2015 AT SHVS Ertiga-V3-V3

00
TABLE OF CONTENTS
NOTE
For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same 0
sections of the service manual mentioned in the “FOREWORD” of this manual.
Volume 1 HVAC System ........................................................7B-1

Restraint...................................................................... 8-i 1
Precautions ...............................................................8-*
Precautions............................................................... 00-i
Seat Belts...............................................................8A-1
Precautions ............................................................ 00-1 Air Bag System ......................................................8B-1
General Information ................................................... 0-i Body, Cab and Accessories ...................................... 9-i 2
General Information ............................................... 0A-1 Precautions ...............................................................9-*
Maintenance and Lubrication ................................. 0B-1 Wiring Systems ......................................................9A-1
Engine ......................................................................... 1-i Lighting Systems....................................................9B-1
Precautions ............................................................... 1-* Instrumentation / Driver Info. / Horn .......................9C-1 3
Engine General Information and Diagnosis ........... 1A-1 Wipers / Washers ................................................... 9D-*
Aux. Emission Control Devices .............................. 1B-1 Glass / Windows / Mirrors ......................................9E-1
Engine Electrical Devices.......................................1C-1 Security and Locks................................................. 9F-1
Engine Mechanical.................................................1D-1 Seats ..................................................................... 9G-1
Engine Lubrication System .................................... 1E-1 Exterior Trim / Interior Trim ....................................9H-1 4
Engine Cooling System.......................................... 1F-1 Hood / Fenders / Doors.......................................... 9J-1
Fuel System ...........................................................1G-1 Body Structure .......................................................9K-1
Ignition System.......................................................1H-1 Paint / Coatings .......................................................9L-*
Starting System....................................................... 1I-1 Audio Visual / Navigation ...................................... 9O-1
5
Charging System.....................................................1J-1 Control Systems....................................................... 10-i
Exhaust System ..................................................... 1K-1 Precautions ............................................................ 10-1
Suspension................................................................. 2-i Body Electrical Control System ............................10B-1
Precautions ............................................................... 2-* Immobilizer Control System .................................10C-1
Suspension General Diagnosis...............................2A-* Keyless Start System ...........................................10E-1 6
Front Suspension ....................................................2B-* Communication System .......................................10H-1
Rear Suspension.................................................... 2C-* Engine Auto Stop Start System............................. 10I-1
Wheels and Tires ...................................................2D-1 Electric Power Train................................................. 11-i
Driveline / Axle ........................................................... 3-i Precautions ............................................................ 11-1 7
Precautions ............................................................... 3-* Hybrid / EV Controls.............................................11A-1
Drive Shaft / Axle ................................................... 3A-1
Brakes ......................................................................... 4-i
Precautions .............................................................. 4-1 8
Brake Control System and Diagnosis .................... 4A-1
Front Brakes............................................................4B-*
Rear Brakes ........................................................... 4C-*
Parking Brake......................................................... 4D-*
9
ABS ........................................................................ 4E-1
Transmission / Transaxle .......................................... 5-i
Precautions ............................................................... 5-*
Automatic Transmission/Transaxle ........................ 5A-1
Manual Transmission/Transaxle ............................ 5B-1 10
Clutch .....................................................................5C-1
Steering....................................................................... 6-i
Precautions .............................................................. 6-1
Steering General Diagnosis ....................................6A-* 11
Steering Wheel and Column .................................. 6B-1
Power Assisted Steering System ...........................6C-1
HVAC ........................................................................... 7-i
Precautions ............................................................... 7-*
Table of Contents 00- i
Section 00
00
Precautions
CONTENTS
NOTE
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual
mentioned in the “FOREWORD” of this manual.
Precautions ...............................................00-1 Wheel and Brake Caution ....................................00-*

Precautions........................................................... 00-1 Air Bag Warning ...................................................00-*
Precautions for ENG A-STOP System................ 00-1 Precautions for Vehicles Equipped with
General Precautions ........................................... 00-1 Supplemental Restraint (Air Bag) System..........00-*
Precautions for CNG Vehicles ............................ 00-3 Precautions for CAN Communication System .....00-*
CNG Warning...................................................... 00-3 Precautions for Installing Mobile
Precautions for Electrical Circuit Service ............. 00-* Communication Equipment ................................00-*
Fastener Caution ................................................. 00-* Repair Instructions ...............................................00-*
Precautions for Catalytic Converter (Petrol Electrical Circuit Inspection Procedure ................00-*
Engine Model) .................................................... 00-* Intermittent Connection and Poor Contact
Precautions for Catalytic Converter (Diesel Inspection...........................................................00-*
Engine Model) .................................................... 00-* Special Tools and Equipment ............................. 00-4
Suspension Caution ............................................. 00-* Recommended Service Material ......................... 00-4
Warning for Wheel (with Tire) Removal ............... 00-* Special Tool ........................................................ 00-4
00-1 Precautions:
Precautions
Precautions
Precautions
Precautions for ENG A-STOP System Continuous contact with used engine oil
AENFL80B0000013 has been found to cause skin cancer in
! WARNING laboratory animals. Brief contact with used
oil may irritate skin. To minimize your
There is a risk of personal injury due to
exposure to used engine oil, wear a long-
accidental starting of the engine if service
sleeve shirt and moisture-proof gloves
work is performed while the ENG A-STOP
(such as dish washing gloves) when
OFF switch turns off, i.e. the ENG A-STOP
changing engine oil. If engine oil contacts
warning light does not light.
your skin, wash thoroughly with soap and
Turn on the ENG A-STOP OFF switch and
water. Launder any clothing or rags if wet
check that the ENG A-STOP warning light
with oil. Recycle or properly dispose of
lights before the service work, except when
used oil and filters.
the service manual instructs to turn it off.
– Whenever handling any of these service
materials, wear safety glasses to protect
General Precautions your eyes. If such a material gets into
AENFL80B0000001 your eye, it may cause inflammation.
The WARNING and CAUTION describe some general
precautions that you should observe when servicing a – Whenever handling any of these service
vehicle. These general precautions apply to many of the materials, wear moisture-proof gloves to
service procedures, but they will not necessarily be protect your skin. If it adheres to your
repeated for every procedure to which they apply. skin, it may cause inflammation.
– Do not swallow any of these service
! WARNING materials. It would cause diarrhea or
nausea.
• Whenever raising a vehicle for service, be
– Keep all these materials out of reach of
sure to follow the instructions under
children.
“Vehicle Lifting Points” in Section 0A in
related manual. • Make sure the hood is fully closed and
latched before driving. Unlatched hood
• When it is necessary to do service work
can fly up unexpectedly during driving,
with the engine running, make sure that
obstruct your view and result in an
the parking brake is fully set, drive wheels
accident.
blocked and the transaxle is in “Neutral” or
“P” range. Keep hands, hair, clothing,
• Before starting any service work, cover fenders, seats
tools, etc. away from the fan and belts
and any other parts that are likely to get scratched or
when the engine is running.
stained during servicing. Also, be aware that what you
• When it is necessary to run the engine wear (e.g. buttons) may cause damage to the
indoors, make sure that the exhaust gas is vehicle’s finish.
forcedly emitted.
• 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.
• Engine oil can be hazardous. Children and I2RH01010025-01
pets may be harmed by swallowing new or • When performing service to electrical parts that does
used oil. Keep new and used oil and used not require use of battery power, disconnect negative
engine oil filters away from children and (–) cable at battery.
pets.
Precautions: 00-2
• 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 I2RH01010029-01
Throttle Control System Calibration”: Petrol and Bi- • Make sure that all parts used for reassembly are
Fuel CNG in Section 1C in related manual after thoroughly clean.
reconnecting the negative (–) cable at the battery. When the use of a certain type of lubricant, adhesive
• When removing the battery, be sure to disconnect the or sealant is specified, be sure to use only the
negative (–) cable first and then the positive (+) cable. specified material.
When reconnecting the battery, connect the positive
(+) cable first and then the negative (–) cable. “A”: Water tight sealant 99000–31250 (SUZUKI
Reinstall the terminal cover. Bond No. 1207F)
I2RH01010027-01 I2RH01010030-01
• When removing parts that are to be reused, be sure to • Be sure to use special tools when instructed.
keep them arranged in an orderly manner so that they
can be reinstalled in the proper order and into the Special tool
correct positions. (A): 09917M98221
(B): 09916M58210
I5RW0A000002-01
• Do not reuse oil seals, gaskets, packing, O-rings, lock

washers, split pins, self-locking nuts, and other I2RH01010031-01
specified parts, but use new ones. Also, before • After servicing any system that is concerned with fuel,
installing new gaskets, packing, etc., be sure to oil, coolant, vacuum, exhaust gases or brakes, check
remove any residual material from the mating all related lines for leaks.
surfaces.
00-3 Precautions:
Precautions for CNG Vehicles

AENFL80B0000014
CNG Feature
• CNG is fossil fuel that consists primarily of methane
with a small quantity of ethane and other gaseous
paraffinic hydrocarbons. CNG itself is combustible,
odorless, colorless, invisible and tasteless gas, but
added odorant by its manufacturer in order to detect
gas leakage easily.
• When CNG leaks, CNG dissipates into atmosphere.
Because CNG is lighter than air.
I2RH01010033-01
• Never disconnect any of the fuel lines between fuel Condition of Workshop
pump and injectors without first releasing the fuel • There should be no leaks in the fuel system, referring
pressure, or fuel can be sprayed out under pressure. to “Fuel Leakage Check Procedure”: Bi-Fuel CNG in
• When performing any work that produces a heat Section 1G in related manual.
exceeding 80 °C (176 °F) in the vicinity of the • There should be enough ventilation system.
electrical parts, remove the heat-sensitive electrical • Vehicles should not be parked within 3 m of any
part(s) beforehand. sources of ignition.
• CNG fueled vehicles being repaired in workshops,
unless the fuel is required for engine operation,
should have the manual shut off valve closed and the
CNG in the service line exhausted by running the
engine or depressurizing the line in a well ventilated
area.
• Vehicles undergoing repairs involving welding or the
application of heat, to any part within 1 m of the CNG
cylinder, should have the CNG cylinder removed or
I2RH01010034-01
shielded from the source of heat.
• Do not expose connectors and electrical parts to
Servicing and Handling
water, which will cause trouble to electrical systems.
• Make sure to stop engine when inspecting engine
system.
• Repair operation involving heat should be carried out
with due regard to fire safety.
• Damaged CNG pipes or hoses should not be
repaired; in all cases they should be replaced.
• Welding, brazing and the application of heat should
not be carried out on any part of the CNG cylinder
subsequent to manufacture.
• Make sure to relieve CNG pressure before removing
CNG pipes or hoses. Check for fuel leakage after
I2RH01010035-01 installing them.
• Always be careful not to handle electrical components • The CNG cylinder, piping and all components of the
(computers, relays, etc.) in a rough manner or drop system should be examined for corrosion,
them. deterioration and for any modification affecting
compliance, at least once in a year or in case of
malfunction or accident.
• A vehicle, which is about to be scrapped, should have
its CNG cylinder removed prior to disposal.
• The CNG cylinder, which passed more than 20 years
from its production, should not be used.
CNG Warning
AENFL80B0000015
I2RH01010036-01
Precautions: 00-4
! WARNING
• Make sure to relieve CNG pressure

referring to “Fuel Pressure Relief
Procedure”: Bi-Fuel CNG in Section 1G in
related manual, before removing line parts.
Otherwise, the part can pop out suddenly
from CNG line and personal injury can
result.
• CNG is combustible and can cause fire.
Take special precaution when handling
CNG referring to “Precautions for CNG
Vehicles” (Page 00-3).
Special Tools and Equipment

Recommended Service Material
AENFL80B0008001
Material SUZUKI recommended product or Specification Note
Water tight sealant SUZUKI Bond No. 1207F P/No.: 99000–31250 (Page 00-2)
Special Tool
AENFL80B0008002
09916M58210 09917M98221
Valve guide installer handle Valve guide stem
attachment
(Page 00-2) (Page 00-2)
00-5 Precautions:
Section 0
General Information
0
CONTENTS
NOTE
General Information ................................ 0A-1 CNG Fuel Filter Replacement ............................. 0B-*
General Description .............................................0A-1 Receptacle O-Ring Replacement........................ 0B-*
Abbreviations .......................................................0A-* CNG Cylinder Inspection..................................... 0B-*
ISO-to-SUZUKI Term ...........................................0A-* Air Cleaner Filter Inspection................................ 0B-*
Symbols ...............................................................0A-* Air Cleaner Filter Replacement ........................... 0B-*
Wire Color Symbols .............................................0A-* Fuel Tank, Cap Gasket and Fuel Lines
Ignition Modes and Ignition Switch Positions ...... 0A-1 Inspection.......................................................... 0B-*
Fasteners Information ..........................................0A-* Fuel Filter Replacement ...................................... 0B-*
Vehicle Lifting Points............................................0A-* Water Draining of Fuel Filter (Diesel Engine
Vehicle Identification Number ..............................0A-* Model) ............................................................... 0B-*
Engine Identification Number ...............................0A-* Clutch Pedal Inspection ...................................... 0B-*
Component Location ........................................... 0A-* Clutch Fluid Inspection........................................ 0B-*
Warning, Caution and Information Label Manual Transaxle Oil Inspection......................... 0B-*
Location .............................................................0A-* Manual Transaxle Oil Replacement .................... 0B-*
ATF Level Inspection (A/T Model).......................0B-3
Maintenance and Lubrication................. 0B-1 ATF Replacement (A/T Model) ...........................0B-3
ATF Cooler Hose Inspection (A/T Model) ...........0B-3
Scheduled Maintenance ......................................0B-1
Drive Shaft (Axle) Boot Inspection ...................... 0B-*
Maintenance Schedule under Normal Driving
Brake Disc and Pad Inspection ........................... 0B-*
Conditions ......................................................... 0B-1
Brake Drum and Shoe Inspection ....................... 0B-*
Repair Instructions ..............................................0B-3
Brake Hose and Pipe Inspection......................... 0B-*
Accessory Drive Belt Inspection.......................... 0B-3
Brake Fluid Replacement.................................... 0B-*
Accessory Drive Belt Replacement..................... 0B-3
Brake Lever and Cable Inspection ...................... 0B-*
Valve Lash (Clearance) Inspection (Petrol
Tire Inspection..................................................... 0B-*
Engine Model) ....................................................0B-*
Wheel Disc Inspection......................................... 0B-*
Engine Oil and Filter Change ...............................0B-*
Wheel Bearing Inspection ................................... 0B-*
Engine Coolant Change .......................................0B-*
Suspension System Inspection ........................... 0B-*
Exhaust System Inspection..................................0B-*
Steering System Inspection ................................ 0B-*
PCV Valve Inspection (Petrol Engine Model).......0B-*
All Latches, Hinges and Locks Inspection........... 0B-*
Fuel Evaporative Emission Control System
Final Inspection for Maintenance Service ...........0B-3
Inspection (Petrol Engine Model) .......................0B-*
Special Tools and Equipment ............................. 0B-*
Spark Plug Replacement (Petrol Engine
Recommended Fluids and Lubricants................. 0B-*
Model) ................................................................0B-*
CNG Leakage Inspection .....................................0B-*
0A-1 General Information:
General Information
General Information
General Description
Ignition Modes and Ignition Switch Positions

AENFL80B0101005
In this manual, each ignition switch position (models with a conventional ignition switch system) and the corresponding
ignition mode (models with a keyless push start system) are indicated using the following unified word / acronym
preceded by “ignition”: START, ON, ACC or OFF (e.g. “ignition ON”) unless there is need to express it otherwise.
Maintenance and Lubrication: 0B-1
Maintenance and Lubrication

General Information
Scheduled Maintenance
Maintenance Schedule under Normal Driving Conditions
AENFL80B0205001
NOTE
• This interval should be judged by odometer reading or months, whichever comes first.
• This table includes service as scheduled up to 80,000 km. Beyond 80,000 km, 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
Petrol and Bi-
Water pump drive belt (tension, — — I I I I I I I R
Fuel CNG
wear) (I: (Page 0B-3), R:
Diesel
(Page 0B-3)) — — I I I I I R I I
(with ISG)
ISG drive belt (Diesel with ISG) (I: (Page 0B-3),
— — I I R I I R I I
R: (Page 0B-3))
Engine coolant (level, leakage)
I I I R I R I R I R
(R: )
Engine oil, oil filter and drain plug gasket (R: ) — — R R R R R R R R
Cooling system hoses and connections (leakage,
I I I I I I I I I I
damage)
Engine cylinder head bolts (Petrol and Bi-Fuel
— T — T — T — T — T
CNG)
Engine mounting and manifold fixing (loose,
— I — I — I — I — I
damage)
Valve lash (clearance) (Petrol and Bi-Fuel CNG)
— — — — I — — I — —
(I: )
Exhaust system (noise, leakage, otherwise
— I — I — I — I — I
defective) (I: )
PCV valve (Petrol and Bi-Fuel CNG) (hoses,
— I — I — I — I — I
connections and valve) (I: )
EGR valve (Diesel) — — — — C — — C — —
Ignition system
Ignition wiring (Petrol and Bi-Fuel CNG) (damage,
— — — I — I — I — I
deterioration)
Spark plugs (Petrol) (R: ) — — — — — R — — — R
Spark plugs (Bi-Fuel CNG) (clean and adjust gap) — — I R I R I R I R
Fuel system
Paved road Clean after every 5,000 km. Replace after every 40,000 km.
Air cleaner filter (Petrol and Bi-
Dusty Clean after every 2,500 km or as required. Replace after every
Fuel CNG) (R: , I: )
condition 40,000 km.
Paved road Replace after every 20,000 km. Cleaning not required.
Air cleaner filter (Diesel) (R: , I:
Dusty Replace after every 20,000 km. Cleaning not required. More
)
condition frequent replacement if dust condition is severe.
Fuel tank cap, fuel lines and connections
— I — — — I — — — I
(leakage, damage) (I: )
All joints (CNG leakage)  I I I I I I I I I I
All CNG fasteners T T T T T T T T T T
CNG low pressure filter cartridge with O-ring  — — — R — R — R — R
Fuel filter (Petrol and Bi-Fuel CNG) (leakage) (R:
— — — — — R — — — R

Fuel filter and water draining (Diesel) (R: ,
I I I R I R I R I R
Drain: )
Every 3 years from the date of initial testing by government
CNG cylinder leak testing and certification 
approved testing agency.
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
CNG filler receptacle O-ring  Replace every 4 years or 300,000 km whichever comes first.
Clutch and Transmission
Clutch fluid (level, leakage) (I: ) 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
Manual transaxle oil (level, leakage) (I: , R: ) Replace every 1,60,000 km or 10 years whichever comes first.
Automatic transaxle fluid (level, leakage) (I: , R:
Replace every 1,65,000 km or 11 years whichever comes first.
)
Hose, automatic transaxle fluid (I: (Page 0B-3)) I I I I I I I I I I
Drive Shaft
Drive shaft boots (damage) (I: ) — I I I I I I I I I
Drive shaft (Noise) I I I I I I I I I I
Brake
Brake fluid (level, leakage) (R: ) 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
Parking brake lever and cable (damage, play) (I:
I I I I I I I I I I
)
Brake discs and pads (wear) (I: ) — I I I I I I I I I
Brake drums and shoes (wear) (I: ) — — I I I I I I I I
Brake hoses and pipes (leakage, damage, clamp)
I I I I I I I I I I
(I: )
Master cylinder, wheel cylinder and caliper piston
(fluid leakage, boot/seal damage) (Replace piston I I I I I I I I I I
and boot kits)
Wheel
Tire (air pressure, abnormal wear, crack and
I I&O I&O I&O I&O I&O I&O I&O I&O I&O
rotation) (I: )
Wheels (damage) (I: ) I I I I I I I I I I
Front / rear wheel bearings (loose, damage) (I: ) I I I I I I I I I I
Suspension
Suspension strut (oil leakage, damage) (I: ) I I I I I I I I I I
Suspension arms and knuckle supports (loose,
— I I I I I I I I I
damage) (I: )
Rear spring (damage) (I: ) I I I I I I I I I I
Shock absorbers (oil leakage, damage) (I: ) I I I I I I I I I I
All bolts and nuts (loose) (I: ) — T T T T T T T T T
Suspension arms and torsion rods (I: ) — I I I I I I I I I
Steering
Steering wheel (play, loose) (I: ) 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 (loose, 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 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
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
Tighten compressor mounting bolts — T T T T T T T T T
Air conditioner filter element I I I I R I I R I I
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
Maintenance and Lubrication: 0B-3
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
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
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 ATF Replacement (A/T Model)
AENFL80B0206001 AENFL80B0206033
! WARNING Replace ATF with new specified fluid. (Page 5A-104)
Check that ENGINE IS NOT RUNNING before ATF Cooler Hose Inspection (A/T Model)
performing the service work described AENFL80B0206034
below. Check ATF cooler hose for fluid leakage, crack, damage
and deterioration. Replace hose and/or clamp if any
Inspect belt for cracks, cuts, deformation, wear and defect is found. (Page 5A-123)
contamination. If any defect is found, replace belt.
Check belt for tension. Final Inspection for Maintenance Service
AENFL80B0206031
• Petrol engine model:
! WARNING
– Water pump / generator drive belt: 
– Compressor drive belt for single A/C model: When carrying out road tests, select a safe
(Page 7B-17) place without people and running vehicles to
prevent any accident.
– Compressor drive belt for dual A/C model: 
• Diesel engine model (with ISG): Seats
– Water pump drive belt: (Page 1F-10) Check that each front seat slides smoothly and locks
– ISG drive belt: (Page 1J-25) securely at any position. Also check that reclining
• Diesel engine model (without ISG):  mechanism of each front seat allows the seatback to be
locked at any angle.
Accessory Drive Belt Replacement Seat Belts
AENFL80B0206002
Replace accessory drive belt with new one. Inspect seat belt systems including webbing, buckles,
• Petrol engine model: latch plates, retractors and anchors for damage or wear.
Check that each seat belt locks securely. If “REPLACE
– Water pump / generator drive belt:  BELT” label on seat belt is visible, replace belt.
– Compressor drive belt for single A/C model:
(Page 7B-18) Battery Electrolyte Level Check
– Compressor drive belt for dual A/C model:  • If battery is equipped with electrolyte level checks
• Diesel engine model (with ISG): lines on the case, check that the electrolyte level of all
– Water pump drive belt: (Page 1F-10) battery cells is between the upper and lower level
lines.
– ISG drive belt: (Page 1J-25)
• If battery is equipped with built-in indicator, check
• Diesel engine model (without ISG): 
battery condition by the indicator.
• If battery is not equipped with check lines and built-in
ATF Level Inspection (A/T Model)
AENFL80B0206032 indicator, it is not necessary to perform electrolyte
Check ATF for leakage, contamination and level. level check.
(Page 5A-103)
0B-4 Maintenance and Lubrication:
Accelerator Pedal Operation • Brake pedal has proper travel.

Check that accelerator pedal operates smoothly without • Brakes work properly.
getting caught by or interfering any other part.
• Brakes do not generate abnormal noise.
Engine Start • Vehicle does not pull to one side when brakes are
Check the engine starts readily. applied.
• Brakes do not drag.
! WARNING
Parking brake
Be sure to observe the following precautions
Check that lever stroke is proper.
to prevent personal injuries and property
damages in the event of accidental ! WARNING
movements of vehicle.
• Provide enough spaces around the Observe the following precautions when
vehicle. performing parking brake test on a slope.
• Firmly apply both the parking brake and • Make sure that no person and obstruction
foot brakes. is in the way ahead.
• Do not use the accelerator pedal. • Be prepared to apply foot brakes quickly in
case of a vehicle movement.
• Set ignition “OFF” immediately when
engine starts.
Check that parking brake is fully effective when the
vehicle is stopped on a slope by pulling parking brake
For A/T model, try to start the engine in each select lever
lever all the way.
position. The starting motor should crank only in P or N
range.
Steering
For keyless push start model, place the gear shift lever
in “Neutral”, depress clutch pedal halfway and try to • Check that steering wheel is not instable and has no
start. Starting motor should crank only when clutch pedal abnormally large resistance to turn.
is fully depressed. • Check that vehicle does not wander or pull to one
side.
Exhaust System Check
Check for leakage, cracks or loose supports. Engine
• Check that speed changes responsively to
Clutch (Manual Transaxle Model) accelerator positions.
Check for the following: • Check that engine is free from abnormal noise and
• Clutch is completely released when clutch pedal is abnormal vibration.
depressed.
• No slipping clutch occurs when releasing pedal and Body, Wheels and Power Train Components
accelerating. Check that body, wheels and power train components
• Clutch itself is free from any abnormal conditions. are free from any abnormal conditions such as abnormal
noise and vibration.
Gear Shift or Select Lever
Check gear shift or select lever for smooth movement to Meters and Gauges
all positions and for good and correct response of Check that speedometer, odometer, fuel gauge,
transaxle in any position. temperature gauge, etc. operate accurately.
For A/T model, also check that the shift indicator
indicates position correctly according to select lever Lights
position. Check that all lights operate properly.
For A/T model, also check that vehicle is at complete
stop when select lever is placed P range and all brakes Windshield Defroster
are released. Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Brakes Set mode control lever to defroster position and fan
Foot brakes switch lever to highest position for this check.
Check the following:
Section 1
Engine
CONTENTS
NOTE
1
Precautions ................................................. 1-* MIL Does Not Come ON with Ignition “ON”
Precautions.............................................................. 1-* and Engine Stopped (but Engine Can Be
Precautions for Engine (K14B) .............................. 1-* Started) ............................................................. 1A-*
Precautions for Engine (D13A) .............................. 1-* MIL Remains ON after Engine Starts.................. 1A-*
DTC P0010 / P2088 / P2089.............................1A-32
Engine General Information and DTC P0011 .......................................................1A-33
Diagnosis ................................................. 1A-1 DTC P0030 / P0031 / P0032.............................1A-35
DTC P0036 / P0037 / P0038.............................1A-37
Petrol ........................................................................1A-1
DTC P0107 / P0108 ..........................................1A-39
General Description .............................................1A-1
DTC P0112 / P0113 ..........................................1A-40
Statement on Cleanliness and Care ....................1A-*
DTC P0116 .......................................................1A-42
Engine Diagnosis General Description ................1A-*
DTC P0117 / P0118 ..........................................1A-43
OBD System Description .................................... 1A-1
DTC P0122 / P0123 ..........................................1A-44
DLC Description .................................................. 1A-3
DTC P0130 .......................................................1A-46
Engine and Emission Control System
DTC P0131 / P0132 ..........................................1A-48
Description .........................................................1A-*
DTC P0133 .......................................................1A-50
Air Intake System Description ..............................1A-*
DTC P0134 .......................................................1A-52
Description of Electric Throttle Control
DTC P0137 / P0138 / P0140.............................1A-54
System Calibration .............................................1A-*
DTC P0171 / P0172 ..........................................1A-56
Electric Throttle Control System Description........1A-*
DTC P0222 / P0223 ..........................................1A-59
Generator Control System Description ............... 1A-4
DTC P0300 / P0301 / P0302 / P0303 / P0304 ..1A-60
Electronic Control System Description................ 1A-5
DTC P0327 / P0328 ..........................................1A-63
Engine and Emission Control Input / Output
DTC P0335 / P0336 ..........................................1A-64
Table ................................................................. 1A-6
DTC P0340 .......................................................1A-66
Schematic and Routing Diagram......................1A-10 DTC P0351 / P0352 / P0353 / P0354 / P2300
Engine and Emission Control System / P2301 / P2303 / P2304 / P2306 / P2307 /
Diagram .......................................................... 1A-10 P2309 / P2310 ................................................1A-68
Engine and Emission Control System Flow DTC P0420 .......................................................1A-70
Diagram .......................................................... 1A-12 DTC P0443 / P0458 / P0459.............................1A-73
Electronic Control System Circuit Diagram ....... 1A-13 DTC P0480 / P0692 ..........................................1A-74
Component Location .........................................1A-15 DTC P0481 / P0694 ..........................................1A-77
Electronic Control System Component DTC P0500 .......................................................1A-78
Location .......................................................... 1A-15 DTC P0515 .......................................................1A-81
Diagnostic Information and Procedures..........1A-16 DTC P0530 .......................................................1A-83
Engine and Emission Control System Check.......1A-* DTC P0557 / P0558 ..........................................1A-84
MIL Check ......................................................... 1A-16 DTC P0560 / P0562 / P0563.............................1A-86
DTC Check ....................................................... 1A-16 DTC P0602 .......................................................1A-87
DTC Clearance ................................................. 1A-16 DTC P0606 .......................................................1A-88
DTC Table......................................................... 1A-17 DTC P0607 .......................................................1A-89
Fail-Safe Table.................................................. 1A-22 DTC P0645 / P0646 / P0647.............................1A-89
Scan Tool Data ................................................. 1A-26 DTC P0A5A.......................................................1A-91
Visual Inspection ............................................... 1A-31 DTC P2100 .......................................................1A-93
Engine Basic Inspection.......................................1A-* DTC P2101 / P2119 ..........................................1A-95
Engine Symptom Diagnosis .................................1A-* DTC P2122 / P2123 ..........................................1A-96
DTC P2127 / P2128 ..........................................1A-99
1-ii Table of Contents
DTC P2135 ..................................................... 1A-100 Engine Symptom Diagnosis ................................ 1A-*

DTC P2138 ..................................................... 1A-102 MIL Does Not Come ON with Ignition Switch
DTC P2176 ..................................................... 1A-103 in ON Position and Engine Stopped (but
DTC P2228 / P2229 ........................................ 1A-104 Engine Can Be Started) .................................... 1A-*
DTC U0073 ..................................................... 1A-105 MIL Remains ON after Engine Starts.................. 1A-*
DTC U0101 ..................................................... 1A-105 CNG Warning Light Does Not Come ON with
DTC U0121 ..................................................... 1A-105 Ignition Switch in ON Position and Engine
DTC U0131 ..................................................... 1A-105 Stopped.........................................................1A-147
DTC U0140 ..................................................... 1A-105 CNG Warning Light Remains ON after Engine
DTC U0141 ..................................................... 1A-105 Starts................................................................. 1A-*
DTC U0155 ..................................................... 1A-105 DTC P0601 / P0602 ............................................ 1A-*
DTC U2001 ..................................................... 1A-105 DTC U0073 ......................................................... 1A-*
DTC U2021 ..................................................... 1A-107 DTC U0108 ......................................................... 1A-*
Inspection of ECM and Its Circuits .................. 1A-107 DTC U0131 ......................................................... 1A-*
ECM Power Supply and Ground Circuit DTC U0140 ......................................................... 1A-*
Check ............................................................ 1A-118 DTC P0005 / P0007 ........................................1A-149
Fuel Cut Operation Inspection ........................ 1A-121 DTC P0182 / P0183 ............................................ 1A-*
Repair Instructions ..........................................1A-121 DTC P0192 / P0193 ............................................ 1A-*
Idle Speed and IAC Throttle Valve Opening DTC P0201 / P0202 / P0203 / P0204 .............1A-152
Inspection...................................................... 1A-121 DTC P062F ......................................................... 1A-*
Special Tools and Equipment .........................1A-122 DTC P0607 ......................................................... 1A-*
Special Tool .................................................... 1A-122 DTC P0612 ......................................................... 1A-*
Bi-Fuel CNG .........................................................1A-123 DTC P1432 / P1433 ............................................ 1A-*
DTC P1601 ......................................................... 1A-*
Precautions........................................................... 1A-*
DTC P2408 ......................................................... 1A-*
Precautions for Engine Service........................... 1A-*
DTC P2665 / P2667 ............................................ 1A-*
Precautions for Diagnosing Trouble.................... 1A-*
DTC P2668 ......................................................... 1A-*
Precaution for CNG Control Module Circuit
DTC U0100 ......................................................... 1A-*
Inspection.......................................................... 1A-*
Inspection of ECM and Its Circuit....................1A-155
General Description .........................................1A-123
Inspection of CNG Control Module and Its
Statement of Cleanliness and Care .................... 1A-*
Circuit ............................................................1A-165
Engine Diagnosis General Description ............... 1A-*
ECM Power and Ground Circuit Check............... 1A-*
OBD System Description ................................ 1A-123
CNG Control Module Power and Ground
DLC Description .................................................. 1A-*
Circuit Check.................................................1A-172
Engine and Emission Control System
Repair Instructions ..........................................1A-174
Description ........................................................ 1A-*
Idle Speed and IAC Throttle Valve Opening
Bi-Fuel CNG System Description........................ 1A-*
Inspection......................................................1A-174
Air Intake System Description ............................. 1A-*
Electronic Control System Description................ 1A-* Special Tools and Equipment .........................1A-174
Engine and Emission Control Input / Output Special Tool ....................................................1A-174
Table ............................................................. 1A-125 Diesel....................................................................1A-175
Schematic and Routing Diagram....................1A-128 General Description .........................................1A-175
Engine and Emission Control System Flow Statement on Cleanliness and Care ................... 1A-*
Diagram ........................................................ 1A-128 Engine Diagnosis General Description ............... 1A-*
Engine Control System Circuit Diagram.......... 1A-130 OBD System Description ................................1A-175
Component Location ........................................... 1A-* DLC Description ..............................................1A-176
Electronic Control System Component Schematic and Routing Diagram ....................1A-178
Location ............................................................ 1A-* Electronic Control System Diagram .................... 1A-*
Diagnostic Information and Procedures........1A-133 Electronic Control System Circuit Diagram .....1A-178
Engine and Emission Control System Check...... 1A-* Component Location .......................................1A-180
MIL Check ........................................................... 1A-* Electronic Control System Component
CNG Warning Light Check.............................. 1A-133 Location.........................................................1A-180
DTC Check...................................................... 1A-133 Diagnostic Information and Procedures ........1A-181
DTC Clearance ................................................... 1A-* Engine and Emission Control System Check...... 1A-*
DTC Table....................................................... 1A-134 MIL Check .......................................................1A-181
Fail-Safe Table.................................................... 1A-* DTC Check......................................................1A-181
Scan Tool Data (ECM) .................................... 1A-142 DTC Clearance ...............................................1A-182
Scan Tool Data (CNG Control Module)............... 1A-* DTC Table.......................................................1A-182
Visual Inspection ................................................. 1A-* Fail-Safe Table................................................1A-190
Engine Basic Inspection...................................... 1A-* Scan Tool Data ...............................................1A-198
Table of Contents 1-iii
Visual Inspection ............................................. 1A-209 Table A-3: Fuel Temperature Sensor Check ..1A-284
Engine Basic Inspection.................................. 1A-210 Table A-4: Fuel Pressure Sensor Circuit
Engine Symptom Diagnosis .................................1A-* Check ............................................................1A-286
MIL Does Not Come ON with Ignition “ON” Table A-5: Fuel Flow Actuator Operation
and Engine Stopped (but Engine Can Be Check ............................................................1A-288
Started) ..............................................................1A-* Table B-1: Air Intake / Turbocharger Circuit
MIL Remains ON after Engine Starts...................1A-* Check ............................................................1A-289
Serial Data Link Circuit Check ........................ 1A-210 Table B-2: MAF Sensor Check .......................1A-290
DTC P0001 ..................................................... 1A-212 Table B-3: Boost Pressure Sensor Check ......1A-292
DTC P0069 / P0107 / P0234 .......................... 1A-214 Table B-4: Barometric Pressure Check...........1A-294
DTC P0087 / P0089 ........................................ 1A-215 Table B-5: EGR Valve Operation Check.........1A-294
DTC P0088 ..................................................... 1A-217 Table B-6: A/F Sensor Check .........................1A-296
DTC P0095 ..................................................... 1A-218 Table B-7: Boost Pressure Control Solenoid
DTC P0100 ..................................................... 1A-219 Valve Operation Check .................................1A-297
DTC P0101 ..................................................... 1A-221 Table C-1: Main Relay Operation Check ........1A-299
DTC P0110 ..................................................... 1A-222 Table C-2: Engine Speed Check.....................1A-301
DTC P0115 ..................................................... 1A-223 Table C-3: ECT Sensor Check........................1A-302
DTC P0120 ..................................................... 1A-224 Table C-4: IAT-1 Sensor Check ......................1A-304
DTC P0130 / P2244 ........................................ 1A-226 Table C-5: IAT-2 Sensor Check ......................1A-305
DTC P0135 ..................................................... 1A-227 Table C-6: Accelerator Pedal Check...............1A-307
DTC P0168 / P0180 ........................................ 1A-228 Table C-7: Speed Signal Check......................1A-309
DTC P0190 ..................................................... 1A-229 Table C-8: Glow Plug Operation Check ..........1A-311
DTC P0201 / P0202 / P0203 / P0204 / P2146 1A-231 Table C-9: Radiator Cooling Fan Operation
DTC P0217 ..................................................... 1A-233 Check ............................................................1A-314
DTC P0219 ..................................................... 1A-235 Inspection of ECM and Its Circuits ..................1A-318
DTC P0220 ..................................................... 1A-236 Repair Instructions ..........................................1A-329
DTC P0230 ..................................................... 1A-237 Idle Speed Inspection......................................1A-329
DTC P0235 ..................................................... 1A-239 Special Tools and Equipment .........................1A-329
DTC P0243 ..................................................... 1A-240 Special Tool ....................................................1A-329
DTC P0335 ..................................................... 1A-241
DTC P0340 ..................................................... 1A-243 Aux. Emission Control Devices ............. 1B-1
DTC P0380 / P0683 ........................................ 1A-245 Petrol and Bi-Fuel CNG...........................................1B-1
DTC P0401 / P0402 ........................................ 1A-246 Diagnostic Information and Procedures ............1B-1
DTC P0403 ..................................................... 1A-248 EVAP Canister Purge System Inspection ...........1B-1
DTC P0480 ..................................................... 1A-249
DTC P0481 ..................................................... 1A-251
EVAP System Components ................................1B-2
DTC P0500 ..................................................... 1A-253
EVAP Canister Purge Valve Inspection ..............1B-2
DTC P0520 ..................................................... 1A-256
EVAP Canister Inspection................................... 1B-*
DTC P0530 ..................................................... 1A-257
EVAP Connection Hose Inspection..................... 1B-*
DTC P0560 ..................................................... 1A-259
PCV Hose Inspection .......................................... 1B-*
DTC P0571 / P1571 ........................................ 1A-261
PCV Valve Inspection ......................................... 1B-*
DTC P0600 / P0601 / P0604 / P060B / P2226 1A-262
DTC P0641 ..................................................... 1A-264 Specifications.......................................................1B-3
DTC P0645 ..................................................... 1A-265 Tightening Torque Specifications........................1B-3
DTC P0651 ..................................................... 1A-267 Special Tools and Equipment .............................1B-3
DTC P0657 / P0685 ........................................ 1A-269 Special Tool ........................................................1B-3
DTC P0697 ..................................................... 1A-271 Diesel........................................................................ 1B-*
DTC P0704 ..................................................... 1A-272 Repair Instructions .............................................. 1B-*
DTC P1647 ..................................................... 1A-274 EGR Valve and EGR Cooler Components.......... 1B-*
DTC P2135 ..................................................... 1A-275 EGR Valve and EGR Cooler Removal and
DTC P2237 / P2297 ........................................ 1A-276 Installation ......................................................... 1B-*
DTC P2264 ..................................................... 1A-278 EGR Valve Inspection ......................................... 1B-*
DTC P268A ..................................................... 1A-279 Cleaning Procedure for EGR Valve .................... 1B-*
DTC U0073 ..................................................... 1A-280 A/F Sensor On-Vehicle Inspection ...................... 1B-*
DTC U0121 ..................................................... 1A-280 A/F Sensor Removal and Installation.................. 1B-*
DTC U0140 ..................................................... 1A-280 Specifications....................................................... 1B-*
DTC U0141 ..................................................... 1A-280 Tightening Torque Specifications........................ 1B-*
DTC U2101 ..................................................... 1A-280
Table A-1: Fuel Pump Relay Operation Check 1A-281 Engine Electrical Devices ....................... 1C-1
Table A-2: Fuel Injector Circuit Check ............ 1A-283 Petrol and Bi-Fuel CNG...........................................1C-1
1-iv Table of Contents
Repair Instructions ..............................................1C-1 MAF Sensor Data Initialization ............................ 1C-*

ECM Removal and Installation............................ 1C-* Rail Pressure Sensor Initialization ...................... 1C-*
CNG Control Module Removal and MAF Sensor with IAT Sensor-1 Removal and
Installation (Bi-Fuel CNG Model) ...................... 1C-* Installation ......................................................... 1C-*
Procedure after ECM Replacement .................... 1C-* MAF Sensor with IAT Sensor-1 Inspection ......... 1C-*
Electric Throttle Body Assembly On-Vehicle Glow Plug Removal and Installation ................... 1C-*
Inspection.......................................................... 1C-* Glow Plug Inspection .......................................... 1C-*
Electric Throttle Control System Calibration ....... 1C-* APP Sensor Assembly On-Vehicle Inspection .... 1C-*
APP Sensor On-Vehicle Inspection .................... 1C-* APP Sensor Assembly Removal and
Accelerator Pedal Assembly (Incorporating Installation ......................................................... 1C-*
APP Sensor) Removal and Installation ............. 1C-* APP Sensor Assembly Inspection....................... 1C-*
APP Sensor Inspection ....................................... 1C-* Brake Stroke Sensor On-Vehicle Inspection.......1C-5
ECT Sensor Removal and Installation ................ 1C-* Brake Stroke Sensor Removal and
ECT Sensor Inspection ....................................... 1C-* Installation .........................................................1C-5
HO2S-1 and HO2S-2 On-Vehicle Inspection ...... 1C-* Brake Stroke Sensor Inspection and
HO2S-1 and HO2S-2 Removal and Adjustment ........................................................1C-6
Installation ......................................................... 1C-* Brake Stroke Sensor Zero Point Reset ...............1C-7
CMP Sensor On-Vehicle Inspection.................... 1C-* ECT Sensor Removal and Installation ................ 1C-*
CMP Sensor Removal and Installation ............... 1C-* ECT Sensor Inspection ....................................... 1C-*
CMP Sensor Inspection ...................................... 1C-* CMP Sensor Removal and Installation ............... 1C-*
CKP Sensor Removal and Installation ................ 1C-* CMP Sensor Inspection ...................................... 1C-*
CKP Sensor Inspection ....................................... 1C-* CKP Sensor Removal and Installation ................ 1C-*
Knock Sensor On-Vehicle Inspection.................. 1C-* CKP Sensor Inspection ....................................... 1C-*
Knock Sensor Removal and Installation ............. 1C-* Boost Pressure Sensor with IAT Sensor-2
Engine and Emission Control System Relay Removal and Installation................................... 1C-*
Inspection.......................................................... 1C-* Boost Pressure Sensor with IAT Sensor-2
MAP Sensor Removal and Installation................ 1C-* Inspection.......................................................... 1C-*
MAP Sensor Inspection....................................... 1C-* Fuel Pump Relay, Starting Motor Control
IAT Sensor Removal and Installation.................. 1C-* Relay and Main Relay Inspection...................... 1C-*
IAT Sensor Inspection......................................... 1C-* Glow Plug Control Module Removal and
CNG Cylinder Pressure-and-Temperature Installation ......................................................... 1C-*
Sensor Removal and Installation (Bi-Fuel Boost Pressure Control Solenoid Valve
CNG Model) ...................................................... 1C-* Removal and Installation................................... 1C-*
CNG Cylinder Pressure-and-Temperature Boost Pressure Control Solenoid Valve
Sensor Inspection (Bi-Fuel CNG Model)...........1C-1 Inspection.......................................................... 1C-*
Fuel Filler Lid Switch Removal and VSS Removal and Installation (Non-ABS
Installation (Bi-Fuel CNG Model) ...................... 1C-* Model) ............................................................... 1C-*
Fuel Filler Lid Switch Inspection (Bi-Fuel CNG VSS Inspection (Non-ABS Model) ...................... 1C-*
Model) ............................................................... 1C-* Specifications .......................................................1C-8
OCV Inspection ................................................... 1C-* Tightening Torque Specifications........................1C-8
Electric Load Current Sensor On-Vehicle Special Tools and Equipment .............................1C-8
Inspection..........................................................1C-2 Special Tool ........................................................1C-8
VSS Removal and Installation............................. 1C-*
VSS Inspection.................................................... 1C-* Engine Mechanical .................................. 1D-1
Specifications....................................................... 1C-* Petrol and Bi-Fuel CNG...........................................1D-1
Tightening Torque Specifications........................ 1C-* General Description .............................................1D-1
Special Tools and Equipment .............................1C-3 Engine Construction Description .........................1D-1
Special Tool ........................................................1C-3 Diagnostic Information and Procedures ............1D-1
Diesel........................................................................1C-4 Compression Check............................................1D-1
General Description .............................................1C-4 Engine Vacuum Check........................................1D-2
Description of ECM Registration .........................1C-4 Valve Clearance Inspection and Adjustment ...... 1D-*
Repair Instructions ..............................................1C-5 Repair Instructions ..............................................1D-3
ECM Removal and Installation............................ 1C-* Air Cleaner Components.....................................1D-3
Registration for ECM Replacement..................... 1C-* Air Cleaner Filter Removal and Installation......... 1D-*
Vehicle Variant Data (Including CAN Vehicle Air Cleaner Filter Inspection and Cleaning.......... 1D-*
Configuration Data) Registration....................... 1C-* Air Cleaner Assembly Removal and
Injector Calibration Code Registration ................ 1C-* Installation .........................................................1D-4
Flywheel Data Initialization.................................. 1C-* Throttle Body and Intake Manifold
A/F Sensor Data Initialization.............................. 1C-* Components......................................................1D-5
Table of Contents 1-v
Throttle Body On-Vehicle Inspection .................. 1D-* Specifications.....................................................1D-24

