04] (A)

[L04]

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23

[L04]

(A)

IBL80A820010-01

Are they in good condition?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.

DTC B1054 / B1058

AENBL80A8204028
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1054: Driver Seat Belt Pretensioner Circuit Shorted • Driver / passenger seat belt pretensioner circuit
to Power Supply • SDM
Driver seat belt pretensioner circuit has been shorted to
power supply.
B1058: Passenger Seat Belt Pretensioner Circuit
Shorted to Power Supply
Passenger seat belt pretensioner circuit has been shorted
to power supply.
 Air Bag System: 8B-46

Circuit Diagram

[L283] 3
1 A1

GRN/WHT L04-6
A2

GRN/YEL L04-5
[L285]
A3
2
BLU/WHT L04-7
A4

BLU/YEL L04-8

[A] [B]
:4
[a] 1 2 3 4 5 6 7 8
1 2
:5 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23
IBL80A820007-02

[A]: “L283” and “L285” connector (view: [a]) A3. Passenger seat belt pretensioner operation signal 3. SDM
output circuit
[B]: “L04” connector (view: [a]) A4. Passenger seat belt pretensioner operation signal 4. Shorting bar
ground circuit
A1. Driver seat belt pretensioner operation signal 1. Driver seat belt pretensioner 5. Floor harness
output circuit
A2. Driver seat belt pretensioner operation signal 2. Passenger seat belt pretensioner
ground circuit

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
8B-47 Air Bag System:

Step Action Yes No

2 Floor harness circuit check Replace SDM and Replace floor harness.
1) Confirm that ignition is in “OFF”. recheck DTC. )(Page
8B-61)
2) Disconnect “L283” or “L285” connector.
3) Disconnect “L04” connector.
4) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
5) Set ignition “ON”.
6) Check the following points.
• Voltage between each of “A1” and “A2” circuits and
ground (DTC B1054): 0 V
• Voltage between each of “A3” and “A4” circuits and
ground (DTC B1058): 0 V
Special tool
(A): 09932–76010

[L04] (A)

[L04]

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23

[L04]

(A)

IBL80A820011-01

Are they in good condition?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.
 Air Bag System: 8B-48

DTC B1071 / B1072

AENBL80A8204029
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1071: Driver Forward Impact sensor Communication • Forward impact sensor
Data Inconsistent • Forward impact sensor circuit
Forward impact sensor has communicated with no
• SDM
response or inconsistent ID code.
B1072: Driver Forward Impact sensor Communication
Data Invalid
Forward impact sensor has communicated with invalid
data.

Circuit Diagram

[E40] [E382] [G334] 2

A1 A3
1

BEG BEG G11-10

A2 A4

PNK/BLK PNK/BLK G11-9

[A] [B] [C]

:3 1 2
[a] 1 2 3 4 1 2 3 4 5 6 7 8
:4 9 10 11 12 13 14
15 16 17 18 19 20 21
IBP80A820015-01

[A]: “E40” connector (view: [a]) A1: Forward impact sensor signal A4: Forward impact sensor signal 3. Instrument panel harness
output circuit ground circuit
[B]: “G334” connector (view: [a]) A2: Forward impact sensor signal 1. Forward impact sensor 4. Main harness
ground circuit
[C]: “G11” connector (view: [a]) A3: Forward impact sensor signal 2. SDM
output circuit

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
2 DTC check Go to applicable DTC Go to Step 3.
1) Check if DTC B1073 or B1074 is detected. )(Page 8B- troubleshooting.
8)

Is relevant DTC detected?

3 Forward impact sensor check Replace SDM and End.
1) Confirm that ignition is in “OFF”. recheck DTC. )(Page
8B-61)
2) Replace forward impact sensor. )(Page 8B-65)
3) Set ignition “ON”.
4) Check DTC. )(Page 8B-8)

Is DTC detected?
8B-49 Air Bag System:

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.

DTC B1073 / B1074

AENBL80A8204030
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1073: Driver Forward Impact sensor Circuit Shorted to Ground • Forward impact sensor
Forward impact sensor circuit has been shorted to ground. • Forward impact sensor circuit
B1074: Driver Forward Impact Sensor Circuit Open
• SDM
Forward impact sensor circuit has been shorted to power supply or
opened.

Circuit Diagram

[E40] [E382] [G334] 2

A1 A3
1

BEG BEG G11-10

A2 A4

PNK/BLK PNK/BLK G11-9

[A] [B] [C]

:3 1 2
[a] 1 2 3 4 1 2 3 4 5 6 7 8
:4 9 10 11 12 13 14
15 16 17 18 19 20 21
IBP80A820015-01

[A]: “E40” connector (view: [a]) A1: Forward impact sensor signal A4: Forward impact sensor signal 3. Instrument panel harness
output circuit ground circuit
[B]: “G334” connector (view: [a]) A2: Forward impact sensor signal 1. Forward impact sensor 4. Main harness
ground circuit
[C]: “G11” connector (view: [a]) A3: Forward impact sensor signal 2. SDM
output circuit

DTC Troubleshooting
Step Action Yes No
1 Was “Air Bag Diagnostic System Check” performed? Go to Step 2. Go to “Air Bag
Diagnostic System
Check” (Page 8B-7).
 Air Bag System: 8B-50

Step Action Yes No

2 Instrument panel harness circuit check Go to Step 3. Replace instrument
1) Confirm that ignition is in “OFF”. panel harness.
2) Disconnect “G11” and “G334” connectors.
3) Check the following point.
• Resistance of “A3” and “A4” circuits: 1 Ω or less
Special tool
(A): 09932–76010

[G334]

1 2 3 4

[G11]
(A)

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
I9P60A820103-02

Are they in good condition?

3 Instrument panel harness circuit check Go to Step 4. Replace instrument
1) Check the following point. panel harness.
• Resistance between “G11-10” and “G11-9” terminals:
infinity
Special tool
(A): 09932–76010

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21 (A)

IAW101820131-01

Are they in good condition?

8B-51 Air Bag System:

Step Action Yes No

4 Instrument panel harness circuit check Go to Step 5. Replace instrument
1) Check the following point. panel harness.
• Resistance between each of “A3” and “A4” circuits
and ground: infinity
Special tool
(A): 09932–76010

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21 (A)

IAW101820132-01

Are they in good condition?

5 Instrument panel harness circuit check Go to Step 6. Replace instrument
1) Set ignition “ON”. panel harness.
2) Check the following point.
• Voltage between each of “A3” and “A4” circuits and
ground: 0 V
Special tool
(A): 09932–76010

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21 (A)

IAW101820133-01

Are they in good condition?

6 Main harness circuit check Go to Step 7. Replace main harness.
1) Set ignition “OFF”.
2) Disconnect “E40” connector.
3) Check the following point.
• Resistance of “A1” and “A2” circuits: 1 Ω or less
Special tool
(A): 09932–76010

[E382]

4 3 2 1

[E40] (A)

1 2

IBP80A820016-01

Are they in good condition?

 Air Bag System: 8B-52

Step Action Yes No

7 Main harness circuit check Go to Step 8. Replace main harness.
1) Check the following point.
• Resistance between “E40-1” and “E40-2” terminals:
infinity
Special tool
(A): 09932–76010

[E40]

1 2
(A)

IBP80A820018-01

Are they in good condition?

8 Main harness circuit check Go to Step 9. Replace main harness.
1) Check the following point.
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
Special tool
(A): 09932–76010

[E40]

1 2
(A)

IBP80A820019-01

Are they in good condition?

9 Main harness circuit check Go to Step 10. Replace main harness.
1) Set ignition “ON”.
2) Check the following point.
• Voltage between each of “A1” and “A2” circuits and
ground: 0 V
Special tool
(A): 09932–76010

[E40]

1 2
(A)

IBP80A820020-01

Are they in good condition?

8B-53 Air Bag System:

Step Action Yes No

10 Forward impact sensor check Replace SDM and End.
1) Confirm that ignition is in “OFF”. recheck DTC. )(Page
8B-61)
2) Replace forward impact sensor. )(Page 8B-65)
3) Set ignition “ON”.
4) Check DTC. )(Page 8B-8)

Is DTC detected?

NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs, referring to “DTC Clearance” (Page 8B-8) if any DTC is detected.
• Repeat “Air Bag Diagnostic System Check” (Page 8B-7) to confirm that the trouble has been solved.

DTC U0073
AENBL80A8204031
Refer to “Troubleshooting for Communication Bus Off”: K14B Model in Section 10H (Page 10H-12) / “Troubleshooting
for Communication Bus Off”: D13A Model in Section 10H (Page 10H-32).

SDM Power Supply and Ground Circuit Check

AENBL80A8204032
Circuit Diagram

5 3

2
1 RED L04-18

BLK L04-23

[A]

:4 [a] 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23
I9P60A820108-02

[A]: “L04” connector (view: [a]) 2. “A/B” fuse 4. Floor harness

1. Ignition power supply 3. SDM 5. J/B

DTC Troubleshooting
Step Action Yes No
1 Battery voltage check Go to Step 2. Check charging system
1) Check battery voltage. and repair it. )(Page
1J-5) / )(Page 1J-18)
Is voltage in 9 – 16 V?
2 SDM connection check Go to Step 3. Check for intermittent
1) Check for proper connection to SDM connector. trouble. )(Page 00-11)
If OK, substitute a
Is it connected securely?
known-good SDM and
recheck connection.
)(Page 8B-61)
3 Fuse check Go to Step 4. Replace floor harness
1) Confirm that ignition is in “OFF”. and then replace “A/B”
fuse.
2) Check “A/B” fuse.

Is “A/B” fuse in good condition?

 Air Bag System: 8B-54

Step Action Yes No

4 Power circuit check Go to Step 5. Replace floor harness.
1) Confirm that ignition is in “OFF”.
2) Disconnect “L04” connector.
3) Set ignition “ON”.
4) Measure voltage between “L04-18” terminal and ground.
Special tool
(A): 09932–76010

[L04]

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
(A)
17 18 19 20 21 22 23

IAW101820157-01

Is voltage in 10 – 14 V?
5 Ground circuit check SDM power supply Replace floor harness.
1) Set ignition “OFF”. circuit and ground circuit
are in good condition.
2) Measure resistance between “L04-23” terminal and
ground.
Special tool
(A): 09932–76010

[L04]

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
(A)
17 18 19 20 21 22 23

IAW101820158-01

Is resistance 1 Ω or less?
8B-55 Air Bag System:

Contact Coil and Its Circuit Check

AENBL80A8204033
Circuit Diagram

[S121] [S172] [G347]

A1
1 2

GRN/RED G11-6
A2

GRN G11-5

[A] [B] [C]

:4
[a] 1 2 1 2 3 4 5 6 7 8
:5 1 2
9 10 11 12 13 14
15 16 17 18 19 20 21
IBP80A820023-01

[A]: “S121” connector (view: [a]) A2. Driver air bag (inflator) module deployment 4. Shorting bar
signal ground circuit
[B]: “G347” connector (view: [a]) 1. Driver air bag (inflator) module 5. Instrument panel harness
[C]: “G11” connector (view: [a]) 2. Contact coil assembly
A1. Driver air bag (inflator) module deployment 3. SDM
signal output circuit

Troubleshooting
Step Action Yes No
1 Driver air bag (inflator) module circuit check Go to Step 2. Check for defective wire
1) Remove driver air bag (inflator) module from steering harness. If check result
column. )(Page 8B-62) is OK, replace contact
coil assembly. )(Page
2) Disconnect “G11” connector.
6B-5)
3) Release shorting bar in SDM connector inserting release
tool included in special tool (A).
4) Check the following point.
• Resistance between “G11-5” and “G11-6” terminals:
infinity
Special tool
(A): 09932–76010

[G11] (A)

[G11]

1 2 3 4 5 6 7 8
9 10 11 12 13 14
15 16 17 18 19 20 21
IAW10A820057-01

Are they in good condition?

 Air Bag System: 8B-56

Step Action Yes No

2 Contact coil circuit (driver air bag (inflator) module Go to Step 3. Replace contact coil
circuit) check assembly. )(Page 6B-
1) Remove contact coil assembly. )(Page 6B-5) 5)
2) Check the following points.
• Resistance between “S121-1” and “S172-2” terminals:
1 Ω or less
• Resistance between “S121-2” and “S172-1” terminals:
1 Ω or less
Special tool
(A): 09932–76010

[S172]

2 1

(A)

[S121]

1 2

IAP70B820008-01

Are they in good condition?

8B-57 Air Bag System:

Step Action Yes No

3 Contact coil circuit (horn circuit) check Go to Step 4. Replace contact coil
1) Check the following point. assembly. )(Page 6B-
5)
• Resistance between “S61-1” and “S171-1” terminals:
1 Ω or less
Special tool
(A): 09932–76010

[S61]

6 5 4 3 2 1

(A)

[S171]

6 5 4 3 2 1

IBL80A820012-01

Is it in good condition?
4 Contact coil circuit check Contact coil and its Replace contact coil
1) Measure resistance between each terminal of contact circuit are in good assembly. )(Page 6B-
coil and other terminals. condition. 5)

Is each measured resistance infinite?

 Air Bag System: 8B-58

Repair and Inspection Required after Accident – Check for damage and bend according to “Steering
AENBL80A8204034 Column Inspection” in Section 6B (Page 6B-9).
! CAUTION • Steering wheel and driver air bag (inflator) module
• All air bag system components and their – Check air bag (inflator) module for damage and
mounting points, including electrical installation condition.
harness, must be inspected after an – Check trim cover (pad surface) for cracks.
accident. If any component is damaged or – Check wire harness and connector for damage and
deformed, it must be replaced even if air tightness.
bag system has not activated.
• Never use air bag system parts from
another vehicle.
• Do not attempt to repair parts below. If any
defect is found for these parts, replace it.
– Driver / Passenger air bag (inflator)
modules
– Driver / Passenger seat belt
pretensioners
– Forward impact sensor
– SDM
– Contact coil
I9P60A820040-01
– Air bag wire harnesses (in main
• Contact coil assembly
harness, instrument panel harness and
floor harness), passenger air bag – Check wire harness and connectors for damage
harness and seat harness. and tightness.
• Proper operation of sensors and air bag – Check contact coil case for damage.
system requires that any repairs to vehicle – Check contact coil circuit referring to “Contact Coil
structure return it to its original production and Its Circuit Check” (Page 8B-55).
configuration.
• Never use SDM which has detected a
condition that meets any of deployment
conditions.
Refer to “Air Bag Diagnostic System
Check” (Page 8B-7) when checking SDM.

Accident with Deployment / Activation – Component

Replacement
Replace the following components when driver and
passenger air bags are deployed.
• Driver and passenger air bag (inflator) modules
I9P60A820041-01
• Driver-side / passenger-side seat belt pretensioners
• Instrument panel member and reinforcement
• SDM
– Check for any distortion, bending, cracking and
• Forward impact sensor other damage.
• Instrument panel – Check instrument panel for cracks and
deformation.
Accident with or without Deployment / Activation –
• Passenger air bag (inflator) module
Component Inspections
Inspect the following air bag system components after – Check for dents, cracks, damage and installation
any crash, whether air bag system was activated or not. condition.
If any faulty condition is found in the following checks, – Check harness and connector for damage and
replace faulty component. tightness.
• Steering column and steering lower shaft
– Check for length, damage and bend according to
“Steering Column Inspection” in Section 6B (Page
6B-9).
• Steering column bracket
8B-59 Air Bag System:

• Forward impact sensor

– Check sensor (1) and apron side member (2) for
damage, bend and rust.
– Check connector (3) and lead wire (4) of forward
impact sensor for scorch, melt and damage.

3
4

IAP70P821015-02

• SDM
– Check for external damage such as deformation,
scratch, crack and peeled paint.
– Check SDM for deformation which prevents its
proper installation (gap between SDM and SDM
plate, etc.).
– Check connector or lead wire of SDM for scorch, 2

melt or damage. IBP80A820024-01

– Check SDM connector and terminals for tightness. • Seat belt pretensioner
– Check DTC and follow referring corresponding – Check for dents, cracks, damage and installation
diagnostic flow if any DTC is found. condition.
– Check harness and connector for damage and
tightness.

IAW101820087-01

• Air bag wire harnesses and connectors

– Check for damages, deformities and poor
1
connections.
Refer to “Intermittent Connection and Poor Contact
Inspection” in Section 00 (Page 00-11).
– Check wire harnesses for tightness. 2
I9P60A820003-01

2 1. Webbing 2. Retractor assembly

• Seat belts and mounting points

3
– Refer to “Front Seat Belt Components” in Section
8A (Page 8A-3).
1 • “AIR BAG” warning light
– Perform “Air Bag Diagnostic System Check” (Page
3 8B-7) after vehicle is completely repaired.

IBL80A820001-01

1. Main harness 3. Floor harness

2. Instrument panel harness 4. Grounding point
 Air Bag System: 8B-60

Repair Instructions
Disabling Air Bag System
AENBL80A8206001
! WARNING
Disabling of air bag system must be started at least 90 seconds after setting ignition “OFF” and
disconnecting negative (–) cable at battery. Otherwise, system may be activated by reserve energy in
SDM.

When servicing air bag system, related parts and working around air bag (inflator) module, disable air bag (inflator)
modules as follows.
Servicing item Disabling procedure
• When disconnecting or connecting air bag system Disconnect negative (–) cable at battery. )(Page 8B-60)
connectors.
• When removing or installing air bag system
components.
• When servicing air bag system, related parts or working
around air bag (inflator) module.
• When performing electric welding. Disconnect negative (–) cable at battery, and remove all
• When there is a possibility that air bag system or air bag (inflator) modules. )(Page 8B-60)
related parts would be heated up to 93 °C (200 °F) and
more by electric welding or paint baking process.

Disabling Procedure (Disconnecting Negative (–) Battery Cable)

1) Set front wheels in straight-ahead position.
2) Set ignition “OFF”.
3) Disconnect negative (–) cable at battery.
4) Wait for at least 90 seconds after performing Step 3).

Disabling Procedure (Disconnecting Negative (–) Battery Cable and Removing All Air Bag (Inflator) Modules)
1) Set front wheels in straight-ahead position.
2) Set ignition “OFF”.
3) Disconnect negative (–) cable at battery.
4) Wait for at least 90 seconds after performing Step 3).
5) Remove all air bag (inflator) modules.

Enabling Air Bag System

AENBL80A8206002
1) Make sure that removed components are installed and/or disconnected connectors are connected properly.
2) Check that ignition is in “OFF”.
3) Connect negative (–) cable at battery.
4) Set ignition “ON”.
5) Check if “AIR BAG” warning light turns on for about 6 seconds and then comes off.
6) Perform “Air Bag Diagnostic System Check” (Page 8B-7) if defective.
8B-61 Air Bag System:

SDM Removal and Installation
AENBL80A8206003
! WARNING
During service procedures, be careful when
handling an SDM.
Be sure to read “Precautions for Handling
and Storage of Air Bag System Components”
(Page 8B-1) before starting to work and
observe every precaution during work.
Neglecting them may result in personal
injury, death or inactivation of air bag system
when necessary.
• Check that none of the following faulty conditions
exists.
a. Bend, scratch, deformation on mating surface of
vehicle body where SDM is mounted.
b. Foreign matter or rust on mating surface of vehicle
body where SDM is mounted.
• Ensure that arrow (1) on SDM points toward front of
vehicle.
• Tighten SDM nuts (2) to specified torque.
Tightening torque
SDM nut (a): 9.0 N·m (0.92 kgf-m, 7.0 lbf-ft)

Removal 2,(a)
1) Disable air bag system. )(Page 8B-60)
2) Remove floor console rear box and floor console
front box. )(Page 9H-9)
3) Turn over floor carpet.
4) Remove bolts (1), then remove bracket (2).

2
1
2,(a)

IBL80A820018-02

• Enable air bag system. )(Page 8B-60)

SDM Inspection
AENBL80A8206004

! CAUTION

• Do not connect a tester whatever type it

may be.
1

IBP80A820025-01

5) Disconnect SDM connectors (1).

6) Remove SDM nuts (2) and ground cable (4).
7) Remove SDM (3).

4 I9W10P821002-01

• Never repair or disassemble SDM.

• Be careful when handling an SDM so as
not to cause vibration or impact including
dropping. If SDM has been dropped,
replace it even if there is no defect in
appearance. Replace with new one in case
3 of defect such as deformation and cracks.
2
1
IBL80A820013-03 If any faulty condition is found in the following checks,
replace the SDM with new one.
Installation
• Air bag is deployed.
Reverse removal procedure noting the following points.
 Air Bag System: 8B-62

• Check SDM for dents, cracks or deformation.

• Check SDM connector for damage, cracks or lock
mechanism.
• Check SDM terminal for bend, corrosion or rust.
• DTC B1013, B1021 or B1026 is stored in SDM. “b” “a”

Driver Air Bag (Inflator) Module Removal and

Installation
AENBL80A8206005
! WARNING
2 3
• When handling an air bag (inflator)
module, be sure to read “Precautions for 1
I9P60A820051-02
Handling and Storage of Air Bag System
Components” (Page 8B-1) and observe 5) Remove driver air bag (inflator) module from
each instruction. Failure to follow them steering wheel.
could cause damage to driver air bag
(inflator) module or result in personal Installation
injury. Reverse removal procedure noting the following points.
• Never insert foreign matter such as flat- • Lock connector for driver air bag (inflator) module
end screwdriver between driver air bag securely.
(inflator) module and “S121” connector as • Tighten driver air bag (inflator) module bolts to
static electricity may cause accidental specified torque.
deployment. Tightening torque
Driver air bag (inflator) module bolt (a): 9.0 N·m (
NOTE 0.92 kgf-m, 7.0 lbf-ft)
Refer to “Repair and Inspection Required
after Accident” (Page 8B-58) before replacing (a)
deployed air bag.

Removal
1) Disable air bag system. )(Page 8B-60)
2) Remove driver air bag (inflator) module bolts (2) of
driver air bag (inflator) module at both sides of
steering wheel (1) using TORX® wrench (T30).

(a)
I9P60A820052-01
1
• Enable air bag system. )(Page 8B-60)

2
IBL80A820014-01

3) Disconnect horn connector (1).

4) Disconnect driver air bag (inflator) module connector
(2) as shown in figure.
a) Release lock (3).
b) Disconnect connector with lock released.
8B-63 Air Bag System:

Driver Air Bag (Inflator) Module Inspection Passenger Air Bag (Inflator) Module Removal
AENBL80A8206006
and Installation
AENBL80A8206007
! WARNING
! WARNING
• Never measure resistance of air bag
• When handling an air bag (inflator)
(inflator) module. Current of tester can
module, be sure to read “Precautions for
deploy air bag.
Handling and Storage of Air Bag System
Components” (Page 8B-1) and observe
each instruction. Failure to follow them
could cause damage to air bag (inflator)
module or result in personal injury.
• Never insert foreign matter such as flat-
end screwdriver between passenger air
bag (inflator) module and “G259”
connector as static electricity may cause
accidental deployment.

NOTE
I9P60A820053-01
Refer to “Repair and Inspection Required
• Never repair or disassemble air bag after Accident” (Page 8B-58) before replacing
(inflator) module. a deployed air bag.

! CAUTION
When handling air bag (inflator) module, be
careful not to give shock to it. If air bag
(inflator) module has received shock,
regardless of its deformation, replace the
module with a new one.
Check air bag (inflator) module and if any of the following
conditions is found, replace air bag (inflator) module or
steering wheel with new one.
• Air bag being deployed
• Air bag (inflator) module being deformed or damaged
• Connector being damaged
• Air bag (inflator) module bracket of steering wheel
being deformed or damaged
• Unable to install new air bag (inflator) module
smoothly (Clearance between steering wheel and air
bag (inflator) module is uneven)
Removal
1) Disable air bag system. )(Page 8B-60)
2) Remove audio unit. )(Page 9O-5)
3) Remove glove box.
4) Remove passenger air bag door screws (1).
5) Remove passenger air bag (inflator) module bolts
(2).
6) Disconnect passenger air bag (inflator) module
connector (4) as shown in figure.
a) Release lock (3).
b) Disconnect connector with lock released.
A
4

3
“1” “2”

A
A
A
A

A
2
A
A
A

I9P60A820054-01
2
IBP80A820026-02
 Air Bag System: 8B-64

7) Remove claws (1), then remove passenger air bag

(inflator) module (2) from passenger air bag door (3).

1 (a)
IAP70P821031-02
IAP70P821019-02
• Enable air bag system. )(Page 8B-60)
Installation
Reverse removal procedure noting the following points. Passenger Air Bag (Inflator) Module Inspection
AENBL80A8206008
• Fit claws (1) of passenger air bag (inflator) module (2)
to passenger air bag door (3) securely. ! WARNING

3 • Never measure resistance of air bag

(inflator) module. Current of tester can
deploy air bag.

IAP70P821019-02 I9P60A820062-01

• Lock connector for air bag (inflator) module securely.
• Tighten passenger air bag (inflator) module bolts to
specified torque.
Tightening torque
Passenger air bag (inflator) module bolt (a): 23
N·m (2.3 kgf-m, 17.0 lbf-ft)
• Never repair or disassemble air bag
(inflator) module.
! CAUTION
When handling air bag (inflator) module, be
careful not to give shock to it. If air bag
(inflator) module has received shock,
regardless of its deformation, replace the
module with a new one.

Check air bag (inflator) module and if any of the following

condition is found, replace air bag (inflator) module with
new one.
• Air bag being deployed.
• Air bag (inflator) module being deformed or damaged.
• Connector being damaged.
8B-65 Air Bag System:
• Bend or deformation of air bag (inflator) module
bracket.
Seat Belt Pretensioner Components
AENBL80A8206009
Refer to “Front Seat Belt Components” in Section 8A
(Page 8A-3).
Seat Belt Pretensioner Removal and Installation
AENBL80A8206010
Refer to “Front Seat Belt Assembly Removal and
Installation” in Section 8A (Page 8A-4).
Seat Belt Pretensioner Inspection
AENBL80A8206011
Refer to “Front Seat Belt Assembly Removal and
Installation” in Section 8A (Page 8A-4).
! WARNING
• Never measure resistance of retractor
pretensioner. Current of tester can activate
pretensioner.
I9P60A820063-01
• Do not face exhaust hole (1) side
downward or place anything on it when
placing seat belt pretensioner which has
not been activated.
1 3
IBP80A820036-01
• Never repair or disassemble seat belt
assembly.
Check seat belt assembly (retractor pretensioner) and if
any of the following conditions is found, replace seat belt
assembly (retractor pretensioner) with new one.
• Pretensioner being activated.
NOTE
As retractor pretensioner is controlled with
driver and passenger air bag, you should
judge that pretensioner has been activated if
air bag has deployed.
• Deformation or damage of retractor pretensioner.
• Connector being damaged.
Forward Impact Sensor Removal and
Installation
AENBL80A8206012
! CAUTION
• Never repair or disassemble sensor.
• Never drop, strike or shake sensor.
If dropped, replace it even if there is no
apparent defect.
If sensor is deformed or cracked, replace
sensor.
• Sensor bolt must be carefully tightened to
specification to assure proper operation.
Loosely connected sensor may cause
improper operation of air bag system.
Removal
1) Disable air bag system. )(Page 8B-60)
2) Remove front bumper. )(Page 9H-1)
3) Disconnect forward impact sensor connector (2) as
follows.
a) Release locking slider (1) by sliding it in direction
of arrow “1”.
b) Disconnect forward impact sensor connector (2)
by pulling it in direction of arrow “2”.
4) Remove forward impact sensor bolt (3) and remove
forward impact sensor (4) from apron side member
(5).
1
“2” “1” 4
5
IBP80A820030-01

Installation
1) Check that none of the following faulty conditions
exists.
• Bend, deformation or rust on apron side member.
• Foreign material on sensor.
• Direct arrow (1) on forward impact sensor
frontward.
1
I9W10P821033-01
2) Align mounting pin (1) to mounting hole (2) of vehicle
to install forward impact sensor (3).
3) Tighten forward impact sensor bolt to specified
torque.
Tightening torque
Forward impact sensor bolt (a): 9.0 N·m (0.92
kgf-m, 7.0 lbf-ft)
4) Connect forward impact sensor connector securely.
2 • Procedure should be followed strictly as
1 • Be sure to read “Precautions on Air Bag
(a) 3
IBP80A820031-01
5) Install front bumper. )(Page 9H-1)
6) Enable air bag system. )(Page 8B-60)
Forward Impact Sensor Inspection
AENBL80A8206013
Check forward impact sensor and if any of the following
condition is found, replace it with new one.
• Driver air bag or passenger air bag has deployed.
• Check sensor for dents, cracks or deformation.
• Check sensor connector (sensor side and harness
side) and sensor connector lock mechanism for
damage or crack.
• Check connector terminals for bend, corrosion or rust.
Air Bag System: 8B-66
Air Bag (Inflator) Module and Seat Belt
Pretensioner Disposal
AENBL80A8206014
! WARNING
Failure to follow proper disposal procedures
of air bag (inflator) modules and seat belt
pretensioners can result in air bag
deployment and pretensioner activation
which may cause personal injury. Do not
dispose of live (undeployed) air bag (inflator)
modules and seat belt pretensioners.
Undeployed air bag (inflator) modules and
inactivated seat belt pretensioners contain
substances that can cause severe illness or
personal injury if sealed container is
damaged during disposal.
Air bag (inflator) module / seat belt pretensioner can be
deployed / activated inside or outside the vehicle.
Deployment / Activation method depends upon final
disposition of vehicle. Review the following instructions
in order to determine which method will work best in a
given situation.
Deployment / Activation Outside the Vehicle: When you
intend to return vehicle to service, deploy air bag
(inflator) module(s) and/or activate seat belt
pretensioner(s) outside the vehicle.
Deployment / Activation Inside the Vehicle: When
vehicle will be destroyed or salvaged for component
parts, deploy air bag module(s) and/or activate seat belt
pretensioner(s) installed on vehicle.
! WARNING
The following precautions must be observed
for this work. Failure to observe any of them
may result in personal injury.
described here.
System Service” beforehand.
• To avoid accidental deployment /
activation, this work should be performed
by no more than one person.
• Since smoke is produced when air bag
(inflator) module is deployed and
pretensioner is activated, select well-
ventilated area.
• Wear safety glasses throughout this entire
deployment / activation and disposal
procedure.
• Wear suitable ear protection when
deploying air bag (inflator) module /
activating seat belt pretensioner. Also,
advise those who are in area close to
deployment / activation site to wear
suitable ear protection.
8B-67 Air Bag System:

• Do not deploy / activate two or more air
bag system components (air bag (inflator)
modules and seat belt pretensioners) at
same time.
• Never connect deployment harness to any
12 volts vehicle battery before connecting
deployment harness to air bag (inflator)
module and seat belt pretensioner.
Deployment harness shall remain shorted
and not be connected to 12 volts vehicle
where there is no activity is preferred. If outdoor
location is not available, use space on shop floor
where there is no activity and sufficient ventilation is
provided.
Ensure no loose or flammable object exists within
deployment area.
2) Place driver air bag (inflator) module (1) with its vinyl
trim cover facing up (2) on ground in Step 1).
3

battery till you are ready to deploy air bag

(inflator) module or activate seat belt
2
pretensioner.
• Never disconnect banana plug (1) till
deployment harness (A) is connected to
vehicle battery as static may cause 1
accidental deployment of air bag.
Special tool
(A): 09932–75031

(A)

1 I9P60A820083-01

I8G001821052-01 3) Connect deployment harness (A) and adapter cable

• Never attempt to insert foreign matter such (B) to driver air bag (inflator) module.
as flat-end screwdriver into connectors of
Special tool
air bag (inflator) module and seat belt
(A): 09932–75031
pretensioner as static electricity may
(B): 09932–76510
cause accidental deployment.

Deployment / Activation Outside the Vehicle

! CAUTION

• Since smoke is produced when air bag

(inflator) module is deployed and
pretensioner is activated, select well-
ventilated area.
• Wear safety glasses during this 1 (B)
deployment / activation procedure.
• Check that there is no open, short or (A)
damage in special tools (deployment I9P60A820084-01

harness and adapter cable). 1. Banana plug

Removal Passenger Air Bag (Inflator) Module

Remove air bag (inflator) module or seat belt
pretensioner from vehicle.
• Driver air bag (inflator) module )(Page 8B-62)
• Passenger air bag (inflator) module )(Page 8B-63)
• Seat belt pretensioner )(Page 8A-3)
Setting
Driver Air Bag (Inflator) Module
1) Clear space (3) on ground about 185 cm (6.1 ft) in
diameter where driver air bag (inflator) module (1) is
set for deployment. Paved and outdoor location
1) Turn deployment surface upward and tighten to
deployment fixture (A) to specified torque using
passenger air bag (inflator) module bolt.
Tightening torque
Passenger air bag (inflator) module bolt (a): 23
N·m (2.3 kgf-m, 17.0 lbf-ft)
Special tool
(A): 09932–75041
 Air Bag System: 8B-68

[a] 3

5
1 4

2
1

(A)
(a)
I9W10P821043-02 I9P60A820085-01

[a]: Air bag deployment direction 3) Hold seat belt pretensioner (1) vertically, tie webbing
1. Passenger air bag (inflator) module (2) tightly at 10 cm (3.9 in.) from cutting edge as
shown.
2) Connect deployment harness (A) and adapter cable
(B) to passenger air bag (inflator) module.
2
Special tool
“a”
(A): 09932–75031
(B): 09932–76510
1

(B)

I9P60A820086-01
1
“a”: 10 cm (3.9 in.)

(A)
4) Tie seat belt pretensioner with wire harness (1) to
I9W10P821044-01
tire at least 3 times as shown.
1. Banana plug Wire harness section
1.25 mm2 (0.0019 in.2 or more)
Retractor Pretensioner
1) Cut webbing (1) at tongue plate stopper (2) of seat
belt pretensioner (3) side as shown.
2) Remove tongue plate (4) and shoulder anchor (5)
from webbing.

1
I9P60A820087-01

5) Connect deployment harness (A) and adapter cable

(B) to seat belt pretensioner.
Special tool
(A): 09932–75031
(B): 09932–76510
8B-69 Air Bag System:

2) Separate two banana plugs (2) on deployment

(B) harness.

! CAUTION
(A)
Notify all people in immediate area that you
intend to deploy air bag (inflator) module or
activate seat belt pretensioner.

3) Connect deployment harness to 12 V vehicle battery.

1
I9P60A820088-01
1. Banana plug
6) Pile 3 tires (2) and wheel-installed tire (1) on top of
tire with seat belt pretensioner, and tie them with
wire harness (3) as shown.
! CAUTION
• Harness of special tools (A) and (B) should
not be too tight under tire. Otherwise,
harness may be pulled to cause breakage
when seat belt pretensioner activates.
• Secure tires with wire harness.
! WARNING
• Do not place deployed air bag (inflator)
module and activated seat belt
pretensioner near any flammable objects.
• Do not apply water, oil, etc. to deployed air
bag (inflator) module and activated seat
belt pretensioner.
• Wait for about 30 minutes before touching
any metal surface of air bag (inflator)
module or seat belt pretensioner.

(B)

(A)
4

I9P60A820089-01

4. Banana plug

7) Drape blanket over those tires.

Deployment
1) Stretch deployment harness (A) to its full length 10 m
(33 ft), and then place 12 V vehicle battery (1) near
shorted end of deployment harness.
Special tool
(A): 09932–75031
(B): 09932–76510
 Air Bag System: 8B-70

(A) (B) 4
“a”

2 4 (B)

1 (B)
(A)

(A)
“a”

2
“a”
1

2
1

IAP70P821022-01

3. Blanket 4. Clear space 185 cm (6 ft) “a”. 10 m (33 ft)

4) Put on safety glasses (1) and pair of shop gloves (2) ! CAUTION
to protect your eyes and hands from possible
irritation and heat when handling deployed air bag Completely cover windshield area and all
(inflator) module or activated seat belt pretensioner. door window opening with drop cloth, a
blanket or any similar item (1). This reduces
5) Dispose of deployed air bag (inflator) module or
possibility of injury due to possible
activated seat belt pretensioner through normal
fragmentation of vehicle’s glass or interior.
refuse channels after it has cooled for at least 30
minutes and tightly seal air bag (inflator) module or
seat belt pretensioner in a strong vinyl bag. 1

IBL80A820015-01

2) Disable air bag system. )(Page 8B-60)

3) Connect special tool according to part to be
activated.
I8T201821025-01 Driver Air Bag (Inflator) Module
6) Wash your hands with mild soap and water a) Remove steering column lower cover. )(Page
afterward. 6B-1)
b) Disconnect contact coil assembly connector (2)
Deployment / Activation Inside the Vehicle as follows.
1) Place vehicle on safe place and fully close all i) Release locking slider (1) by sliding it in
windows. direction of arrow “1”.
ii) Disconnect contact coil assembly connector
(2) by pulling it in direction of arrow “2”.
8B-71 Air Bag System:

c) Connect deployment harness (A) and adapter ii) Disconnect connector (2) with lock released.
cable (B) to contact coil side. c) Connect deployment harness (A) and adapter
Special tool cable (B) to retractor pretensioner.
(A): 09932–75031 Special tool
(B): 09932–78332 (A): 09932–75031
(B): 09932–76510

i)
1 ii)
2

(B) “1”

)i
1 “2”
(A) 2 (A)

IBP80A820032-01
(B)
Passenger Air Bag (Inflator) Module IBP80A820034-01

a) Remove center pillar lower trim. )(Page 9H-6) 4) Check that there is no person inside vehicle or in
b) Disconnect passenger air bag (inflator) module close area. Remove any object that can be flown off
connector (2) as follows. or flammable object due to deployed air bag (inflator)
module or activated seat belt pretensioner.
i) Release locking slider (1) by sliding it in
direction of arrow “1”. 5) Place 12 volts vehicle battery (1) near shorted end of
deployment harness.
ii) Disconnect passenger air bag (inflator)
module connector (2) by pulling it in direction Special tool
of arrow “2”. (A): 09932–75031
c) Connect deployment harness (A) and adapter
2
cable (B) at passenger air bag (inflator) module
side.
Special tool
(A): 09932–75031
(B): 09932–78332

1 4
2
(A)
“1”
“2” 3
IBL80A820017-01

1 2. Blanket 4. 10 m (33 ft)

3. Banana plug

(B)
6) Separate banana plug of deployment harness.

! CAUTION
(A)

IBL80A820016-01
Notify all people in immediate area that you
intend to deploy air bag (inflator) module or
Retractor Pretensioner
activate seat belt pretensioner.
a) Remove center pillar lower trim. )(Page 9H-6)
b) Disconnect pretensioner connector (2) from 7) Connect banana plug of deployment harness to
retractor pretensioner as shown in figure. battery.
i) Release lock (1).
 Air Bag System: 8B-72

! WARNING • Never apply water and oil etc. to deployed air bag
(inflator) module and activated seat belt pretensioner
• Do not place deployed air bag (inflator) to cool them off. Do not get on deployed air bag
module and activated seat belt (inflator) module and activated seat belt pretensioner.
pretensioner near any flammable objects.
• Do not apply water, oil, etc. to deployed air
bag (inflator) module and activated seat
belt pretensioner.
• Wait for about 30 minutes before touching
any metal surface of air bag (inflator)
module or seat belt pretensioner.

Deployed Air Bag (Inflator) Module and

Activated Seat Belt Pretensioner Disposal
AENBL80A8206015 IYSQ01820095-01

! WARNING • After air bag (inflator) module has been deployed,

surface of air bag may contain a powdery residue. As
Failure to follow proper air bag (inflator)
with many service procedures, wear gloves and safety
module and seat belt pretensioner disposal
glasses.
procedures can result in air bag deployment
and pretensioner activation which may cause • When disposing of deployed air bag (inflator) module
personal injury. Undeployed air bag (inflator) and activated seat belt pretensioner, be sure to seal it
module and inactivated seat belt in a vinyl bag.
pretensioner must not be disposed of
through normal refuse channels.
Undeployed air bag (inflator) module and
inactivated seat belt pretensioner contains
substances that can cause severe illness or
personal injury if sealed container is
damaged during disposal.

Deployed air bag (inflator) module and activated seat

belt pretensioner can be disposed of in the same way
which is used for disposal of any other parts. For their
I3JA01820119-01
disposal, however, the following points should be noted.
• When air bag (inflator) module and seat belt
• Immediately after deployment / activation air bag pretensioner have been deployed / activated inside
(inflator) module and seat belt pretensioner are hot. vehicle leave them as installed to vehicle and scrap
Wait for 30 minutes to cool them off before handling them.
them.
• Be sure to wash your hands with mild soap and water
after handling them.

Specifications
Tightening Torque Specifications
AENBL80A8207001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
SDM nut 9.0 0.92 7.0 )
Driver air bag (inflator) module bolt 9.0 0.92 7.0 )
Passenger air bag (inflator) module bolt 23 2.3 17.0 )/)
Forward impact sensor bolt 9.0 0.92 7.0 )

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
8B-73 Air Bag System:

Special Tools and Equipment

Use of Special Tools
AENBL80A8208001
! WARNING 2
1
To avoid deployment when troubleshooting
air bag system, do not use electrical
equipment such as a battery powered or AC
powered voltmeter, ohmmeter, etc., or any
type of electrical equipment other than that 3
I8G001821058-01
specified. Do not use a non-powered probe
type tester. Special tool
Instructions must be followed carefully, (B): 09932–75010
otherwise personal injury may result.
This tool is used as a diagnostic aid and safety device to
prevent inadvertent air bag (inflator) module deployment.
Be familiar with tools listed under heading “Special Tool”.
The load tool has three connectors attached to its case
Study proper use of measurement tools such as Air Bag
which are electrically functional and serve as resistive
Driver / Passenger Load Tool, Connector Test Adapter
load substitutions.
Kit and digital multimeter.
Use “STEERING WHEEL” connector instead of
Special tool resistance load of all inflator modules and pretensioners.
(A): 09932–76010 Do not use “BASE OF COLUMN” and “PASSENGER
INFLATOR”.
This must be used whenever a diagnostic procedure
By connecting load tool instead of inflator modules and
requests checking or probing a terminal.
pretensioners, service work to decide location of cause
Using appropriate adapter in special tool will ensure that
of trouble - whether it is in harness or in component - can
no damage to terminal will occur from multimeter probe,
be performed.
such as spreading or bending.