Electric Throttle Body Assembly Removal and Tightening Torque Specifications......................1D-24
Installation.........................................................1D-5 Special Tools and Equipment ...........................1D-25
Throttle Body Cleaning ....................................... 1D-* Recommended Service Material .......................1D-25
Intake Manifold Removal and Installation Special Tool ......................................................1D-25
(Petrol Model) ...................................................1D-6 Diesel......................................................................1D-27
Cylinder Head Cover Components .....................1D-7 Diagnostic Information and Procedures ..........1D-27
Cylinder Head Cover Removal and Compression Check............................................ 1D-*
Installation.........................................................1D-7 Timing Check ....................................................1D-27
Camshaft, Tappet and Shim Components .......... 1D-*
Repair Instructions ............................................1D-29
Camshaft and Tappet Removal and
Air Cleaner Components...................................1D-29
Installation......................................................... 1D-*
Air Cleaner Filter Removal and Installation......... 1D-*
Camshaft and Tappet Inspection ........................ 1D-*
Air Cleaner Filter Inspection and Cleaning.......... 1D-*
Crankshaft Oil Seal Replacement ....................... 1D-*
Air Cleaner Assembly Removal and
Engine Mounting Components............................1D-9
Installation ......................................................... 1D-*
Engine Assembly Removal and Installation
Intercooler Components....................................1D-31
(Petrol Model) .................................................1D-10
Intercooler Removal and Installation................... 1D-*
Timing Chain Cover Components .....................1D-14
Vacuum Pump Removal and Installation ............ 1D-*
Timing Chain Cover Removal and Installation .... 1D-*
Vacuum Pump Inspection ................................... 1D-*
Timing Chain Cover Inspection ........................... 1D-*
Crankcase Ventilation System Components....... 1D-*
OCV Removal and Installation ............................ 1D-*
Oil Separator and Crankcase Ventilation
Flywheel / Drive Plate Removal and
Cover Removal and Installation ........................ 1D-*
Installation.......................................................1D-14
Turbocharger and Exhaust Manifold
Flywheel / Drive Plate Inspection ......................1D-15
Components....................................................1D-32
Timing Chain and Chain Tensioner
Turbocharger Removal and Installation .............. 1D-*
Components...................................................... 1D-*
Turbocharger Inspection ...................................1D-33
Timing Chain and Chain Tensioner Removal
Exhaust Manifold Removal and Installation ........ 1D-*
and Installation.................................................. 1D-*
Intake Manifold Components ............................1D-33
Timing Chain and Chain Tensioner Inspection .... 1D-*
Intake Manifold Removal and Installation (ISG
Valve and Cylinder Head Components ............... 1D-*
Model) .............................................................1D-34
Valve and Cylinder Head Removal and
Crankshaft Oil Seal Replacement (ISG
Installation......................................................... 1D-*
Model) .............................................................1D-35
Valve and Cylinder Head Disassembly and
Engine Mounting Components............................ 1D-*
Reassembly ...................................................... 1D-*
Engine Assembly Removal and Installation
Valve and Valve Guide Inspection ...................... 1D-*
(ISG Model).....................................................1D-37
Cylinder Head Inspection .................................... 1D-*
Timing Chain Cover and Timing Chain
Cylinder Head Bolt Inspection............................. 1D-*
Components (ISG Model) ...............................1D-41
Valve Spring Inspection ...................................... 1D-*
Piston, Piston Ring, Connecting Rod and
Removal and Installation (ISG Model) ............1D-42
Cylinder Components ....................................... 1D-*
Inspection.......................................................... 1D-*
Cylinder Removal and Installation .................... 1D-*
Camshaft Housing Components .......................1D-48
Camshaft Housing Assembly Removal and
Cylinder Disassembly and Reassembly..........1D-15
Installation ......................................................... 1D-*
Cylinder, Piston and Piston Ring Inspection .....1D-17
Camshaft Housing Assembly Disassembly
Piston Pin and Connecting Rod Inspection.......1D-18
and Reassembly .............................................1D-48
Crankshaft Pin and Connecting Rod Bearing
Camshaft Inspection .........................................1D-50
Inspection.......................................................... 1D-*
Valve and Cylinder Head Components .............1D-52
Main Bearing, Crankshaft and Cylinder Block
Valve and Cylinder Head Assembly Removal
Components....................................................1D-20
and Installation .................................................. 1D-*
Valve and Cylinder Head Assembly
Removal and Installation.................................1D-21
Disassembly and Reassembly ........................1D-52
Crankshaft Inspection ......................................... 1D-*
Valve and Valve Guide Inspection ...................... 1D-*
Main Bearing Inspection ..................................... 1D-*
Cylinder Head Inspection .................................... 1D-*
Sensor Plate Inspection ...................................... 1D-*
Valve Spring Inspection ...................................... 1D-*
Rear Oil Seal Inspection ..................................... 1D-*
Timing Chain Jet Inspection................................ 1D-*
Cylinder Components......................................1D-54
Water Jacket Spacer Inspection .......................1D-24
Cylinder Block Inspection.................................... 1D-*
Cylinder Removal and Installation...................1D-54
1-vi Table of Contents
Piston, Piston Ring, Connecting Rod and Oil Pump Strainer Cleaning................................. 1E-*
Cylinder Disassembly and Reassembly............ 1D-* Oil Pump Inspection ............................................ 1E-*
Cylinder, Piston and Piston Ring Inspection .....1D-56 Specifications .....................................................1E-15
Piston Pin and Connecting Rod Inspection.......1D-58 Tightening Torque Specifications......................1E-15
Crankshaft Pin and Connecting Rod Bearing Special Tools and Equipment ...........................1E-16
Inspection........................................................1D-58 Recommended Service Material .......................1E-16
Main Bearing, Crankshaft and Cylinder Block Special Tool ......................................................1E-16
Components....................................................1D-62
Main Bearing, Crankshaft and Cylinder Block Engine Cooling System ...........................1F-1
Removal and Installation (ISG Model) ............1D-62 Petrol and Bi-Fuel CNG........................................... 1F-1
Main Bearing, Crankshaft and Cylinder Block Precautions............................................................1F-*
Inspection.......................................................... 1D-* Precautions for Cooling System...........................1F-*
Main Bearing Inspection (ISG Model) ...............1D-66
General Description ..............................................1F-*
Cylinder Block Inspection..................................1D-72
Cooling System Description .................................1F-*
Specifications.....................................................1D-72 Coolant Description..............................................1F-*
Tightening Torque Specifications......................1D-72 Cooling Fan Operation Description ......................1F-*
Special Tools and Equipment ...........................1D-73 Schematic and Routing Diagram ........................ 1F-1
Recommended Service Material .......................1D-73 Coolant Circulation...............................................1F-*
Special Tool ......................................................1D-73 Radiator Cooling Fan Control System Circuit
Diagram............................................................. 1F-1
Engine Lubrication System .....................1E-1
Diagnostic Information and Procedures ............ 1F-2
Petrol and Bi-Fuel CNG ..........................................1E-1
Engine Cooling Symptom Diagnosis....................1F-*
General Description ............................................. 1E-* Radiator Cooling Fan System Check .................. 1F-2
Engine Lubrication Description ........................... 1E-*
Repair Instructions .............................................. 1F-5
Diagnostic Information and Procedures............ 1E-1 Cooling System Components.............................. 1F-5
Oil Pressure Check ............................................. 1E-1 Coolant Level Check ............................................1F-*
Repair Instructions .............................................. 1E-2 Engine Cooling System Inspection ......................1F-*
Engine Oil and Filter Change .............................. 1E-2 Cooling System Draining......................................1F-*
Oil Pressure Switch On-Vehicle Inspection......... 1E-* Cooling System Refilling ......................................1F-*
Oil Pan and Oil Pump Strainer Components....... 1E-4 Cooling Water Pipe or Hose Removal and
Oil Pan and Oil Pump Strainer Removal and Installation ..........................................................1F-*
Installation ......................................................... 1E-4 Thermostat Assembly (Incorporating ECT
Oil Pump Assembly Components ....................... 1E-6 Sensor) Removal and Installation ......................1F-*
Oil Pump Assembly Removal and Installation .... 1E-* Thermostat Assembly (Incorporating ECT
Oil Pump Assembly Disassembly and Sensor) Inspection .............................................1F-*
Reassembly ...................................................... 1E-7 Radiator Cooling Fan Assembly On-Vehicle
Oil Pump Inspection ............................................ 1E-8 Inspection.......................................................... 1F-6
Specifications....................................................... 1E-9 Radiator Cooling Fan Relay Inspection................1F-*
Tightening Torque Specifications........................ 1E-9 Radiator Cooling Fan Assembly Removal and
Special Tools and Equipment ............................. 1E-9 Installation ..........................................................1F-*
Recommended Service Material ......................... 1E-9 Radiator Cooling Fan Disassembly and
Special Tool ........................................................ 1E-9 Reassembly .......................................................1F-*
Diesel...................................................................... 1E-11 Radiator On-Vehicle Inspection and Cleaning .....1F-*
General Description ............................................. 1E-* Radiator Removal and Installation ...................... 1F-6
Engine Lubrication Description ........................... 1E-* Water Pump Removal and Installation.................1F-*
Diagnostic Information and Procedures............ 1E-* Water Pump Inspection........................................1F-*
Oil Pressure Check ............................................. 1E-* Specifications ....................................................... 1F-7
Repair Instructions ............................................ 1E-11 Tightening Torque Specifications........................ 1F-7
Engine Oil Level Check..................................... 1E-11 Special Tools and Equipment ............................. 1F-7
Engine Oil and Filter Change ............................ 1E-11 Recommended Service Material ..........................1F-*
Oil Pressure Switch On-Vehicle Inspection......... 1E-* Special Tool ........................................................ 1F-7
Oil Pressure Switch Removal and Installation .... 1E-* Diesel........................................................................ 1F-8
Oil Cooler Components..................................... 1E-12 Precautions............................................................1F-*
Oil Cooler Removal and Installation.................... 1E-* Precautions for Cooling System...........................1F-*
Oil Pan Components ......................................... 1E-13 General Description ............................................. 1F-8
Oil Pan Removal and Installation ...................... 1E-13 Cooling System Description .................................1F-*
Oil Pump / Oil Pump Strainer Components....... 1E-15 Coolant Description..............................................1F-*
Oil Pump / Oil Pump Strainer Removal and Coolant Degassing Tank Description ...................1F-*
Installation ....................................................... 1E-15
Table of Contents 1-vii
Water Pump Drive Belt Description (ISG Repair Instructions ............................................. 1G-4
Model) ............................................................... 1F-8 Fuel System Components.................................. 1G-4
Schematic and Routing Diagram.........................1F-* Fuel Hose Disconnection and Reconnection ...... 1G-*
Coolant Circulation...............................................1F-* Fuel Pressure Relief Procedure ......................... 1G-5
Diagnostic Information and Procedures............ 1F-9 Fuel Leakage Check Procedure.......................... 1G-*
Engine Cooling Symptom Diagnosis................... 1F-9 Fuel Lines On-Vehicle Inspection ....................... 1G-*
Radiator Fan Control System Inspection .............1F-* Fuel Pipe Removal and Installation..................... 1G-*
Repair Instructions ............................................ 1F-10 Fuel Injector On-Vehicle Inspection ................... 1G-5
Cooling System Components ..............................1F-* Fuel Injector Removal and Installation ............... 1G-5
Coolant Level Check ............................................1F-* Fuel Injector Inspection ...................................... 1G-6
Engine Cooling System Inspection and Fuel Filler Cap Inspection ................................... 1G-*
Cleaning.............................................................1F-* Fuel Tank Inlet Valve Removal and
Cooling System Draining .....................................1F-* Installation ........................................................ 1G-8
Cooling System Flush and Refill ..........................1F-* Fuel Tank Inlet Valve Inspection ........................ 1G-8
Cooling System Refill ...........................................1F-* Fuel Tank Removal and Installation.................... 1G-*
Cooling Water Pipe or Hose Removal and Fuel Tank Inspection........................................... 1G-*
Installation..........................................................1F-* Fuel Tank Flushing Procedure ............................ 1G-*
Thermostat Assembly Removal and Fuel Pump On-Vehicle Inspection....................... 1G-*
Installation..........................................................1F-* Fuel Pump Assembly Removal and
Radiator Cooling Fan Assembly On-Vehicle Installation ......................................................... 1G-*
Inspection...........................................................1F-* Fuel Pump Inspection ......................................... 1G-*
Radiator Cooling Fan Relay Inspection................1F-* Fuel Level Sensor Removal and Installation....... 1G-*
Radiator Cooling Fan Assembly Removal and Fuel Level Sensor Inspection.............................. 1G-*
Installation..........................................................1F-* Fuel Filter Removal and Installation.................... 1G-*
Radiator On-Vehicle Inspection and Cleaning .....1F-* Specifications...................................................... 1G-9
Radiator Removal and Installation .......................1F-* Tightening Torque Specifications....................... 1G-9
Water Pump Removal and Installation.................1F-* Special Tools and Equipment ............................ 1G-9
Water Pump Inspection........................................1F-* Special Tool ....................................................... 1G-9
Water Pump Drive Belt Inspection (ISG Bi-Fuel CNG .......................................................... 1G-10
Model) ............................................................. 1F-10 Precautions........................................................ 1G-10
Water Pump Drive Belt Removal and Precautions for Fuel System Service ............... 1G-10
Installation (ISG Model) .................................. 1F-10 General Description ............................................. 1G-*
Water Pump Removal and Installation (ISG Fuel System Description ..................................... 1G-*
Model) ............................................................. 1F-12 Fuel Delivery System Description ....................... 1G-*
Water Pump Inspection (ISG Model) ................ 1F-12 Fuel Pump Description........................................ 1G-*
Specifications..................................................... 1F-13 CNG Receptacle Description .............................. 1G-*
Tightening Torque Specifications...................... 1F-13 CNG Cylinder Description ................................... 1G-*
Special Tools and Equipment ........................... 1F-13 CNG Cylinder Valve Description ......................... 1G-*
Special Tool ...................................................... 1F-13 CNG Fuel Filter Description ................................ 1G-*
CNG Cylinder Pressure Regulator
Fuel System ............................................. 1G-1 Description ........................................................ 1G-*
Petrol ........................................................................1G-1 Schematic and Routing Diagram ..................... 1G-11
Precautions...........................................................1G-1 Fuel Delivery System Diagram............................ 1G-*
Precautions for Fuel System Service ..................1G-1 Fuel Injector Control System Circuit Diagram .. 1G-11
General Description ............................................. 1G-* Fuel Pump Control System Circuit Diagram ....... 1G-*
Fuel System Description ..................................... 1G-* Diagnostic Information and Procedures ......... 1G-12
Fuel Delivery System Description ....................... 1G-* Fuel System Inspection....................................... 1G-*
Fuel Pump Description........................................ 1G-* Power Balance Test ......................................... 1G-12
Schematic and Routing Diagram........................1G-1 Fuel Injector Circuit Check .................................. 1G-*
Fuel Delivery System Diagram............................1G-1 Fuel Pump and Its Circuit Check......................... 1G-*
Fuel Injector Control System Circuit Diagram .....1G-2 Fuel Pressure Check........................................... 1G-*
Fuel Pump Control System Circuit Diagram .......1G-3 Fuel Pressure Basic Check.............................. 1G-13
Diagnostic Information and Procedures............1G-3 Fuel Cut Operation Check................................... 1G-*
Fuel System Inspection....................................... 1G-* Repair Instructions ........................................... 1G-14
Power Balance Test ............................................1G-3 Fuel System Components................................... 1G-*
Fuel Injector Circuit Check .................................. 1G-* Fuel Hose Disconnection and Reconnection ...... 1G-*
Fuel Pump and Its Circuit Check......................... 1G-* Fuel Pressure Relief Procedure .......................... 1G-*
Fuel Pressure Check .......................................... 1G-* Fuel Leakage Check Procedure.......................... 1G-*
Fuel Pressure Basic Check................................. 1G-* Fuel Line On-Vehicle Inspection ......................... 1G-*
1-viii Table of Contents
Fuel Pipe Removal and Installation..................... 1G-* Fuel Tank Inspection........................................... 1G-*
Fuel Filter Removal and Installation.................... 1G-* Fuel Tank Flushing Procedure ............................ 1G-*
Fuel Injector On-Vehicle Inspection .................... 1G-* Fuel Pump On-Vehicle Inspection....................... 1G-*
Fuel Injector Removal and Installation ................ 1G-* Fuel Pump Assembly Removal and
Fuel Injector Inspection ....................................... 1G-* Installation ......................................................... 1G-*
CNG Cylinder Pressure Regulator On- Fuel Pump Inspection ......................................... 1G-*
Vehicle Inspection .......................................... 1G-14 Fuel Level Sensor Inspection........................... 1G-26
CNG Cylinder Pressure Regulator Removal Fuel Filter Element Removal and Installation...... 1G-*
and Installation .................................................. 1G-* Fuel Filter Assembly Removal and Installation .... 1G-*
CNG Cylinder Pressure Regulator Inspection..... 1G-* Fuel Temperature Sensor Removal and
Fuel Filler Cap Inspection ................................... 1G-* Installation ......................................................... 1G-*
Fuel Tank Removal and Installation.................... 1G-* Fuel Temperature Sensor Inspection .................. 1G-*
Fuel Tank Inspection........................................... 1G-* Fuel Filter Water Detection Sensor Inspection .... 1G-*
Fuel Tank Flushing Procedure ............................ 1G-* Specifications .................................................... 1G-26
Fuel Pump On-Vehicle Inspection....................... 1G-* Tightening Torque Specifications..................... 1G-26
Fuel Pump Relay Inspection ............................... 1G-* Special Tools and Equipment .......................... 1G-27
CNG Valve Control Relay Inspection .................. 1G-* Special Tool ..................................................... 1G-27
Fuel Pump Assembly Removal and
Installation ......................................................... 1G-* Ignition System........................................ 1H-1
Fuel Pump Inspection ......................................... 1G-* General Description ............................................. 1H-*
CNG Cylinder with Valve On-Vehicle Ignition System Construction .............................. 1H-*
Inspection.......................................................... 1G-* Schematic and Routing Diagram ........................1H-1
CNG Cylinder with Valve Removal and Ignition System Circuit Diagram ..........................1H-1
Installation ......................................................... 1G-*
Component Location ........................................... 1H-*
CNG Receptacle On-Vehicle Inspection ............. 1G-*
Ignition System Component Location ................. 1H-*
CNG Receptacle Removal and Installation......... 1G-*
Diagnostic Information and Procedures ............ 1H-*
Specifications....................................................... 1G-*
Ignition System Check ........................................ 1H-*
Tightening Torque Specifications........................ 1G-*
Ignition Spark Test .............................................. 1H-*
Special Tools and Equipment .......................... 1G-14
Repair Instructions ..............................................1H-2
Special Tool ..................................................... 1G-14
Spark Plug Removal and Installation .................. 1H-*
Diesel..................................................................... 1G-15
Spark Plug Inspection .........................................1H-2
Precautions........................................................ 1G-15 Ignition Coil Assembly Removal and
Precautions for Fuel System Service ............... 1G-15 Installation ......................................................... 1H-*
General Description ............................................. 1G-* Ignition Coil Assembly Inspection ....................... 1H-*
Fuel System Description ..................................... 1G-* Ignition Timing Inspection ...................................1H-2
Diagnostic Information and Procedures............ 1G-* Specifications ....................................................... 1H-*
Low-Pressure Fuel Supply Circuit Check............ 1G-* Tightening Torque Specifications........................ 1H-*
High-Pressure Fuel Supply Circuit Check........... 1G-* Special Tools and Equipment .............................1H-3
Repair Instructions ........................................... 1G-18 Special Tool ........................................................1H-3
Fuel Hose Disconnection and Reconnection ...... 1G-*
Fuel Pressure Relief Procedure ....................... 1G-18 Starting System .........................................1I-1
Fuel Leakage Check Procedure.......................... 1G-* Petrol and Bi-Fuel CNG............................................ 1I-1
Water Draining of Fuel Filter ............................... 1G-* General Description .............................................. 1I-1
Air Bleeding of Fuel System................................ 1G-* Cranking System Description ............................... 1I-1
Fuel System Components................................ 1G-19
Schematic and Routing Diagram ......................... 1I-1
High Pressure Pipe Removal and Installation.. 1G-22
Cranking System Circuit Diagram ........................ 1I-1
Fuel Injector On-Vehicle Inspection .................... 1G-*
Diagnostic Information and Procedures ............. 1I-2
Fuel Injector Removal and Installation ................ 1G-*
Cranking System Symptom Diagnosis................. 1I-2
Common Rail Removal and Installation ........... 1G-23
Cranking System Test...........................................1I-*
High Pressure Pump Removal and
Installation ...................................................... 1G-24 Repair Instructions ............................................... 1I-4
Fuel Pressure Sensor Removal and Starting Motor Control Relay Inspection .............. 1I-4
Installation ......................................................... 1G-* Starting Motor Removal and Installation ...............1I-*
Fuel Flow Actuator On-Vehicle Inspection .......... 1G-* Starting Motor Components ..................................1I-*
Fuel Line and Connection Inspection.................. 1G-* Starting Motor Inspection ......................................1I-*
Fuel Pipe Removal and Installation.................. 1G-26 Specifications .........................................................1I-*
Fuel Filler Cap Inspection ................................... 1G-* Cranking System Specifications............................1I-*
Fuel Tank On-Vehicle Inspection ........................ 1G-* Tightening Torque Specifications..........................1I-*
Fuel Tank Removal and Installation.................... 1G-* Special Tools and Equipment ...............................1I-*
Table of Contents 1-ix
Recommended Service Material ........................... 1I-* Generator Test .................................................. 1J-14

Diesel......................................................................... 1I-5 Repair Instructions ............................................ 1J-15
General Description .............................................. 1I-5 Jump-Starting in Case of Emergency .................. 1J-*
Cranking System Description............................... 1I-5 Battery Removal and Installation ......................... 1J-*
Schematic and Routing Diagram......................... 1I-5 Accessory Drive Belt Tension Inspection............. 1J-*
Cranking System Circuit Diagram ........................ 1I-5 Accessory Drive Belt Removal and
Diagnostic Information and Procedures............. 1I-6 Installation .......................................................... 1J-*
Cranking System Symptom Diagnosis................. 1I-6 Accessory Drive Belt Tensioner Removal and
Installation .......................................................... 1J-*
Repair Instructions ............................................... 1I-8
Generator Removal and Installation..................... 1J-*
Starting Motor Control Relay Inspection ............... 1I-*
Generator Components........................................ 1J-*
Starting Motor Removal and Installation .............. 1I-8
Generator Disassembly and Reassembly......... 1J-15
Starting Motor Components .................................. 1I-*
Generator Inspection......................................... 1J-18
Starting Motor Disassembly and Reassembly ...... 1I-*
Starting Motor Inspection ...................................... 1I-* Specifications..................................................... 1J-20
Charging System Specifications ....................... 1J-20
Specifications...................................................... 1I-10
Tightening Torque Specifications...................... 1J-21
Cranking System Specifications............................ 1I-*
Tightening Torque Specifications....................... 1I-10 Special Tools and Equipment ........................... 1J-21
Special Tool ...................................................... 1J-21
Special Tools and Equipment ............................... 1I-*
Recommended Service Material ........................... 1I-* Diesel (with ISG) .................................................... 1J-22
Special Tool .......................................................... 1I-* Precautions......................................................... 1J-22
Precautions for Handling Battery ...................... 1J-22
Charging System ......................................1J-1 Precautions for Replacing Battery..................... 1J-22
Petrol and Bi-Fuel CNG .......................................... 1J-1 General Description ........................................... 1J-22
Precautions............................................................ 1J-* Battery Description............................................ 1J-22
Precautions for Handling Battery ......................... 1J-* Generator Description ....................................... 1J-22
General Description ............................................. 1J-1 Diagnostic Information and Procedures .......... 1J-23
Battery Description............................................... 1J-* Battery Inspection ............................................. 1J-23
Generator Description ..........................................1J-1 Generator Symptom Diagnosis ......................... 1J-23
Diagnostic Information and Procedures............ 1J-2 Generator Test .................................................. 1J-24
Battery Inspection ................................................ 1J-* Repair Instructions ............................................ 1J-25
Generator Symptom Diagnosis ............................1J-2 Jump-Starting in Case of Emergency ............... 1J-25
Generator Test .....................................................1J-3 Battery Removal and Installation ...................... 1J-25
Repair Instructions .............................................. 1J-4 ISG Drive Belt Inspection .................................. 1J-26
Jump-Starting in Case of Emergency ..................1J-4 ISG Drive Belt Removal and Installation ........... 1J-26
Battery Removal and Installation ......................... 1J-* ISG Drive Belt Tensioner and Idler Pulley
Water Pump / Generator Drive Belt Tension Removal and Installation................................. 1J-28
Inspection and Adjustment................................. 1J-* ISG Drive Belt Tensioner and Idler Pulley
Water Pump / Generator Drive Belt Removal Inspection........................................................ 1J-28
and Installation................................................... 1J-* ISG Removal and Installation............................ 1J-28
Generator Removal and Installation .................... 1J-* ISG Inspection................................................... 1J-29
Generator Bracket Removal and Installation ....... 1J-* Specifications..................................................... 1J-30
Generator Components .......................................1J-6 Charging System Specifications ....................... 1J-30
Generator Disassembly and Reassembly............1J-6 Tightening Torque Specifications...................... 1J-30
Generator Inspection ...........................................1J-9 Special Tools and Equipment ........................... 1J-30
Specifications..................................................... 1J-11 Special Tool ...................................................... 1J-30
Charging System Specifications ........................1J-11
Tightening Torque Specifications.......................1J-11 Exhaust System ....................................... 1K-1
Special Tools and Equipment ........................... 1J-11 Petrol and Bi-Fuel CNG...........................................1K-1
Special Tool .......................................................1J-11 General Description ............................................. 1K-*
Diesel (without ISG) .............................................. 1J-12 Exhaust System Description ............................... 1K-*
Precautions............................................................ 1J-* Diagnostic Information and Procedures ............ 1K-*
Precautions for Handling Battery ......................... 1J-* Exhaust System Check ....................................... 1K-*
General Description ........................................... 1J-12 Repair Instructions ..............................................1K-1
Battery Description............................................... 1J-* Exhaust System Components.............................1K-1
Generator Description ........................................1J-12 Exhaust Manifold Removal and Installation ........1K-2
Exhaust Pipe and Muffler Removal and
Diagnostic Information and Procedures.......... 1J-13
Installation ......................................................... 1K-*
Battery Inspection ................................................ 1J-*
Generator Symptom Diagnosis ..........................1J-13 Specifications.......................................................1K-3
1-x Table of Contents
Tightening Torque Specifications........................ 1K-3 Exhaust Manifold Components ........................... 1K-*

Diesel........................................................................1K-4 Exhaust Manifold Removal and Installation ........ 1K-*
General Description ............................................. 1K-* Exhaust Manifold Inspection ............................... 1K-*
Exhaust System Description ............................... 1K-* Catalytic Converter Removal and Installation ..... 1K-*
Diagnostic Information and Procedures............ 1K-* Exhaust Pipe and Muffler Removal and
Exhaust System Check ....................................... 1K-* Installation ......................................................... 1K-*
Repair Instructions ..............................................1K-4 Specifications .......................................................1K-4
Exhaust System Components............................. 1K-4 Tightening Torque Specifications........................1K-4
Engine General Information and Diagnosis: Petrol 1A-1
Engine General Information and Diagnosis

Engine
Petrol
General Description
OBD System Description
AENFL80B1111003
General Description [A]
ECM in this model 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 (1).
• When ECM detects a malfunction which gives an
adverse effect to vehicle emission while the engine is
running, ECM makes the MIL (1) in the meter cluster
of the instrument panel turn on or blink (blinking only
when detecting a misfire which can cause damage to
[B]
the catalyst) and stores the malfunction area in its
memory.
1
(If ECM detects a malfunction only in the first driving
cycle (refer to “Driving Cycle”: Petrol (Page 1A-1).) but
does not detect the same malfunction in the next 2
consecutive driving cycles, ECM does not turn on MIL
(1) although it retains the associated DTC in its
memory.)
• For some malfunctions, ECM adopts the 3 driving
cycle detection logic (refer to “3 Driving Cycle
Detection Logic”: Petrol (Page 1A-2)) to prevent
erroneous detection.
With this logic, MIL is turned on when the same
malfunction is detected in 3 consecutive driving
cycles.
3
• When a malfunction is detected, engine and driving
conditions at the moment the malfunction was
detected are stored in ECM memory as freeze frame
data. (For the details, refer to description on “Freeze
frame data clearance:”: Petrol (Page 1A-3).)
2
• Not only SUZUKI scan tool (2) but also CAN
communication OBD-II generic scan tool can
communicate with ECM via DLC (3). (Diagnostic
information can be accessed using a scan tool.)
IFL80B111009-01
[A] Without tachometer

[B] With tachometer
Warm-Up Cycle
A “warm-up cycle” means keeping the engine operating
after the start until the coolant temperature rises by at
least 22 °C (40 °F) or reaches a minimum temperature of
71 °C (160 °F).
Driving Cycle
A “Driving Cycle” is a duration from an engine startup to
the following engine shutoff.
1A-2 Engine General Information and Diagnosis: Petrol
3 Driving Cycle Detection Logic NOTE

The malfunction detected in the first driving cycle is
stored in ECM memory (in the form of pending DTC) but • Freeze frame data with asterisk (*)
MIL does not light at this time. ECM causes the MIL to indicates the ratio of the output voltage to
light up when it detects third time the same malfunction the power supply voltage of related sensor.
in the next two driving cycles. When power supply voltage is 5.0 V and
output voltage is 4.0 V, freeze frame data is
Pending DTC displayed as follows.
“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 proportional to the input voltage, it
detected and stored temporarily during the first of three displays 80% (= the percent of maximum
consecutive driving cycles, the DTC is called “pending input reference voltage).
DTC”. – For systems where the output is
inversely proportional to the input
Freeze Frame Data voltage, it displays 20% (=100% minus
ECM stores the engine and driving conditions at the the percent of maximum input reference
moment of the detection of a malfunction in its memory. voltage).
This data is called “Freeze frame data”. • For relative TP with asterisks (**) in above
Therefore, it is possible to know engine and driving table, it indicates value calculated by
conditions (e.g. whether the engine was warm or not, formula ((output voltage – output voltage
whether the vehicle was running or stopped, whether air/ at closed throttle position) / power supply
fuel mixture was lean or rich) when a malfunction was voltage).
detected by checking the freeze frame data. Also, ECM When power supply voltage is 5.0 V and
has a function to store each freeze frame data for three output voltage at closed throttle position is
different malfunctions in the order of their detection. 1.0 V, freeze frame data is displayed as
Utilizing this function, it is possible to know the order of follows.
detection of these malfunctions. This is helpful when
– At closed throttle position (output
rechecking or diagnosing a problem.
voltage = 1.0 V), it displays 0%.
For details of freeze data that can be read from ECM,
refer to the following table. – At wide open throttle position (output
DTC voltage = 4.0 V), it displays 60%.
Fuel System However, for systems where the output is
Calculated Load inversely proportional to the input voltage, it
ECT displays 100% minus above-mentioned
Short Term Fuel Trim formula.
Long Term Fuel Trim
MAP Freeze frame data (for example)
Engine Speed
Vehicle Speed Function View System Bar Help
Ignition Advance Engine / Powertrain / Freeze Frame Data
Intake Air Temperature P0118
Engine Coolant Temperature Sensor1
Circuit High
Absolute TP 1*
Time Since Engine Start Parameter Value Unit
EVAP Canist Prg Duty DTC P0118

Fuel System -
Fuel Tank Level
Calculated Load 0.00 %
Barometric Pres ECT -40 C
Battery Voltage Short Term Fuel Trim 0.00 %
Relative TP** Long Term Fuel Trim 0.00 %
Absolute TP 2* MAP 102 kPa
Absolute APP 1* Engine Speed 0 rpm
Vehicle Speed 0 km/h
Absolute APP 2*
Target Throt Pos Exit
Data Active
DTC View Utility
List Test
I9R90A111029-01
Priority of freeze frame data:

ECM has 4 freeze frames from 0 to 3 where freeze frame data can be stored.
Frame 0 is a special frame where freeze frame data concerning emission-affecting malfunction has priority over data
related to other (general) malfunctions. If any emission-affecting malfunction is detected while Frame 0 is holding a
data related to general malfunctions (priority “2” data in the following table), then the currently stored data is replaced
by the data concerning the newly detected malfunction (priority “1” data in the following table).
Priority Freeze frame data in Frame 0
1 Data concerning any of the following malfunctions: Misfire Detected (P0300 – P0304), System Too
Lean (P0171) and System Too Rich (P0172)
2 Data concerning malfunctions other than the above.
Frames 1 to 3 are assigned to general malfunctions. They individually store the freeze frame data for 3 different
general malfunctions in the order of detection (i.e., Frame 1 stores the data for the first detected malfunction and
Frame 3 the data for the last detected malfunction). Unlike the Frame 0 data, the data in these 3 frames are not
updated, so freeze frame data for any malfunction detected subsequently are not stored anywhere.
Frame 0 Frame 1 Frame 2 Frame 3
Freeze frame 1st freeze frame 2nd freeze frame 3rd freeze frame
data data data data
1 No DTC
2 P0443 P0443 data P0443 data
DTC 3 P0112 P0443 data P0443 data P0112 data
detection
order 4 P0117 P0443 data P0443 data P0112 data P0117 data
5 P0480 P0443 data P0443 data P0112 data P0117 data
6 P0171 P0171 data P0443 data P0112 data P0117 data
IFL80B111012-01
—: 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.
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 on-board diagnosis.
Monitoring item of system readiness test table

Monitoring item DTC related to monitoring item
Catalyst P0420 — —
O2 Sensor P0133 — —
DLC Description
AENFL80B1111004
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-II)
(7) or CAN communication OBD-II generic scan tool to communicate with ECM and other control modules.
2
3
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
6 5
4
1
IFL80B111010-02
2. B + (Continuous battery power)

4. ECM ground (Signal ground)
5. Ground (Chassis ground)
Generator Control System Description

AENFL80B1111011
Generator control system consists of a generator (1), electric load current sensor (5) and ECM (4).ECM controls
generated electricity (adjusting voltage of IC regulator (2)) so that it is suitable for the engine and electric load
conditions. To prevent drop in idling speed that would result from quick increase in electric load and consequent
increase in engine load, ECM performs a control so that the generator output increases gradually. In the case of a
temporary increase in electricity generation demand while driving, ECM performs a control to limit operation of the
generator and thus limits increase in load on the engine to maintain the engine performance whenever necessary
(during acceleration, for example).
Operation
ECM optimally controls the generator output voltage by changing the excitation current and regulated voltage based
on the following information.
• Engine condition (ECT, vehicle speed, engine speed, TP, etc.) (7)
• Battery voltage (ECM power voltage) (8)
• Electric load condition (blower motor, rear window defogger, headlights, radiator cooling fan, A/C compressor,
etc.)(9)
• Field coil (3) control duty which indicates the operation rate of the field coil
• The signal to the “LIN” terminal of the generator adjusts the regulating voltage of the IC regulator, which in turn
controls the duty ratio of the field coil and thus the output voltage (“B” terminal output) of the generator.
(For more information on the generator output voltage, refer to Charging System in Section 1J.)Furthermore, the
generating condition of the generator is controlled to the optimum level using the electric load current sensor which
detects the electrical load condition (current consumption) linearly even when a sudden electrical load variation occurs
and thus the engine load is reduced.
1
B
10
11
4
7
2 11
8 6
9
LIN 5
IEL10A111003-01
6. Battery 10. Combination meter 11. CAN driver
Electronic Control System Description

AENFL80B1111009
The electronic control system consists of various sensors which detect the state of engine and driving conditions and
ECM which controls various devices according to the signals from the sensors and 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
• VVT system
• Generator control system
• Immobilizer control system
• Controller (computer) communication system
ECM uses CAN communication system to communicate with other control modules. For more detail of CAN
communication, refer to “Communication System Description”: Petrol and Bi-Fuel CNG Model in Section 10H (Page
10H-1).
Engine and Emission Control Input / Output Table

AENFL80B1111010
Function Output Input
• Ignition “ON” signal
• Ignition “ST” signal
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
• APP sensor
• MAP sensor
• IAT sensor
• HO2S-1
Injection control Fuel injector
• HO2S-2
• Barometric pressure sensor
• A/C refrigerant pressure sensor
• Battery voltage
• Brake light switch
• BCM (A/C switch status signal)
• VSS (non-ABS model)
• ABS control module (wheel speed signal) (ABS model)
• P/S control module
• TCM (torque reduction request signal) (A/T model)
Immobilizer control Fuel injector • BCM (ignition switch model)
• Keyless start control module (keyless push start model)
• Ignition START signal
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
• APP sensor
• MAP sensor
Ignition control Ignition coil with igniter • IAT sensor
• Knock sensor
• Battery voltage
• BCM (electric load signal)

• Ignition “ST” signal
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
• APP sensor
• MAP sensor
• IAT sensor
• HO2S-1
Idle speed control Throttle actuator
• HO2S-2
• Battery voltage
• ECT sensor
• CKP sensor
• TP sensor
• APP sensor
• MAP sensor
• IAT sensor
Throttle valve control Throttle actuator
• HO2S-1
• HO2S-2
• CKP sensor
• APP sensor
• Electric load current sensor signal
Generator control Generator
• Battery voltage

• ECT sensor
• TP sensor
HO2S-1 heater control HO2S-1 • MAP sensor
• IAT sensor
• CKP sensor
• Battery voltage
• ECT sensor
• TP sensor
HO2S-2 heater control HO2S-2 • MAP sensor
• IAT sensor
• CKP sensor
• Battery voltage
• ECT sensor
• CKP sensor
• TP sensor
• MAP sensor
• IAT sensor
EVAP canister purge • HO2S-1
EVAP purge control
valve • HO2S-2
• ECT sensor
• CKP sensor
• CMP sensor
• IAT sensor
VVT control OCV
• MAP sensor
• TP sensor

• ECT sensor
• CKP sensor
• TP sensor
• APP sensor
A/C compressor control A/C compressor relay • MAP sensor
• ECT sensor
• CKP sensor
Radiator cooling fan Radiator cooling fan • A/C refrigerant pressure sensor
control relay • BCM (electric load signal)
Fuel pump control Fuel pump relay • Ignition START signal
• CKP sensor
Starting motor control Starting motor control
relay control relay
• CKP sensor
Main relay control Main relay • Ignition “ON” signal
Schematic and Routing Diagram

Engine and Emission Control System Diagram
AENFL80B1112001
28
35
24
20
21
38
18
19
[B] 32
[A] 30
34
[B] 31
29
36
33
27
26
17
37
25
24
23
22
15
16
2
13
14
12
1
6
4
7
5
11
10
8
IFL80B111020-01
[A]. Ignition switch model 13. ECT sensor 27. CKP sensor
[B]. Air cleaner 14. HO2S-1 28. Brake light
1. Air cleaner 15. HO2S-2 29. Starting motor control relay
2. IAT sensor 16. OCV 30. Ignition switch
3. TP sensor 17. ECM 31. Keyless control module
4. Throttle actuator 18. Radiator cooling fan relay 32. IG1 relay
5. MAP sensor 19. A/C compressor relay 33. Main relay
6. Ignition coil assembly 20. A/C refrigerant pressure sensor 34. CPP No.1 switch (M/T model with keyless push
start system) or transmission range sensor (A/T
model)
7. Fuel injector 21. Generator 35. Starting motor
8. EVAP canister purge valve 22. Fuel pump relay 36. Electric load current sensor
9. EVAP canister 23. CPP No.2 switch (M/T model) 37. Barometric pressure sensor
10. Fuel filter 24. Brake light switch 38. Control modules and sensors connected by CAN
11. Fuel pump (with pressure regulator) 25. APP sensor
12. Knock sensor 26. CMP sensor
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
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
AENFL80B1112002
Electronic Control System Circuit Diagram

AENFL80B1112003
1
2 29 +B
BRN E01-15 IG1
C01-53 LT GRN +BB
3 LT BLU E01-18 30
BLU E01-21 C01-54 YEL/RED
C01-14 RED
BLK E01-4 31
C01-26 GRN
4 YEL E01-5 32
C01-8 WHT
WHT E01-20 C01-17 BLK
+B
C01-5 BLK 77
BLU
5 33
RED/YEL C01-28 C01-11 BLU/YEL
C01-12 BLU/WHT 34
6 35
PNK C01-31 C01-10 BLU/RED
GRY
C01-22 LT GRN/BLK 36
7 77
+B BLU C01-18
BLU RED C01-7
GRN/WHT C01-52 C01-40 BLU/BLK 37
YEL/GRN C01-37
38
77 C01-41 YEL
8
YEL C01-16
BRN C01-19 39
RED/BLU C01-49 E01-54 YEL
YEL/BLK C01-38 BLK PNK
9 40
BLK/YEL C01-25 41
E01-46 LT GRN 65
GRY/BLU C01-36 BLU/RED
10 BLK
LT GRN C01-20 42
GRY/BLU C01-45 43
11 E01-36 GRN 66
WHT C01-1 RED
BLU C01-13 BLK
44
12 GRY/RED C01-2 45
E01-48 GRY
RED/BLK C01-39 67
WHT
GRY/BLU C01-6 46
13 PNK E01-14 47
GRN E01-17 C01-32 GRN/YEL
GRY E01-8 48
[C] +B C01-33 GRN/WHT
49
14 PPL C01-27
C01-34 BRN
50
[A] 15
+BB PPL E01-27 C01-35 LT GRN
16
64
74 C01-4 BLU 51
17
GRN E01-28
18 52
E01-49 PNK
68
LT BLU E01-13 E01-55 BLU
GRN E01-7 E01-56 BLU
19
PNK E01-32 E01-6 WHT
[E] 75
YEL E01-22 70
+BB
IG2 63 [B] 53
20 GRY E01-40 69
IG2 [F]
62 57
IG1 69
54
IG2
M 21 55 ST
GRY GRY E01-19 73
22 61
71
56
23 [G]
58
[H] 59
[B]
WHT C01-15 E01-16 GRN
+BB 24 76
RED C01-3
72 60
E01-52 LT GRN
28 WHT E01-2
27 26 25 C01-50 BLK
RED E01-1 C01-51 BLK
[D] : 78 : 79 : 12V : 5V : 3.3V
IFL80B111021-01
[A]. M/T model 22. Blower speed selector 51. Generator

[B]. A/T model 23. A/C switch 52. Main relay
[C]. Non-ABS model 24. TCM 53. IG1 relay
[D]. ABS model 25. ABS control module 54. IG2 relay
[E]. Manual A/C model 26. BCM 55. Engine switch
[F]. Ignition switch model 27. Combination meter 56. Keyless start control module
[G]. Keyless push start model 28. DLC 57. Ignition switch
[H]. Ignition switch model (M/T model) 29. Electric throttle body assembly 58. Starting motor control relay
1. ECM 30. Throttle actuator 59. Starting motor
2. APP sensor 31. TP sensor (main) 60. CPP No.1 switch (M/T model with
keyless push start system) or
transmission range sensor (A/T
model)
3. APP sensor (main) 32. TP sensor (sub) 61. Main fuse box
4. APP sensor (sub) 33. Fuel injector No.1 62. Blower motor relay
5. CMP sensor 34. Fuel injector No.2 63. “BLW” fuse
6. CKP sensor 35. Fuel injector No.3 64. “STOP” fuse
7. HO2S-1 36. Fuel injector No.4 65. “RDTR” fuse
8. HO2S-2 37. EVAP canister purge valve 66. “CDSR” fuse
9. IAT sensor 38. OCV 67. “CPRSR” fuse
10. ECT sensor 39. Fuel pump relay 68. “FI” fuse
11. Knock sensor 40. Fuel pump 69. “IG1” fuse
12. MAP sensor 41. Radiator cooling fan relay No.1 70. “IG COIL” fuse
13. A/C refrigerant pressure sensor 42. Radiator cooling fan No.1 71. “ST” fuse
14. VSS 43. Radiator cooling fan relay No.2 72. “ST SIG2” fuse
15. CPP No.2 switch 44. Radiator cooling fan No.2 73. “ST SIG” fuse
16. Brake light switch 45. A/C compressor relay 74. LIN driver
17. Brake light 46. A/C compressor 75. Barometric pressure sensor
18. Electric load current sensor 47. Ignition coil assembly No.1 76. Battery
19. Battery temperature sensor 48. Ignition coil assembly No.2 77. Shield wire
20. Brake booster switch 49. Ignition coil assembly No.3 78. Engine ground
21. Blower motor 50. Ignition coil assembly No.4 79. Body ground
Terminal Arrangement of ECM Connector
NOTE
For circuit names and terminal voltages, refer to “Inspection of ECM and Its Circuits”: Petrol (Page 1A-
107).
[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])

Component Location
Electronic Control System Component Location
AENFL80B1113001
[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
IFL80B111019-04
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
Diagnostic Information and Procedures

MIL Check
AENFL80B1114002
1) Set ignition “ON” (with engine at stop) and check that
MIL (1) lights.
If MIL does not light up but engine can be started, go
to “MIL Does Not Come ON with Ignition “ON” and
Engine Stopped (but Engine Can Be Started)”:
Petrol in related manual for troubleshooting.
If MIL does not light with ignition “ON” and engine
1
does not start though it is cranked, go to “ECM
Power Supply and Ground Circuit Check”: Petrol
(Page 1A-118). 2
2) Start engine and check that MIL turns OFF.
If MIL remains ON and no DTC is stored in ECM, go
(A)
to “MIL Remains ON after Engine Starts”: Petrol in
related manual for troubleshooting.
[A]
IFL80B111018-04
3) Set ignition “ON” and confirm that MIL lights up.