(A) (A)

I8G001821057-01

The adapter (1) will also give an idea of whether or not

contact tension is sufficient, helping to find an open or
intermittent open due to poor terminal contact. SDM
shorting bar release tool (2) is included in connector test
I1JA01820004-01
adapter kit. Inserting it into SDM connector (3) will
release shorting bar. 1. Not used
2. ALL air bag (inflator) modules and all pretensioners
3. Not used

Special Tool
AENBL80A8208002
09932–75010 09932–75031
Air bag load tool Air bag deployment harness
)/)/)/)/)/)/) )/)/)/)/)/)/)/
)/)
 Air Bag System: 8B-74

09932–75041 09932–76010
Passenger air bag (inflator) Connector test adapter set
module deployment fixture
) This set includes the
following items. 1.
Connector test adapter kit
(09932-75020), 2.
Connector test adapter &
shorting bar release tool
(09932-76020)) / ) / ) / )
/)/)/)/)/)/)/)/
)/)/)/)/)/)/)/
)/)/)/)/)/)/)/
)/)/)/)/)/)/)/
)/)/)/)/)/)
09932–76510 09932–78310
Deployment adapter cable Adapter cable
)/)/)/)/) )/)/)/)

09932–78332 09932–78340
Deployment adapter cable Deployment adapter cable
)/) )/)

SUZUKI scan tool (SUZUKI- 6

SDT)
— 1 2
This kit includes following
4
items. 1. SUZUKI-SDT 2. 3
DLC cable 3. USB cable 4. 5
AC/DC power supply 5.
Voltage meter probe 6.
Storage case) / )

Section 9
Body, Cab and Accessories
CONTENTS
Precautions .................................................9-1
Precautions............................................................. 9-1
Precautions for Body, Cab and Accessories......... 9-1
Wiring Systems........................................ 9A-1
Precautions...........................................................9A-1
Cautions in Body Electrical System Servicing..... 9A-1
General Description .............................................9A-1
Abbreviations ...................................................... 9A-1
Wire / Connector Color Symbols......................... 9A-1
Symbols and Marks ............................................ 9A-1
How to Read Connector Layout Diagram ........... 9A-2
How to Read Connector Codes and Terminal
Nos.................................................................... 9A-3
How to Read Ground Point ................................. 9A-6
How to Read Power Supply Diagram.................. 9A-6
How to Read System Circuit Diagram................. 9A-7
Connector Layout Diagram .................................9A-9
Connector Layout Diagram ................................. 9A-9
Engine Compartment .......................................... 9A-9
Instrument Panel ............................................... 9A-16
Door, Roof......................................................... 9A-18
Floor .................................................................. 9A-21
Rear .................................................................. 9A-23
Ground Point ......................................................9A-23
Ground Point ..................................................... 9A-23
Power Supply Diagram ......................................9A-25
Power Supply Diagram (Petrol Engine Model) .. 9A-25
Power Supply Diagram (Diesel Engine Model) .. 9A-29
Fuses and the Protected Parts ......................... 9A-32
J/B Connector / Fuse Layout ............................ 9A-36
J/B Inner Circuit (Detail) .................................... 9A-38
System Circuit Diagram.....................................9A-45
System Circuit Diagram .................................... 9A-45
A-1 Cranking System Circuit Diagram (Petrol
Engine Model) ................................................. 9A-46
A-1 Cranking System Circuit Diagram (Diesel
Engine Model) ................................................. 9A-47
A-2 Charging System Circuit Diagram (Petrol
Engine Model) ................................................. 9A-48
A-2 Charging System Circuit Diagram (Diesel
Engine Model) ................................................. 9A-49
A-3 Ignition System Circuit Diagram (Petrol
Engine Model) ................................................. 9A-50
Table of Contents 9- i
A-4 Cooling System Circuit Diagram (Petrol
Engine Model) .................................................9A-51
A-4 Cooling System Circuit Diagram (Diesel
Engine Model) .................................................9A-52
A-5 Engine and A/C Control System Circuit
Diagram (Petrol Engine Model).......................9A-53
A-5 Engine and A/C Control System Circuit
Diagram (Diesel Engine Model) ......................9A-58
A-8 Body Control System Circuit Diagram ........9A-63
A-9 CAN Circuit Diagram ..................................9A-67
A-10 Security Control System Circuit Diagram ..9A-68
B-1 Windshield Wiper and Washer Circuit
Diagram...........................................................9A-70
B-2 Rear Wiper and Washer Circuit Diagram ...9A-71
B-3 Rear Defogger Circuit Diagram ..................9A-72
B-4 Power Window Circuit Diagram..................9A-73
B-5 Power Door Lock Circuit Diagram ..............9A-75
B-6 Power Mirror Circuit Diagram .....................9A-77
B-7 Horn Circuit Diagram ..................................9A-78
C-1 Combination Meter Circuit Diagram ...........9A-79
D-1 Headlight System Circuit Diagram .............9A-81
D-2 Position, Tail and Licence Plate Light
System Circuit Diagram ..................................9A-82
D-3 Front Fog Light System Circuit Diagram ....9A-83
D-4 Illumination Light System Circuit Diagram ..9A-84
D-5 Interior Light System Circuit Diagram.........9A-85
D-6 Turn Signal and Hazard Warning Light
System Circuit Diagram ..................................9A-86
D-7 Brake Light System Circuit Diagram ..........9A-88
D-8 Back-Up Light System Circuit Diagram ......9A-89
D-9 Headlight Leveling System Circuit
Diagram...........................................................9A-90 9
D-10 Rear Fog Light Circuit Diagram................9A-91
E-1 Heater System Circuit Diagram ..................9A-92
E-3 Rear A/C System Circuit Diagram ..............9A-93
F-1 Air Bag System Circuit Diagram .................9A-94
F-2 Anti-Lock Brake System Circuit Diagram....9A-96
F-4 Power Steering System Circuit Diagram ....9A-98
G-1 Audio System Circuit Diagram ...................9A-99
G-2 Accessory Socket System Circuit
Diagram.........................................................9A-101
List of Connector .............................................9A-102
List of Connectors ...........................................9A-102
A Connector ....................................................9A-102
C Connector ....................................................9A-102
9-ii Table of Contents
D Connector .................................................... 9A-103
E Connector .................................................... 9A-104
G Connector.................................................... 9A-105
J Connector..................................................... 9A-107
K Connector .................................................... 9A-107
L Connector..................................................... 9A-108
O Connector.................................................... 9A-109
R Connector .................................................... 9A-109
S Connector .................................................... 9A-109
Reassembling Note for Wiring Harness.........9A-109
Reassembling Note for Wiring Harness .......... 9A-109
Around Engine ................................................ 9A-110
Around Battery ................................................ 9A-112
Around Strut .................................................... 9A-115
Around Instrument Panel ................................ 9A-118
Around Main Floor........................................... 9A-121
Around Rear End Door.................................... 9A-124
Around Fuel Tank............................................ 9A-125
Specifications...................................................9A-126
Tightening Torque Specifications.................... 9A-126
Lighting Systems .................................... 9B-1
Component Location ...........................................9B-1
Lighting System Component Location ................ 9B-1
Diagnostic Information and Procedures............9B-2
Lighting System Diagnosis Function ................... 9B-2
Lighting System Symptom Diagnosis.................. 9B-2
Repair Instructions ..............................................9B-3
Headlight Unit Removal and Installation .............9B-3
Headlight Aiming and Light Intensity Check........ 9B-4
Front Fog Light Removal and Installation (If
Equipped).......................................................... 9B-5
Front Fog Light Aiming Adjustment (If
Equipped).......................................................... 9B-5
Rear Fog Light Assembly Removal and
Installation ......................................................... 9B-6
Side Turn Signal Light Removal and
Installation ......................................................... 9B-6
License Plate Light Removal and Installation ..... 9B-6
Rear Combination Light Removal and
Installation ......................................................... 9B-7
High Mount Stop Light Removal and
Installation ......................................................... 9B-7
Dome Light Removal and Installation ................. 9B-7
Headlight Leveling Actuator Inspection............... 9B-8
Lighting and Turn Signal Switch Removal and
Installation ......................................................... 9B-8
Lighting and Turn Signal Switch Inspection ........ 9B-8
Hazard Warning Switch Removal and
Installation ......................................................... 9B-9
Hazard Warning Switch Inspection ..................... 9B-9
Front Fog Light Switch Removal and
Installation (If Equipped) ................................. 9B-10
Front Fog Light Switch Inspection (If
Equipped)........................................................ 9B-10
Headlight Relay / Tail Light Relay / Front Fog
Light Relay Inspection..................................... 9B-10
Headlight Leveling Switch Removal and
Installation ....................................................... 9B-10
Headlight Leveling Switch Inspection................9B-10
Specifications .....................................................9B-10
Electric Bulb Capacity .......................................9B-10
Instrumentation / Driver Info. / Horn ...... 9C-1
General Description .............................................9C-1
Combination Meter Description ...........................9C-1
Schematic and Routing Diagram ........................9C-2
Combination Meter Circuit Diagram ....................9C-2
Diagnostic Information and Procedures ............9C-3
Combination Meter Diagnosis Function
Description ........................................................9C-3
Combination Meter Self-Diagnosis Function .......9C-3
DTC Table...........................................................9C-3
DTC B1802 .........................................................9C-3
DTC B1810 .........................................................9C-4
DTC B1820 .........................................................9C-5
DTC U0073 / U0100 / U0121 / U0140 ................9C-5
Scan Tool Active Test .........................................9C-5
Inspection of Combination Meter and Its
Circuit ................................................................9C-5
Combination Meter Diagnosis .............................9C-8
Repair Instructions ..............................................9C-9
Instrument Panel Components............................9C-9
Horn Removal and Installation ..........................9C-12
Horn Inspection .................................................9C-12
Specifications .....................................................9C-13
Tightening Torque Specifications......................9C-13
Wipers / Washers..................................... 9D-1
Component Location ...........................................9D-1
Wiper and Washer Component Location ............9D-1
Diagnostic Information and Procedures ............9D-2
Wiper and Washer Symptom Diagnosis .............9D-2
Repair Instructions ..............................................9D-2
Washer Tank and Washer Pump Removal
and Installation ..................................................9D-2
Washer Pump Inspection ....................................9D-3
Windshield Wiper Motor Removal and
Installation .........................................................9D-3
Windshield Wiper Motor Operation Inspection ....9D-4
Rear Wiper Removal and Installation..................9D-5
Rear Wiper Motor Inspection ..............................9D-5
Wiper and Washer Switch Removal and
Installation .........................................................9D-6
Wiper and Washer Switch Inspection .................9D-6
Specifications .......................................................9D-9
Tightening Torque Specifications........................9D-9
Glass / Windows / Mirrors....................... 9E-1
Precautions...........................................................9E-1
Precautions for Working on Glass.......................9E-1
Precautions for Working on Power Window ........9E-1
General Description .............................................9E-2
Power Window System Description ....................9E-2
Rear End Door Window Defogger (If
Equipped) Description.......................................9E-2
Component Location ...........................................9E-3
Power Window Component Location ..................9E-3

Power Door Mirror Component Location (If
Equipped).......................................................... 9E-4
Rear Defogger Component Location .................. 9E-5
Diagnostic Information and Procedures............ 9E-5
Power Window System Symptom Diagnosis ...... 9E-5
Power Door Mirror Control System Symptom
Diagnosis (If Equipped)..................................... 9E-6
Rear Defogger (If Equipped) Symptom
Diagnosis .......................................................... 9E-6
Inspection of Power Window Main Switch and
Its Circuit ........................................................... 9E-6
Repair Instructions .............................................. 9E-7
Windshield Components ..................................... 9E-7
Windshield Removal and Installation .................. 9E-7
Rear End Door Window Glass Components..... 9E-10
Rear End Door Window Glass Removal and
Installation....................................................... 9E-10
Inner Rear View Mirror Removal and
Installation....................................................... 9E-11
Front Door Components ................................... 9E-12
Front Door Glass Removal and Installation ...... 9E-14
Front Window Regulator Assembly Removal
and Installation................................................ 9E-16
Front Window Regulator Assembly Inspection .. 9E-16
Rear Door Components .................................... 9E-18
Rear Door Glass Removal and Installation ....... 9E-18
Rear Window Regulator Assembly Removal
and Installation................................................ 9E-21
Rear Window Regulator Assembly Inspection .. 9E-21
Power Window Main Switch Inspection ............ 9E-21
Power Window Sub Switch Inspection.............. 9E-21
Door Mirror Removal and Installation................ 9E-22
Power Door Mirror Switch Inspection (If
Equipped)........................................................ 9E-22
Rear Window Defogger Relay and Mirror
Heater Relay (If Equipped) Inspection ............ 9E-23
Specifications..................................................... 9E-23
Tightening Torque Specifications...................... 9E-23
Special Tools and Equipment ........................... 9E-24
Recommended Service Material ....................... 9E-24
Security and Locks...................................9F-1
Precautions........................................................... 9F-1
Precautions for Replacing Keyless Entry /
Security Controller ............................................ 9F-1
General Description ............................................. 9F-1
Key Code Construction ....................................... 9F-1
Keyless Entry / Security Controller General
Description (If Equipped) .................................. 9F-1
Keyless Entry System Description (If
Equipped).......................................................... 9F-1
Emergency Lever of Back Door Description ....... 9F-1
Security System Description (If Equipped).......... 9F-2
Back Door Opener System Description (If
Equipped).......................................................... 9F-2
Schematic and Routing Diagram........................ 9F-3
Keyless Entry / Security Controller Input /
Output Diagram (if equipped)............................ 9F-3
Table of Contents 9-iii
Keyless Entry / Security Controller Circuit
Diagram (If Equipped) ....................................... 9F-4
Component Location ........................................... 9F-5
Keyless Entry System Component Location ....... 9F-5
Diagnostic Information and Procedures ............ 9F-6
Keyless Entry / Security System Symptom
Diagnosis .......................................................... 9F-6
Inspection of Keyless Entry / Security
Controller and Its Circuits.................................. 9F-6
Repair Instructions .............................................. 9F-8
Front Door Lock Components ............................. 9F-8
Front Door Lock Assembly Removal and
Installation ......................................................... 9F-9
Front Door Lock Assembly Inspection .............. 9F-10
Rear Door Lock Components............................ 9F-10
Rear Door Lock Assembly Removal and
Installation ....................................................... 9F-11
Rear Door Lock Assembly Inspection ............... 9F-11
Door Lock Switch and Actuator On-Vehicle
Inspection (If Equipped) .................................. 9F-11
Front and Rear Door Switch Inspection ............ 9F-12
Power Door Lock Switch Inspection (If
Equipped)........................................................ 9F-12
Back Door Lock Components ........................... 9F-13
Back Door Latch On-Vehicle Inspection ........... 9F-13
Back Door Lock Removal and Installation ........ 9F-14
Ignition Key Registration (Ignition Switch
Model) ............................................................. 9F-15
Replacement of Transmitter Battery (If
Equipped)........................................................ 9F-15
Programming Transmitter Code for Keyless
Entry System................................................... 9F-15
Security Controller Removal and Installation
(If Equipped).................................................... 9F-15
Valet Switch Inspection (If Equipped) ............... 9F-16
Hood Switch Removal and Installation (If
Equipped)........................................................ 9F-16
Hood Switch Inspection (If Equipped) ............... 9F-16
Siren Removal and Installation (If Equipped).... 9F-16
Siren Inspection (If Equipped)........................... 9F-17
Specifications..................................................... 9F-17
Tightening Torque Specifications...................... 9F-17
Special Tools and Equipment ........................... 9F-17
Recommended Service Material ....................... 9F-17
Seats ......................................................... 9G-1
Repair Instructions ............................................. 9G-1
Front Seat Components ..................................... 9G-1
Front Seat Removal and Installation .................. 9G-1
Rear Seat Components...................................... 9G-3
Rear Seat Removal and Installation................... 9G-4
3rd Row Seat Components ................................ 9G-4
3rd Row Seat Removal and Installation ............. 9G-5
Specifications...................................................... 9G-6
Tightening Torque Specifications....................... 9G-6
Exterior Trim / Interior Trim .................... 9H-1
Repair Instructions ..............................................9H-1
Front Bumper Removal and Installation..............9H-1
9-iv Table of Contents
Front Bumper Member Removal and
Installation .........................................................9H-2
Rear Bumper Removal and Installation ..............9H-3
Cowl Top Garnish Removal and Installation .......9H-3
Hood Silencer Removal and Installation .............9H-5
Roof Molding Removal and Installation...............9H-6
Trim Removal and Installation.............................9H-6
Floor Carpet Removal and Installation................9H-7
Head Lining Removal and Installation.................9H-8
Center Console Box Removal and Installation ..9H-10
Accessory Socket Removal and Installation .....9H-10
Specifications.....................................................9H-11
Plastic Part Specifications.................................9H-11
Hood / Fenders / Doors ............................ 9J-1
Repair Instructions .............................................. 9J-1
Hood Removal and Installation ........................... 9J-1
Hood Inspection and Adjustment ........................ 9J-1
Hood Latch Release Cable Components............ 9J-2
Front Fender Components .................................. 9J-2
Front Fender Removal and Installation ............... 9J-3
Front Door Components...................................... 9J-4
Front Door Assembly Removal and
Installation ......................................................... 9J-4
Rear Door Components ...................................... 9J-5
Rear Door Assembly Removal and
Installation ......................................................... 9J-6
Fuel Filler Door Removal and Installation ........... 9J-6
Fuel Filler Door Opener Cable Removal and
Installation ......................................................... 9J-7
Back Door Assembly Components ..................... 9J-7
Back Door Assembly Removal and
Installation ......................................................... 9J-8
All Latches, Hinges and Locks Inspection........... 9J-9
Specifications..................................................... 9J-10
Tightening Torque Specifications...................... 9J-10
Special Tools and Equipment ........................... 9J-10
Recommended Service Material ....................... 9J-10
Body Structure ........................................ 9K-1
Precautions...........................................................9K-1
Precautions for Body Structure ........................... 9K-1
General Description .............................................9K-2
Body Repair Description ..................................... 9K-2
Sheet Metal Description ...................................... 9K-5
Body Structure Description ............................... 9K-17
Checking and Straightening Benches
Instruction ....................................................... 9K-19
Component Location .........................................9K-20
Silencer Sheet Installation Area ........................ 9K-20
Diagnostic Information and Procedures..........9K-21
Inspection for Body Damage............................. 9K-21
Transmission Routes of Impact......................... 9K-21
Panel Clearance................................................ 9K-22
Front Body Dimensions..................................... 9K-23
Rear End Door Dimensions .............................. 9K-25
Side Body Outside Dimensions......................... 9K-27
Side Body Inside Dimensions ........................... 9K-28
Windshield Dimensions..................................... 9K-30
Under Body Dimensions ...................................9K-32
Engine Room Dimensions with Mechanical
Parts................................................................9K-34
Front Under Body Dimensions with
Mechanical Parts.............................................9K-35
Front Suspension Frame Dimensions...............9K-36
Repair Instructions ............................................9K-38
Hood Lock Member and Lamp Support Brace
Removal and Installation.................................9K-38
Front Fender Lower Bracket Removal and
Installation .......................................................9K-42
Apron Side Member Removal and Installation ..9K-44
Apron Side Member (Partial) Removal and
Installation .......................................................9K-46
Cowl Side Outer Member Removal and
Installation .......................................................9K-50
Dash Side Front Panel, Cowl Side Panel and
Front Fender Center Bracket Removal and
Installation .......................................................9K-54
Fender Apron Panel Removal and Installation ..9K-56
Fender Apron Extension Removal and
Installation .......................................................9K-60
A-Pillar Outer Panel Removal and Installation ..9K-66
A-Pillar Outer Panel, Front Door Hinge
Reinforcement and Dash Side Panel
Removal and Installation.................................9K-70
A-Pillar Outer Panel, Front Door Hinge
Reinforcement, Dash Side Panel, Front
Pillar Inner Panel and Front Pillar Upper
Reinforcement Removal and Installation ........9K-80
B-Pillar Outer Panel Removal and Installation ..9K-94
B-Pillar Outer Panel, Rear Door Hinge
Reinforcement and Center Pillar Inner Panel
Removal and Installation.................................9K-97
Side Sill Outer Panel Removal and
Installation .....................................................9K-103
Quarter-Pillar Outer Panel Removal and
Installation .....................................................9K-105
Wheel House Outer Panel Removal and
Installation .....................................................9K-111
Back Panel Removal and Installation..............9K-115
Rear Floor Panel and Rear Floor 5th Cross
Member Removal and Installation.................9K-118
Quarter Inner Lower Panel, Rear Floor Side
Rear Member (Partial), Rear Floor Side
Extension and Rear Floor Side Rear Panel
(Partial) Removal and Installation .................9K-122
Rear Lamp House Outer Panel and Rear
Lamp House Inner Lower Panel Removal
and Installation ..............................................9K-129
Roof Panel Removal and Installation ..............9K-131
Foamed Material Filling Area Repair...............9K-134
Specifications ...................................................9K-136
Tightening Torque Specifications....................9K-136
Special Tools and Equipment .........................9K-137
Recommended Service Material .....................9K-137
Paint / Coatings ........................................9L-1
Precautions........................................................... 9L-1

Precautions for Working on Air Bag System ....... 9L-1
General Description ............................................. 9L-1
Anti-Corrosion Treatment.................................... 9L-1
Repair Instructions .............................................. 9L-2
Sealant Application Areas ................................... 9L-2
Undercoating Application Areas........................ 9L-11
Anti-Corrosion Compound Application Area ..... 9L-14
Audio Visual / Navigation ....................... 9O-1
Schematic and Routing Diagram........................9O-1
Audio System Circuit Diagram ............................9O-1
Component Location ...........................................9O-2
Audio System Component Location....................9O-2
Diagnostic Information and Procedures............9O-2
Audio System Inspection ....................................9O-2
Audio System Symptom Diagnosis .....................9O-4
Table of Contents 9-v
Repair Instructions ............................................. 9O-5
Audio Unit Removal and Installation .................. 9O-5
Front Speaker and Rear Speaker Removal
and Installation ................................................. 9O-5
Tweeter Removal and Installation...................... 9O-5
Radio Antenna Removal and Installation ........... 9O-6
Radio Antenna Feeder Cable Inspection ........... 9O-6
Steering Switch (Audio Control Switch)
Removal and Installation (If Equipped) ............ 9O-6
USB / AUX Socket Removal and Installation ..... 9O-7
USB / AUX Socket Inspection ............................ 9O-7
USB Harness Inspection .................................... 9O-7
AUX Harness Inspection .................................... 9O-8
Specifications...................................................... 9O-8
Tightening Torque Specifications....................... 9O-8
9-1 Precautions:

Precautions
Body, Cab and Accessories

Precautions
Precautions for Body, Cab and Accessories
AENBL80A9000001
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).

Precautions for Electrical Circuit Service

Refer to “Precautions for Electrical Circuit Service” in Section 00 (Page 00-3).

Fastener Caution
Refer to “Fastener Caution” in Section 00 (Page 00-5).

Air Bag Warning

Refer to “Air Bag Warning” in Section 00 (Page 00-5).

Precautions for Vehicle Equipped with Supplemental Restraint (Air Bag) System
Refer to “Precautions for Vehicles Equipped with Supplemental Restraint (Air Bag) System” in Section 00 (Page 00-6).

Reassembling Note for Wiring Harness

Be sure to observe the Wiring Diagram Manual whenever installing wiring harness. Otherwise, electrical trouble may
occur.

Precautions for CAN Communication System

Refer to “Precautions for CAN Communication System” in Section 00 (Page 00-8).

Precautions for Working on Glass

Refer to “Precautions for Working on Glass” in Section 9E (Page 9E-1).

Precautions for Working on Power Window

Refer to “Precautions for Working on Power Window” in Section 9E (Page 9E-1).

Precautions for Diagnosing Trouble

• Observe the following or memorized diagnosis code may be deleted.
– Do not disconnect the system connector.
– Do not disconnect negative (–) cable at the battery.
– Do not disconnect the system grounding.
– Do not disconnect the system fuse.
– Do not set ignition “OFF” during troubleshooting.
• Before using scan tool, read its “Operator’s (Instruction) Manual” to know how to use it.
• Be sure to clear all DTCs after completing troubleshooting.
 Wiring Systems: 9A-1

Wiring Systems
Body, Cab and Accessories

Precautions
Cautions in Body Electrical System Servicing
AENBL80A9100001
When servicing the electric systems, observe the cautions described in “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-3) to protect electrical parts and to prevent a fire.

General Description
Abbreviations
AENBL80A9101001
Refer to the “Abbreviations” in Section 0A (Page 0A-1) for the general abbreviations.

Wire / Connector Color Symbols

AENBL80A9101002
Refer to “Wire Color Symbols” in Section 0A (Page 0A-5).

Symbols and Marks

AENBL80A9101003
Battery Ring-terminal ground Ground Normal fuse Slow blow fuse

I2RH01910910-01 IYSQ01910915-01 IYSQ01910916-01

IYSQ01910917-01 IYSQ01910918-01
Circuit breaker Coil, Solenoid Heater Bulb Bulb

IYSQ01910922-01 IYSQ01910923-01
IYSQ01910919-01 IYSQ01910920-01 IYSQ01910921-01
Cigarette lighter Motor Pump Horn Speaker

H
IYSQ01910924-01
I5JB0B910995-02
IYSQ01910925-01 IYSQ01910926-01 I2RH01910911-01

Buzzer Chime Capacitor Thermistor Reed switch

IYSQ01910929-01 IYSQ01910930-01
IYSQ01910931-01
IYSQ01910932-01 IYSQ01910933-01
Resistance Variable resistance Variable resistance Transistor NPN Transistor PNP

IYSQ01910934-01 IYSQ01910935-01 IYSQ01910936-01 IYSQ01910937-01 IYSQ01910938-01

Photo transistor Diode Zener diode Light emitting diode Photo diode

IYSQ01910939-01
IYSQ01910940-01 IYSQ01910941-01 IYSQ01910942-01 IYSQ01910943-01
Piezoelectric element Connected harnesses Crossing harnesses Ring terminal Connector
9A-2 Wiring Systems:

IYSQ01910944-01
IYSQ01910945-01 IYSQ01910946-01 IYSQ01910948-01
IYSQ01910947-01
Normally-open relay Normally-closed relay Normally-open switch Normally-closed switch

IYSQ01910949-01 IYSQ01910950-01 IYSQ01910951-01 IYSQ01910952-01

Ignition switch Keyless entry Immobilizer system Combination meter Lighting switch

I3JA01910902-01 I5RH01910901-01 I2RH01910915-01

I2RH01910912-01 I2RH01910916-01

Headlight leveling Hazard warning light Front fog light Rear fog light Spark plug

I3JA01910904-01 I3JA01910905-01 I3JA01910906-01 I3JA01910907-01

I2RH01910921-01
Radiator cooling fan Fuel pump Fuel injector XX control module Windshield wiper

XX
Cont M
I3JA01910908-01 I3JA01910909-01
I2RH01910925-01
I2RH01910922-01 I2RH01910924-01
Windshield washer Rear wiper Rear washer Rear defogger Power window

I3JA01910910-01 I3JA01910911-01 I3JA01910912-01 I2RH01910930-01 I3JA01910913-01

Power door lock Power mirror A/B Pretensioner Passenger side

I3JA01910914-01 I3JA01910915-01 I3JA01910916-01 I3JA01910917-01 I3JA01910918-01

Driver side Seat heater A/C Power steering Side-air bag (R)

I3JA01910919-01 I2RH01910938-01 I3JA01910920-01 I3JA01910921-01 I4JA01910901-01

Side-air bag (L) Side curtain air bag (R) Side curtain air bag (L) Glow plug

I4JA01910902-01 I5RS0A910958-01 I5RS0A910959-01

I4JA01910903-01

How to Read Connector Layout Diagram

AENBL80A9101004
[A-1]: Harness Symbol and Corresponding Harness Name
A: Battery cable
B: A/C harness
C: Engine harness
D: Injector harness, Oil pressure switch wire
E: Main harness, Power steering wire
F: Console wire
G: Instrument panel harness, Instrument panel antenna wire
 Wiring Systems: 9A-3

J: Side door wire (including P/W related wires)

K: Interior light harness, Roof wire, Roof radio antenna wire, Rear speaker wire
L: Floor harness, Floor antenna wire, Coupling harness, Accessory socket wire, G sensor wire
M: Rear bumper wire
O: Rear end area harness/wires (except Rear bumper wire)
Q: Curtain air bag wire, Side-air bag harness, Pretensioner wire
R: Fuel pump wire
S: Contact coil
[A-2]: Connector Number
[B]: Ground Point No.

11 [B]

L33 L25 L24 L26 (TO O01) L36

L20 L28 R02 Connector code
L09
L10 L 36
L11
L12
[A-1] [A-2]
L14

{ L15
R01

L42
R04

L01 (TO G01)

L02 (TO E04) L05
[B] R05 L13
L03 (TO E05)
L19 L32 L16 L07 (TO K02)

12
I2RH01910901-01

How to Read Connector Codes and Terminal Nos.

AENBL80A9101005
1) Connector code/Terminal No./Terminal layout
• The connector shape and terminal layout shown in this manual are those when viewed from “Z” in the
illustration.
Refer to “List of Connectors” (Page 9A-102).
9A-4 Wiring Systems:

View Z

"CONNECTOR LIST"

Male terminal A40 Connector code.

4 3 2 1
8 7 6 5

(View Z) A40
5
D18
Female terminal D18
1 2 3 4
5 6 7 8
(View Z) Connector code.
Terminal No.
I5RS0A910901-01

NOTE
Molded terminal numbers that are different from the above can be found on some connectors in rare
cases.
These molded numbers are not applied in this manual.

2) Connector type

I2RH01910903-01

3) Terminals in one connector (Broken line) (B15)/Terminals in different connectors (B14, B16)

B15
B14 B16

B15 5 7 B14 5 B16 7

I2RH01910904-01

4) Joint connector (J/C)

 Wiring Systems: 9A-5

• The joint connector (J/C) connects several different wires with the same wire color at one place instead of
connecting them by welding or caulking one by one. It is not an ordinary connector but a part of the continuous
wire in the harness.

Example
J/C
WHT/BLK WHT/BLK
WHT/BLK WHT/BLK WHT/BLK
A A A A A
J/C

A
WHT/BLK WHT/BLK RED/YEL
B
A A A A B B C C
A A A A B B C C
RED/YEL
B
RED/YEL
BLK
BLK
C
C
BLK

C
BLK

I9Y10A910A59-02

5) Weld splice (W/S)

• Several different wires with the same wire color are joined by welding at a W/S.

Example Connector layout diagram

W/S
ORN W/S
ORN ORN ORN ORN ORN

Weld W/S
W/S W/S W/S
ORN

I7RW0A910A03-02

6) Junction block (J/B)

Example
J/B inner circuit
Connector No. / Terminal No. J/B
J/B BCM E39 E40 E41 G32 G33 G34 K01 L04 L05 L06

IG1 IG1
2

IMMOBI IG
6

IG Coil
23
15A IG Coil, etc
5
BLK/WHT
BCM ;IG1
11
25
MTR 10A MTR Power, etc
6

30
A/B 15A A/B CONT
1

K-LINE
8

K-LINE
3

A/B SIGNAL
9

A/B SIGNAL
2

J/B A/B SIG

4 ORN
A/B SIG
13
MTA
11

IG Sig
29
10A EPS AT
12
J/B

GRN BLU

I4RS0A910903-01

7) Connector location, shape and terminal No.

9A-6 Wiring Systems:

Refer to “Connector Layout Diagram” (Page 9A-9).

Refer to “System Circuit Diagram” (Page 9A-45).
Refer to “List of Connectors” (Page 9A-102).

"SYSTEM CIRCUIT DIAGRAM"

-Connector code and terminal No.

"CONNECTOR LAYOUT DIAGRAM" "CONNECTOR LIST"

-Connector location. -Connector shape and terminal position.

C02

C02 C02

C02

C02

C02 CROSS-REFERENCE
I2RH01910906-01

How to Read Ground Point

AENBL80A9101006
Refer to “System Circuit Diagram” (Page 9A-45).
Refer to “Ground Point” (Page 9A-23).

"SYSTEM CIRCUIT DIAGRAM" "GROUND POINT"

Individual
20 circuit
15A fuse box

YEL/BLU 10
10 11 12

E40
16 20 5 6 7

BLU/BLK BLK BLU BLU/RED BLU/WHT

E09 2 E20 2 1 3 4
Windoshield Windoshield
washer wiper
M motor motor
M
1

Off
BLK BLK BLK On
Circuit
breaker Left side shown
60A-B003-
1 10 9

10
Device body grounding is not given the ground point number.

CROSS-REFERENCE
I4JA01910985-01

How to Read Power Supply Diagram

AENBL80A9101007
 Wiring Systems: 9A-7

Refer to “Power Supply Diagram (Petrol Engine Model)” (Page 9A-25).

Refer to “System Circuit Diagram” (Page 9A-45).

"POWER SUPPLY DIAGRAM"

Battery

- + BLK
Fuse number
Main fuse box Supplementary fuse box

1 2 3 4 5 6 7 8 29 9
80A 15A 15A 15A 25A 50A 30A 60A 30A 60A

32
E44 3 2 1 B01 1 E45 1 E40 2 1 15A

WHT/BLU WHT/RED BLU/RED RED WHT/BLU WHT/YEL WHT/GRN

2 3 4 WHT/GRN WHT/GRN

BLU

Individual
circuit 11 12 13 14 15 16 17 18 19 20 21
fuse box
15A 15A 15A 20A 20A 15A 15A 15A 15A 15A 15A

WHT WHT/GRN WHT/BLK YEL YEL/GRN PNK/BLK

1 2 GRN RED BLK/WHT YEL/BLU LT GRN YEL/BLK BLU/RED

"SYSTEM CIRCUIT DIAGRAM" 11 12 13 14 15 16 17 18 19 20 21 29 32

13 17
15A 15A Connection to the system
RY indicated.
Fuse WHT/GRN YEL RED/YEL

I4JA01910986-01

How to Read System Circuit Diagram

AENBL80A9101008
The circuit diagram is designed so the current flows from the top of the diagram (power source) to the bottom of the
diagram (ground) as if giving an image of water flow.
[A]: Fuse No.
[B]: Circuit Jumping Page / Direction

NOTE
This means “Jump to the page directed with the arrow(s) by their number”.
(For example:” Two arrows directing left” means” Jump to two pages before”.)
You will find the same symbol with the arrows directing opposite in the referenced page. The circuit
continues between the symbols.

[C]: Circuit Jumping Point / Direction

NOTE
The circuit continues to the same symbol with opposite direction within the page.
You will find the other symbol in the direction of the arrow.

[D]: Terminals-in-One-Connector Mark

[E]: Wire Color
[F]: Shield Wire
[G]: Ground Point
[H]: “From” or “To” (With ID Letter (s))
[I]: Specification Variation
The white arrow between A and B means “or”.
[J]: “From” (With ID Letter (s))
[K] “To” (With ID Letter (s))
[L]: Connector Code
[M]: Terminal No.
[N]: Symbol Mark
9A-8 Wiring Systems:

[O]: “SEE” Mark

4-DOOR
A
B 2-DOOR [I] [J] [K] [L] [M] [N] [O]

3 Fuse 1 6
Fuse
15A 15A 20A
[A] "XX"
GB

[B] 3 BLK/RED GRN/BLK

BLU ORN C40 1
E08 2 1
C71 A 5 GB GR
E03 B 6 Solenoid
Main
4 GRN/RED GRN/RED relay

4 3 2
[C] YEL
BLU GRN/BLK GRN/RED GRN GRN

[D] GRN

GRN
2 E34 2 1
E33 1 E34 7 5 1 O06

XX
Cont.M
GRN GRN

[E] 2 5 6 4 4 6

GRN
GRN/BLK ORN WHT BLK YEL 2
C26
2 1 2 A B
Switch
[F] RED BRN/RED
OFF ON
Sensor E52 1 E52 1
Y
[G] 1
M Motor M Motor

[H] 2 2
BLK

BLK BRN/RED C31 5

E19

Other system circuit

RED BRN/RED BRN/RED BLK

Y Y
G20 3 8 5 5 6 1
GRN/RED

YEL/RED YEL
L50 1 3
GR GR
P

2 4

I8RW0A910A46-02
 Wiring Systems: 9A-9

Connector Layout Diagram

Connector Layout Diagram
AENBL80A910A001
Refer to “Engine Compartment” (Page 9A-9).
Refer to “Instrument Panel” (Page 9A-16).
Refer to “Door, Roof” (Page 9A-18).
Refer to “Floor” (Page 9A-21).
Refer to “Rear” (Page 9A-23).

Engine Compartment
AENBL80A910A002
A: Battery Cable / C: Engine Harness (Petrol Engine Model)

C91 C36 C195 C196 C94

C92 C192 C93 C123 C38 C48 C371 C33
W/S
C A72

18

C343
(To E371)
C194
C01
C101
A
C31 C282
C283
C133
19
C165

C141

C37 C104
C162 5 6 C102 C103 C56 C42 C39
IBL80A910901-06
A: Battery Cable
No. Color Connective position Remarks
A72 - Battery (–)

C: Engine Harness
No. Color Connective position Remarks
C01 BLK ECM
C31 GRY CKP sensor
C33 GRY VSS
C36 BLK MAP sensor
C37 GRY Knock sensor
C38 BLK IAT sensor
C39 BLK ECT sensor
C42 GRY HO2S-2
C48 BLK Electric throttle body
C56 BLK HO2S-1
9A-10 Wiring Systems:

No. Color Connective position Remarks

C91 GRY Fuel injector #1
C92 GRY Fuel injector #2
C93 GRY Fuel injector #3
C94 GRY Fuel injector #4
C101 GRY Ignition coil #1
C102 GRY Ignition coil #2
C103 GRY Ignition coil #3
C104 GRY Ignition coil #4
C123 BLK EVAP canister purge valve
C133 BLK OCV
C141 BLK A/C compressor
C162 N Engine oil pressure switch
C165 BLK Back-up light switch
C192 - Generator (+B)
C194 GRN Generator
C195 BLK Starting motor
C196 - Starting motor (+B)
C282 - Main fuse box
C283 - Main fuse box
C343 N Main harness (To E371)
C371 BLU CMP sensor

C: Engine Harness / D: Glow Plug Control Module Wire (Diesel Engine Model)

C51 C93 C
C122 C01 C345
(To E373)

C50

C91

C92
C94
C32
C374
C69

C13

D02

C141

C115 C116 C117 C118 C31 C162 C D245 D

(To E404)
IBL80A910902-04
 Wiring Systems: 9A-11

C192 C196 C C191

18

C343
(To E371)

C283
C194

C282

C195 20 5 C33 C165

IBL80A910903-03
C: Engine Harness
No. Color Connective position Remarks
C01 BLK ECM
C13 N Glow control module
C31 BLK CKP sensor
C32 GRY CMP sensor
C33 GRY VSS
C50 BLK Fuel flow actuator
C51 BLK Boost pressure sensor
C69 BLK High pressure pump
C91 BLK Fuel injector #1
C92 BLK Fuel injector #2
C93 BLK Fuel injector #3
C94 BLK Fuel injector #4
C115 BLK Glow plug #1
C116 BLK Glow plug #2
C117 BLK Glow plug #3
C118 BLK Glow plug #4
C122 GRY EGR Valve
C141 GRY A/C compressor
C162 BLK Engine oil pressure switch
C165 BLK Back-up light switch
C191 - Battery (–)
C192 - Generator (+B)
C194 GRY Generator
C195 N Starting motor
C196 - Starting motor (+B)
C282 - Main fuse box
C283 - Main fuse box
C343 N Main harness (To E371)
C345 BLK Main harness (To E373)
9A-12 Wiring Systems:

No. Color Connective position Remarks

C374 GRN ECT sensor

D: Glow Plug Control Module Wire

No. Color Connective position Remarks
D02 N Glow plug control module
D245 GRY Main harness (To E404)

E: Main Harness (Petrol Engine Model)

E223
E224

E221

E229

E225

E227

E234 E222

E64 E183 E312 E311 E01 32 33 34 W/S

E
E165
E166
27
E371
35 (To C343)

36 E160
E24
E35
E304
E152
E159
E36 E162
W/S
E69
E161

E151 E65

E68
W/S
E34
E164
2
E63

E62
E163

E40 3 E303 E302 E210 E37 E282 E281

IBL80A910904-05
E: Main Harness
No. Color Connective position Remarks
E01 BLK ECM
E24 BLK ABS control module ABS model
E34 GRY Wheel speed sensor (Front-right) ABS model
 Wiring Systems: 9A-13

No. Color Connective position Remarks

E35 BLK Wheel speed sensor (Front-left) ABS model
E36 BLK A/C refrigerant pressure sensor
E37 BLK Outside air temperature sensor If equipped
E40 N Forward impact-sensor ABS model
E62 BLU Windshield washer motor
E63 GRN Rear washer motor If equipped
E64 GRY Windshield wiper motor
E65 GRY Radiator cooling fan motor
E68 GRY Headlight leveling actuator (R)
E69 GRY Headlight leveling actuator (L)
E151 BLK Headlight (R)
E152 BLK Headlight (L)
E159 GRY Front turn signal light (R)
E160 GRY Front turn signal light (L)
E161 GRY Front position light (R)
E162 GRY Front position light (L)
E163 BLK Front fog light (R) If equipped
E164 BLK Front fog light (L) If equipped
E165 N Side turn signal light (R) If equipped
E166 N Side turn signal light (L) If equipped
E183 GRY Brake fluid level switch
E210 BLK Security hood switch If equipped
E221 BLK Main relay
E222 BLK Radiator cooling fan relay #1
E223 BLK Radiator cooling fan relay #2
E224 BLK Radiator cooling fan relay #3
E225 BLK Starting motor relay
E227 BLK Fuel pump relay
E229 BLK A/C compressor relay
E234 BLK Front fog light relay If equipped
E281 BLK Horn
E282 BLK Horn
E302 BLK Horn HI
E303 BLK Horn HI
E304 GRY Security horn (Siren) If equipped
E311 BRN Main fuse box
E312 GRY Main fuse box
E371 N Engine harness (To C343)
9A-14 Wiring Systems:

E: Main Harness (Diesel Engine Model)

E223 E224

E221
E229
E222
E225

E227

E234

E373 33
E36 E64 E183 E210 E311 E47 E59 (To C345) E01
29 32 34

E 28 30
E166
E165

27
35
36
E371
E24 (To C343)
E304

E159
E135 W/S
W/S E35
E161
E151
E160
E68
W/S E162
E34
E152

E69
2

E07
E63
E164

E163

E62 E40 3 E303 E302 E57 E282 E37 E281 E124 E65 E312 E404
(To D245)
IBL80A910905-05
E: Main Harness
No. Color Connective position Remarks
E01 BLK ECM
E07 BLK Glow control module
E24 BLK ABS control module
E34 GRY Wheel speed sensor (Front-right)
E35 BLK Wheel speed sensor (Front-left)
E36 BLK A/C refrigerant pressure sensor
E37 BLK Outside air temperature sensor If equipped
 Wiring Systems: 9A-15

No. Color Connective position Remarks

E40 N Forward impact-sensor
E47 BLK Fuel filter water detection sensor
E57 BLK A/F sensor
E59 BLK Fuel temperature sensor
E62 BLU Windshield washer motor
E63 GRN Rear washer motor If equipped
E64 GRY Windshield wiper motor
E65 BLK Radiator cooling fan motor
E68 GRY Headlight leveling actuator (R)
E69 GRY Headlight leveling actuator (L)
E124 BLK MAF and IAT sensor
E135 BLK Boost pressure regulator
E151 BLK Headlight (R)
E152 BLK Headlight (L)
E159 GRY Front turn signal light (R)
E160 GRY Front turn signal light (L)
E161 GRY Front position light (R)
E162 GRY Front position light (L)
E163 BLK Front fog light (R) If equipped
E164 BLK Front fog light (L) If equipped
E165 N Side turn signal light (R) If equipped
E166 N Side turn signal light (L) If equipped
E183 GRY Brake fluid level switch
E210 BLK Security hood switch
E221 BLK Main relay
E222 BLK Radiator cooling fan relay #1
E223 BLK Radiator cooling fan relay #2
E224 BLK Radiator cooling fan relay #3
E225 BLK Starting motor relay
E227 BLK Fuel pump relay
E229 BLK A/C compressor relay
E234 BLK Front fog light relay If equipped
E281 BLK Horn
E282 BLK Horn
E302 BLK Horn HI
E303 BLK Horn HI
E304 GRY Security horn (Siren) If equipped
E311 BRN Main fuse box
E312 GRY Main fuse box
E371 N Engine harness (To C343)
E373 BLK Engine harness (To C345)
E404 GRY Glow wire (To D245)
9A-16 Wiring Systems:

Instrument Panel
AENBL80A910A003
E: Main Harness

E192 E11 E12 E13 31

E191 E181 E266

FWD
E336
E337
E325
E323 E324
E04

E387 E382
(To L371) (To G334)
E383
(To G335)
E384
(To G336)

IBL80A910906-02
E: Main Harness
No. Color Connective position Remarks
E04 GRY BCM
E11 - P/S control module (Torque sensor)
E12 - P/S control module (P/S motor)
E13 BLK P/S control module
E181 N Brake light switch
E191 BLK APP (Acceleration pedal position) sensor
E192 N CPP (Clutch pedal position) switch
E266 N Security option #1 Option
E323 N J/B
E324 N J/B
E325 BLU J/B
E336 N J/B
E337 N J/B
E382 YEL Instrument panel harness (To G334)
E383 GRY Instrument panel harness (To G335)
E384 N Instrument panel harness (To G336)
E387 N Floor harness (To L371)
 Wiring Systems: 9A-17

G: Instrument Panel Harness, USB / AUX Cable, Instrument Panel Antenna Wire / S: Contact Coil

Instrument panel antenna wire

G354 G259 G372 G153 G240 G347 G144 G369 G340
(To K154) G373 G141 S121 S172 G370 (To K156)
G247 G267 G221 G202 G248 G50 S G145 G246

G306
23
24

G151

G152
G194

G62
G164
G195

G04

21
26
22 G 25
S
G147

G17
S61
G349 G101 G154 G251 G216 G217 G211 or G371 or G346
(To L399) G61 G32 G155 G11 S62 S173 S171
USB / AUX Cable
FWD
Fuse box

G273
G274
G275
G336
(To E384)
G272 G334
(To E382)
G271
G335
(To E383)

IBL80A910907-02
G: Instrument Panel Harness
No. Color Connective position Remarks
G04 GRY BCM
G11 YEL A/B SDM with Air bag
G17 N Immobilizer control module
G32 N Evaporator temperature sensor
G50 N P/S control module
G61 N Blower motor
G62 GRN Air intake control actuator
G101 N Blower motor resistor
G141 BLK Combination switch
G144 N Combination switch
G145 N Main switch (key)
G147 N Ignition switch
G151 GRN Front fog light switch If equipped
9A-18 Wiring Systems:

No. Color Connective position Remarks

G152 BLK Headlight leveling switch
G153 N Hazard switch
G154 N HVAC control unit
G155 BRN Blower speed selector
G164 BLU Valet switch If equipped
G194 N Heater relay
G195 N Fan relay without Rear A/C
G211 BLK DLC
G240 N Combination meter
G246 BLK Tweeter (R) If equipped
G247 BLK Tweeter (L) If equipped
G248 BLU Audio
G251 BLK Accessory socket
G271 N J/B
G272 BRN J/B
G273 N J/B
G274 N J/B
G275 N J/B
G306 BLU J/C If equipped
G334 YEL Main harness (To E382)
G335 GRY Main harness (To E383)
G336 N Main harness (To E384)
G340 N Roof wire (To K156)
G346 N Contact coil (To S171) with Air bag
G347 YEL Contact coil (To S172)
G349 N Floor harness (To L399)
G369 YEL Instrument panel harness (To G370) with Air bag
G370 YEL Instrument panel harness (To G369) with Air bag
G371 N Contact coil (To S173) without Air bag
G372 YEL Instrument panel harness (To G373) with Air bag

G: USB / AUX Cable

No. Color Connective position Remarks
G202 - Audio (AUX) If equipped
G216 - USB socket If equipped
G217 - AUX socket If equipped
G221 - Audio (USB) If equipped

G: Air Bag Harness (Passenger side)

No. Color Connective position Remarks
G259 ORN Front-passenger air bag (inflator) module with Air bag
G373 YEL Instrument panel harness (To G372) with Air bag

G: Instrument Panel Antenna Wire

No. Color Connective position Remarks
G267 - Audio
G354 - Roof audio antenna wire (To K154)

S: Contact Coil
No. Color Connective position Remarks
S61 - Steering switch (Horn, Audio control) with Air bag
S62 - Steering switch (Horn) without Air bag
S121 - Driver air bag (inflator) module with Air bag
S171 - Instrument panel harness (To G346) with Air bag
S172 - Instrument panel harness (To G347) with Air bag
S173 - Instrument panel harness (To G371) without Air bag

Door, Roof
AENBL80A910A004
 Wiring Systems: 9A-19

J: Front and Rear Door Wire

J87 J81 J31 J217 J145

(To L381) J25 J83 J35 Rear door wire (R)

J32

J27

J21

Front door wire

(Driver side)
J36

J215
(To L379)

Rear door
J141 wire (L)

J26

J84

J146

J216 J218
(To L380) (To L382)
J28 J142 J22 J82
Front door wire (Passenger side)
IBL80A910908-02
J: Front Door Wire (Drive Side)
No. Color Connective position Remarks
J21 BLK Front power window motor (R) If equipped
J27 N Power mirror assembly (Driver side) If equipped
J31 N Front door lock assembly (R) If equipped
J81 BLK Power window master switch If equipped
J87 N Power mirror switch If equipped
J141 N Front speaker (R)
J215 N Floor harness (To L379)

J: Front Door Wire (Passenger Side)

No. Color Connective position Remarks
J22 BLK Front power window motor (L) If equipped
J28 N Power mirror assembly (Passenger side) If equipped
J32 N Front door lock motor (L) If equipped
J82 N Power window sub switch If equipped
J142 N Front speaker (L)
J216 N Floor harness (To L380)

J: Rear Door Wire (R)

9A-20 Wiring Systems:

No. Color Connective position Remarks

J25 BLK Rear power window motor (R) If equipped
J35 N Rear door lock motor (R) If equipped
J83 N Rear power window sub switch (R) If equipped
J145 N Rear speaker (R)
J217 N Floor harness (To L381)

J: Rear Door Wire (L)

No. Color Connective position Remarks
J26 BLK Rear power window motor (L) If equipped
J36 N Rear door lock motor (L) If equipped
J84 N Rear power window sub switch (L) If equipped
J146 N Rear speaker (L)
J218 N Floor harness (To L382)

K: Roof Wire, Roof Audio Antenna Wire

K121 K53 Roof audio K52 K154

antenna wire (To G354) K

K156
(To G340)

K02 K131
IBL80A910909-03
K: Roof Wire
No. Color Connective position Remarks
K02 N Rear A/C unit If equipped
K52 N Spot light with Rear A/C
K53 N Dome light without Rear A/C
K131 N J/B
K156 N Instrument panel harness (To G340) If equipped
 Wiring Systems: 9A-21

K: Roof Audio Antenna Wire

No. Color Connective position Remarks
K121 - Roof audio antenna amplifier
K154 - Instrument panel antenna wire (To G354)

Floor
AENBL80A910A005
L: Floor Harness / R: Fuel Pump Wire

L380
L285 L162 10 L167 (To J216) L10 L04 L170 L01
L393 L382 9 8 40 L266 L399 L381 L161
(To O233) (To J218) (To G349) (To J217)

L
L164
L390
(To O231)
12
11
L134

L379
(To J215)

L32

L135 L133 13 14 15 L31 L163 R101 R L389 38 L283 16 17

R151

L315
L371
(To E387)

L313

L322 L314

L319

FWD

IBL80A910910-02
L: Floor Harness
No. Color Connective position Remarks
L01 GRY BCM
L04 YEL A/B SDM with Air bag
9A-22 Wiring Systems:

No. Color Connective position Remarks

L10 GRY Keyless / security control module If equipped
L31 BLK Wheel speed sensor (Rear-right) ABS model
L32 BLK Wheel speed sensor (Rear-left) ABS model
L133 N Rear combination light (R)
L134 N Rear combination light (L)
L135 N Rear fog light If equipped
L161 N Front door switch (Driver side)
L162 N Front door switch (Passenger side)
L163 N Rear door switch (R) If equipped
L164 N Rear door switch (L) If equipped
L167 BLK Parking brake switch
L170 N Seat belt switch
L266 BLK Security option #2 Option
L283 BLK Pretensioner (Driver side) with Air bag
L285 BLK Pretensioner (Passenger side) with Air bag
L313 YEL J/B
L314 N J/B
L315 N J/B
L319 BLU J/B
L322 GRY J/B
L371 N Main harness (To E387)
L379 N Front door wire (Driver side) (To J215)
L380 N Front door wire (Passenger side) (To J216)
L381 N Rear door wire (R) (To J217)
L382 N Rear door wire (L) (To J218)
L389 GRY Fuel pump wire (To R151)
L390 N Rear end door harness (To O231)
L393 N Rear washer wire (To O233)
L399 N Instrument panel harness (To G349)

R: Fuel Pump Wire

No. Color Connective position Remarks
R101 BLK Fuel pump and gauge
R151 GRY Floor harness (To L389)
 Wiring Systems: 9A-23

Rear
AENBL80A910A006
O: Rear End Door Harness, Rear Washer Wire

Rear washer wire

O

O92 O91

O231
(To L390)

O181

O21

O94
O95

B O122

A O122

O233 A with Rear A/C

O121 1 O182 (To L393) B without Rear A/C
IBL80A910911-03
O: Rear End Door Harness
No. Color Connective position Remarks
O21 N Rear wiper motor If equipped
O92 N High mounted stop light
O94 N License plate light #1
O95 N License plate light #2
O121 N Rear end door solenoid If equipped
O122 N or GRN Rear end door opener switch If equipped
O181 BLK Rear defogger (+) If equipped
O182 BLK Rear defogger (–) If equipped
O231 N Floor harness (To L390)

O: Rear Washer Wire

No. Color Connective position Remarks
O91 N Rear dome light
O233 N Floor harness (To L393)

Ground Point
Ground Point
AENBL80A910C001
Refer to “Connector Layout Diagram” (Page 9A-9).
9A-24 Wiring Systems:

Petrol engine model Diesel engine model

38 Outside the room 38 Outside the room

Left side Shown
Right side shown
23 24
FWD

13 14 15 (R)
25 26 (R)
11 12 (L)
FWD
21 22 (L)

7 16 17

40

8 9 10

18 28 29 30
31

32 33 34
3
FWD

2
27 35 36

Diesel engine model Petrol engine model

Petrol engine model

20

19
5 6
IBL80A910912-01
 Wiring Systems: 9A-25

Power Supply Diagram

Power Supply Diagram (Petrol Engine Model)
AENBL80A910D001
9A-26 Wiring Systems:

A72

1 72 74 75 76
Battery Main fuse box
100A 100A 100A 50A

C282 1 C283 1 E311 1 2 E312 2

BLK BLK/GRY WHT BLK WHT BLK WHT

Starting motor Generator

E323 2
"A-1" "A-2"
1

Relay
J/B

4
20A

Relay
box 52 54 55
15A 15A 20A

WHT/BLU WHT/RED WHT/GRN

52 54 55

18 19
IBP80A910913-02
 Wiring Systems: 9A-27

17 31 32 18 11 25
15A 10A 20A 10A 10A 7.5A

Horn
relay 23 30
7.5A 15A
5

J/B E324 1

4
3
WHT WHT/BLK BLK

Relay box

2 6

53 62 48 47 57 50 41 44 46 42
25A 7.5A 30A 40A 40A 30A 10A 60A 40A 15A

WHT/BLU BLU/YEL RED BLU BLU/YEL GRN WHT/RED

BLK/YEL BLK/YEL
YEL
E221 1 4
Main
53 62 49 41 44 46 relay

E225 1 3 3 5
W/S
Starting
motor
BLK/RED BLK/RED BLK/RED
relay
E227 1 4
2 4

YEL
Relay
2 3
YEL PNK

48 42
IBL80A910913-02
9A-28 Wiring Systems:

J/B

35 10 22 21 9 15 34 33 27 20 19 14 13 8
7.5A 30A 25A 15A 15A 15A 10A 7.5A 7.5A 10A 10A 10A 15A 7.5A
5

G271 1 4 E323 1 G271 7 E324 3 G271 5 3 8 E336 2

WHT/BLU YEL BLU WHT WHT GRN BRN RED/WHT

Starting
WHT/BLU motor
relay
"A-1"
6 G147 4 3 5 6 1 2

OUT LOCK
45 37 Relay
box
ACC
30A 50A
IN ON

GRY
ST

GRY
E222 1 4 E223 3 5

Relay #1 Relay #2
2 3 1 4

BLU BLU/BLK

45 45
IBL80A910914-02
 Wiring Systems: 9A-29

Power Supply Diagram (Diesel Engine Model)

AENBL80A910D002

C191

1 72 74 75 76 77
Battery Main fuse box
120A 100A 100A 50A 80A

C282 1 C283 1 E311 1 2 E312 2 1

BLK/GRY BLK/GRY BLK WHT WHT BLK WHT RED

Starting motor Generator Glow

"A-1" "A-2" Cont.M

E323 2 "A-5"

Relay
J/B

4
20A

Relay
box 52 54 55
15A 15A 20A

WHT/BLU WHT/RED WHT/GRN

52 54 55

20 18
IBL80A910993-01
9A-30 Wiring Systems:

17 31 32 18 11 25
15A 10A 20A 10A 10A 7.5A

Horn
relay 23 30
7.5A 15A
5

J/B E324 1

4
3
WHT WHT/BLK BLK

Relay box

2 6

53 62 48 47 57 50 41 38 44 46 43
25A 7.5A 30A 40A 40A 30A 10A 7.5A 60A 40A 30A

WHT/BLU BLU/YEL RED BLU BLU/YEL YEL/GRN GRN WHT/RED

YEL BLK/YEL BLK/YEL

E221 1 4
Main
53 62 49 41 38 44 46 relay

E225 1 3 3 5
Starting
motor
BLK/RED
relay
2 4

YEL
Relay
box 69 70 71
YEL
20A 10A 15A

48 BLK/RED BLU BLK/RED

69 70 71
IBL80A910915-02
 Wiring Systems: 9A-31

J/B

35 10 22 21 9 15 34 33 27 20 19 14 13 8
7.5A 30A 25A 15A 15A 15A 10A 7.5A 7.5A 10A 10A 10A 15A 7.5A
5

G271 1 4 E323 1 G271 7 E324 3 G271 5 3 8 E336 2

WHT/BLU YEL BLU WHT WHT GRN BRN RED/WHT
4

Starting
WHT/BLU motor
relay
6 "A-1"
G147 4 3 5 6 1 2

45 37 Relay
box OUT LOCK
30A 50A
ACC

IN ON
GRY

ST

GRY
E222 1 4 E223 3 5

Relay #1 Relay #2
2 3 1 4

BLU BLU/BLK

45 45
IBL80A910916-02
9A-32 Wiring Systems:

Fuses and the Protected Parts

AENBL80A910D003
The chart below describes what parts each fuse protects.

Fuses in Main Fuse Box

NOTE
Refer to “Around Battery” (Page 9A-112) for the installation.

[A] [B]

74 74
72
72 75 75

76 76
73
77
IBL80A910917-01

[A]: Petrol engine model [B]: Diesel engine model

No. Fuse Protected circuit

All electric circuit
100 A (Petrol engine model),
Battery
120 A (Diesel engine model)
Generator
BLANK BLANK
100 A Individual circuit fuse box No.1 (In Relay box)
100 A Individual circuit fuse box No.1 (In Relay box)
50 A Individual circuit fuse box No.2 (In J/B)
80 A Glow control module
 Wiring Systems: 9A-33

Individual Circuit Fuse Box No. 1

Diesel engine model

69
70
E221
71

1
2
3

58
59
60 E223 E224
61
Petrol engine model
37 47

38 E221
48
39
40
41 49
42 E229
50 62
43 51 4
52
E222 E225
53
44 54
55
56 E227
45

46 57 E234 6

9 9 5
8
IBP80A910921-03

1. Radiator cooling fan relay #2 4. A/C compressor relay 7. Fuel pump relay
2. Radiator cooling fan relay #3 5. Radiator cooling fan relay #1 8. Front fog light relay
3. Main relay 6. Starting motor relay 9. BLANK

No. Fuse Description on the cover Protected circuit

50 A IGN2 Individual circuit fuse box No.2 (In J/B)
ECM
7.5 A ECM
Main relay (In relay box)
15 A AT/CVT BLANK
BLANK BLANK BLANK
10 A CPRSR A/C compressor relay (In relay box)
15 A FI (Petrol engine model) Main relay (In relay box)
30 A FI (Diesel engine model) Main relay (In relay box)
60 A P/S P/S control module
Radiator cooling fan relay #1 (In relay box)
30 A RDTR
Radiator cooling fan relay #2 (In relay box)
40 A ABS1 ABS control module
40 A BLW Heater relay
30 A ST Starting motor relay (In relay box)
BLANK BLANK BLANK
30 A B/U Individual circuit fuse box No.2 (In J/B)
9A-34 Wiring Systems:

No. Fuse Description on the cover Protected circuit

BLANK BLANK BLANK
15 A H/L L Headlight (L)
25 A ABS2 ABS control module
15 A H/L R Headlight (R)
20 A FR FOG Front fog light relay (In relay box)
7.5 A CNG VLV BLANK
40 A IGN Individual circuit fuse box No.2 (In J/B)
BLANK BLANK BLANK
BLANK BLANK BLANK
7.5 A CNG BLANK
BLANK BLANK BLANK
Starting motor
ST SIG2 (Petrol engine
7.5 A Starting motor relay (In relay box)
model)
ECM
Individual circuit fuse box No.2 (In J/B)
INJ DRV (Diesel engine
20 A ECM
model)
Main relay (In relay box)
Individual circuit fuse box No.2 (In J/B)
Main relay (In relay box)
A/C compressor relay (In relay box)
VSS
A/F sensor
10 A FI2 (Diesel engine model) EGR valve
ECM
Radiator cooling fan relay #1 (In relay box)
Radiator cooling fun relay #2 (In relay box)
Radiator cooling fun relay #3 (In relay box)
Boost pressure regulator valve
Individual circuit fuse box No.2 (In J/B)
15 A F/P (Diesel engine model) Main relay (In relay box)
Fuel pump relay (In relay box)

Individual Circuit Fuse Box No. 2

1
2 3 4
5 6 7 8 9 10
11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26 27 28 29
30 31 32 33 34 35 36

IAP7WP910922-01

No. Fuse Description on the cover Protected circuit

30 A BELT BLANK
20 A P/W T BLANK
20 A STL BLANK
Rear defogger relay (In J/B)
20 A RR DEF Rear defogger
HVAC control unit
20 A S/R BLANK
15 A DEICER BLANK
 Wiring Systems: 9A-35

No. Fuse Description on the cover Protected circuit

10 A MRR HTR BLANK
Ignition switch
7.5 A ST SIG
Starting motor relay (In relay box)
15 A ACC2 Accessory socket
Power window master switch
Power window sub switch
30 A P/W
Rear power window sub switch (R)
Rear power window sub switch (L)
10 A HAZ BCM
7.5 A BCM BLANK
Generator
Ignition coil #1
Ignition coil #2
Ignition coil #3
15 A IG COIL Ignition coil #4
ECM
Glow control module
Fuel filter water detection sensor
MAF and IAT sensor
10 A ABS ABS control module
BCM
15 A ACC Power mirror switch
Audio
10 A A-STOP BLANK
15 A HORN Horn relay (In J/B)
10 A STOP Brake light switch
10 A A/B A/B SDM
Back-up light switch
10 A BACK HVAC control unit
Air intake control actuator
Windshield washer motor
15 A WIP Rear washer motor
Rear wiper motor
Combination switch
25 A FR WIP
Windshield wiper motor
DLC
BCM
Main switch (key)
Keyless / security control module
7.5 A DOME
Combination meter
Dome light
Spot light
Rear dome light
BLANK BLANK BLANK
7.5 A RR FOG Combination switch
BLANK BLANK BLANK
7.5 A IG1 SIG P/S control module
15 A RADIO2 BLANK
10 A ACC3 BLANK
15 A RADIO Audio
10 A TAIL Combination switch
BCM
20 A D/L
Security option #2
Brake light switch
7.5 A CRUISE
CPP switch
BCM
10 A MTR Keyless / security control module
Combination meter
9A-36 Wiring Systems:

No. Fuse Description on the cover Protected circuit

Rear defogger relay (In J/B)
7.5 A IG2 SIG Heater relay
Fan relay
20 A S/H BLANK

Fuse Box (Rear A/C)

65 66
IBL80A910918-01

No. Fuse Description on the cover Protected circuit

BLANK BLANK BLANK
Heater relay
7.5 A BLANK
Rear A/C unit

J/B Connector / Fuse Layout

AENBL80A910D004
 Wiring Systems: 9A-37

Fuse Side

K131

E336 E337

E325 1

G273 G274 G275

E324

G271
E323

G272

IBL80A910919-01

1. Fuse box
9A-38 Wiring Systems:

Relay Side

1
3

3
3

3
2

L314

L313

L315

L322

L319

IBL80A910920-01

1. Horn relay 2. Rear defogger relay 3. BLANK

J/B Inner Circuit (Detail)

AENBL80A910D005
Abbreviations
Abbreviation Full term Abbreviation Full term
AS Assistant (Front passenger) LP Light
CTR Center O/H Overhead
DR Driver R/B Relay box
F-L Front L R-L Rear L
F-R Front R R-R Rear R
FR Front RR Rear
 Wiring Systems: 9A-39

Abbreviation Full term Abbreviation Full term

INP Instrument panel S/H Seat heater
LEV (Headlight) leveling
9A-40 Wiring Systems:

Connector No. / Terminal No.

J/B E323 E324 E325 E336 E337 G271 G272 G273 G274 G275 K131 L313 L314 L315 - L319 L322

3
13
IG COIL 15A
5

12

27
IG1 SIG 7.5A
2

6
33
CRUISE 7.5A
6
34
MTR 10A
3

19
A/B 10A
2
14
ABS 10A
11

20
BACK 10A
9

10

15
ACC 15A
8

16

7
9
ACC2 15A
3

(Continued)
E323 E324 E325 E336 E337 G271
1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 1 2 3 4
1 2
3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 9 10 11 12 13 14 15 16 5 6 7 8

G272 G273 G274 G275 K131 L313

1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5
1 2 3 4 5
5 6 7 8 9 10 7 8 9 10 11 12 9 10 11 12 13 14 15 16 1 2
6 7 8 9 10 6 7 8 9 10 11 12 13

L314 L315 L319 L322

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8 9 10 11 14 15 16 17 18 19 20 21 22 23 24 25

IBL80A910921-02
 Wiring Systems: 9A-41

Connector No. / Terminal No.

J/B E323 E324 E325 E336 E337 G271 G272 G273 G274 G275 K131 L313 L314 L315 - L319 L322

4
22
FR WIP 25A
7

15

10
P/W 30A
4

10

35 21
IG2 SIG 7.5A WIP 15A
1

8
8
ST SIG 7.5A
2

(Continued)
E323 E324 E325 E336 E337 G271
1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 1 2 3 4
1 2
3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 9 10 11 12 13 14 15 16 5 6 7 8

G272 G273 G274 G275 K131 L313

1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5
1 2 3 4 5
5 6 7 8 9 10 7 8 9 10 11 12 9 10 11 12 13 14 15 16 1 2
6 7 8 9 10 6 7 8 9 10 11 12 13

L314 L315 L319 L322

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8 9 10 11 14 15 16 17 18 19 20 21 22 23 24 25

IBL80A910922-02
9A-42 Wiring Systems:

Connector No. / Terminal No.

J/B E323 E324 E325 E336 E337 G271 G272 G273 G274 G275 K131 L313 L314 L315 - L319 L322

5
4
RR DEF 20A
1

Relay

2
17
HORN 15A
6

4
Horn relay

31
TAIL 10A
5

11

14
32
D/L 20A
20
18
STOP 10A
5
3

(Continued)
E323 E324 E325 E336 E337 G271
1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 1 2 3 4
1 2
3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 9 10 11 12 13 14 15 16 5 6 7 8

G272 G273 G274 G275 K131 L313

1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5
1 2 3 4 5
5 6 7 8 9 10 7 8 9 10 11 12 9 10 11 12 13 14 15 16 1 2
6 7 8 9 10 6 7 8 9 10 11 12 13

L314 L315 L319 L322

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8 9 10 11 14 15 16 17 18 19 20 21 22 23 24 25

IBL80A910923-01
 Wiring Systems: 9A-43

Connector No. / Terminal No.

J/B E323 E324 E325 E336 E337 G271 G272 G273 G274 G275 K131 L313 L314 L315 - L319 L322

3
11
HAZ 10A
13

11

2
25
RR FOG 7.5A
13

10

12

14

20

15

(Continued)
E323 E324 E325 E336 E337 G271
1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 1 2 3 4
1 2
3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 9 10 11 12 13 14 15 16 5 6 7 8

G272 G273 G274 G275 K131 L313

1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5
1 2 3 4 5
5 6 7 8 9 10 7 8 9 10 11 12 9 10 11 12 13 14 15 16 1 2
6 7 8 9 10 6 7 8 9 10 11 12 13

L314 L315 L319 L322

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8 9 10 11 14 15 16 17 18 19 20 21 22 23 24 25

IBL80A910924-02
9A-44 Wiring Systems:

Connector No. / Terminal No.

J/B E323 E324 E325 E336 E337 G271 G272 G273 G274 G275 K131 L313 L314 L315 - L319 L322

13

25

1
30
RADIO 15A
1
23
DOME 7.5A
1

11

11

12

E323 E324 E325 E336 E337 G271

1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 1 2 3 4
1 2
3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 9 10 11 12 13 14 15 16 5 6 7 8

G272 G273 G274 G275 K131 L313

1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5
1 2 3 4 5
5 6 7 8 9 10 7 8 9 10 11 12 9 10 11 12 13 14 15 16 1 2
6 7 8 9 10 6 7 8 9 10 11 12 13

L314 L315 L319 L322

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8 9 10 11 14 15 16 17 18 19 20 21 22 23 24 25

IBL80A910925-03
 Wiring Systems: 9A-45

System Circuit Diagram

System Circuit Diagram
AENBL80A910E001
Refer to “A-1 Cranking System Circuit Diagram (Petrol Engine Model)” (Page 9A-46).
Refer to “A-1 Cranking System Circuit Diagram (Diesel Engine Model)” (Page 9A-47).
Refer to “A-2 Charging System Circuit Diagram (Petrol Engine Model)” (Page 9A-48).
Refer to “A-2 Charging System Circuit Diagram (Diesel Engine Model)” (Page 9A-49).
Refer to “A-3 Ignition System Circuit Diagram (Petrol Engine Model)” (Page 9A-50).
Refer to “A-4 Cooling System Circuit Diagram (Petrol Engine Model)” (Page 9A-51).
Refer to “A-4 Cooling System Circuit Diagram (Diesel Engine Model)” (Page 9A-52).
Refer to “A-5 Engine and A/C Control System Circuit Diagram (Petrol Engine Model)” (Page 9A-53).
Refer to “A-5 Engine and A/C Control System Circuit Diagram (Diesel Engine Model)” (Page 9A-58).
Refer to “A-8 Body Control System Circuit Diagram” (Page 9A-63).
Refer to “A-9 CAN Circuit Diagram” (Page 9A-67).
Refer to “A-10 Security Control System Circuit Diagram” (Page 9A-68)
Refer to “B-1 Windshield Wiper and Washer Circuit Diagram” (Page 9A-70).
Refer to “B-2 Rear Wiper and Washer Circuit Diagram” (Page 9A-71).
Refer to “B-3 Rear Defogger Circuit Diagram” (Page 9A-72).
Refer to “B-4 Power Window Circuit Diagram” (Page 9A-73).
Refer to “B-5 Power Door Lock Circuit Diagram” (Page 9A-75).
Refer to “B-6 Power Mirror Circuit Diagram” (Page 9A-77).
Refer to “B-7 Horn Circuit Diagram” (Page 9A-78).
Refer to “C-1 Combination Meter Circuit Diagram” (Page 9A-79).
Refer to “D-1 Headlight System Circuit Diagram” (Page 9A-81).
Refer to “D-2 Position, Tail and Licence Plate Light System Circuit Diagram” (Page 9A-82).
Refer to “D-3 Front Fog Light System Circuit Diagram” (Page 9A-83).
Refer to “D-4 Illumination Light System Circuit Diagram” (Page 9A-84).
Refer to “D-5 Interior Light System Circuit Diagram” (Page 9A-85).
Refer to “D-6 Turn Signal and Hazard Warning Light System Circuit Diagram” (Page 9A-86).
Refer to “D-7 Brake Light System Circuit Diagram” (Page 9A-88).
Refer to “D-8 Back-Up Light System Circuit Diagram” (Page 9A-89).
Refer to “D-9 Headlight Leveling System Circuit Diagram” (Page 9A-90).
Refer to “D-10 Rear Fog Light Circuit Diagram” (Page 9A-91).
Refer to “E-1 Heater System Circuit Diagram” (Page 9A-92).
Refer to “F-1 Air Bag System Circuit Diagram” (Page 9A-94).
Refer to “F-2 Anti-Lock Brake System Circuit Diagram” (Page 9A-96).
Refer to “F-4 Power Steering System Circuit Diagram” (Page 9A-98).
Refer to “G-1 Audio System Circuit Diagram” (Page 9A-99).
Refer to “G-2 Accessory Socket System Circuit Diagram” (Page 9A-101).
9A-46 Wiring Systems:

A-1 Cranking System Circuit Diagram (Petrol Engine Model)

AENBL80A910E002

OUT LOCK
Relay 48
box ST
ACC
30A
A72 ON
Main
IN
1 fuse
box ST
Battery

C282 1
G147 2

BLK BLK/GRY WHT BRN

G271 8

J/B
8 ST SIG
7.5A

E336 2

RED RED/WHT

E225 3 1

Starting
motor
relay

4 2
YEL

YEL

Relay 62 ST
box SIG2
7.5A

BLU/YEL YEL
E371 2 6
C343
BLU/YEL YEL BLK
BY

ECM

"A-5" W/S

C196 1 C195 1

BLK
Starting
motor

18 19 34
IBL80A910926-01
 Wiring Systems: 9A-47

A-1 Cranking System Circuit Diagram (Diesel Engine Model)

AENBL80A910E003

OUT LOCK
Relay 48
box ST
ACC
30A
C191 ON
Main
IN
1 fuse
box ST
Battery

C282 1
G147 2

BLK/GRY BLK/GRY BLK BRN

G271 8

J/B
8 ST SIG
7.5A

E336 2

RED RED/WHT

E225 3 1

Starting
motor
relay

4 2

YEL
E371 6
C343
YEL BLK

W/S

C196 1 C195 1

BLK
Starting
motor

20 18 34
IBL80A910927-01
9A-48 Wiring Systems:

A-2 Charging System Circuit Diagram (Petrol Engine Model)

AENBL80A910E004

Main
fuse
72 13 IG COIL J/B
box
100A 15A

C283 1 E336 5

BCM

"A-8"
WB

BLK BLK/WHT WHT/BLU

E371 5 7
C343

BLK/WHT WHT/BLU

W/S

BLK/WHT

C192 1 C194 2 4

Stator
coil

Generator
IC regulator

Field
coil

IBL80A910928-01
 Wiring Systems: 9A-49

A-2 Charging System Circuit Diagram (Diesel Engine Model)

AENBL80A910E005

Main
fuse
72 13 IG COIL J/B
box
120A 15A

C283 1 E336 5

BCM

"A-8"
WB

WHT BLK/WHT WHT/BLU

E371 8 7
C343

BLK/WHT WHT/BLU

C192 1 C194 2 1

Stator
coil

Generator
IC regulator

Field
coil

IBL80A910994-01
9A-50 Wiring Systems:

A-3 Ignition System Circuit Diagram (Petrol Engine Model)

AENBL80A910E006

13 IG COIL J/B
15A

E336 5

BLK/WHT

E371 5
C343

ECM

BLK/WHT

C01 4 17 5 6

GY GW B Lg

W/S W/S
W/S

GRN/YEL BLK/WHT GRN/WHT BLK/WHT BRN BLK/WHT LT GRN BLK/WHT

C101 3 1 C102 3 1 C103 3 1 C104 3 1

2 Ignition 2 Ignition 2 Ignition 2 Ignition

coil #1 coil #2 coil #3 coil #4

BLK BLK BLK BLK

BLK

5
IBP80A910932-01
 Wiring Systems: 9A-51

A-4 Cooling System Circuit Diagram (Petrol Engine Model)

AENBL80A910E007

Relay 45 RDTR
box
30A

Main relay
"A-5"
BR

BLK/RED GRY

W/S

BLK/RED GRY GRN GRY GRN BLU/WHT

E222 1 4 E223 3 5 E224 1 5

Relay #1 Relay #2 Relay #3

2 3 1 4 3 4

LT GRN BLU BLU BLU BLK

Lg G

ECM ECM
B BB BW
"A-5" "A-5"
BLU BLU/BLK BLU/WHT

E65 2 4 3

M
Motor

BLK

33
IBP80A910933-02
9A-52 Wiring Systems:

A-4 Cooling System Circuit Diagram (Diesel Engine Model)

AENBL80A910E008

Relay 45 RDTR
box
30A

GRY

BLU BLU GRY BLU GRY BLU BLU/WHT

E222 1 4 E223 1 5 E224 3 5

Relay #1 Relay #2 Relay #3

2 3 3 4 1 4

LT GRN/RED GRN GRN BLK

ECM

B LgR "A-5"

ECM ECM
B BB BW
"A-5" "A-5"
BLU BLU/BLK BLU/WHT

E65 1 2 4

M
Motor

BLK BLK

29 33
IBL80A910929-01
 Wiring Systems: 9A-53

A-5 Engine and A/C Control System Circuit Diagram (Petrol Engine Model)
AENBL80A910E009

41 CPRSR 42 FI Relay
box
13 IG COIL J/B

10A 15A 15A

E336 12
BLK/YEL BLK/YEL
E221 1 4
1
Main
relay

3 5
BLU/YEL BRN/WHT BLK/RED
BR
W/S W/S W/S W/S

W/S BLK/RED
BLK/RED BLK/RED BLK/RED E371 14
C343
E229 3 1 E227 4 1 W/S
BLK/RED
C123 1
Compressor Relay BLK/WHT BLK/RED BLK/RED BLK/RED EVAP
relay canister
4 2 3 2 purge
valve
YEL/RED
2
GRY W/S BLU/BLK
E01 37 54 49 5 56 55 C01 38

ECM

C01 49 27 22 23 54 40 41 26

WHT PNK BLK/RED YEL/BLK BLK/RED YEL/GRN

E371 19 E387 5
C343 L371
WHT PNK RED/BLU
L389 2
R151
PNK

R101 3 BRN YEL GRN/WHT RED BLU

P
and Gauge
C42 3 4 2 1 C56 3 4 2 1
4
BLK

C141 1
BLK HO2S-2 HO2S-1

1
BLK BLK

Compressor
38 13
IBL80A910930-02
9A-54 Wiring Systems:

45 RDTR Relay
box
30A

GRY

W/S W/S
1 4

BLK/RED GRY GRY GRN BLU/WHT BLK/RED

E222 1 4 E223 3 5 E224 1 5 E371 10
C343
BLK/RED

Relay #1 Relay #2 Relay #3

2 3 1 4 3 4 BLK/RED BLK/RED BLK/RED BLK/RED
LT GRN BLU GRN BLU BLU/BLK BLU BLK
C91 1 C92 1 C93 1 C94 1

BLU

Lg B BB BW G
#1 2 #2 2 #3 2 #4 2

BLU/YEL BLU/WHT BLU/RED LT GRN/BLK

Motor
"A-4"
E01 42 41 C01 13 37 25 1

ECM

C01 36 31 43 32 34 20 2 29 E01 30 35 14

GRY LT GRN BLK/YEL GRY/BLU GRY/RED RED/BLK GRY/RED RED/GRN BLU/RED

C39 2 C38 1 C36 1 3 E36 3 2

WHT BLK
ECT IAT
sensor sensor Refrigerant
pressure
sensor
C37 1
1 2 2 MAP 1
GRY/BLU GRY/BLU GRY/BLU sensor

Knock 2
sensor

33
IBL80A910931-02
 Wiring Systems: 9A-55

E371 C343
4 BLK/RED BLK/RED BLK/RED
4 W/S
BLK/RED
14 BLK/RED BLK/RED BLK/RED

C133 2 C31 3 C371 3 C33 3

OCV CKP CMP

VSS
sensor sensor

1
1 2 1 2 2 1

RED/WHT YEL GRY PNK GRY RED/YEL GRY PPL

C01 46 19 9 8 10

ECM

C01 50 51 53

GRY BLK BLK BLK

BLK

6 5
IBL80A910932-01
9A-56 Wiring Systems:

J/B 18 STOP
10A

E337 5

PNK

E181 3
Relay
box
Brake
"A-1"
light
switch BY

GRN/WHT BLU/YEL
E337 4

J/B

E336 4
GW
GRN/WHT

E01 8 C01 52

ECM

E01 2 1 48 C01 6 5 17 4
(CAN)
WHT RED BLU/WHT LT GRN BRN GRN/WHT GRN/YEL

E383 7
G335
BLU/WHT

W R BW Lg B GW GY
A Blower Ignition Ignition Ignition Ignition
speed coil #4 coil #3 coil #2 coil #1
ABS
Cont.M selector "A-3" "A-3" "A-3" "A-3"
"E-1"
"A-9","F-2"

BCM

A with ABS model

"A-8,9"
B without ABS model
IBL80A910933-01
 Wiring Systems: 9A-57

Electric throttle body

TP sensor APP sensor

MAIN SUB
SUB MAIN
M
close open close open
close open close open
Throttle
actuator

C48 5 6 2 1 3 4 E191 1 6 5 2 3 4

WHT BLU
LT GRN YEL/RED RED GRN WHT BLK RED YEL BRN GRN/RED

BLK

C01 55 56 14 42 30 21 35 E01 43 32 22 31 29 24

ECM

E01 10

YEL/BLK

E192 1

CPP
switch

2
BLK

W/S

BLK

35
IBL80A910934-01
9A-58 Wiring Systems:

A-5 Engine and A/C Control System Circuit Diagram (Diesel Engine Model)
AENBL80A910E010

Main
J/B 18 STOP 33 CRUISE 77 fuse 13 IG COIL J/B
box
10A 7.5A 80A 15A

E337 5 6 E312 1
E336 5 12

RED

E404 1
D245
PNK LT GRN/BLK WHT BLK/WHT

E181 2 4
D02 1 E07 3
Brake
light
Glow
switch Cont.M

1 3
C13 1 2 3 4 5 2 1

GRN/WHT GRN/YEL BLU RED YEL GRN BLU GRY/BLU GRY BLK/WHT

GY
E337 4

J/B C115 1 C116 1 C117 1 C118 1

E336 4
GRN/WHT
GW

E01 81 68 70 74 23

ECM

37 87 10 83 65 35 15 41 32

GRY/RED RED/GRN BLU/RED BRN BLU YEL WHT

GRN/RED RED

E36 1 3 2 E191 2 3 4 1 6 5

open close open close

MAIN SUB

APP sensor

Refrigerant
pressure sensor
BLK

29 33
IBL80A910935-01
 Wiring Systems: 9A-59

A with ABS model

B without ABS model
J/B 13 IG COIL 33 CRUISE
15A 7.5A

E336 5 E337 6

BLK/WHT LT GRN/BLK

E47 3 E192 2

Fuel filter CPP

water detection switch
sensor

2 1 1

GRY YEL/RED YEL/GRN

E01 90 22

ECM

E01 61 13 1 2 3 40 64
(CAN)

BLK/YEL RED/BLU BRN BRN BRN WHT RED

E59 4

Fuel
temperature
sensor W R
A

3 ABS
Cont.M

"A-9","F-2"

BLK BCM

"A-8,9"

29 33 28 30
IBL80A910936-02
9A-60 Wiring Systems:

Relay Relay
box
38 ECM 43 FI 41 CPRSR 69 INJ DRV 71 F/P box
7.5A 30A 10A 20A 15A

BLK/RED BLK/RED

BLU BLK/RED

E371 5
C343
YEL/GRN BLK/YEL BLU BLU/YEL BLU BLK/RED BLK/RED

E221 1 2 E229 1 3 C33 3 E227 1 4

Main
VSS
relay Compressor
relay Relay

3 4 2 4 2 1 2 3

YEL/GRN BRN/WHT BLK/RED GRY WHT GRY PPL BLK/RED PPL/WHT PNK
BLK/RED BLK/RED

20 1
PPL
E01 50 80 79 89 4 5 6 75

ECM

C01 29 54 59 43 4 20

E373 4 E387 5
C345 L371

GRN PPL/WHT YEL/RED GRY/BLK WHT GRY YEL/BLK ORN/BLK PNK

C141 2 C69 1 L389 2

R151
High PNK
C374 1 C31 1 pressure
pump
P R101 3
Compressor

1 P
2 and
BLK Gauge

ECT CKP 4
2 2 BLK
sensor sensor 5
BLK
W/S
1
BLK BLK BLK BLK

34 29 33 38 13
IBL80A910937-04
 Wiring Systems: 9A-61

Relay
70 FI2 45 RDTR box
10A 30A

BLK/RED BLU GRY

1 BLU
B
BLU
E373 1
C345
BLU/RED BLU GRY BLU GRY BLU BLU/WHT

E222 1 4 E223 1 5 E224 3 5

BLU BLU/RED BLU/RED
C345 3
A/F sensor E57 6 C122 1 E373
YEL
2 3 3 4 1 4
E135 2
Relay #1 Relay #2 Relay #3
Boost BLU GRN GRN BLK
pressure
EGR 2 regulator
2 3 1 4 5 valve valve

1 BLU BLU/BLK BLU/WHT

YEL/GRN
LgR G B BB BW

2
RED/WHT GRN/WHT YEL BLK LT GRN GRY/RED BLU/RED YEL/GRN LT GRN/RED
Motor
E01 44 46 45 47 12 C01 15 5 30 E01 7 8 "A-4"

ECM

C01 47 16 49 17 48 31 46 1

ORN ORN/WHT YEL YEL/BLK GRN WHT/GRN BLU WHT/BLU

C91 1 C92 1 C93 1 C94 1

#1 2 #2 2 #3 2 #4 2

BLK

29 33
IBL80A910938-03
9A-62 Wiring Systems:

IG
J/B 13 COIL 23 DOME
15A 7.5A

E336 5 G275 2

BLK/WHT

Fuel pressure sensor E124 1

MAF and IAT

sensor

C50 3 2 1 4 2 3

GRN/YEL ORN/BLK YEL/RED BLU/RED BLU/YEL BLU/ORN

C01 8 38 6 E01 56 34 62

ECM

C01 25 56 21 23 41 24 37 9 66

C343 15
E371
PNK PNK/BLK PPL RED/BLK ORN BLK WHT/GRN GRY/YEL GRY GRY PPL/WHT
E383 14 6
G335 "A-9","C-1"
GRY PPL/WHT WB RB
PW
C32 3 2 1 C51 3 4 1 2

CMP sensor Boost pressure sensor C162 1 BLK WHT/RED WHT/BLK RED/BLK
(CAN)
G211 4 5 7 16 14 6
Engine oil
pressure
switch
DLC

5 25
IBL80A910939-01
 Wiring Systems: 9A-63

A-8 Body Control System Circuit Diagram

AENBL80A910E011

A with ABS model

B without ABS model
J/B 23 DOME 11 HAZ 15 ACC
7.5A 10A 15A

E337 9 13 G275 8

If equipped

E37 2

Outside air
temperature Immobilizer
sensor control module

1 G17 1 3 4 6

YEL/BLK YEL/RED BRN BLK/RED WHT/BLK BEG YEL/BLK YEL/RED YEL

E04 9 2 6 7 G04 32 22 6 23 7

BCM

Petrol engine model

14 1 12 10 3 11 4 8

GRN/RED BLU/YEL WHT/BLU RED/BLK BLU WHT RED GRY

E371 20 (CAN)
C343
WB E183 1 W R E337 14
BLU
A
Generator
J/B
"A-2" Brake ABS
fluid Cont.M
level L322 20
switch "A-9","F-2"

B
2
ECM

GRN/RED GRN/RED BLU/YEL BLU/YEL BLK "A-5,9" GRY

GR GR BY BY
C162 1
W/S
Side turn Front turn Side turn Front turn
signal light signal light signal light signal light Engine oil
(L) (L) (R) (R) BLK pressure
"D-6" "D-6" "D-6" "D-6" switch

35 16
IBL80A910940-01
9A-64 Wiring Systems:

J/B 23 DOME
7.5A

G275 3

WHT/RED

G32 1 G145 2
J/B
"B-3" "D-2,4" Evaporator Main switch
BY RY temperature (Key)
sensor

RED/YEL 1
2
G272 6

BLK/YEL J/B BEG WHT/BLK BLU/YEL

G273 8
RED/YEL
RY
G04 12 30 28 29 31

BCM

G04 10 11 25 24 14 3 18 2

GRN/RED BRN BLU/RED RED/BLU WHT PPL WHT RED

(CAN)

GR B BR RB W P W R

HVAC HVAC Audio P/S

control control "G-1" Cont.M
unit unit Switch
"E-1" "B-3","E-1" "D-6" "A-9","F-4"
"D-6"
IBL80A910941-01
 Wiring Systems: 9A-65

34
J/B MTR
10A

L315 3

WHT/GRN

L01 10

BCM

L01 26 1 15 12 25
GRN GRN/BLK BLU/RED RED/BLU

BLK GRN GRN/BLK GRN GRN/BLK GRN GRN/BLK GRN GRN/BLK GRN GRN/BLK BLU/RED BLU/RED RED/BLU RED/BLU

G GB G GB G GB G GB G GB BR BR RB RB

Front Front Rear Rear Rear end Rear Rear

combination combination
light (L) light (R)
assembly motor motor motor solenoid Turn signal Turn signal
"D-6" "D-6" light (R)
(R) (L) light (L)
"B-5"
"B-5" "B-5" "D-6" "D-6"
"B-5" "B-5"
with Power door lock

BLK BLK

8 14
IBL80A910942-01
9A-66 Wiring Systems:

A with ABS model

B without ABS model
32 32 C with Security
J/B D/L J/B D/L D without Security
20A 20A

L315 20 L315 20

BLK/RED

L266 1

J/B
Security option #2
"D-5"
D WB

BLK/RED WHT/BLK

C
L01 13 18

with Power door lock

BCM

with Power door lock

L01 20 22 17 4 6 19 21 8 7

BRN/YEL RED/BLK GRY GRY/BLU LT GRN/BLK BRN BLK/RED BLK/WHT BLK/YEL

L390 11
O231
L170 1 G GB LgB B
BLK/YEL

O122 2
Seat
Switch Assembly
belt Rear end
switch
OFF
ON
"B-5" "B-5"
switch
2
1

GRY GRY BLK/RED BLK/RED BLK/RED BLK

L322 3
L167 1
J/B
L164 1 L163 1 L162 1 L161 1
BLK
Front door Front door O231 1
Parking OFF (L) (R) OFF OFF OFF
G274 6
brake
switch switch L390
Rear
GRY ON ON ON ON
switch door BLK BLK
switch