4) Read DTC, pending DTC and freeze frame data
according to instructions displayed on scan tool and
print them or write them down. Refer to scan tool
operator's manual for further details.
If communication between scan tool and ECM is
impossible, go to “Troubleshooting for
[B] Communication Bus Off”: Petrol and Bi-Fuel CNG
Model in Section 10H (Page 10H-19).
1 5) After completing the check, set ignition “OFF” and
disconnect scan tool from DLC.
DTC Clearance
IFL80B111017-03 AENFL80B1114004
[A]: Without tachometer [B]: With tachometer

1) Connect SUZUKI scan tool or CAN communication
OBD-II generic scan tool to DLC.
DTC Check 2) Set ignition “OFF” and then “ON”.
AENFL80B1114003 3) Clear DTC and pending DTC according to
1) Prepare SUZUKI scan tool or CAN communication instructions displayed on scan tool. Refer to scan
OBD-II generic scan tool (2). tool operator's manual for further details.
Special tool 4) After completing the clearance, set ignition “OFF”
(A): SUZUKI scan tool (Suzuki SDT-II) and disconnect scan tool from DLC.
2) With ignition “OFF”, connect scan tool to DLC (1). NOTE
DTC and freeze frame data stored in ECM
memory are also cleared when the same
malfunction (DTC) is not detected again for
40 engine warm-up cycles. (See “Warm-Up
Cycle” of “OBD System Description”: Petrol
(Page 1A-1).) Be careful not to clear them
before keeping their record.
DTC Table
AENFL80B1114005
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”: Petrol (Page
1A-60).
• 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-32) 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-33) specified time.
System Performance
*P0030 HO2S Heater Control
HO2S-1 heater control circuit is open. 3 D/C Lights up
(Page 1A-35) Circuit (Sensor 1)
HO2S-1 heater control circuit is shorted to ground. 3 D/C Lights up
(Page 1A-35) Circuit Low (Sensor 1)
*P0032 HO2S Heater Control HO2S-1 heater control circuit is shorted to power
3 D/C Lights up
(Page 1A-35) Circuit High (Sensor 1) supply.
HO2S-2 heater control circuit is open. 3 D/C Lights up
(Page 1A-37) Circuit (Sensor 2)
HO2S-2 heater control circuit is shorted to ground. 3 D/C Lights up
(Page 1A-37) Circuit Low (Sensor 2)
*P0038 HO2S Heater Control HO2S-2 heater control circuit is shorted to power
3 D/C Lights up
(Page 1A-37) 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-39) 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-39) 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-40) 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-40) 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-42) Circuit Range /
with engine running.
Performance
Engine Coolant
*P0117 Output voltage of ECT sensor signal circuit is lower
Temperature Sensor 1 3 D/C Lights up
(Page 1A-43) 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-43) 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-44) lower than 0.2 V.
Low
*P0123 Output voltage of TP sensor (main) signal circuit is
Sensor / Switch “A” Circuit 1 D/C Lights up
(Page 1A-44) higher than 4.8 V.
High
DTC
logic
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-46) 1)
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-48) Voltage (Sensor 1)
*P0132 O2 Sensor Circuit High Output voltage of HO2S-1 circuit is higher than
3 D/C Lights up
(Page 1A-48) 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-50) 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-52) 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-54) 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-54) Voltage (Sensor 2) than 1.27 V for 25 sec.
*P0140 Output voltage of HO2S-2 circuit stays between
Activity Detected (Sensor 3 D/C Lights up
(Page 1A-54) 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-56) 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-56) for specified time under specified vehicle condition.
*P0222 Output voltage of TP sensor (sub) signal circuit is
Sensor / Switch “B” Circuit 1 D/C Lights up
Low
*P0223 Output voltage of TP sensor (sub) signal circuit is
Sensor / Switch “B” Circuit 1 D/C Lights up
High
• 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-60) Cylinder Misfire Detected lasts.)
• Misfire, which affects exhaust emission
adversely during 1000 engine revolutions, is
detected at 2 or more cylinders.
*P0301 Cylinder 1 Misfire Any of the following conditions is met.
3 D/C Lights up
(Page 1A-60) 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-60) Detected specific cylinder. (MIL blinks as long as misfire
*P0303 Cylinder 3 Misfire lasts.) 3 D/C Lights up
(Page 1A-60) Detected
*P0304 Cylinder 4 Misfire adversely during 1000 engine revolutions, is 3 D/C Lights up
(Page 1A-60) Detected detected at specific cylinder.
Output voltage of knock sensor signal circuit is
*P0327 Knock Sensor 1 Circuit
lower than specified value for specified time with 3 D/C Lights up
(Page 1A-63) Low
engine running.
DTC
logic
*P0328 Knock Sensor 1 Circuit
lower than specified value for specified time with 3 D/C Lights up
(Page 1A-63) High
engine running.
*P0335 Crankshaft Position CKP sensor signal is not inputted while CMP
3 D/C Lights up
(Page 1A-64) Sensor “A” Circuit sensor signal is being inputted.
Crankshaft Position
*P0336 Non-toothed position of sensor plate is out of the
Sensor “A” Circuit Range/ 3 D/C Lights up
(Page 1A-64) specified range.
Performance
• CMP sensor signal is not inputted while CKP
*P0340 Camshaft Position Sensor
sensor signal is being inputted. 3 D/C Lights up
(Page 1A-66) “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
3 D/C Lights up
(Page 1A-68) Secondary Circuit open with engine running.
*P0352 Ignition Coil “B” Primary / Ignition coil assembly No.2 and/or its circuit is
3 D/C Lights up
*P0353 Ignition Coil “C” Primary / Ignition coil assembly No.3 and/or its circuit is
3 D/C Lights up
*P0354 Ignition Coil “D” Primary / Ignition coil assembly No.4 and/or its circuit is
3 D/C Lights up
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-70) Below Threshold
condition.
Evaporative Emission
*P0443
System Purge Control EVAP canister purge valve control circuit is open. 3 D/C Lights up
(Page 1A-73)
Valve Circuit
*P0458 EVAP canister purge valve control circuit is
System Purge Control 3 D/C Lights up
(Page 1A-73) shorted to ground.
Valve Circuit Low
*P0459 EVAP canister purge valve control circuit is
System Purge Control 3 D/C Lights up
(Page 1A-73) shorted 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-74) 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-77) circuit is shorted to ground or open.
• Vehicle speed is slower than 4 km/h (2.5 mile/h)
*P0500 for 13 sec. at fuel cut condition.
Vehicle Speed Sensor “A” 3 D/C Lights up
(Page 1A-78) • Lost communication with ABS control module if
ABS is equipped. (M/T model)
• Lost communication with TCM. (A/T model)
• Output voltage of battery temperature sensor
*P0515 Battery Temperature
signal circuit is lower than 0.10 V for 5 sec. 3 D/C Lights up
(Page 1A-81) Sensor Circuit
signal circuit is higher than 4.85 V for 5 sec.
• 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-83) Sensor “A” Circuit
sensor signal circuit is higher than 4.93 V.
DTC
logic
Brake booster switch ON signal is input for more
P0557 (Page Brake Booster Pressure
than 3 sec. even if intake manifold negative 3 D/C Off
1A-84) Sensor Circuit Low
pressure is higher than specification.
Brake booster switch OFF signal is input for more
P0558 (Page Brake Booster Pressure
than 10 sec. even if intake manifold negative 3 D/C Off
1A-84) Sensor Circuit High
pressure is lower than specification.
*P0560 Main power supply voltage is lower than 2.54 V for
System Voltage 3 D/C Lights up
(Page 1A-86) 10 sec.
*P0562 Main power supply circuit voltage is lower than 9.8
System Voltage Low 3 D/C Lights up
(Page 1A-86) 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-86)
more.
P0602 (Page Control Module
ECM internal failure (data programming error). 1 D/C Off
1A-87) Programming Error
P0606 (Page
Control Module Processor ECM internal processor failure 3 D/C Off
1A-88)
1 D/C
*P0607 Control Module
Internal failure in ECM is detected. or Lights up
(Page 1A-89) Performance
3 D/C
P0645 (Page A/C Clutch Relay Control
A/C compressor relay drive circuit is open. 3 D/C Off
1A-89) Circuit
P0646 (Page A/C Clutch Relay Control A/C compressor relay drive circuit is shorted to
3 D/C Off
1A-89) Circuit Low ground.
P0647 (Page A/C Clutch Relay Control A/C compressor relay drive circuit is shorted to
3 D/C Off
1A-89) 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-74) 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-77) circuit is shorted to power supply.
• Output voltage of electric load current sensor
signal circuit is more than 4.80 V for 5 sec.
Generator Current Sensor
P0A5A (Page • Output voltage of electric load current sensor
Circuit Range / 3 D/C Off
1A-91) signal circuit is lower than 0.20 V for 5 sec.
Performance
signal circuit fluctuates less than specified value
for 5 sec.
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”: Ignition Switch Model in
Immobilizer Section 10C in related manual.
P1642 1 D/C Off
Communication Line Error
Immobilizer ID
P1644 1 D/C Off
Mismatched
P1646 ID Code Incorrectness 1 D/C Off
*P2088
Actuator Control Circuit OCV control circuit is shorted to ground. 3 D/C Lights up
(Page 1A-32)
Low
*P2089
Actuator Control Circuit OCV control circuit is shorted to power supply. 3 D/C Lights up
(Page 1A-32)
High
DTC
logic
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-93)
Open detected.
• 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-95) more than specified value.
Range / Performance
• Duty ratio of throttle actuator signal is out of
specified range for specified time.
• 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-95) return spring check process after setting ignition
Performance
“OFF”.
• Measured default throttle position is out of
specified range.
*P2122 Output voltage of APP sensor (main) signal circuit
Sensor / Switch “D” Circuit 1 D/C Lights up
(Page 1A-96) is lower than 0.6 V.
Low
*P2123 Output voltage of APP sensor (main) signal circuit
Sensor / Switch “D” Circuit 1 D/C Lights up
(Page 1A-96) is higher than 4.4 V.
High
*P2127 Output voltage of APP sensor (sub) signal circuit is
Sensor / Switch “E” Circuit 1 D/C Lights up
Low
*P2128 Output voltage of APP sensor (sub) signal circuit is
Sensor / Switch “E” Circuit 1 D/C Lights up
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
100) 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
102) Voltage Correlation specified value.
• 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.
103) Learned
• Electric throttle control system calibration is not
completed.
*P2228
Barometric Pressure Barometric pressure sensor signal voltage is lower
(Page 1A- 3 D/C Lights up
Sensor “A” Circuit Low than specified value for specified time.
104)
*P2229
Barometric Pressure Barometric pressure sensor signal voltage is
(Page 1A- 3 D/C Lights up
Sensor “A” Circuit High higher than specified value for specified time.
104)
*P2300 Ignition Coil “A” Primary Ignition coil assembly No.1 drive circuit voltage is
3 D/C Lights up
(Page 1A-68) 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-68) 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-68) 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-68) Control Circuit High shorted to power supply with engine running.
DTC
logic
*P2306 Ignition Coil “C” Primary Ignition coil assembly No.3 drive circuit voltage is
3 D/C Lights up
(Page 1A-68)
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-68)
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-68)
*P2310 Ignition Coil “D” Primary Ignition coil assembly No.4 drive circuit voltage is
3 D/C Lights up
(Page 1A-68)
Control Module
U0073 1 D/C Off
Communication Bus Off
Lost Communication With
U0101 1 D/C Off
TCM
U0121 ABS / ESP® Control 1 D/C Off
Module
Refer to “CAN DTC (Lost Communication and
U0131 Power Steering Control 1 D/C Off
Communication Bus Off) Table”: Petrol and Bi-Fuel
Module
CNG Model in Section 10H (Page 10H-10).
U0140 1 D/C Off
Body Control Module
U0141 Instrument Panel Cluster 1 D/C Off
(IPC) Control Module
U2001(Page LIN Lost Communication
Received data from generator via LIN is faulty. 1 D/C Off
1A-105) With Generator
U2021(Page LIN Invalid Data from ECM Transmitted data from ECM to generator via LIN is
1 D/C Off
1A-107) to Generator faulty.
Fail-Safe Table
AENFL80B1114006
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-32) Open
ECM stops CMP actuator control.
P0011 (Page “A” Camshaft Position Timing Over
1A-33) Advanced or System Performance
P0030 (Page
HO2S Heater Control Circuit (Sensor 1)
1A-35)
P0031 (Page HO2S Heater Control Circuit Low (Sensor
—
1A-35) 1)
P0032 (Page HO2S Heater Control Circuit High (Sensor
1A-35) 1)
P0036 (Page
HO2S Heater Control Circuit (Sensor 2)
1A-37)
P0037 (Page HO2S Heater Control Circuit Low (Sensor
—
1A-37) 2)
P0038 (Page HO2S Heater Control Circuit High (Sensor
1A-37) 2)
P0107 (Page Manifold Absolute Pressure / Barometric
1A-39) Pressure Circuit Low
ECM calculates MAP value from TP sensor.
P0108 (Page Manifold Absolute Pressure / Barometric
1A-39) Pressure Circuit High

P0112 (Page Intake Air Temperature Sensor 1 Circuit
1A-40) Low ECM controls actuators assuming that intake air
P0113 (Page Intake Air Temperature Sensor 1 Circuit temperature is 20 °C (68 °F).
1A-40) High
P0116 (Page Engine Coolant Temperature Sensor 1
1A-42) Circuit Range / Performance
P0117 (Page Engine Coolant Temperature Sensor 1 • ECM calculates ECT value from engine load.
1A-43) Circuit Low • ECM operates radiator cooling fan. (high speed)
P0118 (Page Engine Coolant Temperature Sensor 1
1A-43) Circuit High
P0122 (Page Throttle / Pedal Position Sensor / Switch
1A-44) “A” Circuit Low • ECM performs fuel cut at specified engine speed.
P0123 (Page Throttle / Pedal Position Sensor / Switch • ECM stops CMP actuator control.
1A-44) “A” Circuit High
P0130 (Page
O2 Sensor Circuit (Sensor 1)
1A-46)
P0131 (Page
O2 Sensor Circuit Low Voltage (Sensor 1) ECM stops A/F feedback (closed-loop) control.
1A-48)
P0132 (Page
O2 Sensor Circuit High Voltage (Sensor 1)
1A-48)
P0133 (Page O2 Sensor Circuit Slow Response (Sensor
—
1A-50) 1)
P0134 (Page O2 Sensor Circuit No Activity Detected
ECM stops A/F feedback (closed-loop) control.
1A-52) (Sensor 1)
P0137 (Page
O2 Sensor Circuit Low Voltage (Sensor 2)
1A-54)
P0138 (Page
O2 Sensor Circuit High Voltage (Sensor 2) —
1A-54)
P0140 (Page O2 Sensor Circuit No Activity Detected
1A-54) (Sensor 2)
P0171 (Page
System Too Lean
1A-56)
—
P0172 (Page
System Too Rich
1A-56)
1A-59) “B” Circuit Low • ECM performs fuel cut at specified engine speed.
P0223 (Page Throttle / Pedal Position Sensor / Switch • ECM stops CMP actuator control.
1A-59) “B” Circuit High
P0300 (Page Random / Multiple Cylinder Misfire
—
1A-60) Detected
P0301 (Page • ECM stops fuel injector No.1 control.
Cylinder 1 Misfire Detected
1A-60) • ECM stops A/F feedback (closed-loop) control.
P0327 (Page
Knock Sensor 1 Circuit Low
1A-63)
ECM retards ignition timing.
P0328 (Page
Knock Sensor 1 Circuit High
1A-63)
P0335 (Page
Crankshaft Position Sensor “A” Circuit
1A-64)
ECM calculates CKP based on CMP sensor signal.
P0336 (Page Crankshaft Position Sensor “A” Circuit
1A-64) Range/Performance
P0340 (Page • ECM stops CMP actuator control.
Camshaft Position Sensor “A” Circuit
1A-66) • ECM retards ignition timing.

P0351 (Page Ignition Coil “A” Primary / Secondary
1A-68) Circuit
P0352 (Page Ignition Coil “B” Primary / Secondary
1A-68) Circuit
—
P0353 (Page Ignition Coil “C” Primary / Secondary
1A-68) Circuit
P0354 (Page Ignition Coil “D” Primary / Secondary
1A-68) Circuit
P0420 (Page Catalyst System Efficiency Below
—
1A-70) Threshold
P0443 (Page Evaporative Emission System Purge
1A-73) Control Valve Circuit
ECM stops EVAP canister purge valve control.
1A-73) Control Valve Circuit Low
1A-73) Control Valve Circuit High
P0480 (Page
Fan 1 Control Circuit
1A-74)
—
P0481 (Page
Fan 2 Control Circuit
1A-77)
P0500 (Page ECM controls actuators assuming that vehicle speed is 0
Vehicle Speed Sensor “A”
1A-78) km/h (0 mile/h).
P0515 (Page
Battery Temperature Sensor Circuit ECM stops generator control.
1A-81)
• ECM operates radiator cooling fan. (high speed)
P0530 (Page A/C Refrigerant Pressure Sensor “A”
1A-83) Circuit • ECM controls actuators assuming that A/C refrigerant
pressure is 94.1 kPa.
P0557 (Page Brake Booster Pressure Sensor Circuit
1A-84) Low ECM performs A/C cut-off control according to estimated
P0558 (Page Brake Booster Pressure Sensor Circuit brake booster pressure.
1A-84) High
P0560 (Page ECM controls actuators assuming that system voltage is
System Voltage
1A-86) 13.5 V.
P0562 (Page
System Voltage Low
1A-86)
—
P0563 (Page
System Voltage High
1A-86)
P0602 (Page
Control Module Programming Error —
1A-87)
P0606 (Page
Control Module Processor —
1A-88)
Any one of the following operations will be taken:
• Fail-safe A:
– None
P0607 (Page • Fail-safe B:
Control Module Performance – ECM fixes throttle valve at default position (about
1A-89)
7°).
– ECM performs fuel cut at specified engine speed.
• Fail-safe C:
– ECM inhibits restarting engine.
P0645 (Page
A/C Clutch Relay Control Circuit
1A-89)
P0646 (Page
A/C Clutch Relay Control Circuit Low —
1A-89)
P0647 (Page
A/C Clutch Relay Control Circuit High
1A-89)

P0692 (Page
Fan 1 Control Circuit High
1A-74)
—
P0694 (Page
Fan 2 Control Circuit High
1A-77)
P0A5A (Page Generator Current Sensor Circuit Range /
ECM stops generator control.
1A-91) Performance
P2088 (Page “A” Camshaft Position Actuator Control
1A-32) Circuit Low
ECM stops CMP actuator control.
P2089 (Page “A” Camshaft Position Actuator Control
1A-32) Circuit High
P2100 (Page Throttle Actuator Control Motor Circuit /
ECM performs fuel cut at specified engine speed.
1A-93) Open
P2101 (Page Throttle Actuator Control Motor Circuit
1A-95) Range / Performance
ECM performs fuel cut at specified engine speed.
P2119 (Page Throttle Actuator Control Throttle Body
1A-95) Range / Performance
ECM limits APP signal within specified range.
1A-96) “D” Circuit Low
If DTC P2127 or P2128 is detected at the same time,
ECM controls engine speed at specified value.
1A-96) “D” Circuit High
ECM limits APP within specified range.
1A-99) “E” Circuit Low
If DTC P2122 or P2123 is detected at the same time,
ECM controls engine speed at specified value.
1A-99) “E” Circuit High
P2135 (Page Throttle / Pedal Position Sensor / Switch • ECM performs fuel cut at specified engine speed.
1A-100) “A” / “B” Voltage Correlation • ECM stops CMP actuator control.
ECM limits APP within specified range.
1A-102) “D” / “E” Voltage Correlation
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-103) Position Not Learned • ECM fixes minimum throttle valve position to specified
throttle valve position.
P2228 (Page Barometric Pressure Sensor “A” Circuit
1A-104) Low
ECM calculates BARO value from TP sensor signal.
P2229 (Page Barometric Pressure Sensor “A” Circuit
1A-104) High
P2300 (Page Ignition Coil “A” Primary Control Circuit
1A-68) Low
—
P2301 (Page Ignition Coil “A” Primary Control Circuit
1A-68) High
P2303 (Page Ignition Coil “B” Primary Control Circuit
1A-68) Low
—
P2304 (Page Ignition Coil “B” Primary Control Circuit
1A-68) High
P2306 (Page Ignition Coil “C” Primary Control Circuit
1A-68) Low
—
P2307 (Page Ignition Coil “C” Primary Control Circuit
1A-68) High
P2309 (Page Ignition Coil “D” Primary Control Circuit
1A-68) Low
—
P2310 (Page Ignition Coil “D” Primary Control Circuit
1A-68) High
U0073 Control Module Communication Bus Off —

U0101 Lost Communication With TCM
Lost Communication With ABS / ESP®
U0121
Control Module
Lost Communication With Power Steering
U0131
Control Module Refer to “CAN DTC (Lost Communication and
Lost Communication With Body Control Communication Bus Off) Table”: Petrol and Bi-Fuel CNG
U0140
Module Model in Section 10H (Page 10H-10).
Lost Communication With Keyless Start
U0141
Control Module
Lost Communication With Instrument
U0155
Panel Cluster (IPC) Control Module
U2001 (Page
LIN Lost Communication With Generator
1A-105)
ECM stops generator control.
U2021 (Page
LIN Invalid Data from ECM to Generator
1A-107)
Scan Tool Data

AENFL80B1114007
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.
Use a timing light to check the ignition timing. (Page 1H-2)
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-29)
Long Term Fuel Trim
(Page 1A-29)
Total Fuel Trim (Page
Engine: Idle speed after warming up Approx. –30 to 30%
1A-29)
Inj Pulse Width (Page
Engine: Idle speed with no load after warming up Approx. 1.6 to 4.0 msec
1A-29)
Ignition Advance (Page
* Engine: Idle speed with no load after warming up –5 to 15° BTDC
1A-29)
Calculated Load (Page
* Engine: Idle speed with no load after warming up Approx. 10 to 30%
1A-29)
Normal condition /
reference value
Engine: Idle speed after warming up
Engine Speed (Page Radiator cooling fan: Stopped
* 600 to 700 rpm
1A-29) All electrical equipment: OFF
Shift lever: “Neutral”
Desired Idle (Page 1A- Radiator cooling fan: Stopped
Approx. 650 rpm
29) All electrical equipment: OFF
Vehicle Speed (Page
* Vehicle running Vehicle speed is displayed.
1A-29)
* MAP (Page 1A-29) Engine: Idle speed after warming up Approx. 20 to 55 kPa
Approx. 80 to 105 °C (176
* ECT (Page 1A-29) 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-29) to 40 °C (104 °F) +
environmental temperature
Barometric Pres (Page Barometric pressure is
* —
1A-29) displayed.
EVAP Canist Prg Duty
* Engine: Idle speed after warming up 0%
(Page 1A-29)
VVT Gap (Page 1A-29) 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-29) 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-29) Ignition: “ON”
4.2 to 4.7 V
Accelerator pedal: Fully depressed
Ignition: “ON”
3.9 to 4.4 V
0.3 to 0.8 V
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
Ignition: “ON”
0.3 to 0.5 V
1.8 to 2.2 V
Ignition: “ON”
0 to 2%
Accel Position (Page Accelerator pedal: Released
*
90 to 100%
Ignition: “ON”
0 to 10%
Throttle Position (Page Accelerator pedal: Released
*
90 to 100%
Ignition: “ON”
0 to 10%
Target Throttle Posi Accelerator pedal: Released
*
90 to 100%
O2S B1 S1 (Page 1A-
* Engine: Idle speed after warming up 0 to 1.0 V
30)
* Engine: 2,000 rpm for 3 min. or more after warming up 0 to 1.0 V
30)
Normal condition /
reference value
Battery Voltage (Page
* Engine: Idle speed Approx. 13 to 15 V
1A-30)
Fuel Tank Level (Page
Ignition: “ON” 0 to 100%
1A-30)
Engine: Idle speed
A/C Pressure (Page
A/C switch: ON 600 to 1,300 kPa
1A-30)
Blower speed selector: MAX
Generator Field Duty
Engine: Idle speed after warming up Approx. 20 to 100%
(Page 1A-30)
Ignition: “ON” 2 to 8 A
Ignition: “ON”
10 to 24 A
Battery Current (Page Headlight: ON
Headlight: ON 24 to 33 A
Blower speed selector: Max position
Battery Temperature Battery temperature is
—
(Page 1A-30) displayed.
Generator Reg Volt
Engine: Idle speed 10.4 to 16.3 V
(Com) (Page 1A-30)
Radiator cooling fan: Off Off
Radiator Fan (Page 1A-
Radiator cooling fan: Low speed Low
30)
Radiator cooling fan: High speed High
A/C switch: ON
A/C Comp Relay (Page ON
Blower speed selector: ON
1A-30)
Other than above condition OFF
Fuel Pump (Page 1A- Engine running ON
30) Other than above condition OFF
Starter SW (Page 1A- Ignition: “ST” (engine cranking) ON
A/C switch: ON
A/C Switch (Page 1A- ON
Blower speed selector: ON0
30)
Manual A/C: 2nd or higher speed position
ON
Blower Fan (Page 1A- Auto A/C: 4th or higher speed position
30) • Engine condition: Stopped
OFF
• Brake pedal: Fully depressed several times
Specified idle speed after warming up Value Hi (sufficient)
Brake Booster Vacuum
Manual A/C: Other than above condition
Condition (Page 1A-30) Value Lo (insufficient)
Auto A/C: Other than above condition
Brake Switch (Page Brake pedal: Depressed ON
1A-30) Brake pedal: Released OFF
Electric Load (Page 1A- Headlight switch: ON ON
30) Headlight switch: OFF OFF
A/T model
Engine: Running D
PNP Signal (Page 1A- Shift select lever: Other than P or N position
31) A/T model
Engine: Running P/N
Shift select lever: P or N position
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
OFF
Normal condition /
reference value
O2S B1 S1 Act (Page
Engine: Idle speed after warming up Active
1A-31)
1A-31)
Scan Tool Data Definitions Engine Speed (rpm):

Fuel System (Fuel system status): The engine speed is calculated from reference pulses
A/F ratio feedback loop status is displayed as follows. from the camshaft position sensor.
OL: Open-loop control before satisfaction of closed loop
control conditions (ECT > 10 °C, IAT, TP, HO2S-1/ Desired Idle (Desired idle speed, rpm):
system = OK). The Desired Idle Speed is an ECM internal parameter
CL: Closed-loop control using oxygen sensor(s) as which indicates idle speed requested by ECM. If the
feedback sensor(s). engine is not running, this number is not valid.
OL-DRIVE: Open-loop control due to driving requirement
(power-up enrichment etc.). Vehicle Speed (km/h, mph):
OL-FAULT: Open-loop control due to system fault The vehicle speed is calculated based on pulse signals
detected. from VSS.
CL-FAULT: Closed-loop control due to system fault
detected. MAP (Manifold absolute pressure, kPa, mmHg, inHg,
psi, inH2O):
Short Term Fuel Trim (%): This parameter indicates the calculated manifold
Short term fuel trim value represents short term pressure based on MAP sensor signal.
corrections to air/fuel mixture. 0 (zero) indicates no
correction, a value greater than 0 indicates enrichment ECT (Engine coolant temperature, °C, °F):
correction, and a value less than 0 indicates enleanment It is detected by engine coolant temperature sensor.
correction.
Intake Air Temperature. (°C, °F):
Long Term Fuel Trim (%): It is detected by intake air temperature sensor.
Long term fuel trim value represents long term
corrections to air/fuel mixture. 0 (zero) indicates no Barometric Pres (Barometric pressure, kPa, mmHg,
correction, a value greater than 0 indicates enrichment inHg, psi, inH2O):
correction, and a value less than 0 indicates enleanment This parameter represents barometric air pressure
correction. measurement and is used for altitude correction of the
fuel injection rate.
Total Fuel Trim (%):
Total Fuel Trim is calculated from Short Term Fuel Trim Evap Canist Prg Duty (Evap canister purge flow
and Long Term Fuel Trim. This value indicates how duty, %):
much correction is necessary to keep the air/fuel mixture This parameter indicates valve ON (valve open) time
stoichiometrical. rate within a certain set cycle of EVAP canister purge
valve which controls the amount of EVAP purge.
Inj Pulse Width (Fuel injection pulse width, msec.):
This parameter indicates the injector drive pulse width VVT Gap (Variable valve timing difference between
(time) during which the injector valve stays open as target and actual position, °CA):
commanded by ECM. (For multipoint fuel injection, the This parameter indicates difference between target
injector drive time means that of the No.1 cylinder.) camshaft position and actual camshaft position.
Ignition Advance (Ignition timing advance for No.1 IAC Throttle Opening (Idle air throttle valve opening,
cylinder, ° BTDC): %):
This parameter indicates the ignition timing of No.1 This parameter indicates throttle valve opening of idle air
cylinder commanded by ECM. The actual ignition timing control in % (100% indicates the maximum idle air flow).
should be checked using a timing light.
TP Sensor 1 Volt (TP sensor (main) output voltage,
Calculated Load (Calculated load value, %): V):
This parameter indicates calculated engine load in TP Sensor (Main) data provides throttle valve opening
percent. The load is calculated based on input signals to information in the form of voltage.
ECM from various engine sensors.
TP Sensor 2 Volt (TP sensor (sub) output voltage, V): Battery Current (A):
TP Sensor (Sub) data provides throttle valve opening This parameter indicates electric load value (current
information in the form of voltage. consumption) that is detected by electric load current
sensor.
APP Sensor 1 Volt (APP sensor (main) output
voltage, V): Battery Temperature (°C, °F):
APP Sensor (Main) data provides accelerator pedal This parameter indicates battery temperature measured
position information in the form of voltage. by battery temperature sensor.
APP Sensor 2 Volt (APP sensor (sub) output voltage, Generator Reg Volt (Com) (V):
V): This parameter indicates commanded regulated-voltage
APP Sensor (Sub) data provides accelerator pedal to generator.
position information in the form of voltage.
Radiator Fan (Radiator cooling fan control relay,
Accel Position (Absolute accelerator pedal position, Low/High/Off):
%): Low: ON command is being output to the radiator
This parameter indicates calculated accelerator pedal cooling fan relay No.1.
position in percent based on input from accelerator pedal High: ON command is being output to radiator cooling
position sensor. fan relays No.2 and No.3.
Off: No command is being output.
Throttle Position (Absolute throttle position, %):
This parameter indicates calculated throttle opening in A/C Comp Relay (A/C compressor relay, ON/OFF):
percent based on input from throttle position sensor. This parameter indicates the state of the A/C
compressor relay.
Target Throttle Posi (Target throttle valve position,
%): Fuel Pump (ON/OFF):
Target Throttle Valve Position is an ECM internal ON is displayed when ECM activates the fuel pump via
parameter which indicates throttle valve position the fuel pump relay switch.
requested by ECM.
Starter SW (Starter switch, ON/OFF):
O2S B1 S1 (HO2S-1, V): This parameter indicates state of starting motor relay
It indicates output voltage of HO2S-1 installed on output.
exhaust manifold (Pre-TWC). ON: Starting motor relay is ON.
OFF: Starting motor relay is OFF.
O2S B1 S2 (HO2S-2, V):
It indicates output voltage of HO2S-2 installed on A/C Switch (ON/OFF):
exhaust manifold (post-TWC). It is used to detect ON: Command for A/C operation is being output from
catalyst deterioration. ECM to HVAC.
OFF: Command for A/C operation is not being output.
Battery Voltage (V):
This parameter indicates battery voltage inputted from Blower Fan (ON/OFF):
main relay to ECM. This parameter indicates the state of the blower speed
selector.
Fuel Tank Level (%):
This parameter indicates approximate fuel level in the Brake Booster Vacuum Condition (Value Hi
fuel tank. The fuel level data is provided in percentage (sufficient), Value Lo (insufficient):
from 0 to 100%. This parameter indicates the state of brake booster
negative pressure.
A/C Pressure (A/C refrigerant absolute pressure,
kPa, mmHg, inHg, psi, inH2O): Brake Switch (ON/OFF):
This parameter indicates A/C refrigerant absolute This parameter indicates the state of the brake switch.
pressure detected by A/C refrigerant pressure sensor.
Electric Load (ON/OFF):
Generator Field Duty (%): ON: ON signal of headlight, clearance lights or rear end
This parameter indicates operating rate (status of door window defogger is input.
output) of the generator by field coil duty ratio. OFF: Above electric loads all turned off.
100%: Maximum operation
0%: Minimum operation
PNP Signal (P/N or D range) (A/T model): Closed Throttle Pos (Closed throttle position, ON/
Whether the transmission range switch is in P / N range OFF):
or other ranges is displayed. If it is in P or N range, “P/N” This parameter is ON when throttle valve is at idle
is displayed and if it is in other than P and N ranges, “D” position and OFF when the valve is not at idle position.
is displayed.
O2S B1 S1 ACT (HO2S-1, Active / Inactive):
Clutch SW (Clutch switch, Declutch / Clutch): This parameter indicates the activation condition of
Declutch: Clutch pedal depressed fully HO2S-1.
Clutched: Clutch pedal released ACTIVE: The sensor is activated.
INACTIVE: The sensor is being warmed up or not
Fuel Cut (ON/OFF): activated.
ON: Fuel injection is cut (output signal to injector is
stopped). O2S B1 S2 ACT (HO2S-2, Active / Inactive):
OFF: Fuel injection is not cut. 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
AENFL80B1114008
• Visually check the following parts and systems.
Inspection Item Referring section
“Engine Oil and Filter Change” in Section 0B
Level
Engine oil in related manual
Leakage —
“Coolant Level Check”: Petrol and Bi-Fuel
Level
CNG in Section 1F in related manual
Engine coolant “Engine Cooling System Inspection”: Petrol
Leakage and Bi-Fuel CNG in Section 1F in related
manual
Level —
Fuel “Fuel Leakage Check Procedure”: Petrol in
Leakage
Section 1G in related manual
Dirt “Air Cleaner Filter Inspection and Cleaning”:
Air cleaner filter Petrol and Bi-Fuel CNG in Section 1D in
Clogging
related manual
Fluid level “Battery Inspection”: Petrol and Bi-Fuel CNG
Battery
Corrosion of terminal in Section 1J in related manual
Tension “Water Pump / Generator Drive Belt Tension
Accessory drive belt Inspection and Adjustment”: Petrol and Bi-
Damage
Fuel CNG in Section 1J in related manual
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 and nuts Looseness —
• Additionally check the following items at engine start, if possible.

MIL Operation “MIL Check”: Petrol (Page 1A-16)
“Generator Symptom Diagnosis”: Petrol and
Charging light Operation
Bi-Fuel CNG in Section 1J (Page 1J-2)

“Oil Pressure Switch On-Vehicle Inspection”:
Engine oil pressure light Operation Petrol and Bi-Fuel CNG in Section 1E in
related manual
“ECT Sensor Inspection”: Petrol and Bi-Fuel
Engine coolant temperature meter Operation
CNG in Section 1C in related manual
“Fuel Level Sensor Inspection”: Petrol in
Fuel level sensor Operation
Section 1G in related manual
Tachometer Operation Section 9C.
“Exhaust System Check”: Petrol and Bi-Fuel
Exhaust system Leakage of exhaust gas, noise
CNG in Section 1K in related manual
Abnormal air being inhaled at air intake system —
Other parts that can be checked visually —
DTC P0010 / P2088 / P2089

AENFL80B1114013
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.
P2089: “A” Camshaft Position Actuator Control Circuit High
OCV control circuit is shorted to power supply.
Circuit Diagram
1 A1
C01-41 YEL 3
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
IEL10A111008-01
[A]: ECM connector (View: [a]) A2: OCV drive circuit 2. ECM
A1: OCV power supply circuit 1. OCV 3. To main relay
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”: Petrol
in related manual.
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?

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. 
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. 
Is other DTC(s) detected together?
DTC P0011
AENFL80B1114014
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
• OCV oil passage
• CMP actuator
• Valve timing
• ECM
Circuit Diagram
1 A1
C01-41 YEL 3
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
IEL10A111008-01
[A]: ECM connector (View: [a]) A2: OCV drive circuit 2. ECM
A1: OCV power supply circuit 1. OCV 3. To main relay
! WARNING
If you do not select a suitable route and take proper precautions when performing a road test, an
accident can occur.
• Select a level road with no traffic to minimize the risk of accident.
• Perform 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
Check that the following DTC is not detected in this “DTC Confirmation Procedure”.
• OCV (P0010, P2088 and P2089)
1) Warm up engine and repeat acceleration and deceleration between 30 and 80 km/h (18 to 50 mile/h) more than 10
times.
DTC Troubleshooting
Step Action Yes No
in related manual.
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”: Petrol (Page 1A-
32).
Is check result OK?

Step Action Yes No

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

5 OCV oil circuit visual check Go to Step 6. Repair or replace
1) Remove cylinder head cover. (Page 1D-7) 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: 
• Sensor plate: 
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: 
• Signal rotor:
Is check result OK?

8 OCV check Go to Step 9. Replace OCV.
1) Check OCV. 
Is check result OK?

9 CMP actuator check Go to Step 10. Replace CMP actuator.
1) Check CMP actuator.  
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.  timing chain correctly, or
condition.  replace defective parts.
Is check result OK?
DTC P0030 / P0031 / P0032

AENFL80B1114015
P0030: HO2S Heater Control Circuit (Sensor 1) • HO2S-1 heater and/or its circuit
HO2S-1 heater control circuit is open. • ECM
P0031: HO2S Heater Control Circuit Low (Sensor 1)
HO2S-1 heater control circuit is shorted to ground.
P0032: HO2S Heater Control Circuit High (Sensor 1)
HO2S-1 heater control circuit is shorted to power supply.
Circuit Diagram
+B 1 4 A3
BLU C01-18 5V
A2
RED C01-7
A4
BLU GRN/WHT C01-52
A1 YEL/GRN C01-37
2 4 B3
YEL C01-16 5V
B2
BRN C01-19
B4
BLU RED/BLU C01-49
B1 YEL/BLK C01-38
[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
IEL10A111009-01
[A]: ECM connector (View: [a]) B1: HO2S-2 heater power supply circuit 2. HO2S-2
A1: HO2S-1 heater power supply circuit B2: HO2S-2 signal circuit 3. ECM
A2: HO2S-1 signal circuit B3: HO2S-2 ground circuit 4. Shield wire
A3: HO2S-1 ground circuit B4: HO2S-2 heater drive circuit
A4: HO2S-1 heater drive circuit 1. HO2S-1
NOTE
1) Warm up engine to normal operating temperature and run engine at idle speed for 60 sec.
DTC Troubleshooting
Step Action Yes No
in related manual.
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.
4) Check that voltage between “A1” circuit and ground is
battery voltage.
Is check result OK?

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.
terminal at HO2S-1 connector: infinity
“ON”)
Is check result OK?

4 HO2S-1 heater check Replace ECM and Replace HO2S-1. 
1) Check HO2S-1 heater.  recheck DTC. 
Is check result OK?
DTC P0036 / P0037 / P0038

AENFL80B1114016
P0036: HO2S Heater Control Circuit (Sensor 2) • HO2S-2 heater and/or its circuit
HO2S-2 heater control circuit is open. • ECM
P0037: HO2S Heater Control Circuit Low (Sensor 2)
HO2S-2 heater control circuit is shorted to ground.
P0038: HO2S Heater Control Circuit High (Sensor 2)
HO2S-2 heater control circuit is shorted to power supply.
Circuit Diagram
+B 1 4 A3
BLU C01-18 5V
A2
RED C01-7
A4
BLU GRN/WHT C01-52
A1 YEL/GRN C01-37
2 4 B3
YEL C01-16 5V
B2
BRN C01-19
B4
BLU RED/BLU C01-49
B1 YEL/BLK C01-38
[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
IEL10A111009-01
NOTE
Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
1) Warm up engine to normal operating temperature and run engine at idle speed for 60 sec.
DTC Troubleshooting
Step Action Yes No
in related manual.
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.
4) Check that voltage between “B1” circuit and ground is
battery voltage.
Is check result OK?

Step Action Yes No

3 HO2S-2 heater drive circuit check Go to Step 4. Repair or replace
connectors.
• 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.  recheck DTC. 
Is check result OK?
DTC P0107 / P0108

AENFL80B1114017
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
P0108: Manifold Absolute Pressure / Barometric Pressure Circuit High
Output voltage of MAP sensor signal circuit is higher than 4.9 V for 5 sec.
Circuit Diagram
1 5V
A1
GRY/RED C01-2
A2
RED/BLK C01-39
A3
GRY/BLU C01-6
[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
IEL10A111010-01
[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

DTC Troubleshooting
Step Action Yes No
in related manual.
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.
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.

4 MAP sensor signal circuit check Go to Step 5. Repair or replace
connectors.
terminal at MAP sensor connector: infinity
“ON”)
Is check result OK?

5 MAP sensor check Replace ECM and Replace MAP sensor. 
1) Check MAP sensor.  recheck DTC. 
Is check result OK?
DTC P0112 / P0113

AENFL80B1114018
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
P0113: Intake Air Temperature Sensor 1 Circuit High
Output voltage of IAT sensor signal circuit is higher than 3.2 V for 5 sec.
Circuit Diagram
2
A1 5V
1
BLK/YEL C01-25
GRY/BLU C01-36
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
IEL10A111011-01
[A]: ECM connector (View: [a]) A2: IAT sensor ground circuit 2. ECM
A1: IAT sensor signal circuit 1. IAT sensor
NOTE
Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
• ECT sensor (P0116, P0117 and P0118)
DTC Troubleshooting
Step Action Yes No
in related manual.
2 IAT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
connectors from ECM and connector from IAT sensor.
2) Check for proper terminal connection to connectors of
“C01”, “E01” and IAT sensor.
• Resistance of “A1” and “A2” circuits: less than 1Ω
• Resistance between each of “A1” and “A2” circuits
and ground: infinity
terminal at IAT sensor connector: infinity
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.  recheck DTC. 
Is check result OK?

DTC P0116
AENFL80B1114019
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
2
A1 5V
1
LT GRN C01-20
GRY/BLU C01-45
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
IEL10A111012-01
[A]: ECM connector (View: [a]) A2: ECT sensor ground circuit 2. ECM
A1: ECT sensor signal circuit 1. ECT sensor
! WARNING

• Road test should be performed by two persons, a driver and a tester, on a level road.
NOTE
• ECT sensor (P0118)
1) Warm up engine to normal operating temperature.

2) Run engine at idle speed for 5 min.
DTC Troubleshooting
Step Action Yes No
in related manual.
2 Coolant level check Go to Step 3. Check coolant leakage
1) Check coolant level.  and add coolant, then
recheck DTC.
Is check result OK?
Step Action Yes No

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”: Petrol (Page 1A-43).
Is check result OK?

4 Thermostat check Go to Step 5. Replace thermostat. 
1) Check thermostat. 
Is check result OK?

5 ECT sensor check Replace ECM and Replace ECT sensor. 
1) Check ECT sensor.  recheck DTC. 
Is check result OK?
DTC P0117 / P0118

AENFL80B1114020
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
P0118: Engine Coolant Temperature Sensor 1 Circuit High
Output voltage of ECT sensor signal circuit is higher than 3.2 V for 5 sec.
Circuit Diagram
2
A1 5V
1
LT GRN C01-20
GRY/BLU C01-45
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
IEL10A111012-01
[A]: ECM connector (View: [a]) A2: ECT sensor ground circuit 2. ECM
A1: ECT sensor signal circuit 1. ECT sensor

P0117
1) Set ignition “ON” for 10 sec.
P0118
NOTE
• IAT sensor (P0112 and P0113)
DTC Troubleshooting
Step Action Yes No
in related manual.
2 ECT sensor signal circuit and ground circuit check Go to Step 3. Repair or replace
connectors from ECM and connector from ECT sensor.
“C01”, “E01” and ECT sensor.
• Resistance of “A1” and “A2” circuits: less than 1Ω
terminal at ECT sensor connector: infinity
Is check result OK?

Is check result OK?
DTC P0122 / P0123

AENFL80B1114021
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
P0123: Throttle / Pedal Position Sensor / Switch “A” Circuit High
Output voltage of TP sensor (main) signal circuit is higher than 4.8 V.
Circuit Diagram
5
12V
A1 1
C01-53 LT GRN
4
C01-54 YEL/RED M
5V A2 B1
C01-14 RED
B2 2
C01-26 GRN
B3 3
C01-8 WHT
B4
C01-17 BLK
C01-5 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
IEL10A111013-01
[A]: ECM connector (View: [a]) B3: TP sensor (sub) signal circuit 4. Throttle actuator
A1: Throttle actuator control circuit (close) B4: TP sensor ground circuit 5. ECM
A2: Throttle actuator control circuit (open) 1. Electric throttle body assembly 6. Shield wire
B1: TP sensor power supply circuit 2. TP sensor (main)
B2: TP sensor (main) signal circuit 3. TP sensor (sub)

P0122
NOTE
• TP sensor (P0123)

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) 3 times.
P0123
DTC Troubleshooting
Step Action Yes No
in related manual.
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.
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

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.
connectors.
• Resistance of “B2” circuit: less than 1 Ω
terminal at TP sensor connector: infinity
“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.  body assembly. (Page
Performance Check” under . 1D-5)
Is check result OK?
DTC P0130
AENFL80B1114022
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.
Circuit Diagram
+B 1 4 A3
BLU C01-18 5V
A2
RED C01-7
A4
BLU GRN/WHT C01-52
A1 YEL/GRN C01-37
2 4 B3
YEL C01-16 5V
B2
BRN C01-19
B4
BLU RED/BLU C01-49
B1 YEL/BLK C01-38
[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
IEL10A111009-01
! WARNING
accident can occur.
• Perform the test extremely carefully.
• Perform the road test with 2 persons, a driver and an assistant.
NOTE
• Check that the following conditions are met in this “DTC Confirmation Procedure”.
– A/F feedback (closed loop) control is activated.
– Battery voltage > 11 V
• Check that the following DTCs are not detected in this “DTC Confirmation Procedure”.
– HO2S-1 heater (P0030, P0031 and P0032)
– HO2S-2 (P0137, P0138 and P0140)

2) Drive vehicle at 50 to 80 km/h (31 to 50 mile/h) constantly for 10 min. or more.
3) Release accelerator pedal, and keep vehicle coasting for 15 sec. with engine braking applied (fuel cut condition).
DTC Troubleshooting
Step Action Yes No
in related manual
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: 
• HO2S-1 circuit: Step 3 under “DTC P0131 / P0132”:
Petrol (Page 1A-48)
• HO2S-1 heater circuit: Step 2 through 3 under “DTC
P0030 / P0031 / P0032”: Petrol (Page 1A-35)
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.
• HO2S-2 heater: 
• HO2S-2 circuit: Step 3 under “DTC P0137 / P0138 /
P0140”: Petrol (Page 1A-54)
• HO2S-2 heater circuit: Step 2 through 3 under “DTC
P0036 / P0037 / P0038”: Petrol (Page 1A-37)
Is check result OK?

5 DTC recheck Go to Step 6. END.
1) Replace HO2S-1. 
2) Perform DTC confirmation procedure, and check DTC.
Is DTC P0130 still detected?

6 DTC recheck Replace ECM and END.
1) Replace HO2S-2.  recheck DTC. 
DTC P0131 / P0132

AENFL80B1114023
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.
P0132: O2 Sensor Circuit High Voltage (sensor 1)
Output voltage of HO2S-1 circuit is higher than 1.27 V for 25 sec.
Circuit Diagram
+B 1 4 A3
BLU C01-18 5V
A2
RED C01-7
A4
BLU GRN/WHT C01-52
A1 YEL/GRN C01-37
2 4 B3
YEL C01-16 5V
B2
BRN C01-19
B4
BLU RED/BLU C01-49
B1 YEL/BLK C01-38
[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
IEL10A111009-01

P0131
NOTE
• Confirm that the following conditions are met in this “DTC Confirmation Procedure”.
– ECT sensor (P0116, P0117 and P0118)

P0132
NOTE

DTC Troubleshooting
Step Action Yes No
in related manual.
for applicable DTC.
Is there any DTC(s) other than P0131 and P0132?
3 HO2S-1 signal circuit check Go to Step 4. Repair or replace
connectors from ECM and connector from HO2S-1.
“C01”, “E01” and HO2S-1.
• Resistance of “A2” and “A3” circuits: less than 1 Ω
• Voltage of “A2” and “A3” circuits: approx. 0 V (when
Is check result OK?

4 DTC recheck Replace ECM and End.
2) Perform DTC confirmation procedure to check for DTCs.
Is DTC P0131 or P0132 still detected?
DTC P0133
AENFL80B1114024
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
• Exhaust system
• Fuel system
• ECM
Circuit Diagram
+B 1 4 A3
BLU C01-18 5V
A2
RED C01-7
A4
BLU GRN/WHT C01-52
A1 YEL/GRN C01-37
2 4 B3
YEL C01-16 5V
B2
BRN C01-19
B4
BLU RED/BLU C01-49
B1 YEL/BLK C01-38
[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
IEL10A111009-01
! WARNING
accident can occur.
NOTE
– A/F feedback (closed-loop) control is activated.
– HO2S-1 (P0130, P0131, P0132 and P0134)
– Fuel trim system (P0171 and P0172)
– Cylinder misfire detected (P0300)
– CKP sensor (P0335)
– CMP sensor (P0340)
– EVAP canister purge valve (P0443, P0458 and P0459)
– System voltage (P0560, P0562 and P0563)

2) With engine speed at 1,600 to 2,500 rpm, drive vehicle at 50 to 80 km/h (31 to 50 mile/h) for 5 min.
3) Check whether O2 sensor readiness / monitoring test has completed or not 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
in related manual.
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”: Petrol in Section 1G in related manual.
Is check result OK?

1) Check “A2” circuit according to Step 3 under “DTC defective wire harness.
P0131 / P0132”: Petrol (Page 1A-48).
Is check result OK?