25 17 1 12
If equipped
IBL80A910943-01
 Wiring Systems: 9A-67

A-9 CAN Circuit Diagram

AENBL80A910E012

A Petrol engine model

B Diesel engine model

CAN
BCM

E04 11 4 G04 18 2

W R
WHT RED
(CAN)
G50 6 5

P/S
Cont.M CAN

7 4
W R

WHT RED
(CAN)

G240 9 21

CAN CAN
ECM

E01 A 2 A 1
B 40 B 64 12 24 10 22
W R W R W R WB RB
WHT RED

G369 1 2
(CAN) (CAN) G370
WHT RED WHT RED WHT RED WHT/BLK RED/BLK
ABS model (CAN) (CAN)
E24 15 2 16 3 G11 14 13 G211 14 6

CAN
DLC
CAN
ABS
Cont.M A/B
SDM

IBL80A910944-01
9A-68 Wiring Systems:

A-10 Security Control System Circuit Diagram

AENBL80A910E013

A with Security
B without Security

Keyless / Security control module

L10 24 11 B
26 21 9 22
Security option #1

RED RED/WHT E266 1 2 YEL WHT/RED PPL WHT

YEL WHT/RED
L399 16 7 L371 2 1 L399 17 6
G349 E387 G349
RED RED/WHT YEL WHT/RED PPL WHT
P W

Audio
G164 7 6 E304 2 "G-1"
Switch
"D-6"
Valet
switch Security
horn H
8 5
1
GRY GRY

BLK
GRY
W/S

GRY
G274 6 BLK

J/B E210 1

L322 3 Security
GRY hood
switch

25 17 35
IBL80A910945-02
 Wiring Systems: 9A-69

J/B 23 DOME 34 MTR

7.5A 10A

G275 3 L322 12 L315 3

WHT/RED
G145 2

Main switch
(Key)

1
BLU/YEL BLU WHT/GRN
G349 4
L399
BLU/YEL

L10 10 25 23

Keyless / Security control module

19 7 4 15 20 6 18

GRY GRY/BLU GRY/BLU BLK BLK/RED BLK/WHT BLK/YEL

GRY/BLU

G GB

L390 11
Switch O231
BLK/YEL
"B-5" O122 2
Rear end
OFF
ON
switch

BLK/RED BLK/RED BLK/RED BLK

L164 1 L163 1 L162 1 L161 1

BLK
Front door Front door O231 1
OFF (L) (R) OFF OFF OFF
Rear
switch switch L390
ON ON ON ON
door BLK BLK
switch

10 1 12
If equipped
IBL80A910946-01
9A-70 Wiring Systems:

B-1 Windshield Wiper and Washer Circuit Diagram

AENBL80A910E014

22 21
FR WIP WIP
J/B
25A 15A

G275 15 E325 1 E337 7

YEL
E62 2

M
Motor

1
YEL/GRN RED/BLK YEL/GRN
E383 2
G335
RED/BLK

G141 3 7

OFF
ON
Switch
Switch
MIST
OFF
INT
LO
HI

INT Unit

2 4 5 6
and

BLU/RED BLU/YEL BLU/WHT Switch

(Combination switch)
G335 1 12 11 BLK
E383
BLU/RED BLU/YEL BLU/WHT

E64 3 5 1 2
LO
HI
M
Motor

4
BLK
W/S
BLK

35 24
IBL80A910947-01
 Wiring Systems: 9A-71

B-2 Rear Wiper and Washer Circuit Diagram

AENBL80A910E015

21 WIP
J/B
15A

L319 7 E325 5
YEL

E63 2

M
Motor

1
YEL/RED
E383 5
G335
YEL/RED

G141 8

WASH
OFF
ON
ON+WASH Switch
(Combination switch)
9 6

BEG

G349 11
L399

YEL BEG

L390 8 9
O231
YEL BEG BLK

O21 2 1

M
Motor

24
IBL80A910948-01
9A-72 Wiring Systems:

B-3 Rear Defogger Circuit Diagram

AENBL80A910E016

35 IG2
SIG
7.5A

J/B

Relay

4 RR DEF
20A

L319 9 G274 1 G273 5

BY

BLK/RED BLK/YEL

G04 12

BCM

L390 2
O231
11

BR B

BLK/RED BLK/RED BRN

G154 2 8
O182 O181
REAR
DEF

1 1 HVAC
control
unit

12

BLK GRY GRY

BLK
G274 6

O231 1 J/B
L390
L322 3
BLK GRY

1 12 25 17
IBL80A910949-01
 Wiring Systems: 9A-73

B-4 Power Window Circuit Diagram

AENBL80A910E017

J/B
10 P/W
30A

L314 4 5

WHT/BLU
L379 22 WHT/BLU
J215
WHT/BLU
1
J81 15 Master switch

AUTO AUTO
LOCK

Window lock
switch
ILL

UP DOWN

Driver switch

CPU

Passenger
switch
UP DOWN UP DOWN UP DOWN

Rear Rear
(R) (L)
switch switch

10 9 20 6 5 19 18 17 16
1 GRN/YEL 3
BLK RED/WHT GRN/WHT

J215 15 20 19 BLU/YEL 4
L379
RED/WHT GRN/WHT WHT/BLU WHT/GRN 5
20 19 22
L380
RED/BLK 6
J216
RED GRN BLK RED/WHT GRN/WHT WHT/BLU

J82 4 6 8

Sub switch
UP DOWN

7 5
RED GRN
J21 1 2
Front
J22 1 2
Front

M M
motor motor
UP UP

9
IBL80A910950-01
9A-74 Wiring Systems:

J/B
10 P/W
30A

L314 10 9

WHT/BLU WHT/BLU

3 GRN/YEL

4 BLU/YEL

5 WHT/GRN

6 RED/BLK
6 5 28 27
J215 J215
L379 L379
BLU/YEL GRN/YEL RED/BLK WHT/GRN
L382 7 5 6 L381 7 5 6
J218 J217
RED/BLK WHT/GRN WHT/BLU RED/BLK WHT/GRN WHT/BLU
J84 4 6 8 J83 4 6 8

Rear Rear

UP DOWN UP DOWN
sub switch (L) sub switch (R)

7 5 7 5
RED GRN RED GRN
J26 1 2 J25 1 2

Rear Rear
M M
UP motor (L) UP motor (R)
IBL80A910951-01
 Wiring Systems: 9A-75

B-5 Power Door Lock Circuit Diagram

AENBL80A910E018

BCM

L01 17 4 6 19

G GB LgB B G GB

GRY GRY/BLU LT GRN/BLK BRN GRN GRN/BLK

L379 9 17 18 10 21 25
J215
GRY GRY/BLU LT GRN/BLK BRN GRN GRN/BLK
J81 8 7 J31 6 5 1 3

Front Front Front

LOCK UNLOCK LOCK UNLOCK M

Switch
switch LOCK motor assembly

20 8

BLK BLK

15
BLK

9
IBL80A910952-02
9A-76 Wiring Systems:

J/B 32 D/L J/B 32 D/L

20A 20A

L315 20 L315 20

BLK/RED BLK/RED

L266 1

Security option #2

without Security

L01 13

with Security
BCM

1 15
GRN GRN/BLK

1 GRN/BLK

2 GRN
G GB G GB G GB G GB

GRN GRN/BLK GRN GRN/BLK GRN GRN/BLK GRN GRN/BLK

L380 21 25 L382 4 8 L381 4 8 L390 6 5
J216 J218 J217 O231
GRN GRN/BLK GRN GRN/BLK GRN GRN/BLK GRN GRN/BLK
J32 1 4 J36 1 4 J35 1 4 O121 2 1

M M M M
LOCK LOCK LOCK LOCK
Front Rear Rear Rear end

motor motor (L) motor (R) solenoid

IBL80A910953-02
 Wiring Systems: 9A-77

B-6 Power Mirror Circuit Diagram

AENBL80A910E019

15 ACC
J/B
15A

L314 6
BLU/WHT

L379 14
J215
BLU/WHT

J87 3

N N
UP UP
LH DOWN RH DOWN
L L
R R Switch

13 10 4 9 12 5

BLK BRN/WHT BEG LT GRN

J215 15 12 13 11
L379
BRN/WHT BEG LT GRN RED BLU LT GRN

L380 12 13 11
J216
BLK BRN/WHT BEG LT GRN

J28 5 8 3 J27 5 8 3
R DOWN R DOWN

M M M M

L UP L UP

Assembly Assembly

9
IBL80A910954-01
9A-78 Wiring Systems:

B-7 Horn Circuit Diagram

AENBL80A910E020

A with Air bag

B without Air bag
17 HORN
15A
J/B

Horn
relay

E325 6 G273 4

GRY BLU

GRY GRY
A G346
S171
B G371
E302 1 E281 1 S173 1

Contact
Horn Horn coil
HI H H

E303 1 E282 1

BLK BLK

W/S

BLK
A S61
B S62 1

Steering switch
(Horn switch)

34
IBL80A910955-01
 Wiring Systems: 9A-79

C-1 Combination Meter Circuit Diagram

AENBL80A910E021

J/B 23 DOME 34 MTR

7.5A 10A

G275 2 G273 11 3 "D-10"

B
HVAC P/S A/B
Cont.M Cont.M SDM
BEG
"A-9","E-2" "A-9","F-4" "A-9","F-1" G275 11
W R W R W R
J/B
WHT RED WHT RED WHT RED WHT/RED RED/WHT
G273 6
(CAN) (CAN) (CAN) BEG
B
G240 11 23 9 21 12 24 2 3 17

1
CAN

POSITION LIGHT
SPEED TACHO FUEL TEMP

REAR FOG
METER METER METER METER Power

TURN (R)
TURN (L)

HI BEAM

IMMOBI
DOOR
circuit

CPU

LCD
(ODO-TRIP)
Lighting LED

Mode
switch

10 22 15 16 8
ECM YEL/RED YEL/BLK RED
G349 1 12
"A-5" L399
PW YEL/RED YEL/BLK R
G335 14 L389 3
(CAN)
E383 R151
WHT/RED WHT/BLK RED/BLK PPL/WHT GRY GRY YEL/RED
E371 15
A 1
C343 R101 B 6
G211 16 14 6 7 5 4 "D-1"

DLC and Gauge

A 2
B 5
BLK GRY YEL/BLK

R151 4
L389

A B

A Petrol engine model

15
25 6 5 B Diesel engine model
IBL80A910956-02
9A-80 Wiring Systems:

ABS model Diesel engine model

1

WATER IN FUEL
CHECK ENGINE

OIL SERVICE
SEAT BELT
CHARGE

AIRBAG
BRAKE

GLOW
FUEL

ABS

DPF
OIL

P/S
CPU

G240 18 20 5
RB

HVAC
Steering control
Switch Audio switch Switch Switch unit
"D-6" "G-1" "G-1" "D-9" "D-3" "E-1"
RB RB RB RB RB RB

RED/BLU RED/BLU RED/BLU RED/BLU RED/BLU RED/BLK RED/BLU RED/BLU GRY

GRY

G274 6

J/B

L322 3
GRY

25 17
IBL80A910957-02
 Wiring Systems: 9A-81

D-1 Headlight System Circuit Diagram

AENBL80A910E022

Relay 52 54
J/B 23 DOME 31 TAIL box H/L L H/L R
15A 15A
7.5A 10A

G273 11 G275 5 WHT/BLU WHT/RED

E152 3 E151 3

Headlight Headlight
(L) (R)

2 1 2 1

WHT/RED RED RED/WHT RED RED/WHT

G240 2
HI BEAM

RED RED/WHT
CPU
E383 10 18
J/B
"D-2,4" G335
8 RY
R

RED WHT/GRN RED/YEL RED RED/WHT

RED

G144 5 8 9 10

OFF FLASH
TAIL Dimmer / Passing
LO
HEAD switch
UP
(Combination switch) Light switch

BLK

BLK BLK

22 23
IBL80A910958-01
9A-82 Wiring Systems:

D-2 Position, Tail and Licence Plate Light System Circuit Diagram
AENBL80A910E023

31 TAIL J/B
10A

G275 5 G272 6 L319 11 4 L322 14 E325 3 4

RY RY RY RY RY RY

WHT/GRN RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL

L390 7
G144 5 O231
RED/YEL
Head

OFF
(Combination switch) Tail
Light switch

RED/YEL

O94 2 O95 2 L134 3 L133 3 E162 2 E161 2

Licence Licence
plate plate
light #1 light #2

1 1 5 (L) (R) 5 1 (L) (R) 1

Tail light Front
(Rear combination position
light) light
BLK BLK BLK BLK BLK BLK

W/S W/S
O231 1
L390
BLK BLK BLK BLK BLK
L390 1
O231
BLK

12 1 12 1 13 34 35
IBL80A910959-02
 Wiring Systems: 9A-83

D-3 Front Fog Light System Circuit Diagram

AENBL80A910E024

55 FR Relay
FOG box
20A

G335 8
E383
WHT/GRN WHT/GRN
"D-4"
RY
E234 2 4

RED/YEL
Relay
1 3
RY RY
BLK
RED/YEL RED/YEL WHT/GRN

G151 7 4 6

Switch

LT GRN LT GRN
8 5

E164 1 E163 1
BLK RED/BLK

RB (L) (R)
2 2

"C-1" BLK BLK

W/S W/S

BLK BLK BLK BLK

22 23 34 35
IBL80A910960-01
9A-84 Wiring Systems:

D-4 Illumination Light System Circuit Diagram

AENBL80A910E025

J/B 31 TAIL
10A

G275 5 G272 6 L314 11 4 L322 14 E325 3 4 G273 8

WHT/GRN RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL

G144 5
RY RY
Tail light (L)
Head "D-2"
BCM

OFF "A-8"
(Combination switch) Tail
Light switch

8
RED/YEL RED/YEL
RY
RY RY RY RY
Licence plate Tail light (R) Front
light "D-2" position
"D-2" light (R)
Actuator (R)
"D-2" "D-9"

RED/YEL RED/YEL

RED/YEL RY RY
Front
position
light (L)
Actuator (L)
"D-9" "D-2"

RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL

RY RY RY RY RY RY RY RY
HVAC Steering Audio
control unit switch "G-1"
"E-1" "G-1"
Switch Switch Switch
"D-3" "D-6" "D-9"
IBL80A910961-03
 Wiring Systems: 9A-85

D-5 Interior Light System Circuit Diagram

AENBL80A910E026

A with Rear A/C

23 B without Rear A/C
J/B DOME
7.5A

K131 4 L322 11

B A

BLK/RED BLK/RED WHT/RED

L393 3
O233
WHT/RED
K53 2 K52 2 O91 3

Rear
Dome Spot
dome
light ON light ON
OFF OFF light ON OFF

DOOR DOOR DOOR

3 1 3 1 2 1

WHT/BLK BLK

4 2
WHT BLK WHT BLK BLK/YEL BLK

K131 9 10 L322 5

J/B

L315 15 12

WHT/BLK BLK
WB

L01 18

BCM

BLK BLK

8 14
IBL80A910962-02
9A-86 Wiring Systems:

D-6 Turn Signal and Hazard Warning Light System Circuit Diagram
AENBL80A910E027

A with Side turn signal light

B with Power mirror turn signal light
11
HAZ J/B
10A

E337 13

BLK/RED

E04 7

BCM

G04 25 24 14 E04 14 1

GRN/RED BLU/YEL
A

"D-4"
RY
BR RB W GR BY GR BY

BLU/RED RED/BLU WHT RED/YEL GRN/RED BLU/YEL GRN/RED BLU/YEL

G144 11 13 G153 5 1 E166 1 E165 1 E160 1 E159 1

L
TURN N
R Switch
Turn signal switch 2 2 2 2
(L) (R) (L) (R)
12 6 2 Side turn Front turn
signal light signal light

GRY GRY RED/BLU BLK BLK BLK BLK

RB W/S
W/S

GRY BLK BLK

"C-1"

GRY
G274 6

J/B

L322 3
GRY

17 25 34 35
IBL80A910963-02
 Wiring Systems: 9A-87

A with Side turn signal light

B with Power mirror turn signal light

BCM

L01 12 25

BLU/RED RED/BLU
B

BR RB BR RB

BLU/RED RED/BLU BLU/RED RED/BLU

L380 26 L379 26
J216 J215
BLU/RED RED/BLU
L134 6 L133 6 J28 4 J27 4

5 5 6 6
(L) (R) (L) (R)
Rear turn
signal light
(Rear Turn signal
combination light
BLK BLK
light)
J216 16
L380 16
BLK BLK BLK BLK

BLK BLK

L390 1 L399 20
O231 G349
BLK BLK BLK BLK BLK

12 1 13 21 10 11 14 8
IBL80A910964-01
9A-88 Wiring Systems:

D-7 Brake Light System Circuit Diagram

AENBL80A910E028

A Petrol engine model

B Diesel engine model
J/B
33 18
CRUISE STOP
7.5A 10A

E337 6 5

LT GRN/BLK PNK

A 3
E181 B 4 B 2

Brake
light
switch

B 3 1

GRN/YEL GRN/WHT

GY

ECM

"A-5"
E337 4

J/B

L322 25 L319 3 L322 13 E336 4

GRN/WHT GRN/WHT GRN/WHT GRN/WHT

L390 4
O231
GW
GRN/WHT
ECM

O92 1 L134 2 L133 2 "A-5"

High mounted
stop light
(L) (R)
2 5 Brake light
5
(Rear
combination
light)
BLK

BLK BLK BLK BLK BLK

O231 1 L390 1
L390 O231
BLK BLK

1 12 12 1 13
IBL80A910965-01
 Wiring Systems: 9A-89

D-8 Back-Up Light System Circuit Diagram

AENBL80A910E029

20
BACK J/B
10A

E336 9

RED/BLK

E371 18
C343
RED/BLK

C165 2

Back-up
light
switch

OFF ON

RED

17

RED

E336 1

J/B

L319 5 L322 1

RED RED

L134 1 L133 1

(L) (R)
5 5
Back-up light
(Rear combination light)

BLK BLK BLK

L390 1
O231
BLK

12 1 13
IBP80A910971-01
9A-90 Wiring Systems:

D-9 Headlight Leveling System Circuit Diagram

AENBL80A910E030

31
TAIL J/B
10A

G275 5 G272 6 E325 3 4

RY RY

WHT/GRN RED/YEL RED/YEL RED/YEL

G144 5 E69 3 E68 3

Head

OFF Actuator (L) M Control circuit M Control circuit

Actuator (R)
(Combination Tail
switch) Light switch
2 1 2 1
8
RED/YEL GRN GRN

RED/YEL GRN

E383 16
G335
RY RY

RED/YEL RED/YEL GRN

G152 6 5 3

R1 P0
R2
P1
R3 P2
R4
ILL

P3
switch
R5

R6 P4

2 4

RED/BLU BLK BLK BLK

15
RB

"C-1" BLK

BLK BLK

32 36
IBP80A910972-03
 Wiring Systems: 9A-91

D-10 Rear Fog Light Circuit Diagram

AENBL80A910E031

25
RR
J/B
7.5A FOG

G275 13

YEL/BLK

G144 2

Switch
(Combination switch)

BEG

G275 11

J/B

L319 2 G273 6

BEG BEG

"C-1"
L135 1

BLK

BLK BLK

8 14
IBP80A910973-02
9A-92 Wiring Systems:

E-1 Heater System Circuit Diagram

AENBL80A910E032

J/B
20 BACK
10A

G274 5

RED/WHT

BCM BCM
J/B
"B-3" "A-8","B-3" "D-4" "A-8"
BR B RY GR

BLK/RED BRN RED/YEL RED/WHT RED/WHT GRN/RED

G62 7

M Air intake
control
actuator 1

3 1
GRN/YEL BLU LT GRN
G154 2 8 9 6 5 11 7 1
REAR
DEF

HARF REC
A/C

CIRCUIT
HVAC control
unit
FRE

REC

3 12

RED/BLK GRY

RB
GRY
G274 6
"C-1"
J/B

L322 3
GRY

25 17
IBL80A910992-01
 Wiring Systems: 9A-93

Relay 47 BLW 35 IG2 J/B

box
SIG
40A 7.5A

without Rear A/C

BLU G274 8
E384 1
RED/WHT
G336
BLU
G194 1 3

Heater
relay

4 2

BLK/YEL BLK/YEL
G61 2
BY
Fuse box Blower
"E-3" motor M

Blower motor resister

Petrol engine model
1
ECM

"A-5"
BW
G101 4 3 2 1

BLU/WHT BLK/WHT BLU/WHT BLK/WHT

BLK/WHT RED/WHT

G195 4 3
1

Fan
relay

1 2

LT GRN RED YEL BLU/WHT WHT BLK

G155 5 2 7 3 6

Blower speed
selector
FAN

1
BLK BLK

BLK BLK
G349 20
L399
BLK BLK BLK BLK

22 23 21 10 11
IBL80A910966-04

E-3 Rear A/C System Circuit Diagram

AENBL80A910E039
9A-94 Wiring Systems:

Relay 47 BLW 35 IG2 J/B

box
SIG
40A 7.5A

BLU G274 8
E384 1
RED/WHT
G336
BLU
G194 1 3

Heater
relay

4 2
BLK/YEL BLK
BY

Fuse 66
box
7.5A

RED/WHT
G340 4
K156
RED/WHT
K02 2
Blower motor resister

5A

Blower
motor M
Rear A/C
unit

Blower
speed
selector
FAN

1
BLK
K131 10

J/B

L315 12
BLK

BLK BLK
G349 20
L399
BLK BLK BLK BLK

8 14 21 10 11
IBL80A910967-02

F-1 Air Bag System Circuit Diagram

AENBL80A910E034
 Wiring Systems: 9A-95

19
A/B J/B
10A

L313 2

Forward impact sensor

"A-9","C-1"
W R
E40 1 2

WHT RED BEG PNK/BLK

G369 1 2 E382 1 2
G370 G334
(CAN)

RED WHT RED BEG PNK/BLK

Check terminal

L04 18 L05 L04 G11 14 13 10 9

A/B
SDM

23 G11 6 5 19 18 L04 6 5 7 8

BLU/RED YEL/RED
G372 1 2
G373
BLK GRN/RED GRN BLU/RED YEL/RED GRN/WHT GRN/YEL BLU/WHT BLU/YEL BLK

G347
S172 2 1

Contact
coil

S121 2 1 G259 1 2 L283 1 2 L285 1 2

Driver Front-passenger Driver seat belt Front-passenger

seat belt

(inflator) (inflator)
module module

7 40 15
IBL80A910968-01
9A-96 Wiring Systems:

F-2 Anti-Lock Brake System Circuit Diagram

AENBL80A910E035

53 46 Relay
14
ABS2 ABS1 box ABS J/B
25A 40A 10A

E325 11

ECM

"A-5,9"
W R

(CAN)

WHT/BLU WHT/RED BEG WHT RED

E24 1 26 4 16 3

ABS
Cont.M

14 38 15 2

WHT RED

BLK BLK (CAN)

W R

BCM

"A-8,9"

W/S

BLK

27
IBL80A910969-01
 Wiring Systems: 9A-97

Wheel speed Wheel speed Wheel speed Wheel speed

sensor sensor sensor sensor
(Rear-left) (Rear-right) (Front-left) (Front-right)

L32 1 2 L31 1 2 E35 1 2 E34 1 2

LT GRN LT GRN/BLK YEL BRN

L371 3 9 4 10
E387
LT GRN LT GRN/BLK YEL BRN RED RED/BLK WHT WHT/BLK

E24 7 19 18 5 20 33 17 29

ABS
Cont.M

IBL80A910970-01
9A-98 Wiring Systems:

F-4 Power Steering System Circuit Diagram

AENBL80A910E036

Relay
J/B 27 IG1 SIG box
44 P/S
7.5A 60A

G275 6

BCM

"A-8,9"
W R

(CAN)

WHT RED LT GRN/BLK GRN

G50 6 5 3 E13 1

P/S
Cont.M

7 4 E11 2 1 8 5 7 3 E12 1 2 2

BLU
(CAN)

WHT RED

WHT RED GRN YEL BLK RED BLK BLK

W R

"A-9","C-1"

R
M
Torque sensor
L

Motor

31
IBP80A910981-01
 Wiring Systems: 9A-99

G-1 Audio System Circuit Diagram

AENBL80A910E037

30 RADIO 15 ACC J/B

If equipped
15A 15A
Steering switch (Remote audio control switch)

G273 1 G275 16

BCM
S61 5 6 4 3
"A-8"
Keyless /
security
control Contact
module coil
"A-10" "D-4"
P RY
S171 5 6 4 3
G346
WHT/RED PPL BLU/WHT RED/YEL RED/YEL RED/BLU GRN BLK/YEL

RY

RED/YEL

RY
G248 1 18 9 2 19 20

Audio

If equipped 3 13 4 14 12
PNK BLU YEL/RED YEL/BLK RED/BLU
G306 C D B A RB RB

J/C

C D C D B A B A RED/BLU
PNK BLU YEL/RED YEL/BLK
G349 9 18 G349 3 14 RB
L399 L399
PNK BLU YEL/RED YEL/BLK

L380 3 4 L379 3 4 "C-1"

J216 J215
PNK BLU PNK BLU YEL/RED YEL/BLK YEL/RED YEL/BLK

J142 2 1 G247 2 1 J141 2 1 G246 2 1

Front speaker (L) Tweeter (L) Front speaker (R) Tweeter (R)
IBL80A910971-02
9A-100 Wiring Systems:

Antenna

Antenna amplifier

K121 1 2
BLK

K154 1 2
G354
BLK

G267 1 2

Audio

If equipped

G248 5 15 6 16 11 G217 1 2 3 4 G221 1 2 3 4

LT GRN LT GRN/BLK GRY/RED GRY BLK

G349 10 19 2 13
L399
LT GRN LT GRN/BLK GRY/RED GRY WHT BLK RED GRN BLK RED GRN WHT

L382 2 1 L381 2 1
J218 J217
LT GRN LT GRN/BLK GRY/RED GRY

G220 2 3 4 6 7 G216 1 2 4 3

AUX socket USB socket

J146 2 1 J145 2 1

Rear speaker (L) Rear speaker (R)

26
IBL80A910990-01
 Wiring Systems: 9A-101

G-2 Accessory Socket System Circuit Diagram

AENBL80A910E038

J/B 9
ACC2
15A

G272 3

WHT/BLK

G251 2

Accessory
socket

BLK

BLK BLK

22 23
IBL80A910972-01
9A-102 Wiring Systems:

List of Connector
List of Connectors
AENBL80A910F001
Refer to “A Connector” (Page 9A-102).
Refer to “C Connector” (Page 9A-102).
Refer to “D Connector” (Page 9A-103).
Refer to “E Connector” (Page 9A-104).
Refer to “G Connector” (Page 9A-105).
Refer to “J Connector” (Page 9A-107).
Refer to “K Connector” (Page 9A-107).
Refer to “L Connector” (Page 9A-108).
Refer to “O Connector” (Page 9A-109).
Refer to “R Connector” (Page 9A-109).
Refer to “S Connector” (Page 9A-109).

A Connector
AENBL80A910F002
A72

MCONF010134-01
Petrol engine
model

C Connector
AENBL80A910F003
C01 C01

1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
13 14 15 16 17 18 19 20 21 22 23 24 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
25 26 27 28 29 30 31 32 33 34 35 36

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
37 38 39 40 41 42 43 44 45 46 47 48 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
49 50 51 52 53 54 55 56
MCONF600006-01
MCONF560005-01
Petrol engine model Diesel engine model
C13 C31 C31 C32 C33 C36

1 2 3 4 5 6 1 2 3 1 2 1 2 3 1 2 3 1 2 3
MCONF060068-01 MCONF030103-02 MCONF020377-01 MCONF030103-02 MCONF030085-01
MCONF030163-01
Diesel engine Petrol engine Diesel engine Diesel engine Petrol engine
model model model model model
C37 C38 C39 C42 C48 C50

1 2
1 2 1 2 1 2 1 2 3 4 5 6 1 2 3
MCONF020150-01 MCONF020293-01 MCONF020176-01
3 4 MCONF060068-01 MCONF030162-01
MCONF040092-01
Petrol engine Petrol engine Petrol engine Petrol engine Petrol engine Diesel engine
model model model model model model
C51 C56 C69 C91 C91 C92

1 2 1 1
1 2 3 4 1 2 1 2
3 4 2 2
MCONF040080-01 MCONF020378-01 MCONF020378-01
MCONF020328-01 MCONF020328-01
MCONF040081-01
 Wiring Systems: 9A-103

Diesel engine Petrol engine Diesel engine Petrol engine Diesel engine Petrol engine
model model model model model model
C92 C93 C93 C94 C94 C101

1 1
1 2 1 2 1 2 1 2 3
2 2
MCONF020378-01 MCONF020378-01 MCONF020378-01 MCONF030103-02
MCONF020328-01 MCONF020328-01
Diesel engine Petrol engine Diesel engine Petrol engine Diesel engine Petrol engine
model model model model model model
C102 C103 C104 C115 C116 C117

1 2 3 1 2 3 1 2 3 1 1 1
MCONF030103-02 MCONF030103-02 MCONF030103-02 MCONF010135-01 MCONF010135-01 MCONF010135-01

Petrol engine Petrol engine Petrol engine Diesel engine Diesel engine Diesel engine
model model model model model model
C118 C122 C123 C133 C141 C141

1 1 2 1 2 1 1 2
1 2
MCONF010135-01 MCONF020150-01 MCONF010076-01 MCONF020335-01
MCONF020176-01
MCONF020379-01
Diesel engine Diesel engine Petrol engine Petrol engine Petrol engine Diesel engine
model model model model model model
C162 C162 C165 C191 C192 C194

1 1 2
1 1
1 1 2
3 4
MCONF010029-01 MCONF010136-01 MCONF020176-01 MCONF010057-03
MCONF010134-01 MCONF040153-01

Petrol engine Diesel engine Diesel engine Petrol engine

model model model model
C194 C195 C195 C196 C196 C282

1 1 1 1 1
2 1
MCONF010046-01
MCONF020194-01 MCONF010021-01 MCONF010138-01 MCONF010078-01
MCONF010072-03
Diesel engine Petrol engine Diesel engine Petrol engine Diesel engine
model model model model model
C283 C343 (To E371) C345 (To E373) C371 C374
1 2 3 4
5 6 7 8 9 10 3 2 1
1 1 2 3 1 2
11 12 13 14 6 5 4
MCONF030139-01 MCONF020380-01
MCONF010082-01 15 16 17 18 19 20
MCONF200011-01 MCONM060024-01

Diesel engine Petrol engine Diesel engine

model model model

D Connector
AENBL80A910F004
D02 D245 (To E404)

1 1
MCONF010046-01
MCONM010036-01
Diesel engine Diesel engine
model model
9A-104 Wiring Systems:

E Connector
AENBL80A910F005
E01 E01

1 2 3 4 5 6 7 8 9 10 11 12
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36
3 4

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
37 38 39 40 41 42 43 44 45 46 47 48 5 6
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
49 50 51 52 53 54 55 56
MCONF940001-01

MCONF560006-01
Petrol engine model Diesel engine model
E04 E07 E11 E12 E13

1 2 3 4 5 6 7 1 2 3 4 1 1
1 2 3 4 5
8 9 10 11 12 13 14 5 6 7 8 2 2
MCONF050050-01 MCONF020185-01 MCONF020185-01
MCONF140036-01 MCONF080035-01

Diesel engine
model
E24 E34 E35 E36 E36
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 1 2
15 16 17 18 19 20 21 22 23 24 25 1 2 1 2
26 27 28 29 30 31 32 33 34 35 36 37 38 MCONF020315-01 MCONF020315-01 MCONF030083-01 3
MCONF380002-01 MCONF030097-01

Petrol engine Diesel engine

ABS model ABS model ABS model
model model
E37 E40 E47 E57 E59 E62

1 2 3 1
1 2 1 2 1 2 3 1 2 3 4
4 5 6 2
MCONF020200-01 MCONF020191-01 MCONF030115-01 MCONF040085-01
MCONF060107-01 MCONF020008-01

Diesel engine Diesel engine Diesel engine

If equipped ABS model
model model model
E63 E64 E65 E68 E69 E124

1 1 2 3 1 2 1 2 1 2
1 2 3 4
2 4 5 3 4 3 3
MCONF040110-01
MCONF020008-01 MCONF050027-01 MCONF040077-01 MCONF030133-01 MCONF030133-01
Diesel engine
If equipped
model
E135 E151 E152 E159 E160 E161
1 1
1 2 2 3 2 3 1 2 1 2 1 2
MCONF020382-01 MCONF020289-01 MCONF020289-01 MCONF020150-01
MCONF030137-01 MCONF030137-01
Diesel engine
model
E162 E163 E164 E165 E166 E181

1 2 1 2
1 2 1 2 1 2 1 2 3 4
MCONF020150-01 MCONF020084-01 MCONF020084-01
MCONF020162-01 MCONF020162-01 MCONF040009-01
Petrol engine
If equipped If equipped If equipped If equipped
model
E181 E183 E191 E192 E210 E221
 Wiring Systems: 9A-105

1 2 3
1 2 1
1 2 3 4 5 6 1 2 1 4
3 4
2 MCONF060068-01 MCONF020268-01 MCONF010076-01 5
MCONF040135-01 MCONF020182-01 MCONF050044-01

Diesel engine Petrol engine

If equipped
model model
E221 E222 E223 E224 E225 E227
1 1 2 1 2 3 1 2 3 1 2 1 2
2 3 3 4 4 3 3
4 4 5 5 4 4
MCONF040131-01 MCONF050044-01 MCONF050044-01 MCONF040131-01 MCONF040131-01
MCONF040086-01
Diesel engine
model
E229 E234 E266 E281 E282 E302
1 2 1 2
1
3 3 1 1 1
4 4 2 MCONF010130-01 MCONF010130-01 MCONF010130-01
MCONF040131-01 MCONF040131-01 MCONF020008-01

If equipped Option
E303 E304 E311 E312 E323 E324
1 1 1 2
1 1 2 1 2
MCONF010130-01 2 2 MCONF020202-01
3 4
MCONF020277-01
MCONF020169-01 MCONF020170-01 MCONF040097-01
If equipped
E325 E336 E337

1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8
5 6 7 8 9 10 11 8 9 10 11 12 13 14 9 10 11 12 13 14 15 16
MCONF110016-01
MCONF140037-01 MCONF160065-01

E371 (To C343) E373 (To C345) E382 (To G334) E383 (To G335) E384 (To G336)
4 3 2 1
10 9 8 7 6 5 1 2 3 10 9 8 7 6 5 4 3 2 1
4 3 2 1 2 1
14 13 12 11 4 5 6 18 17 16 15 14 13 12 11
MCONM040047-01 MCONM020026-01
20 19 18 17 16 15
MCONF060056-01 MCONM180010-01
MCONM200005-01
Diesel engine
model
E387 (To L371) E404 (To D245)

1 2 3 4 5 6
1
7 8 9 10 11 12
MCONF120072-01 MCONF010097-01

Diesel engine
model

G Connector
AENBL80A910F006
G04 G11

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
9 10 11 12 13 14
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
MCONF320022-01 15 16 17 18 19 20 21
MCONF210002-01
with Air bag
G17 G32 G50 G61 G62
9A-106 Wiring Systems:

1 1 2 3
1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 4 5 6 7 8 1 2
2
MCONF080040-01 MCONF020273-01 MCONF070024-01
MCONF020008-01 MCONF080020-01

G101 G141 G144 G145

1 2 1 2 3 4
1 2 3 4 5 6 7 8 9 10 1 2
3 4 MCONF100038-01
5 6 7 8 9 10 11 12 13
MCONF020274-01
MCONF040097-01 MCONF130010-01

G147 G151 G152 G153 G154 G155

1 2 3 1 2 3 1 2 1 2 3 4 1 2 3
1 2 3 4 5 6
4 5 6 4 5 6 7 8 3 4 5 6 5 6 7 8 9 10 4 5 6 7
7 8 9 10 11 12
MCONF060063-01 MCONF080004-01 MCONF060078-01 MCONF070016-01
MCONF100103-01 MCONF120052-01

If equipped
G164 G194 G195 G202 G211
1 1
1 2 3 1 2 3 4 5 6 7 8
2 3 2 3 1 2 3 4 5 6
4 5 6 7 8 7 8 9 10 11 12 9 10 11 12 13 14 15 16
MCONF080050-01 4 4
MCONF120052-01 MCONF160023-01
MCONF040086-01 MCONF040086-01
If equipped without Rear A/C If equipped
G216 G217 G221 G240 G246
1 2 1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 1 2 3 4 1 2
3 4 13 14 15 16 17 18 19 20 21 22 23 24
MCONF040146-01 MCONF040146-01
MCONF020159-01
MCONF040183-01 MCONF240014-01

If equipped If equipped If equipped If equipped

G247 G248 G251 G259 G267
1 2
1 2 3 4 5 6 7 8 9 10 1
1 2 1 2
11 12 13 14 15 16 17 18 19 20 2 MCONF020305-01
MCONF020159-01
MCONF200012-01 MCONF020116-01
MCONF020235-01
If equipped with Air bag
G271 G272 G273 G274 G275

1 2 3 4 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 8
1 2 3 4 5
5 6 7 8 5 6 7 8 9 10 7 8 9 10 11 12 6 7 8 9 10 9 10 11 12 13 14 15 16
MCONF080017-01 MCONF100054-01
MCONF120073-01 MCONF100108-01 MCONF160065-01

G306 G334 (To E382) G335 (To E383) G336 (To E384)
A B B D D

A A B C C C D D

( )
1 2 3 4 5 6 7 8 9 10
1 2 3 4 1 2
MCONF040180-01 11 12 13 14 15 16 17 18 MCONF020114-01
MCONF180028-01

MCONF130038-01
If equipped
G340 (To K156) G346 (To S171) G347 (To S172) G349 (To L399)

11 10 9 8 7 6 5 4 3 2 1
4 3 2 1 1 2 3 4 5 6 1 2
MCONF060080-01 MCONF020212-01 20 19 18 17 16 15 14 13 12
MCONM040047-01
MCONM200011-01
with Air bag
G354 (To K154) G369 (To G370) G370 (To G369) G371 (To S173) G372 (To G373) G373 (To G372)
 Wiring Systems: 9A-107

1 2 4 3 2 1 1 2 3 4 1 1 2 2 1
MCONF020305-01 MCONF040180-01 MCONF010121-01 MCONF020212-01
MCONM040047-01 MCONM020065-01
with Air bag with Air bag without Air bag with Air bag with Air bag

J Connector
AENBL80A910F007
J21 J22 J25 J26 J27 J28

3 2 1 3 2 1
1 2 1 2 1 2 1 2 5 4 5 4
MCONF020208-01 MCONF020208-01 MCONF020208-01 MCONF020208-01 8 7 6 8 7 6
MCONM080011-01 MCONM080011-01
If equipped If equipped If equipped If equipped If equipped If equipped
J31 J32 J35 J36 J81

1 2
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 3 4
5 6 7 8 9 10 5 6 7 8 9 10 5 6 7 8 9 10 5 6 7 8 9 10 5 6 7 8 9 10 11 12
MCONF100061-01 MCONF100061-01 MCONF100061-01 MCONF100061-01 13 14 15 16 17 18 19 20
MCONF200035-01
If equipped If equipped If equipped If equipped If equipped
J82 J83 J84 J87

1 2 3 1 2 3 1 2 3 1 2 3 4 5
4 5 6 7 8 4 5 6 7 8 4 5 6 7 8 6 7 8 9 10 11 12 13
MCONF080041-01 MCONF080041-01 MCONF080041-01
MCONF130011-01
If equipped If equipped If equipped If equipped
J141 J142 J145 J146 J215 (To L379) J216 (To L380)

22 14 22 14
21 13 21 13
28 20 12 6 28 20 12 6
27 19 11 5 27 19 11 5
1 1 1 1 26 4 26 4
2 2 2 2 25 3 25 3
MCONF020008-01 MCONF020008-01 MCONF020008-01 MCONF020008-01 24 18 10 2 24 18 10 2
23 17 9 1 23 17 9 1
16 8 16 8
15 7 15 7
MCONM280004-01 MCONM280004-01

J217 (To L381) J218 (To L382)

1 2 3 4 1 2 3 4
5 6 7 8 5 6 7 8
MCONF080035-01 MCONF080035-01

K Connector
AENBL80A910F008
K02 K52 K53 K121 K131
1 2 3 4 5
1 2 1 2 3 1 2 3 1
MCONF010046-01 6 7 8 9 10 11 12 13
MCONF020268-01 MCONF030134-01 MCONF030134-01
MCONF130017-01
If equipped with Rear A/C without Rear A/C
K154 (To G354) K156 (To G340)
2 1 1 2 3 4
MCONM020067-01 MCONF040180-01
If equipped
9A-108 Wiring Systems:

L Connector
AENBL80A910F009
L01 L04 L10

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13
9 10 11 12 13 14 15 16
14 15 16 17 18 19 20 21 22 23 24 25 26 14 15 16 17 18 19 20 21 22 23 24 25 26
17 18 19 20 21 22 23
MCONF260026-01 MCONF260026-01
MCONF230004-01
with Air bag
L31 L32 L133 L134 L135 L161
1 2 3 1 2 3
1 2 1 2 2 1 1
4 5 6 4 5 6 MCONF010100-01
MCONF020315-01 MCONF020315-01 MCONM020066-01
MCONF060075-01 MCONF060075-01
ABS model ABS model If equipped
L162 L163 L164 L167 L170 L266

1
1 1 1 1 1 2
MCONF010021-01
2
MCONF010100-01 MCONF010100-01 MCONF010100-01 MCONF020268-01
MCONF020008-01
If equipped If equipped Option
L283 L285 L313 L314 L315

1 2 1 2
1 2 3 4 5 1 2 3 4 5 6 7 8 9 10
1 2
MCONF020151-01
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
MCONF100090-01 MCONF200021-01
MCONF020207-01 MCONF020207-01
with Air bag with Air bag
L319 L322 L371 (To E387) L379 (To J215)
14 22
13 21
6 12 20 28
5 11 19 27
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 6 5 4 3 2 1 4 26
5 6 7 8 9 10 11 14 15 16 17 18 19 20 21 22 23 24 25 12 11 10 9 8 7 3 25
MCONF110016-01 2 10 18 24
MCONF250004-01 MCONM120010-01
1 9 17 23
8 16
7 15
MCONF280006-01

L380 (To J216) L381 (To J217) L382 (To J218) L389 (To R151) L390 (To O231) L393 (To O233)
14 22
13 21
6 12 20 28
5 11 19 27 2 1
4 26 4 3 2 1 4 3 2 1 2 1
7 6 5 4 3 4 3 2 1
3 25 4 3
8 7 6 5 8 7 6 5 11 10 9 8 MCONM040044-01
2 10 18 24
MCONM080018-01 MCONM080018-01 MCONM040048-01 MCONM110006-01
1 9 17 23
8 16
7 15
MCONF280006-01

L399 (To G349)

1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20
MCONF200039-01
 Wiring Systems: 9A-109

O Connector
AENBL80A910F010
O21 O91 O92 O94 O95 O121
1 1
1 2 1 2 3 1 2 1 2
2 2
MCONF020212-01 MCONF030134-01 MCONF020026-01 MCONF020224-02
MCONF020013-01 MCONF020013-01
If equipped If equipped
O122 O122 O181 O182 O231 (To L390) O233 (To L393)
1 2
1 2
1 2 1 1 3 4 5 6 7 1 2 3 4
3 4
MCONF020026-01 MCONM010034-01 MCONM010034-01 8 9 10 11 MCONF040033-01
MCONF040143-01
MCONF110014-01
with Rear A/C without Rear A/C If equipped If equipped

R Connector
AENBL80A910F011
R101 R101 R151 (To L389)

1 2 1 2
1 2 3 4 5 6
3 4 3 4
MCONF060105-01
MCONF040145-01 MCONF040181-01

Petrol engine Diesel engine

model model

S Connector
AENBL80A910F012
S61 S62 S121 S171 (To G346) S172 (To G347)

1 2
1 2 3 4 5 6 1 6 5 4 3 2 1 2 1
MCONF060080-01 MCONF010121-01 MCONM060037-01 MCONM020065-01
MCONF020207-01
with Air bag without Air bag with Air bag with Air bag with Air bag
S173 (To G371)

1
MCONM010042-01
without Air bag

Reassembling Note for Wiring Harness

Reassembling Note for Wiring Harness
AENBL80A910H001
Refer to “Around Engine” (Page 9A-110)
Refer to “Around Battery” (Page 9A-112)
Refer to “Around Strut” (Page 9A-115)
Refer to “Around Instrument Panel” (Page 9A-118)
Refer to “Around Main Floor” (Page 9A-121)
Refer to “Around Fuel Tank” (Page 9A-125)
ESP®: ESP is a registered trademark of Daimler AG.