6 HO2S-1 heater check Go to Step 7. Replace HO2S-1. 
1) Check HO2S-1 heater. 
Is check result OK?

2) Perform DTC confirmation procedure and check DTC.
DTC P0134
AENFL80B1114025
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 heater
• Air intake system
• Exhaust system
• ECM
Circuit Diagram
+B 1 4 A3
BLU C01-18 5V
A2
RED C01-7
A4
BLU GRN/WHT C01-52
A1 YEL/GRN C01-37
2 4 B3
YEL C01-16 5V
B2
BRN C01-19
B4
BLU RED/BLU C01-49
B1 YEL/BLK C01-38
[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
IEL10A111009-01
! WARNING
accident can occur.
NOTE

DTC Troubleshooting
Step Action Yes No
in related manual.
Step Action Yes No

2 HO2S-1 heater check Go to Step 3. Replace HO2S-1. 
1) Check HO2S-1 heater. 
Is check result OK?

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”: Petrol (Page 1A-
35).
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.  defective wire harness,
P0131 / P0132”: Petrol (Page 1A-48). and recheck DTC. If
DTC P0134 still
Is check result OK? detected, replace
HO2S-1. 
DTC P0137 / P0138 / P0140

AENFL80B1114026
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
• 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.
Circuit Diagram
+B 1 4 A3
BLU C01-18 5V
A2
RED C01-7
A4
BLU GRN/WHT C01-52
A1 YEL/GRN C01-37
2 4 B3
YEL C01-16 5V
B2
BRN C01-19
B4
BLU RED/BLU C01-49
B1 YEL/BLK C01-38
[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
IEL10A111009-01

P0137
! WARNING
accident can occur.
NOTE

P0138 / P0140
! WARNING
accident can occur.
NOTE

DTC Troubleshooting
Step Action Yes No
in related manual.
for applicable DTC(s).
Is there any DTC(s) other than P0137, P0138 and P0140?
Step Action Yes No

3 HO2S-2 signal circuit and ground circuit check Go to Step 4. Repair or replace
connectors from ECM and connector from HO2S-2. harness.
“C01”, “E01” and HO2S-2.
• Resistance of “B2” and “B3” circuits: less than 1 Ω
• Resistance between each of “B2” and “B3” circuits
• Voltage of “B2” and “B3” circuits: approx. 0 V (When
Is check result OK?

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”: Petrol
(Page 1A-37).
Is check result OK?

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

Is DTC P0137, P0138 or P0140 still detected?
DTC P0171 / P0172

AENFL80B1114027
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
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
Circuit Diagram
+B 1 4 A3
BLU C01-18 5V
A2
RED C01-7
A4
BLU GRN/WHT C01-52
A1 YEL/GRN C01-37
2 4 B3
YEL C01-16 5V
B2
BRN C01-19
B4
BLU RED/BLU C01-49
B1 YEL/BLK C01-38
[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
IEL10A111009-01
! WARNING
accident can occur.
NOTE
– ECT > 70 °C (158 °F)
– IAT ≤ 75 °C (167 °F)
– IAT sensor (P0112 and P0113)

DTC Troubleshooting
Step Action Yes No
in related manual.
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: 
• Fuel injector circuit: 
• Fuel injector: (Page 1G-6)
• MAP sensor: 
• EVAP canister purge valve: (Page 1B-2)
• PCV valve: 
Is check result OK?

Is check result OK?

1) Check HO2S-1 signal circuits according to Step 3 under defective wire harness.
Is check result OK?

2) Perform DTC confirmation procedure and check DTCs.

DTC P0222 / P0223

AENFL80B1114028
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
P0223: Throttle / Pedal Position Sensor / Switch “B” Circuit High
Output voltage of TP sensor (sub) signal circuit is higher than 4.8 V.
Circuit Diagram
5
12V
A1 1
C01-53 LT GRN
4
C01-54 YEL/RED M
5V A2 B1
C01-14 RED
B2 2
C01-26 GRN
B3 3
C01-8 WHT
B4
C01-17 BLK
C01-5 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
IEL10A111013-01

P0222
NOTE
• TP sensor (P0223)

P0223
DTC Troubleshooting
Step Action Yes No
in related manual.
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.
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. 
Is check result OK?
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.
terminal at TP sensor connector: infinity
“ON”)
Is check result OK?

1) Check TP sensor for performance.  recheck DTC.  body assembly. (Page
1D-5)
Is check result OK?
DTC P0300 / P0301 / P0302 / P0303 / P0304

AENFL80B1114029
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
• 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

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.
! WARNING
accident can occur.
NOTE
– IAT ≥ –10 °C (14 °F)
– ECT > –10 °C (14° F)
– Engine speed < 4,500 rpm

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
in related manual.
2 Ignition system check Go to Step 3. Repair or replace
1) Check ignition system.  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 fuel with
1) Is correct type fuel used? correct type 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.
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: 
Is check result OK?

Step Action Yes No

7 Engine mechanical system check Check ECM power Repair or replace
1) Check the following points which can be cause of rough supply and ground defective parts.
idling or poor performance. circuits. (Page 1A-
118)
• Engine compression: (Page 1D-1)
• Valve clearance:  If circuit is OK, replace
• Valve timing:  
Is check result OK?
DTC P0327 / P0328

AENFL80B1114030
P0327: Knock Sensor 1 Circuit Low • Knock sensor and/or its circuit
Output voltage of knock sensor signal circuit is lower than specified value for • ECM
specified time with engine running.
P0328: Knock Sensor 1 Circuit High
Output voltage of knock sensor signal circuit is higher than specified value for
specified time with engine running.
Circuit Diagram
2
1 A1
WHT C01-1
B1
BLU C01-13
[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
IDAA0A111014-02
[A]: ECM connector (View: [a]) B1: Knock sensor signal circuit 2 2. ECM
A1: Knock sensor signal circuit 1 1. Knock sensor
! WARNING
accident can occur.
NOTE
– ECT > 40 °C (104° F)

2) Drive vehicle at 80 to 100 km/h (50 to 62 mile/h) constantly for 5 min. while engine keeps running at 2,400 rpm or
more. (Keep throttle valve opening constant in this step.)
DTC Troubleshooting
Step Action Yes No
in related manual.
2 Knock sensor signal circuit check Go to Step 3. Repair or replace
connectors from ECM and connector from knock sensor.
“C01”, “E01” and knock sensor.
• Resistance of “A1” and “B1” circuits: less than 1 Ω
• Resistance between each of “A1” and “B1” circuits
terminal at knock sensor connector: infinity
• Voltage of “A1” and “B1” circuits: approx. 0 V (When
Is check result OK?

3 Knock sensor check Go to Step 4. Replace knock sensor.
1) Check knock sensor.  
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. 
Is other DTC(s) detected together?
DTC P0335 / P0336

AENFL80B1114031
P0335: Crankshaft Position Sensor “A” Circuit • CKP sensor and/or its circuit
CKP sensor signal is not inputted while CMP sensor signal is being inputted. • Sensor plate
• ECM
P0336: Crankshaft Position Sensor “A” Circuit Range/Performance
Non-toothed position of sensor plate is out of the specified range.
Circuit Diagram
+B 3
A1 BLU
A2 5V
1
RED/YEL C01-28
A3
B1
B2 5V
2
PNK C01-31
GRY
B3
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
IEL10A111015-01
[A]: ECM connector (View: [a]) B1: CKP sensor power supply circuit 2. CKP sensor
A1: CMP sensor power supply circuit B2: CKP sensor signal circuit 3. ECM
A2: CMP sensor signal circuit B3: CKP sensor ground circuit
A3: CMP sensor ground circuit 1. CMP sensor
NOTE
• CMP sensor (P0340)
DTC Troubleshooting
Step Action Yes No
in related manual.
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.
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?

Step Action Yes No

4 CKP sensor signal circuit check Go to Step 5. Repair or replace
connectors.
terminal at CKP sensor connector: infinity
“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.  defective parts.
• CKP sensor 
• Sensor plate 
Is check result OK?
DTC P0340
AENFL80B1114032
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.
Circuit Diagram
+B 3
A1 BLU
A2 5V
1
RED/YEL C01-28
A3
B1
B2 5V
2
PNK C01-31
GRY
B3
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
IEL10A111015-01
[A]: ECM connector (View: [a]) B1: CKP sensor power supply circuit 2. CKP sensor
A1: CMP sensor power supply circuit B2: CKP sensor signal circuit 3. ECM
A2: CMP sensor signal circuit B3: CKP sensor ground circuit
A3: CMP sensor ground circuit 1. CMP sensor

DTC Troubleshooting
Step Action Yes No
in related manual.
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.
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.
voltage.
Is check result OK?

4 CMP sensor signal circuit check Go to Step 5. Repair or replace
connectors.
• Resistance of “A2” circuit: less than 1 Ω
terminal at CMP sensor connector: infinity
“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.  defective parts.
• CMP sensor 
• Signal rotor 
Is check result OK?

DTC P0351 / P0352 / P0353 / P0354 / P2300 / P2301 / P2303 / P2304 / P2306 / P2307 / P2309 / P2310
AENFL80B1114033
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
P0352: Ignition Coil “B” Primary / Secondary Circuit
Ignition coil assembly No.2 and/or its circuit is open with engine running.
P0353: Ignition Coil “C” Primary / Secondary Circuit
P0354: Ignition Coil “D” Primary / Secondary Circuit
P2300: Ignition Coil “A” Primary Control Circuit Low
Ignition coil assembly No.1 drive circuit voltage is shorted to ground with
engine running.
P2301: Ignition Coil “A” Primary Control Circuit High
Ignition coil assembly No.1 drive circuit voltage is shorted to power supply with
engine running.
P2303: Ignition Coil “B” Primary Control Circuit Low
engine running.
P2304: Ignition Coil “B” Primary Control Circuit High
engine running.
P2306: Ignition Coil “C” Primary Control Circuit Low
engine running.
P2307: Ignition Coil “C” Primary Control Circuit High
engine running.
P2309: Ignition Coil “D” Primary Control Circuit Low
engine running.
P2310: Ignition Coil “D” Primary Control Circuit High
engine running.
Circuit Diagram
IG1
5 A1 WHT
1
5V A2
C01-32 GRN/YEL
A3 B1
BLK
2
5V B2
C01-33 GRN/WHT
B3 C1
BLK 3
5V C2
C01-34 BRN
C3 D1
BLK 4
5V D2
C01-35 LT GRN
D3
BLK
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
IEL10A111016-01
[A]: ECM connector (View: [a]) B3: Ignition coil assembly No.2 ground circuit D3: Ignition coil assembly No.4 ground circuit
A1: Ignition coil assembly No.1 power supply circuit C1: Ignition coil assembly No.3 power supply circuit 1. Ignition coil assembly No.1
A2: Ignition coil assembly No.1 drive circuit C2: Ignition coil assembly No.3 drive circuit 2. Ignition coil assembly No.2
A3: Ignition coil assembly No.1 ground circuit C3: Ignition coil assembly No.3 ground circuit 3. Ignition coil assembly No.3
B1: Ignition coil assembly No.2 power supply circuit D1: Ignition coil assembly No.4 power supply circuit 4. Ignition coil assembly No.4
B2: Ignition coil assembly No.2 drive circuit D2: Ignition coil assembly No.4 drive circuit 5. ECM
NOTE
DTC Troubleshooting
Step Action Yes No
in related manual.
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.
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
2) Check for proper terminal connections to “C01” and
• Resistance of “A2”, “B2”, “C2” or “D2” circuit: less than
1Ω
• Resistance between each of “A2”, “B2”, “C2” or “D2”
circuit and ground: infinity
terminal at ignition coil connector: infinity
• Resistance between “C2” circuit terminal and other
• Resistance between “D2” circuit terminal and other
• Voltage of “A2”, “B2”, “C2” or “D2” circuit: approx. 0 V
(When ignition is “ON”)
Is check result OK?

5 DTC check Replace ECM and End.
1) Replace ignition coil assembly related to DTC with recheck DTC. 
normal ignition coil assembly.
2) Perform “DTC Confirmation Procedure” and recheck
DTC.
Is the same DTC still detected?
DTC P0420
AENFL80B1114034
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
• TWC
• ECM
Circuit Diagram
5V
BLU C01-18
RED C01-7
1
3
5V
YEL C01-16
BRN C01-19
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
IEL10A111017-01
[A]: ECM connector (View: [a]) 2. TWC 4. ECM

1. HO2S-1 3. HO2S-2
! WARNING
accident can occur.
NOTE
– ECT at engine start > –9 °C (16 °F)
– TP sensor (P0122, P0123, P0222 and P0223)
– HO2S-1 (P0130, P0131, P0132, P0133 and P0134)
– HO2S-2 (P0137, P0138, P0140 and P2271)
– Fuel trim system (P0171 and P0172)
– Cylinder misfire detected (P0300)

2) With engine speed at 2,600 to 3,500 rpm, drive vehicle at 100 to 120 km/h (62 to 75 mile/h) constantly for 5 min. or
more at 5th gear (M/T model) or D range (A/T model). (Keep throttle valve opening constant in this step.)
3) Check whether catalyst readiness / monitoring test has completed or not using scan tool. If catalyst readiness /
monitoring test has not completed, check vehicle conditions (environmental) and repeat Step 2) – 3).
DTC Troubleshooting
Step Action Yes No
in related manual.
1) Check DTC. for applicable DTC.
Is there DTC(s) detected other than P0420?

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

4 HO2S-2 circuit check Go to Step 5. Repair or replace
1) Check signal and ground circuits according to Step 3 defective wire harness.
under “DTC P0137 / P0138 / P0140”: Petrol (Page 1A-
54).
Is check result OK?

1) Check HO2S-1 signal circuit according to Step 3 under defective wire.
Is check result OK?

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

1) Replace HO2S-2. 
2) Check DTC.

2) Check DTC.

DTC P0443 / P0458 / P0459

AENFL80B1114035
P0443: Evaporative Emission System Purge Control Valve Circuit • EVAP canister purge valve and/or
EVAP canister purge valve drive circuit is open with engine running. its circuit
P0458: Evaporative Emission System Purge Control Valve Circuit Low
EVAP canister purge valve drive circuit is shorted to ground with engine
running.
P0459: Evaporative Emission System Purge Control Valve Circuit High
EVAP canister purge valve drive circuit is shorted to power supply with engine
running.
Circuit Diagram
3
B1 A1
1
C01-40 BLU/BLK BLU 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
IEL10A111018-01
[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
NOTE
DTC Troubleshooting
Step Action Yes No
in related manual.
Step Action Yes No

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.
voltage.
Is check result OK?

3 EVAP canister purge valve drive circuit check Go to Step 4. Repair or replace
connectors from ECM and connector from EVAP
canister purge valve.
“C01”, “E01” and EVAP canister purge valve.
terminal at EVAP canister purge valve connector:
infinity
“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.  purge valve.
(Page 1B-2)
Is check result OK?
DTC P0480 / P0692

AENFL80B1114036
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
1
+BB +B
A1 A3
3
BLU LT GRN E01-46
BLU/RED
4
2
A2 C1
BLK C2
B1 B3
6
BLU GRN E01-36
RED
7
5
B2 D1
BLK D2
[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
IFL80B111015-03
[A]: ECM connector (View: [a]) D1: Radiator cooling sub fan power supply circuit
A1: Radiator cooling fan relay No.1 power supply circuit (coil side) D2: Radiator cooling sub fan ground circuit
A2: Radiator cooling fan relay No.1 power supply circuit (switch side) 1: ECM
A3: Radiator cooling fan relay No.1 drive circuit 2. Radiator cooling fan motor
B1: Radiator cooling fan relay No.2 power supply circuit (coil side) 3. Radiator cooling fan relay No.1
B2: Radiator cooling fan relay No.2 power supply circuit (switch side) 4. “RDTR” fuse
B3: Radiator cooling fan relay No.2 drive circuit 5. Radiator cooling sub fan motor
C1: Radiator cooling fan power supply circuit 6. Radiator cooling fan relay No.2
C2: Radiator cooling fan ground circuit 7. “CDSR” fuse
NOTE

2) Keep engine at idle speed until engine coolant temperature reaches 100 °C (212 °F) or more.
DTC Troubleshooting
Step Action Yes No
in related manual.
Step Action Yes No

2 Radiator cooling fan relay No.1 power supply circuit Go to Step 3. Repair or replace
check defective wire harness.
1) With ignition “OFF”, remove radiator cooling fan relay
No.1.
2) Check for proper terminal connection to radiator cooling
fan relay No.1 connector.
4) Check that voltage between each of “A1” and “A2”
circuits 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.  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.  defective wire harness.
connectors.
terminal at radiator cooling fan relay No.1 connector:
infinity
“ON”)
Is check result OK?

DTC P0481 / P0694

AENFL80B1114037
P0481: Fan 2 Control Circuit • Radiator cooling fan relay No.2 (coil
Radiator cooling fan relay No.2 drive circuit is shorted to ground or open. side) and/or its circuit
P0694: Fan 2 Control Circuit High
Radiator cooling fan relay No.2 drive circuit is shorted to power supply.
Circuit Diagram
1
+BB +B
A1 A3
3
BLU LT GRN E01-46
BLU/RED
4
2
A2 C1
BLK C2
B1 B3
6
BLU GRN E01-36
RED
7
5
B2 D1
BLK D2
[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
IFL80B111015-03
A2: Radiator cooling fan relay No.1 power supply circuit (switch side) 1: ECM
NOTE
– Battery voltage > 8.5 V
– Radiator cooling fan relay No.1 (P0480 and P0692)

DTC Troubleshooting
Step Action Yes No
in related manual.
1) With ignition “OFF”, remove radiator cooling fan relay
No.2.
4) Check that voltage between each of “B1” and “B2”
Is check result OK?

1) Check radiator cooling fan relays, No.2.  fan relays No.2.
Is check result OK?

4 Radiator cooling fan relay No.2 drive circuit check Replace ECM and Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” recheck DTC defective wire harness.
connectors.
• Resistance between each of “B3” circuit and ground:
infinity
terminal at drive circuit connector of radiator cooling
fan relay No.2: infinity
“ON”)
Is check result OK?
DTC P0500
AENFL80B1114038
P0500: Vehicle Speed Sensor “A” • VSS and/or its circuit (non-ABS model)
Any of the following conditions is met. • CAN communication line (ABS model)
• Vehicle speed is slower than 4 km/h (2.5 mile/h) for 13 sec. at fuel cut • Wheel speed sensor and/or its circuit
condition. (ABS-M/T model)
• Lost communication with ABS control module if ABS is equipped. (M/T • ABS control module (ABS-M/T model)
model)
• Output shaft speed sensor and/or its
• Lost communication with TCM. (A/T model) circuit (ABS-A/T model)
• TCM (ABS-A/T model)
• ECM
Circuit Diagram
[A]
+B 1
BLU A1
A2
2 PPL C01-27
GRY A3
[B] 3
4 GRN
BLK 1
GRN
5
BEG RED E01-1
8 8
WHT E01-2
BRN
6
YEL
LT BLU
7
PNK
[C]
10
1
9
WHT 8 RED C01-3
WHT C01-15 8
BLK
[D] 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
IEL10A111020-02
[A]: Non-ABS model A3: VSS ground circuit 6. Left-rear wheel speed sensor
[B]: ABS-M/T model 1: ECM 7. Right-rear wheel speed sensor
[C]: ABS-A/T model 2: VSS 8. CAN driver
[D]: ECM connector (View: [a]) 3: ABS control module 9. Output shaft speed sensor
A1: VSS power supply circuit 4: Left-front wheel speed sensor 10. TCM
A2: VSS signal circuit 5: Right-front wheel speed sensor
! WARNING
accident can occur.
NOTE
– ECT > 40 °C (104 °F)
– Engine speed < 4,500 rpm
– ECT sensor (P0116, P0117 and P0118)CKP sensor (P0335)
– CMP sensor (P0340)

2) With engine speed at 4,500 rpm or less, drive vehicle at 60 km/h (37 mile/h) constantly for 1 min. or more at 5th
gear (M/T model) or D range (A/T model). (Keep throttle valve opening constant in this step.)
3) Release accelerator pedal, and keep vehicle coasting for 10 sec. in engine braking condition. (Fuel cut)
DTC Troubleshooting
Non-ABS model
Step Action Yes No
in related manual.
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.
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.
voltage.
Is check result OK?

4 VSS signal circuit check Go to Step 5. Repair or replace
connectors.
terminal at VSS connector: infinity
“ON”)
Is check result OK?

5 VSS check Replace ECM and Replace VSS. 
1) Check VSS.  recheck DTC. 
Is check result OK?

ABS model
Step Action Yes No
in related manual.
for CAN-DTC. Refer to
Is there any CAN-DTC detected? “CAN DTC (Lost
Communication and
Communication Bus
Off) Table”: Petrol and
Bi-Fuel CNG Model in
Section 10H (Page 10H-
10).
3 DTC check Go to troubleshooting Replace ECM and
1) Check DTC in ABS control module. (Page 4E-3). for applicable DTC. recheck DTC. 
Is there any DTC(s) detected?

1) Check DTC in TCM. Refer to “DTC Check” in Section 5A for applicable DTC. recheck DTC. 
(Page 5A-15)
Is check result OK?
DTC P0515
AENFL80B1114060
P0515: Battery Temperature Sensor Circuit • Electric load current sensor
Any of the following conditions is met. and/or its circuit
• Output voltage of battery temperature sensor signal circuit is lower than 0.10 V for • ECM
5 sec.
• Output voltage of battery temperature sensor signal circuit is higher than 4.85 V for
5 sec.
Circuit Diagram
1 A1 5V
LT BLU E01-13
A2
GRN E01-7
A3 5V
3
PNK E01-32
A4
YEL 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
IDAA0A111034-02
[A]: ECM connector (View: [a]) A3: Battery temperature sensor signal circuit 1. ECM
A1: Electric load current sensor power supply circuit 1. Electric load current sensor ground circuit 2. Battery temperature sensor
A2: Electric load current sensor signal circuit 2. Electric load current sensor

DTC Troubleshooting
Step Action Yes No
in related manual.
2 Battery temperature sensor signal circuit and ground Go to Step 3. Repair or replace
circuit check defective wire harness.
1) With ignition “OFF”, disconnect “C01” and “E01”
connectors of ECM and electric load current sensor
connector.
connectors and electric load current sensor connector.
terminal at electric load current sensor connector:
infinity
infinity
Is check result OK?

Step Action Yes No

3 Electric load current sensor check Replace ECM and Replace electric load
1) Check electric load current sensor. (Page 1C-2) recheck DTC.  current load sensor.
Is check result OK?
DTC P0530
AENFL80B1114039
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.
Circuit Diagram
2
A1 5V
PNK E01-14
1 A2 5V
GRN E01-17
A3
GRY E01-8
[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
IEL10A111021-01
[A]: ECM connector (View: [a]) A2: A/C refrigerant pressure sensor signal circuit 1. A/C refrigerant pressure sensor
A1: A/C refrigerant pressure sensor power supply circuit A3: A/C refrigerant pressure sensor ground circuit 2. ECM

2) Set A/C switch to ON for 10 sec.
3) Set A/C switch to OFF.
DTC Troubleshooting
Step Action Yes No
in related manual.
Step Action Yes No

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
Is check result OK?

3 A/C refrigerant pressure sensor ground circuit check Check “A3” circuit. Check “A1” circuit.
1) Check that voltage between “A1” and ground is approx. If defective circuit is If defective circuit is
5 V. found, repair “A3” found, repair “A1”
circuit. circuit.
Is check result OK?
If circuit is OK, replace If circuit is OK, replace
ECM and recheck DTC. ECM and recheck DTC.
 
4 A/C refrigerant pressure sensor signal circuit check Go to Step 5. Repair or replace
connectors.
terminal at A/C refrigerant pressure sensor connector:
infinity
“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.  pressure sensor.
• Single A/C type:  • Single A/C type: 
• Dual A/C type:  • Dual A/C type: 
Is check result OK?
DTC P0557 / P0558

AENFL80B1114061
P0557: Brake Booster Pressure Sensor Circuit Low • Brake booster switch
Brake booster switch ON signal is input for more than 3 sec. even if intake manifold and/or its circuit
negative pressure is higher than specification. • ECM
P0558: Brake Booster Pressure Sensor Circuit High
Brake booster switch OFF signal is input for more than 10 sec. even if intake manifold
negative pressure is lower than specification.
Circuit Diagram
12V
1
A1
GRY E01-40
[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
IEL10A111022-01
[A]: ECM connector (View: [a]) 1: Brake booster switch

A1: Brake booster switch signal circuit 2. ECM

2) Drive vehicle at 10 km/h (6 mile/h) or more once.
3) Stop vehicle.
4) Repeat Step 2) – 3) 2 times.
DTC Troubleshooting
Step Action Yes No
in related manual
2 Brake booster switch signal circuit check Go to Step 3. Repair or replace
connectors of ECM and brake booster switch connector.
connectors and brake booster switch connector.
3) If connections are OK, check that following points.
• Voltage of “A1” circuit: 0 to 1 V (When ignition is “ON”)
Is check result OK?

3 Brake booster switch check Replace ECM and Replace brake booster
1) Check brake booster switch. Refer to “Brake Booster recheck DTC.  assembly. (Page 4A-
Switch Inspection (ISG Model)” in Section 4A (Page 4A- 5).
9).
Is check result OK?

DTC P0560 / P0562 / P0563

AENFL80B1114040
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
running.
P0563: System Voltage High
Main power supply circuit voltage is higher than 16.5 V for 5 sec. with engine
running.
Circuit Diagram
1
A1
2 5V 12V
BRN E01-15 9
3 LT BLU E01-18 C01-53 LT GRN
BLU E01-21 10
C01-54 YEL/RED M
A2 E1
5V
BLK E01-4 5V
4 C01-14 RED
YEL E01-5 11
WHT E01-20 C01-26 GRN
12
C01-8 WHT
C01-17 BLK
B1 5V
5 C01-5 BLK
LT BLU E01-13
GRN E01-7 5V 12V

6
PNK E01-32 F1 13 G1
YEL E01-22 5V
E01-49 PNK 14
E01-55 BLU
C1 5V F2
7 3.3V G2
GRY/RED C01-2 E01-56 BLU F3
RED/BLK C01-39 H1 16
15 17
GRY/BLU C01-6 E01-6 WHT
I1 18
D1 5V C01-50 BLK
8 PNK E01-14 5V I2
C01-51 BLK 19
GRN E01-17
GRY E01-8
[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
IEL10A111023-02
[A]: ECM connector (View: [a]) H1: Ignition “ON” signal circuit 10. Throttle actuator
A1: APP sensor (main) power supply circuit I1: ECM ground circuit 1 11. TP sensor (main)
A2: APP sensor (sub) power supply circuit I2: ECM ground circuit 2 12. TP sensor (sub)
B1: Electric load current sensor power supply circuit 1. ECM 13. Main relay
C1: MAP sensor power supply circuit 2. APP sensor 14. “FI” fuse
D1: A/C refrigerant pressure sensor power supply circuit 3. APP sensor (main) 15. “IG COIL” fuse
E1: TP sensor power supply circuit 4. APP sensor (sub) 16. Ignition switch (ignition switch model)
or IG1 relay (keyless push start model)
F1: Main relay drive circuit 5. Electric load current sensor 17. “IG1” fuse
F2: Main power supply circuit 2 6. Battery temperature sensor 18. Main fuse box
F3: Main power supply circuit 1 7. MAP sensor 19. Battery
G1: Main relay power supply circuit (coil side) 8. A/C refrigerant pressure sensor
G2: Main relay power supply circuit (switch side) 9. Electric throttle body assembly

P0560:
1) Set ignition “ON” for 1 min.
P0562 / P0563:
1) Run engine at 2,500 rpm or more for 1 min.
DTC Troubleshooting
Step Action Yes No
in related manual.
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.  supply and/or ground
1A-118) circuit.
Is check result OK?

3 Charging system check Replace ECM and Repair or replace
1) Check that charging system is working properly. recheck DTC.  defective parts.
Is check result OK?
DTC P0602
AENFL80B1114041
NOTE
After reprogramming of ECM is executed, if DTC P0602 is indicated, it is possible that the
reprogramming of ECM is not completed correctly.

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

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. Check for intermittent
1) Clear DTC. (Page 1A-16) trouble. 
2) Set ignition “OFF”.

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 or replace
1) Check ECM power and ground circuit. (Page 1A-118) recheck DTC. defective wire harness.
Is check result OK?
DTC P0606
AENFL80B1114062
P0606: Control Module Processor • ECM power supply circuit and/or ground circuit
ECM internal processor failure. • HO2S-2
• ECM
System Description
Internal control module is installed in ECM.
NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.
• 8.5 V < battery voltage < 16.5 V
DTC Troubleshooting
Step Action Yes No

2 ECM power and ground circuit check Go to Step 3. Repair or replace
1) Check ECM power and ground circuit. (Page 1A-118) defective wire harness.
Is check result OK?

1) Replace HO2S-2. Refer to “HO2S-1 and HO2S-2 On- recheck DTC. 
Vehicle Inspection”: Petrol and Bi-Fuel CNG in Section
1C in related manual.
2) Perform “DTC Confirmation Procedure”, and check
DTC.

DTC P0607
AENFL80B1114042
P0607: Control Module Performance • ECM power supply circuit and/or ground circuit
Internal failure in ECM is detected. • ECM
(1 D/C detection logic or 3 D/C detection logic but MIL does not
light up)
NOTE
• Battery voltage > 8 V
1) Set ignition “ON” for 1 min. or more.

2) Start engine, if possible.
DTC Troubleshooting
Step Action Yes No

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.  or ground circuit.
circuit. (Page 1A-118)
Is check result OK?
DTC P0645 / P0646 / P0647

AENFL80B1114043
P0645: A/C Clutch Relay Control Circuit • A/C compressor relay and/or its
A/C compressor relay drive circuit is open. circuit
P0646: A/C Clutch Relay Control Circuit Low
A/C compressor relay drive circuit is shorted to ground.
P0647: A/C Clutch Relay Control Circuit High
A/C compressor relay drive circuit is shorted to power supply.
Circuit Diagram
B1 1 A1
E01-48 GRY BLU 3
2 6
WHT GRN 4
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
IDAA0A111025-01
[A]: ECM connector (View: [a]) 1. A/C compressor relay 4. To main fuse box
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 6. “CPRSR” fuse
NOTE
• Confirm that the following condition is met in this “DTC Confirmation Procedure”.
– Battery voltage > 8.5 V
– Evaporator temperature > 3 °C (37 °F)
– A/C refrigerant pressure sensor (P0530)

2) Set A/C switch to ON for 10 sec.
3) Set A/C switch to OFF.
DTC Troubleshooting
Step Action Yes No
in related manual.
2 A/C compressor relay power supply circuit (coil side) Go to Step 3. Repair or replace
1) When ignition is “OFF”, remove A/C compressor relay.
2) Check for proper terminal connection to A/C compressor
relay connector.
voltage.
Is check result OK?

Step Action Yes No

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: 
• Dual A/C type: 
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.  defective wire harness.
connectors.
terminal at A/C compressor relay connector: infinity
“ON”)
Is check result OK?
DTC P0A5A
AENFL80B1114063
P0A5A: Generator Current Sensor Circuit Range / Performance • Electric load current sensor and/or
Any of the following conditions is met. its circuit
• Output voltage of electric load current sensor signal circuit is more than 4.80 • ECM
V for 5 sec.
• Output voltage of electric load current sensor signal circuit is lower than
0.20 V for 5 sec.
• Output voltage of electric load current sensor signal circuit fluctuates less
than specified value for 5 sec.
Circuit Diagram
1 A1 5V
LT BLU E01-13
A2
GRN E01-7
A3 5V
3
PNK E01-32
A4
YEL 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
IDAA0A111034-02
[A]: ECM connector (View: [a]) A3: Battery temperature sensor signal circuit 2. ECM
A1: Electric load current sensor power supply circuit A4: Electric load current sensor ground circuit 3. Battery temperature sensor
A2: Electric load current sensor signal circuit 1. Electric load current sensor

2) Start engine at idle speed for 10 min.
DTC Troubleshooting
Step Action Yes No
in related manual.
2 Electric load current sensor power supply circuit check Go to Step 4. Go to Step 3.
1) With ignition “OFF”, disconnect electric load current
sensor connector.
2) Check for proper terminal connection to electric load
current sensor connector.
3) If connection is OK, set ignition “ON”.
Is check result OK?

3 Electric load current sensor ground circuit check Repair “A4” circuit.If this Repair “A1” circuit.If this
1) Check that voltage between “A1” and ground is approx. DTC is detected again, DTC is detected again,
5 V. replace ECM and replace ECM and
recheck DTC.  recheck DTC. 
Is check result OK?
Step Action Yes No

4 Electric load current sensor signal circuit check Go to Step 5. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors.
infinity
“ON”)
Is check result OK?

5 Electric load current sensor check Replace ECM and Replace electric load
1) Check electric load current sensor. recheck DTC.  current sensor.
Is check result OK?
DTC P2100
AENFL80B1114044
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.
Circuit Diagram
5
12V
A1 1
C01-53 LT GRN
4
C01-54 YEL/RED M
5V A2 B1
C01-14 RED
B2 2
C01-26 GRN
B3 3
C01-8 WHT
B4
C01-17 BLK
C01-5 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
IEL10A111013-01

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
in related manual.
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.
“C01”, “E01” and electric throttle body assembly.
terminal at electric throttle body assembly connector:
infinity
terminal at electric throttle body assembly connector:
infinity
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.  body assembly. (Page
 1D-5)
Is check result OK?

DTC P2101 / P2119

AENFL80B1114045
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
P2119: Throttle Actuator Control Throttle Body Range / Performance
• 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.
Circuit Diagram
5
12V
A1 1
C01-53 LT GRN
4
C01-54 YEL/RED M
5V A2 B1
C01-14 RED
B2 2
C01-26 GRN
B3 3
C01-8 WHT
B4
C01-17 BLK
C01-5 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
IEL10A111013-01

P2101
NOTE
Check that the following condition is met in this “DTC Confirmation Procedure”.

3) Release accelerator pedal for 2 sec.

4) Set ignition “OFF” for 1 min. and then set ignition “ON”.
P2119
NOTE
• 6 °C (43 °F) < ECT < 100 °C (212 °F)
• IAT > 6°C (43 °F)

DTC Troubleshooting
Step Action Yes No
in related manual.
1) Clear DTC.
2) Perform electric throttle control system calibration. 
3) Recheck DTC.
Is DTC P2101 / P2119 still detected?

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”: Petrol (Page 1A-93).
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.  body assembly. (Page
 1D-5)
Is check result OK?
DTC P2122 / P2123

AENFL80B1114046
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
P2123: Throttle / Pedal Position Sensor / Switch “D” Circuit High
Output voltage of APP sensor (main) signal circuit is higher than 4.4 V.
Circuit Diagram
4
1
A1 5V
BRN E01-15
A2
2 LT BLU E01-18
A3
BLU E01-21
B1 5V
BLK E01-4
B2
3 YEL E01-5
B3
WHT E01-20
[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
IDAA0A111027-01
[A]: ECM connector (View: [a]) B1: APP sensor (sub) power supply circuit 2. APP sensor (main)
A1: APP sensor (main) power supply circuit B2: APP sensor (sub) signal circuit 3. APP sensor (sub)
A2: APP sensor (main) signal circuit B3: APP sensor (sub) ground circuit 4. ECM
A3: APP sensor (main) ground circuit 1. APP sensor
NOTE
DTC Troubleshooting
Step Action Yes No
in related manual.
2 Accelerator pedal assembly (incorporating APP sensor) Go to Step 3. Reinstall accelerator
mounting check pedal assembly
1) Check that accelerator pedal assembly (incorporating (incorporating APP
APP sensor) has been mounted to vehicle body properly sensor) properly. 
(no pinched floor carpet, etc.).
Is check result OK?

3 APP sensor (main) power supply circuit check Go to Step 5. Go to Step 4.
1) When ignition is “OFF”, disconnect APP sensor
connector.
2) Check for proper terminal connection to APP sensor
connector.
Is check result OK?

4 APP sensor (main) ground circuit check Repair “A3” circuit. Repair “A1” circuit.
1) Check that voltage between “A1” and ground is approx. If this DTC is detected If this DTC is detected
5 V. again, replace ECM and again, replace ECM and
Is check result OK?
5 APP sensor (main) signal circuit check Go to Step 6. Repair or replace
connectors.
terminal at APP sensor connector: infinity
“ON”)
Is check result OK?

6 APP sensor check Replace ECM and Replace accelerator
1) Check APP sensor.  recheck DTC.  pedal assembly
(incorporating APP
Is check result OK? sensor). 
DTC P2127 / P2128

AENFL80B1114047
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
P2128: Throttle / Pedal Position Sensor / Switch “E” Circuit High
Output voltage of APP sensor (sub) signal circuit is higher than 2.5 V.
Circuit Diagram
4
1
A1 5V
BRN E01-15
A2
2 LT BLU E01-18
A3
BLU E01-21
B1 5V
BLK E01-4
B2
3 YEL E01-5
B3
WHT E01-20
[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
IDAA0A111027-01
NOTE
DTC Troubleshooting
Step Action Yes No
in related manual.
Step Action Yes No

2 Accelerator pedal assembly (incorporating APP sensor) Go to Step 3. Reinstall accelerator
mounting check pedal assembly
1) Check that accelerator pedal assembly (incorporating (incorporating APP
APP sensor) has been mounted to vehicle body properly sensor) properly. 
(no pinched floor carpet, etc.).
Is check result OK?

3 APP sensor (sub) power supply circuit check Go to Step 5. Go to Step 4.
connector.
connector.
Is check result OK?

4 APP sensor (sub) ground circuit check Repair “B3” circuit. Repair “B1” circuit.
1) Check that voltage between “B1” and ground is approx. If this DTC is detected If this DTC is detected
5 V. again, replace ECM and again, replace ECM and
Is check result OK?
5 APP sensor (sub) signal circuit check Go to Step 6. Repair APP sensor
1) When ignition is “OFF”, disconnect “C01” and “E01” (sub) signal circuit.
connectors.
“ON”)
Is check result OK?

6 APP sensor check Replace ECM and Replace accelerator
1) Check APP sensor.  recheck DTC.  pedal assembly
(incorporating APP
Is check result OK? sensor). 
DTC P2135
AENFL80B1114048
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.
Circuit Diagram
5
12V
A1 1
C01-53 LT GRN
4
C01-54 YEL/RED M
5V A2 B1
C01-14 RED
B2 2
C01-26 GRN
B3 3
C01-8 WHT
B4
C01-17 BLK
C01-5 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
IEL10A111013-01
NOTE
• TP sensor (P0122, P0123, P0222 and P0223)

3) Release accelerator pedal for 2 sec.
DTC Troubleshooting
Step Action Yes No
in related manual.
2 Wire harness check Go to Step 3. Repair or replace
1) Check the following points. defective wire harness.
• “B1”, “B2” and “B4” circuits: Refer to Step 2 through 4
under “DTC P0122 / P0123”: Petrol (Page 1A-44).
• “B3” circuit: Refer to Step 2 through 4 under “DTC
P0222 / P0223”: Petrol (Page 1A-59).
Is check result OK?

Step Action Yes No

1) Check TP sensor for performance referring to “Throttle recheck DTC.  body assembly. (Page
Position (TP) Sensor Performance Check” under . 1D-5)
Is check result OK?
DTC P2138
AENFL80B1114049
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.
Circuit Diagram
4
1
A1 5V
BRN E01-15
A2
2 LT BLU E01-18
A3
BLU E01-21
B1 5V
BLK E01-4
B2
3 YEL E01-5
B3
WHT E01-20
[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
IDAA0A111027-01
NOTE
– System voltage > 8 V
– APP sensor (P2122, P2123, P2127 and P2128)

4) Repeat Step 2) - 3) 3 times.
DTC Troubleshooting
Step Action Yes No
in related manual.
• “A1”, “A2” and “A3” circuits: Refer to Step 3 through 5
• “B1”, “B2” and “B3” circuits: Refer to Step 3 through 5
Is check result OK?

3 APP sensor check Replace ECM and Replace APP sensor
1) Check APP sensor for performance.  recheck DTC.  assembly (incorporated
with APP sensor). 
Is check result OK?
DTC P2176
AENFL80B1114050
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.
Circuit Diagram
5
12V
A1 1
C01-53 LT GRN
4
C01-54 YEL/RED M
5V A2 B1
C01-14 RED
B2 2
C01-26 GRN
B3 3
C01-8 WHT
B4
C01-17 BLK
C01-5 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
IEL10A111013-01
NOTE
• 6 °C (43 °F) < ECT < 100 °C (212 °F)
• IAT > 6 °C (43 °F)
1) Set ignition “ON” with accelerator pedal released for 1 min.

DTC Troubleshooting
Step Action Yes No
in related manual.
2 Electric throttle control system calibration Go to Step 3. End.
1) Perform electric throttle control system calibration. 
2) Recheck DTC.

• “B1”, “B2” and “B4” circuits: Refer to Step 2 – 4 under
• “B3” circuit: Refer to Step 4 under “DTC P0222 /
P0223”: Petrol (Page 1A-59).
Is check result OK?

1) Check TP sensor referring to “Throttle Position (TP) recheck DTC.  body assembly. (Page
Sensor Performance Check” under . 1D-5)
Is check result OK?
DTC P2228 / P2229

AENFL80B1114064
P2228: Barometric Pressure Sensor “A” Circuit Low Barometric pressure sensor in ECM
Barometric pressure sensor signal voltage is lower than specified value for
specified time.
P2229: Barometric Pressure Sensor “A” Circuit High
Barometric pressure sensor signal voltage is higher than specified value for
specified time.

DTC Troubleshooting
Step Action Yes No
in related manual.
1) Check ECM power supply and ground circuits. “ECM recheck DTC.  supply and ground
Power Supply and Ground Circuit Check”: Petrol (Page circuits.
1A-118)
Is check result OK?
DTC U0073 Refer to “Troubleshooting for Lost Communication”:

AENFL80B1114052 Petrol and Bi-Fuel CNG Model in Section 10H (Page
Refer to “Troubleshooting for Communication Bus Off”:
10H-12).
Petrol and Bi-Fuel CNG Model in Section 10H (Page
10H-19).
DTC U0140
AENFL80B1114055
Refer to “Troubleshooting for Lost Communication”:
10H-12).
10H-12).
DTC U0141
AENFL80B1114066
10H-12).
10H-12).
DTC U0155
AENFL80B1114056
10H-12).
DTC U2001
AENFL80B1114067
U2001: LIN Lost Communication With Generator • Generator LIN communication
Received data from generator via LIN is faulty. circuit
(1 D/C detection logic but MIL does not light up) • Regulator (stator assembly)
• ECM
Circuit Diagram
1 3
A1
2 BLU C01-4 4
[A] C01 E01
[a]
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25 36 35 34 33 32 31 30 29 28 27 26 25
48 47 46 45 44 43 42 41 40 39 38 37 48 47 46 45 44 43 42 41 40 39 38 37
56 55 54 53 52 51 50 49 56 55 54 53 52 51 50 49
IDAA0A111028-01
[A]: ECM connector (View: [a]) 1. Generator 3. ECM

A1: Generator LIN communication circuit 2. Regulator 4. LIN driver

DTC Troubleshooting
Step Action Yes No
in related manual.
2 Generator LIN communication circuit check Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C01” and “E01” defective wire harness.
connectors of ECM and generator connector.
connectors and generator connector.
terminal at ECM connector: infinity
“ON”)
Is check result OK?

1) Replace stator assembly. Refer to “Generator recheck DTC. 
Disassembly and Reassembly”: Petrol and Bi-Fuel CNG
in Section 1J (Page 1J-5).
2) Perform “DTC Confirmation Procedure” and check DTC.
Is DTC U2001 still detected?

DTC U2021
AENFL80B1114068
U2021: LIN Invalid Data from ECM to Generator • ECM power supply circuit and/or
Transmitted data from ECM to generator via LIN is faulty. ground circuit

DTC Troubleshooting
Step Action Yes No
1) Clear DTC. Refer to “DTC Clearance”: Petrol (Page 1A- trouble.
16).
3) Perform “DTC Confirmation Procedure” and check DTC.

1) Check ECM power supply and ground circuits. “ECM recheck DTC.  supply and ground
Power Supply and Ground Circuit Check”: Petrol (Page circuits.
1A-118)
Is check result OK?
Inspection of ECM and Its Circuits

AENFL80B1114057
Voltage Check
NOTE
• As each terminal voltage is affected by battery voltage, check that battery voltage 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 in related manual.
[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
Terminal No. Wire color Circuit Normal voltage Condition

1 to 2 V Engine: Idle speed
Knock sensor signal Refer to reference waveform.
C01-1* WHT
circuit 1
• “Knock sensor signal”: Petrol (Page 1A-117)
MAP sensor power
C01-2 GRY/RED 4.5 to 5.5 V Ignition: “ON”
supply circuit

CAN (high) Refer to reference waveform.
C01-3 RED
communication circuit “CAN communication signal”: Petrol (Page 1A-117)
0 to 1 V Ignition: “ON”
Generator LIN Refer to reference waveform.
C01-4* BLU
communication circuit • “Generator LIN communication signal”: Petrol (Page 1A-
117)
TP sensor shield ground
C01-5 BLK Below 0.3 V Ignition: “ON”
circuit
MAP sensor ground
C01-6 GRY/BLU Below 0.3 V Ignition: “ON”
circuit
Refer to reference waveform.
C01-7* RED HO2S-1 signal circuit
“HO2S-1 signal”: Petrol (Page 1A-114)
Ignition: “ON”
4.0 to 4.4 V
TP sensor (sub) signal Accelerator Pedal: Released
C01-8 WHT
circuit Ignition: “ON”
0.5 to 0.9 V
Accelerator Pedal: Fully depressed
C01-9 — — — —
Fuel injector No.3 drive
C01-10* BLU/RED • “Fuel injector signal”: Petrol (Page 1A-112)
circuit
• “Fuel injector No.3 signal and ignition coil No.3 signal”:
Petrol (Page 1A-113)
C01-11* BLU/YEL • “Fuel injector signal”: Petrol (Page 1A-112)
circuit
C01-12* BLU/WHT • “Fuel injector signal”: Petrol (Page 1A-112)
circuit
Knock sensor signal Refer to reference waveform.
C01-13* BLU
circuit 2
• “Knock sensor signal”: Petrol (Page 1A-117)
TP sensor power supply
C01-14 RED 4.5 to 5.5 V Ignition: “ON”
circuit
CAN (low) Refer to reference waveform.
C01-15* WHT
C01-16 YEL HO2S-2 ground circuit Below 0.3 V Ignition: “ON”
C01-17 BLK TP sensor ground circuit Below 0.3 V Ignition: “ON”
C01-18 BLU HO2S-1 ground circuit Below 0.3 V Ignition: “ON”
C01-19* BRN HO2S-2 signal circuit
“HO2S-2 signal”: Petrol (Page 1A-115)
Ignition: “ON”
3.4 to 3.5 V
ECT: 0 °C (32 °F)
C01-20 LT GRN ECT sensor signal circuit
1.1 to 1.2 V Ignition: “ON”ECT: 50 °C (122 °F)
0.3 to 0.4 V Ignition: “ON”
C01-21 — — — —
Below 0.3 V Ignition: “ON”
LT GRN/ Fuel injector No.4 drive
C01-22 • “Fuel injector signal”: Petrol (Page 1A-112)
BLK circuit
C01-23 — — — —
C01-24 — — — —

Ignition: “ON”
Approx. 2.5 V
IAT: 20 °C (68°F)
C01-25 BRN/YEL IAT sensor signal circuit
Ignition: “ON”
Approx. 0.6 V
IAT: 80 °C (176 °F)
Ignition: “ON”
0.6 to 1.0 V
TP sensor (main) signal Accelerator pedal: Released
C01-26 GRN
4.1 to 4.5 V
VSS signal circuit (non- Refer to reference waveform.
C01-27* PPL
ABS model) “VSS signal”: Petrol (Page 1A-114)
Approx. 0 V or 4 to 5 V Ignition: “ON”
C01-28* RED/YEL CMP sensor signal circuit
“CKP sensor signal and CMP sensor signal”: Petrol (Page 1A-
116)
C01-29 — — — —
C01-30 — — — —
C01-31* PNK CKP sensor signal circuit
“CKP sensor signal and CMP sensor signal”: Petrol (Page 1A-
116)
Approx. 0 V Ignition: “ON”
Ignition coil No.1 drive
C01-32* GRN/YEL • “Ignition coil signal”: Petrol (Page 1A-115)
circuit
C01-33* GRN/WHT • “Ignition coil signal”: Petrol (Page 1A-115)
circuit
C01-34* BRN • “Ignition coil signal”: Petrol (Page 1A-115)
circuit
C01-35* LT GRN • “Ignition coil signal”: Petrol (Page 1A-115)
circuit
C01-36 GRY/BLU IAT sensor ground circuit Below 0.3 V Ignition: “ON”
HO2S-1 shield ground
C01-37 YEL/GRN Below 0.3 V Ignition: “ON”
circuit
C01-38 YEL/BLK Below 0.3 V Ignition: “ON”
circuit
1.5 to 1.8 V Barometric pressure: 100 kPa, 760
C01-39 RED/BLK MAP sensor signal circuit
mmHg
“MAP sensor signal”: Petrol (Page 1A-115)
EVAP canister purge
C01-40* BLU/BLK Refer to reference waveform.
valve drive circuit
“EVAP canister purge valve signal”: Petrol (Page 1A-115)
C01-41* YEL OCV drive circuit Refer to reference waveform.
“OCV signal”: Petrol (Page 1A-117)

C01-42 — — — —
C01-43 — — — —
C01-44 — — — —
ECT sensor ground
circuit
C01-46 — — — —
C01-47 — — — —
C01-48 — — — —
HO2S-2 heater drive
C01-49* RED/BLU Refer to reference waveform.
circuit
“HO2S-2 heater signal”: Petrol (Page 1A-115)
C01-50 BLK ECM ground circuit 1 Below 0.3 V Ignition: “ON”
HO2S-1 heater drive Refer to reference waveform.
C01-52 GRN/WHT
circuit “HO2S-1 heater signal”: Petrol (Page 1A-114)
Throttle actuator drive Refer to reference waveform.
C01-53 LT GRN
circuit (close) “Throttle actuator signal”: Petrol (Page 1A-116)
C01-54* YEL/RED
circuit (open) “Throttle actuator signal”: Petrol (Page 1A-116)
C01-55* — — — —
C01-56* — — — —

E01-1* RED
E01-2* WHT
E01-3 — — — —
APP sensor (sub) power
E01-4 BLK 4.5 to 5.5 V Ignition: “ON”
circuit
Ignition: “ON”
0.2 to 0.5 V
APP sensor (sub) signal Accelerator pedal: Released
E01-5 YEL
1.8 to 2.2V
Approx. 0 V Ignition: “OFF” or “ACC”
E01-6 WHT Ignition ON signal circuit
Approx. 2.4 V Ignition: “ON”
Electric load current Ignition: “ON”
E01-7 GRN
sensor signal circuit Approx. 1.9 V Headlight: “ON”
A/C refrigerant pressure
E01-8 GRY Below 0.3 V Ignition: “ON”
sensor ground circuit
E01-9 — — — —
E01-10 — — — —
E01-11 — — — —
E01-12 — — — —
Electric load current
E01-13 LT BLU sensor power supply 4.5 to 5.5 V Ignition: “ON”
circuit
E01-14 PNK 4.5 to 5.5 V Ignition: “ON”
APP sensor (main)
E01-15 BRN 4.5 to 5.5 V Ignition: “ON”
power supply circuit

Ignition: “ON”
Select lever: “P” or “N” (A/T model)
Transmission range Approx. 0 V
Clutch pedal: Fully depressed (M/T
switch (A/T model) or
model with keyless push start system)
CPP No.1 switch (M/T
E01-16 GRN Ignition: “ON”
model with keyless push
Select lever: Other than “P” or “N” (A/T
start system) signal
10 to 14 V model)
circuit
Clutch pedal: Released (M/T model
with keyless push start system)
Engine: Running
0.9 to 1.3 V
A/C refrigerant pressure A/C compressor: Not operating
E01-17 GRN
sensor signal circuit Engine: Running
10 to 14 V
A/C compressor: Operating
Ignition: “ON”
0.6 to 0.9 V
APP sensor (main) Accelerator pedal: Released
E01-18 LT BLU
signal circuit Ignition: “ON”
3.7 to 4.4 V
Ignition: “ON”
Approx. 0 V
Blower speed switch: 2nd or more
Blower motor signal
Ignition: “ON”
E01-19 GRY circuit (Manual A/C 5 to 7 V
Blower speed switch: 1st position
model)
Ignition: “ON”
10 to 14 V
Blower speed switch: OFF
APP sensor (sub)
E01-20 WHT Below 0.3 V Ignition: “ON”
ground circuit
APP sensor (main)
E01-21 BLU Below 0.3 V Ignition: “ON”
ground circuit
E01-22 YEL Below 0.3 V Ignition: “ON”
E01-23 — — — —
E01-24 — — — —
E01-25 — — — —
E01-26 — — — —
Ignition: “ON”
10 to 14 V
CPP No.2 switch signal Clutch pedal: Released
E01-27 PPL
circuit (M/T model) Ignition: “ON”
Approx. 0 V
Clutch pedal: Fully depressed
Ignition: “ON”
Approx. 0 V
Brake light switch signal Brake pedal: Released
E01-28 GRN
10 to 14 V
Brake pedal: Fully depressed
E01-29 — — — —
E01-30 — — — —
E01-31 — — — —
Ignition: “ON”
2.0 to 2.3 V Temperature in the vicinity of battery:
Battery temperature 25 °C (77 °F)
E01-32 PNK
sensor signal circuit Ignition: “ON”
90 °C (194 °F)
E01-33 — — — —
E01-34 — — — —
E01-35 — — — —
Engine: Idle speed
10 to 14 V ECT < 101°C (214 °F)
Radiator cooling fan A/C switch: OFF
E01-36 GRN
relay No.2 drive circuit Engine: Idle speed
Approx. 0 V ECT < 103°C (217 °F)
A/C switch: OFF

E01-37 — — — —
E01-38 — — — —
E01-39 — — — —
Ignition: “ON”
Approx. 0 V
Brake pedal: Fully depressed after
Brake booster switch (A/
E01-40 GRY depressing several times
T model)
Engine: “Running”
10 to 14 V
Brake pedal: Not depressed
E01-41 — — — —
E01-42 — — — —
E01-43 — — — —
E01-44 — — — —
E01-45 — — — —
Engine: Idle speed
10 to 14 V ECT < 98 °C (208.4 °F)
E01-46 LT GRN
Approx. 0 V ECT < 100°C (212 °F)
A/C switch: OFF
E01-47 — — — —
A/C compressor: Not operating
10 to 15 V
A/C compressor relay A/C compressor: Operating
E01-48 GRY
drive circuit Ignition: “ON”
Approx. 0 V
Blower speed switch: “OFF”
E01-49 PNK Main relay drive circuit
10 to 14 V Ignition: 15 sec. after ignition “OFF”
E01-50 — — — —
E01-51 — — — —
Starting motor control Approx. 0 V Ignition: “ON”
E01-52 LT GRN
relay signal circuit 6 to 12 V Ignition: “START”
E01-53 — — — —
Fuel pump relay drive Refer to reference waveform.
E01-54 YEL
circuit “Fuel pump relay signal”: Petrol (Page 1A-117)
Main power supply
E01-55 BLU 10 to 14 V Ignition: “ON”
circuit 2
Main power supply
circuit 1
Reference Waveform [A]: Waveform of channel 1 [C]: VOLT/DIV of each channel

[B]: Ground level of each channel [D]: TIME/DIV
NOTE
• Display includes the following types of • Waveform varies depending on
data: measurement condition and vehicle spec.
Fuel injector signal

Channel Probe Terminal No.
C01-11 (No.1)
C01-12 (No.2)
+
1 C01-10 (No.3)
C01-22 (No.4)
– C01-50
Measurement condition
ICP70A110009-01
Ignition coil No.2 signal (2):

+ C01-33
2
– C01-50
CMP sensor signal (3):

+ C01-28
3
– C01-50
CKP sensor signal (4):

I7V20A111014-02 Channel Probe Terminal No.
1. Fuel injector signal + C01-31
4
– C01-50
Fuel injector No.1 signal and ignition coil No.1 signal
Fuel injector No.1 signal (1): Engine: Idle speed after warming up
+ C01-11
1
– C01-50

+ C01-32
2
– C01-50

+ C01-28
3 I8RW0A110014-01
– C01-50
5. Camshaft 360° angle 6. Crankshaft 720° angle

Channel Probe Terminal No. Fuel injector No.3 signal and ignition coil No.3 signal
+ C01-31
4 Fuel injector No.3 signal (1):
– C01-50
Measurement condition + C01-10
1
Engine: Idle speed after warming up – C01-50

+ C01-34
2
– C01-50

+ C01-28
3
– C01-50

I8RW0A110013-01 Channel Probe Terminal No.
5. Camshaft 360° angle 6. Crankshaft 720° angle + C01-31
4
– C01-50
Fuel injector No.2 signal (1): Engine: Idle speed after warming up
+ C01-12
1
– C01-50
Vehicle: Running at 40 km/h (25 mile/h)
I8RW0A110016-01

IBP80A112067-01
Fuel injector No.4 signal (1):
Channel Probe Terminal No. HO2S-1 heater signal
+ C01-22 Channel Probe Terminal No.
1
– C01-50 + C01-52
1
– C01-50
Channel Probe Terminal No. Measurement condition
+ C01-35 Engine: Idle speed after warming up
2
– C01-50

+ C01-28
3
– C01-50

+ C01-31
4
– C01-50
IBP60B110036-01
Engine: Idle speed after warming up 1. HO2S-1 heater signal
HO2S-1 signal
+ C01-7
1
– C01-50
I8RW0A110017-01
VSS signal
+ C01-27
1
– C01-50
Ignition coil signal

C01-32 (No.1)
C01-33 (No.2)
1 +
C01-34 (No.3)
C01-35 (No.4)
– C01-50
IBP60B110037-02
1. HO2S-1 signal
HO2S-2 heater signal

+ C01-49
1
– C01-50
Engine: Idle speed after warming up IBP60B110043-01
1. Ignition coil signal
MAP sensor signal
MAP sensor signal (1):

+ C01-39
1
– C01-50
TP sensor (main) signal circuit (2):

IBP60B110033-03
+ C01-26
2
1. HO2S-2 heater signal – C01-50
HO2S-2 signal Measurement condition

Channel Probe Terminal No. Engine: Racing after warming up
+ C01-19
1
– C01-50
Engine: Racing after warming up
IBP80A111033-01
3. Engine: Idle speed 4. Engine: Racing

IBP60B110034-01
1. Engine: Racing 3. HO2S-2 signal

EVAP canister purge valve signal
2. Engine: Idle speed
+ C01-40
1
– C01-50
EVAP canister purge valve: 10% open
(using “Active Test” of SUZUKI scan tool)
IDAA0A111030-01
I7V20A111065-02
• Ignition: “ON”
1. EVAP canister purge valve signal
• Accelerator pedal: Fully depressed position
Throttle actuator signal
Throttle actuator signal (Open) (1):

+ C01-54
1
– C01-50
Throttle actuator signal (Close) (2):

+ C01-53
2
– C01-50
I8C50B111049-01
CKP sensor signal and CMP sensor signal
• Ignition: For 10 sec. after ignition “ON”
• Accelerator pedal: Idle position CMP sensor signal (1):
+ C01-28
1
– C01-50

+ C01-31
2
– C01-50
IDAA0A111029-01
• Accelerator pedal: Idle position
I8C50B111039-01
Knock sensor signal

C01-1
+
1 C01-13
– C01-50
Engine: Running at 4,000 rpm after warming up
IAW101110042-01
1. Fuel pump relay signal 3. Ignition: “ON”

2. Ignition: “OFF” 4. Ignition: “START”
CAN communication signal
CAN communication signal (High) (1):

C01-3
IBP60B110038-01 +
1 E01-1
1. Knock sensor signal – C01-50
OCV signal CAN communication signal (Low) (2):

Channel Probe Terminal No. Channel Probe Terminal No.
+ C01-41 C01-15
1 +
– C01-50 2 E01-2
– C01-50
• Engine: Racing after warming up Measurement condition
• Accelerator pedal: Fully depressed position • Engine: Stop
IDAA0A111031-01
I8C50B111041-01
Fuel pump relay signal Generator LIN communication signal

+ E01-54 + C01-4
1 1
– C01-50 – C01-50
Measurement condition Measurement condition
Ignition: “OFF” → “ON” → “START” Engine: Idle speed after warming up
ICV00P111021-02
1. Generator LIN communication signal
ECM Power Supply and Ground Circuit Check

AENFL80B1114058
Circuit Diagram
1
A1
2 5V 12V
BRN E01-15 9
3 LT BLU E01-18 C01-53 LT GRN
BLU E01-21 10
C01-54 YEL/RED M
A2 E1
5V
BLK E01-4 5V
4 C01-14 RED
YEL E01-5 11
WHT E01-20 C01-26 GRN
12
C01-8 WHT
C01-17 BLK
B1 5V
5 C01-5 BLK
LT BLU E01-13
GRN E01-7 5V 12V

6
PNK E01-32 F1 13 G1
YEL E01-22 5V
E01-49 PNK 14
E01-55 BLU
C1 5V F2
7 3.3V G2
GRY/RED C01-2 E01-56 BLU F3
RED/BLK C01-39 H1 16
15 17
GRY/BLU C01-6 E01-6 WHT
I1 18
D1 5V C01-50 BLK
8 PNK E01-14 5V I2
C01-51 BLK 19
GRN E01-17
GRY E01-8
[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
IEL10A111023-02
[A]: ECM connector (View: [a]) H1: Ignition “ON” signal circuit 10. Throttle actuator
A1: APP sensor (main) power supply circuit I1: ECM ground circuit 1 11. TP sensor (main)
A2: APP sensor (sub) power supply circuit I2: ECM ground circuit 2 12. TP sensor (sub)
B1: Electric load current sensor power supply circuit 1. ECM 13. Main relay
C1: MAP sensor power supply circuit 2. APP sensor 14. “FI” fuse
D1: A/C refrigerant pressure sensor power supply circuit 3. APP sensor (main) 15. “IG COIL” fuse
E1: TP sensor power supply circuit 4. APP sensor (sub) 16. Ignition switch (ignition switch model) or
IG1 relay (keyless push start model)
F1: Main relay drive circuit 5. Electric throttle body assembly 17. “IG1” fuse
F2: Main power supply circuit 2 6. Battery temperature sensor 19. Main fuse box
F3: Main power supply circuit 1 7. MAP sensor 19. Battery
G1: Main relay power supply circuit (coil side) 8. A/C refrigerant pressure sensor
G2: Main relay power supply circuit (switch side) 9. Electric throttle body assembly
Circuit Description
When ignition is set to “ON”, the main relay turns on (contacts close) and the main power is supplied to ECM. ECM
then supplies 5 V power to the following sensors: A/C refrigerant pressure sensor, MAP sensor, APP sensor, TP
sensor and electric load current sensor.
Troubleshooting
NOTE
• Before troubleshooting, be sure to read “Precautions for ECM Circuit Inspection” under
• 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? Petrol and Bi-Fuel CNG
in Section 1J in related
manual and “Generator
Test”: Petrol and Bi-Fuel
CNG in Section 1J
(Page 1J-3).
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.
4) Check that voltage between each of “G1” and “G2”
circuit and ground is battery voltage.
Is check result OK?

Step Action Yes No

3 Main relay check Go to Step 4. Replace main relay.
1) Check main relay. 
Is check result OK?

4 Ignition switch circuit check Go to Step 5. Check that “IG COIL”
1) When ignition is “OFF”, install main relay to individual fuse or “IG1” fuse has
circuit fuse box No.1. not blown. If check
result is OK, repair or
2) Disconnect “C01” and “E01” connectors from ECM.
replace defective wire
3) Check for proper terminal connection to “C01” and “E01” harness.
connectors.
5) Check that voltage between “H1” 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 “F1” and ground is battery
voltage.
Is check result OK?

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

7 ECM ground circuit check Go to Step 8. Repair or replace
2) Check that resistance between each of “I1” and “I2”
circuit and ground is less than 1 Ω.
Is check result OK?

8 Sensor power supply circuit check ECM power supply and Check wiring harness
1) 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 circuits. 
5) Check that voltage between each of the following circuits
and ground is approx. 5 V.
• A1
• A2
• B1
• C1
• D1
• E1
Is check result OK?

Fuel Cut Operation Inspection

AENFL80B1114059
1) For M/T model, place gear shift lever in neutral 1
position and apply parking brake.
For A/T model, place select lever in P range and 2
apply parking brake.
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 decreases to 1,500 rpm.
Repair Instructions
Idle Speed and IAC Throttle Valve Opening 1) With ignition “OFF”, connect SUZUKI scan tool (2) to
Inspection DLC (1).
AENFL80B1116001
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-II)
engine and emission control systems are connected
securely.
• Valve clearance is checked according to maintenance
schedule.
• Ignition timing is within specification.
• All electrical systems (wipers, heater, lights, A/C, etc.)
are off.
• Air cleaner is properly installed and is in good 1
condition.
• There are no air abnormally drawn in from air intake
2
system.
• There is no obstruction in PCV valve or its hoses.
(A)
• There is no DTCs in ECM.
• The following items are turned OFF as checked using
“Data List” mode on SUZUKI scan tool.
– A/C Comp Relay
IFL80B111018-04
– A/C Switch
– Brake Switch
3) Check engine idle speed and “IAC throttle opening”
– Electric Load using “Data List” mode on SUZUKI scan tool.
– Blower Fan 4) If check result is not as specified, check engine idle
After confirming all items, check idle speed and IAC speed referring to “Improper engine idling or engine
throttle opening as follows. fails to idle” under “Engine Symptom Diagnosis”:
NOTE Petrol in related manual.
Before starting engine, place gear shift lever Engine idle speed (M/T model)
in neutral position (M/T model), or select A/C OFF: 550 to 650 rpm
lever in P range (A/T model), apply parking A/C ON: 700 to 900 rpm
brake and block drive wheels. Engine idle speed (A/T model)
A/C OFF: 600 to 700 rpm
A/C ON: 700 to 900 rpm

Special Tool
AENFL80B1118002
SUZUKI scan tool (Suzuki
SDT-II)
—
/
Engine General Information and Diagnosis: Bi-Fuel CNG 1A-123
Bi-Fuel CNG
General Description
AENFL80B1121003
ECM [A]
Refer to “OBD System Description”: Petrol (Page 1A-1).
NOTE
For bi-fuel CNG, three freeze frame data,
which can be read from ECM, are added.
They are “Type of Fuel”, “CNG/LPG
Temperature” and “CNG Cylinder Pressure”.
CNG Control Module [B]
General description
1
CNG control module in this vehicle has the following
functions.
• When the ignition switch is turned to ON position with
the engine stopped, CNG warning light (1) turns on for
2 sec. in order to check the CNG warning light (1) and
its circuit.
• When CNG control module detects a malfunction in
CNG control system for more than specified driving
cycles, it turns on or flashes CNG warning light in the
combination meter and stores the DTC in its memory.
(If it detects normal condition for 3 consecutive driving
cycles after detecting a malfunction, it turns OFF CNG
warning light although DTC stored in its memory 3
remains as a history DTC.)
• For some malfunctions, CNG control module adopts
2
the 3 D/C detecting logic to prevent erroneous
detection. With this logic, CNG warning light is turned
on when the malfunction is detected for 3 consecutive (A)
driving cycles.
• When a malfunction is detected, engine and driving
conditions at that moment are stored in CNG control
module memory as freeze frame data. For details,
IFL80B112001-02
refer to description on “Freeze frame data”: Bi-Fuel
[A] Without tachometer
CNG (Page 1A-124).
[B] With tachometer
• CNG control module, ECM and DLC are connected
through CAN line. Warm-up cycle
CNG control module information can be checked via Warm-up cycle means that the coolant temperature has
DLC (3) by SUZUKI scan tool (2). risen by at least 22 °C (72 °F) from engine starting and
reaches a minimum temperature of at least 71 °C (160
°F).
Driving cycle (D/C)

Driving cycle means a period which starts at engine
starting and ends at engine shut off.
3 Driving cycle detection logic

stored in CNG control module memory (in the form of
pending DTC and freeze frame data) but the CNG
warning light does not turn on at this time. CNG control
1A-124 Engine General Information and Diagnosis: Bi-Fuel CNG
module causes the CNG warning light to light up when it CNG Inj Pulse Width #1
detects third time the same malfunction in the next two CNG Inj Pulse Width #2
driving cycle. CNG Inj Pulse Width #3
CNG Inj Pulse Width #4
Pending DTC Battery Voltage
Pending DTC means a DTC detected and stored Ignition Switch
temporarily at the first driving cycle of the 3 driving cycle Fuel Select Switch
detection logic. Fuel Filler Lid SW 1
Fuel Filler Lid SW 2
Freeze frame data Fuel Change Relay1
CNG control module stores the engine and driving Fuel Change Relay2
conditions (in the form of data as shown) at the moment Fuel Change Relay3
of the detection of a malfunction in its memory. This data Fuel Change Relay4
is called “Freeze frame data”. Power Supply Relay
It is possible to know engine and driving conditions (e.g., Power Supply Relay (Mon)
whether the fuel was petrol or CNG, whether the engine Shut Off V Tank
was warm or not, whether the vehicle was running or Shut Off V Tank (Mon)
stopped, whether air / fuel mixture was lean or rich) Shut Off V Reg
when a malfunction was detected by checking the freeze Shut Off V Reg (Mon)
frame data. Also, CNG control module has a function to Fuel Cut Request
store each freeze frame data for three different Fuel Cut Active
malfunctions in the order of their detection. Utilizing this Fuel System 1 Status
function, it is possible to know the order of detection of
these malfunctions. This is helpful when rechecking or Freeze frame data (for example)
diagnosing a trouble.
For details of freeze frame data that can be read from Function View System Bar Help
CNG control module, refer to table below. CNG / Freeze Frame Data
DTC P2408 Fuel Cap Sensor / Switch Circuit

Engine Load Rate
Parameter Value Unit
ECT
DTC P2408
ECT 25 C
Long Term Fuel Trim Short Term Fuel Trim 0.00 %
MAP Long Term Fuel Trim 0.00 %
Engine Speed MAP 102 kPa
Vehicle Speed Engine Speed 0 rpm
Intake Air Temperature Vehicle Speed 0 km/h
Absolute TP 1* Intake Air Temperature 26 C
Absolute TP 1 0.00 %
Time Since Engine Start
Fuel Pressure Exit
Fuel Temperature
Data Active
CNG Pressure DTC
List
View
Test
Utility
Fuel Select Mode I9R90A112003-02
Fuel Running status
Injection Pressure Freeze frame data clearance
Engine Running status The freeze frame data is cleared at the same time as
Inj Pulse Width #1 clearance of DTC.
Inj Pulse Width #2
Inj Pulse Width #3
Inj Pulse Width #4

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.
NOTE
• The system readiness test status may change from “Complete” to “Incomplete” if any of the
following service operations is performed.
– 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 on-board diagnosis.
Monitoring item of system readiness test table

Catalyst P0420 — —
O2 Sensor P0133 — —
Engine and Emission Control Input / Output Table

AENFL80B1121011
ECM
• Ignition switch
• Starter switch
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
• MAP sensor
Injection control CNG control module
• IAT sensor
• HO2S-1
• HO2S-2
• Battery voltage
• VSS
• CNG control module
CNG control module • Ignition switch
Immobilizer control
Ignition coil assembly • Immobilizer control module
• Ignition switch
• Starter switch
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
Ignition control Ignition coil assembly
• MAP sensor
• IAT sensor
• Knock sensor
• Battery voltage
• VSS

• Ignition switch
• Starter switch
• ECT sensor
• CKP sensor
• CMP sensor
• TP sensor
• MAP sensor
Idle speed control ISC valve
• IAT sensor
• EVAP canister purge valve
• Battery voltage
• VSS
• A/C switch (if equipped)
• CKP sensor
• TP sensor
• APP sensor
Throttle valve control Throttle actuator
• IAT sensor
• BCM (electric load signal and A/C OFF/ON request
signal)
• Ignition switch
• Starter switch
• ECT sensor
• CKP sensor
HO2S heater control HO2S
• TP sensor
• MAP sensor
• IAT sensor
• Battery voltage
• Ignition switch
• ECT sensor
• CKP sensor
• TP sensor
EVAP canister purge • MAP sensor
EVAP purge control
valve • IAT sensor
• HO2S-1
• HO2S-2
• VSS
• BCM (A/C OFF/ON request signal)

• Ignition switch
• ECT sensor
• CKP sensor
• TP sensor
A/C compressor control A/C compressor relay
• APP sensor
• A/C evaporator outlet air temperature sensor
• VSS
• Ignition switch
• ECT sensor
• CKP sensor
Radiator cooling fan
Radiator cooling fan control • A/C refrigerant pressure sensor
relay
• VSS
• Ignition switch
Fuel pump control Fuel pump relay
• CKP sensor
Starting motor control relay Starting motor control
control relay • Ignition switch
Main relay control Main relay
CNG Control Module

• Ignition switch
• ECT sensor
• CKP sensor
• CMP sensor
• IAT sensor
Fuel select control ECM • TP sensor
• HO2S-1
• HO2S-2
• CNG pressure-and-temperature sensor
• Fuel select switch
• Battery voltage
• Ignition switch
Petrol injection control Petrol fuel injector
• Fuel filler lid switch
• ECM
• Ignition switch
• ECT sensor
• MAP sensor
CNG injection control CNG fuel injector • CNG pressure-and-temperature sensor
• ECM

• Ignition switch
• CKP sensor
Petrol fuel injector / CNG • TP sensor
Fuel cut control
fuel injector • MAP sensor
• VSS
• ECM
• ECT sensor
Shut off valve of CNG • Ignition switch
cylinder pressure • Fuel select switch
CNG shut off valve control
regulator / CNG cylinder
• CNG valve control relay
valve

Engine and Emission Control System Flow Diagram
AENFL80B1122001
Electric signal Air Vapor
CAN signal Exhaust gas Fuel (Petrol)
Fuel (CNG)
MAP sensor Exhaust Three way Exhaust

Engine manifold catalyst pipe
Intake manifold
Electric throttle
Air cleaner HO2S-1 HO2S-2
body assembly
IAT CMP CKP Knock Ignition coil
Throttle TP Petrol fuel CNG fuel sensor sensor sensor with igniter
sensor
actuator sensor injector injector
EVAP EVAP
canister canister
purge
ECT sensor valve Fuel EVAP Fuel
valve pump CNG fuel delivery pipe
CNG MAP and CNG fuel pressure regulator
Fuel tank temperature sensor
CNG fuel pressure sensor
Shut off valve
ECM
Shut off valve
CNG cylinder valve
CNG Cylinder
A/C evaporator A/C compressor
outlet air temp sensor relay
Combination meter CNG valve Fuel select Fuel filler
· MIL A/C refrigerant control relay switch lid switch
Radiator cooling
· CNG warning light pressure sensor fan relay
· Coolant temperature
· Immobilizer indicator light
· Tachometer VSS
· Speedometer Generator CNG control module
· Odometer
A/C switch
Main relay
Brake light
DLC switch Ignition switch
Starting motor P/S

control module
Immobilizer
control module
IFL80B112011-01
Engine Control System Circuit Diagram

AENFL80B1122002
ECM
1
2 29 +B
BRN E01-15 IG1
C01-53 LT GRN +BB
3 LT BLU E01-18 30
BLU E01-21 C01-54 YEL/RED
C01-14 RED
BLK E01-4 31
C01-26 GRN
4 YEL E01-5 32
C01-8 WHT
WHT E01-20 C01-17 BLK
+B
C01-5 BLK 56
BLU
5 C01-11 BRN/YEL a
RED/YEL C01-28
C01-12 BRN b
6
PNK C01-31 C01-10 WHT/GRN c
GRY
C01-22 BRN d
7 56
+B BLU C01-18
BLU RED C01-7
GRN/WHT C01-52 C01-40 BLU/BLK 37
YEL/GRN C01-37
38
56 C01-41 YEL
8
YEL C01-16
BRN C01-19 39
RED/BLU C01-49 E01-54 YEL
YEL/BLK C01-38 BLK PNK
9 40
BLK/YEL C01-25 41
E01-46 LT GRN 65
GRY/BLU C01-36 BLU/RED
10 BLK
LT GRN C01-20 42
GRY/BLU C01-45 43
11 E01-36 GRN 66
WHT C01-1 RED
BLK C01-13 BLK
44
12 GRY/RED C01-2 45
E01-48 GRY
RED/BLK C01-39 67
WHT
GRY/BLU C01-6 46
13 PNK E01-14 47
GRN E01-17 C01-32 GRN/YEL
GRY E01-8 48
[A] +B C01-33 GRN/WHT

49
14 PPL C01-27
C01-34 BRN
50
15
+BB PPL E01-27 C01-35 LT GRN
16
64
53 C01-4 BLU 51
17
GRN E01-28
18 52
E01-49 PNK
20
+BB LT BLU E01-13 E01-55 BLU
GRN E01-7 E01-56 BLU
IG2 63 19
PNK E01-32 E01-6 WHT
54 IG2
62 YEL E01-22 33 57
IG1 68
M 21
GRY GRY E01-19 ST
22 36 61
34
+BB 58 59
23
35 55
28 WHT E01-2
27 26 25 E01-52 LT GRN
RED E01-1
[B]
C01-50 BLK
C01-51 BLK
e RED C01-3
f WHT C01-15
: 60 : 69 : 12V : 5V : 3.3V
IFL80B112010-01
a: To CNG control module “C12-8” 19. Battery temperature sensor 45. A/C compressor relay
b: To CNG control module “C12-16” 20. “FI” fuse 46. A/C compressor
c: To CNG control module “C12-7” 21. Blower motor 47. Ignition coil assembly No.1
d: To CNG control module “C12-15” 22. Blower speed selector 48. Ignition coil assembly No.2
e: To CNG control module “C12-25” 23. A/C switch 49. Ignition coil assembly No.3
f: To CNG control module “C12-33” 24. TCM 50. Ignition coil assembly No.4
[A]: Non-ABS model 25. ABS control module 51. Generator
[B]: ABS model 26. BCM 52. Main relay
1. ECM 27. Combination meter 53. LIN driver
2. APP sensor 28. DLC 54. Barometric pressure sensor
3. APP sensor (main) 29. Electric throttle body assembly 55. Battery
4. APP sensor (sub) 30. Throttle actuator 56. Shield wire
5. CMP sensor 31. TP sensor (main) 57. Ignition switch
6. CKP sensor 32. TP sensor (sub) 58. Starting motor control relay
7. HO2S-1 33. “IG COIL” fuse 59. Starting motor
8. HO2S-2 34. “ST” fuse 60. Engine ground
9. IAT sensor 35. “ST SIG2” fuse 61. Main fuse box
10. ECT sensor 36. “ST SIG” fuse 62. Blower motor relay
11. Knock sensor 37. EVAP canister purge valve 63. “BLW” fuse
12. MAP sensor 38. OCV 64. “STOP” fuse
13. A/C refrigerant pressure sensor 39. Fuel pump relay 65. “RDTR” fuse
14. VSS 40. Fuel pump 66. “CDSR” fuse
15. CPP No.2 switch 41. Radiator cooling fan relay No.1 67. “CPRSR” fuse
16. Brake light switch 42. Radiator cooling fan No.1 68. “IG1” fuse
17. Brake light 43. Radiator cooling fan relay No.2 69. Body ground
18. Electric load current sensor 44. Radiator cooling fan No.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
I9P60A111006-02
[A]: ECM connector (View: A)

NOTE
For circuit name and terminal voltage, refer to “Inspection of ECM and Its Circuit”: Bi-Fuel CNG (Page
1A-155).
CNG Control Module
+B
BLK/RED
1 5
C12-6 21
BLU/YEL
9 RED/WHT
C12-1 WHT/BLK
a BRN/YEL C12-8
6
C12-14 BLU/WHT
10
C12-10 GRY
b BRN C12-16
7
C12-5 BLU/RED
11
C12-18 WHT/BLU
c WHT/GRN C12-7
8
C12-13 LT GRN/BLK
12
C12-27 BRN/YEL
d BLK/RED C12-15
12V 5V
E23-1 RED/WHT
3
LT GRN/RED E23-5 E23-10 RED/WHT
GRY E23-14 2
GRY/RED E23-13
BLU/RED E23-24 IG1
4 E23-21 WHT
RED/BLU E23-6
RED/BLK E23-15 20
E23-30 GRN/BLK
RED/YEL E23-23 BLK +BB2
E23-31 GRN/WHT
RED/WHT
e RED C12-25
f WHT C12-33
13 14
E23-22 LT GRN/BLK BLK
15
E23-4 BLK/BLU
16
E23-34 BLU/BLK
BLK C12-9
BLK C12-17 17
E23-26 BLU/WHT
BLK C12-26
: 18 : 19 : 5V : 12V
IFL80B112005-00
a: To ECM “C01-11” 2. CPU 9. CNG fuel injector No.1 16. Shut off valve of CNG cylinder valve
b: Shut off valve of CNG cylinder pressure
To ECM “C01-12” 3. CNG pressure-and-temperature sensor 10. CNG fuel injector No.2 17.
regulator
c: To ECM “C01-10” 4. CNG cylinder pressure sensor 11. CNG fuel injector No.3 18. Engine ground
d: To ECM “C01-22” 5. Petrol fuel injector No.1 12. CNG fuel injector No.4 19. Body ground
e: To ECM “C01-3” 6. Petrol fuel injector No.2 13. Fuel select switch 20. Fuel filler lid switch
f: To ECM “C01-15” 7. Petrol fuel injector No.3 14. “CNG VLV” fuse 21. “CNG” fuse
1. CNG control module 8. Petrol fuel injector No.4 15. CNG valve control relay
Terminal Arrangement of CNG Control Module Connector
[A]
E23 C12
9 8 7 6 5 4 3 2 1 9 8 7 6
5 4 3 2 1
A
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
IDL80A113005-01
[A]: CNG control module connector (View: A)
NOTE
For circuit name and terminal voltage, refer to “Inspection of CNG Control Module and Its Circuit”: Bi-
Fuel CNG (Page 1A-165).

CNG Warning Light Check
AENFL80B1124003
[A] [B]
1) Turn ignition switch to ON position (with engine
1
stopped) and check that CNG warning light (1) lights
for approx. 2 sec. and then turns OFF.
If CNG warning light does not light up (or CNG
warning light dims), go to “CNG Warning Light Does
Not Come ON with Ignition Switch in ON Position
and Engine Stopped”: Bi-Fuel CNG (Page 1A-147)
for troubleshooting.
2) Start engine and check that CNG warning light turns
OFF.
If CNG warning light remains ON and no DTC is
stored in CNG control module, go to “CNG Warning
Light Remains ON after Engine Starts”: Bi-Fuel CNG
in related manual for troubleshooting.
IFL80B112004-00
[A] Without tachometer [B] With tachometer
DTC Check
AENFL80B1124004
ECM
Refer to “DTC Table”: Petrol (Page 1A-17).
CNG Control Module
NOTE
In case that CNG warning light lights while
engine is running, the malfunction(s) is
detected by CNG control module and it
1
stores the trouble information (DTC, freeze
frame data, etc.) in its memory.
2
1) With ignition switch turned OFF, connect SUZUKI
scan tool (to DLC (1) located on underside of
(A)
instrument panel at driver’s seat side.
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II)
IFL80B111018-04
2) Turn ignition switch to ON position and confirm that

CNG warning light lights.
3) Read DTC and freeze frame data according to
instructions displayed on scan tool and print them or
write them down. Refer to Operator’s Manual of
SUZUKI scan tool for further details.
If communication between scan tool and CNG
control module is not possible, go to
“Troubleshooting for Communication Bus Off”: Petrol
and Bi-Fuel CNG Model in Section 10H (Page 10H-
19).
4) After completing the check, turn OFF ignition switch
and disconnect scan tool from DLC.
DTC Table
AENFL80B1124006
ECM
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”: Petrol.
• With the CAN communication generic scan tool, only DTC marked with asterisk (*) in the following
table can be read.
DTC
logic
*P0010 OCV control circuit is open. 3 D/C Lights up
Actuator Circuit / Open
Measured CMP does not reach target CMP for
*P0011 Timing Over Advanced or 3 D/C Lights up
specified time.
System Performance
HO2S Heater Control
*P0030 HO2S-1 heater control circuit is open. 3 D/C Lights up
Circuit (Sensor 1)
HO2S Heater Control
*P0031 HO2S-1 heater control circuit is shorted to ground. 3 D/C Lights up
Circuit Low (Sensor 1)
HO2S Heater Control HO2S-1 heater control circuit is shorted to power
*P0032 3 D/C Lights up
Circuit High (Sensor 1) supply.
HO2S Heater Control
*P0036 HO2S-2 heater control circuit is open. 3 D/C Lights up
Circuit (Sensor 2)
DTC
logic
HO2S Heater Control
*P0037 HO2S-2 heater control circuit is shorted to ground. 3 D/C Lights up
Circuit Low (Sensor 2)
HO2S Heater Control HO2S-2 heater control circuit is shorted to power
Circuit High (Sensor 2) supply.
Manifold Absolute
Output voltage of MAP sensor signal circuit is
*P0107 Pressure / Barometric 3 D/C Lights up
lower than 0.1 V for 5 sec.
Pressure Circuit Low
Manifold Absolute
Output voltage of MAP sensor signal circuit is
*P0108 Pressure / Barometric 3 D/C Lights up
higher than 4.9 V for 5 sec.
Pressure Circuit High
Intake Air Temperature Output voltage of IAT sensor signal circuit is lower
Sensor 1 Circuit Low than 0.09 V for 5 sec.
Intake Air Temperature Output voltage of IAT sensor signal circuit is higher
Sensor 1 Circuit High than 3.2 V for 5 sec.
Engine Coolant
Difference between measured ECT and estimated
Temperature Sensor 1
*P0116 ECT is more than specified value for specified time 3 D/C Lights up
Circuit Range /
with engine running.
Performance
Engine Coolant
Output voltage of ECT sensor signal circuit is lower
*P0117 Temperature Sensor 1 3 D/C Lights up
Circuit Low
Engine Coolant
Output voltage of ECT sensor signal circuit is
*P0118 Temperature Sensor 1 3 D/C Lights up
Circuit High
Output voltage of TP sensor (main) signal circuit is
*P0122 Sensor / Switch “A” Circuit 1 D/C Lights up
lower than 0.2 V.
Low
Output voltage of TP sensor (main) signal circuit is
*P0123 Sensor / Switch “A” Circuit 1 D/C Lights up
higher than 4.8 V.
High
0.42 V even if HO2S-2 signal voltage is higher
O2 Sensor Circuit (Sensor
*P0130 than 0.6 V for 30 sec. 3 D/C Lights up
1)
1.27 V even if HO2S-2 signal voltage is lower
Output voltage of HO2S-1 circuit is lower than 0.06
O2 Sensor Circuit Low
*P0131 V and output voltage of HO2S-2 circuit is higher 3 D/C Lights up
Voltage (Sensor 1)
O2 Sensor Circuit High Output voltage of HO2S-1 circuit is higher than
Voltage (Sensor 1) 1.27 V for 25 sec.
O2 Sensor Circuit Slow Cycle duration from rich to lean and lean to rich of
Response (Sensor 1) HO2S-1 is longer than specified time.
Output voltage of HO2S-1 circuit stays between
*P0134 Activity Detected (Sensor 3 D/C Lights up
0.42 and 0.50 V for 25 sec.
1)
O2 Sensor Circuit Low Output voltage of HO2S-2 circuit is lower than 0.06
Voltage (Sensor 2) V for 30 sec.
O2 Sensor Circuit High Output voltage of HO2S-2 signal circuit is higher
Voltage (Sensor 2) than 1.27 V for 25 sec.
Output voltage of HO2S-2 circuit stays between
*P0140 Activity Detected (Sensor 3 D/C Lights up
0.42 to 0.50 V for 500 sec.
2)
Fuel trim correction is higher than specified value
*P0171 System Too Lean 3 D/C Lights up
for specified time under specified vehicle condition.
DTC
logic
Fuel trim correction is lower than specified value
*P0172 System Too Rich 3 D/C Lights up
for specified time under specified vehicle condition.
Output voltage of TP sensor (sub) signal circuit is
*P0222 Sensor / Switch “B” Circuit 1 D/C Lights up
lower than 0.2 V.
Low
Output voltage of TP sensor (sub) signal circuit is
*P0223 Sensor / Switch “B” Circuit 1 D/C Lights up
higher than 4.8 V.
High
• Misfire, which causes catalyst to overheat
during 200 engine revolutions, is detected at 2
Random / Multiple or more cylinders. (MIL blinks as long as misfire
Cylinder Misfire Detected lasts.)
adversely during 1000 engine revolutions, is
Cylinder 1 Misfire Any of the following conditions is met.
Detected • Misfire, which causes catalyst to overheat
Cylinder 2 Misfire during 200 engine revolutions, is detected at
Detected specific cylinder. (MIL blinks as long as misfire
Cylinder 3 Misfire lasts.)
Detected
Cylinder 4 Misfire adversely during 1000 engine revolutions, is
Detected detected at specific cylinder.
Knock Sensor 1 Circuit
*P0327 lower than specified value for specified time with 3 D/C Lights up
Low
engine running.
Knock Sensor 1 Circuit
*P0328 lower than specified value for specified time with 3 D/C Lights up
High
engine running.
Crankshaft Position CKP sensor signal is not inputted while CMP
Sensor “A” Circuit sensor signal is being inputted.
Crankshaft Position
Non-toothed position of sensor plate is out of the
*P0336 Sensor “A” Circuit Range/ 3 D/C Lights up
specified range.
Performance
• CMP sensor signal is not inputted while CKP
Camshaft Position Sensor
*P0340 sensor signal is being inputted. 3 D/C Lights up
“A” Circuit
• CMP sensor signal pattern is not equal to the
expected pattern.
Ignition Coil “A” Primary / Ignition coil assembly No.1 and/or its circuit is
Secondary Circuit open with engine running.
Ignition Coil “B” Primary / Ignition coil assembly No.2 and/or its circuit is
Ignition Coil “C” Primary / Ignition coil assembly No.3 and/or its circuit is
Ignition Coil “D” Primary / Ignition coil assembly No.4 and/or its circuit is
Average amplitude of HO2S-2 signal is more than
Catalyst System Efficiency
*P0420 specified value for 60 sec. under specified vehicle 3 D/C Lights up
Below Threshold
condition.
*P0443 System Purge Control EVAP canister purge valve control circuit is open. 3 D/C Lights up
Valve Circuit
DTC
logic
EVAP canister purge valve control circuit is
*P0458 System Purge Control 3 D/C Lights up
shorted to ground.
Valve Circuit Low
EVAP canister purge valve control circuit is
*P0459 System Purge Control 3 D/C Lights up
shorted to power supply.
Valve Circuit High
Radiator cooling fan relay No.1 drive circuit is
P0480 Fan 1 Control Circuit 3 D/C Off
shorted to ground or open.
Radiator cooling fan relay No.2 and/or No.3 drive
P0481 Fan 2 Control Circuit 3 D/C Off
circuit is shorted to ground or open.
• Vehicle speed is slower than 4 km/h (2.5 mile/h)
for 13 sec. at fuel cut condition.
*P0500 Vehicle Speed Sensor “A” 3 D/C Lights up
• Lost communication with ABS control module if
ABS is equipped. (M/T model)
• Lost communication with TCM. (A/T model)
Battery Temperature
*P0515 signal circuit is lower than 0.10 V for 5 sec. 3 D/C Lights up
Sensor Circuit
A/C Refrigerant Pressure
P0530 sensor signal circuit is lower than 0.15 V. 3 D/C Off
Sensor “A” Circuit
sensor signal circuit is higher than 4.93 V.
Main power supply voltage is lower than 2.54 V for
*P0560 System Voltage 3 D/C Lights up
10 sec.
Main power supply circuit voltage is lower than 9.8
*P0562 System Voltage Low 3 D/C Lights up
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
more.
Control Module
P0602 ECM internal failure (data programming error). 1 D/C Off
Programming Error
P0606 Control Module Processor ECM internal processor failure 3 D/C Off
1 D/C
Control Module
*P0607 Internal failure in ECM is detected. or Lights up
Performance
3 D/C
A/C Clutch Relay Control
P0645 A/C compressor relay drive circuit is open. 3 D/C Off
Circuit
A/C Clutch Relay Control A/C compressor relay drive circuit is shorted to
P0646 3 D/C Off
Circuit Low ground.
A/C Clutch Relay Control A/C compressor relay drive circuit is shorted to
P0647 3 D/C Off
Circuit High power supply.
Radiator cooling fan relay No.1 drive circuit is
P0692 Fan 1 Control Circuit High 3 D/C Off
shorted to power supply.
Radiator cooling fan relay No.2 and/or No.3 drive
P0694 Fan 2 Control Circuit High 3 D/C Off
circuit is shorted to power supply.
DTC
logic
signal circuit is more than 4.80 V for 5 sec.
Generator Current Sensor
P0A5A Circuit Range / • Output voltage of electric load current sensor 3 D/C Off
Performance signal circuit is lower than 0.20 V for 5 sec.
signal circuit fluctuates less than specified value
for 5 sec.
P1610 1 D/C Off
EEPROM Reading /
P1622 1 D/C Off
Writing Error Refer to “DTC Table”: Keyless Push Start Model in
Immobilizer Section 10C (Page 10C-6).
P1642 1 D/C Off
Communication Line Error
Immobilizer ID
P1644 1 D/C Off
Mismatched
*P2088 Actuator Control Circuit OCV control circuit is shorted to ground. 3 D/C Lights up
Low
*P2089 Actuator Control Circuit OCV control circuit is shorted to power supply. 3 D/C Lights up
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
Open detected.
• Difference between measured throttle valve
Throttle Actuator “A”
position and targeted throttle valve position is
*P2101 Control Motor Circuit 1 D/C Lights up
more than specified value.
Range / Performance
• Duty ratio of throttle actuator signal is out of
specified range for specified time.
• Time taken by throttle valve to return from
partially open position to mechanical default
position is more than specified time during
*P2119 Throttle Body Range / 1 D/C Lights up
return spring check process after setting ignition
Performance
“OFF”.
• Measured default throttle position is out of
specified range.
Output voltage of APP sensor (main) signal circuit
*P2122 Sensor / Switch “D” Circuit 1 D/C Lights up
is lower than 0.6 V.
Low
Output voltage of APP sensor (main) signal circuit
*P2123 Sensor / Switch “D” Circuit 1 D/C Lights up
is higher than 4.4 V.
High
Output voltage of APP sensor (sub) signal circuit is
*P2127 Sensor / Switch “E” Circuit 1 D/C Lights up
lower than 0.3 V.
Low
Output voltage of APP sensor (sub) signal circuit is
*P2128 Sensor / Switch “E” Circuit 1 D/C Lights up
higher than 2.5 V.
High
DTC
logic
Throttle / Pedal Position Difference between TP sensor (main) signal
*P2135 Sensor / Switch “A” / “B” voltage and TP sensor (sub) signal voltage is 1 D/C Lights up
Voltage Correlation higher than specified value.
Throttle / Pedal Position Difference between half of APP (main) sensor
*P2138 Sensor / Switch “D” / “E” signal and APP (sub) sensor signal is more than 1 D/C Lights up
Voltage Correlation specified value.
• TP sensor (main) or TP sensor (sub) signal
voltage at default position is out of specified
*P2176 System-Idle Position Not 1 D/C Lights up
range for specified time.
Learned
• Electric throttle control system calibration is not
completed.
Barometric Pressure Barometric pressure sensor signal voltage is lower
Sensor “A” Circuit Low than specified value for specified time.
Barometric Pressure Barometric pressure sensor signal voltage is
Sensor “A” Circuit High higher than specified value for specified time.
Ignition Coil “A” Primary Ignition coil assembly No.1 drive circuit voltage is
Ignition Coil “A” Primary Ignition coil assembly No.1 drive circuit voltage is
Ignition Coil “B” Primary Ignition coil assembly No.2 drive circuit voltage is
Ignition Coil “B” Primary Ignition coil assembly No.2 drive circuit voltage is
Ignition Coil “C” Primary Ignition coil assembly No.3 drive circuit voltage is
Ignition Coil “C” Primary Ignition coil assembly No.3 drive circuit voltage is
Ignition Coil “D” Primary Ignition coil assembly No.4 drive circuit voltage is
Ignition Coil “D” Primary Ignition coil assembly No.4 drive circuit voltage is
Control Module
U0073 Communication Bus Off) Table”: Petrol and Bi-Fuel 1 D/C Off
Receiving error of ECM from CNG control module
U0108 Alternative Fuel Control 1 D/C Lights up
for specified time continuously.
Module
U0121 ABS / ESP® Control 1 D/C Off
Module
U0131 Power Steering Control 1 D/C Off
Module
U0140 Communication Bus Off) Table”: Petrol and Bi-Fuel 1 D/C Off
Body Control Module
LIN Lost Communication
U2001 Received data from generator via LIN is faulty. 1 D/C Off
With Generator
LIN Invalid Data from Transmitted data from ECM to generator via LIN is
U2021 1 D/C Off
ECM to Generator faulty.
CNG Control Module
NOTE
When DTC with asterisk (*) No. in the following table is detected, CNG warning light blinks.
DTC CNG
DTC DTC name DTC detecting condition detection warning MIL
logic light
Measured voltage of shut off valve of
P0005* CNG cylinder pressure regulator is
Fuel Shutoff Valve “A” Control Not
(Page lower than specified voltage for 5 1 D/C Applicable
Circuit/Open applicable
1A-149) sec, only if CNG valve control relay
is not faulty and is ON.
CNG cylinder pressure regulator is
P0007*
Fuel Shutoff Valve “A” Control higher than specified voltage for 5 Not
(Page 1 D/C Applicable
Circuit High sec, only if its command signal is applicable
1A-149)
output and CNG valve control relay
is ON.
Voltage of CNG temperature sensor
Fuel Temperature Sensor “A”
P0182  signal circuit is lower than 0.1 V for 5 3 D/C Applicable Applicable
Circuit Low
sec.
Voltage of CNG temperature sensor
Fuel Temperature Sensor “A”
P0183  signal circuit is higher than 4.9 V for 3 D/C Applicable Applicable
Circuit High
5 sec.
Voltage of CNG pressure sensor
Fuel Rail Pressure Sensor “A”
P0192  signal circuit is lower than 0.1 V for 5 3 D/C Applicable Applicable
Circuit Low
sec.
Voltage of CNG pressure sensor
Fuel Rail Pressure Sensor “A”
P0193  signal circuit is higher than 4.9 V for 3 D/C Applicable Applicable
Circuit High
5 sec.
Measured voltage of CNG fuel
P0201
Injector Circuit/Open - Cylinder injector No.1 is lower than specified
(Page 3 D/C Applicable Applicable
1 voltage for 5 sec. even if its
1A-152)
command signal is not output.
P0202
1A-152)
P0203
1A-152)
P0204
1A-152)
Internal Control Module CNG control module internal failure
P0601  3 D/C Applicable Applicable
Memory Check Sum Error related to check sum error.
Control Module Programming CNG control module internal failure Not Not
P0602  —
Error (data programming error). applicable applicable
DTC CNG
logic light
This DTC is detected if any one of
the following conditions is met.
• Measured voltage of CNG valve
control relay is lower than
specified voltage for 3 sec. even if Not
P0607*  Control Module Performance 1 D/C Applicable
its command signal is output. applicable
• Measured voltage of CNG valve
control relay is higher than
specified voltage for 3 sec. even if
its command signal is output.
• Measured signal of either of fuel
control relays is “Petrol” side for 5
sec. with engine running on CNG.
Fuel Injector Control Module
P0612  • Measured signal of either of fuel 3 D/C Applicable Applicable
Relay Control
control relays is “CNG” side for 5
sec. with engine running on petrol.
• Petrol injector is disconnected or
shorted to ground with engine
running on CNG.
Internal Control Module CNG control module internal failure.
P062F  3 D/C Applicable Applicable
EEPROM Error (EEPROM error)
Voltage of CNG cylinder pressure
Remaining Fuel Sensor Low Not
P1432  sensor signal circuit is lower than 0.1 1 D/C Applicable
Voltage applicable
V for 5 sec.
Voltage of CNG cylinder pressure
Remaining Fuel Sensor High Not
P1433  sensor signal circuit is higher than 1 D/C Applicable
Voltage applicable
4.9 V for 5 sec.
• Changeover of the state from
“Petrol” to “CNG” is detected
P1601*  Monitor Circuit Fault 3 D/C Applicable Applicable
continuously for 5 sec.
• Changeover of the state from
“CNG” to “Petrol” is detected
continuously for 5 sec.
• Both fuel filler lid switch No.1 and
Fuel Cap Sensor/Switch No.2 ON signals are input for 5 Not
P2408  3 D/C Applicable
Circuit sec. applicable
• Both fuel filler lid switch No.1 and
No.2 OFF signals are input for 5
sec.
CNG cylinder valve is lower than
Fuel Shutoff Valve “B” Control Not
P2665*  specified voltage for 5 sec. only if its 1 D/C Applicable
Circuit/Open applicable
command signal is not output and
CNG valve control relay is ON.
CNG cylinder valve is higher than
Fuel Shutoff Valve “B” Control Not
P2667*  specified voltage for 5 sec. only if its 1 D/C Applicable
Circuit High applicable
command signal is output and CNG
valve control relay is ON.
DTC CNG
logic light
Fuel Mode Indicator Lamp Fuel select switch ON signal is input Not
P2668  1 D/C Applicable
Control Circuit continuously for more than 120 sec. applicable
CNG control module fails to transmit
Control Module Not
U0073*  and receive the data via CAN for 1 D/C Applicable
Communication Bus Off applicable
specified time continuously
Receiving error of CNG control
U0100*  Lost Communication with ECM 1 D/C Applicable Applicable
module from ECM for 2 sec.
Scan Tool Data (ECM)