Ground Bolt Used on Painted Panels

The bolts are specially designed to get good metal-to-metal contact on painted panels.
Be sure to use the specified ground bolt.
Using an ordinary bolt can cause poor grounding on painted panels.

! CAUTION
Using this bolt on aluminum blocks will damage the screw hole of the block. Never use this bolt on
aluminum blocks.
9A-110 Wiring Systems:

NOTE
This ground bolt is not used on the engine block, the transmission case or the steering column
mounting bracket (non-painted). Identify the bolt with the paint-scratch shape (1) on the screw.

I7V10A910944-03

Around Engine
AENBL80A910H002
Engine Harness

[A]

[a]
6 5 4 3

10 9 8 7
11

1 1 1
1

[b]

[B] 14 [C]
[D]
17
15 [D]
[F]
[E]

16

1
[c]

18

1 13

13
12
19 (a)
IBL80A910973-02
 Wiring Systems: 9A-111

[A]: View [a] 4. Ignition coil #2 13. Knock sensor

[B]: View [b] 5. Ignition coil #3 14. MAP sensor
[C]: View [c] 6. Ignition coil #4 15. Starting motor (+B)
: Tighten the terminal like this angle.
[D]: Upward 7. Fuel injector #1 16. Starting motor
: Fix the connector as the lock is upside.
[E]: Forward 8. Fuel injector #2 17. Generator (+B)
: Tighten the terminal like this angle. Keep away this wire from intake manihold.
[F]: Backward 9. Fuel injector #3 18. Generator
1. Clamp 10. Fuel injector #4 19. GND bolt
2. Engine harness 11. CMP sensor : 11 N⋅m (1.1 kgf-m, 8.5 lbf-ft)
3. Ignition coil #1 12. CKP sensor

[C]
10
[C]

[a]
(b) 6

4
3

1
5 [C]
(a) “a”
5
[B]
(a)
1 [C]
2
“a”

[A]

8
7
9

IBL80A910991-01

[A]: View [a] 4. VSS 10. Generator

[B]: Around starter 5. GND bolt “a”. 90°
: Wire position should be within range of 90° shown left
drawing.
[C]: Forward 6. GND bolt : 11 N⋅m (1.1 kgf-m, 8.5 lbf-ft)
1. Clamp 7. Starting motor (+B) : 25 N⋅m (2.5 kgf-m, 18.5 lbf-ft)
2. Engine harness 8. Starting motor
: Tighten the terminal with touched to the detention.
3. Back-up light switch 9. Generator (+B)
: Set into the detention.
9A-112 Wiring Systems:

Around Battery
AENBL80A910H003
Petrol Engine Model

[A]
[a]
[B]
6
3

2 5

2 1

4
1 1
1
1

1 9 7 (a)

IBL80A910974-01

[A]: View [a] 3. Battery (+) 7. Nut

[B]: Forward 4. ECM 8. Wire terminal
1. Clamp 5. To main harness 9. Intermediate terminal
: Close the hinged side cover after connecting “Main harness”.
2. Engine harness 6. GND bolt : 14 N⋅m (1.4 kgf-m, 10.5 lbf-ft)
 Wiring Systems: 9A-113

[C]

[E]

[C]
1
3

[a] [b]
1

[C]

[A] [B]

1
[D]

[F]
5
4
(a)
(a)

IBL80A910975-01

[A]: Detail [a] [E]: Leftward 3. Battery (–)

[B]: Detail [b] [F]: Rightward 4. GND bolt
[C]: Forward 1. Clamp 5. GND bolt
: Set into the body hole.
[D]: Upward 2. Battery cable : 25 N⋅m (2.5 kgf-m, 18.5 lbf-ft)
9A-114 Wiring Systems:

Diesel Engine Model

[A]

6 [C] 4
7 [a]
1
4
3

[b]
1 1

1
3

1
1
[C] 5
2
1 [B]

10 8 (a)

9
7

IBL80A910976-01

[A]: View [a] 3. Battery (+) 8. Nut

[B]: View [b] 4. Battery (–) 9. Wire terminal
[C]: Forward 5. Main fuse box 10. Intermediate terminal
1. Clamp 6. To main harness : 14 N⋅m (1.4 kgf-m, 10.5 lbf-ft)
: Close the hinged side cover after connecting “Main harness”.
2. Battery cable 7. GND bolt
: Set into the body hole.
 Wiring Systems: 9A-115

Around Strut
AENBL80A910H004
Right Side

3 [B] 5

[a] 16
10

17
7

8
[b]

1
1

14 1
6
9
1
[C] 1

4 2
18 1 15

[A]

1
11
12

1 13

IBL80A910977-02

[A]: View [a] 5. Windshield wiper motor 12. Hood release cable
[B]: Detail [b] 6. Headlight (R) 13. Washer hose
[C]: Forward 7. Headlight leveling actuator (R) 14. GND bolt
: Set the terminal to hole, and tighten bolt.
1. Clamp 8. Grommet 15. A/C refrigerant pressure sensor
2. Main harness 9. Brake fluid level switch 16. Security horn
3. Front turn signal light (R) 10. ABS control module (ABS model) 17. Boost pressure regulator (Diesel engine model)
4. Front position light (R) 11. Side turn signal light (R) 18. Hood opener cable
9A-116 Wiring Systems:

[A]

[b]

1 3

1 [a]

[B]
1
[C] [D]
4

4 (a)

(a)

[E]

IBL80A910978-01

[A]: View [a] [E]: Forward 4. Engine - Body connecting GND bolt
: Tighten the terminal with touched to the boss.
[B]: Detail [b] 1. Clamp : 11 N⋅m (1.1 kgf-m, 8.5 lbf-ft)
[C]: Petrol engine model 2. Main harness
[D]: Diesel engine model 3. Engine - Body connecting GND bolt
: Set the terminal to hole, and tighten bolt.

Left Side

[B] 8

1
[a]
[b] 7 6 10

10
10
3 1
4

1
5
1 2
1

[A]

1
1 9

IBL80A910979-01
 Wiring Systems: 9A-117

[A]: View [a] 3. To engine harness 7. ECM (Petrol engine model)

[B]: Detail [b] 4. Fuel temperature sensor 8. ECM (Diesel engine model)
1. Clamp 5. Fuel filter water detection sensor 9. Side turn signal light (L)
2. Main harness 6. Relay box 10. GND bolt
: Set the terminal to hole, and tighten bolt.
9A-118 Wiring Systems:

Around Instrument Panel

AENBL80A910H005
On Dash Panel

[B] [A]
1
1 1 1 1
[c] 4
[a] 6

1
2 5

3
1
7
4 8 10
4
9 7
[b]
8

[C] [D] 12 9
1
15

“a”

11 1
1 13
[d]

14
IBL80A910980-02

[A]: Detail [a] 4. J/B (Connector color: N) 11. CPP switch

[B]: View [b] 5. J/B (Connector color: BLU) 12. P/S control module
[C]: Detail [c] 6. To floor harness (Connector color: N) 13. Brake light switch
[D]: View [d] 7. To instrument panel harness (Connector color: N) 14. APP sensor
1. Clamp 8. To instrument panel harness (Connector color: YEL) 15. GND bolt
2. Main harness 9. To instrument panel harness (Connector color: GRY) “a”. ±45°
3. Grommet 10. BCM (Connector color: GRY)
 Wiring Systems: 9A-119

Inside the Instrument Panel (Right Side)

[a] [C] [B]

(a)
[D] 15 8
9 10 11

4 3

2
13

6
14 1 7
1

1 6

1
[A]
5 12
[b]
1

1
8
1

IBL80A910981-02

[A]: Detail [a] (Front view) 4. P/S control module 11. Headlight leveling switch (Connector color: BLK)
[B]: View [b] 5. To roof wire 12. Tweeter (R)
[C]: Around option switch (Back view) 6. BCM (Connector color: GRY) 13. A/B connector
[D]: Forward 7. J/B 14. J/C
1. Clamp 8. GND bolt 15. Fuse box
: Set the terminal to hole, and tighten bolt.
2. Instrument panel harness 9. Valet switch (Connector color: BLU) : 8.8 N⋅m (0.9 kgf-m, 6.5 lbf-ft)
3. Combination meter 10. Front fog light switch (Connector color: GRN)
9A-120 Wiring Systems:

Inside the Instrument Panel (Left Side)

[c] [A] [B]

[D]

[a] 1
1
1 1
1

1
9
2 1
1 7
3 1
1 1
1 5
[C]
1
12 4 1
8 [b]
1

1
11

10
1
1
1

IBL80A910982-01

[A]: Detail [a] 3. Front-passenger air bag (inflator) module 9. Air intake control actuator
[B]: View [b] 4. Tweeter (L) 10. Blower motor
[C]: Detail [c] 5. To floor harness (Connector color: N) 11. Blower motor resistor
[D]: Forward 6. GND bolt 12. Evaporator temperature sensor
: Set the terminal to hole, and tighten bolt.
1. Clamp 7. Heater relay
2. Instrument panel harness 8. Fan relay
 Wiring Systems: 9A-121

Around Main Floor

AENBL80A910H006
Front Part

[A] 1
1
1
[D] [D]
[c]
1

1
[a] 7

1 3 1

[b] (a) 6

1 1

1
4

[B] [C]
5
5

1 1

IBL80A910983-01

[A]: Detail [a] 1. Clamp 5. GND bolt

: Set the terminal to hole, and tighten bolt.
[B]: Detail [b] 2. Floor harness 6. Nut
[C]: Detail [c] 3. Seat belt switch 7. A/B SDM (with Air bag)
[D]: Forward 4. Parking brake switch : 9 N⋅m (0.9 kgf-m, 6.5 lbf-ft)

Right Side

5 9
10
4
1 1
1 2
[A] 1 2
1
2
1
6
1

2
1 1
2
2 8
7
1

IBL80A910984-03
9A-122 Wiring Systems:

[A]: Forward 4. Front door switch (Driver side) 8. Grommet

1. Clamp 5. Rear door wire (R) 9. A/C pipe
2. Clamp 6. To rear door wire (R) 10. Drain hose
: Fix to clamp with hook for line.
3. Floor harness 7. Pretensioner (Driver side) (with Air bag)
: Pass the harness under of the
washer hose.

[A] [B]

1 6
[C]
9

1 2
[C]
4 8
7

1 1 1
1
5
1
[a] 3

1
2 1
1
1
1

[b] 2
IBL80A910985-01

[A]: Detail [a] 2. Grommet 6. GND bolt

: Set the terminal to hole, and tighten bolt.
[B]: Detail [b] (Outside view) 3. Floor harness 7. Rear combination light (R)
[C]: Forward 4. Rear washer wire 8. Wheel speed sensor (Rear-right) (ABS model)
1. Clamp 5. Rear door switch (R) 9. Washer hose

Left Side

9 5 [A]
1 8

4
1
1 1
2
2
1
2
6 1

2
1
2
2
7 1
1
3

IBL80A910986-05
 Wiring Systems: 9A-123

[A]: Forward 4. Front door switch (Passenger side) 8. A/C pipe

1. Clamp 5. Rear door wire (L) 9. Drain hose
2. Clamp 6. To rear door wire (L)
: Fix to clamp with hook for line.
3. Floor harness 7. Pretensioner (Passenger side) (with
: Pass the harness downside of Air bag)
the A/C pipe and drain hose.

[A] [B]
4 6

1
1
[C] 2

1
1
1 [C]
8 1

9 1

3
1 [a] 5

2
[b]
1

IBL80A910987-01

[A]: Detail [a] 2. Grommet 6. GND bolt

: Set the terminal to hole, and tighten bolt.
[B]: Detail [b] (Outside view) 3. Floor harness 7. Rear combination light (L)
: Pass the harness outside of the cable.
[C]: Forward 4. Rear end door harness 8. Wheel speed sensor (Rear-left) (ABS model)
1. Clamp 5. Rear door switch (L) 9. To rear end door harness
9A-124 Wiring Systems:

Around Rear End Door

AENBL80A910H007

4 3

1 1
5 1

2 1

7
1 1
1
[a]
1

[c]
[b]

[A] [B] [C]

6
10
“a”

IBL80A910988-01

[A]: Detail [a] 3. Rear defogger (+) 8. License plate light #2

[B]: Detail [b] (Electric latch)
[C]: Detail [c] (Manual latch)
1. Clamp
2. Rear end door harness
: Harness should not pressed between “Rear end door trim” and “Rear end door panel”.
4. Rear defogger (–) 9. Rear end door solenoid
: Harness should not pressed between “Rear end door trim” and “Rear end door panel”.
5. Rear wiper motor 10. GND bolt
6. Rear end door opener switch “a”. ±45°
7. License plate light #1
 Wiring Systems: 9A-125

Around Fuel Tank

AENBL80A910H008

[B]
3

1
4

[E] 1

5
[a]
1

[b]
4

3
2
1

[E]
[A]

[C] [D]

6
6

7
7

IBL80A910989-01

[A]: Detail [a] [E]: Forward 4. Grommet

[B]: Detail [b] 1. Clamp 5. To floor harness
: Set connector to fuel tank.
[C]: Petrol engine model 2. Fuel pump wire 6. Fuel pump and gauge
[D]: Diesel engine model 3. Floor harness 7. GND bolt
9A-126 Wiring Systems:

Specifications
Tightening Torque Specifications
AENBL80A910S001
NOTE
The tightening torque(s) also specified in:
“Around Engine”:
“Around Battery”:
“Around Strut”:
“Around Instrument Panel”:
“Around Main Floor”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
 Lighting Systems: 9B-1

Lighting Systems
Body, Cab and Accessories

Component Location
Lighting System Component Location
AENBL80A9203001

7 5
1

8**

2 3*

12

17

16
14 15

9 13
11 10
IBL80A920009-02

1. Headlight unit 7. License plate light 13. BCM

2. Front fog light (if equipped) 8. Dome Light 14. “H/L L” fuse
** With RR A/C - (Front + Rear)
Without RR A/C - (Centre + Rear)
3. Side turn signal light (* in ORVM for higher 9. Lighting switch 15. “H/L R” fuse
variant)
4. Rear combination light 10. Headlight leveling switch 16. “FR FOG” fuse
5. High mount stop light 11. Front fog light switch (if equipped) 17. Front fog light relay
6. Rear fog light 12. Hazard warning switch
9B-2 Lighting Systems:

Diagnostic Information and Procedures

Lighting System Diagnosis Function
AENBL80A9204001
Lighting System
SUZUKI scan tool provides the following functions about BCM with regard to the lighting system.
• Active tests: )(Page 10B-13)
• Setting change: )(Page 10B-13)

Lighting System Symptom Diagnosis

AENBL80A9204002

Condition Possible cause Correction / Reference Item

Only one low-beam Blown fuse Replace fuse and check for short circuit.
headlight lights up Blown bulb Replace bulb.
Faulty wiring or ground Repair wiring.
Both low-beam headlights Faulty lighting and turn signal switch Refer to “Lighting and Turn Signal Switch
do not light up Inspection” (Page 9B-8).
Blown bulbs Replace bulbs if all above items are normal.
Faulty wiring or ground Repair wiring.
Only one high-beam Blown fuse Replace fuse and check for short circuit.
headlight lights up Blown bulb Replace bulb.
Faulty wiring or ground Repair wiring.
Both high-beam Blown bulbs Replace bulbs.
headlights do not light up Faulty lighting and turn signal switch Refer to “Lighting and Turn Signal Switch
Inspection” (Page 9B-8).
Faulty wiring or ground Repair wiring.
Fog lights do not light up Faulty system circuit (including relays Repair circuit.
(if equipped) and fuses)
Blown bulbs Replace bulbs.
Faulty fog light switch Refer to “Front Fog Light Switch Inspection (If
Equipped)” (Page 9B-10).
Dome light does not light Faulty BCM Refer to “Inspection of BCM and Its Circuits” in
up Section 10B.
Ignition switch model: )(Page 10B-19)
Faulty system circuit (including relays Repair circuit.
and fuses)
Blown bulbs Replace bulbs.
Faulty door switch Refer to “Front and Rear Door Switch
Inspection” in Section 9F (Page 9F-12).
Clearance lights, tail Faulty system circuit (including relays Repair circuit.
lights or license plate and fuses)
lights do not light up Blown bulbs Replace bulbs.
Faulty lighting and turn signal switch Refer to “Lighting and Turn Signal Switch
Inspection” (Page 9B-8).
Back up lights do not light Faulty system circuit (including relays Repair circuit.
up and fuses)
Blown bulbs Replace bulbs.
Faulty back up light switch Refer to “Back Up Light Switch Inspection” in
Section 5B.
K14B model: “Back Up Light Switch
Inspection”: K14B Model in Section 5B (Page
5B-10)
D13A model: )(Page 5B-47)
Brake lights do not light Faulty system circuit (including relays Repair circuit.
up and fuses)
Blown bulbs Replace bulbs.
Faulty brake light switch Refer to “Brake Light Switch Inspection” in
Section 4A (Page 4A-11).
 Lighting Systems: 9B-3

Condition Possible cause Correction / Reference Item

Turn signal / hazard Faulty BCM Refer to “Inspection of BCM and Its Circuits” in
warning lights do not Section 10B.
flash Ignition switch model: )(Page 10B-19)
Faulty system circuit (including relays Repair circuit.
and fuses)
Blown bulbs Replace bulbs.
Faulty lighting and turn signal switch Refer to “Lighting and Turn Signal Switch
Inspection” (Page 9B-8).
Faulty hazard switch Refer to “Hazard Warning Switch Inspection”
(Page 9B-9).

Repair Instructions
Headlight Unit Removal and Installation
AENBL80A9206001
! WARNING
Headlight bulbs may be extremely hot. There
is risk of burn if you touch them carelessly.
2
1
! CAUTION
Do not touch glass surface of bulb with bare
hands. Bulb surface with dirt deteriorates 1

and becomes unclear when bulb lights up.

NOTE
1
• Bulb(s) can be replaced as headlight unit
is installed on vehicle.
• After replacing headlight unit and/or
headlight bulb(s), check and adjust 1
headlight. )(Page 9B-4) 3

Removal
1) Disconnect negative (–) cable at battery.
2) Remove front bumper. )(Page 9H-1)
3) Disconnect headlight unit connectors.
4) Remove headlight unit screws (1) and clip (2) and
then remove headlight unit (3).
IBL80A920001-02
5) Remove bulbs, if necessary.
Installation
Reverse removal procedure, noting the following points.
• Install headlight unit clip (1).
• Install screws (2, “1” – 2, “4”) according to numerical
order as shown in figure.
9B-4 Lighting Systems:

1
2,”4”

2,”2”

2,”1” IBL80A920003-01

Procedure Using Tester

Follow tester manufacturer’s instructions.
2,”3”

Procedure Using Adjustment Screen

IBL80A920002-02
1) Prepare aiming screen as shown in figure.

Headlight Aiming and Light Intensity Check “a”

AENBL80A9206002
NOTE
• Unless otherwise required by local “c” “d” 1
regulations, perform headlight aiming “b”
using either of the procedures described
below. “e” “e”

• After any of the following services, be sure

to aim headlights. : [a]
I8T201920067-02
– Headlight bulb replacement
[a]: Elbow point adjustment range “d”: 20 mm (0.8 in.)
– Headlight unit removal and installation
“a”: About 420 mm (16.5 in.) “e”: 270 mm (10.6 in.)
• When inspecting and adjusting headlight “b”: About 350 mm (13.8 in.) 1. Light center (Make a ø 10 mm
with leveling system, make sure to set the (ø 0.4 in.) hole.)

headlight leveling switch to “0” position “c”: About 150 mm (5.9 in.)

with ignition in “ON”.

2) Park vehicle on a level floor with vehicle front facing
Preparation vertical wall (1).
1) Adjust air pressure of all tires to specified value. 3) Put a mark (3) on wall at same height as headlight
2) Remove any load from vehicle. center position (2).
3) Have one person of 75 kg (165 lb) sit on driver seat. 4) Align light center hole made in screen (4) with mark
on wall and fix screen with its horizontal edges
4) Start engine to fully charge battery.
parallel with floor surface.
Aiming Adjustment Screws 2
Use aiming adjustment screws as shown in figure. 4

1
3

[a]

I8T201920064-02

[a]: Headlight center height

5) Locate vehicle 10 m (33 ft) away from screen (1) with

its front directly against screen ([a] = [b]).
 Lighting Systems: 9B-5

[a] [a]

[b] “a”

“b”
1 4

1
2 [b]
I9P60A920008-01

[a]: Dark portion 1. Elbow point

[b]: Bright portion 2. Brightness measurement point
“a”: 110 mm (4.33 in.) 3. Headlight center
“b”: 230 mm (9.05 in.) 4. Bright / dark boundary
“a”
I8B701920016-02
Front Fog Light Removal and Installation (If
“a”: 10 m (33 ft.) 2. Vehicle center
Equipped)
AENBL80A9206003
6) Block light from headlight not being adjusted by Removal
placing light shield in front of the light.
NOTE
7) Turn on headlights (low beams).
8) Adjust aiming screw so that elbow point (1) of low After replacing front fog light and/or front fog
beam on screen is within adjustment range (2) as light bulb(s), check and adjust front fog light.
shown in figure. )(Page 9B-5)

1) Remove front fog light bezel (1). )(Page 9H-1)

2) Remove fog light screws (2) and then remove front
[a] fog light (3).
3 3) Disconnect connector from front fog light.
4) Turn socket (4) counterclockwise to remove bulb.

2
4
[b]
1

I9P60A920007-01

[a]: Dark portion 3. Headlight center 2

[b]: Bright portion 4. Bright / dark boundary

2
9) Check that light intensity measured on screen at a
point 110 mm (4.33 in.) below and 230 mm (9.05 in.) 1
to right of light center is at or higher than specified
3
value.

IBL80A920005-01

Installation
Reverse removal procedure.

Front Fog Light Aiming Adjustment (If

Equipped)
AENBL80A9206004
9B-6 Lighting Systems:

NOTE
After any of the following services, be sure to
aim fog lights.
• Front fog light bulb replacement.
• Front fog light removal and installation.

1) Adjust air pressure of all tires to specified value.

2) Have one person sit on driver seat.
3) Turn on fog lights.
4) Place screen (1) 3 m (9.8 ft.) ahead of vehicle. 2
5) Adjust with aiming screw so that bright / dark
boundary is 60 mm (2.4 in.) below fog light center. 1
I9P60A920011-03

Installation
Reverse removal procedure.

Side Turn Signal Light Removal and Installation

AENBL80A9206006
Removal
1) Unlock a hook (3) by moving the side turn signal light
in directions “1”, “2” and “3” in sequence as shown in
figure. Then remove side turn signal light (1).
2) Disconnect connector (2) from side turn signal light.
2 3
[A] [B]
“1” [a] “1”
IBL80A920010-01 [a]

1 “2” “2”
3 3

2 2
“a”

1 1
I8T201920080-01

“a”: 3 m (9.8 ft.) 3. Downward adjustment “3” “3”

I9P60A920034-01
2. Upward adjustment
[A]: Left side turn signal light [a]: Vehicle forward
[B]: Right side turn signal light
Rear Fog Light Assembly Removal and
Installation
AENBL80A9206005 NOTE
! WARNING Side turn signal light cannot be
disassembled. Replace side turn signal light
• To avoid danger of being burned, do not as a unit when bulb is blown or lens is
touch when the bulb is hot. broken.
• Do not touch glass surface of bulb to avoid
deteriorate as the case may be unclear Installation
when bulb lights on at dirty condition. Reverse removal procedure.

Removal
License Plate Light Removal and Installation
1) Remove rear fog light nuts (2), and remove rear fog AENBL80A9206007
light assembly. Removal
2) Disconnect connector from rear fog light assembly 1) Disconnect negative (-) cable at battery.
(1). 2) Remove license light lens (1) and bulbs (2).
3) Push locking part (4) to arrow direction using flat
head screwdriver (5) and then remove license light
bulb socket (3).
4) Disconnect coupler from license light bulb socket (3).
 Lighting Systems: 9B-7

Removal
3
1) Remove high mount stop light nuts (1) and rear
washer hose (2), and then remove high mount stop
light.
2) Disconnect high mount stop light connector.
3) If necessary, remove bulbs (3).

5
1 2
4 “1”
2

5
3
“2”
IBL80A920011-02

Installation
4
Reverse removal procedure for installation. IBP80A920024-01

4. Rear washer nozzle 5. Bulb housing

Rear Combination Light Removal and
Installation Installation
AENBL80A9206008
Removal Reverse removal procedure.
1) Remove rear combination light screws (1).
Dome Light Removal and Installation
2) Pull rear combination light (2) in arrow direction AENBL80A9206010
shown in figure and remove rear combination light. NOTE
3) Disconnect rear combination light connector. Vehicle with Rear A/C is equipped with dome
light in front and rear portion of the vehicle
whereas vehicle without Rear A/C is
equipped with these lights in centre and rear
portion of the vehicle.

Removal
2
1) Push dome light (1) in arrow direction “1” and
3 remove dome light in arrow direction “2”.
1
2) Disconnect connector from dome light.
3) If necessary, remove bulb (3).
1

IBL80A920008-02

3. Grommet

NOTE
Check grommet for deterioration.
Replace as necessary.

4) If necessary, remove bulbs.

Installation
Reverse removal procedure.

High Mount Stop Light Removal and Installation

AENBL80A9206009
9B-8 Lighting Systems:

“1”

2
“2”

3
1
2 1

4
IBP80A920013-01
IBL80A920013-01
2. Lock 4. Lens

Installation Lighting and Turn Signal Switch Removal and

Reverse removal procedure. Installation
AENBL80A9206013
Removal
Headlight Leveling Actuator Inspection 1) Remove steering column cover.
AENBL80A9206012
1) Disconnect headlight levering actuator connector. 2) Remove immobilizer control module (4) from
2) Arrange 3 new 1.5 V batteries (1) in series (check steering lock.
that total voltage is 4.5 – 5.0 V), and connect it as 3) Disconnect lighting and turn signal switch connector
shown in figure. Check that reflector of headlight (3).
moves downward. 4) Remove lighting and turn signal switch (1) from
steering column while pushing claw (2) in direction of
arrow.

1
1

2 1 3

3 4

IBL80A920012-01

3) Arrange 5 new 1.5 V batteries (1) in series (check IBP80A920014-01

that total voltage is 7.5 – 8.0 V) and connect it as

shown in figure. Check that reflector of headlight Installation
moves upward. Reverse removal procedure.

Lighting and Turn Signal Switch Inspection

AENBL80A9206014
 Lighting Systems: 9B-9

Check continuity between terminals at each switch Rear fog light switch continuity
position. If check result is not as specified, replace
switch. [A] 2 1
[B]
OFF
“5” “10” “9” “11” “13” “1” ON
IBP80A920018-01
[B] [D]
LO LO [A]: Terminal [B]: Switch position
PASS HI PASS HI OFF

Hazard Warning Switch Removal and

[A] Installation
[C] AENBL80A9206015
OFF OFF Removal
1) Remove center ventilation louver (1). )(Page 9C-9)
2) Disconnect connector, and then remove hazard
warning switch (2) from center upper box while
“8” “7” “12” “2”
releasing the locks (3).

1
2
4 3 2 1
13 12 11 10 9 8 7 6 5
3
IBP80A920015-01
2
[A]: Lighting switch [C]: Turn signal switch
[B]: Dimmer / Passing switch [D]: Rear fog light switch

Dimmer / Passing switch and lighting switch

continuity I9P60A920023-01

[A]
Installation
8 5 10 9 7
[B] Reverse removal procedure.
OFF
Hazard Warning Switch Inspection
AENBL80A9206016
LO
Check continuity between terminals at each switch
HI position. If check result is not as specified, replace
PASS hazard warning switch.
IBP80A920016-01

[A]: Terminal [B]: Switch position

NOTE
Dimmer / Passing switch does not have dead
point. (Both high and low beam lights light up
simultaneously at transition point.)

Turn signal switch continuity

[A]
[B] 13 12 11

IBP80A920017-01

[A]: Terminal [B]: Switch position

9B-10 Lighting Systems:

NOTE Front fog light switch continuity

Set tester to diode range when checking
Terminal
continuity between terminals at each switch 7 6 8 4 5
Switch position
position.
Free (OFF)

ON

IBP80A920022-01
4 3 2 1

10 9 8 7 6 5
Headlight Relay / Tail Light Relay / Front Fog
Light Relay Inspection
AENBL80A9206019
5 1 Refer to “Control Relay Inspection” in Section 10B (Page
[A] 10B-28).

Headlight Leveling Switch Removal and

Installation
6 2 AENBL80A9206020
Refer to “Instrument Panel Components” in Section 9C
IBP80A920019-01 (Page 9C-9).
[A]: Hazard warning light
Headlight Leveling Switch Inspection
AENBL80A9206021
Hazard warning switch continuity
Check resistance between terminals at each switch
[A] position.
5 6 1 2
[B] If check result is not as specified, replace switch.

OFF NOTE
When measuring resistance between
terminals “4” and “5”, set circuit tester in
ON
diode mode, because there is a diode
IBP80A920020-01 between these terminals.
[A]: Terminal [B]: Switch position

Front Fog Light Switch Removal and

Installation (If Equipped) 5
AENBL80A9206017
Refer to “Instrument Panel Components” in Section 9C 4
(Page 9C-9). 1
“4” “5”
2 “3”
Front Fog Light Switch Inspection (If Equipped)
AENBL80A9206018 3
Check continuity between terminals at each switch “1” “2”
I8C50A920027-02
position. If check result is not as specified, replace
switch. Switch position Terminal Resistance (Ω)
— 1 and 2 Approx. 4,600
7 4 0 2 and 3 Approx. 3,920
8 3 1 2 and 3 Approx. 3,240
7 2 2 and 3 Approx. 2,560
6 3 2 and 3 Approx. 1,880
5 2 4 2 and 3 Approx. 1,200
— 2 and 3 Continuity
4 1 6 8 5

IBP80A920021-01
 Lighting Systems: 9B-11

Specifications
Electric Bulb Capacity
AENBL80A9207001
Name Capacity Name Capacity
Headlight 60 / 55 W (H4) Tail light and stop light 21 / 5 W
Front turn signal light 21 W Rear turn signal light 21 W
Side turn signal light 5W Back up light 21 W
Front fog light 35 W (H8) High mount stop light 5Wx5
Rear fog light 21 W License plate light 5W
9C-1 Instrumentation / Driver Info. / Horn:

Instrumentation / Driver Info. / Horn

Body, Cab and Accessories

General Description
Combination Meter Description
AENBL80A9301001
• Information display is built into combination meter.
• Warning buzzer is incorporated in the combination meter.
• Fuel gauge data is supplied to the combination meter directly from the fuel level sensor.

[A] [B]

IBP80A930002-05

[A]: Without tachometer [B]: With tachometer

Information Display
The information display indicates various items of information including odometer, trip meter, outside temperature,
instantaneous fuel consumption, average fuel consumption and brightness of instrument panel.
 Instrumentation / Driver Info. / Horn: 9C-2

Schematic and Routing Diagram

Combination Meter Circuit Diagram
AENBL80A9302001
Circuit Diagram

GRY G240-5

3 6

1 4
WHT/RED G240-2 7

8
G240-3
9
2
RED/BLK
10

11

12

14
G240-15 YEL/RED

G240-16 YEL/BLK

G240-9 WHT
15
G240-21 RED

G240-10 WHT/BLK
13 16
G240-22 RED/BLK
5
G240-11 WHT
17
G240-23 RED

G240-12 WHT
18
G240-24 RED

G240-8 RED
19
20
[A] G240-17 BEG
[A]

G240-20 RED/BLK 21

G240-18 RED/BLU 22

IBP80A930001-03

[A]: D13A model 8. Fuel meter 16. DLC

1. “DOME” fuse 9. Temperature meter 17. Auto A/C
2. “MTR” fuse 10. LCD 18. SDM
3. Buzzer 11. Trip switch 19. Dimmer switch
4. Voltage regulator circuit 12. Mode switch 20. Rear fog light switch
5. CPU 13. CAN driver 21. Bulb illumination signal
6. Speedometer 14. Fuel level sensor 22. LED illumination signal
7. Tachometer (if equipped) 15. EPS
9C-3 Instrumentation / Driver Info. / Horn:

Diagnostic Information and Procedures

Combination Meter Diagnosis Function
Description
AENBL80A9304001
SUZUKI scan tool provides the following functions about
the combination meter / parking sensor system.
• DTC check: )(Page 10B-10)
• DTC clearing: )(Page 10B-10)
• DTC list display: )(Page 9C-3)
• Active tests: )(Page 9C-6)
Combination Meter Self-Diagnosis Function
AENBL80A9304002
Self-Diagnosis Function
Combination meter control module have self-diagnosis
function that stores content (DTC) of a detected error.
A recorded DTC will be retained until it is cleared.

DTC Table
AENBL80A9304003
DTC DTC name DTC detecting condition Warning Fail-safe
B1802 Power Source Voltage too Voltage across “MTR” fuse is less than lower limit
)(Page 9C- Low (8.0 V) for specified or longer time. Off —
3)
B1810 Fuel Level Sensor Circuit / Fuel level signal has not been input for specified
)(Page 9C- Open or longer time. Off —
4)
B1820 Internal Control Module Memory in combination meter is faulty.
)(Page 9C- EEPROM Error Off —
5)
U0073 Control Module
Lights
)(Page 9C- Communication Bus Off —
up
5)
U0100 Lost Communication With
Refer to “CAN DTC (Lost Communication and Lights
)(Page 9C- ECM —
Communication Bus Off) Table” in Section 10H. up
5)
U0121 Lost Communication With • K14B model: )(Page 10H-6)
Lights
)(Page 9C- ABS Control Module • D13A model: )(Page 10H-25) —
up
5)
U0140 Lost Communication With
Lights
)(Page 9C- Body Control Module —
up
5)

DTC B1802
AENBL80A9304004
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1802: Power supply voltage too low • Combination meter power supply circuit
Voltage across “MTR” fuse is less than lower limit voltage • Combination meter ground circuit
(8.0 V) for specified or longer time.
• Combination meter

Circuit Diagram

GRY G240-5

[a]
1 4
WHT/RED G240-2

[A] G240
5
G240-3 12 11 10 9 8 7 6 5 4 3 2 1
2 24 23 22 21 20 19 18 17 16 15 14 13
RED/WHT

IBP80A930003-03
 Instrumentation / Driver Info. / Horn: 9C-4

[A]: Combination meter connector (View: [a]) 2. “MTR” fuse 4. Voltage regulator circuit
1. “DOME” fuse 3. Combination meter 5. CPU

DTC Troubleshooting
Step Action Yes No
1 DTC check Go to Step 2. Check for intermittent
1) Clear DTC. )(Page 10B-10) trouble. )(Page 00-11)
2) Confirm that ignition is “OFF”.
3) Set ignition “ON”.
4) Check DTC. )(Page 10B-10)

Is DTC B1802 still detected?

2 Combination meter power supply and ground circuits Go to Step 3. Repair defective wire
check harness.
1) Check combination meter power supply and ground
circuits. )(Page 9C-6)

Are they in good condition?

3 Combination meter power supply voltage check Replace combination • Check charging
1) Check power supply voltage with engine speed at 3,000 meter and recheck system.
rpm. DTC. )(Page 9C-9) – K14B model:
“Generator Test”:
Is voltage 10 – 15 V?
K14B in Section 1J
(Page 1J-5)
– D13A model:
)(Page 1J-18)

DTC B1810
AENBL80A9304005
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1810: Fuel level sensor circuit / open • Combination meter
Fuel level signal has not been input for specified or longer • Fuel level sensor
time.
• Fuel level sensor circuit

Circuit Diagram

1
[a]
3
G240-15 YEL/RED
2 [A] G240
G240-16 YEL/BLK

12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
I9P60A930006-02

[A]: Combination meter connector (View: [a]) 2. CPU

1. Combination meter 3. Fuel level sensor
9C-5 Instrumentation / Driver Info. / Horn:

DTC Troubleshooting
Step Action Yes No
1 DTC check Go to Step 2. Check for intermittent
1) Clear DTC. )(Page 10B-10) trouble. )(Page 00-11)
2) Confirm that ignition is “OFF”.
3) Set ignition “ON”.
4) Check DTC. )(Page 10B-10)

Is DTC B1810 still detected?

2 Fuel level sensor check Go to Step 3. Replace fuel level
1) Check fuel level sensor. sensor and recheck
DTC.
• K14B model: “Fuel Level Sensor Inspection”: K14B in
Section 1G (Page 1G-22) K14B model: “Fuel
• D13A model: )(Page 1G-52) Level Sensor Removal
and Installation”: K14B
Is it in good condition? in Section 1G (Page
1G-22)
D13A model: “Fuel
Pump Assembly
Removal and
Installation”: D13A in
Section 1G (Page 1G-
51)
3 Fuel level sensor circuit check Replace combination Repair defective wire
1) Confirm that ignition is “OFF”. meter and recheck harness and recheck
DTC. )(Page 9C-9) DTC.
2) Disconnect combination meter and fuel level sensor
connectors.
3) Check for proper connection to combination meter and
fuel level sensor terminals.
4) If connections are OK, check circuit between
combination meter connector and fuel level sensor for
open circuit, short to ground or short to power supply.

Are they in good condition?

DTC B1820
AENBL80A9304006
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
B1820: Internal control module EEPROM Error • Combination meter
Memory in combination meter is faulty. • Parking sensor system control module
• LIN communication circuit

DTC Troubleshooting
Step Action Yes No
1 DTC check Replace combination Check for intermittent
1) Clear DTC. )(Page 10B-10) meter and recheck trouble. )(Page 00-11)
DTC. )(Page 9C-9)
2) Confirm that ignition is “OFF”.
3) Set ignition “ON”.
4) Check DTC. )(Page 10B-10)

Is DTC B1820 still detected?

DTC U0073 / U0100 / U0121 / U0140

AENBL80A9304007
Refer to “CAN DTC (Lost Communication and Communication Bus Off) Table” in Section 10H.
 Instrumentation / Driver Info. / Horn: 9C-6

• K14B model: )(Page 10H-6)

• D13A model: )(Page 10H-25)

Scan Tool Active Test

AENBL80A9304008
Active control is possible for the following items using active test function of SUZUKI scan tool.
Test item Test content
ECT Meter (Sweep) Water temperature meter is forcedly operated from MIN to MAX.
Fuel Meter (Sweep) Fuel meter is forcedly operated from MIN to MAX.
Tacho meter (Sweep) Tachometer is forcedly operated from MIN to MAX.
Speed meter (Sweep) Speedometer is forcedly operated from MIN to MAX.
ECT Meter (Direct) Water temperature meter is forcedly set to specified level.
Fuel Meter (Direct) Fuel meter is forcedly operated to specified level.
Tacho meter (Direct) Tachometer is forcedly operated to specified level.
Speed meter (Direct) Speedometer is forcedly operated to specified level.
Warning Buzzer Buzzer in combination meter is forcedly operated.

Inspection of Combination Meter and Its Circuit

AENBL80A9304009
Voltage and Signal Check
1) Remove combination meter (with connectors connected). )(Page 9C-9)
2) Check voltage and/or pulse signal using voltmeter and oscilloscope.

NOTE
• Confirm that battery voltage is 11 V or more.
• Outputs from terminals marked with asterisk (*) cannot be measured with voltmeter because they
are pulse signals. Use oscilloscope for measuring these outputs.

[A] G240

[a] 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
I9P60A930009-03

[A]: Combination meter connector (View: [a])

9C-7 Instrumentation / Driver Info. / Horn:

Terminal Normal
Wire color Circuit Condition
No. voltage
Approx.
2 WHT/RED Backup power supply Ignition: “OFF”, “ACC” or “ON”
12.0 V
Approx.
3 RED/BLK Power supply Ignition: “ON”
12.0 V
5 GRY GND 0V Ignition: All
Approx. Dimmer switch: Other than high
12.0 V beam position
8 RED Dimmer switch signal (high beam)
Dimmer switch: High beam
0V
position
9* WHT CAN communication signal (low) to EPS
10* WHT/BLK CAN communication signal (low) to DLC
CAN communication signal (low) to Auto Refer to reference waveform. )(Page 9C-7)
11* WHT
A/C
G240
12* WHT CAN communication signal (low) to SDM
15* YEL/RED Fuel level sensor signal (power supply) Refer to reference waveform. )(Page 9C-8)
16 YEL/BLK Ground for fuel level sensor signal (GND) 0V Ignition: All
Approx.
Rear fog light switch: ON position
17 BEG Rear fog light switch signal 12.0 V
0V Rear fog light switch: OFF position
18* RED/BLU LED illumination signal Refer to reference waveform. )(Page 9C-8)
20* RED/BLK Bulb illumination signal Refer to reference waveform. )(Page 9C-8)
21* RED CAN communication signal (high) to J/C
22* RED/BLK CAN communication signal (high) to DLC
23* CAN communication signal (high) to Auto Refer to reference waveform. )(Page 9C-7)
RED
A/C
24* RED CAN communication signal (high) to SDM

Reference Waveform • Waveforms may vary with measurement

Oscilloscope display conditions and vehicle specifications.
Shown below is typical waveform display provided by
oscilloscope. CAN communication signal
NOTE
CAN communication signal (high):
• Display includes the following types of Channel Probe Terminal No.
data: G240-21
G240-22
+
1 G240-23
G240-24
– G240-5

CAN communication signal (low):

Channel Probe Terminal No.
G240-9
G240-10
+
2 G240-11
G240-12
– G240-5

Measurement condition
IAW101970026-01

[a]: Waveform of channel 1 [c]: VOLT/DIV of each channel

• Ignition: “ON”
[b]: Ground level of each channel [d]: TIME/DIV
 Instrumentation / Driver Info. / Horn: 9C-8

Illumination control signal

Channel Probe Terminal No.
G240-18
+
1 G240-20
– G240-5

Measurement condition
• Ignition: “ON”
• Lighting switch: Other than OFF position
• Illumination control: 7th position (Brightest)

IAW101A20014-01

1. CAN communication signal (high) 1

2. CAN communication signal (low)

Fuel level sensor signal

Channel Probe Terminal No.
+ G240-15
1
– G240-16
I9P60A930012-01
Measurement condition 1. Illumination control signal
• Ignition: “ON”
• Fuel: Full • Ignition: “ON”
• Lighting switch: Other than OFF position
• Illumination control: 4th position

I9R90A930005-01

1. Fuel level sensor signal

I9P60A930013-01
• Ignition: “ON” 1. Illumination control signal
• Fuel: Empty
• Ignition: “ON”
• Lighting switch: Other than OFF position
• Illumination control: 1st position (Dimmest)

I9R90A930006-01

1. Fuel level sensor signal

9C-9 Instrumentation / Driver Info. / Horn:

I9P60A930038-01

1. Illumination control signal

Combination Meter Diagnosis

AENBL80A9304010
Combination meter operates meters, indicators and information display according to input signals and CAN
communication data from control modules. Conduct diagnosis as follows if there are problems with combination meter.
1) Check combination meter power supply and ground circuits. )(Page 9C-6)
2) Using SUZUKI scan tool, check every DTC of all systems concerned.
• If any DTC is found during inspection in Step 2), go to applicable DTC troubleshooting referring to the section for
the system (control module) in question.
• If any of troubles described in table below has occurred independently even though display shows no abnormal
DTC during inspection in Step 2), inspect concerned item according to instructions given below.

NOTE
When checking each circuit, perform diagnosis of the circuit referring to “Circuit Diagram”.

Defective item Check item Reference

High beam indicator Lighting and turn signal switch Refer to “Lighting and Turn Signal Switch Inspection” in
light (Ignition switch Section 9B (Page 9B-8).
model) Circuit (including relays and fuses) —
Rear fog light Lighting and turn signal switch Refer to “Lighting and Turn Signal Switch Inspection” in
indicator light Section 9B (Page 9B-8).
(Ignition switch Circuit (including relays and fuses)
—
model)
Circuit (including relays and fuses) Refer to ““AIR BAG” Warning Light Comes ON Steady”
Air bag warning light in Section 8B (Page 8B-10) or ““AIR BAG” Warning
Light Does Not Come ON” in Section 8B (Page 8B-11).
Fuel level sensor Refer to “Fuel Level Sensor Inspection” in Section 1G.
K14B model: “Fuel Level Sensor Inspection”: K14B in
Low fuel level sensor Section 1G (Page 1G-22)
D13A model: )(Page 1G-52)
Circuit (including relays and fuses) —

Repair Instructions
Instrument Panel Components
AENBL80A9306001
 Instrumentation / Driver Info. / Horn: 9C-10

NOTE
• To remove instrument panel, remove parts (1) through (12) and disconnect instrumental panel
harness connector beforehand.