AENFL80B1124008
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.
Use a timing light to check the ignition timing. (Page 1H-2)
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 /
reference value
–5 °C (–9 °F) +
CNG/LPG Temperature • Engine condition: Idle speed after warming up environmental temperature
(Page 1A-145) • Fuel select mode: Forced CNG MODE to 40 °C (72 °F) +
CNG Cylinder Pressure • Engine condition: Idle speed after warming up
(Page 1A-145) Approx. 200 to 265 KPa
• Fuel select mode: Forced CNG MODE
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.)
*
145) 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” —
(Page 1A-145)
Long Term Fuel Trim
(Page 1A-145)
Total Fuel Trim (Page
Engine: Idle speed after warming up Approx. –30 to 30%
1A-145)
Inj Pulse Width (Page
Engine: Idle speed with no load after warming up Approx. 1.6 to 4.0 msec
1A-145)
Ignition Advance (Page
* Engine: Idle speed with no load after warming up –2 to 12° BTDC
1A-145)
Calculated Load (Page
* Engine: Idle speed with no load after warming up Approx. 10 to 40%
1A-145)
Normal condition /
reference value
Engine Speed (Page Radiator cooling fan: Stopped
* Approx. 600 to 700 rpm
1A-145) All electrical equipment: OFF
Desired Idle (Page 1A- Radiator cooling fan: Stopped
Approx. 650 rpm
145) All electrical equipment: OFF
* Vehicle running Vehicle speed is displayed.
1A-145)
* MAP (Page 1A-145) Engine: Idle speed after warming up Approx. 20 to 55 kPa
Approx. 80 to 105 °C (176
* ECT (Page 1A-145) Engine: Idle speed after warming up
– 221 °F)
–5 °C (–9 °F) +
Intake Air Temperature environmental temperature
* Engine: Idle speed after warming up
(Page 1A-145) to 40 °C (72 °F) +
Barometric Pres (Page Barometric pressure is
* —
1A-145) displayed.
EVAP Canist Prg Duty
* Engine: Idle speed after warming up 0%
(Page 1A-145)
VVT Gap (Page 1A-
Engine: Idle speed after warming up –1.0 to 1.0° CA
145)
Engine: Idle speed with no load after warming up Approx. 10 to 45%
IAC Throttle Opening Engine: Idle speed after warming up
(Page 1A-145) A/C switch: ON Approx. 10 to 65%
Blower speed selector: Max
Ignition: “ON”
0.6 to 1.0 V
4.2 to 4.7 V
Ignition: “ON”
3.9 to 4.4 V
0.3 to 0.8 V
Ignition: “ON”
0.6 to 0.9 V
3.7 to 4.4 V
Ignition: “ON”
0.3 to 0.5 V
1.8 to 2.2 V
Ignition: “ON”
0 to 2%
Accel Position (Page Accelerator pedal: Released
*
90 to 100%
Ignition: “ON”
0 to 10%
Throttle Position (Page Accelerator pedal: Released
*
90 to 100%
Ignition: “ON”
0 to 10%
Target Throttle Posi Accelerator pedal: Released
*
90 to 100%
* Engine: Idle speed after warming up 0 to 1.0 V
146)
Normal condition /
reference value
* Engine: 2,000 rpm for 3 min. or more after warming up 0 to 1.0 V
146)
Battery Voltage (Page
* Engine: Idle speed Approx. 13 to 15 V
1A-146)
Fuel Tank Level (Page
Ignition: “ON” 0 to 100%
1A-146)
Engine: Idle speed
A/C Pressure (Page
A/C switch: ON 600 to 1,300 kPa
1A-146)
Blower speed selector: MAX
Type of Fuel (Page 1A- Engine condition: Running on petrol Petrol
146) Engine condition: Running on CNG CNG
• Engine condition: Specified idle speed with no load after
warming up 0 msec
Inj Pulse Width (CNG) • Fuel select mode: Petrol MODE
(Page 1A-146) • Engine condition: Specified idle speed with no load after
warming up Approx. 3.5 – 5.5 msec
Fuel select mode: AUTO MODE Auto
Fuel Select Mode
Fuel select mode: Petrol MODE Petrol
(Page 1A-146)
Fuel select mode: Forced CNG MODE Gas
Generator Reg Volt
Engine: Idle speed 10.4 to 16.3 V
(Com) (Page 1A-146)
Radiator cooling fan: Off Off
Radiator Fan (Page 1A-
Radiator cooling fan: Low speed Low
146)
Radiator cooling fan: High speed High
A/C switch: ON
A/C Comp Relay (Page ON
1A-146)
Fuel Pump (Page 1A- Engine running ON
146) Other than above condition (or engine running on CNG) OFF
Starter SW (Page 1A- Ignition: “ST” (engine cranking) ON
A/C switch: ON
A/C Switch (Page 1A- ON
146)
Manual A/C: 2nd or higher speed position
ON
Blower Fan (Page 1A- Auto A/C: 4th or higher speed position
146) Manual A/C: Other than above condition
OFF
Auto A/C: Other than above condition
Brake Switch (Page Brake pedal: Depressed ON
1A-146) Brake pedal: Released OFF
Electric Load (Page 1A- Headlight switch: ON ON
146) Headlight switch: OFF OFF
Clutch SW (Page 1A- Clutch pedal: Depressed fully Declutch
146) Clutch pedal: Released Clutched
Fuel Cut (Page 1A-146) Accelerator pedal: Released
ON
Engine condition: 2,000 rpm or more after warming up
Ignition: “ON”
ON
Closed Throttle Pos Accelerator pedal: Released
OFF
1A-147)
1A-147)
Scan Tool Data Definitions Engine Speed (rpm):

CNG/LPG Temperature (°C, °F) The engine speed is calculated from reference pulses
This parameter indicates the calculated CNG from the camshaft position sensor.
temperature based on CNG temperature sensor signal.
Desired Idle (Desired idle speed, rpm):
CNG Cylinder Pressure (kPa) The Desired Idle Speed is an ECM internal parameter
This parameter indicates the calculated CNG pressure in which indicates idle speed requested by ECM. If the
CNG fuel delivery pipe based on CNG pressure sensor engine is not running, this number is not valid.
signal.
Vehicle Speed (km/h, mph):
Fuel System (Fuel system status): The vehicle speed is calculated based on pulse signals
A/F ratio feedback loop status is displayed as follows. from VSS.
OL: Open-loop control before satisfaction of closed loop
control conditions (ECT > 10 °C, IAT, TP, HO2S-1/ MAP (Manifold absolute pressure, kPa, mmHg, inHg,
system = OK). psi, inH2O):
CL: Closed-loop control using oxygen sensor(s) as This parameter indicates the calculated manifold
feedback sensor(s). pressure based on MAP sensor signal.
OL-DRIVE: Open-loop control due to driving requirement
(power-up enrichment etc.). ECT (Engine coolant temperature, °C, °F):
OL-FAULT: Open-loop control due to system fault It is detected by engine coolant temperature sensor.
detected.
CL-FAULT: Closed-loop control due to system fault Intake Air Temperature. (°C, °F):
detected. It is detected by intake air temperature sensor.
Short Term Fuel Trim (%): Barometric Pres (Barometric pressure, kPa, mmHg,
Short term fuel trim value represents short term inHg, psi, inH2O):
corrections to air/fuel mixture. 0 (zero) indicates no This parameter represents barometric air pressure
correction, a value greater than 0 indicates enrichment measurement and is used for altitude correction of the
correction, and a value less than 0 indicates enleanment fuel injection rate.
correction.
Evap Canist Prg Duty (Evap canister purge flow
Long Term Fuel Trim (%): duty,%):
Long term fuel trim value represents long term This parameter indicates valve ON (valve open) time
corrections to air/fuel mixture. 0 (zero) indicates no rate within a certain set cycle of EVAP canister purge
correction, a value greater than 0 indicates enrichment valve which controls the amount of EVAP purge.
correction, and a value less than 0 indicates enleanment
correction. VVT Gap (Variable valve timing difference between
target and actual position, °CA):
Total Fuel Trim (%): This parameter indicates difference between target
Total Fuel Trim is calculated from Short Term Fuel Trim camshaft position and actual camshaft position.
and Long Term Fuel Trim. This value indicates how
much correction is necessary to keep the air/fuel mixture IAC Throttle Opening (Idle air throttle valve
stoichiometrical. opening,%):
This parameter indicates throttle valve opening of idle air
Inj Pulse Width (Fuel injection pulse width, msec.): control in% (100% indicates the maximum idle air flow).
This parameter indicates the injector drive pulse width
(time) during which the injector valve stays open as TP Sensor 1 Volt (TP sensor (main) output voltage,
commanded by ECM. (For multipoint fuel injection, the V):
injector drive time means that of the No.1 cylinder.) TP Sensor (Main) data provides throttle valve opening
information in the form of voltage.
Ignition Advance (Ignition timing advance for No.1
cylinder, ° BTDC): TP Sensor 2 Volt (TP sensor (sub) output voltage, V):
This parameter indicates the ignition timing of No.1 TP Sensor (Sub) data provides throttle valve opening
cylinder commanded by ECM. The actual ignition timing information in the form of voltage.
should be checked using a timing light.
APP Sensor 1 Volt (APP sensor (main) output
Calculated Load (Calculated load value,%): voltage, V):
This parameter indicates calculated engine load in APP Sensor (Main) data provides accelerator pedal
percent. The load is calculated based on input signals to position information in the form of voltage.
ECM from various engine sensors.
APP Sensor 2 Volt (APP sensor (sub) output voltage, Petrol: Petrol MODE is selected.
V): Gas: Forced CNG MODE is selected.
APP Sensor (Sub) data provides accelerator pedal
position information in the form of voltage. Generator Reg Volt (Com) (V):
This parameter indicates commanded regulated-voltage
Accel Position (Absolute accelerator pedal to generator.
position,%):
This parameter indicates calculated accelerator pedal Radiator Fan (Radiator cooling fan control relay,
position in percent based on input from accelerator pedal Low/High/Off):
position sensor. Low: ON command is being output to the radiator
cooling fan relay No.1.
Throttle Position (Absolute throttle position,%): High: ON command is being output to radiator cooling
This parameter indicates calculated throttle opening in fan relays No.2 and No.3.
percent based on input from throttle position sensor. Off: No command is being output.
Target Throttle Posi (Target throttle valve A/C Comp Relay (A/C compressor relay, ON/OFF):
position,%): This parameter indicates the state of the A/C
Target Throttle Valve Position is an ECM internal compressor relay.
parameter which indicates throttle valve position
requested by ECM. Fuel Pump (ON/OFF):
ON is displayed when ECM activates the fuel pump via
O2S B1 S1 (HO2S-1, V): the fuel pump relay switch.
It indicates output voltage of HO2S-1 installed on
exhaust manifold (Pre-TWC). Starter SW (Starter switch, ON/OFF):
This parameter indicates state of starting motor relay
O2S B1 S2 (HO2S-2, V): output.
It indicates output voltage of HO2S-2 installed on ON: Starting motor relay is ON.
exhaust manifold (post-TWC). It is used to detect OFF: Starting motor relay is OFF.
catalyst deterioration.
A/C Switch (ON/OFF):
Battery Voltage (V): ON: Command for A/C operation is being output from
This parameter indicates battery voltage inputted from ECM to HVAC.
main relay to ECM. OFF: Command for A/C operation is not being output.
Fuel Tank Level (%): Blower Fan (ON/OFF):

This parameter indicates approximate fuel level in the This parameter indicates the state of the blower speed
fuel tank. The fuel level data is provided in percentage selector.
from 0 to 100%.
Brake Switch (ON/OFF):
A/C Pressure (A/C refrigerant absolute pressure, This parameter indicates the state of the brake switch.
kPa, mmHg, inHg, psi, inH2O):
This parameter indicates A/C refrigerant absolute Electric Load (ON/OFF):
pressure detected by A/C refrigerant pressure sensor. ON: ON signal of headlight, clearance lights or rear end
door window defogger is input.
Type of Fuel (Petrol / CNG) OFF: Above electric loads all turned off.
This parameter indicates the state of fuel.
Petrol: Engine is running on petrol. Clutch SW (Clutch switch, Declutch / Clutch):
CNG: Engine is running on CNG. Declutch: Clutch pedal depressed fully
Clutched: Clutch pedal released
Inj Pulse Width (CNG) (Injection Pulse Width (CNG),
msec.) Fuel Cut (ON/OFF):
This parameter indicates CNG fuel injector drive pulse ON: Fuel injection is cut (output signal to injector is
width (time) during which the injector valve stays open stopped).
as commanded by CNG control module. (For multipoint OFF: Fuel injection is not cut.
fuel injection, the injector drive time means that of the
No.1 cylinder.) Closed Throttle Pos (Closed throttle position, ON/
OFF):
Fuel Select Mode (Auto / Petrol / Gas) This parameter is ON when throttle valve is at idle
This parameter indicates the state of fuel select mode. position and OFF when the valve is not at idle position.
Auto: AUTO MODE is selected.
O2S B1 S1 ACT (HO2S-1, Active / Inactive): O2S B1 S2 ACT (HO2S-2, Active / Inactive):
This parameter indicates the activation condition of This parameter indicates the activation condition of
HO2S-1. HO2S-2.
ACTIVE: The sensor is activated. ACTIVE: The sensor is activated.
INACTIVE: The sensor is being warmed up or not INACTIVE: The sensor is being warmed up or not
activated. activated.
CNG Warning Light Does Not Come ON with Ignition Switch in ON Position and Engine Stopped
AENFL80B1124015
Wiring Diagram
9
IG1
10
A1
11 7
G240-1 RED/WHT
13 B1
12
E01-1 RED G240-4
E01-2 WHT BLK
12 15
C01-3 RED RED C12-25 E23-21 WHT
C01-15 WHT WHT C12-33
5V 12V
C12-9 BLK
RED/WHT E23-1
C12-17 BLK
RED/WHT E23-10 C12-26 BLK
14
E01-6 WHT 5
8 3
6
E01-49 PNK
5V 12V E01-55 BLU 4
E01-56 BLK
WHT
C01-50 BLK
C01-51 BLK
2
+
[A] 1
E23 C12
9 8 7 6 5 4 3 2 1 9 8 7 6
5 4 3 2 1
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18 A
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
[B] C01 E01
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
IFL80B112006-00
[A]: CNG control module connector (View: A) 2. Main fuse box 7. “MTR” fuse 12. CAN communication line
[B]: ECM connector (View: A) 3. “IGN” fuse 8. “IG COIL” fuse 13. ECM
A1: Combination meter power supply circuit 4. “FI” fuse 9. Combination meter 14. “CNG” fuse
B1: Combination meter ground circuit 5. Ignition switch 10. MIL 15. CNG control module
1. Battery 6. Main relay 11. CNG warning light
Circuit Description
Operation (ON/OFF) of CNG warning light is controlled by CNG control module. If the CNG system is in good
condition, CNG control module turns CNG warning light on with ignition switch “ON”, keeps it on for approx. 2 sec. and
then turns it off. If an abnormality in the system is detected, CNG warning light remains on or blinks.
Troubleshooting
Step Action Yes No
1 CNG warning light power supply check Go to Step 2. Go to Step 4.
1) Turn ignition switch to ON position.
Do other warning lights come ON?

2 DTC check in ECM and CNG control module for CAN- Go to troubleshooting Go to Step 3.
DTC for applicable DTC.
1) Turn ignition switch to OFF position and then connect
scan tool to DLC.
2) Turn ignition switch to ON position and check DTC in
ECM and CNG control module.
Is there any CAN-DTC(s) detected?

3 CAN communication circuit check Go to Step 5. Repair or replace
1) Check CAN communication circuit between control defective wire harness.
modules for open, short, high resistance and
connections referring to Step 1 of “Troubleshooting”
under “Troubleshooting for Communication Bus Off”:
10H-19).
Is circuit in good condition?

4 “RADIO DOME” fuse check Go to Step 5. Replace “RADIO
1) When ignition switch is turned to “OFF” position DOME” fuse and check
for short.
2) Check if “RADIO DOME” fuse in junction block is blown.
Is “RADIO DOME” fuse in good condition?

5 Combination meter power supply circuit check Go to Step 6. Repair or replace
1) Remove combination meter. (Page 9C-24) defective wire harness.
2) Check for proper connection to combination meter
connector at combination meter power supply circuit and
combination meter ground circuit.
3) If OK, turn ignition switch to ON position and measure
voltage between combination meter power supply circuit
(A1) and vehicle body ground.
Is it 10 – 14 V?
6 Combination meter ground circuit check Substitute a known- Repair or replace
1) When ignition switch is turned to “OFF” position good combination meter defective wire harness.
and recheck. If CNG
2) Measure resistance between combination meter ground
warning light still
circuit (B1) and vehicle body ground.
remains OFF, substitute
Is resistance 1 Ω or less? a known-good CNG
control module and
recheck.
DTC P0005 / P0007

AENFL80B1124022
P0005: Fuel Shutoff Valve “A” Control Circuit/Open • Shut off valve of CNG cylinder pressure
Measured voltage of shut off valve of CNG cylinder pressure regulator is regulator and/or its circuit
lower than specified voltage for 5 sec. only if its command signal is not • CNG valve control relay and/or its circuit
output and CNG valve control relay is ON.
P0007: Fuel Shutoff Valve “A” Control Circuit High
Measured voltage of shut off valve of CNG cylinder pressure regulator is
higher than specified voltage for 5 sec. only if its command signal is
output and CNG valve control relay is ON.
Wiring Diagram
+B
BLK/RED
1
5
12V 5V
RED/WHT
E23-1 RED/WHT
E23-10 RED/WHT
IG1 +BB2
E23-21 WHT
RED/WHT
12V B1 C1
4
E23-4 BLK/ORN BLK 6
B2 2 A2
E23-34 BLU/BLK
BLK C12-9
BLK C12-17 A1
B3 A3
BLK C12-26 3
E23-26 BLU/WHT
[A]
E23 C12
9 8 7 6 5 4 3 2 1 9 8 7 6
5 4 3 2 1
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10 A
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
IFL80B112007-00
[A]: CNG control module connector (View: A) C1: CNG valve control relay ground circuit (coil side)
A1: CNG valve control relay power supply circuit (switch side) 1. CNG control module
A2: Shut off valve of CNG cylinder valve power supply circuit 2. Shut off valve of CNG cylinder valve
A3: Shut off valve of CNG cylinder pressure regulator power supply circuit 3. Shut off valve of CNG cylinder pressure regulator
B1: CNG valve control relay drive circuit 4. CNG valve control relay
B2: Shut off valve of CNG cylinder valve control circuit 5. “CNG” fuse
B3: Shut off valve of CNG cylinder pressure regulator control circuit 6. “CNG VLV” fuse
NOTE
Check that the following conditions are satisfied in this “DTC Confirmation Procedure”.
• DTC P0607 is not detected.

2) Operate fuel select switch and select “Forced CNG MODE”.
3) Keep it for 10 sec.
4) Select “Petrol MODE”.
5) Start engine and run it for 1 min.
DTC Troubleshooting
Step Action Yes No
System Check”: Bi-Fuel
CNG in related manual.
2 DTC check Go to Step 3. Go to Step 7.
Is there DTC P2665 and/or P2667?

3 CNG valve control relay power supply circuit (switch Go to Step 5. Go to Step 4.
side) check
1) Turn ignition switch to OFF position and then remove
CNG valve control relay.
2) Check for proper terminal connections to CNG valve
control relay connector.
3) If connections are OK, turn ignition switch to ON position
and then check that voltage between CNG valve control
relay power supply circuit (switch side) (A1) and vehicle
body ground is battery voltage.
Is check result OK?

4 “CNG VLV” fuse check Repair or replace Check that CNG valve
1) Turn OFF ignition switch. defective wire harness. control relay power
supply circuit (switch
2) Check if “CNG VLV” fuse in relay box is blown.
side) is shorted to
Is “CNG VLV” fuse in good condition? ground. If OK, replace
“CNG VLV” fuse.
5 CNG valve control relay check Go to Step 6. Replace CNG valve
1) Check CNG valve control relay. (Page 10B-35) control relay.
Is check result OK?

6 Shut off valve power supply circuit check Go to Step 7. Shut off valve of CNG
1) Turn ignition switch to OFF position and then disconnect cylinder pressure
connectors from shut off valve of CNG cylinder pressure regulator power supply
regulator and shut off valve of CNG cylinder valve. circuit and/or shut off
valve of CNG cylinder
2) Check for proper terminal connection to shut off valve of
valve power supply
CNG cylinder pressure regulator and shut off valve of
circuit are shorted to
CNG cylinder valve connectors.
ground.
3) If connections are OK, measure resistance between shut
off valve of CNG cylinder pressure regulator power
supply circuit (A3) and vehicle body ground.
Is resistance infinity?
Step Action Yes No

7 Shut off valve of CNG cylinder pressure regulator power Go to Step 8. Repair or replace shut
supply circuit check off valve of CNG
1) Turn ignition switch to OFF position and then disconnect cylinder pressure
connector from shut off valve of CNG cylinder pressure regulator power supply
regulator. circuit.
2) Remove CNG valve control relay.
3) Check for proper terminal connection to CNG valve
control relay and shut off valve of CNG cylinder pressure
regulator connectors.
4) If connections are OK, measure wiring harness
resistance of shut off valve of CNG cylinder pressure
regulator power supply circuit (A3).
Is resistance 1 Ω or less?
8 Shut off valve of CNG cylinder pressure regulator Go to Step 9. Repair or replace shut
control circuit check off valve of CNG
1) Disconnect connectors from CNG control module. cylinder pressure
regulator control circuit.
2) Check for proper terminal connections to CNG control
module connectors.
• Resistance of “B3” circuit: less than 1 Ω.
• Resistance between “B3” circuit and ground: infinity.
terminal at shut off valve of CNG cylinder pressure
regulator connector: infinity
• Voltage of “B3” circuit: approx.0V (When ignition is
“ON”)
Are they in good condition?

9 Shut off valve of CNG cylinder pressure regulator check Substitute a known- Replace CNG cylinder
1) Check shut off valve of CNG cylinder pressure regulator. good CNG control pressure regulator. 
 module and recheck
DTC.
Is check result OK?
DTC P0201 / P0202 / P0203 / P0204

AENFL80B1124025
P0201: Injector Circuit/Open - Cylinder 1 • CNG fuel injector and/or its circuit
Measured voltage of CNG fuel injector No.1 is lower than • CNG control module
specified voltage for 5 sec. even if its command signal is not
output.
P0202: Injector Circuit/Open - Cylinder 2
Measured voltage of CNG fuel injector No.2 is lower than
output.
output.
output.
Wiring Diagram
+B
BLK/RED
2
1 C1 A1
5 4
C12-6 BLU/YEL
E1 F1
D1 8 B1 RED/WHT
C12-1 WHT/BLK
C01-11 BRN/YEL C12-8
12V
C2 A2
6
C12-14 BLU/WHT
E2
F2 D2 9 B2
C12-10 GRY
C01-12 BRN C12-16 3
12V
C3 A3
7
C12-5 BLU/RED
E3 10
F3 D3 B3
C12-18 WHT/BLU
C01-10 WHT/GRN C12-7
12V
C4 A4
11
C12-13 LT GRN/BLK
E4 12
F4 D4 B4
C12-27 BRN/YEL
C01-22 BLK/RED C12-15
12V
G1 12V 5V
C01-3 RED C12-25 E23-1 RED/WHT

C01-15 WHT C12-33
E23-10 RED/WHT
[A]
E23 C12
9 8 7 6 5 4 3 2 1 9 8 7 6
5 4 3 2 1
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10 A
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
[B] C01 E01
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
IFL80B112008-00
[A]: CNG control module connector (View: A) C4: Petrol fuel injector No.4 control circuit G1: CAN communication circuit
[B]: ECM connector (View: A) D1: CNG fuel injector No.1 control circuit 1. ECM
A1: Petrol fuel injector No.1 power supply circuit D2: CNG fuel injector No.2 control circuit 2. CNG control module
A2: Petrol fuel injector No.2 power supply circuit D3: CNG fuel injector No.3 control circuit 3. CPU
A3: Petrol fuel injector No.3 power supply circuit D4: CNG fuel injector No.4 control circuit 4. “CNG” fuse
A4: Petrol fuel injector No.4 power supply circuit E1: Fuel injector No.1 control signal from ECM circuit 5. Petrol fuel injector No.1
B1: CNG fuel injector No.1 power supply circuit E2: Fuel injector No.2 control signal from ECM circuit 6. Petrol fuel injector No.2
B2: CNG fuel injector No.2 power supply circuit E3: Fuel injector No.3 control signal from ECM circuit 7. Petrol fuel injector No.3
B3: CNG fuel injector No.3 power supply circuit E4: Fuel injector No.4 control signal from ECM circuit 8. CNG fuel injector No.1
B4: CNG fuel injector No.4 power supply circuit F1: Fuel control relay No.1 9. CNG fuel injector No.2
C1: Petrol fuel injector No.1 control circuit F2: Fuel control relay No.2 10. CNG fuel injector No.3
C2: Petrol fuel injector No.2 control circuit F3: Fuel control relay No.3 11. Petrol fuel injector No.4
C3: Petrol fuel injector No.3 control circuit F4: Fuel control relay No.4 12. CNG fuel injector No.4

1) Turn ignition switch to ON position and keep it for 10 sec.
DTC Troubleshooting
Step Action Yes No
System Check”: Bi-Fuel
2 CNG fuel injector power supply circuit check Go to Step 3. Repair or replace CNG
1) Turn ignition switch to OFF position and then disconnect fuel injector power
connectors from CNG fuel injectors. supply circuit.
2) Check for proper terminal connection to CNG fuel
injector connectors.
3) If connections are OK, turn ignition switch to ON
position.
4) Check that voltage between CNG fuel injector power
supply circuits (B1, B2, B3 and B4) and vehicle body
ground is battery voltage.
Is check result OK?

3 CNG fuel injector control circuit check Go to Step 4. Repair or replace CNG
1) Turn ignition switch to OFF position and then disconnect fuel injector control
connectors from CNG control module. circuit.
2) Check for proper terminal connections to CNG control
module connectors.
• Resistance of “D1”, “D2”, “D3” and “D4” circuits: less
than 1 Ω.
• Resistance between each of “D1”, “D2”, “D3” and “D4”
circuits and ground: infinity.
terminal at CNG fuel injector connector: infinity
• Voltage of “D1”, “D2”, “D3” and “D4” circuits: approx. 0
V (When ignition is “ON”)
Is check result OK?

Step Action Yes No

4 CNG fuel injector check Substitute a known- Replace CNG fuel
1) Check CNG fuel injector.  good CNG control injector. 
module and recheck
Is check result OK? DTC.
Inspection of ECM and Its Circuit

AENFL80B1124035
Voltage Check
NOTE
• 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
[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

Knock sensor signal
C01-1* WHT Refer to reference waveform.
circuit 1
“Knock sensor signal”: Bi-Fuel CNG (Page 1A-164)
MAP sensor power
C01-2 GRY/RED 4.5 to 5.5 V Ignition: “ON”
supply circuit
C01-3* RED
communication circuit “CAN communication signal”: Bi-Fuel CNG (Page 1A-164)
Generator LIN Refer to reference waveform.
C01-4* BLU
communication circuit “Generator LIN communication signal”: Bi-Fuel CNG (Page
1A-164)
TP sensor shield ground
circuit
MAP sensor ground
circuit
C01-7* RED HO2S-1 signal circuit
“HO2S-1 signal”: Bi-Fuel CNG (Page 1A-162)
Ignition: “ON”
4.0 to 4.4 V
TP sensor (sub) signal Accelerator Pedal: Released
C01-8 WHT
0.5 to 0.9 V
Accelerator Pedal: Fully depressed
C01-9 — — — —
C01-10* WHT/GRN • “Fuel injector signal”: Bi-Fuel CNG (Page 1A-160)
circuit
• “Fuel injector No.3 signal and ignition coil No.3 signal”: Bi-
Fuel CNG (Page 1A-161)

C01-11* BRN/YEL • “Fuel injector signal”: Bi-Fuel CNG (Page 1A-160)
circuit
C01-12* BRN • “Fuel injector signal”: Bi-Fuel CNG (Page 1A-160)
circuit
Knock sensor signal
C01-13* BLK Refer to reference waveform.
circuit 2
“Knock sensor signal”: Bi-Fuel CNG (Page 1A-164)
TP sensor power supply
C01-14 RED 4.5 to 5.5 V Ignition: “ON”
circuit
C01-15* WHT
C01-16 YEL HO2S-2 ground circuit Below 0.3 V Ignition: “ON”
C01-17 BLK TP sensor ground circuit Below 0.3 V Ignition: “ON”
C01-18 BLU HO2S-1 ground circuit Below 0.3 V Ignition: “ON”
C01-19* BRN HO2S-2 signal circuit
“HO2S-2 signal”: Bi-Fuel CNG (Page 1A-162)
Ignition: “ON”
3.4 to 3.5 V
ECT: 0 °C (32 °F)
C01-20 LT GRN ECT sensor signal circuit
1.1 to 1.2 V Ignition: “ON”ECT: 50 °C (122 °F)
C01-21 — — — —
Below 0.3 V Ignition: “ON”
C01-22* BRN • “Fuel injector signal”: Bi-Fuel CNG (Page 1A-160)
circuit
C01-23 — — — —
C01-24 — — — —
Ignition: “ON”
Approx. 2.5 V
IAT: 20 °C (68°F)
C01-25 BRN/YEL IAT sensor signal circuit
Ignition: “ON”
Approx. 0.6 V
IAT: 80 °C (176 °F)
Ignition: “ON”
0.6 to 1.0 V
TP sensor (main) signal Accelerator pedal: Released
C01-26 GRN
4.1 to 4.5 V
VSS signal circuit (non- Refer to reference waveform.
C01-27* PPL
ABS model) “VSS signal”: Bi-Fuel CNG (Page 1A-161)
C01-28* RED/YEL CMP sensor signal circuit
“CKP sensor signal and CMP sensor signal”: Bi-Fuel CNG
(Page 1A-163)
C01-29 — — — —
C01-30 — — — —
C01-31* PNK CKP sensor signal circuit
“CKP sensor signal and CMP sensor signal”: Bi-Fuel CNG
(Page 1A-163)

C01-32* GRN/YEL • “Ignition coil signal”: Bi-Fuel CNG (Page 1A-162)
circuit
C01-33* GRN/WHT • “Ignition coil signal”: Bi-Fuel CNG (Page 1A-162)
circuit
C01-34* BRN • “Ignition coil signal”: Bi-Fuel CNG (Page 1A-162)
circuit
C01-35* LT GRN • “Ignition coil signal”: Bi-Fuel CNG (Page 1A-162)
circuit
C01-36 GRY/BLU IAT sensor ground circuit Below 0.3 V Ignition: “ON”
C01-37 YEL/GRN Below 0.3 V Ignition: “ON”
circuit
C01-38 YEL/BLK Below 0.3 V Ignition: “ON”
circuit
1.5 to 1.8 V Barometric pressure: 100 kPa, 760
C01-39* RED/BLK MAP sensor signal circuit
mmHg
“MAP sensor signal”: Bi-Fuel CNG (Page 1A-162)
EVAP canister purge Refer to reference waveform.
C01-40* BLU/BLK
valve drive circuit “EVAP canister purge valve signal”: Bi-Fuel CNG (Page 1A-
163)
C01-41* YEL OCV drive circuit Refer to reference waveform.
“OCV signal”: Bi-Fuel CNG (Page 1A-164)
C01-42 — — — —
C01-43 — — — —
C01-44 — — — —
ECT sensor ground
circuit
C01-46 — — — —
C01-47 — — — —
C01-48 — — — —
HO2S-2 heater drive
C01-49* RED/BLU Refer to reference waveform.
circuit
“HO2S-2 heater signal”: Bi-Fuel CNG (Page 1A-162)
HO2S-1 heater drive Refer to reference waveform.
C01-52* GRN/WHT
circuit “HO2S-1 heater signal”: Bi-Fuel CNG (Page 1A-161)
C01-53* LT GRN
circuit (close) “Throttle actuator signal”: Bi-Fuel CNG (Page 1A-163)
C01-54* YEL/RED
circuit (open) “Throttle actuator signal”: Bi-Fuel CNG (Page 1A-163)

C01-55 — — — —
C01-56 — — — —

E01-1* RED
E01-2* WHT
E01-3 — — — —
E01-4 BLK 4.5 to 5.5 V Ignition: “ON”
circuit
Ignition: “ON”
0.2 to 0.5 V
APP sensor (sub) signal Accelerator pedal: Released
E01-5 YEL
1.8 to 2.2V
Approx. 0 V Ignition: “OFF” or “ACC”
E01-6 WHT Ignition ON signal circuit
Approx. 2.4 V Ignition: “ON”
Electric load current Ignition: “ON”
E01-7 GRN
sensor signal circuit Approx. 1.9 V Headlight: “ON”
E01-9 — — — —
E01-10 — — — —
E01-11 — — — —
E01-12 — — — —
E01-13 LT BLU sensor power supply 4.5 to 5.5 V Ignition: “ON”
circuit
E01-14 PNK 4.5 to 5.5 V Ignition: “ON”
APP sensor (main)
E01-15 BRN 4.5 to 5.5 V Ignition: “ON”
E01-16 — — — —
Engine: Running
0.9 to 1.3 V
A/C refrigerant pressure A/C compressor: Not operating
E01-17 GRN
sensor signal circuit Engine: Running
10 to 14 V
A/C compressor: Operating
Ignition: “ON”
0.6 to 0.9 V
APP sensor (main) Accelerator pedal: Released
E01-18 LT BLU
3.7 to 4.4 V
Ignition: “ON”
Approx. 0 V
Blower motor signal
Ignition: “ON”
E01-19 GRY circuit (Manual A/C 5 to 7 V
Blower speed switch: 1st position
model)
Ignition: “ON”
10 to 14 V
APP sensor (sub)
ground circuit
APP sensor (main)
ground circuit
E01-22 YEL Below 0.3 V Ignition: “ON”
E01-23 — — — —
E01-24 — — — —
E01-25 — — — —
E01-26 — — — —

Ignition: “ON”
10 to 14 V
CPP No.2 switch signal Clutch pedal: Released
E01-27 PPL
circuit (M/T model) Ignition: “ON”
Approx. 0 V
Ignition: “ON”
Approx. 0 V
Brake light switch signal Brake pedal: Released
E01-28 GRN
10 to 14 V
E01-29 — — — —
E01-30 — — — —
E01-31 — — — —
Ignition: “ON”
Battery temperature 25 °C (77 °F)
E01-32 PNK
sensor signal circuit Ignition: “ON”
90 °C (194 °F)
E01-33 — — — —
E01-34 — — — —
E01-35 — — — —
Engine: Idle speed
10 to 14 V ECT < 101°C (214 °F)
E01-36 GRN
Approx. 0 V ECT < 103°C (217 °F)
A/C switch: OFF
E01-37 — — — —
E01-38 — — — —
E01-39 — — — —
E01-40 — — — —
E01-41 — — — —
E01-42 — — — —
E01-43 — — — —
E01-44 — — — —
E01-45 — — — —
Engine: Idle speed
10 to 14 V ECT < 98 °C (208.4 °F)
E01-46 LT GRN
Approx. 0 V ECT < 100°C (212 °F)
A/C switch: OFF
E01-47 — — — —
A/C compressor: Not operating
10 to 15 V
A/C compressor relay A/C compressor: Operating
E01-48 GRY
drive circuit Ignition: “ON”
Approx. 0 V
Blower speed switch: “OFF”
10 to 14 V Ignition: 15 sec. after ignition “OFF”
E01-50 — — — —
E01-51 — — — —
Starting motor control Approx. 0 V Ignition: “ON”
E01-52 LT GRN
relay signal circuit 6 to 12 V Ignition: “START”
E01-53 — — — —
Fuel pump relay drive Refer to reference waveform.
E01-54* YEL
circuit “Fuel pump relay signal”: Bi-Fuel CNG (Page 1A-164)
Main power supply
circuit 2
Main power supply
circuit 1
Reference Waveform Ignition coil No.1 signal (2):

NOTE + C01-32
2
• Display includes the following types of – C01-50
data:
+ C01-28
3
– C01-50

+ C01-31
4
– C01-50
ICP70A110009-01
[A]: Waveform of channel 1 [C]: VOLT/DIV of each channel

• Waveform varies depending on

measurement condition and vehicle spec.
Fuel injector signal

C01-11 (No.1)
I8RW0A110013-01
C01-12 (No.2)
+ 5. Camshaft 360° angle 6. Crankshaft 720° angle
1 C01-10 (No.3)
C01-22 (No.4)
– C01-50 Fuel injector No.2 signal and ignition coil No.2 signal
Measurement condition Fuel injector No.2 signal (1):

Engine: Idle speed after warming up Channel Probe Terminal No.
+ C01-12
1
– C01-50

+ C01-33
2
– C01-50

+ C01-28
3
I7V20A111014-02 – C01-50
1. Fuel injector signal
Fuel injector No.1 signal and ignition coil No.1 signal Channel Probe Terminal No.
+ C01-31
4
Fuel injector No.1 signal (1): – C01-50
+ C01-11 Measurement condition
1 Engine: Idle speed after warming up
– C01-50

+ C01-35
2
– C01-50

+ C01-28
3
– C01-50

I8RW0A110014-01 + C01-31
4
5. Camshaft 360° angle 6. Crankshaft 720° angle – C01-50
Fuel injector No.3 signal and ignition coil No.3 signal Measurement condition
+ C01-10
1
– C01-50

+ C01-34
2
– C01-50

+ C01-28 I8RW0A110017-01
3
– C01-50 5. Camshaft 360° angle 6. Crankshaft 720° angle
CKP sensor signal (4): VSS signal

+ C01-31 + C01-27
4 1
– C01-50 – C01-50

Engine: Idle speed after warming up Vehicle: Running at 40 km/h (25 mile/h)
I8RW0A110016-01
IBP80A112067-01
+ C01-52
+ C01-22 1
1 – C01-50
– C01-50
Measurement condition HO2S-2 signal

+ C01-19
1
– C01-50
IBP60B110036-01
1. HO2S-1 heater signal
HO2S-1 signal
IBP60B110034-01
+ C01-7
1 1. Engine: Racing 3. HO2S-2 signal
– C01-50
2. Engine: Idle speed
Engine: Idle speed after warming up Ignition coil signal
C01-32 (No.1)
C01-33 (No.2)
1 +
C01-34 (No.3)
C01-35 (No.4)
– C01-50
IBP60B110037-02
1. HO2S-1 signal

+ C01-49
1
– C01-50
Measurement condition IBP60B110043-01
Engine: Idle speed after warming up 1. Ignition coil signal
MAP sensor signal
MAP sensor signal (1):

+ C01-39
1
– C01-50
TP sensor (main) signal circuit (2):

+ C01-26
2
IBP60B110033-03 – C01-50
1. HO2S-2 heater signal
IDAA0A111029-01
IBP80A111033-01 • Ignition: For 10 sec. after ignition “ON”
3. Engine: Idle speed 4. Engine: Racing • Accelerator pedal: Idle position
EVAP canister purge valve signal

+ C01-40
1
– C01-50
EVAP canister purge valve: 10% open
(using “Active Test” of SUZUKI scan tool)
IDAA0A111030-01
I7V20A111065-02
1. EVAP canister purge valve signal
Throttle actuator signal
Throttle actuator signal (Open) (1):

+ C01-54
1
– C01-50 I8C50B111049-01
Throttle actuator signal (Close) (2): CKP sensor signal and CMP sensor signal
+ C01-53 CMP sensor signal (1):
2 Channel Probe Terminal No.
– C01-50
+ C01-28
1
Measurement condition – C01-50
• Accelerator pedal: Idle position Channel Probe Terminal No.
+ C01-31
2
– C01-50
Measurement condition Fuel pump relay signal

+ E01-54
1
– C01-50
Ignition: “OFF” → “ON” → “START”
I8C50B111039-01
Knock sensor signal

C01-1
+
1 C01-13 IAW101110042-01
– C01-50 1. Fuel pump relay signal 3. Ignition: “ON”

2. Ignition: “OFF” 4. Ignition: “START”
Engine: Running at 4,000 rpm after warming up CAN communication signal
CAN communication signal (High) (1):

C01-3
+
1 E01-1
– C01-50
CAN communication signal (Low) (2):

C01-15
+
2 E01-2
– C01-50
IBP60B110038-01
1. Knock sensor signal

• Engine: Stop
OCV signal
Channel Probe Terminal No. • Ignition: “ON”
+ C01-41
1
– C01-50
• Engine: Racing after warming up
I8C50B111041-01
Generator LIN communication signal

+ C01-4
1
– C01-50
IDAA0A111031-01
ICV00P111021-02
1. Generator LIN communication signal
Inspection of CNG Control Module and Its Circuit

AENFL80B1124036
Voltage Check
NOTE
when ignition switch is turned to ON position.
• Terminal No. with asterisk (*) cannot be measured with voltmeter because it is pulse signal. Use
oscilloscope for its check if necessary.
• Before performing this check, be sure to read “Precaution for CNG Control Module Circuit
Inspection”: Bi-Fuel CNG in related manual.
[A]
E23 C12
9 8 7 6 5 4 3 2 1 9 8 7 6
5 4 3 2 1
A
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
I9R90A112008-01
[A]: CNG control module connector (View: A)

10 – 14 V Ignition switch: ON
0–1V
↑↓
10 – 14 V
Engine: Idle speed after
CNG fuel injector No.1 “CNG fuel injector signal”:
C12-1* WHT/BLK warming up
control circuit Bi-Fuel CNG (Page 1A-170)
Fuel select mode: Forced
/ “Petrol fuel injector signal
CNG MODE
and CNG fuel injector
signal”: Bi-Fuel CNG (Page
1A-171)
C12-2 — — — —
C12-3 — — — —
C12-4 — — — —

0–1V
↑↓
10 – 14 V
Petrol fuel injector “CNG fuel injector signal”:
C12-5* BLU/RED warming up
No.3 control circuit Bi-Fuel CNG (Page 1A-170)
Fuel select mode: Petrol
MODE
1A-171)
0–1V
↑↓
10 – 14 V
C12-6* BLU/YEL warming up
MODE
1A-171)
0–1V
Fuel injector No.3
↑↓
C12-7* WHT/GRN control signal from Engine: Idle speed after
10 – 14 V
ECM circuit warming up
“Petrol fuel injector signal”:
Bi-Fuel CNG (Page 1A-170)
0–1V
↑↓
Fuel injector No.1
10 – 14 V
C12-8* BRN/YEL control signal from Engine: Idle speed after
“Petrol fuel injector signal
1A-171)
CNG control module
C12-9 BLK Below 0.3 V Ignition switch: ON
ground circuit
0–1V
↑↓
10 – 14 V
C12-10* GRY warming up
CNG MODE
1A-171)
C12-11 — — — —
C12-12 — — — —
0–1V
↑↓
10 – 14 V
C12-13* LT GRN/BLK warming up
MODE
1A-171)

0–1V
↑↓
10 – 14 V
C12-14* BLU/WHT warming up
MODE
1A-171)
0–1V
↑↓
10 – 14 V
Fuel injector No.4 “Petrol fuel injector signal
C12-15* BLK/RED control signal from and CNG fuel injector Engine: Idle speed after
ECM circuit signal”: Bi-Fuel CNG (Page warming up
1A-171)“Petrol fuel injector
signal and CNG fuel injector
1A-171)
0–1V
↑↓
Fuel injector No.2
10 – 14 V
C12-16* BRN control signal from Engine: Idle speed after
“Petrol fuel injector signal
1A-171)
CNG control module
ground circuit
0–1V
↑↓
10 – 14 V
C12-18* WHT/BLU warming up
CNG MODE
1A-171)
C12-19 — — — —
C12-20 — — — —
C12-21 — — — —
C12-22 — — — —
C12-23 — — — —
C12-24 — — — —
2.5 – 3.5 V
CAN (high) “CAN communication
C12-25* RED Ignition switch: ON
communication circuit signal”: Bi-Fuel CNG (Page
1A-171)
CNG control module
ground circuit

0–1V
↑↓
10 – 14 V
C12-27* BRN/YEL warming up
CNG MODE
1A-171)
C12-28 — — — —
C12-29 — — — —
C12-30 — — — —
C12-31 — — — —
C12-32 — — — —
1.5 – 2.5 V
CAN (low) “CAN communication
C12-33* WHT Ignition switch: ON
communication circuit signal”: Bi-Fuel CNG (Page
1A-171)
C12-34 — — — —

Main power supply 10 – 14 V Ignition switch: ON
E23-1 RED/WHT
circuit 1 0–1V Ignition switch: OFF
E23-2 — — — —
E23-3 — — — —
CNG valve control 0–1V Ignition switch: OFF
E23-4 BLK/BLU
relay drive circuit 10 – 14 V Engine: Running
CNG pressure sensor 4.5 – 5.5 V Ignition switch: ON
E23-5 LT GRN/RED
power supply circuit 0–1V Ignition switch: OFF
CNG cylinder 4.5 – 5.5 V Ignition switch: ON
E23-6 RED/BLU pressure sensor
0–1V Ignition switch: OFF
E23-7 — — — —
E23-8 — — — —
E23-9 — — — —
Main power supply 10 – 14 V Ignition switch: ON
E23-10 RED/WHT
circuit 2 0–1V Ignition switch: OFF
E23-11 — — — —
E23-12 — — — —
Ignition switch: ON
3.21 – 3.93 V CNG temperature: 20 °C (68
°F)
Ignition switch: ON
CNG temperature
E23-13 GRY/RED 2.43 – 2.97 V CNG temperature: 40 °C
sensor signal circuit
(104 °F)
Ignition switch: ON
1.67 – 2.05 V CNG temperature: 60 °C
(140 °F)
Ignition switch: ON
0.78 – 0.96 V
CNG pressure: 100 kPa
CNG pressure sensor Ignition switch: ON
E23-14 GRY 1.43 – 1.75 V
signal circuit CNG pressure: 200 kPa
Ignition switch: ON
2.08 – 2.55 V
CNG pressure: 300 kPa

Ignition switch: ON
0.73 – 0.89 V CNG MODE
CNG cylinder pressure: 2
MPa
Ignition switch: ON
CNG cylinder Fuel select mode: Forced
E23-15 RED/BLK pressure sensor 1.15 – 1.41 V CNG MODE
signal circuit CNG cylinder pressure: 5
MPa
Ignition switch: ON
1.86 – 2.27 V CNG MODE
CNG cylinder pressure: 10
MPa
E23-16 — — — —
E23-17 — — — —
E23-18 — — — —
E23-19 — — — —
E23-20 — — — —
Ignition switch signal 10 – 14 V Ignition switch: ON
E23-21 WHT
circuit 0–1V Ignition switch: OFF
Ignition switch: ON
0–1V
Fuel select switch: Pushed
Fuel select switch
E23-22 LT GRN/BLK Ignition switch: ON
signal circuit
8 – 13 V Fuel select switch: Not
pushed
CNG cylinder
E23-23 RED/YEL pressure sensor Below 0.3 V Ignition switch: ON
ground circuit
CNG pressure-and-
E23-24 BLU/RED temperature sensor Below 0.3 V Ignition switch: ON
ground circuit
E23-25 — — — —
0–1V Ignition switch: ON
Engine: Running
Shut off valve of CNG
10 – 14 V Fuel select mode: Petrol
cylinder pressure
E23-26 BLU/WHT MODE
regulator control
Engine: Running
circuit
0–1V Fuel select mode: Forced
CNG MODE
E23-27 — — — —
E23-28 — — — —
E23-29 — — — —
Ignition switch: ON
Fuel filler lid switch 0–1V
E23-30 GRN/BLK Fuel filler lid: Open
No.2 signal circuit
Ignition switch: ON
8 – 13 V
Fuel filler lid: Closed
Ignition switch: ON
Fuel filler lid switch 8 – 13 V
E23-31 GRN/WHT Fuel filler lid: Open
No.1 signal circuit
Ignition switch: ON
0–1V
Fuel filler lid: Closed
E23-32 — — — —
E23-33 — — — —

0–1V Ignition switch: ON
Engine: Running
Shut off valve of CNG 10 – 14 V Fuel select mode: Petrol
E23-34 BLU/BLK cylinder valve control MODE
circuit Engine: Running
0–1V Fuel select mode: Forced
CNG MODE
Reference waveform
NOTE
• Waveform analysis is as follows.
I7V20A111014-02
CNG fuel injector signal

Fuel injector control signal from ECM (1):
C12-8 (No.1)
C12-16 (No.2)
+
1 C12-7 (No.3)
C12-15 (No.4)
IBP80A111034-01 – C12-9
[B]: Ground level of each channel [D]: TIME/DIV CNG fuel injector control signal (2):
• Waveform varies depending on C12-1 (No.1)
measurement condition and vehicle spec. C12-10 (No.2)
+
2 C12-18 (No.3)
C12-27 (No.4)
Petrol fuel injector signal
– C12-9
Petrol fuel injector control signal (1):
C12-6 (No.1)
C12-14 (No.2) • Engine: Idle speed after warming up
+
1 C12-5 (No.3) • Fuel select mode: Forced CNG MODE
C12-13 (No.4)
– C12-9
• Engine: Idle speed after warming up
• Fuel select mode: Petrol MODE
I9R90A112018-01
Petrol fuel injector signal and CNG fuel injector CAN communication signal
signal CAN communication signal (High) (1):
Fuel injector control signal from ECM (1): Channel Probe Terminal No.
Channel Probe Terminal No. + C12-25
1
C12-8 (No.1) – C12-9
C12-16 (No.2)
+
1 C12-7 (No.3) CAN communication signal (Low) (2):
C12-15 (No.4) Channel Probe Terminal No.
– C12-9 + C12-33
2
– C12-9
CNG fuel injector control signal (2):
Channel Probe Terminal No. Measurement condition
C12-1 (No.1) • Engine: Stop
C12-10 (No.2)
+ • Ignition switch: ON
2 C12-18 (No.3)
C12-27 (No.4)
– C12-9
Petrol fuel injector control signal (3):

C12-6 (No.1)
C12-14 (No.2)
+
1 C12-5 (No.3)
C12-13 (No.4)
– C12-9
I7RW01110028-01
I9R90A112021-01

• Fuel select mode: Petrol MODE
I9R90A112019-01
CNG Control Module Power and Ground Circuit Check

AENFL80B1124038
Wiring Diagram
1
C1
2 5V
LT GRN/RED E23-5 12V
GRY E23-14
5V IG1
GRY/RED E23-13
BLU/RED E23-24
D1
3 5V
RED/BLU E23-6
A1
RED/BLK E23-15
RED/YEL E23-23 E23-21 WHT
B1 5V 12V E1
5 C12-9 BLK
E2
E3
4 B2
E01-5 BLK/WHT 7
8 6
10
E01-54 BRN/WHT
5V 12V E01-55 BLK/RED 9
E01-56 BLK/RED
WHT
C01-50 BLK
C01-51 BLK
C01-53 BLK 11
+
+
[A] 12
E23 C12
9 8 7 6 5 4 3 2 1 9 8 7 6
5 4 3 2 1
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18 A
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
IFL80B112009-00
[A]: CNG control module connector (View: A) E2: CNG control module ground circuit 2 6. “IGN” fuse
A1: Ignition switch signal circuit E3: CNG control module ground circuit 3 7. Ignition switch
B1: Main power supply circuit 1 1. CNG control module 8. “IG COIL” fuse
B2: Main power supply circuit 2 2. CNG pressure-and-temperature sensor 9. “FI” fuse
C1: CNG pressure sensor power supply circuit 3. CNG cylinder pressure sensor 10. Main relay
D1: CNG cylinder pressure sensor power supply circuit 4. “CNG” fuse 11. Main fuse box
E1: CNG control module ground circuit 1 5. ECM 12. Battery
Circuit Description
When the ignition switch is turned to ON position, the main relay turns ON (the contact point closes) and the main
power is supplied to ECM and CNG control module. And then ECM supplies 5 V power to each sensor (CNG
pressure-and-temperature sensor and CNG cylinder pressure sensor).
Troubleshooting
NOTE
Before troubleshooting, perform the following items.
• Be sure to check related fuses of CNG control module power circuit for blow out.
If fuse is blown out, replace fuse(s) and check circuits connected to blown fuse(s) for short circuit to
ground.
• Confirm that battery voltage is 11 V or more.
Step Action Yes No

1 Ignition signal check Go to Step 2. Ignition switch signal
1) Turn ignition switch to OFF position and then disconnect circuit between battery
connectors from CNG control module. and CNG control
module is open and/or
short circuit.
3) Measure voltage between “E23-21” terminal of CNG
control module connector and body ground.
Is voltage 10 – 14 V?
2 CNG control module ground circuit check Go to Step 3. Repair or replace
1) Measure the following circuit resistances between CNG defective wire harness.
control module connectors and vehicle body ground.
• CNG control module ground circuit 1 (E1)
Are resistances 1 Ω or less?

3 Main relay and its circuit check Go to Step 4. Repair or replace
1) Check main relay and its circuit referring to “ECM Power defective wire harness
and Ground Circuit Check”: Bi-Fuel CNG in related and/or main relay.
manual.
Is check result OK?

4 CNG control module power supply circuit check Go to Step 5. Repair or replace
1) Turn ignition switch to OFF position and then remove defective wire harness.
main relay from relay box.
2) Measure the following circuit resistances between main
relay and CNG control module connector.
• Main power supply circuit 1 (B1)
• Main power supply circuit 2 (B2)

5 Sensor power source circuit check Check internal short Repair or replace
1) Disconnect connectors from CNG pressure-and- circuit of CNG pressure- defective wire harness.
temperature sensor and CNG cylinder pressure sensor. and-temperature sensor
and/or CNG cylinder
2) Measure the following circuit resistances between each
pressure sensor.
sensor and CNG control module connectors.
• CNG pressure-and-temperature sensor power supply
circuit (C1)
• CNG cylinder pressure sensor power supply circuit
(D1)

Repair Instructions
Idle Speed and IAC Throttle Valve Opening Special tool
Inspection (A): SUZUKI scan tool (Suzuki SDT-II)
AENFL80B1126001
Before idle speed check, make sure of the following.
• Lead wires and hoses of electronic fuel injection and
engine and emission control systems are connected
securely.
• Valve clearance is checked according to maintenance
schedule.
• Ignition timing is within specification.
• All electrical systems (wipers, heater, lights, A/C, etc.) 1
are off.
• Air cleaner is properly installed and is in good 2
condition.
• There are no air abnormally drawn in from air intake
(A)
system.
• There is no obstruction in PCV valve or its hoses.
• There is no DTCs in ECM.
• There is no DTC in CNG control module. IFL80B111018-04
• The following items are turned OFF as checked using 2) Warm up engine to normal operating temperature.
“Data List” mode on SUZUKI scan tool.
3) Check engine idle speed and “IAC throttle opening”
– A/C Comp Relay using “Data List” mode on SUZUKI scan tool.
– A/C Switch 4) If check result is not as specified, check engine idle
– Brake Switch speed referring to “Improper engine idling or engine
– Electric Load fails to idle” under “Engine Symptom Diagnosis”: Bi-
Fuel CNG in related manual.
– Blower Fan
After confirming all items, check idle speed and IAC Engine idle speed
throttle opening as follows. A/C OFF: 600 to 700 rpm (IAC throttle opening: 1
to 45%)
NOTE A/C ON: 700 to 900 rpm (IAC throttle opening: 1
Before starting engine, place gear shift lever to 55%)
in “Neutral”, apply parking brake and block
drive wheels.
1) With ignition “OFF”, connect SUZUKI scan tool (2) to

DLC (1).

Special Tool
AENFL80B1128002
SDT-II)
—
/
Engine General Information and Diagnosis: Diesel 1A-175
Diesel
General Description
OBD System Description 3 Driving Cycle Detection Logic
AENFL80B1131003 The malfunction detected in the first driving cycle is
ECM in this vehicle has the following functions.
stored in ECM memory but the MIL does not light up at
• When ignition is “ON” with the engine at a stop, MIL this time.
(1) turns on to check the MIL and its circuit. The MIL does not light up at the second detection of the
same malfunction either in the second driving cycle. The
MIL lights up at the third detection of the same
[A]
malfunction in the third driving cycle.
Freeze Frame Data

ECM stores the engine and driving conditions at the
moment of the detection of a malfunction in its memory.
This data is called “Freeze frame data”.
Therefore, it is possible to know engine and driving
conditions (e.g. whether the engine was warm or not,
whether the vehicle was running or stopped, whether air/
[B]
fuel mixture was lean or rich) when a malfunction was
detected by checking the freeze frame data.
1
Utilizing this function, it is possible to know the order of
detection of these malfunctions.
This is helpful when rechecking or diagnosing a trouble.
For details of freeze frame data that can be read from
IFL80B113002-00
ECM, refer to table below.
DTC
Calculated Load
• When ECM detects a malfunction which gives an ECT
adverse effect to vehicle emission while the engine is MAP
running, it makes the MIL in the meter cluster of the Engine Speed
instrument panel turn on and stores the malfunction Vehicle Speed
area in its memory. Intake Air Temperature
• As a condition for detecting a malfunction in some MAF
areas in the system being monitored by ECM and Fuel Rail Pressure
turning on MIL due to that malfunction, 1 driving cycle
or 3 driving cycle detection logic is adopted to prevent Freeze frame data (Example)
erroneous detection.
Warm-Up Cycle
A “warm-up cycle” is defined in the OBD regulations to
be sufficient vehicle operation such that coolant
temperature rises by at least 22 °C (40 °F) from engine
starting and reaches a minimum temperature of 70 °C
(158 °F).
Driving Cycle
A “driving cycle” consists of two parts, engine startup
and engine shutoff.
1 Driving Cycle Detection Logic

stored in ECM memory and MIL lights up at the same IDL10A110032-01
time.
Freeze frame data clearance
The freeze frame data is cleared at the same time as
clearance of DTC.
1A-176 Engine General Information and Diagnosis: Diesel

The system readiness test is to check if on-board diagnosis of each system related to exhaust emission has been
completed or not using a scan tool (SUZUKI scan tool or OBD generic scan tool).
When the conditions established for each system are met, ECM performs an on-board diagnosis of corresponding
system and changes the status of system readiness test from “Incomplete” to “Complete”. When “Complete” status is
displayed, it is maintained until the “DTC clearance” is performed using scan tool.
NOTE
• The status of system readiness test may be changed as “incomplete” when performing the
following services.
– Removal of ground cables for ECM
– Disconnection of “ECM” fuse
• By utilizing this system readiness test, it is possible to check that all DTC confirmation procedures
for each system have been completed or not (incomplete). For all DTCs related to each system, refer
to the table below.
• The system readiness test is NOT the result (“Normal” or “Abnormal”) of on-board diagnosis but
the result (“Complete” or “Incomplete”) of on-board diagnosis.
Monitor item of system readiness test table

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
AENFL80B1131004
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-II) (6) or OBD generic scan tool to communicate
with ECM.
2
3
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
6 5
4
1
IFL80B111010-02
2. B + (Continuous battery power)

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

Electronic Control System Circuit Diagram
AENFL80B1132002
IG1 101
53 RED E01-56
C01-47 WHT
1 BLU E01-62 26
C01-16 GRY/WHT
WHT YEL E01-34
C01-49 YEL
RED/BLK C01-23 27
C01-17 YEL/BLK
YEL C01-41
2 C01-48 GRN
BLK C01-24 28
WHT/GRN C01-37 C01-31 WHT/GRN
PNK C01-25 C01-46 BLU +B +BB
29
3 PNK/BLK C01-56 C01-1 WHT/BLU
MAIN
PPL C01-21 C01-4 YEL/BLK
GRY/BLK C01-43 30
4 C01-20 YEL
YEL/RED C01-59
GRN/YEL C01-8 C01-5 BLU/RED
5 YEL/BLK C01-38 C01-15 GRY/RED 31
YEL/RED C01-6
6 C01-30 YEL/GRN 32 YEL IG1
PPL/WHT C01-54
7 GRN C01-29 E01-70 PNK WHT
33 WHT
8 BRN E01-83 E01-74 LT BLU
LT BLU E01-65 BLU RED YEL GRN GRY
BLU E01-35 34 35 36 37 38
9 BLK E01-15
YEL E01-41 E01-7 LT GRN BLU
GRY 40
WHT E01-32 BLK BLU/RED
39 41
BLK E01-47 E01-8 GRN BLU
10 LT GRN E01-44 43
BLK RED YEL
YEL E01-46 42 44
MAIN WHT E01-45 E01-75 YEL BLU 46
PNK E01-12 BLK PNK BLU
BLU 47
45
+B E01-79 GRY BLU 48
11
IG1 GRY/YEL C01-9 LT BLU
12 WHT WHT
49
PPL E01-27 BLK BLK
BLK
96 50 51 52
16 25 YEL RED
13 ACC [A]
14 57
IG1
BLU E01-68 ACC
15 55 56
PNK YEL GRN E01-20 53 IG1
E01-23 WHT
IG2
17 54 IG2 94
PNK E01-37 ST
18 GRN E01-87
GRY E01-10 E01-92 GRN 59 61 [B]
58 56
MAIN [C]
IG1
ACC 69
BLU E01-84 LT GRN
19 PPL E01-89
GRY
53 60 IG2
E01-1 BRN
WHT E01-2 BRN 95 94
20 RED E01-90
GRY E01-3 BRN
21
YEL E01-61 E01-50 YEL
BLU E01-13 63 YEL 64
E01-80 PNK
70 62 65
GRY E01-21 E01-4 GRN BLU WHT
71 E01-5 GRN
PNK E01-93 66
E01-6 GRN
YEL E01-26
IG1 E01-51 BRN LT BLU 68
GRN E01-38 79
BLK 67
72 PPL E01-94 E01-59 PPL GRN
97 GRY E01-11 [D]
74 80
BLU E01-9 E01-64 RED
IG2 +BB [A] 22 23 23 23
E01-40 WHT WHT
[B] 82
73 GRY E01-17 81 BLU 83
98 75 22 84
GRN E01-24 85 WHT
[E] 86 PPL LT GRN IG1 +BB ACC
76 GRY C01-39 97
E01-19 LT BLU
77 M E01-85 PPL LT GRN 88
78 90 87 BLU
GRN 89
24 91 BRN
PPL E01-66 92
93 YEL BLK
: 99 : 100 : 12V : 5V
IFL10A110001-04
[A]: Ignition switch model 32. Boost pressure control solenoid valve 68. “FL” fuse
[B]: Keyless push start model 33. Glow plug control module 69. ACC relay
[C]: Non-ABS model 34. Glow plug No.1 70. Brake booster switch
[D]: ABS model 35. Glow plug No.2 71. Neutral position switch
[E]: Manual A/C model 36. Glow plug No.3 72. Brake stroke sensor
1. MAF sensor with IAT sensor-1 37. Glow plug No.4 73. Hood latch switch
2. Boost pressure sensor with IAT sensor-2 38. Radiator cooling fan relay 74. ENG A-STOP OFF switch
3. CMP sensor 39. Radiator cooling fan motor 75. “BLW” fuse
4. CKP sensor 40. “RDTR” fuse 76. Blower motor relay
5. Fuel pressure sensor 41. Radiator cooling sub fan relay 77. Blower motor
6. ECT sensor 42. Radiator cooling sub fan motor 78. Blower speed selector
7. APP sensor 43. “CDSR” fuse 79. ISG
8. APP sensor (main) 44. Fuel pump relay 80. ABS control module
9. APP sensor (sub) 45. Fuel pump 81. Gateway control module
10. A/F sensor 46. “F/P” fuse 82. To keyless start control module
11. Oil pressure switch 47. A/C compressor relay 83. Battery sensor
12. CPP No.2 switch 48. “CPRSR” fuse 84. “A-STOP” fuse
13. Brake light switch / Brake switch 49. A/C compressor 85. “WIP SUB” fuse
14. Brake switch 50. Starting motor 86. To windshield wiper switch
15. Brake light switch 51. Starting motor control relay 87. DC/DC converter
16. “STOP” fuse 52. “ST” fuse 88. “DCDC” fuse
17. Brake light 53. “IG COIL” fuse 89. “ACC” fuse
18. A/C refrigerant pressure sensor 54. “ST SIG” fuse 90. “ACC3” fuse
19. VSS 55. Ignition switch 91. To audio unit
20. Fuel filter water detection sensor 56. “IGN” fuse 92. “RADIO2” fuse
21. Fuel temperature sensor 57. “ST SIG2” fuse (Keyless push start model) 93. To combination meter
22. To BCM 58. CPP No.1 switch 94. “IGN2” fuse
23. CAN driver 59. Engine switch 95. IG2 relay
24. DLC 60. Keyless start control module 96. “CRUISE” fuse
25. Barometric pressure sensor 61. IG1 relay 97. “IG1 SIG” fuse
26. Fuel injector No.1 62. “INJ DRV” fuse 98. “IG2 SIG” fuse
27. Fuel injector No.2 63. Main relay 99. Engine ground
28. Fuel injector No.3 64. “ECM” fuse 100. Ground
29. Fuel injector No.4 65. “FI” fuse 101. ECM
30. Fuel flow actuator 66. “FI2” fuse
31. EGR valve 67. Battery
NOTE
For circuit names and terminal voltages, refer to “Inspection of ECM and Its Circuits”: Diesel (Page 1A-
318).
[A]
E01 C01
[a]
IBL80A112002-01

Component Location
Electronic Control System Component Location
AENFL80B1133001
[3]
[5]
[6]
[g] [f]
15
[4] 12 11 10 20 9
18 [1]
16
17
13
[p]
[2]
14
21 [l] [h] [i] [j]

1
[k]
[m]
19
[a]
[b]
[c] 8
[d]
2
7
[e]
[n]
6
[o]
5 [q]
3
IFL80B113001-04
Information sensors Control devices Others

1. MAF and IAT-1 sensor [a]: Fuel injector No.1 [1]: ECM
2. CMP sensor [b]: Fuel injector No.2 [2]: Glow plug control module
3. A/F sensor [c]: Fuel injector No.3 [3]: Combination meter
4. CKP sensor [d]: Fuel injector No.4 [4]: DLC
5. Oil pressure switch [e]: EGR valve [5]: Gateway control module
6. ECT sensor [f]: MIL [6]: DC/DC converter
7. Boost pressure and IAT-2 sensor [g]: Glow indicator light
8. Fuel pressure sensor [h]: Main relay
9. APP sensor [i]: A/C compressor relay
10. Brake light switch / Brake switch [j]: Starting motor control relay
11. CPP No.2 switch [k]: Fuel pump relay
12. CPP No.1 switch [l]: Radiator cooling sub fan relay
13. A/C refrigerant pressure sensor [m]: Radiator cooling fan relay
14. VSS (non-ABS model) [n]: Glow plug
15. Fuel temperature sensor [o]: Fuel flow actuator
16. Fuel filter water detection sensor [p]: Boost pressure control solenoid valve
17. Battery sensor [q]: ISG
18. Brake booster switch
19. Neutral position switch
20. Brake stroke sensor
21. Hood latch switch

MIL Check DTC Check
AENFL80B1134002 AENFL80B1134003
1) Set ignition “ON” and check that MIL (1) lights. 1) Set ignition “OFF”.
If MIL does not light up (or MIL dims) but engine can 2) Connect SUZUKI scan tool to DLC (1) located on
be started, go to “MIL Does Not Come ON with underside of instrument panel on driver’s seat side.
Ignition “ON” and Engine Stopped (but Engine Can
Be Started)”: Diesel in related manual for Special tool
troubleshooting. (A): SUZUKI scan tool (Suzuki SDT-II)
If MIL does not light with ignition “ON” and engine 3) Set ignition “ON”.
does not start though it is cranked up, go to
4) Read DTC according to instructions displayed on
“Inspection of ECM and Its Circuits”: Diesel (Page
scan tool and print it out or write it down. Refer to
1A-318).
Operator's Manual of SUZUKI scan tool for further
2) Start engine and check that MIL turns off. details.
If MIL remains on and no DTC is stored in ECM, go
to “MIL Remains ON after Engine Starts”: Diesel in
related manual for troubleshooting.
[A]
[B]
IFL80B111017-03

NOTE Special tool

If communication between SUZUKI scan tool (A): SUZUKI scan tool (Suzuki SDT-II)
and ECM is not possible, perform the 3) Set ignition “ON”.
following checks: 4) Clear DTC according to instructions displayed on
• Check communication condition between SUZUKI scan tool. Refer to Operator's Manual of
PC and VCI (2) using SUZUKI scan tool SUZUKI scan tool for further details.
function.
NOTE
• Check DLC power circuit and ground
circuit. If communication between SUZUKI scan tool
• Check DLC cable. If necessary, check DLC and ECM is not possible, perform the
cable by substituting a known-good DLC following checks:
cable. • Check communication condition between
• Check serial data line. (Page 1A-210) PC and VCI (2) using SUZUKI scan tool
function.
• Check ECM power circuit and ground
circuit. (Page 1A-299) • Check DLC power circuit and ground
circuit.
• Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC
cable.
• Check serial data line. (Page 1A-210)
• Check ECM power circuit and ground
circuit. (Page 1A-299)
(A)
IFL80B111018-04 2
5) After completing the check, set ignition “OFF” and
disconnect scan tool from DLC.
(A)
DTC Clearance
AENFL80B1134004
2) Connect SUZUKI scan tool to DLC (1). IFL80B111018-04
DTC Table
AENFL80B1134005
NOTE
With the generic scan tool, only DTCs with asterisks (*) in the following table can be read.
DTC
logic
*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-212) • Measured voltage of fuel flow actuator drive circuit is
lower than specified value.
DTC
logic
• Measured boost pressure is higher than barometric
*P0069 Manifold Absolute pressure by 23 kPa (0.23 kgf/cm2, 3.34 psi, 225
(Page Pressure-Barometric mbar) for 2 sec. 1 D/C Lights up
1A-214) Pressure Correlation • Measured boost pressure is lower than barometric
pressure by 23 kPa (0.23 kgf/cm2, 3.34 psi, 225
mbar) for 2 sec.
*P0087
Fuel Rail / System Measured fuel pressure in common rail is lower than
(Page 1 D/C Lights up
Pressure-Too Low specified value.
1A-215)
*P0088
Fuel Rail / System Measured fuel pressure in common rail is higher than
Pressure-Too High 175 MPa (1,784.5 kgf/cm2, 25,381 psi, 1,750 bar).
1A-217)
*P0089
Fuel Pressure Regulator Measured fuel pressure in common rail is lower than
1 Performance targeted fuel pressure by specified value.
1A-215)
*P0095 • Measured voltage of IAT-2 sensor signal circuit is
Intake Air Temperature
(Page higher than 4.6 V for 2 sec. 3 D/C Lights up
Sensor 2 Circuit
1A-218) • Measured voltage of IAT-2 sensor signal circuit is
*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-219) • Duty ratio of MAF sensor signal is lower than
specified value for 2 sec.
*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-221) Performance • Measured MAF is lower than estimated MAF by
specified value.
*P0107 Manifold Absolute Difference between boost pressure and barometric
(Page Pressure / Barometric pressure is lower than 20 kPa (0.2 kgf/cm2, 2.90 psi, 0.2 1 D/C Lights up
1A-214) Pressure Circuit Low bar).
P0110 • Duty ratio of IAT-1 sensor signal is higher than
Intake Air Temperature
(Page specified value for 3 sec. 1 D/C Off
Sensor 1 Circuit
1A-222) • Duty ratio of IAT-1 sensor signal is lower than
*P0115 Engine Coolant • Measured voltage of ECT sensor signal circuit is
(Page Temperature Sensor 1 higher than 4.85 V for 2 sec. 1 D/C Lights up
1A-223) Circuit • Measured voltage of ECT sensor signal circuit is
• Measured voltage of APP sensor (main) signal circuit
is lower than 0.30 V and output voltage of APP
*P0120 Throttle / Pedal Position sensor (sub) signal circuit is higher than 1.17 V.
(Page Sensor / Switch “A” • Measured voltage of APP sensor (main) signal circuit 1 D/C Lights up
1A-224) Circuit is higher than 4.80 V.
• Both measured voltages of APP sensor (main) and
APP sensor (sub) signal circuits are lower than 0.05
V.
DTC
logic
P0130
Measured voltages of A/F sensor signal circuits are out
(Page O2 Sensor Circuit 1 D/C Off
of specified range.
1A-226)
• Measured voltage of A/F sensor heater drive circuit is
P0135 higher than specified value for 3 sec. even when
(Page O2 Sensor Heater Circuit command signal of A/F sensor heater is ON. 1 D/C Off
1A-227) • Measured voltage of A/F sensor heater drive circuit is
lower than specified value for 3 sec. even when
command signal of A/F sensor heater is OFF.
P0168
Fuel Temperature Too
(Page Fuel temperature is higher than specified value. 1 D/C Off
High
1A-228)
*P0180 • Measured voltage of fuel temperature sensor signal
Fuel Temperature Sensor
(Page circuit is higher than 4.85 V for 3 sec. 1 D/C Lights up
“A” Circuit
1A-228) • Measured voltage of fuel temperature sensor signal
circuit is lower than 0.10 V for 3 sec.
• Measured voltage of fuel pressure sensor signal
circuit is higher than 4.85 V.
*P0190 • Measured voltage of fuel pressure sensor signal
Fuel Rail Pressure
(Page circuit is lower than 0.15 V. 1 D/C Lights up
1A-229) • Difference between current fuel pressure and
previous fuel pressure at specified vehicle condition
is more than 10 MPa (102.0 kgf/cm2, 1,450 psi, 100
bar).
*P0201
Injector Circuit / Open-
Cylinder 1
1A-231)
*P0202 Any of the following conditions is met.
Cylinder 2 • Measured voltage of relevant fuel injector drive circuit
1A-231)
(high side) does not match command signal.
*P0203
Injector Circuit / Open- • Measured voltage of relevant fuel injector drive circuit
Cylinder 3 (low side) does not match command signal.
1A-231)
*P0204
Cylinder 4
1A-231)
P0217
Engine Coolant Over Measured voltage of ECT sensor signal circuit is higher
(Page 1 D/C Off
Temperature Condition than specified value.
1A-233)
*P0219
Engine Overspeed
(Page Engine speed exceeds 6,000 rpm for 2 sec. 1 D/C Lights up
Condition
1A-235)
• Measured voltage of APP sensor (sub) signal circuit
is lower than 0.30 V and output voltage of APP
*P0220 Throttle / Pedal Position sensor (main) signal circuit is higher than 0.86 V.
(Page Sensor / Switch “B” • Measured voltage of APP sensor (sub) signal circuit 1 D/C Lights up
1A-236) Circuit is higher than 4.90 V.
• Both measured voltages of APP sensor (main) and
APP sensor (sub) signal circuits are lower than 0.05
V.
DTC
logic
• Measured voltage of fuel pump relay drive circuit is
*P0230 higher than specified value even when command
Fuel Pump Primary
(Page signal of fuel pump relay is ON. 1 D/C Lights up
Circuit
1A-237) • Measured voltage of fuel pump relay drive circuit is
lower than specified value even when command
signal of fuel pump relay is OFF.
*P0234 Turbocharger /
Boost pressure is higher than barometric pressure by
(Page Supercharger “A” 1 D/C Lights up
200 kPa (2.0 kgf/cm2, 29.0 psi, 2.0 bar) for 1 sec.
1A-214) Overboost Condition
*P0235 Turbocharger / • Measured voltage of boost pressure sensor signal
(Page Supercharger Boost circuit is higher than 4.9 V for 2 sec. 1 D/C Lights up
1A-239) Sensor “A” Circuit • Measured voltage of boost pressure sensor signal
• Measured voltage of boost pressure control solenoid
*P0243 Turbocharger / valve drive circuit does not match command signal of
(Page Supercharger Wastegate boost pressure control solenoid valve. 1 D/C Lights up
1A-240) Solenoid “A” • Difference between actual boost pressure and
estimated boost pressure is more than specified
value when turbocharger is operated.
*P0335
Crankshaft Position CKP sensor signal is not input even if CMP sensor
Sensor “A” Circuit signal is input.
1A-241)
• Measured voltage of CMP sensor signal circuit is
higher or lower than specified value.
*P0340 • Measured voltage of CMP sensor signal circuit is
Camshaft Position
(Page lower than specified value when cylinder No.1 is at 1 D/C Lights up
1A-243) compression TDC.
• Measured voltage of CMP sensor signal circuit is
higher than specified value when cylinder No.4 is at
compression TDC.
P0380
Glow Plug / Heater Circuit Measured voltage of glow plug control module drive
(Page 1 D/C Off
“A” circuit does not match command signal for 2 sec.
1A-245)
*P0401 Exhaust Gas Difference between measured intake air mass and
(Page Recirculation “A” Flow estimated intake air mass is higher than specified value 3 D/C Lights up
1A-246) Insufficient Detected for 10 sec.
*P0402 Exhaust Gas
Difference between measured intake air mass and
(Page Recirculation “A” Flow 3 D/C Lights up
estimated intake air mass is out of specified range.
1A-246) Excessive Detected
*P0403 Exhaust Gas
Measured voltage of EGR valve drive circuit does not
(Page Recirculation “A” Control 3 D/C Lights up
match command signal for 2 sec.
1A-248) Circuit
DTC
logic
• Measured voltage at drive circuit of radiator cooling
fan relay No.1 is higher than specified value even
P0480 though command signal of radiator cooling fan relay
(Page Fan 1 Control Circuit No.1 is ON. 1 D/C Off
1A-249) • Measured voltage at drive circuit of radiator cooling
fan relay No.1 is lower than specified value even
though command signal of radiator cooling fan relay
No.1 is OFF.
• Measured voltage at drive circuit of radiator cooling
fan relay No.2 is higher than specified value even
P0481 though command signal of radiator cooling fan relay
(Page Fan 2 Control Circuit No.2 is ON. 1 D/C Off
1A-251) • Measured voltage at drive circuit of radiator cooling
fan relay No.2 is lower than specified value even
though command signal of radiator cooling fan relay
No.2 is OFF.
Non-ABS model
• Vehicle speed is higher than 250 km/h (155 mile/h).
*P0500 • Vehicle speed is lower than 10 km/h (6 mile/h) for 2
Vehicle Speed Sensor
(Page sec. even though engine speed is in 2,000 to 3,000 3 D/C Lights up
“A”
1A-253) rpm at fuel cut condition.
ABS model
Invalid vehicle speed signal is received from ABS
control module via CAN.
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-256)
P0530 • Measured voltage of A/C refrigerant pressure sensor
A/C Refrigerant Pressure
(Page signal circuit is lower than 0.1 V for 2 sec. 1 D/C Off
1A-257) • Measured voltage of A/C refrigerant pressure sensor
Brake Booster Pressure
P0555 Refer to “DTC Table” in Section 11A (Page 11A-12). 1 D/C Off
Switch Circuit
P0560 • Measured voltage of backup power supply circuit is
(Page System Voltage higher than 16 V. 1 D/C Off
1A-259) • Measured voltage of backup power supply circuit is
lower than 6 V.
• Vehicle speed increases from under 10 km/h (6 mile/
P0571
h) to over 90 km/h (56 mile/h) even through brake
(Page Brake Switch “A” Circuit 1 D/C Off
pedal is depressed.
1A-261)
• Brake light switch signal does not correlate with
brake switch signal.
P0600
Serial Communication
(Page ECM internal failure is detected. 1 D/C Off
Link
1A-262)
*P0601 Internal Control Module
(Page Memory Check Sum ECM internal failure is detected. 1 D/C Lights up
1A-262) Error
DTC
logic
*P0604 Internal Control Module
(Page Random Access Memory ECM internal failure is detected. 1 D/C Lights up
1A-262) (RAM) Error
*P060B Internal Control Module
(Page A/D Processing ECM internal failure is detected. 1 D/C Lights up
1A-262) Performance
*P0641
Sensor Reference Sensor power supply voltage “A” is higher than 5.3 V or
Voltage “A” Circuit / Open lower than 4.7 V.
1A-264)
• Measured voltage of A/C compressor relay drive
circuit is higher than specified value for 2 sec. even
P0645 when command signal of A/C compressor relay is
A/C Clutch Relay Control
(Page ON. 1 D/C Off
Circuit
1A-265) • Measured voltage of A/C compressor relay drive
circuit is lower than specified value for 2 sec. even
when command signal of A/C compressor relay is
OFF.
*P0651
Sensor Reference Sensor power supply voltage “B” is higher than 5.3 V or
Voltage “B” Circuit / Open lower than 4.7 V.
1A-267)
P0657
Actuator Supply Voltage Measured voltage of main relay drive circuit is lower or
(Page 1 D/C Off
“A” Circuit / Open higher than specified value.
1A-269)
P0683 Glow Plug Control
Measured voltage of glow plug drive circuit does not
(Page Module to PCM 1 D/C Off
1A-245) Communication Circuit
• 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-269) • 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 higher than 5.3 V or
Voltage “C” Circuit / Open lower than 4.7 V.
1A-271)
P0704
Clutch Switch Input CPP No.2 switch signal does not change even though
(Page 1 D/C Off
Circuit gear is shifted 60 times.
1A-272)
DTC
logic
P081D Neutral Input Circuit 1 D/C Off
Clutch Pedal Switch “A” /
P083F 1 D/C Off
“B” Correlation
ENG A-STOP DC-DC
P1330 Converter “A” 1 D/C Off
Performance
ENG A-STOP DC-DC
P1353 Converter “A” Output 1 D/C Off
Circuit Short to Ground
ENG A-STOP DC-DC
P135E Converter “A” Input 1 D/C Off
Circuit
ENG A-STOP DC-DC
P135F 1 D/C Off
Converter “A” Feedback
ENG A-STOP Battery
P1360 Refer to “DTC Table” in Section 11A (Page 11A-12). 1 D/C Off
Performance
P1366 Battery Sensor 1 D/C Off
ENG A-STOP OFF
P13A0 1 D/C Off
Switch Circuit
P13B0 ISG Belt 1 D/C Off
P13B8 ISG Wake-up Command 1 D/C Off
P13B9 ISG Inhibition Command 1 D/C Off
P13BA ISG Performance 1 1 D/C Off
P13BB ISG Performance 2 1 D/C Off
Brake Stroke Sensor
P13D0 1 D/C Off
Plausibility
Brake Stroke Sensor
P13D3 1 D/C Off
Offset
Brake Stroke Sensor
P13D6 1 D/C Off
Performance
• Vehicle speed increases from under 10 km/h (6 mile/
P1571
h) to over 90 km/h (56 mile/h) even through brake
(Page Brake Switch Circuit 1 D/C Off
pedal is depressed.
1A-261)
• Brake switch signal does not correlate with brake
light signal.
P1610 1 D/C Off
EEPROM Reading /
P1622 Refer to “DTC Table:” in Section 10C. 1 D/C Off
Writing Error
Immobilizer • Ignition switch model: 
P1642 Communication Line • Keyless push start model: (Page 10C-6) 1 D/C Off
Error
Immobilizer ID
P1644 1 D/C Off
Mismatched
P1647
Vehicle Variant not
(Page Vehicle variant data is not registered in ECM. 1 D/C Off
Programmed
1A-274)
DTC
logic
• Measured voltage of APP sensor (main) signal circuit
is higher than output voltage of APP sensor (sub) by
*P2135 Throttle / Pedal Position 0.22 V though output voltage of APP sensor (main) is
(Page Sensor / Switch “A” / “B” lower than 1.27 V. 1 D/C Lights up
1A-275) Voltage Correlation • Measured voltage of APP sensor (main) signal circuit
is higher than output voltage of APP sensor (sub) by
0.32 V though output voltage of APP sensor (main) is
higher than 1.27 V.
P2146 Fuel Injector Group “A” • Measured voltage of fuel injector drive circuit (high
(Page Supply Voltage Circuit / side) is higher than 50 V. 1 D/C Off
1A-231) Open • Measured voltage of fuel injector drive circuit (high
side) is lower than 30 V.
*P2226 • Measured voltage of barometric pressure sensor
Barometric Pressure
(Page signal circuit is higher than 4.80 V for 2 sec. 1 D/C Lights up
1A-262) • Measured voltage of barometric pressure sensor
signal circuit is lower than 0.20 V for 2 sec.
P2237 O2 Sensor Positive
Any one of A/F sensor signal voltage is in abnormal
(Page Current Control Circuit / 1 D/C Off
condition.
1A-276) Open
P2244
O2 Sensor Reference
(Page A/F power supply voltage is out of specified range. 1 D/C Off
Voltage Performance
1A-226)
P2264 Measured voltage of fuel filter water detection sensor is
Water in Fuel Sensor
(Page higher than specified value even though the voltage is 1 D/C Off
Circuit
1A-278) controlled at low level by ECM during self test.
P2297
O2 Sensor Out of Range
(Page A/F value at fuel cut is not as specified. 1 D/C Off
During Deceleration
1A-276)
Engine Hood Switch
P254F Refer to “DTC Table” in Section 11A (Page 11A-12). 1 D/C Off
Circuit
P268A Fuel Injector Calibration
(Page Not Learned / Injector calibration code is not registered in ECM. 1 D/C Off
1A-279) Programmed
Control Module
U0073 1 D/C Off
*U0121 ABS / ESP® Control 1 D/C Lights up
Module
Lost Communication With Refer to “CAN DTC (Lost Communication and
U0131 Power Steering Control Communication Bus Off) Table”: Diesel Model in 1 D/C Off
Module Section 10H (Page 10H-36).
U0140 1 D/C Off
Body Control Module
U0141 Keyless Start Control 1 D/C Off
Module
U2006 Refer to “CAN DTC (Lost Communication and 1 D/C Off
With ISG
Communication Bus Off) Table”: Diesel Model in
U2007 Section 10H (Page 10H-36). 1 D/C Off
With Battery Sensor
DTC
logic
U2023 ISG LIN Communication 1 D/C Off
Battery Sensor LIN Refer to “DTC Table” in Section 11A (Page 11A-12).
U2024 1 D/C Off
Communication
U2101 CAN Vehicle
CAN vehicle configuration data is not registered in
(Page Configuration List not 1 D/C Off
ECM.
1A-280) Programmed
Fail-Safe Table
AENFL80B1134006
When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction persists but that mode
is canceled when ECM detects normal condition.
• ECM controls actuators assuming that rail pressure is specified
P0001 range.
Fuel Volume Regulator Control Circuit
(Page
/ Open • ECM limits driving performance slightly.
1A-212)
• ECM stops engine.
P0069 • ECM maintains EGR valve at closed position.
Manifold Absolute Pressure-
(Page
Barometric Pressure Correlation • ECM limits driving performance slightly.
1A-214)
P0087
(Page Fuel Rail / System Pressure-Too Low ECM stops engine.
1A-215)
P0088
(Page Fuel Rail / System Pressure-Too High ECM stops engine.
1A-217)
P0089 • ECM controls actuators assuming that rail pressure is specified
Fuel Pressure Regulator1
(Page range.
Performance
1A-215) • ECM limits driving performance slightly.
P0095
Intake Air Temperature Sensor 2
(Page ECM controls actuators assuming that IAT-2 is 40 °C (104 °F).
Circuit
1A-218)
• ECM controls actuators assuming that air flow value is
P0100 specified value.
(Page Mass or Volume Air Flow “A” Circuit
• ECM stops A/F feedback (closed loop) control.
1A-219)
• ECM stops EGR valve control.
• ECM controls actuators assuming that air flow value is
P0101 specified value.
Mass or Volume Air Flow “A” Circuit
(Page
Range / Performance • ECM stops A/F feedback (closed loop) control.
1A-221)
• ECM stops EGR valve control.
P0107 • ECM stops EGR valve control.
Manifold Absolute Pressure /
(Page
Barometric Pressure Circuit Low • ECM limits driving performance slightly.
1A-214)
P0110 • ECM controls actuators assuming that IAT-1 is 40 °C (104 °F).
Intake Air Temperature Sensor 1
(Page • ECM stops idle speed control related to A/C.
Circuit
1A-222) • ECM stops A/F feedback (closed loop) control.
• ECM controls actuators assuming that ECT is at fuel
P0115 temperature at cranking.
Engine Coolant Temperature Sensor • ECM stops A/C control.
(Page
1 Circuit
1A-223) • ECM operates radiator cooling fan at high speed.
• ECM stops idle speed control related to A/C.