A A
A 8
A
A A A
A 11 A A A
A A
AA A
A A A
A A
A
A AA
A A
A A A
14
A 14
A
6
A A 11(a)
A A A
A A A A
A
A A
A A
A A A
20 A A
A
10 9

A
7
A
A

18

A
A

A A 19

A
A

15 A
A

A 17 2 21
A A
A
13
A A
]A[
A A A A
A A
18 16

A
A
A A
12

A
5
4 B B

1 B

IBP80A930004-01
9C-11 Instrumentation / Driver Info. / Horn:

[A]: Release the locks
1. Steering column hole cover
2. Front fog light switch (if equipped)
3. Floor console side cover
4. Support member lower brace
5. Glove box
6. Combination meter cluster panel
7. Combination meter
8. Center ventilation louver 15. Glove box upper cover
9. Audio unit (if equipped) 16. Center side cover
10. Radio hole cover (if equipped) 17. Engine switch bezel
11. Airbag cover (with Passenger airbag) (if equipped) 18. Ornament
11a. Airbag cover (without Passenger airbag) 19. Switch bezel
(if equipped)
12. HVAC control unit (manual A/C model) 20. Instrument panel top silencer
)(Page 7B-35)
13. Auto A/C panel (auto A/C model) 21. Headlight leveling switch
14. Side ventilation louver 22. Front fog light switch (if equipped)

Instrument panel

[D]

(a) 1, “1”

[B]
(a) 1, “2”

[C]
[A]

]A[ [B]

2
2

[C]
3

[D]

3
2

IBP80A930005-01

1. Steering support member side bolt 3. Ground wire

:Tighten driver side bolt first and then tighten passenger side bolt.
2. Instrument panel harness connector : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
 Instrumentation / Driver Info. / Horn: 9C-12

Ventilation duct and steering support member

1 A
1 1

A
1

IBP80A930006-01

[A] Release the locks 1. Ventilation duct

2. Steering support member

Horn Removal and Installation

AENBL80A9306002
NOTE
There are two horns: High pitch (3, “1”) and Low pitch (3, “2”)

Removal
1) Remove front bumper. )(Page 9H-1)
2) Disconnect horn connectors (1).
3) Remove horn bolt (2) and remove horn (3).

3, “2”
2

3, “1”
1
IBL80A930001-01

Installation
Reverse removal procedure.

Horn Inspection
AENBL80A9306003
1) Disconnect horn connectors (1) from horn (2).
2) Check that horn sounds when horn connectors are connected to battery positive (+) terminal and battery negative
(–) terminal as shown. Replace horn if it does not sound.
9C-13 Instrumentation / Driver Info. / Horn:

IBL80A930002-01

Specifications
Tightening Torque Specifications
AENBL80A9307001
NOTE
The tightening torque(s) also specified in:
“Instrument Panel Components”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
9D-1 Wipers / Washers:

Wipers / Washers
Body, Cab and Accessories

Component Location
Wiper and Washer Component Location
AENBL80A9403001

(b) 1 1 (c)
(b)
8
5
7
8 2
2 8
6

4*,“2”
(a)
4,“1” (a)
(a)

3 14
12 13

15

13

12
14
[A] [B]

14
11

9 10

IBL80A940001-02

[A]: Motor side 6. Rear wiper motor 13. Washer nozzle

[B]: Nozzle side 7. Wiper pivot cap 14. Check valve
1. Windshield wiper blade 8. Rear wiper arm cover 15. Wiper and washer switch
2. Windshield wiper arm 9. Windshield washer pump : 8.3 N⋅m (0.85 kgf-m, 6.5 lbf-ft)
3. Windshield wiper motor assembly 10. Rear washer pump : 16 N⋅m (1.6 kgf-m, 12.0 lbf-ft)
4. Windshield wiper motor bolt 11. Washer tank : 7.9 N⋅m (0.81 kgf-m, 6.0 lbf-ft)
:Tighten bolts in specified order. “1” through “2”.
5. Rear wiper arm with blade assembly 12. Washer hose
 Wipers / Washers: 9D-2

Diagnostic Information and Procedures

Wiper and Washer Symptom Diagnosis
AENBL80A9404001
Windshield Wiper and Washer
Condition Possible cause Correction / Reference Item
Wiper malfunctions Faulty windshield wiper motor “Windshield Wiper Motor Operation Inspection”
(Page 9D-4)
Faulty wiper and washer switch (wiper “Wiper and Washer Switch Inspection” (Page
switch) 9D-6)
Faulty wiring or ground Repair wiring.
Washer malfunctions Faulty washer hose (including check Check washer hose or nozzle for clogging and
valve and connector) or nozzle bend. )(Page 9D-1)
Faulty washer pump “Washer Pump Inspection” (Page 9D-3)
Faulty wiper and washer switch (washer “Wiper and Washer Switch Inspection” (Page
switch) 9D-6)
Faulty wiring or ground Repair wiring.

Rear Wiper and Washer

Condition Possible cause
Wiper malfunctions Faulty rear wiper motor
Faulty wiper and washer switch (wiper
switch)
Faulty wiring or ground
Washer malfunctions Faulty washer hose (including check
valve and connector) or nozzle
Faulty washer pump
Faulty wiper and washer switch (washer
switch)
Faulty wiring or ground
Correction / Reference Item
“Rear Wiper Motor Inspection” (Page 9D-5)
“Wiper and Washer Switch Inspection” (Page
9D-6)
Repair wiring.
Check washer hose or nozzle for clogging and
bend.
“Washer Pump Inspection” (Page 9D-3)
“Wiper and Washer Switch Inspection” (Page
9D-6)
Repair wiring.

Repair Instructions
Washer Tank and Washer Pump Removal and
Installation
AENBL80A9406001
Removal
1) Remove front bumper. )(Page 9H-1)
2) Disconnect wire harness clamps (1), washer pump
connectors (2) and washer hoses (3).

2
1

I9P60A940002-01

3) Remove washer tank bolts (1) and remove washer

tank (2).
9D-3 Wipers / Washers:

2) Remove cowl top garnish (4). )(Page 9H-3)

2 2

1 1

3 4 3

IBL80A940003-01

1 2 3) Disconnect wiper motor connector (3).

IBL80A940002-01 4) Remove wiper motor bolts (1) and remove wiper
4) Pull windshield washer pump (1) and rear washer motor (2) in arrow direction as shown in figure.
pump (2) in direction of arrow to remove them from
washer tank (3). 1

1
3

3 2

IBL80A940004-01

Installation
Reverse removal procedure noting the following points.
1 2 • Tighten wiper motor bolts in numerical order (“1”
through “2”) to specified torque.
Tightening torque
Wiper motor bolt (a): 8.3 N·m (0.85 kgf-m, 6.5 lbf-
I9P60A940004-01
ft)
Installation
Reverse removal procedure. 1, (a)

Washer Pump Inspection 2, (a)

AENBL80A9406002
Connect battery positive (+) and negative (–) terminals
to washer pump as shown. If washer pump does not
operate, replace washer pump.

IBL80A940005-01

• Install windshield wiper arms (1) in positions shown in

figure and tighten wiper arm nuts to specified torque.
Tightening torque
Wiper arm nut (a): 16 N·m (1.6 kgf-m, 12.0 lbf-ft)

IBP80A940020-01

Windshield Wiper Motor Removal and

Installation
AENBL80A9406003
Removal
1) Remove wiper pivot caps (1) and wiper arm nuts (2),
and remove windshield wiper arms (3).
 Wipers / Washers: 9D-4

]A[
]A[

1
1
(a)
“1” “5”
5
2

4 IBL80A940008-01

IBL80A940006-01 2) Connect battery positive (+) and negative (–)

[A]: Set blade (5) centre to matchmark. terminals to wiper motor connector terminals as
2. wiper pivot cap shown to operate motor at high speed. If wiper motor
3. Ceramic line does not operate, replace wiper motor.
4. Matchmark on ceramic line
5. Windshield wiper blade

Windshield Wiper Motor Operation Inspection

AENBL80A9406004

“4” “2” “3”

“1” “5”
IBP80A940007-01

Make marks (1) as shown in figure

Wiper motor with wiper motor
connector

“4”
“5”
stopped.

IBL80A940009-01

3) Perform the following steps to check that wiper

1
IBL80A940007-01
1) Connect battery positive (+) and negative (–)
terminals to wiper motor connector terminals as
shown to operate motor at low speed. If wiper motor
does not operate, replace wiper motor.
motor stops at wiper park position.
a) Connect lead from battery positive (+) terminal to
terminal “1” of wiper motor connector. Connect
lead from battery negative (–) terminal to
terminal “5” of wiper motor connector. Wiper
motor will start rotating.
b) Disconnect lead from terminal “1” of wiper motor
connector to stop wiper motor when marks (1)
are not aligned.
c) Connect jumper wire between terminals “3” and
“1” of wiper motor connector. Then connect lead
from battery positive (+) terminal to terminal “2”
of wiper motor connector and connect lead from
battery negative (–) terminal to terminal “5” of
wiper motor connector. Check that wiper motor
starts rotating again and then stops when marks
(1) are aligned.
9D-5 Wipers / Washers:

Installation
Reverse removal procedure noting the following points.
• Tighten rear wiper motor bolts to specified torque.
1
Tightening torque
Rear wiper motor bolt (a): 8.3 N·m (0.85 kgf-m, 6.5
lbf-ft)

(a)

“3”
“2”

“1” “5”

IBL80A940014-01

IBL80A940010-01
• When installing rear wiper pivot cap (2), position a
matchmark (1) topside as shown.
d) Repeat Steps 1) through 3) several times to
check that the motor stops every time when 1
marks are aligned. 2
If check result is not satisfactory, replace wiper
motor.

Rear Wiper Removal and Installation

AENBL80A9406005
Removal
1) Remove rear wiper arm cover (1), rear wiper arm nut
(2), rear wiper arm with blade assembly (3), rear
I9R90A940022-01
wiper pivot cap (4).
• Install rear wiper arms with wiper blades (1) to
specified position as shown in figure, and then tighten
rear wiper nuts to specified torque.
1 Tightening torque
Rear wiper arm nut (a): 7.9 N·m (0.81 kgf-m, 6.0
3
lbf-ft)
2
4

IBL80A940011-01 (a)
2) Remove rear end door trim. )(Page 9F-14)
3) Remove rear wiper motor.
1 2
4) Disconnect connector (1) from rear wiper motor. IBL80A940012-01

2. Heat wire
1

Rear Wiper Motor Inspection

AENBL80A9406006

NOTE
Before inspection, confirm battery voltage is
12 V or higher.

1) Make marks (1) as shown in figure with wiper motor

IBL80A940018-02
(2) stopped.
 Wipers / Washers: 9D-6

1
2
1

IBL80A940015-01

2) Connect battery positive (+) and negative (–)

terminals to wiper motor connector terminals as
shown and check rear wiper motor runs smoothly. If
abnormality is found, replace wiper motor assembly.
1

IBL80A940017-01

7) Repeat Steps 3) through 5) several times and check

that the wiper motor stops at the specified position
every time.
If check result is not as specified, replace wiper
motor.

Wiper and Washer Switch Removal and

Installation
AENBL80A9406007
1 Removal
2 1) Remove steering column cover. )(Page 6B-1)
2) Disconnect wiper and washer switch connector (3).
3) Remove wiper and washer switch (1) from steering
IBL80A940016-01
column while pushing claw (2) in arrow direction.
3) Connect battery positive (+) to wiper motor
connector terminal “1” and negative (–) to terminal
“2” and operate rear wiper motor.
4) Disconnect battery negative (–) from rear wiper
motor connector terminal “2” to stop wiper motor.
5) Connect battery negative (–) to rear wiper motor
body as ground circuit.
6) Observe the wiper motor turns once again then
1
stops at a specified position (1) as shown.
2

IBP80A940011-01

Installation
Reverse removal procedure.

Wiper and Washer Switch Inspection

AENBL80A9406008

Wiper and Washer Switch Circuit Continuity Check

Check continuity between terminals at each switch
position. If check result is not as specified, replace wiper
and washer switch.
9D-7 Wipers / Washers:

Windshield wiper and washer switch 3) Connect voltmeter positive lead to terminal “3” and
its negative lead to terminal “5”.
4) Check that the voltmeter indicates the battery
voltage (10 – 14 V).
5) Connect terminal “4” and terminal “2” by a jumper
wire.

9 8 7 6 5 4 3 2 1

9 8 7 6 5 4 3 2 1

[A]
[B] 1 2 3 4 5 6
V

IBP80A940014-01

6) Disconnect end of the jumper wire from terminal “2”.

7) Connect disconnected jumper wire end to terminal
“5”, then check that voltage between terminal “3” and
IBP80A940012-01
terminal “5” changes as shown.
If check result is not as specified, replace wiper and
[A]: Terminal [B]: Switch position
washer switch.

Rear wiper and washer switch [A] [B]

12V

0V
[C]

9 8 7 6 5 4 3 2 1

[A]
[B] 5 7 8

9 8 7 6 5 4 3 2 1

IBP80A940013-01

[A]: Terminal [B]: Switch position

V

Intermittent Wiper Relay Circuit

IBP80A940015-01
1) Turn the windshield wiper switch to “INT” position.
[A]: Without wiper interval adjustment switch [C]: 3.3 ± 1 sec.
2) Connect battery positive (+) terminal to terminal “2” [B]: Voltage
and its negative (–) terminal to terminal “5”.

Specifications
Tightening Torque Specifications
AENBL80A9407001
 Wipers / Washers: 9D-8

Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Wiper motor bolt 8.3 0.85 6.5 )
Wiper arm nut 16 1.6 12.0 )
Rear wiper motor bolt 8.3 0.85 6.5 )
Rear wiper arm nut 7.9 0.81 6.0 )

NOTE
The tightening torque(s) also specified in:
“Wiper and Washer Component Location”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).
 Glass / Windows / Mirrors: 9E-1

Glass / Windows / Mirrors

Body, Cab and Accessories

Precautions
Precautions for Working on Glass
AENBL80A9500001
Precautions for Applying Primer
• Primer has an important role to enhance adhesion effect of adhesive. Primer to use for body adhesive and that for
glass adhesive are different. Be sure to use appropriate one. (Do not use gauze or nozzle used for one type for
another.)
• Put masking tape to instrument panel and other parts to protect them against primer.
• Shake primer container well before opening it and apply primer evenly.
• Do not apply primer to body surface where adhesive still remains.
• If primer is attached to plastic parts or any place other than intended area by mistake, remove it immediately using
white gasoline.
• Be sure to refer to primer maker’s instruction for proper handling and drying time.

Precautions for Applying Adhesive

• Install glass within five minutes after applying adhesive.
• Adjust adhesive nozzle so that you can apply adhesive to “Shape of Adhesive” specified in section for installation of
each glass.
• If adhesive is attached to plastic parts or any place other than intended area by mistake, remove it immediately
using white gasoline.
• After applying adhesive to windshield, keep windows open when opening and closing door and do not apply any
impact to the windshield until the adhesive is completely dry.
• Do not drive the vehicle until adhesive is fully hardened.
• Do not force the adhesive to dry using infrared light or the like.

Precautions for Working on Power Window

AENBL80A9500002
! CAUTION

• Do not expose power window regulator assembly to any excessive impact like dropping it.
• Do not activate motor when door glass is not installed to regulator assembly.
• If vehicle body near regulator assembly has been damaged, be sure to check if regulator assembly
has also been damaged.

General Description
Power Window System Description
AENBL80A9501001
• Power window system consists of power window main switch (1), power window sub switches (3), driver power
window regulator (2) and other power window regulators (4).
• When driver power window switch (13) is pushed down to the second step (auto switch (5) and down switch (11) is
turned “ON”), CPU (6) in power window main switch turns “ON” down relay (7), thereby causing door glass to move
down fully automatically. After a certain period of time, CPU turns “OFF” the relay to discontinue auto down
operation of door glass.
• When power window lock switch (8) is pushed (lock position), ground line for other than driver power window circuit
is opened and operation (up/down) of all windows other than driver power window is disabled.
9E-2 Glass / Windows / Mirrors:

IG1

13 14 15 16

12

10 11 5 10 11 10 11 10 11

10 11 10 11 10 11
9 7 3 3 3

4 4 4

2 [A] [B] [C]

I9P60A950001-03

[A]: Passenger door power window system 11. Down switch

[B]: Rear right power window system (if equipped) 12. Illumination light
[C]: Rear left power window system (if equipped) 14. Passenger power window switch (in power window main switch)
9. Up relay 15. Rear right power window switch (in power window main switch) (if equipped)
10. Up switch 16. Rear left power window switch (in power window main switch) (if equipped)

Rear End Door Window Defogger (If Equipped) Description

AENBL80A9501002
• Rear end door window defogger consists of rear defogger (1), rear defogger switch (2) (HVAC control unit or auto A/
C panel (3)), rear defogger relay (4) and BCM (5).
• BCM judges rear defogger switch condition when rear defogger relay turns “ON” with engine running, thereby
causing rear defogger to operate. After a certain period of time, BCM turns “OFF” relay to discontinue operation of
rear defogger.

6
3
4
2
5

7
1

IBL80A950041-01

6. Individual circuit fuse box No.2 (in J/B) 7. Rear defogger indicator
 Glass / Windows / Mirrors: 9E-3

Component Location
Power Window Component Location
AENBL80A9503001

3
3
6
6 4

2
6

1
1
2

8 7
IBP80A950012-01

1. Driver / passenger power window motor 5. Power window main switch

2. Driver / passenger power window regulator 6. Power window sub switch (passenger / rear right / rear left)
3. Rear power window motor (R) / (L) 7. “P/W” fuse
4. Rear power window regulator (R) / (L) 8. Individual circuit fuse box No.2 (in J/B)
9E-4 Glass / Windows / Mirrors:

Power Door Mirror Component Location (If Equipped)

AENBL80A9503002

5 4

IBL80A950037-01

1. Power door mirror switch 3. Power door mirror assembly (L) 5. Individual circuit fuse box No.2 (in J/B)
2. Power door mirror assembly (R) 4. “ACC” fuse

Rear Defogger Component Location

AENBL80A9503003

[A]

6 2

IBL80A950038-01
 Glass / Windows / Mirrors: 9E-5

[A]: Manual A/C model 3. Rear defogger 6. Individual circuit fuse box No.2 (in J/B)
1. Rear defogger relay 4. Rear defogger switch
2. “RR DEF” fuse 5. BCM

Diagnostic Information and Procedures

Power Window System Symptom Diagnosis
AENBL80A9504001

Condition Possible cause Correction / Reference Item

All power windows Faulty wiring Repair wiring.
cannot operate Faulty power window main switch “Power Window Main Switch Inspection” (Page
9E-21)
One of the power window Faulty wiring Repair wiring.
cannot operate Faulty power window regulator and/or Front: )(Page 9E-16)
motor Rear: )(Page 9E-20)
Faulty power window main switch “Power Window Main Switch Inspection” (Page
9E-21)
Faulty power window sub switch “Power Window Sub Switch Inspection” (Page
9E-21)
Auto-down function does Faulty power window main switch “Power Window Main Switch Inspection” (Page
not operate 9E-21)
Abnormal noise Loose window regulator mounting bolts Tighten window regulator mounting bolts.
Front: )(Page 9E-13)
Rear: )(Page 9E-17)
Worn or broken power window regulator Replace window regulator.
sliding and rotating parts Front: )(Page 9E-16)
Rear: )(Page 9E-20)
Poor greasing Lubricate.
Front: )(Page 9E-13)
Rear: )(Page 9E-17)

Power Door Mirror Control System Symptom Diagnosis (If Equipped)

AENBL80A9504002

Condition Possible cause Correction / Reference Item

All power door mirrors do Blown fuse Replace fuse and check for short circuit.
not operate Faulty power door mirror switch “Power Door Mirror Switch Inspection (If
Equipped)” (Page 9E-21)
Faulty wiring or ground Repair wiring.
One of the power door Faulty power door mirror switch “Power Door Mirror Switch Inspection (If
mirrors cannot operate Equipped)” (Page 9E-21)
Faulty wiring or ground Repair wiring.
Power door mirrors Some object is pinched in power mirror Remove foreign bodies
cannot move smoothly Mirror comes out of position Install mirror in position. )(Page 9E-21)

Rear Defogger (If Equipped) Symptom Diagnosis

AENBL80A9504003

Condition Possible cause Correction / Reference Item

Rear defogger cannot Faulty system circuits (including relays “Rear End Door Window Defogger (If
operate and fuses) Equipped) Description” (Page 9E-2)
Faulty BCM “Inspection of BCM and Its Circuits”: in Section
10B.
Ignition Switch Model: )(Page 10B-20)

Inspection of Power Window Main Switch and Its Circuit

AENBL80A9504004
Voltage Check
1) Remove sash bracket inner garnish, door trim and power window main switch. )(Page 9E-13)
2) Connect connector to power window main switch and set ignition “ON”.
9E-6 Glass / Windows / Mirrors:

3) Check voltage using circuit tester.

[A] J81

2 1

[a]
4 3
10 9 8 12 11 7 6 5
20 19 18 14 13 17 16 15
I9P60A950061-04

[A]: Power window main switch connector (View: [a])

J81 connector
Terminal No. Wire color Circuit Normal voltage Condition
Passenger power window Approx. 12 V Passenger window switch: UP
J81-6 RED/WHT
switch (UP) Approx. 0 V Other than above condition
Passenger window switch:
Passenger power window Approx. 12 V
J81-5 GRN/WHT DOWN
switch (DOWN)
Approx. 0 V Other than above condition
Driver power window motor Approx. 12 V Driver window switch: DOWN
(DOWN) Approx. 0 V Other than above condition
J81-9 GRN Driver window switch: AUTO
Driver power window motor Approx. 12 V
DOWN
(AUTO DOWN)
Approx. 0 V Other than above condition
Driver power window motor Approx. 12 V Driver window switch: UP
J81-10 RED
(UP) Approx. 0 V Other than above condition
Approx. 12 V Ignition “ON”
J81-15 WHT/BLU IG1 power supply
Approx. 0 V Ignition “OFF” or “ACC”
Rear left power window Approx. 12 V Rear left window switch: UP
J81-17 BLU/YEL
switch (UP) Approx. 0 V Other than above condition
Rear left window switch:
Rear left power window Approx. 12 V
J81-16 GRN/YEL DOWN
switch (DOWN)
Approx. 0 V Other than above condition
Rear right power window Approx. 12 V Rear right window switch: UP
J81-19 RED/BLK
switch (UP) Approx. 0 V Other than above condition
Rear right window switch:
Rear right power window Approx. 12 V
J81-18 WHT/GRN DOWN
switch (DOWN)
Approx. 0 V Other than above condition
Ground for power window
J81-20 BLK Approx. 0 V Ignition “OFF”, “ACC” or “ON”
main switch

Repair Instructions
Windshield Components
AENBL80A9506001
 Glass / Windows / Mirrors: 9E-7

2
3
2

4 4
4

IBL80A950039-01

1. Windshield 3. Windshield molding : Do not reuse.

2. Glass upper fastener 4. Spacer

Windshield Removal and Installation

AENBL80A9506002

Preparation
Item to be prepared Usage
Eyeleteer Drilling hole in adhesive
Piano string and wood stick (or commercial windshield knife) Cutting adhesive
Knife To cut off adhesive for finishing
White gasoline and gauze To degrease and clean adhesive surface
Caulking gun To apply adhesive
Rubber sucker grip To hold glass
Adhesive (Yokohama Rubber WS-212 or equivalent) To bond glass
Primer for glass (Yokohama rubber MS-90S or equivalent) To pretreat adhesive surface
Primer for adhesive surface (Yokohama rubber RC-50E or equivalent) To pretreat adhesive surface
Masking tape Protection against scratch
Alcohol To degrease knife
Adhesive tape To secure windshield molding

Removal
1) Clean inside, outside and around glass.
2) Remove wiper arms.)(Page 9D-3)
3) Remove cowl top garnish. )(Page 9H-3)
4) Using masking tape, cover body surface around
glass to prevent any damage when cutting the
adhesive.
5) Remove inner rear view mirror. )(Page 9E-12)
6) Remove instrument panel, if necessary. )(Page 9C-
9)
7) Remove roof lining, if necessary.)(Page 9H-8) I2RH01950040-01

8) Remove or cut windshield molding.
9) Make hole into adhesive with eyeleteer (1) and pass
piano string through it.
10) Cut all adhesives of windshield (1) with piano string
(2).
! CAUTION
Do not damage windshield when using
windshield knife (3) to cut adhesive.
9E-8 Glass / Windows / Mirrors:

NOTE NOTE
Use piano string as close as possible to Before using knife, degrease it with alcohol
glass to prevent damage to body and or the like.
instrument panel.

I2RH01950042-01

Installation

NOTE
For proper handling and drying time of
primer and adhesive, refer to their maker’s
instruction.

1) To determine installing position of windshield (1) to

body (2), position glass against body so that
clearance between upper end of windshield and
I3RH0A950006-01
body is approximately 4.0 mm (0.16 in.) and
11) Using knife (1), smoothen adhesive remaining (2) on clearances between each side end (right & left) of
body side (3) and thickness of adhesive should be 1 windshield and body are even.
to 2 mm (0.04 to 0.07 in.). Then put alignment marks (3) on windshield and
body.
NOTE
If windshield is to be reused, be careful to Windshield clearance
remove adhesive (1) not to damage primer “a”: Approx. 4.0 mm (0.16 in.)
application surface (2).
1 2 3
2
“a”
1

I2RH01950043-01
I9P60A950013-01

2) Clean contact surfaces of old adhesive (4) left on

body. Apply primer (2) where paint or bare metal is
exposed (3).
 Glass / Windows / Mirrors: 9E-9

NOTE
Do not apply primer on adhesive. “c”
2 1
“b”
3
3 2
1 1
1
“a”

“c”
2
4 4
5
I8G001950046-01
3
1. Do not apply primer. 5. Body panel 1

3) Clean area about 30 to 50 mm (1.19 to 1.96 in.) from 2

the edge of windshield with gauze and white
“d”
gasoline. Dry white gasoline for 10 minutes or more.
4) Apply primer onto windshield molding mounting area
1
on windshield (2) and install new windshield molding
(3) to windshield. 4
2
5) Install new spacers (1) and must apply primer before 2
fixing the fasteners (4) to windshield. “f” “e”

4 1
1
4
3 I9P60A950016-01

3. Windshield molding 4. Spacer

2
8) Holding windshield (3) with rubber sucker grips (1),
align fasteners (2) with holes (4) of body, align
alignment marks put in Step 1) and install
windshield.

3
1
I9P60A950014-01

6) Apply primer to adhesive application area on

windshield.
2
NOTE
Do not touch primer-coated surface. 4

7) Apply adhesive (1) as shown in figure.

! CAUTION

• Attach windshield (2) on body within 5

minutes from applying adhesive.
1 1
• Use rubber sucker grip to carry glass after
adhesive is applied.

Adhesive amount and application area on I9P60A950017-01

windshield 9) Dry adhesive.

Width of adhesive “a”: Approx. 7.0 mm (0.28 in.)
Height of adhesive “b”: Approx. 15.0 mm (0.59
in.)
Application area “c”: Approx. 11.5 mm (0.45 in.),
“d”: Approx. 25.0 mm (0.98 in.), “e”: Approx. 13.4
mm (0.53 in.), “f”: Approx. 34.0 mm (1.34 in.)
9E-10 Glass / Windows / Mirrors:

! CAUTION ! CAUTION

• Open or close doors with all door glasses • Do not apply excessive water pressure
open until adhesive is fully hardened. during water leakage check.
• Hold windshield molding with tape until it
is fixed.
• Do not drive until adhesive is fully
hardened.

10) Check for water leakage 1 or 2 hours after installing

windshield. If leakage is found, remove and install
windshield again.

I2RH01950051-01

• Do not blow compressed air directly to

adhesive applied part when drying.
• Do not dry forcibly using infrared light or
the like.

11) Install head lining if it has been removed. )(Page

9H-8)
12) Install instrument panel if it has been removed.
)(Page 9C-9)
13) Install inner rear view mirror. )(Page 9E-12)
14) Install cowl top garnish. )(Page 9H-3)
15) Install wiper arms. )(Page 9D-5)

Rear End Door Window Glass Components

AENBL80A9506003

3
2

3
2

3
3
2
2

IBL80A950040-01

1. Rear end door window glass 3. Glass fastener (male) : Do not reuse.
2. Glass fastener (female) 4. Spacer

Rear End Door Window Glass Removal and Installation

AENBL80A9506004
Preparation, removal and installation procedure are basically the same as “Windshield Removal and Installation”
(Page 9E-7), however note the following points.
• Remove rear wiper motor before removing rear end door window glass. )(Page 9D-5)
 Glass / Windows / Mirrors: 9E-11

• Be careful not damage to connectors during removal and installation.

• Apply adhesive (1) as shown in figure.
• Locate glass fasteners (female) (2) so that they will fit with glass fastener (male) (3) when attaching glass.
Adhesive amount and application area on rear end door window
Width of adhesive “a”: Approx. 6.0 mm (0.24 in.)
Height of adhesive “b”: Approx. 13.0 mm (0.51 in.)
Application area “c”: Approx. 15.0 mm (0.59 in.), “d”: Approx. 35.6 mm (1.40 in.)

4
1
“c” “b”

1
“a”

“d”
1

4
4

“c”
1

IAP70A950004-01

4. Rear end door window glass 5. Glass fastener clip

9E-12 Glass / Windows / Mirrors:

Inner Rear View Mirror Removal and Installation

AENBL80A9506005
Removal
Remove inner rear view mirror bolt (TORX® T20) (1) and
slide mirror (2) in arrow direction.

IBP80A950001-01

Installation
Reverse removal procedure noting the following point.
• Tighten inner rear view mirror bolt to specified torque.
Tightening torque
Inner rear view mirror bolt: 4.7 N·m (0.47 kgf-m, 3.46
lbf-ft)
 Glass / Windows / Mirrors: 9E-13

Front Door Components

AENBL80A9506006

3 [D]
14

11

15

[C]
14

16 (c)

15

[B]
(b)

[A] 10
4

A A
A [A]
A
(b)
4

A A
A A
A

A
(b)
A
13”1” (d) 12,”1” (a)
A A A 12,”2” (a)
13,”2” (d)
5 (b)

7 A [B]
6 10
A A 12,”2” (a)

A 13”3” (d)

12,”1” (a)
12,”2” (a)

13”1” (d) 13,”2” (d)

IBL80A950011-01
9E-14 Glass / Windows / Mirrors:

[A]: Manual window type 9. Front door rear sash

[B]: Power window type 10. Front window regulator assembly
: Apply grease 99000-25011 to sliding parts.
[C]: Without power door mirror 11. Door panel
[D]: With power door mirror 12. Front door glass screw
: Tighten front door glass screws in order of “1” to “2“.
1. Front door outer weather-strip 13. Front window regulator nut
: Tighten front window regulator nuts in order of “1” to “6”.
2. Front door glass 14. Door mirror
3. Front door inner weather-strip 15. Sash bracket inner garnish
4. Door trim 16. Door mirror nut
: Tighten door mirror nuts in order of “1” to “3”.
5. Inside handle cap : 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)
6. Power window main switch : 3.0 N⋅m (0.31 kgf-m, 2.5 lbf-ft)
7. Power door mirror switch (if equipped) : 7.9 N⋅m (0.81 kgf-m, 6.0 lbf-ft)
8. Door trim bracket : 8.4 N⋅m (0.85 kgf-m, 6.5 lbf-ft)

Front Door Glass Removal and Installation

AENBL80A9506007
A B
A

Removal
1) Lower front door glass to about 150 mm (5.91 in.)
from the lower edge of window.
1

3 2
4

B
A A
[A]
A

A
A
3
IBL80A950012-01

[A]: About 150 mm (5.91 in.)

A
A A
2) Disconnect negative (–) cable at battery.
3) Remove sash bracket inner garnish (1). IBL80A950013-01

4) Remove inside handle cap (2). 6) Disconnect connectors of door harness.

5) Remove screws (3), clips, and remove door trim (4) 7) Remove front door outer weather-strip (1) by moving
by pulling it in arrow direction. it in arrow directions in order (“1” to “2”) as shown in
figure.
 Glass / Windows / Mirrors: 9E-15

1
“2”

“1”

1
1

3 2
3

IBL80A950014-01

2. Claw 3. Front door outer panel IBL80A950016-01

10) Remove screws (2) and remove front door glass (1)
8) Remove front door inner weather-strip (1) by pulling by moving it in arrow directions in order (“1” to “2”) as
it in arrow direction in order (“1” to “2”) as shown in shown in figure.
figure.

“2”
2

“1”
1 “2”

“1”

IBL80A950015-01

2. Front door inner panel

9) Remove door trim bracket (1) and door sealing

1
cover. IBL80A950042-01

Installation
Reverse removal procedure noting the following points.
• Install door glass holders (1) of front door glass (2) if
they are removed from front door glass.
9E-16 Glass / Windows / Mirrors:

1 1
IBL80A950018-02
1

• Tighten front door glass screws in order (“1” to “2”) as 3

shown in figure. IBL80A950044-01

• Tighten front glass screws to specified torque.

Installation
Tightening torque Reverse removal procedure noting the following points.
Front door glass screw* (a): 5.5 N·m (0.56 kgf-m, • Apply grease to sliding parts of front window regulator
4.0 lbf-ft) assembly.
: Grease 99000–25011 (SUZUKI Super Grease A)
• Tighten front window regulator nuts in order (“1” to “6”)
to specified torque.
Tightening torque
Front window regulator nut* (a): 8.4 N·m (0.85
kgf-m, 6.5 lbf-ft)

“1”,(a) “2”,(a)

“2”, (a)
“1”, (a)
“3”,(a) “4”,(a) “5”,(a) “6”,(a)
IBL80A950043-01
IBL80A950019-02
• If front door outer weather-strip is deformed, replace it
with new one. Front Window Regulator Assembly Inspection
• Fix door sealing cover with butyl tape. AENBL80A9506009

! CAUTION
Front Window Regulator Assembly Removal
Check with connectors disconnected from
and Installation
AENBL80A9506008 power window motor.

Removal Check motor movement as follows.

1) Remove front door glass. )(Page 9E-14)
2) Disconnect power window motor connector (3).
3) Remove front window regulator screws (1) and
remove front window regulator assembly (2).
1) Connect battery positive terminal to terminal “2” and
connect battery negative terminal to terminal “1”.
(UP operation)
2) Connect battery positive terminal to terminal “1” and
connect battery negative terminal to terminal “2”.
(DOWN operation)
 Glass / Windows / Mirrors: 9E-17

If operation is not smooth, check glass run, door outer

weather-strip, door inner weather-strip and grease in
link. If those parts are in good condition, replace window
regulator assembly.
Power window motor operation

Terminal number
1 2
Operation direction
UP

DOWN
I9P60A950034-01

2 1

IBL80A950020-01
Rear Door Components
AENBL80A9506010
9E-18 Glass / Windows / Mirrors:

3
1

13

11

10

[A] 8

[B]
(b)
[A]
(b)

A A A
A A A
A
A

A A 15”1” (d) 14,”1” (a)

14,”2” (a)
15,”2” (d)
A A
[B]
8
6
6

A A A A
A A
(b)
12 5 (b)

7 5

A A 15”3” (d)

14”1” (a)
14,”2” (a)

15”1” (d) 15,”2” (d)

IBL80A950021-01

[A]: Manual window type 7. Window regulator handle 15. Rear door sash screw
: Tighten bolts and screw in order of “1” to “3“.
[B]: Power window type 8. Rear window regulator assembly 16. Rear door sash bolt
: Apply grease 99000-25011 to sliding parts. : Tighten bolts and screw in order of “1” to “3”.
1. Rear door outer weather-strip 9. Door panel 17. Rear window regulator screw
: Tighten bolts in order of “1” to “4“.
2. Rear door sash 10. Door trim bracket 18. Rear window regulator motor
3. Rear door inner weather-strip 11. Rear door glass : 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)
4. Glass run 12. Power window sub switch : 3.0 N⋅m (0.31 kgf-m, 2.5 lbf-ft)
5. Door trim 13. Rear door quarter glass : 8.4 N⋅m (0.86 kgf-m, 6.5 lbf-ft)
6. Inside handle cap 14. Rear door inner garnish : 5.4 N⋅m (0.55 kgf-m, 4.0 lbf-ft)

Rear Door Glass Removal and Installation Removal

AENBL80A9506011
1) For manual window type, remove window regulator
handle (2).
 Glass / Windows / Mirrors: 9E-19

For its removal, pull off snap using cloth (1) as

shown in figure.

“2”

“1”

IYSY01950008-01 1 1

2) Lower rear door glass fully.

3) Disconnect negative (–) cable at battery.
2 3
4) Remove rear door inner garnish (1). 3

5) Remove inside handle cap (2).

6) Remove screws (3) and clips, and then remove door
trim (4) by pulling it in arrow direction, and then
disconnect connectors of door harness.
IBL80A950033-01

A 2. Claw 3. Rear door outer panel

1

8) Remove rear door inner weather-strip (1) by pulling it

in arrow direction in order (“1” to “2”) as shown in
figure.
A 4

A
3 2

A
1 “2”

A 3

A “1”

A A
1

IBL80A950032-01

7) Remove rear door outer weather-strip (1) by moving

it in arrow directions in order (“1” to “2”) as shown in 2

figure.

IBL80A950034-01

2. Rear door inner panel

9) Remove door trim bracket (1) and door sealing

cover.
9E-20 Glass / Windows / Mirrors:

“2”
1

“1”

2
IBL80A950027-02

13) Remove glass bottom channel from rear door glass if

1 necessary.

Installation
Reverse removal procedure noting the following points.
IBL80A950035-01
• Install glass bottom channel (1) of rear door glass (2)
10) Turn over glass run (1) and remove rear door sash
if it is removed from rear door glass.
screw (2).
11) Remove rear door sash bolts (3) and remove rear
door sash (4) and glass run.

1
IBL80A950028-01

• Insert rear door glass (2) in direction of arrow “1” and

turn in direction of arrow “2” to move glass bottom
channel (1) and fit to rear window regulator assembly.
3

2 “1”
IBL80A950036-02

12) Turn rear door glass (1) in direction of arrow “1” to

remove glass bottom channel (2) from rear window
regulator assembly and then remove rear door glass
in direction of arrow “2”.

“1”

1
IBL80A950029-02

• Tighten rear door sash screw and rear door sash bolts
in order of “1” to “3” to specified torques.
 Glass / Windows / Mirrors: 9E-21

Tightening torque : Grease 99000–25011 (SUZUKI Super Grease A)

Rear door sash screw* (a): 3.0 N·m (0.31 kgf-m,
• Tighten rear window regulator screws to specified
2.5 lbf-ft)
torque.
Rear door sash bolt* (b): 5.5 N·m (0.56 kgf-m, 4.0
lbf-ft) Tightening torque
Rear window regulator screw* (a): 8.4 N·m (0.86
kgf-m, 6.5 lbf-ft)
2 (a)

Rear Window Regulator Assembly Inspection

2 AENBL80A9506014
1
! CAUTION
Check with connectors disconnected from
power window motor.

Check motor movement as follows.

1) Connect battery positive terminal to terminal “2” and
connect battery negative terminal to terminal “1”.
3 (b)
(UP operation)
2) Connect battery positive terminal to terminal “1” and
connect battery negative terminal to terminal “2”.
(DOWN operation)
IBL80A950045-01 If operation is not smooth, check glass run, door outer
1. Rear door sash 2. Glass run weather-strip, door inner weather-strip and grease in
link. If those parts are in good condition, replace window
• If rear door outer weather-strip is deformed, replace it regulator assembly.
with new one. Power window motor operation
• Fix door sealing cover with butyl tape. Terminal number
1 2
Operation direction
Rear Window Regulator Assembly Removal and
UP
Installation
AENBL80A9506013 DOWN
I9P60A950034-01
Removal
1) Remove rear door glass. )(Page 9E-18)
2) Disconnect power window motor connector.
3) Remove window regulator screw (1) and remove 2 1
rear window regulator assembly (2).

2 IBL80A950047-01

Power Window Main Switch Inspection

AENBL80A9506015
Check power window main switch for terminal voltage.
)(Page 9E-5)
If check result is not as specified, replace power window
1
main switch.

IBL80A950046-01
Power Window Sub Switch Inspection
AENBL80A9506016
Installation Check continuity between terminals at each switch
Reverse removal procedure noting the following points. position.
• Apply grease to sliding parts of rear window regulator If check result is not as specified, replace power window
assembly. sub switch.
9E-22 Glass / Windows / Mirrors:

Power window sub switch (passenger and rear) • Check operation of door mirror after installation.
continuity • Tighten door mirror nuts in order (“1” to “3”) to
specified torque.
Terminal
1 2 3 4 5 Tightening torque
Power window
switch position
Door mirror nut* (a): 7.9 N·m (0.81 kgf-m, 6.0 lbf-
Up
ft)
(Keep pulling up)

OFF

Down
(Keep pushing down)

I9P60A950051-02

“1”,(a)

“2”,(a)

“3”,(a)
I9P60A950057-01

Power Door Mirror Switch Inspection (If

Equipped)
AENBL80A9506018
Check continuity between terminals at each switch
position.
5 4 3 2 1
If check result is not as specified, replace switch.
I9P60A950052-02 Power door mirror switch continuity

Terminal
Door Mirror Removal and Installation
AENBL80A9506017 Switch/Position 3 4 5 9 10 12 13
Removal R/L Angle
switch switch
1) Remove sash bracket inner garnish. )(Page 9E-14)
Up
2) For power door mirror model, remove front door trim.
Down
)(Page 9E-14) L
Right
3) For power door mirror model, disconnect power door
Left
mirror connector (1).
Up
4) Remove door mirror nuts (2) and remove door mirror
(3). Down
R
Right

3 Left
I9P60A950058-02

1
I9P60A950056-01

Installation
Reverse removal procedure noting the following points.
 Glass / Windows / Mirrors: 9E-23

Rear Window Defogger Relay and Mirror Heater

[E] [D] Relay (If Equipped) Inspection
AENBL80A9506019
Refer to )(Page 10B-30).

[C] 1 [F]

[A]

[B]
2

5 4 3 2 1
13 12 11 10 9 8 7 6

I9P60A950060-01

[A]: Right side power door mirror [E]: Right

[B]: Left side power door mirror [F]: Left
[C]: Up 1. Angle switch
[D]: Down 2. R/L switch

Specifications
Tightening Torque Specifications
AENBL80A9507001
NOTE
For fastener(s) with * (asterisk) below, refer to the specified procedure in “Repair Instructions”.

Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Inner rear view mirror bolt 4.7 0.47 3.46 )
Front door glass screw* 5.5 0.56 4.0 )
Front window regulator nut* 8.4 0.85 6.5 )
Rear door sash screw* 3.0 0.31 2.5 )
Rear door sash bolt* 5.5 0.56 4.0 )
Rear window regulator screw* 8.4 0.86 6.5 )
Door mirror nut* 7.9 0.81 6.0 )

NOTE
The tightening torque(s) also specified in:
“Front Door Components”:
“Rear Door Components”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to .
9E-24 Glass / Windows / Mirrors:

Special Tools and Equipment

Recommended Service Material
AENBL80A9508001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 )/)

NOTE
Required service material(s) also described in:
“Front Door Components”:
“Rear Door Components”:
 Security and Locks: 9F-1

Security and Locks

Body, Cab and Accessories

Precautions
Precautions for Replacing Keyless Entry / Security Controller
AENBL80A9600001
When keyless entry / security controller is replaced, it is necessary to perform the following procedure.
• Programming into all transmitter
• Change of Valet mode to Security mode
• Switching of shock sensor from Invalid to Valid

General Description
Key Code Construction
AENBL80A9601001
Key is used for ignition of vehicle and for locking or unlocking the doors using the key cylinder on the doors. Key is cut
on both edges to make them reversible. Key identification is obtained from five character key code stamped on key
code tag. Using this key code, key code cutting combination can be determined from a code list (available with the key
supplier).

Keyless Entry / Security Controller General Description (If Equipped)

AENBL80A9601002
The keyless entry / security controller controls the following systems.
• Keyless entry system
• Security system

Keyless Entry System Description (If Equipped)

AENBL80A9601003
Keyless entry system consists of a keyless entry / security controller, transmitter, door switches, door lock actuators
(door lock assemblies) and BCM.
When the “Lock” or “Unlock” button of the transmitter is pressed, the transmitter sends a “Lock” or “Unlock” signal to
the keyless entry / security controller. And then keyless entry / security controller verifies if the received signal agrees
with the registered code. When keyless entry / security controller verifies the authenticity of the transmitter, “Lock” or
“Unlock” signal is sent from the keyless entry / security controller to BCM. And then BCM makes each door lock
actuator operate so that all door locks are locked or unlocked.
Also, when the door lock is locked or unlocked via transmitter, keyless entry / security controller provides an answer
back” using the hazard warning light and siren. When any door is half open or fully open or the ignition key is inserted
in its cylinder, keyless entry / security controller prevents remote control function from operating. (However, only the
unlock operation by remote control is possible when any door is half open or fully open. In that case, the answer back
is not operated.)

Emergency Lever of Back Door Description

AENBL80A9601004
Emergency lever (1) is provided in back door lock assembly (2). If back door cannot be unlocked due to complete
discharge of the battery or a problem of the door lock system, operating the lever in the following method allows the
back door to be unlocked: Operate emergency lever in the back door lock assembly in the direction of the arrow.

I9P60A960022-01
9F-2 Security and Locks:

Security System Description (If Equipped)

AENBL80A9601005
Security system consists of a keyless entry / security controller (incorporating shock sensor), hood switch, valet
switch, theft deterrent light (includes valet switch), siren, each door switches, and each door lock actuators (door lock
assemblies).
The keyless entry / security controller monitors vehicle conditions through the signals from shock sensor and switches
(hood, door and key reminder).
When it detects an abnormal condition (door is opened by some way other than using registered keyless entry
transmitter, shock sensor detects the breaking of glass or ignition switch is turned ON position while security system is
operating, etc.), it activates the theft deterrent light, the hazard warning light and the siren to provide a warning of an
abnormal condition to those who are around.

Back Door Opener System Description (If Equipped)

AENBL80A9601006
Back door opener system consists of back door opener switch (1), back door opener relay (in BCM), back door lock
assembly (2) and BCM (3).
Back door opener system is activated by pushing back door opener switch after all doors are unlocked.
When back door opener switch is pushed, back door opener relay is turned ON. Then, BCM releases latch of back
door lock assembly from striker and back door can be opened.

IBL80A960001-02
 Security and Locks: 9F-3

Schematic and Routing Diagram

Keyless Entry / Security Controller Input / Output Diagram (if equipped)
AENBL80A9602001

keyless entry / security controller

Driver door switch Driver door

lock actuator

Passenger door Door lock

and rear door switch signal Passenger door
BCM lock actuator

Rear door
Ignition Switch lock actuator
Signal

Left turn signal light

Right turn signal light

CPU
Keyless entry
transmitter

Vehicle Speed
(from BCM)

Hood switch Theft deterrent light

(in valet switch)

Valet switch
Siren
Key reminder switch

Shock sensor

IBP80A960013-01
9F-4 Security and Locks:

Keyless Entry / Security Controller Circuit Diagram (If Equipped)

AENBL80A9602002

+B

BLK/WHT L10-8 +B G28-5 GRY/BLU

9 10 11 11
2 6
BLK/RED L10-22 G28-6 GRY
3 3 3

20
+B
19 G28-11 WHT
GRY/BLU L10-6

+BB 8 15
YEL/GRN L10-12 G28-10 WHT/RED

G28-9 YEL
4 16
5
RED G28-3 12
RED/WHT G28-13 L10-16 WHT/GRN
5V
13
L10-25 BLK/WHT
6 PPL G28-4
+B

RED L10-21
7
L10-15 BLK 14

17 18
IBP80A960014-01

1. Keyless entry / security controller 8. Key reminder switch 15. Hood switch
2. Driver side door switch 9. Driver side door lock actuator 16. Siren
3. Passenger side and rear door switch 10. Passenger side door lock actuator 17. Body ground
4. Valet switch 11. Rear door lock actuator 18. Engine ground
5. Theft deterrent light 12. Junction block assembly 19. Power door lock switch
6. BCM 13. Ignition switch 20. Hazard warning switch
7. Back door switch 14. Battery
 Security and Locks: 9F-5

Component Location
Keyless Entry System Component Location
AENBL80A9603001

13

12

1
3

10

4
7

11

IBL80A960002-05

1. Rear door lock actuator (door lock assembly) 6. Hazard warning switch 11. Security controller
2. Front door lock actuator (door lock assembly) 7. Key reminder switch 12. Hood switch
3. Back door lock actuator (door lock assembly) 8. Door lock switch 13. Keyless entry transmitter
4. Power door lock switch 9. Door switch
5. BCM 10. Valet switch (Theft deterrent light)
9F-6 Security and Locks:

Diagnostic Information and Procedures

Keyless Entry / Security System Symptom Diagnosis
AENBL80A9604001

Condition Possible cause Correction / Reference Item

Only one door cannot be Faulty system circuit (including relays —
locked / unlocked and fuses)
Faulty door lock assembly (including Replace door lock open rod and door lock
door lock open rod and door lock wires) wires. )(Page 9F-9)
Damaged and deformed inside door Replace inside door handle. )(Page 9F-9)
handle
All doors cannot be Faulty transmitter battery • Replace transmitter battery. Refer to
locked / unlocked “Replacement of Transmitter Battery (If
Equipped)” (Page 9F-15).
Faulty BCM • Refer to )(Page 10B-20).
Faulty Keyless entry / security controller • Check keyless entry / security controller.
Refer to “Inspection of Keyless Entry /
Security Controller and Its Circuits” (Page
9F-6).
Faulty system circuit (including relays —
and fuses)
Faulty power door lock switch Refer to “Power Door Lock Switch Inspection
(If Equipped)” (Page 9F-12).
Faulty key cylinder Check key cylinder. )(Page 9F-11)
Faulty answer-back Faulty BCM • Check if answer-back function of hazard
function light is in no-flashing mode.
Refer to )(Page 10B-20).
Faulty Keyless entry / security controller • Check keyless entry / security controller.
Refer to “Inspection of Keyless Entry /
Security Controller and Its Circuits” (Page
9F-6).
Faulty system circuit (including relays —
and fuses)

Inspection of Keyless Entry / Security Controller and Its Circuits

AENBL80A9604002
Keyless entry / security controller and its circuits can be checked at keyless entry / security controller wiring connector
by measuring voltage and resistance.

! CAUTION
Power door lock or Keyless entry / security controller cannot be checked by itself. It is strictly
prohibited to connect voltmeter or ohmmeter to keyless entry / security controller with connector
disconnected from it.

Voltage Check
1) Remove keyless entry / security controller. “Security Controller Removal and Installation (If Equipped)” (Page 9F-
15)
2) Connect connectors to keyless entry / security controller (1).
3) Check voltage at each terminal number of connectors connected.
 Security and Locks: 9F-7

IBP80A960016-01

NOTE
As each terminal voltage is affected by the battery voltage, confirm that it is 11 V or more when ignition
switch is turned ON.

Controller Connector
• Power door lock controller connector “L09”
• Keyless entry / security controller connector “L10”

[A] L10 [A] G28

2 7 6 5 4 3 1
4 3 13 12 11 10 9 8 7 6 5 2 1 A
9 14 13 12 11 10 8
17 16 26 25 24 23 22 21 20 19 18 15 14

IBP80A960017-01

[A]: Controller connector (view: A)

Terminal Circuit Normal voltage Condition

Power door lock switch 10 – 14 V Power door lock switch is not pressed in lock direction
L10-6
(Lock) 0V Power door lock switch is pressed in lock direction
10 – 14 V Driver side door is closed
L10-8 Driver side door switch
0V Driver side door is opened
10 – 14 V Ignition key is inserted to ignition key cylinder
L10-12 Key reminder switch
0V Ignition key is pulled out from ignition key cylinder
L10-15 Ground for controller 0V Ignition switch is at all positions
L10-16 Backup power supply 10 – 14 V Ignition switch is at all positions
10 – 14 V back door is closed
L10-21 Back door switch
0V back door is opened
Other than driver side 10 – 14 V Other than driver side door is closed
L10-22
door switch 0V Any one of other than driver side door is opened
10 – 14 V Ignition switch is at ON position
L10-25 Power source (IG)
0V Ignition switch is at OFF position
9F-8 Security and Locks:

Terminal Circuit Normal voltage Condition

0V Ignition switch is at ACC position
G28-3 Theft deterrent light
1–2V Ignition switch is at OFF position
G28-4 Vehicle speed signal Refer to )(Page 10B-20)
10 – 14 V Unlock signal is not output for BCM
G28-5 Door lock control (Unlock)
0V Unlock signal is output for BCM
10 – 14 V Lock signal is not output for BCM
G28-6 Door lock control (Lock)
0V Lock signal is output for BCM
10 – 14 V Siren circuit is activated
G28-9 Siren control
0V Siren circuit is not activated
10 – 14 V Hood switch is at closed
G28-10 Hood switch
0V Hood switch is at opened
10 – 14 V Hazard warning switch is at OFF position
Hazard warning switch Hazard warning switch is at ON position or lock or
G28-11
output 0V unlock button of keyless entry transmitter (answer
back control) is pushed
0V Valet switch is pushed
G28-13 Valet switch
10 – 14 V Valet switch is released

Repair Instructions
Front Door Lock Components
AENBL80A9606001

2 A

3,“2” (c)

(b)

(a)
6 A

3,“1” (c)

(c)
1 A 5
(c)
IBL80A960003-01
 Security and Locks: 9F-9

1. Front door lock assembly
: Apply SUZUKI super grease A 99000-25011 to
rotation / sliding parts.
2. Outside door handle (outer)
: Apply SUZUKI super grease A 99000-25011 to
rotation / sliding parts.
3. Outside door handle screw
: Tighten in the shown order (“1” to “2”).
4. Front door sash
5. Inside door handle : 4.5 N⋅m (0.46 kgf-m, 3.5 lbf-ft)
: Install screw after installing door trim.
6. Outside door handle (inner) : 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft)
: Apply SUZUKI super grease A 99000-
25011 to rotation / sliding parts.
7. Door latch striker : 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)
8. Key cylinder

Front Door Lock Assembly Removal and

Installation
AENBL80A9606002
“4”
6
Removal
1) Remove door trim and sealing cover referring to Step
2) to 8) of )(Page 9E-14).

NOTE
Perform this work with front door glass fully “3”
closed.

2) Remove inside door handle (6) by moving it in

8
directions of arrow “3” and “4”.
3) Remove inside door handle wire clip (8). 4 6
4) Remove lock (1) in direction of arrow “1” and then 5
move door lock open rod (2) in direction of arrow “2”
to remove it from outside door handle (3).
5) For power door lock model, disconnect door lock
connector (4) from front door lock assembly (5).
6) Remove door lock screws (7).
7
7) Remove inside door handle and door lock assembly
as a unit.
3
“1”

“2”
1
2

I9P60A960005-01

8) Remove door lock wires (1) from inside door handle

(2) by pulling them in arrow direction to remove.

IAW101960011-02

Installation
Reverse removal procedure noting the following points.
• Apply grease to sliding parts and rotation parts of door
lock assembly.
9F-10 Security and Locks:

: Grease 99000–25011 (SUZUKI Super Grease A) Tightening torque

Door latch striker screw: 10 N·m (1.0 kgf-m, 7.5
• Tighten each screw to specified torque referring to
lbf-ft)
“Front Door Lock Components” (Page 9F-8).
• Move door latch striker (2) up or down to align its
center with the center of groove (3) on door lock 2 3
assembly (1) as shown in figure.

2 3 1

I9W10P960005-01

Front Door Lock Assembly Inspection

AENBL80A9606003
I9W10P960004-01
• Check that door opens and closes smoothly.
• Move door latch striker (1) to adjust front door panel • Check that door stops in the secondary latch position
surface (2) flat with rear door panel surface (3) as properly (preventing door from opening freely) and
shown in figure. that door closes completely in the full latch position.
• Adjust door latch striker position, if necessary.
)(Page 9F-9)

Rear Door Lock Components

AENBL80A9606004

1 A

3 (a)
(b)

5,“2” (c)

6 A

5,“1” (c)

2 A
IBL80A960004-01
 Security and Locks: 9F-11

1. Outside door handle (outer) 6. Outside door handle (inner)

: Apply SUZUKI super grease A 99000-25011 to rotation / sliding parts. : Apply SUZUKI super grease A 99000-25011 to rotation / sliding parts.
2. Rear door lock assembly : 4.5 N⋅m (0.46 kgf-m, 3.5 lbf-ft)
: Apply SUZUKI super grease A 99000-25011 to rotation / sliding parts.
3. Door latch striker : 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft)
4. Inside door handle : 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)
: Install screw after installing door trim.
5. Outside door handle screw
: Tighten in the shown order (“1” – “2”).

Rear Door Lock Assembly Removal and Driver Door Lock

Installation
AENBL80A9606005
Door lock switch continuity and actuator operation
Refer to “Front Door Lock Assembly Removal and
Installation” (Page 9F-9) as removal and installation
Off
procedures are basically the same. However, note the
following point. Lock
Unlock Unlock
• Tighten door latch striker screws to specified torque.
Lock

Rear Door Lock Assembly Inspection

AENBL80A9606006
Refer to “Front Door Lock Assembly Inspection” (Page
9F-10).

Door Lock Switch and Actuator On-Vehicle

Inspection (If Equipped)
AENBL80A9606007
1) Remove door trim.
• Front: )(Page 9E-14)
• Rear: )(Page 9E-18) 4 3 2 1
2) Disconnect door lock connector from door lock 10 9 8 7 6 5
assembly.
3) Check door lock switch for continuity between its
terminals. Replace door lock assembly if defective. Terminal
1 4 5 6 8
4) Check door lock actuator by checking operation of Operation
door lock lever when battery voltage is applied to the
Unlock
following terminals of door lock assembly as shown
in tables. Replace door lock assembly if defective. Lock

Unlock Lock

Lock Unlock

IBL80A960005-01
9F-12 Security and Locks:

Passenger Door Lock Front and Rear door switch continuity

Door lock switch continuity and actuator operation

Lock 1
Unlock [A]
[B]

I9W10P960018-01

[A]: Pushed [B]: Released

4 3 2 1 Terminal
1 Switch body
10 9 8 7 6 5 Switch position

Pushed

Terminal Released
1 4
Operation IAW101960030-01

Unlock Lock
Power Door Lock Switch Inspection (If
Lock Unlock Equipped)
AENBL80A9606009
IBL80A960006-01
)(Page 9E-13)
Rear Door Lock 1) Check continuity between terminals at each switch
position.
If check results are not as specified, replace switch.
Rear door lock actuator operation
Driver power door lock switch continuity
Terminal
Rear right side 2 Lock
4
Unlock

Rear left side 1 3 6 5 4 3 2 1

Operation
12 11 10 9 8 7
Lock Unlock

Unlock Lock

I9P60A960009-05

Front and Rear Door Switch Inspection

AENBL80A9606008
1) Remove door switch.
2) Check continuity between switch body and terminal
at each switch position. If check result is not as
Terminal
specified, replace switch. 10 8 9
Operation
Lock

Unlock
IBP80A960009-01
 Security and Locks: 9F-13

Back Door Lock Components

AENBL80A9606010

A “1” B

“2”

B
B
B
B B

A
A
A

1 A
A A
A

(b) [B]
[A]
3
(a)
(a)

4 2
2

IBL80A960008-01

[A]: Manual door lock model 3. Back door lock assembly : 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft)
[B]: Power door lock model 4. Back door key cylinder : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
1. Back door trim 5. Back door opener switch : 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)
2. Back door lower garnish 6. Latch striker

Back Door Latch On-Vehicle Inspection

AENBL80A9606011
• Check that back door opens and closes smoothly.
• Check that back door closes completely.
1
Back Door Opener Actuator (If Equipped)
1) Remove back door trim. )(Page 9F-14)
2) Disconnect back door lock connector (1) from back
door lock assembly (2).

2
I9P60A960013-01

3) Check operation of actuator with battery voltage

applied to the following terminals of back door lock
assembly connector.
Replace back door lock assembly if defective.
9F-14 Security and Locks:

back door opener actuator operation

[A]

3
Lock

“1”
Unlock
2

5
“2” 4
1
2 1
4 3
[B]

Terminal
3 4
Operation 2

Lock Unlock
IBP80A960010-01

1
Back Door Lock Removal and Installation
AENBL80A9606012 I9P60A960017-03

[A]: Manual door lock model [B]: Power door lock model
Removal
1) Remove back door trim (1). Installation
Reverse removal procedure noting the following points.
A “1” B
• Tighten back door lock bolts to specified torque.
Tightening torque
“2”
Back door lock bolt: 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
• Adjust back door latch striker as follows if necessary.
a. Loosen back door latch striker screws (1)
b. Adjust back door latch striker (2) position so that
back door can be opened and closed smoothly.
A c. Tighten back door latch striker screws to specified
A
A torque.
B A
B A
Tightening torque
Back door latch striker screw (a): 23 N·m (2.3
B
A kgf-m, 17.0 lbf-ft)
B
1

I9P60A960016-01

2) Disconnect back door lock connector (1) from back

door lock assembly (2). 2

3) For manual door lock model, remove lock (4) in

direction of arrow “1” and then move lock cable (5) in
direction of arrow “2” to remove it from back door
lock.
1,(a)
4) Remove back door lock bolts (3) and remove back
door lock assembly (2).

I9P60A960018-02
 Security and Locks: 9F-15

Ignition Key Registration (Ignition Switch

Model)
AENBL80A9606015
Refer to)(Page 10B-26).

Replacement of Transmitter Battery (If

Equipped)
AENBL80A9606016
Refer to)(Page 10B-28). 1
2
3
Programming Transmitter Code for Keyless
Entry System
AENBL80A9606017
NOTE
• Perform ignition key registration before IBP80A960018-01

programming transmitter code. Refer to

)(Page 10B-26) Security Controller Removal and Installation (If
• Four transmitter codes can be registered. Equipped)
AENBL80A9606018
• When four transmitters are registered and Removal
then new transmitter code is registered, 1) Disconnect negative cable at battery.
the oldest one will be cleared.
2) Disconnect security controller coupler.
If transmitter or Security controller is replaced or 3) Remove security controller (2) by opening screws (1)
additional transmitter(s) is required, program transmitter as shown.
code(s).
1) Confirm that all doors are closed and ignition key is
out of ignition key cylinder.
2) Open driver side door.
3) Turn ignition switch to ON position, and then take out
ignition key from ignition key cylinder within 10
seconds after that. 2
1
4) Push and release driver side door switch (1) at 3
times by hand within 20 seconds after removing
ignition key from ignition key cylinder. IBP80A960019-01

5) Turn ignition switch to ON position, and then drawn

Installation
ignition key from ignition key cylinder within 10
Reverse removal procedure.
seconds after that. All doors automatically lock and
unlock once.
With this, registration mode. Valet Switch Inspection (If Equipped)
AENBL80A9606019
6) Push “UNLOCK” button (2) on transmitter (3) within Check for continuity between terminals at each switch
20 seconds after Step 5). All doors automatically lock position. If check result is not as specified, replace
and unlock once. switch.
With this, code registration is completed.
7) If an additional transmitter, needs to be programed
1
repeat the procedure of Step 1).
2

[A] 3 4 1 2
[B]

OFF

ON

IBP80A960020-01
9F-16 Security and Locks:

NOTE
ON
• Measure it by diode range of circuit tester
as shown because there is diode between
terminal “1” and “2”.
OFF 1
• Connect circuit tester positive (+) probe to
“1” terminal of valet switch and negative
(–) probe to “2” terminal.

Hood Switch Removal and Installation (If

Equipped)
AENBL80A9606020
Removal
1) Disconnect negative (–) cable from battery.
2) Remove bolt (3), and then hood switch (1).
3) Disconnect connector (2) from hood switch (1). Terminal
1 Body
Switch Position

1 OFF (hood closed)

ON (hood open)
3
IBP80A960022-01

Siren Removal and Installation (If Equipped)

AENBL80A9606022
Removal
1) Disconnect negative (–) cable from battery.
2) Disconnect connector (2) from siren (1).
3) Remove nuts (3), and then siren (1).
2
IBP80A960021-01

Installation
Reverse removal procedure and tighten hood switch bolt
(3) to specified torque.
Tightening torque
Hood switch bolt (a): 8.0 N·m (0.82 kgf-m, 6.0 lbf-ft)

Hood Switch Inspection (If Equipped)

AENBL80A9606021
Remove hood switch from vehicle and check switch for
continuity. If found defective, replace hood switch.

1
IBP80A960023-01

Installation
Reverse removal procedure and tighten siren nut to
specified torque.
Tightening torque
Siren nut (a): 7.0 N·m (0.71 kgf-m, 5.5 lbf-ft)
 Security and Locks: 9F-17

Siren Inspection (If Equipped)

AENBL80A9606023
Connect battery positive (+) terminal to siren connector
(1) and negative (–) terminal to body ground. If siren is
1
not sounding, replace siren (2).

2
IBP80A960024-01

Specifications
Tightening Torque Specifications
AENBL80A9607001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Door latch striker screw 10 1.0 7.5 )
Back door lock bolt 10 1.0 7.5 )
Back door latch striker screw 23 2.3 17.0 )
Hood switch bolt 8.0 0.82 6.0 )
Siren nut 7.0 0.71 5.5 )

NOTE
The tightening torque(s) also specified in:
“Front Door Lock Components”:
“Rear Door Lock Components”:
“Back Door Lock Components”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to .

Special Tools and Equipment

Recommended Service Material
AENBL80A9608001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 )

NOTE
Required service material(s) also described in:
“Front Door Lock Components”:
“Rear Door Lock Components”:
9G-1 Seats:

Seats
Body, Cab and Accessories

Repair Instructions
Front Seat Components
AENBL80A9706001
When replacing any seat component, be sure to select correct one referring to parts catalog.

5 1

2
7 6

4
3

(b)
(a) 14

“2”

“4”

13 9

“1”

“3”

10
(c)

11

12
IBL80A970004-01

1. Headrest 8. Front seat cushion frame : 8.5 N⋅m (0.86 kgf-m, 6.26 lbf-ft)
: Tightening order: “1” → “2” → “3” → “4”
2. Headrest guide 9. Reclining outside cover : 50 N⋅m (5.0 kgf-m, 37.0 lbf-ft)
3. Front seatback trim 10. Reclining knob : 35 N⋅m (3.6 kgf-m, 26.0 lbf-ft)
4. Front seatback pad 11. Seat lifter lever (if equipped) : Do not reuse.
5. Front seatback frame 12. Seat lifter lever cap (if equipped)
6. Front seat cushion trim 13. Riser inside cover (if equipped)
7. Front seat cushion pad 14. Trim ring

Front Seat Removal and Installation

AENBL80A9706002
 Seats: 9G-2

Removal
1) Disconnect connectors from front seat.
2) Remove 4 mounting bolts and remove seat assembly.
3) Disassemble and repair parts if necessary. )(Page 9G-1)

Installation
Reverse removal procedure noting the following points.

NOTE
Tighten the bolts front seatback frame bolt and front seat cushion frame in sequence referring to
“Front Seat Components” (Page 9G-1)

• Refer to “Front Seat Components” (Page 9G-1) for tightening torque.

9G-3 Seats:

Rear Seat Components

AENBL80A9706003

1
3

[A]
7
8

10

11

12

13

IBL80A970002-01

[A}. Walk-in Assembly 6. Rear seat armrest bolt 12. Rear seat reclining cover outside
1. Headrest 7. Rear seatback frame 13. Rear seat reclining knob
 Seats: 9G-4

2. Headrest guide 8. Walk-in lever : 12.5 N⋅m (1.27 kgf-m, 9.22 lbf-ft)
3. Rear seatback trim 9. Rear seat cushion trim : 50 N⋅m (5.09 kgf-m, 36.87 lbf-ft)
4. Rear seatback pad 10. Rear seat cushion frame : 13 N⋅m (1.32 kgf-m, 9.6 lbf-ft)
5. Armrest assembly 11. Rear seat mounting

Rear Seat Removal and Installation

AENBL80A9706004

Removal
1) Remove seatback assemblies by removing rear seat hinge bolts. )(Page 9G-3)
2) Remove seat cushion assembly. )(Page 9G-3)
3) Disassemble and repair seat if necessary. )(Page 9G-3)

Installation
Reverse removal procedure noting the following point.
• Refer to “Rear Seat Components” (Page 9G-3) for tightening torque.
9G-5 Seats:

3rd Row Seat Components

AENBL80A9706005

5
4

7
(a)
10

IBL80A970003-02

1. Rear back lock band 5. 3rd seat cushion trim 9. 3rd seat hinge outside cover
2. 3rd seatback trim 6. 3rd seat cushion pad 10. 3rd seat cushion stay
3. 3rd seatback pad 7. 3rd seat cushion frame 8.4 N⋅m (0.85 kgf-m, 6.19 lbf-ft)
4. 3rd seatback frame 8. 3rd seat center hinge
 Seats: 9G-6

3rd Row Seat Removal and Installation

AENBL80A9706006

Removal
1) Remove seatback assemblies by removing 3rd seat hinge bolts. )(Page 9G-5)
2) Remove seat cushion assembly. )(Page 9G-5)
3) Disassemble and repair seat if necessary. )(Page 9G-5)

Installation
Reverse removal procedure noting the following point.
• Refer to “” (Page 9G-5) for tightening torque.

Specifications
Tightening Torque Specifications
AENBL80A9707001
NOTE
The tightening torque(s) also specified in:
“Front Seat Components”:
“Rear Seat Components”:
“”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to .
9H-1 Exterior Trim / Interior Trim:

Exterior Trim / Interior Trim

Body, Cab and Accessories

Repair Instructions
Front Bumper Removal and Installation
AENBL80A9806001
Remove and install parts referring to figure.

2 8

[A] 4 5 [B]

IBL80A980001-01

[A]: Without front fog light 3. Radiator upper grille 7. Front bumper side holder
[B]: With front fog light 4. Front fog light hole cover 8. Front bumper front holder
1. Front bumper 5. Front fog light bezel
2. Radiator lower grille 6. Front bumper cap
 Exterior Trim / Interior Trim: 9H-2

Front Bumper Member Removal and Installation

AENBL80A9806002
Remove and install parts referring to figure.

4
3
1

2 4
3

5
A

IBL80A980003-01

1. Front bumper member plate 4. Front bumper upper absorber 7. Front bumper lower cover
2. Front bumper upper member 5. Engine undercover
3. Front bumper lower absorber 6. Front lower cross member
9H-3 Exterior Trim / Interior Trim:

Rear Bumper Removal and Installation

AENBL80A9806003
Remove and install parts referring to figure.

A
2

2 1
3

4
A

IBL80A980004-01

1. Rear bumper 2. Rear bumper rear holder 3. Rear bumper side holder 4. Rear fender lining

Cowl Top Garnish Removal and Installation

AENBL80A9806004
Removal
1) Remove windshield wiper arms. )(Page 9D-3)
2) Remove cowl top garnish (1) with cowl top side garnishes (3) and then remove washer hose. )(Page 9D-1)
3) Remove washer nozzle from cowl top garnish if necessary. )(Page 9D-1)
4) Remove the following parts from cowl front panel (2) and then remove cowl front panel.
• Engine control module (ECM) (D13A model): )(Page 1C-14)
• Windshield wiper motor and wiper motor harness: )(Page 9D-3)
 Exterior Trim / Interior Trim: 9H-4

A A B

1
3

IBL80A980005-01

4. Hood rear seal 5. Cowl front silencer

Installation
Reverse removal procedure.
9H-5 Exterior Trim / Interior Trim:

Hood Silencer Removal and Installation

AENBL80A9806005
Remove and install parts referring to figure.

IBL80A980006-01

1. Hood silencer

Roof Molding Removal and Installation

AENBL80A9806007
Remove and install parts referring to figure.

IBL80A980007-01
 Exterior Trim / Interior Trim: 9H-6

1. Roof molding 3. Positioning rib

: Press down until click is heard to install roof molding and roof molding clip. : Align with roof molding positioning location.
2. Roof molding clip 4. Roof panel
: Install roof molding clips so that they are in close contact with roof panel.

Trim Removal and Installation

AENBL80A9806008
Removal
Front pillar trim
• Remove front pillar trim (1) pulling it in arrow direction.

B 1 A

1
A

A
A
A

IBL80A980009-01

Center pillar trims

A B
A
1) Remove front and rear side sill scuffs (4).
2) Remove center pillar lower trim (1) pulling it in arrow
direction.
3) Remove front seat belt anchor plate bolt (3).
IBP80A980017-01 4) Remove upper trim (2) pulling them in arrow
directions.
Dash side trim and front side sill scuff
• Remove front side sill scuff (1) and then remove dash A
side trim (2) pulling them in arrow directions.
2

A B
A 3

A
C
1 A

4
C 4
2

B 1
A
I9P60A980017-03
A
B A
Tail end trim
• Remove clips and then remove tail end trim (1) pulling
it in arrow direction.
IBL80A980008-01

Rear side sill scuff

• Remove rear side sill scuff (1) pulling it in arrow
direction.
9H-7 Exterior Trim / Interior Trim:

A A B 4
2

B A
B
3
B
1

A
A
A

IBL80A980010-01
1

Quarter inner trims

1) Remove tail end trim (2). IBL80A980011-01

2) Remove rear seat. )(Page 9G-4) Installation

3) Remove clips and then remove rear quarter inner
Reverse removal procedure noting the following points.
lower trim (3) pulling it in arrow direction.
• Tighten front seat belt anchor plate bolt to specified
4) Remove rear quarter inner upper trim (4) pulling it in
torque. )(Page 8A-3)
arrow direction.
1

1
IBL80A980012-01

Installation – Front seat: )(Page 9G-1)

Reverse removal procedure noting the following point. – Rear seat: )(Page 9G-4)
• Tighten mounting bolts of each seat to specified
torque.

Head Lining Removal and Installation

AENBL80A9806010
 Exterior Trim / Interior Trim: 9H-8

Removal
1) Remove sun visors (1).
2) Remove dome light (2).
3) Remove the following trims. )(Page 9H-6)
• Front pillar trims
• Center pillar upper trims
• Rear quarter inner upper trims
4) Remove inside rearview mirror (3).
5) Remove assist grips (4).
6) Remove clips and remove head lining (5).

1 3

A 4 A

A A

IBL80A980013-01

Installation
Reverse removal procedure noting the following point.
• Enable air bag system. )(Page 8B-61)
9H-9 Exterior Trim / Interior Trim:

Center Console Box Removal and Installation

AENBL80A9806011
Remove and install parts referring to figure.

4 1

2 A
A
3

A B
A “1” B

“2”

IBP80A980018-01

1. Floor console box front garnish 3. Floor console rear box

2. Floor console front box 4. Cup holder

Accessory Socket Removal and Installation

AENBL80A9806012
Removal
1) Push claws (3) outward and pull out inner part (1) of
accessory socket.
2) Push claws (4) inward and pull out outer cover (2) of
accessory socket.

1
3

2 4
IAW101980034-01

Installation
Reverse removal procedure.
 Exterior Trim / Interior Trim: 9H-10

Specifications
Plastic Part Specifications
AENBL80A9807001
Plastic Parts and Materials

! CAUTION
As exterior and interior plastic parts have material description on back side of each part, use it as
reference information. Also, when heating work is needed, remove or protect plastic parts if
necessary.

Description of material classification code is as follows.

1 2 3 4 5
I8C50A980018-01

1. Material
2. Material variation (PA only)
: 6, 66, etc.
3. Sub-material
: “G” means glass, “M” means metal and “T” means talc.
4. Sub-material shape: “B” means bead, “D” means dust (powder) and “F” means fiber.
5. Mixture ratio of sub material

Abbreviation Material
ABS Acrylonitrile-Butadiene-Styrene
AEPDS Acrylonitrile-Ethylene-Propylene-Diene-styrene
ASA Acrylonitrile-Styrene-Acrylate
EPDM Ethylene-Propylene-Diene-Monomer
EPM Ethylene-Propylene-Monomer
PA Polyamide
PBT Polybutylene terephthalate
PC Polycarbonate
PE Polyethylene
PET Polyethylene terephthalate
PMMA Poly methyl methacrylate
POM Polyoxymethylene
PP Polypropylene
PPE Polyphenylene ether
PS Polystyrene
PVC Polyvinyl chloride
TEO Thermoplastic elastomer, olefin
TPE Thermoplastic elastomer
UP Unsaturated polyester
9H-11 Exterior Trim / Interior Trim:

Major Plastic Parts and Installation Positions

Body exterior

5 6

1
3 4
3
2 7 8
IBL80A980014-01

Heat resistant
Part name Mark
temperature limit (°C (°F))
Lens PC 130 (266)
1 Headlight
Housing PP - T30 125 (257)
Lens PMMA 100 (212)
2 Rear combination light
Housing ABS + PC 80 (176)
3 Bumper Front / Rear PP + EPM - TD15 80 (176)
Upper AEPDS 80 (176)
4 Radiator grill
Lower PP 80 (176)
5 Cowl top garnish PP - TD15 80 (176)
6 Roof molding PVC + SUS 430 80 (176)
Housing AAS 80 (176)
7 Door mirror
Visor mirror cover AAS 80 (176)
Frame PA 80 (176)
8 Outside door handle
Handle PC + PBT 80 (176)
 Exterior Trim / Interior Trim: 9H-12

Body interior

7
3

8 5 4 6
10
9
IBL80A980016-01

Heat resistant
Part name Mark
temperature limit (°C (°F))
1 Front pillar trim PP 80 (176)
Upper PP 80 (176)
2 Center pillar trim
Lower PP + EPM -TD15 80 (176)
Upper PP 80 (176)
3 Rear quarter inner trim
Lower PP 80 (176)
4 Side sill scuff Front / Rear PP 80 (176)
5 Dash side trim PP 80 (176)
6 Tail end trim PP 80 (176)
7 Door trim Front / Rear PP + EPM 80 (176)
8 Instrument panel PP + EPM 80 (176)
Front PP + EPM 80 (176)
9 Floor console box
Rear PP + EPM 80 (176)
10 Floor console box front garnish PP + EPM 80 (176)
 Hood / Fenders / Doors: 9J-1

Hood / Fenders / Doors

Body, Cab and Accessories

Repair Instructions
Hood Removal and Installation Adjustment
AENBL80A9A06001
Horizontal adjustment of hood
Removal
Loosen hood hinge bolts and adjust installation position
! CAUTION of hood. )(Page 9K-22)

Cover the vehicle body with cloth to prevent Vertical adjustment of hood
any damage.
• Turn hood cushion (1) if there is a step between hood
and front fender.
1) Remove 4 hood hinge bolts (1) to detach hood (2).
2) Remove hood hinge after removing front fender, if
necessary. )(Page 9J-3)

Installation 1
Reverse removal procedure noting the following points.
• Apply sealant to contact face “A” of hood hinge.
“A”: Sealant 99000–31110 (SUZUKI Bond
No.1215)
• Adjust hood latch position if necessary. )(Page 9J-1)

2 IBL80A9A0001-01

• Turn hood cushion (2) if there is a step between hood

and front fender.

“A”

IBL80A9A0002-01

Hood latch position adjustment

1) Loosen hood latch bolts (1) and adjust height of
hood latch (2).
I9P60A9A0001-01 2) Tighten hood latch bolts to specified torque.
Tightening torque
Hood Inspection and Adjustment Hood latch bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
AENBL80A9A06002
Inspection
• Check that hood opens and closes smoothly and
properly. Lubricate it if necessary.
• Check that hood stops in secondary latch position
properly when hood lock is released.
• Check that hood closes completely in full latch
position.
• Adjust hood latch position if necessary.
9J-2 Hood / Fenders / Doors:

3) Make sure hood is locked smoothly and securely.

1,(a)
IBP80A9A0002-01

Hood Latch Release Cable Components

AENBL80A9A06003

(a)
2

4
3
IBL80A9A0003-01

1. Hood latch release cable 3. Hood latch release lever : 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft)
2. Grommet 4. Instrument panel

Front Fender Components

AENBL80A9A06004
 Hood / Fenders / Doors: 9J-3

A
IBP80A9A0006-01

1. Front fender lining 2. Front fender 3. Front fender cover

Front Fender Removal and Installation

AENBL80A9A06005

Removal
1) Remove front bumper and front bumper holder. )(Page 9H-1)
2) Remove cowl top garnish and cowl top side garnish. )(Page 9H-3)
3) Remove headlight unit. )(Page 9B-3)
4) Remove side turn signal light. )(Page 9B-6)
5) Remove side sill guard.
6) Remove front fender lining.
7) Remove front fender and front fender cover.

Installation
Reverse removal procedure noting the following points.
• Adjust front fender panel clearance. )(Page 9K-22)
• If paint on front fender bolts is peeled off, be sure to apply paint again to prevent rust.
9J-4 Hood / Fenders / Doors:

• Perform headlight aiming after installation. )(Page 9B-4)

• Apply sealant in front fender mounting near front door upper.

Front Door Components

AENBL80A9A06006

(a)

“1” (b)
4
“2” (b)

(d)

(a)

“2” (b)

“1” (b)

2 3

(c)
IBL80A9A0004-01

1. Door panel 4. Front door opening weather-strip

2. Door hinge : 27 N⋅m (2.8 kgf-m, 20.0 lbf-ft)
: Apply grease 99000-25011 to rotating part. : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
: Apply sealant 99000-31110 to mounting face.
: Tighten door hinge bolt (door side) in order of “1” to “2”. : 21 N⋅m (2.1 kgf-m, 15.5 lbf-ft)
: 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)
3. Door open stopper
: Install in correct direction. )(Page 9J-4)

Front Door Assembly Removal and Installation

AENBL80A9A06007

Removal
1) Remove door trim.
• Front: )(Page 9E-14)
• Rear: )(Page 9E-18)
2) Disconnect door harness connectors from door.
3) Remove door open stopper bolt (1).

I9W10P9A0009-02
 Hood / Fenders / Doors: 9J-5

4) Support door panel (1) using a jack (2) with rags (3) “B”: Grease 99000–25011 (SUZUKI Super Grease
and a piece of wood (4) placed between jack and A)
door panel as shown in figure.

“B” “A”

I2RH019A0003-01

5) Remove bolts (2) and remove front door (1). “A”

I9W10P9A0010-01

• Tighten front door hinge bolts and door open stopper

2
bolt to specified torques. )(Page 9J-4)
• When door open stopper (1) is installed, face proper
1
matching mark (2) upward.
– Right side door: Mark “R” faces upward
– Left side door: Mark “L” faces upward

I9W10P9A0023-02

6) Remove door hinge after removing front fender if

necessary. )(Page 9J-3)

Installation
Reverse removal procedure noting the following points.
• When replacing door, coat inside of replacement door 2
with anti-corrosion wax for proper anti-corrosion
treatment. )(Page 9L-14) 1

• Apply sealant to mounting face “A” of door hinge (1)

and apply grease to rotating part “B” of door hinge (1).
“A”: Sealant 99000–31110 (SUZUKI Bond
No.1215)
I9W10P9A0011-02
• Adjust door striker position. )(Page 9F-9)
• After installation, open and close the door to check if it
can be closed smoothly and securely.

Rear Door Components

AENBL80A9A06008
9J-6 Hood / Fenders / Doors:

“1” (a)

“2” (a)

(a)
(c)

“2” (a)

“1” (a)

(a)

2 3

(b)
IBL80A9A0005-01

1. Door panel 3. Door open stopper

: Install in correct direction. )(Page 9J-6)
2. Door hinge 4. Rear door opening weather-strip
: Apply grease 99000-25011 to rotating part. : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)
: Apply sealant 99000-31110 to mounting face.
: Tighten door hinge bolt (door side) in order of “1” to “2”. : 21 N⋅m (2.1 kgf-m, 15.5 lbf-ft)
: 5.5 N⋅m (0.56 kgf-m, 4.0 lbf-ft)

Rear Door Assembly Removal and Installation

AENBL80A9A06009
Removal and installation procedure for rear door is basically the same as “Front Door Assembly Removal and
Installation” (Page 9J-4). However, note the following point.
• Tighten bolts and nuts to specified torques. )(Page 9J-5)

Fuel Filler Door Removal and Installation

AENBL80A9A06010 3
Removal 2

1) Remove fuel filler cap tether (1) from fuel filler door
(2).
2) Remove fuel filler door bolts (3) and remove fuel filler
door.

I9P60A9A0009-02

Installation
Reverse removal procedure.
 Hood / Fenders / Doors: 9J-7

Fuel Filler Door Opener Cable Removal and Installation

AENBL80A9A06011
• For removal and installation of fuel filler door opener cable (3), refer to the figure.
• When removing fuel filler door opener cable, remove fuel filler door opener (1) and fuel filler door opener lever (2)
first.

IBL80A9A0006-01

Back Door Assembly Components

AENBL80A9A06012
9J-8 Hood / Fenders / Doors:

(a)
(a)

2
2

(c)
(b) 1
(c)

(b)

(b)

(b)

IBL80A9A0007-01

1. Back door panel 4. Back door opening weather-strip : 13 N⋅m (1.3 kgf-m, 9.5 lbf-ft)
2. Back door hinge : 10 N⋅m (1.0 kgf-m, 7.5 lbf-ft)
: Apply lithium grease 99000-25011 to door
hinge moving section.
: Apply sealant 99000-31110 to contact face.
3. Back door balancer : 23 N⋅m (2.3 kgf-m, 17.0 lbf-ft)

Back Door Assembly Removal and Installation ! CAUTION

AENBL80A9A06013

• If back door is opened with back door

balancers not installed, the door will slam
shut by its own weight.
• Use care to avoid getting personal injury
and damage of vehicle body caused by the
door slamming shut.
 Hood / Fenders / Doors: 9J-9

Removal
1) Remove head lining. )(Page 9H-8)
2) Disconnect back door harness connectors (1) and
washer hose (5).
3) Remove back door balancers (2) from vehicle.
4) Remove back door hinge nuts (4), and then remove
back door assembly (3) with back door hinges.
5) Remove back door hinges, back door balancers and/
or back door opening weather-strip if necessary. I2RH019A0010-01

)(Page 9J-7)
Installation
6) Remove rear wiper motor assembly if necessary.
Reverse removal procedure noting the following points.
)(Page 9D-5)
• Tighten bolts and nuts to specified torque. )(Page
3 9J-7)
• Adjust door latch striker position. )(Page 9F-14)
• Adjust door cushion to prevent door from contacting
the body when closed.
• Apply sealant to contact face “A” of door hinge (1) and
apply grease to rotating part “B” of door hinge (1).
“A”: Sealant 99000–31110 (SUZUKI Bond
2 No.1215)
5 “B”: Grease 99000–25011 (SUZUKI Super Grease
A)
2

1
1
4
I9P60A9A0012-01

! WARNING
Handling of back door balancer (damper)
• Handle balancer carefully. Do not scar or
scratch exposed surface of its piston rod,
and never allow any paint or oil stuck on
its surface.
• Do not turn piston rod with balancer fully
extended.
• Do not disassemble balancer (1) because
its cylinder is filled with gas.
Discarding of back door balancer (damper)
• The gas itself in balancer is harmless but it
may gush out of the hole together with
chips generated by the drill (2). Therefore,
be sure to wear goggle when drilling.
• Using a 2 to 3 mm (0.08 to 0.11 in.) drill (2),
make a hole and remove gas inside as
shown before discarding.
I2RH019A1012-01
All Latches, Hinges and Locks Inspection
AENBL80A9A06014
Doors
• Check that front and rear doors stop in the secondary
latch position properly (preventing doors from opening
freely) and that doors close completely in the full latch
position.
• Check that door opens and closes smoothly.
• Check that door closes completely in full latch
position.
If any malfunction is found, lubricate hinges and latch, or
replace door lock if necessary.
Hood
• Check that hood is held in secondary latch position
when hood lock is released.
• Check that hood opens and closes smoothly.
• Check that hood closes completely in full latch
position.
If any malfunction is found, lubricate hinges and latch, or
replace hood latch if necessary.
9J-10 Hood / Fenders / Doors:

Specifications
Tightening Torque Specifications
AENBL80A9A07001
Tightening torque
Fastening part Note
N⋅m kgf-m lbf-ft
Hood latch bolt 10 1.0 7.5 )

NOTE
The tightening torque(s) also specified in:
“Hood Latch Release Cable Components”:
“Front Door Components”:
“Rear Door Components”:
“Back Door Assembly Components”:

Reference:
For the tightening torques of fasteners not specified in this section, refer to “Fasteners Information” in Section 0A
(Page 0A-5).

Special Tools and Equipment

Recommended Service Material
AENBL80A9A08001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011 )/)
Sealant SUZUKI Bond No.1215 P/No.: 99000–31110 )/)/)

NOTE
Required service material(s) also described in:
“Front Door Components”:
“Rear Door Components”:
“Back Door Assembly Components”:
 Body Structure: 9K-1

Body Structure
Body, Cab and Accessories

Precautions
Precautions for Body Structure
AENBL80A9B00001
Operation

! WARNING
Wear clothing and protective items suitable for operation. Before attempting any body repair, be sure
to disconnect negative (–) cable at battery. When using the body frame repair device for pulling-out
operation, avoid standing in front of the pulling chain. Also use safety wires to prevent accidental
release of the chains. Before using flames or sparks near the fuel tank, be sure to remove the fuel tank
from the vehicle and properly plug the disconnected hoses and pipes to prevent from fuel leakage.

High-Strength Steel

! CAUTION
Cutting, joining, or heating a high-strength steel panel with tensile strength of 590 MPa or more will
reduce its stiffness, resulting in deterioration in performance.
Repair the damaged panel only by replacing it with a new one as a spare part unit.

NOTE
• Cutting and welding operations performed for reducing the number of man-hours are, however,
allowed for body panels made of steel sheets with a tensile strength of 590 MPa and having a simple
shape. No portions apply in this model.
• Refer to “Sheet Metal Description” (Page 9K-5) for tensile strength of steel panels.

Body Panel Repair

NOTE
• The number of spot welded points should be increased by 20 to 30% in number from original
welding points. The figure shows the number and locations of the original spot welding points.
• Although the spot welding is recommended in the repair procedure, you shall adopt the plug
welding when the thickness of the welding points exceeds the performance of your spot welding
machine.
• Select proper hole diameter for plug welding from those values indicated in the table based on
thickness and type of the steel sheet to be welded.
Panel thickness Hole diameter for plug weld
1.0 mm (0.04 in.) or less * ø 6.0 (ø 0.24 in.) or more
1.0 mm – 1.5 mm (0.04 in. – 0.06 in.)* ø 8.0 (ø 0.31 in.) or more
1.5 mm (0.06 in.) or more * ø 10.0 (ø 0.39 in.) or more
9K-2 Body Structure:

* ø10.0 (ø0.39 in.) or more for parts using high-tensile steel panel
• Refer to “Sheet Metal Description” (Page 9K-5) for types and thickness of steel panels.
• Before welding, be sure to remove paint film and surface finishing from the new parts or the vehicle
body at each welded point, apply the weld through primer (spot sealer) to contact surface to prevent
rust.
• When installing each part, refer to “Tightening Torque Specifications” (Page 9K-136) and “Panel
Clearance” (Page 9K-22).
• After repairing body panels, be sure to apply seam sealer, cavity protection, underbody coating and
anti-corrosion compound to all areas originally protected by the manufacture referring to “Sealant
Application Areas” in Section 9L (Page 9L-2), “Undercoating Application Areas” in Section 9L (Page
9L-11) and “Anti-Corrosion Compound Application Area” in Section 9L (Page 9L-14).

Precautions for Working on Air Bag System

! WARNING

• Before performing any works which will generate high temperature (93 °C (199 °F) or higher),
remove air bag system related parts.
• When performing repair work around air bag system related parts, be sure to remove these
components from the vehicle.
• To avoid accidental activation of the air bag system, refer to “Precautions for Air Bag System
Service” in Section 8B (Page 8B-1).
• When performing repair work near harness of air bag system (covered with yellow protection tube),
use full care not to damage the harness and connector.
• When external damage or deformation is found with any air bag system related parts, be sure to
replace it with new one.
• When performing sheet metal work near air bag system related parts, be sure to check system for
function (that air bag warning light lights up properly).

General Description
Body Repair Description
AENBL80A9B01001
 Body Structure: 9K-3

NOTE
Body repair work consists of “diagnosis, removal, installation and replacement” of body parts and
“rust-proofing” etc.
• Use SUZUKI genuine service parts and materials and follow repair instructions in this manual to
ensure repair quality. Body repair work should be performed by qualified technicians.
• This manual dose not describe most of panel repair works as cutting, drilling and welding and frame
corrections. Refer to the SUZUKI body repair training DVD for such technics.
• Welding methods, number of welding points, method required for installation and removal of body
panel are shown using a symbol or mark.
• Most of repair procedures are described on the left side of the vehicle. Most parts of the vehicle are
almost symmetrical in the welding spots. A repair procedure for the right side is separately shown
only if the construction or welding spots are significantly different between right and left sides.
• Most drawings are viewed from worker’s eyes with work efficiency taken into consideration, but
they are only typical. Determine the working direction according to vehicle conditions.
• Refer to the following for plastic parts and sealer application area.
– “Plastic Part Specifications” in Section 9H (Page 9H-11)
– “Sealant Application Areas” in Section 9L (Page 9L-2)

Symbols
9K-4 Body Structure:

(3)

in.)
(12 0 m m
.20
31
(4)

(1)
(2)
(3)
(1)

(12)

(4)

(2)
65mm (1)
(2.56 in.)

(3)

(4)

(1)
(7)

(1) (1)
(1)
(2)
(4)
(3)

(1) (3)
(5)
(3) (2) (3)
(4) (2)
(3)

(5) (1)
(5) (3)
(2) (2)
(5)
(5)

IBP80A9B0001-01
 Body Structure: 9K-5

Symbol Definition Remarks

Detach Welding (one panel thickness)
Detach Welding (two panel thickness)
Make Cut
This symbol indicates that only one panel
should be removed from panel structure.
This symbol indicates that two panels
should be removed from panel structure.

Spot Welding (two panel thickness) Use a spot weld machine appropriate for the
type and thickness of the panel of the
Spot Welding (three panel thickness) welding point.

Plug Welding (two panel thickness)

Plug Welding (three panel thickness)

Either Spot or Plug Welding

(two panel thickness)
Either Spot or Plug Welding
(three panel thickness)
If the spot welding is conducted, be sure to
use a spot weld machine appropriate for
the type and thickness of the panel of the
welding point.

Tack Welding

Continuous MIG-Welding

Brazing

Adhesive
This mark is used for important points that
Body Sealer need water proof treatment especially.
Foamed Material

The Number of Welding

IBL80A9B0149-01

Sheet Metal Description

AENBL80A9B01002
This section contains information for body repair (welding) work.

NOTE
All the numbered panels in figure are supplied available as spare parts.
9K-6 Body Structure:

Front Body

83

83-1 82

84 85 82
82
81

83

86-1 83-1
86
86-2 85 84
77

76

74
77
75 74-1 78-2
78-1
71
72 78-2
78

74

51-1 75 74-1
51-4
51-5
51-3

31-1
52-1
52-9 52-4 31-2
51-2 73-2
53 73-1
52-6 73-2
31
52-5 33 61-1
73
32-2 41-1
52-3 61-4
52 51 32-1 32
41-2 61-5
32-3
41 61-2
52-2
41-3
63
22 42
52-7 52-8
33
65 64 62-1
61-3
21-2
21
21-1 66

21-2 62-3
21
21-1 62-4
62-2
62-7 62-6
61
62-5
62-8
62

IBL80A9B0150-01
 Body Structure: 9K-7

Double sided High-strength

Thickness
No. Part name Qty. galvannealed steel (Tensile
(mm (in.))
steel strength (MPa))
R: 1
21 Lamp support brace (R, L)
L: 1
21-1 Lamp support brace (R, L) 1.0 (0.039)
21-2 Lamp support outer brace (R, L) 1.4 (0.055)
22 Hood lock member 1 (bolt-on part)
31 Fender apron panel (R) 1
31-1 Suspension upper bracket (R) 2.3 (0.091)
31-2 Fender apron panel (R) 1.0 (0.039)
32 Fender apron extension (R) 1
32-1 Fender apron extension (R) 0.8 (0.031)
32-2 Engine mount right No. 1 bracket 1.4 (0.055)
32-3 Fender apron extension reinforcement 1.6 (0.063)
R: 1
33 Front fender lower bracket (R, L) 1.2 (0.047)
L: 1
41 Fender apron panel (L) 1
41-1 Suspension upper bracket (L) 2.3 (0.091)
41-2 Fender apron panel (L) 1.0 (0.039)
41-3 Fender apron reinforcement 1.6 (0.063)
42 Fender apron extension (L) 1 0.8 (0.031)
51 Front side member (R) 1
51-1 Dash lower member (R) 2.0 (0.079)
51-2 Dash lower inner extension (R) 1.0 (0.039)
51-3 Dash lower outer extension (R) 1.4 (0.055)
51-4 Dash lower member reinforcement (R) 2.0 (0.079)
51-5 Dash lower member upper reinforcement (R) 440 1.2 (0.047)
52 Apron side member (R) 1
52-1 Apron side member (R) 1.8 (0.071)
52-2 Apron side member extension (R) 440 1.4 (0.055)
52-3 Apron side member lower reinforcement (R) 1.6 (0.063)
52-4 Apron side outer member (R) 1.4 (0.055)
52-5 Apron side outer member extension (R) 440 1.4 (0.055)
52-6 Lamp support brace extension (R) 1.4 (0.055)
52-7 Front bumper member upper plate (R) 440 1.6 (0.063)
52-8 Front bumper member lower plate (R) 590 1.4 (0.055)
52-9 Engine mount right No. 2 bracket 2.3 (0.091)
53 Dash upper cross member (R) 1 1.2 (0.047)
61 Front side member (L) 1
61-1 Dash lower member (L) 2.0 (0.079)
61-2 Dash lower inner extension (L) 1.0 (0.039)
61-3 Dash lower outer extension (L) 1.4 (0.055)
61-4 Dash lower member reinforcement (L) 2.0 (0.079)
61-5 Dash lower member upper reinforcement (L) 440 1.2 (0.047)
62 Apron side member (L) 1
62-1 Apron side member (L) 1.8 (0.071)
62-2 Apron side member extension (L) 440 1.4 (0.055)
62-3 Apron side member lower reinforcement (L) 1.6 (0.063)
62-4 Apron side outer member (L) 1.4 (0.055)
62-5 Apron side outer member extension (L) 440 1.4 (0.055)
62-6 Lamp support brace extension (L) 1.4 (0.055)
62-7 Front bumper member upper plate (L) 1.6 (0.063)
62-8 Front bumper member lower plate (L) 590 1.4 (0.055)
63 Dash upper cross member (L) 1 1.2 (0.047)
64 Battery tray bracket 1 2.0 (0.079)
65 Battery tray bracket gusset 1 1.2 (0.047)
66 Battery tray gusset reinforcement 1 1.6 (0.063)
71 Dash panel 1 0.8 (0.031)
72 Dash panel side reinforcement (R) 1 1.2 (0.047)
9K-8 Body Structure:

Double sided High-strength

Thickness
No. Part name Qty. galvannealed steel (Tensile
(mm (in.))
steel strength (MPa))
73 Dash upper cross member 1
73-1 Dash upper cross member 1.0 (0.039)
73-2 Dash upper side cross member (R, L) 2.0 (0.079)
R: 1
74 Dash side panel (R, L)
L: 1
74-1 Dash side panel (R, L) 440 1.2 (0.047)
R: 1
75 Dash side front panel (R, L) 1.0 (0.039)
L: 1
76 Cowl upper panel 1 0.8 (0.031)
R: 1
77 Cowl side outer member (R, L) 0.65 (0.026)
L: 1
78 Cowl upper front member 1
78-1 Cowl upper front member 1.0 (0.039)
78-2 Cowl upper front member reinforcement (R, L) 0.8 (0.031)
81 Cowl top panel 1 0.7 (0.028)
82 Instrument panel upper bracket 3 0.7 (0.028)
R: 1
83 Cowl top side panel (R, L)
L: 1
83-1 Cowl top side panel (R, L) 1.4 (0.055)
R: 1
84 Cowl side panel (R, L) 1.4 (0.055)
L: 1
R: 1
85 Front fender center bracket (R, L) 1.0 (0.039)
L: 1
86 Wiper link center bracket 1
86-1 Wiper link center bracket 1.0 (0.039)
86-2 Cowl box gusset 1.0 (0.039)
 Body Structure: 9K-9

Floor

109-2

109-1

103-3 109-2
103
103-2 109
102 108
106 109-3
103-1

105

104 106 103-3

105
103-2
103
103-1
107

97 92 96
101 104
96
95-2 92 113 135-3
111 135-1
95-1 135
95-2 134-3
111-2 134-2
95
93 97 111-1 135-4 135-2
111-4 134-1 134-3
133
93 111-3 134
112 111-5
132-3 121-2
132-4 121-3 123

132-1 121-1
91 132 121-5
132-2 121-4
94
131-2
91 131-1

131 131-2

122

121

IBL80A9B0151-01
9K-10 Body Structure:

Double sided High-strength

Thickness
No. Part name Qty. galvannealed steel (Tensile
(mm (in.))
steel strength (MPa))
R: 1
91 Main floor panel (R, L) 0.65 (0.026)
L: 1
R: 1
92 Front seat rear outside bracket (R, L) 1.4 (0.055)
L: 1
R: 1
93 Floor panel upper cross member (R, L) 1.2 (0.047)
L: 1
94 Main floor tunnel 1 1.0 (0.039)
95 Front seat rear inside bracket 1
95-1 Front seat rear inside center bracket 1.2 (0.047)
95-2 Front seat rear inside bracket (R, L) 1.6 (0.063)
96 Floor side rear member 2 0.8 (0.031)
R: 1
97 Side sill inner panel (R, L) 1.4 (0.055)
L: 1
101 Rear floor front panel 1 1.0 (0.039)
102 Rear floor panel 1 0.7 (0.028)
R: 1
103 Rear floor side panel (R, L)
L: 1
103-1 Rear floor side rear panel (R, L) 1.2 (0.047)
103-2 Rear floor side extension (R, L) 0.65 (0.026)
103-3 Rear floor end reinforcement 0.7 (0.028)
104 Rear floor side front panel (R, L) 1.2 (0.047)
105 3rd seat front bracket 2 2.0 (0.079)
106 3rd seat rear bracket 2 2.0 (0.079)
107 Fuel hose clamp bracket 1 1.0 (0.039)
108 Luggage box bracket 2 0.8 (0.031)
109 Back panel 1
109-1 Back panel 0.7 (0.028)
109-2 Tail end member extension (R, L) 1.0 (0.039)
109-3 Jacking mount reinforcement 1.2 (0.047)
111 Rear floor side member (R) 1
111-1 Rear floor side front member (R) 1.6 (0.063)
111-2 Rear floor side member front reinforcement (R) 1.2 (0.047)
111-3 Rear floor 3rd cross member extension (R) 1.4 (0.055)
111-4 Trailing arm outside bracket (R) 1.4 (0.055)
111-5 Rear floor 2nd cross member extension (R) 1.4 (0.055)
112 Rear floor compartment (R) 1 1.6 (0.063)
113 Rear floor side rear member (R) 1 1.4 (0.055)
121 Rear floor side member (L) 1
121-1 Rear floor side front member (L) 1.6 (0.063)
121-2 Rear floor side member front reinforcement (L) 1.2 (0.047)
121-3 Rear floor 3rd cross member extension (L) 1.4 (0.055)
121-4 Trailing arm outside bracket (L) 1.4 (0.055)
121-5 Rear floor 2nd cross member extension (L) 1.4 (0.055)
122 Rear floor compartment (L) 1 1.6 (0.063)
123 Rear floor side rear member (L) 1 1.4 (0.055)
131 Rear floor front cross member 1
131-1 Rear floor front cross member 440 1.0 (0.039)
131-2 Floor side member cap 0.8 (0.031)
132 Rear floor 2nd cross member 1
132-1 Rear floor 2nd cross member 1.4 (0.055)
132-2 Rear seat rail center reinforcement 1.4 (0.055)
132-3 Fuel tank rear bracket (R) 1.2 (0.047)
132-4 Fuel tank rear bracket (L) 1.2 (0.047)
133 Rear floor 3rd cross member 1 1.2 (0.047)
134 Rear floor 4th cross member 1
134-1 Rear floor 4th cross member 1.2 (0.047)
134-2 3rd seat belt reinforcement 1.4 (0.055)
 Body Structure: 9K-11

Double sided High-strength

Thickness
No. Part name Qty. galvannealed steel (Tensile
(mm (in.))
steel strength (MPa))
134-3 Rear floor 4th cross member extension 2.0 (0.079)
135 Rear floor 5th cross member 1
135-1 Rear floor 5th cross member 1.2 (0.047)
135-2 Jacking mount 1.0 (0.039)
135-3 Rear floor 5th cross reinforcement 1.2 (0.047)
135-4 Jacking mount reinforcement 2.0 (0.079)
9K-12 Body Structure:

Side Body

159-4 156

152

151

153-1 153
144 141

143 142 141-1 154

148-1
150
155
157-3
148

156
148-2 157
145 157-2
159-3
149
147 157-1

159-2

149

146 159
145 158 159-1

160-2
146

160-1

160
160-3

IBL80A9B0152-03
 Body Structure: 9K-13

207mm 350mm
(8.15in) (13.78in)
177

175 171

176 172-1

172

477mm 172-2
(18.78in)

503mm 247mm
(19.80in) (9.72in)
174

173

227mm
(8.94in) 91mm 294mm
(3.58in) (11.57in)

178

IBL80A9B0153-01
9K-14 Body Structure:

Double sided High-strength

Thickness
No. Part name Qty. galvannealed steel (Tensile
(mm (in.))
steel strength (MPa))
R: 1
141 Front pillar inner panel (R, L)
L: 1
141-1 Roof side inner rail (R, L) 1.0 (0.039)
R: 1.2
R: 1 R: 440 (0.047)
142 Front pillar inner panel (R, L)
L: 1 L: 270 L: 1.0
(0.039)
R: 1
143 Front pillar upper extension (R, L) 0.65 (0.026)
L: 1
144 Front pillar upper reinforcement (R) 1 440 1.4 (0.055)
R: 1.6
R: 1 R: 440 (0.063)
145 Front door hinge reinforcement (R, L)
L: 1 L: 270 L: 1.4
(0.055)
R: 2
146 Front door hinge No. 1 retainer (R, L) 1.2 (0.047)
L: 2
R: 1
147 Center pillar inner panel (R, L) 440 1.2 (0.047)
L: 1
R: 1
148 Center pillar reinforcement (R, L)
L: 1
148-1 Roof side reinforcement (R, L) 440 1.0 (0.039)
148-2 Rear door hinge reinforcement (R, L) 440 1.4 (0.055)
R: 2
149 Rear door hinge retainer (R, L) 4.5 (0.177)
L: 2
R: 1
150 Quarter inner front reinforcement (R, L) 0.8 (0.031)
L: 1
R: 1
151 Quarter inner upper panel (R, L) 0.65 (0.026)
L: 1
R: 1
152 Quarter inner upper extension (R, L) 1.6 (0.063)
L: 1
R: 1
153 Rear lamp house inner panel (R, L)
L: 1
153-1 Rear lamp house inner upper panel (R, L) 0.8 (0.031)
R: 1
154 Rear lamp house inner lower panel (R, L) 0.8 (0.031)
L: 1
R: 1
155 3rd seat belt retractor panel (R, L) 1.2 (0.047)
L: 1
R: 1
156 Quarter inner lower panel (R, L) 0.65 (0.026)
L: 1
R: 1
157 Wheel house inner panel (R, L)
L: 1
157-1 Wheel house inner panel (R, L) 0.7 (0.028)
157-2 Quarter inner center panel (R, L) 0.65 (0.026)
157-3 Quarter inner center reinforcement (R, L) 1.0 (0.039)
R: 1
158 Rear wheel house front reinforcement (R, L) 2.3 (0.091)
L: 1
R: 1
159 Wheel house outer panel (R, L)
L: 1
159-1 Wheel house outer front reinforcement (R, L) 1.6 (0.063)
159-2 Wheel house outer front panel (R, L) 0.65 (0.026)
159-3 Wheel house outer rear panel (R, L) 0.65 (0.026)
159-4 Side body outer support (R) 1 0.65 (0.026)
R: 1
160 Side sill strength (R, L)
L: 1
160-1 Side sill strength (R, L) 590 1.4 (0.055)
160-2 Side sill rear strength (R, L) 440 1.0 (0.039)
 Body Structure: 9K-15

Double sided High-strength

Thickness
No. Part name Qty. galvannealed steel (Tensile
(mm (in.))
steel strength (MPa))
R: 1
160-3 Side sill strength front reinforcement 1.4 (0.055)
L: 1
R: 1
171 Side body outer extension (R, L) 1.2 (0.047)
L: 1
R: 1
172 Rear lamp house outer panel (R, L)
L: 1
172-1 Rear lamp house outer panel (R, L) 0.65 (0.026)
172-2 Side body outer lower extension (R, L) 0.65 (0.026)
173 Fuel filler box 1 0.7 (0.028)
174 Fuel filler door 1 0.7 (0.028)
R: 1
175 Side body outer (A pillar) panel (R, L) 0.65 (0.026)
L: 1
R: 1
176 Side body outer (B pillar) panel (R, L) 0.65 (0.026)
L: 1
R: 1
177 Side body outer (Quarter) panel (R, L) 0.65 (0.026)
L: 1
R: 1
178 Side body outer (Side sill) panel (R, L) 0.65 (0.026)
L: 1
9K-16 Body Structure:

Hood / Fenders / Doors / Roof

181

198 197

198
188-2

188 188-1

188-2

187

186
185
182-2 184
183
12
182 182-1

11
195
12

196

192 194

193
13
191

IBL80A9B0154-01
 Body Structure: 9K-17

Double sided High-strength

Thickness
No. Part name Qty. galvannealed steel (Tensile
(mm (in.))
steel strength (MPa))
11 Front hood panel 1 340 0.6 (0.024)
R: 1
12 Front hood hinge (R, L) (bolt-on part)
L: 1
R: 1
13 Front fender panel (R, L) 340 0.65 (0.026)
L: 1
181 Roof panel 1 0.65 (0.026)
182 Roof front inner member 1
182-1 Roof front inner member 0.65 (0.026)
182-2 Roof lamp bracket 0.65 (0.026)
183 Roof panel center No. 2 member 1 0.6 (0.024)
184 Roof center inner member 1 1.0 (0.039)
185 Roof panel center No. 3 member 1 0.6 (0.024)
186 Roof panel center No. 4 member 1 0.6 (0.024)
187 Roof panel center No. 5 member 1 0.6 (0.024)
188 Roof back inner member 1
188-1 Roof back inner member 1 0.65 (0.026)
R: 1
188-2 Roof back inner reinforcement (R, L) 1.0 (0.039)
L: 1
R: 1
191 Front door panel (R, L) 0.7 (0.028)
L: 1
R: 1
192 Front door upper hinge (R, L) (bolt-on part)
L: 1
R: 1
193 Front door lower hinge (R, L) (bolt-on part)
L: 1
R: 1
194 Rear door panel (R, L) 0.7 (0.028)
L: 1
R: 1
195 Rear door upper hinge (R, L) (bolt-on part)
L: 1
R: 1
196 Rear door lower hinge (R, L) (bolt-on part)
L: 1
197 Rear end door panel 1 0.65 (0.026)
R: 1
198 Rear end door hinge (bolt-on part)
L: 1

Body Structure Description

AENBL80A9B01003
9K-18 Body Structure:

Cross-Sections

C
B
A D D
C
B
A

E G G I I
F K

H J K

E F

H J

A-A B-B C-C

[B] 1 [A] [B] 4 [A] 4 4
1
1 1 1

5 3 3 5
6
3 3
2 5
2

D-D E-E F-F

[A] [B] 11
7 10
9

8 10 11 11 12 10
8
13

14
1
31 1

G-G H-H I-I

[A] 24
18
1
21
19 1
23 25
20
22 26

15 17 1

16

[B] J-J K-K

1 1
15 17 30
20 28
27
29

18

IBL80A9B0155-01
 Body Structure: 9K-19

[A]: Right side
[B]: Left side
1. Side body outer panel
2. Front pillar upper reinforcement
3. Front pillar inner panel
4. Roof panel
5. Roof side inner rail
6. Roof side reinforcement
7. Rear lamp house inner upper panel
8. Quarter inner upper panel
9. Side body outer upper extension
10. Apron side outer member
11. Apron side member
12. Apron side member upper reinforcement
13. Suspension frame front mounting reinforcement
14. Apron side member lower reinforcement
15. Dash panel
16. Dash panel side reinforcement
17. Dash side panel
18. Front door hinge reinforcement
19. Front pillar No. 3 brace
20. Side sill strength
21. Side sill inner panel
22. Main floor panel
23. Side sill strength front reinforcement
24. Center pillar inner panel
25. Rear door hinge reinforcement
26. Rear door hinge lower reinforcement
27. Side sill rear strength
28. Rear floor compartment
29. Wheel house outer front panel
30. Wheel house inner panel
31. Quarter inner front reinforcement

Checking and Straightening Benches Instruction

AENBL80A9B01004
General Notes

I9W10P9B0256-01

• Bench and jig systems are essential for accurate and efficient repairs of deformed body structures.
• On the Bench and jig system, it will be easy to check chassis parts for dimensional accuracy, alignment,
components location and secure exact welding of new body parts.
• Universal jig systems are also available in the market.
• Celette offers a special jig kit for this model. For further information on jig kit, please contact “Celette:
www.celette.com”
• Also the use of universal computerized body measuring system is recommended in case if you do not use the jig
system.

Use of Computerized Measuring Systems

• Reference points for measuring body frame and body structure can be found in the vehicle specific measurement
data sheet from the measuring system manufacturers.
• Contact the system manufacturer for details on installations and operations.
• Always follow the operation manual of the measuring system manufacturer.
9K-20 Body Structure:

Application
The use of a computerized measuring system is recommended in following cases.
• Removals of members, frames, struts and wheel housings are required before completing the frame deformation
correction.
• Dents, creases, buckling or deformation exist on the vehicle floor panels or body frames.

Component Location
Silencer Sheet Installation Area
AENBL80A9B03001

1 2 3

1 2 4

IBL80A9B0156-01

Sheet thickness
No. Part name Thickness
1 Floor front silencer sheet 1.5 mm (0.059 in.)
2 Floor rear silencer sheet 1.5 mm (0.059 in.)
3 Rear floor silencer front sheet 3.0 mm (0.118 in.)
4 Rear floor silencer front No. 2 sheet 3.0 mm (0.118 in.)
5 Rear luggage floor sheet 3.0 mm (0.118 in.)
 Body Structure: 9K-21

Diagnostic Information and Procedures

Inspection for Body Damage
AENBL80A9B04001
Inspect the body damage in the following procedure.
Procedure Reference
1 Identification of transmission routes of impact “Transmission Routes of Impact” (Page 9K-21)
2 Measurement before repair • “Panel Clearance” (Page 9K-22)
• “Front Body Dimensions” (Page 9K-23)
• “Rear End Door Dimensions” (Page 9K-25)
• “Side Body Outside Dimensions” (Page 9K-27)
• “Side Body Inside Dimensions” (Page 9K-28)
• “Windshield Dimensions” (Page 9K-30)
• “Under Body Dimensions” (Page 9K-32)
• “Engine Room Dimensions with Mechanical Parts”
(Page 9K-34)
• “Front Under Body Dimensions with Mechanical
Parts” (Page 9K-35)
3 Repair (maintenance) Perform required work referring to “Repair Instructions”.
4 Measurement after repair • “Panel Clearance” (Page 9K-22)
• “Front Body Dimensions” (Page 9K-23)
• “Rear End Door Dimensions” (Page 9K-25)
• “Side Body Outside Dimensions” (Page 9K-27)
• “Side Body Inside Dimensions” (Page 9K-28)
• “Windshield Dimensions” (Page 9K-30)
• “Under Body Dimensions” (Page 9K-32)
• “Engine Room Dimensions with Mechanical Parts”
(Page 9K-34)
• “Front Under Body Dimensions with Mechanical
Parts” (Page 9K-35)

Transmission Routes of Impact

AENBL80A9B04002
Identify the places to which a collision impact is transmitted referring to the following figures.

Frontal Collision

IBL80A9B0157-01
9K-22 Body Structure:

Sideward Collision

IBL80A9B0158-01

Rear Collision

IBL80A9B0159-01

Panel Clearance
AENBL80A9B04003
 Body Structure: 9K-23

u
k
h p

i
m
t
c e
q s
b
n

j
a d r
o

g l
f

z
aa

w bb
v
y cc
x
dd

IBL80A9B0160-01

1.5 + 0.5, –1.0 mm (0.059 +

a: 0.5 ± 0.5 mm (0.020 ± 0.020 in.)
d: 4.3 ± 1.0 mm (0.169 ± 0.039 in.)
g: 6.0 ± 1.0 mm (0.236 ± 0.039 in.)
j: 4.3 ± 1.0 mm (0.169 ± 0.039 in.)
m: 4.5 ± 1.0 mm (0.177 ± 0.039 in.)
p: 5.2 ± 1.0 mm (0.205 ± 0.039 in.)
s: 1.5 ± 1.0 mm (0.059 ± 0.039 in.)
6.1 + 2.0, –0.0 mm (0.240 +
v:
0.079, –0.000 in.)
2.0 + 0.5, –1.0 mm (0.079 +
y:
0.020, –0.039 in.)
bb: 1.5 ± 1.0 mm (0.059 ± 0.039 in.)
b:
0.020, –0.039 in.)
e: 4.3 ± 1.0 mm (0.169 ± 0.039 in.)
h: 5.0 ± 1.0 mm (0.197 ± 0.039 in.)
k: 5.0 ± 1.0 mm (0.197 ± 0.039 in.)
n: 4.3 ± 1.0 mm (0.169 ± 0.039 in.)
q: 3.5 ± 1.0 mm (0.138 ± 0.039 in.)
t: 1.5 ± 1.0 mm (0.059 ± 0.039 in.)
w: 5.0 ± 1.0 mm (0.197 ± 0.039 in.)
z: 5.0 ± 1.0 mm (0.197 ± 0.039 in.)
cc: 5.0 ± 1.0 mm (0.197 ± 0.039 in.)
c: 5.0 ± 1.0 mm (0.197 ± 0.039 in.)
f: 1.8 ± 1.0 mm (0.071 ± 0.039 in.)
i: 4.3 ± 1.0 mm (0.169 ± 0.039 in.)
l: 6.0 ± 1.0 mm (0.236 ± 0.039 in.)
o: 4.3 ± 1.0 mm (0.169 ± 0.039 in.)
r: 0.5 ± 0.5 mm (0.020 ± 0.020 in.)
u: 7.7 ± 1.0 mm (0.303 ± 0.039 in.)
x: 2.5 ± 1.0 mm (0.098 ± 0.039 in.)
aa: 6.0 ± 1.0 mm (0.236 ± 0.039 in.)
dd: 6.5 ± 1.0 mm (0.256 ± 0.039 in.)

Front Body Dimensions

AENBL80A9B04004
9K-24 Body Structure:

NOTE
• The dimensions with “*” are distance to same point on opposite side.
• In principle, body dimensions in the figure below are symmetrical. Adopt the dimension for the
opposite side if the dimension is not mentioned in the figure below.
• The number with “ø” is circle diameter and measurement unit is “mm”.

29
160 mm (6.30 in.) 20

713
mm
(28.
07 i
n.)
18 700 mm
(27.56 in
.)
22 29
714 mm (28.11 in.)
6 in.)
(28.4 567

722
mm
723 mm
(22

mm
.32 *1400 mm
in.) 21 (55.12 in.)
n.)
(28
i
.91 )
in. .43
24 (25
m .31 in.) (49.41 in.)
16 58
m
(28 1255 mm 23 *1099 mm (43.27 in.)
6
mm
9 1177 mm (46.34 in.) 19
71
*1389 mm
426 mm 10 in.) (54.69 in.)
(16.77 in.) .60
(22

76 in.)
112 mm
6m
m 574

375 mm (14.
12 (44
.33 *760 mm
8 in. 11 (29.92 in.)
6 ) 15
35
947 mm
mm (60
(37. .43
28 in
.) in.
)

4 17 *1595 mm
13 (62.80 in.)
9
934 *850 mm
mm
(36.7 (33.46 in.) 7 *1040 mm
7 in.
) (40.94 in.)

IBL80A9B0161-01

Point Position
Front bumper upper member installation hole (lower side)
4 R Weld nut M8
(Point 5 left-right asymmetry)
↑
5 L ↑
(Point 4 left-right asymmetry)
Front bumper upper member installation hole (upper
6 R Weld nut M8
side)
7 ↑ L ↑
8 Headlight installation hole R ø 9.5 hole center (weld nut M6)
9 ↑ L ↑
10 Hood lock member installation hole R ø 11.5 hole center (weld nut M8)
11 ↑ L ↑
Engine right mounting installation hole (front side)
12 R Weld nut M10
(Point 13 left-right asymmetry)
 Body Structure: 9K-25

Point Position
Engine left mounting installation hole (front side)
13 L ø 14 hole center (weld nut M10)
(Point 12 left-right asymmetry)
16 Front fender installation hole R Weld nut M6
17 ↑ L ↑
18 Front fender installation hole R Weld nut M6
19 ↑ L ↑
20 Hood hinge installation hole (rear side) R ø 7 hole center (weld nut M6)
21 ↑ L ↑
22 Front strut installation hole R ø 53 hole center
23 ↑ L ↑
24 Engine right mounting installation hole R ø 11 hole center (weld nut M10)
29 Cowl top garnish installation hole — 10 mm hole center

Rear End Door Dimensions

AENBL80A9B04005
9K-26 Body Structure:

NOTE
• The dimensions with “*” are distance to same point on opposite side.
• In principle, body dimensions in the figure below are symmetrical. Adopt the dimension for the
opposite side if the dimension is not mentioned in the figure below.
• The number with “ø” is circle diameter and measurement unit is “mm”.

126 *630 mm (24.80 in.)

128 *1174 mm
127 (46.22 in.)

.)
.94 in
130 *1156 mm
(45.51 in.)

m (43
991 m

m
m (39

1116

129
.02 in

10
78 124 *942 mm 134 *1183 mm
mm
.)

(42 (37.09 in.) .) (46.57 in.)

.10 in
81

.44
m (21
8

in. 536 m
m

) 132 *1078 mm
m

(42.44 in.)
(3

.)
2.

in
20

50
)

131 .
6 in.
in.

23
(27.3 m

(
)

61 928 m
3 m m
695

m (36.5 m 97
m 4 in.) 5
(2
4.
842 mm 13
(33.15 in.) in
.)
138 *420 mm (16.54 in.)
135
136 *40 mm (1.57 in.)
461
m 137
(18. m
15 i
n.)

139

136
137

IBL80A9B0162-01

Point Position
124 Seat belt installation hole R ø 16 hole center
125 ↑ L ↑
126 Rear end door hinge installation hole R ø 8.2 hole center
127 ↑ L 8.2 x 10 mm hole center
128 Side body outer upper extension jig hole R ø 10 hole center
129 ↑ L ↑
130 Rear combination light installation hole R ø 7 hole center (weld nut M6)
131 ↑ L ↑
132 Rear lamp house inner lower panel jig hole R ø 10 hole center
133 ↑ L ↑
134 Rear bumper installation hole R Weld nut M6
135 ↑ L ↑
136 Rear end door striker installation hole R 14 mm hole center (weld nut M6)
 Body Structure: 9K-27

Point Position
137 ↑ L ↑
138 Rear bumper installation hole R Weld nut M6
139 ↑ L ↑

Side Body Outside Dimensions

AENBL80A9B04006
NOTE
• The dimensions with “*” are distance to same point on opposite side.
• In principle, body dimensions in the figure below are symmetrical. Adopt the dimension for the
opposite side if the dimension is not mentioned in the figure below.
• The number with “ø” is circle diameter and measurement unit is “mm”.

79
71 77
67

79 *1258 mm
.) (49.53 in.)
1 in
77 *1312 mm m (34.4 )
71 *1324 mm (51.65 in.) 874 m in.
(52.13 in.) . 48
( 42
m
101 m
67 *1284 mm 79
.) (40 8 mm 10
(50.55 in.) (32.52 in .08
826 mm in.)

10
(4 70 75 *1484 mm
2. m
13 m (58.43 in.)
in
.)
) 1031 mm (40.59 in.) 81 *1371 mm
8 in.
5.9 (53.98 in.)
(4
mm
.)
in

68
1 .) in.)
26

1 4.33 in
mm (4 15
1.

.
6 (43
(5

1 1 2
m
m

6m
m

1128 109
02

m
61 (44.41 m
13

*1474 mm in.)
(58.03 in.)
.)

mm .)
in
10

65 in
11 .87
1.

73
(5

(45 1.34 in
.)
m

mm (4 *1504 mm
m

1050
98

(59.21 in.)
12

63
*1514 mm
(59.61 in.)

IBL80A9B0163-01

Point Position
60 Front door upper hinge installation hole (front side) R ø 14 hole center (weld nut M8)
9K-28 Body Structure:

Point Position
61 ↑ L ↑
62 Front door lower hinge installation hole (upper side) R ø 14 hole center (weld nut M8)
63 ↑ L ↑
66 Side body outer panel (rear side of front-pillar) R Notch (concave upper side)
67 ↑ L ↑
70 Side body outer panel (front side of center-pillar) R Notch (concave upper side)
71 ↑ L ↑
72 Rear door lower hinge installation hole (rear side) R ø 14 hole center
73 ↑ L ↑
74 Rear door upper hinge installation hole (upper side) R ø 14 hole center
75 ↑ L ↑
76 Side body outer panel (rear side of center-pillar) R Notch (concave upper side)
77 ↑ L ↑
78 Side body outer panel (front side of quarter-pillar) R Notch (concave upper side)
79 ↑ L ↑
80 Rear door switch installation hole R ø 17 hole center
81 ↑ L ↑

Side Body Inside Dimensions

AENBL80A9B04007
 Body Structure: 9K-29

NOTE
• The dimensions with “*” are distance to same point on opposite side.
• In principle, body dimensions in the figure below are symmetrical. Adopt the dimension for the
opposite side if the dimension is not mentioned in the figure below.
• Use point 36 as datum point to check symmetry of body dimensions.
Measure distance between point 36 and each point on vehicle left side and vehicle right side for
symmetry check.
• The number with “ø” is circle diameter and measurement unit is “mm”.

103

105 *1112 mm
119 *1083 mm 111 *1088 mm
(43.78 in.)
(42.64 in.) (42.83 in.)
in.)
109 *1198 mm
113 *1241 mm (47.17 in.)
(48.86 in.)
103 *1266 mm
(49.84 in.)

1233 mm (48.54 in.)

.)
146

2.40 in
8m

115 *1326 mm
m(

mm (5
(52.20 in.)

729 mm (28.70 in.)

15

57.
65

19
80
m

22 101 *1312 mm

1331
m

in. )

.)
m 107
(6

in
m (51.65 in.)
1.

89
(7 *1350 mm )
61

5. in.

6.
16 67 (53.15 in.)

(5
in

27 23
.)

in 3.

m
mm .) (5

m
(64 m

45
.06 m

14
in. 1023 m
m 52
117 117 ) (40.28 13
4m in.)
*1432 mm m
(46
(56.38 in.) .22 97 *1373 mm
in.)
(54.06 in.)
99 *1350 mm
m (53.15 in.)
2m )
84 5 i n .
. 1
(33 in.)
8.94
m (4
3m
124
36

97

36

IBL80A9B0164-01

Point Position
36 Parking cable bracket installation hole (front side) — ø 11 hole center (weld nut M8)
96 Harness installation hole R 7 x 12 mm hole center
97 ↑ L ↑
98 Dash side trim installation hole R ø 8.5 hole center
99 ↑ L ↑
100 Steering support member installation hole (upper side) R ø 12 hole center
101 ↑ L ↑
102 Baffle plate installation hole R 7 x 12 mm hole center
103 ↑ L ↑
104 Roof side inner rail jig hole R ø 8 hole center
9K-30 Body Structure:

Point Position
105 ↑ L ↑
106 Center pillar inner panel jig hole R ø 10 hole center
107 ↑ L ↑
108 Front shoulder adjuster installation hole R Weld nut M10
109 ↑ L ↑
110 Assistant grip installation hole (rear side) R 12 mm hole center
111 ↑ L ↑
112 Rear seat belt installation hole R ø 14 hole center
113 ↑ L ↑
114 Quarter inner trim installation hole R ø 8.5 hole center
115 ↑ L ↑
116 Wheel house inner panel jig hole R ø 8 hole center
117 ↑ L ↑
118 Quarter inner trim installation hole R ø 8.5 hole center
119 ↑ L ↑

Windshield Dimensions
AENBL80A9B04008
 Body Structure: 9K-31

NOTE
• The dimensions with “*” are distance to same point on opposite side.
• In principle, body dimensions in the figure below are symmetrical. Adopt the dimension for the
opposite side if the dimension is not mentioned in the figure below.
• Use point 36 as datum point to check symmetry of body dimensions.
Measure distance between point 36 and each point on vehicle left side and vehicle right side for
symmetry check.
• The number with “ø” is circle diameter and measurement unit is “mm”.

59

58

54

59
*1115 mm
(43.90 in.)
13
in.)

87
in.)

m 55
.21

m
14

(5
.83

*1080 mm
64
(34

4.
61
(32

(42.52 in.)
m

in.
mm

)
mm

(5
7.
869

64
834

in.
)

n.)
22 i
m (56.
14 28 m 36

.)
(65.00 in
1651 m m

56

57 *1244 mm
(48.98 in.)

IBL80A9B0165-01

Point Position
36 Parking cable bracket installation hole (front side) — ø 11 hole center (weld nut M8)
54 Roof panel jig hole R ø 8 hole center
55 ↑ L ↑
56 Front fender panel installation hole R Weld nut M6
9K-32 Body Structure:

Point Position
57 ↑ L ↑
58 Roof panel R Tip part
59 ↑ L ↑

Under Body Dimensions

AENBL80A9B04009
 Body Structure: 9K-33

NOTE
• The dimensions with “*” are distance to same point on opposite side.
• In principle, body dimensions in the figure below are symmetrical. Adopt the dimension for the
opposite side if the dimension is not mentioned in the figure below.
• The number with “ø” is circle diameter and measurement unit is “mm”.

Bottom View (Straight-Line Dimensions)

2 3 *965 mm (37.99 in.)

)
in.
2 .68 in.)

14 .61
(4 32

(5
mm

38 in
7.

6
84 (4

m .)
557 mm 1 0

m
m
m
(21.93 in.) 02
2 27 *896 mm (35.28 in.)
1
22 23 *1099 mm (43.27 in.)
26
354 mm
in.) mm
(13.94 920 in.)
6 . 2 2
30 (3 m 31 *805 mm (31.69 in.)
5 8 m in.)
0
1 .6 5
334 mm 1
(4 in.)
(13.15 in.) 66
( 33.
mm
855
32 33 *770 mm (30.31 in.)

n.)
485 mm .8 3i
(35 )
in.
(19.09 in.)
m
40

0m
7.

91
(4
m
m
04

34 35 *770 mm (30.31 in.)

46
12

44 n. )
.9 2i
(34 440 mm
7 mm
88 (17.32 in.)

41 *770 mm (30.31 in.)

40
(3 8.82 in.) 261 mm (10.28 in.)
986 mm
42
43 *1174 mm (46.22 in.)
745 m

127
4m
m (29

16 m(
30 50.
16
1166 mm (45.91 in.)

567 mm m in.)
19

.33 in

m
12

(22.32 in.) (6
1182 mm (46.54 in.)

4.
mm

17
.)

in
.)
(7
5.2

45 *1108 mm (43.62 in.)

44
8i
1589 mm (62.56 in.)

46 47 *1265 mm (49.80 in.)

n.)

621 mm
in.) (24.45 in
94 .)
( 50. in.
)
m
4m .01
48 129 (47
mm 49 *1105 mm (43.50 in.)
94
50 11
51 *940 mm (37.01 in.)

104 420 mm
m 1m (16.54 in.)
m n.) m(
5 i 40.
5 8 98
4
1 7. 2 in. )
(5
966 mm (38.03 in.)
52 53

IBL80A9B0166-01
9K-34 Body Structure:

Side View (Projection Dimensions)

22
23
48
49

26 50
27 52
51
53
2 44
42
3 30 32 34 40 45
43
31 33 35 41 602 mm 292 mm
301 mm (23.70 in.) (11.50 in.)
(11.85 in.) 117 mm 52 : 255 mm
159 mm 766 mm 79 mm (4.61 in.) (10.04 in.)
55 mm 61 mm 150 mm
(6.26 in.) (30.16 in.) (3.11 in.) (2.17 in.) (2.40 in.) (5.91 in.) 53 : 244 mm
61 mm (9.61 in.)
(2.40 in.)

[A]

12 mm 272 mm 333 mm 485 mm 440 mm 565 mm 598 mm 417 mm

(0.47 in.) (10.71 in.) (13.11 in.) (19.09 in.) (17.32 in.) (22.24 in.) (23.54 in.) (16.42 in.)
538 mm (21.18 in.) 155 mm 1015 mm (39.96 in.)
(6.10 in.)

810 mm (31.89 in.) 1580 mm (62.20 in.)

IBL80A9B0167-01

Point Position
2 Front lower cross member installation hole R ø 12 hole center (weld nut M8)
3 ↑ L ↑
22 Front strut installation hole R ø 53 hole center
23 ↑ L ↑
26 Suspension frame installation hole (front side) R ø 18 hole center (weld nut M14)
27 ↑ L ↑
30 Suspension frame installation hole (rear side) R ø 18 hole center (weld nut M14)
31 ↑