• ECM maintains charge amount at specified level.
• ECM inhibits deceleration energy regenerating.
• ECM inhibits auto stop control.
• ECM inhibits engine restart when engine auto stop control is
activated.
• ECM inhibits ISG from performing engine power assist.
• ECM inhibits stalling assist control when engine auto stop
control is activated.
Error of APP main sensor:
• ECM controls actuators assuming that value of APP is value of
APP (sub).
• ECM limits driving performance slightly.
P0120
Throttle / Pedal Position Sensor / • If DTC P0220, P0571, P1571 or P2135 is concurrently present,
(Page
Switch “A” Circuit ECM executes the following fail-safe controls:
1A-224)
– When brake pedal is depressed, ECM fixes engine speed at
800 rpm.
– When brake pedal is released, ECM fixes engine speed at
1,000 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:
800 rpm.
1,000 rpm.
P0130
(Page O2 Sensor Circuit ECM stops A/F feedback (closed loop) control.
1A-226)
P0135
(Page O2 Sensor Heater Circuit ECM stops A/F feedback (closed loop) control.
1A-227)
P0168
(Page Fuel Temperature Too High —
1A-228)
• ECM controls actuators assuming that fuel temperature is 38
P0180 °C (100 °F).
(Page Fuel Temperature Sensor “A” Circuit • ECM controls fuel heater according to value of ECT sensor.
1A-228) • ECM controls actuators assuming that fuel temperature is ECT
at cranking.
P0190
(Page Fuel Rail Pressure Sensor “A” Circuit ECM stops engine.
1A-229)
P0201
(Page Injector Circuit / Open-Cylinder1
1A-231)
P0202
1A-231)
ECM stops control of applicable fuel injector.
P0203
1A-231)
P0204
1A-231)

P0217
Engine Coolant Over Temperature
(Page —
Condition
1A-233)
P0219
(Page Engine Overspeed Condition —
1A-235)
activated.
Error of APP sub sensor:
• ECM controls actuators assuming that value of APP is value of
APP (sub).
P0220
Throttle / Pedal Position Sensor / • If DTC P0120, P0571, P1571 or P2135 is concurrently present,
(Page
Switch “B” Circuit ECM executes the following fail-safe controls:
1A-236)
800 rpm.
1,000 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 controls:
800 rpm.
1,000 rpm.
P0230
(Page Fuel Pump Primary Circuit —
1A-237)
P0234 • ECM maintains EGR valve at closed position.
Turbocharger / Supercharger “A”
(Page
Overboost Condition • ECM limits driving performance slightly.
1A-214)
• ECM controls actuators assuming that boost pressure is
P0235 barometric pressure.
Turbocharger / Supercharger Boost
(Page
Sensor “A” Circuit • ECM maintains EGR valve at closed position.
1A-239)
P0243
Turbocharger / Supercharger
(Page ECM limits driving performance slightly.
Wastegate Solenoid “A”
1A-240)
P0335
(Page Crankshaft Position Sensor “A” Circuit —
1A-241)
P0340
(Page Camshaft Position Sensor “A” Circuit —
1A-243)
P0380
(Page Glow Plug / Heater Circuit “A” —
1A-245)

P0401
Exhaust Gas Recirculation “A” Flow
(Page ECM stops EGR valve control.
Insufficient Detected
1A-246)
P0402
Exhaust Gas Recirculation “A” Flow
Excessive Detected
1A-246)
P0403
Exhaust Gas Recirculation “A” Control
Circuit
1A-248)
P0480
(Page Fan1 Control Circuit ECM operates radiator cooling sub fan at low mode.
1A-249)
P0481
(Page Fan2 Control Circuit ECM operates radiator cooling sub fan at low mode.
1A-251)
P0500
ECM controls actuators assuming that vehicle speed is specified
(Page Vehicle Speed Sensor “A”
value.
1A-253)
P0520
Engine Oil Pressure Sensor / Switch
(Page —
Circuit
1A-256)
• ECM controls actuators assuming that A/C refrigerant pressure
P0530 is 1,600 kPa (16.3 kgf/cm2, 232 psi, 16 bar).
A/C Refrigerant Pressure Sensor “A”
(Page • ECM stops A/C control.
Circuit
1A-257) • If DTC P0645 is concurrently present, ECM operates radiator
cooling fan at high mode.
P0555 Brake Booster Pressure Switch Circuit • ECM restarts engine immediately when engine auto stop
• ECM controls actuators assuming that battery voltage is 13.5 V.
P0560 • ECM inhibits auto stop control.
(Page System Voltage • ECM restarts engine immediately when engine auto stop
1A-259) control is activated.
• If DTC P0120, P0220, P1571 or P2135 is concurrently present,
ECM executes the following fail-safe controls:
P0571 – When brake pedal is depressed, ECM fixes engine speed at
(Page Brake Switch “A” Circuit 800 rpm.
1A-261) – When brake pedal is released, ECM fixes engine speed at
1,000 rpm.
P0600
(Page Serial Communication Link —
1A-262)

P0601
Internal Control Module Memory
(Page ECM stops engine.
Check Sum Error
1A-262)
P0604
Internal Control Module Random
Access Memory (RAM) Error
1A-262)
P060B
Internal Control Module A/D
Processing Performance
1A-262)
P0641
Sensor Reference Voltage “A” Circuit /
Open
1A-264)
P0645
(Page A/C Clutch Relay Control Circuit ECM stops idle speed control related to A/C.
1A-265)
P0651 • ECM controls actuators assuming that sensor supply voltage is
Sensor Reference Voltage “B” Circuit /
(Page 5 V.
Open
P0657
Actuator Supply Voltage “A” Circuit /
(Page —
Open
1A-269)
P0683
Glow Plug Control Module to PCM
(Page —
Communication Circuit
1A-245)
P0685
ECM/PCM Power Relay Control
(Page —
Circuit / Open
1A-269)
P0697 • ECM controls actuators assuming that sensor supply voltage is
Sensor Reference Voltage “C” Circuit
(Page 5 V.
/ Open
• ECM controls actuators assuming that clutch pedal is
depressed.
P0704 • ECM inhibits auto stop control.
(Page Clutch Switch Input Circuit • ECM inhibits engine restart when engine auto stop control is
1A-272) activated.
P081D Neutral Input Circuit • ECM inhibits deceleration energy regenerating.
Clutch Pedal Switch “A” / “B” activated.
P083F
Correlation • ECM inhibits ISG from performing engine power assist.
ENG A-STOP DC-DC Converter “A” • ECM inhibits deceleration energy regenerating.
P1330
Performance • ECM inhibits auto stop control.
ENG A-STOP DC-DC Converter “A”
P1353 • ECM restarts engine immediately when engine auto stop
Output Circuit Short to Ground
ENG A-STOP DC-DC Converter “A”
P135E • ECM inhibits ISG from performing engine power assist.
Input Circuit
ENG A-STOP DC-DC Converter “A” • ECM inhibits stalling assist control when engine auto stop
P135F
Feedback control is activated.

P1360 ENG A-STOP Battery Performance • ECM maintains charge amount at specified level.
• ECM restarts engine immediately when engine auto stop
P1366 Battery Sensor control is activated.
ECM restarts engine immediately when engine auto stop control is
P13A0 ENG A-STOP OFF Switch Circuit
activated.
P13B0 ISG Belt • ECM maintains charge amount at specified level.
P13B8 ISG Wake-up Command • ECM inhibits deceleration energy regenerating.
P13B9 ISG Inhibition Command
P13BA ISG Performance 1
activated.
P13BB ISG Performance 2 • ECM inhibits ISG from performing engine power assist.
P13D0 Brake Stroke Sensor Plausibility
P13D3 Brake Stroke Sensor Offset ECM inhibits deceleration energy regenerating.
P13D6 Brake Stroke Sensor Performance
P1571 – When brake pedal is depressed, ECM fixes engine speed at
(Page Brake Switch Circuit 800 rpm.
1A-261) – When brake pedal is released, ECM fixes engine speed at
1,000 rpm.
Immobilizer ID and/or Password Not
P1610
Registered
P1611 Password Not Matched
P1622 EEPROM Reading / Writing Error
Immobilizer Communication Line
P1642
Error —
P1644 Immobilizer ID Mismatched
P1646 ID Code Incorrectness
P1647
(Page Vehicle Variant not Programmed
1A-274)

• ECM controls actuators assuming minimum value of APP
sensor (main) and APP sensor (sub) as APP.
800 rpm.
P2135 – When brake pedal is released, ECM fixes engine speed at
Throttle / Pedal Position Sensor / 1,000 rpm.
(Page
Switch “A” / “B” Voltage Correlation
1A-275) • ECM maintains charge amount at specified level.
activated.
P2146
Fuel Injector Group “A” Supply
(Page ECM stops injector electric diagnosis.
Voltage Circuit / Open
1A-231)
P2226 • ECM controls actuators assuming that boost pressure is
Barometric Pressure Sensor “A”
(Page barometric pressure.
Circuit
P2237
O2 Sensor Positive Current Control
(Page ECM stops A/F feedback (closed loop) control.
Circuit / Open
1A-276)
P2244
O2 Sensor Reference Voltage
Performance
1A-226)
P2264
(Page Water in Fuel Sensor Circuit —
1A-278)
P2297
O2 Sensor Out of Range During
Deceleration
1A-276)
P254F Engine Hood Switch Circuit activated.
P268A
Fuel Injector Calibration Not Learned /
(Page —
Programmed
1A-279)
Control Module Communication Bus • ECM inhibits engine restart when engine auto stop control is
U0073
Off activated.

Lost Communication With ABS / • ECM restarts engine immediately when engine auto stop
U0121
ESP® Control Module control is activated.
Lost Communication With Power
U0131 —
Steering Control Module
Lost Communication With Body • ECM restarts engine immediately when engine auto stop
U0140
Control Module control is activated.
Lost Communication With Keyless
U0141 —
Start Control Module
U2006 LIN Lost Communication With ISG • ECM inhibits engine restart when engine auto stop control is
activated.
LIN Lost Communication With Battery • ECM restarts engine immediately when engine auto stop
U2007
Sensor control is activated.
U2023 ISG LIN Communication Error • ECM inhibits engine restart when engine auto stop control is
activated.
Battery Sensor LIN Communication • ECM restarts engine immediately when engine auto stop
U2024
Error control is activated.

U2101
CAN Vehicle Configuration List not
(Page —
Programmed
1A-280)
Scan Tool Data

AENFL80B1134007
As the data values below are standard values estimated on the basis of values obtained from the normally operating
vehicles using a SUZUKI scan tool, use them as reference values. Even when the vehicle is in good condition, there
may be cases where the checked value does not fall within each specified data range. Therefore, judgment as
abnormal should not be made depending on these data alone. Also, conditions that can be checked by SUZUKI scan
tool are those detected by ECM and output from ECM as commands and there may be cases where the engine or
actuator is not operating (in the condition) as indicated by SUZUKI scan tool.
NOTE
• If communication between SUZUKI scan tool and ECM is not possible, perform the following
checks:
– Check communication condition between PC and VCI using SUZUKI scan tool function.
– Check DLC power circuit and ground circuit.
– Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
– Check serial data line. (Page 1A-210)
– Check ECM power circuit and ground circuit. (Page 1A-299)
• When checking data with engine running at idle or racing, place gear shift lever in neutral position
and apply parking brake fully.
Normal condition /
Scan tool data Vehicle condition Reference item
Reference value
Ignition Switch
Ignition: “ON” ON —
(Page 1A-205)
“Table C-1: Main Relay
Main Relay (Page
Ignition: “ON” ON Operation Check”: Diesel
1A-205)
(Page 1A-299)
“Table A-1: Fuel Pump Relay
Fuel Pump (Page
Engine: Running Active Operation Check”: Diesel
1A-205)
(Page 1A-281)
Oil Pressure Switch Ignition: “ON” ON
—
(Page 1A-205) Engine: Running OFF
Ignition: “ON”
Closed Throttle ON
Accelerator pedal: Not depressed
Position (Page 1A- —
Ignition: “ON”
205) OFF
Accelerator pedal: Depressed
Engine: Idle speed after warming up ON “Table B-5: EGR Valve
EGR Valve (Page
Operation Check”: Diesel
1A-205) Ignition: “ON” OFF
(Page 1A-294)
Ignition: Within a few seconds after setting
Glow Indicator Light ON
ignition “ON” —
(Page 1A-205)
Ignition: Within a few seconds after setting “Table C-8: Glow Plug
Glow Plug (Page ON
ignition “ON” Operation Check”: Diesel
1A-205)
Ignition: “ON” OFF (Page 1A-311)
Engine: Running without faulty condition OFF “MIL Check”: Diesel (Page
MIL (Page 1A-205)
Engine: Running with faulty condition ON 1A-181)
A/C Compressor ON
A/C compressor: ON
Relay (Page 1A- —
205) OFF
A/C compressor: OFF
Normal condition /
Reference value
ON
A/C Switch (Page A/C switch: ON
—
1A-205) Engine: Idle speed after warming up
OFF
A/C switch: OFF
Ignition: “ON”
OFF
Brake Light Switch Brake pedal: Released
—
ON
Ignition: “ON”
OFF
Brake Switch Brake pedal: Released
—
ON
Ignition: “ON”
OFF
Clutch SW (Page Clutch pedal: Released
—
ON
Battery Voltage
Ignition: “ON” 10 to 14 V —
(Page 1A-205)
Approx. 800 rpm “Table C-2: Engine Speed
Engine Speed A/C: Not operating
Check”: Diesel (Page 1A-
(Page 1A-205) Engine: Idle speed after warming up
Approx. 850 rpm 301)
A/C: Operating
Approx. 800 rpm
Desired Idle (Page A/C: Not operating
—
1A-205) Engine: Idle speed after warming up
Approx. 850 rpm
A/C: Operating
“Table C-7: Speed Signal
Vehicle Speed The same value as
Vehicle: Running Check”: Diesel (Page 1A-
(Page 1A-205) Speedometer.
309)
“Table C-3: ECT Sensor
ECT (Page 1A- 80 to 110 °C (176 to
Engine: Idle speed after warming up Check”: Diesel (Page 1A-
205) 230 °F)
302)
–5 °C (–9 °F) +
“Table C-4: IAT-1 Sensor
IAT1 (Page 1A- environmental temp.
Engine: Idle speed after warming up Check”: Diesel (Page 1A-
205) to 40 °C (72 °F) +
304)
environmental temp.
Ignition: “ON” 0.0 g/sec. “Table B-2: MAF Sensor
MAF (Page 1A-
205) Engine: Idle speed after warming up 3 to 9 g/sec.
290)
Barometric pressure “Table B-3: Boost Pressure
MAP (Page 1A- Ignition: “ON”
is displayed. Sensor Check”: Diesel (Page
205)
Engine: Idle speed after warming up 75 to 105 kPa 1A-292)
Boost Pressure Ignition: “ON” 50 to 80% “Table B-7: Boost Pressure
Control Solenoid Control Solenoid Valve
Valve Duty (Page Engine: Accelerated to 3,500 rpm 40 to 60% Operation Check”: Diesel
1A-205) (Page 1A-297)
Ignition: “ON”
0.5 to 0.9 V “Table C-6: Accelerator
APP Sensor 1 Volt Accelerator pedal: Not depressed
Pedal Check”: Diesel (Page
3.6 to 4.2 V 1A-307)
Accelerator pedal: Fully depressed position
Ignition: “ON”
0.2 to 0.6 V “Table C-6: Accelerator
APP Sensor 2 Volt Accelerator pedal: Not depressed
1.7 to 2.3 V 1A-307)
Ignition: “ON”
0% “Table C-6: Accelerator
Accel Position Accelerator pedal: Not depressed
100% 1A-307)
Normal condition /
Reference value
“Table B-5: EGR Valve
EGR Valve Opening
Engine: Idle speed after warming up 0 to 10% Operation Check”: Diesel
(Page 1A-205)
(Page 1A-294)
• “A/C System Performance
Inspection”: Single A/C
Engine: Idle speed Type in Section 7B (Page
A/C Pressure A/C switch: ON 7B-5)
1,200 to 1,540 kPa
(Page 1A-206) Blower speed selector: MAX • “A/C System Performance
Ambient temperature: 30 °C (86 °F) Inspection”: Dual A/C
Type in Section 7B in
related manual
“Table A-3: Fuel
Fuel Temperature Environmental temp.
Engine: Idle speed after warming up Temperature Sensor Check”:
(Page 1A-206) to 95 °C (194 °F)
Diesel (Page 1A-284)
Total Injected Fuel
Engine: Idle speed after warming up 3.0 to 10.0 mm3/str —
(Page 1A-206)
“Table B-4: Barometric
Barometric Pressure Barometric pressure
Ignition: “ON” Pressure Check”: Diesel
(Page 1A-206) is displayed.
(Page 1A-294)
“Table A-4: Fuel Pressure
Fuel Rail Pressure 20,000 to 40,000
Engine: Idle speed after warming up Sensor Circuit Check”:
(Page 1A-206) kPa
Desired Fuel Rail
20,000 to 40,000
Pressure (Page Engine: Idle speed after warming up —
kPa
1A-206)
“Table A-5: Fuel Flow
Fuel Flow Actuator
Engine: Idle speed after warming up 20 to 40% Actuator Operation Check”:
(Page 1A-206)
At rising ECT: ECT < 98 °C (208 °F)
OFF
At falling ECT: ECT < 95 °C (203 °F)
At rising ECT: 98 °C (208 °F) < ECT < 106
“Table C-9: Radiator Cooling
Radiator Fan °C (222 °F)
LOW Fan Operation Check”:
(Page 1A-206) At falling ECT: 95 °C (203 °F) < ECT < 103
°C (217 °F)
At rising ECT: ECT > 106 °C (222 °F)
HIGH
At falling ECT: ECT > 103 °C (217 °F)
Ignition: “ON”
Water in fuel filter: More than specified ON
Fuel Filter Warning
value
Light (Page 1A- —
Ignition: “ON”
206)
Water in fuel filter: Less than specified OFF
value
A/F Sensor Heater Ignition: “ON” OFF
Duty (Page 1A-
Engine: Idle speed after warming up 40 to 70% “Table B-6: A/F Sensor
206)
A/F Sensor Heater
700 to 900 °C (1,292 296)
Temperature Engine: Idle speed after warming up
to 1,652 °F)
(Page 1A-206)
Environmental temp. “Table C-5: IAT-2 Sensor
IAT2 (Page 1A-
Engine: Idle speed after warming up to 60 °C (108 °F) + Check”: Diesel (Page 1A-
206)
environmental temp. 305)
Battery Temperature Battery temperature
— —
(Page 1A-206) is displayed
Battery Voltage
Ignition: “ON” 10 to 14 V —
(Page 1A-206)
Normal condition /
Reference value
Ignition: “ON” –8 to 0 A
Ignition: “ON”
–28 to –10 A
Battery Current Headlight: ON
—
Headlight: ON –33 to –22 A
Blower speed selector: MAX position
Ignition: “ON”
Approx. 0%
Brake Stroke Brake pedal: Released
—
20 to 30%
Count for ISG
Engine auto start
Restart (Page 1A- Ignition: “ON” —
control counter
206)
Ignition: “ON”
Brake Stroke Sensor Approx. 1.0 V
Brake pedal: Released
Voltage (Page 1A- —
Ignition: “ON”
206) 1.5 to 2.5 V
Brake pedal: fully depressed
ISG Rotation Speed
Engine: Idle speed after warming up Approx. 2,200 rpm —
(Page 1A-206)
ISG Belt Slip
Ignition: “ON” 0 times —
(Page 1A-206)
Battery Voltage
Status from Battery
Ignition: “ON” No error —
Sensor (Page 1A-
206)
Battery Current
Status from Battery
Sensor (Page 1A-
206)
Battery Temperature
Status from Battery
Sensor (Page 1A-
206)
Battery Sensor
Calibration (Page Ignition: “ON” Complete —
1A-206)
ISG Equipped
Ignition: “ON” Equipped —
(Page 1A-207)
Ignition: “ON”
ON
Neutral SW (Page Gear position: Neutral
—
OFF
Gear position: Other than neutral
Ignition: “ON”
Opened
Hood Switch 1 Engine hood: Open
—
Closed
Engine hood: Closed
Ignition: “ON”
Opened
Hood Switch 2 Engine hood: Open
—
Closed
Engine hood: Closed
Starting Switch
Starting motor relay: ON ON —
(Page 1A-207)
Ignition: “ON”
ON
Half Clutch Switch Clutch pedal: Halfway depressed
—
OFF
Clutch pedal: Released
Normal condition /
Reference value
Ignition: “ON”
ON
Clutch Switch Clutch pedal: Fully depressed
—
OFF
Ignition: “ON”
ENG A-STOP OFF ON
ENG A-STOP OFF switch: Pushed
Switch (Page 1A- —
Ignition: “ON”
207) OFF
ENG A-STOP OFF switch: Released
Charge Warning
Light (Page 1A- Ignition: “ON” ON —
207)
Ignition: “ON”
ON
Brake Light Switch Brake pedal: Fully depressed
—
OFF
ENG A-STOP Ignition: “ON”
ON
Warning Light Auto stop control: Operating —
(Page 1A-207) Other than above condition OFF
SHVS Indicator Light Deceleration energy regeneration:
ON
(Regeneration) Operating —
SHVS Indicator Light Engine power assist: Operating ON
(Assist) (Page 1A- —
207)
ENG A-STOP ECM detects DTC related to ENG A-STOP
ON
Warning Light system.
—
(Flashing) (Page
1A-207)
Ignition: “ON” Neutral
Machine Mode
Engine: Idle speed after warming up Alternator
Request (Page 1A- —
Auto start control: Operating Restart
207)
Engine power assist: Operating Torque Assist 1
Ignition: “ON” Neutral —
Machine Mode
Engine: Idle speed after warming up Alternator
Status (Page 1A-
Auto start control: Operating Restart
207)
Engine power assist: Operating Torque Assist 1
Stop Mode (Page
Ignition: “ON” ON —
1A-207)
Cranking Mode
Engine: Cranking ON —
(Page 1A-207)
Auto Stop Mode Auto stop control: Operating ON
—
Normal Mode Engine: Idle speed after warming up ON
—
Auto Start Mode Auto start control: Operating ON
—
On Assist (Page Engine power assist: Operating ON
—
1A-207) Other than above condition OFF
On Generation Generation: Operating ON
—
Full Charge (Page
Ignition: “ON” Disable —
1A-207)
Generation Cut
(Page 1A-207)
Generation Minimum
Engine: Idle speed after warming up Enable —
(Page 1A-207)
Generation Normal
(Page 1A-207)
Normal condition /
Reference value
Regeneration Mode
(Page 1A-207)
Auto Stop System
Auto Stop Inhibit
Request (Page 1A- Ignition: “ON” —
Request
208)
Regeneration Enable
Ignition: “ON” Enable —
(Page 1A-208)
Assist Enable
Ignition: “ON” Enable —
(Page 1A-208)
ENG A-STOP
System Status Ignition: “ON” ENG OFF SAS OFF —
(Page 1A-208)
Auto Stop Request
Ignition: “ON” False —
(Page 1A-208)
Auto Start Request
(Page 1A-208)
Driver Door Status Driver door: Closed Close
—
(Page 1A-208) Other than above condition Open
Driver Seatbelt Driver seatbelt: Fastened Fasten
Switch (Page 1A- —
Other than above condition Unfasten
208)
ABS Active (Page ABS: Operating True
—
1A-208) Other than above condition False
Ignition: “ON”
Front Wiper Active Front wiper switch: “INT”, “LO” or “HI” Active
—
(Page 1A-208) position
Other than above condition Not active
Air Conditioning Engine Run
A/C switch: ON
Compressor Engine Requested
—
Run Request
A/C switch: OFF No Action
(Page 1A-208)
ISG Error Flag
(Page 1A-208)
ECM Error Flag
(Page 1A-208)
ABS Error Flag
(Page 1A-208)
Brake Stroke Sensor Brake stroke sensor calibration: Completed False
Not Calibrated —
Other than above condition True
(Page 1A-208)
All Status for A- All of ENG A-STOP execution condition are
True
STOP (Page 1A- satisfied. —
208) Other than above condition False
Diagnostic Status for DTC related to ENG A-STOP system is
False
A-STOP (Page 1A- detected. —
208) Other than above condition True
Battery Status Battery: Normal condition True
(Voltage, Discharge,
—
Charge) for A-STOP Other than above condition False
(Page 1A-208)
Battery Status Battery temperature: In specified value True
(Temperature) for A-
—
STOP (Page 1A- Other than above condition False
208)
Engine Coolant Engine coolant temperature: In specified
True
Temperature Status value
—
for A-STOP (Page
Other than above condition False
1A-208)
Normal condition /
Reference value
Brake Booster Status Brake booster switch: ON True
for A-STOP (Page —
1A-208)
Brake Light Switch Brake pedal: Depressed True
Status for A-STOP —
(Page 1A-208)
Neutral Switch Gear position: Neutral True
(Page 1A-208)
Driver Seating Status Driver door: Closed
True
for A-STOP (Page Driver seatbelt: Fastened —
1A-208) Other than above condition False
Hood Switch Status Engine hood: Closed True
1A-208)
Accelerator Pedal Accelerator pedal: Released True
(Page 1A-209)
Clutch Pedal Status Clutch pedal: Released True
1A-209)
Vehicle Speed After vehicle running under specified
True
History Status for A- condition
—
STOP (Page 1A-
209)
ABS Status for A- ABS: Operating False
STOP (Page 1A- —
Other than above condition True
209)
A/C Status for A- A/C: OFF True
A/C: ON False
209)
ENG A-STOP OFF ENG A-STOP system is not inhibited by
True
Switch Status for A- ENG A-STOP OFF switch.
—
STOP (Page 1A-
209)
ISG Belt Status for A- ISG belt: Normal condition True
209)
Signal of Deceleration energy regeneration: Enable True
Regeneration
—
Permission (Page Other than above condition False
1A-209)
ISG Regulated Ignition: “ON” 10 to 14 V
Voltage (Page 1A- —
Engine: Idle speed after warming up 12 to 15 V
209)
Pb Battery SOC
Ignition: “ON” 50 to 100% —
(Page 1A-209)
Generator Field Duty
Engine: Idle speed after warming up 0 to 100% —
(Page 1A-209)
Battery Voltage at
Last Cranking Peak Engine: Idle speed after warming up 3 to 15 V —
(Page 1A-209)
Scan Tool Data Definitions Battery Voltage (V)

Ignition Switch (ON/OFF) This parameter indicates battery positive voltage
This parameter indicates operating state of ignition inputted from main relay to ECM.
mode.
Engine Speed (rpm)
Main Relay (ON/OFF) This parameter indicates revolutions per minute of
This parameter indicates operating state of main relay. engine.
Fuel Pump (Active / Not Active) Desired Idle (Desired idle speed) (rpm)
ON is displayed when ECM activates fuel pump via fuel The desired idle speed is an ECM internal parameter
pump relay. which indicates idle speed requested by ECM. If the
engine is not running this number is not valid.
Oil Pressure Switch (ON/OFF)
This parameter indicates the state of the oil pressure Vehicle Speed (km/h, MPH)
switch. This parameter indicates vehicle speed.
Closed Throttle Position (ON/OFF) ECT (Engine coolant temperature, °C, °F)
This parameter indicates operating state of accelerator This parameter indicates engine coolant temperature
pedal. measured by ECT sensor.
ON: Accelerator pedal is not depressed.
OFF: Accelerator pedal is depressed. IAT1 (Intake Air Temperature-1, °C, °F)
This parameter indicates intake air temperature-1
EGR Valve (ON/OFF) measured by IAT sensor-1.
This parameter indicates operating state of EGR valve.
MAF (Mass air flow rate) (g/sec., Lb/min)
Glow Indicator Light (ON/OFF) This parameter indicates mass air flow rate measured by
This parameter indicates operating state of glow MAF sensor.
indicator light.
MAP (Manifold Absolute Pressure, kPa, mmHg,
Glow Plug (ON/OFF) in.Hg, psi, inH2O)
This parameter indicates operating signal of glow plug This parameter indicates boost pressure measured by
from ECM to glow control module. boost pressure sensor.
MIL (ON/OFF) Boost Pressure Control Solenoid Valve Duty (%)

This parameter indicates operating state of MIL. This parameter indicates the valve ON (valve open) time
ratio of signal for controlling boost pressure control
A/C Compressor Relay (ON/OFF) solenoid valve which controls the boost pressure.
This parameter indicates operating state of A/C
compressor relay. APP Sensor 1 Volt (APP sensor (main) output
voltage, V)
A/C Switch (ON/OFF) The Accelerator Pedal Position (APP) (Main) reading
ON: Command for A/C operation is being output from provides accelerator pedal opening information in
BCM (Ignition switch model) or HVAC control module voltage.
(keyless push start model) to ECM by CAN
communication signal. APP Sensor 2 Volt (APP sensor (sub) output voltage,
OFF: Command for A/C operation is not being output. V)
The Accelerator Pedal Position (APP) (Sub) reading
Brake Light Switch (ON/OFF) provides accelerator pedal opening information in
This parameter indicates operating state of brake light voltage.
switch.
Accel Position (Accelerator pedal position) (%)
Brake Switch (ON/OFF) When accelerator pedal is at fully released position,
This parameter indicates operating state of brake switch. accelerator pedal is indicated as 0 – 3% and 90 – 100%
fully depressed position.
Clutch SW (Clutch pedal position switch, ON/OFF)
This parameter indicates operating state of CPP No.2 EGR Valve Opening (%)
switch. This parameter indicates the valve ON (valve open) time
ratio EGR valve controls signal.
A/C Pressure (A/C refrigerant pressure) (kPa) Battery Voltage (V)

This parameter indicates A/C refrigerant absolute This parameter indicates battery voltage measured by
pressure detected by A/C refrigerant pressure sensor. battery sensor.
Fuel Temperature (°C, °F) Battery Current (A)

This parameter indicates fuel temperature measured by This parameter indicates battery current measured by
fuel temperature sensor. battery sensor.
Total Injected Fuel (mm3/str) Brake Stroke (%)

This parameter indicates total amount of fuel injected in This parameter indicates calculated brake pedal position
2 engine revolutions. in percent based on input from brake stroke sensor.
Barometric Pressure (kPa, mmHg, in.Hg, psi, inH2O) Count for ISG Restart (Times)
This parameter indicates barometric air pressure This parameter indicates ISG operation times as starting
measured by barometric pressure sensor in ECM. motor. 5 times of engine starting are counted as one.
Fuel Rail Pressure (Fuel pressure in common rail, Brake Stroke Sensor Voltage (V)
kPa, mmHg, in.Hg, psi, inH2O) This parameter indicates brake pedal position
This parameter indicates fuel pressure in common rail information in form of voltage from brake stroke sensor.
measured by fuel pressure sensor.
ISG Rotation Speed (rpm)
Desired Fuel Rail Pressure (Fuel pressure in This parameter indicates ISG speed measured by ISG.
common rail (target)) (kPa, mmHg, in.Hg, psi, inH2O)
The Desired Rail Press is an ECM internal parameter. ISG Belt Slip (Times)
This parameter indicates fuel pressure in common rail This parameter indicates ISG belt slipping times
targeted by ECM. measured by ISG.
Fuel Flow Actuator (%) Battery Voltage Status from Battery Sensor (No
This parameter indicates duty ratio of the signal that Error / Open Circuit Error / HW Defect / LIN
controls opening time of fuel flow actuator. Saturation)
This parameter indicates battery voltage state detected
Radiator Fan (OFF/LOW/HIGH) by battery sensor.
LOW: ON command is being output to radiator cooling No Error: Normal condition
fan relay (“RDTR” relay). Open Circuit Error: Battery sensor circuit is open.
HIGH: ON command is being output to radiator cooling HW Defect: Battery sensor circuit is short.
sub fan relay (“CDSR” relay). LIN Saturation: LIN communication error
OFF: No command is being output.
Battery Current Status from Battery Sensor (No
Fuel Filter Warning Light (ON/ OFF) Error / Open Circuit Error / HW Defect / LIN
The parameter indicates operating state of fuel filter Saturation)
warning light. This parameter indicates battery current state detected
by battery sensor.
A/F Sensor Heater Duty (OFF, %) No Error: Normal condition
This parameter indicates the ON time ratio of control Open Circuit Error: Battery sensor circuit is open.
signal for A/F sensor heater. HW Defect: Battery sensor circuit is short.
LIN Saturation: LIN communication error
A/F Sensor Heater Temperature (°C, °F)
This parameter indicates A/F sensor heater temperature Battery Temperature Status from Battery Sensor (No
measured by A/F sensor. Error / Reserved / HW defect / LIN Saturation)
This parameter indicates battery temperature state
IAT2 (Intake Air Temperature-2, °C, °F) detected by battery sensor.
This parameter indicates intake air temperature-2 No Error: Normal condition
measured by IAT sensor-2. Open Circuit Error: Battery sensor circuit is open.
HW Defect: Battery sensor circuit is short.
Battery Temperature (°C, °F) LIN Saturation: LIN communication error
This parameter indicates battery temperature measured
by battery sensor. Battery Sensor Calibration (Complete/Incomplete)
This parameter indicates whether battery sensor
calibration is completed or not.
ISG Equipped (Equipped / Unequipped) Alternator: Generator mode

This parameter indicates whether this vehicle is Restart: Starter mode when auto start control is active.
equipped with ISG. Stalling Help: Stalling assist mode
Torque Assist 1: Engine power assist mode
Neutral SW (Neutral Switch, ON/OFF) Torque Assist 2: Engine power assist mode
This parameter indicates operating state of neutral
position switch. Machine Mode Status (Neutral / Alternator / Restart /
First Start / Idle Preflux / Stalling Help / Torque
Hood Switch1 (Opened/Closed) Assist 1 / Torque Assist 2)
This parameter indicates operating state of hood latch This parameter indicates actual control state of ISG.
switch 1. Neutral: ISG is not operated.
Alternator: Generator mode
Hood Switch2 (Opened/Closed) Restart: Starter mode when auto start control is active.
This parameter indicates operating state of hood latch Stalling Help: Stalling assist mode
switch 2. Torque Assist 1: Engine power assist mode
Torque Assist 2: Engine power assist mode
Starting Switch (ON/OFF)
This parameter indicates operating state of starting Stop Mode (ON/OFF)
motor control relay. This parameter indicates that engine is stopped.
Half Clutch Switch (ON/OFF) Cranking Mode (ON/OFF)

This parameter indicates operating state of CPP No.2 This parameter indicates that engine is being cranked.
switch.
Auto Stop Mode (ON/OFF)
Clutch Switch (ON/OFF) This parameter indicates operating state of auto stop
This parameter indicates operating state of CPP No.1 control.
switch.
Normal Mode (ON/OFF)
ENG A-STOP OFF Switch (ON/OFF) This parameter indicates engine running normally.
This parameter indicates operating state of ENG A-
STOP OFF switch. Auto Start Mode (ON/OFF)
This parameter indicates operating state of auto start
Charge Warning Light (ON/OFF) control.
This parameter indicates operating state of charge
warning light. On Assist (ON/OFF)
This parameter indicates operating state of engine
Brake Light Switch (ON/OFF) power assist.
This parameter indicates operating state of stop light.
On Generation (ON/OFF)
ENG A-STOP Warning Light (ON/OFF) This parameter indicates generation state.
STOP warning light for ENG A-STOP system operation. Full Charge (Enable / Disable)
This parameter indicates enabled or disabled state of
SHVS Indicator Light (Regeneration) (ON/OFF) battery full charge.
This parameter indicates operating state of SHVS
indicator light for deceleration energy regeneration. Generation Cut (Enable / Disable)
SHVS Indicator Light (Assist) (ON/OFF) generation cut control.
This parameter indicates operating state of SHVS
indicator light for engine power assist. Generation Minimum (Enable / Disable)
ENG A-STOP Warning Light (Flashing) (ON/OFF) generation limit control.
STOP warning light for ENG A-STOP system warning. Generation Normal (Enable / Disable)
Machine Mode Request (Neutral / Alternator / Restart normal generation.
/ First Start / Stalling Help / Torque Assist 1 / Torque
Assist 2) Regeneration Mode (Enable / Disable)
This parameter indicates requested control of ISG. This parameter indicates enabled or disabled state of
Neutral: ISG is not operated. deceleration energy regeneration.
Auto Stop System Request (No Request / Auto Stop ECM Error Flag (True / False)
Inhibit Request / Auto Start Request / Auto Start This parameter indicates detection of ECM error.
Inhibit Request)
This parameter indicates requested state of ENG A- ABS Error Flag (True / False)
STOP system. This parameter indicates detection of ABS error.
Regeneration Enable (Enable / Disable) Brake Stroke Sensor Not Calibrated (True / False)
This parameter indicates enabled state of deceleration This parameter indicates whether brake stroke sensor
energy regeneration. calibration is completed or not.
Assist Enable (Enable / Disable) All Status for A-STOP (True / False)
This parameter indicates enabled state of engine power This parameter indicates whether requirements for ENG
assist A-STOP system activation are satisfied or not.
ENG A-STOP System Status (ENG OFF SAS OFF, Diagnostic Status for A-STOP (True / False)
ENG ON SAS OFF, ENG OFF SAS ON) This parameter indicates whether DTC detecting
This parameter indicates operating state of ENG A- conditions for ENG A-STOP system activation are
STOP system satisfied or not.
ENG OFF SAS OFF: Engine is stopped and ENG A-
STOP system is not active. Battery Status (Voltage, Discharge, Charge) for A-
ENG ON SAS OFF: Engine is operating and ENG A- STOP (True / False)
STOP system is not active. This parameter indicates whether battery requirements
ENG OFF SAS ON: Engine is stopped by ENG A-STOP for ENG A-STOP system activation are satisfied or not.
system command.
Battery Status (Temperature) for A-STOP (True /
Auto Stop Request (True / False) False)
This parameter indicates requested state of auto stop This parameter indicates whether battery temperature
control. requirements for ENG A-STOP system activation are
satisfied or not.
Auto Start Request (True / False)
This parameter indicates requested state of auto start Engine Coolant Temperature Status for A-STOP
control. (True / False)
This parameter indicates whether coolant temperature
Driver Door Status (Open / Close) requirements for ENG A-STOP system activation are
This parameter indicates operating state of driver door satisfied or not.
switch.
Brake Booster Status for A-STOP (True / False)
Driver Seatbelt Switch (Unfasten / Fasten) This parameter indicates whether requirements of brake
This parameter indicates operating state of driver booster negative pressure for ENG A-STOP system
seatbelt switch. activation are satisfied or not.
ABS Active (True / False) Brake Light Switch Status for A-STOP (True / False)
This parameter indicates operating state of ABS. This parameter indicates whether requirements of stop
lamp switch operating state for ENG A-STOP system
Front Wiper Active (Active / Not Active) activation are satisfied or not.
This parameter indicates operating state of windshield
wiper. Neutral Switch Status for A-STOP (True / False)
This parameter indicates whether requirements of
Air Conditioning Compressor Engine Run Request neutral position switch operating state for ENG A-STOP
(Engine Run Requested / No Action) system activation are satisfied or not.
This parameter indicates operating state of A/C
compressor relay. Driver Seating Status for A-STOP (True / False)
Engine Run Requested: A/C compressor relay is ON This parameter indicates enabled state of ENG A-STOP
and auto start control is active. system activation based on driver door open / close and
No Action: A/C compressor relay is OFF. driver seat belt fastening conditions.
ISG Error Flag (True / False) Hood Switch Status for A-STOP (True / False)
This parameter indicates detection of ISG error. This parameter indicates enabled state of ENG A-STOP
system activation based on hood open / close state.
Accelerator Pedal Status for A-STOP (True / False) ISG Belt Status for A-STOP (True / False)
This parameter indicates enabled state of ENG A-STOP This parameter indicates enabled state of ENG A-STOP
system activation based on accelerator pedal operating system activation based on ISG belt operating state.
state.
Signal of Regeneration Permission (True / False)
Clutch Pedal Status for A-STOP (True / False) This parameter indicates enabled state of deceleration
This parameter indicates enabled state of ENG A-STOP energy regeneration.
system activation based on clutch pedal operating state.
ISG Regulated Voltage (V)
Vehicle Speed History Status for A-STOP (True / This parameter indicates regulated voltage requested by
False) ISG.
This parameter indicates enabled state of ENG A-STOP
system activation based on vehicle operating state. Pb Battery SOC (%)
This parameter indicates battery SOC (State of Charge).
ABS Status for A-STOP (True / False)
This parameter indicates enabled state of ENG A-STOP Generator Field Duty (%)
system activation based on ABS operating state. This parameter indicates operating rate (status of
output) of the generator by field coil duty ratio.
A/C Status for A-STOP (True / False) 100%: Maximum operation
This parameter indicates enabled state of ENG A-STOP 0%: Minimum operation
system activation based on A/C operating state.
Battery Voltage at Last Cranking Peak (V)
ENG A-STOP OFF Switch Status for A-STOP (True / This parameter indicates minimum voltage at the latest
False) cranking.
This parameter indicates enabled state of ENG A-STOP
system activation based on ENG A-STOP OFF switch
operating state.
Visual Inspection
AENFL80B1134008
Visually check the following parts and systems.
Inspection item Referring section
• Engine oil-level, leakage “Engine Oil and Filter Change”: Diesel in Section 1E
(Page 1E-11)
• Engine coolant-level, leakage “Coolant Level Check”: Diesel in Section 1F in related
manual
• Fuel-level, leakage “Fuel Leakage Check Procedure”: Diesel in Section
1G in related manual
• Air cleaner filter-dirt, clogging “Air Cleaner Filter Inspection and Cleaning”: Diesel in
Section 1D in related manual
• Battery-corrosion of terminal “Battery Description”: Diesel (with ISG) in Section 1J
(Page 1J-21)
• ISG drive belt-tension, damage “ISG Drive Belt Inspection”: Diesel (with ISG) in
Section 1J (Page 1J-25)
• Water pump drive belt-tension, damage • “Accessory Drive Belt Tension Inspection”: Diesel
(without ISG) in Section 1J in related manual
• “Water Pump Drive Belt Inspection (ISG Model)”:
Diesel in Section 1F (Page 1F-10)
• 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”: Diesel (Page 1A-181)
• Charging light-Operation “Generator Symptom Diagnosis”: Diesel (with ISG) in
Section 1J (Page 1J-22)
Inspection item Referring section

• Oil pressure light-Operation “Oil Pressure Switch On-Vehicle Inspection”: Diesel in
Section 1E in related manual
• Engine coolant temperature meter-Operation —
• Fuel level meter-Operation “Fuel Level Sensor Inspection”: Diesel in Section 1G
(Page 1G-26)
• Tachometer-Operation —
• Abnormal air being inhaled from air intake system —
• Exhaust system-leakage of exhaust gas, noise —
• Other parts that can be checked visually —
Engine Basic Inspection

AENFL80B1134009
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found
in “Visual Inspection”: Diesel (Page 1A-209).
Follow the flow carefully.
Step Action Yes No
System Check”: Diesel
in related manual.
2 Battery voltage check Go to Step 3. Charge or replace
1) Check battery voltage. battery.
Is it 12 V or more?
3 Can engine be cranked? Go to Step 4. Go to “Cranking System
Symptom Diagnosis”:
Diesel in Section 1I
(Page 1I-6).
4 Does engine start? Go to “Engine Symptom Go to Step 5.
Diagnosis”: Diesel in
related manual.
5 Immobilizer system check Go to Step 6. Repair or replace
1) Check immobilizer control system. defective part(s).
• Ignition switch model: 
• Keyless push start model: (Page 10C-6)
Is check result OK?

6 Low fuel pressure circuit check Go to Step 7. Repair or replace
1) Check low fuel pressure circuit.  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.  (Engine Can Be defective part(s).
Cranked)” under
Is check result OK? “Engine Symptom
Diagnosis”: Diesel in
related manual.
Serial Data Link Circuit Check

AENFL80B1134013
Circuit Diagram
+B
4 5
1 3
B1
E01-66 PPL
A1
C1 C2
[A]
E01 C01
[a]
IDL10A110006-03
[A]: ECM connector (View: [a]) C2: Ground circuit 4. “B/U” fuse
A1: Serial communication circuit 1. ECM 5. “DOME” fuse
B1: DLC power supply circuit 2. DLC
C1: Engine ground circuit 3. To combination meter
Troubleshooting
Step Action Yes No
1 MIL check Go to Step 2. Go to applicable
1) Perform “MIL Check”: Diesel (Page 1A-181). troubleshooting.
Is check result OK?

2 Scan tool condition check Go to Step 3. Repair or replace
1) Check that SUZUKI scan tool is as follows. defective part.
• There are no deformation and wear for DLC cable,
USB cable and VCI terminals.
• Connection for DLC cable, USB cable and VCI
terminals are in good condition.
• Communication between VCI and PC is possible.
• Correct software is used.
Is check result OK?

Step Action Yes No

3 Scan tool operation check Go to Step 4. Go to “Troubleshooting
1) Check DLC terminal for deformation and wear. for Lost
Communication”: Diesel
2) If it is in good condition, connect SUZUKI scan tool to
Model in Section 10H
DLC with ignition “OFF”.
(Page 10H-38).
3) Check if communication is possible with other control
modules (BCM, ABS control module (ABS model),
HVAC control module (auto A/C model), combination
meter, SDM, keyless start control module (keyless push
start model) or P/S control module).
Can SUZUKI scan tool communicate with other control

modules?
4 Serial communication circuit check Go to Step 5. Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from defective wire harness.
ECM.
2) Check for proper terminal connection to “E01” connector.
terminal at DLC: infinity
“ON”)
Is check result OK?

5 ECM power and ground circuit check Go to Step 6. Repair or replace
1) Check ECM power supply and ground circuits according defective wire harness.
to Step 3 – 4 of “Table C-1: Main Relay Operation
Check”: Diesel (Page 1A-299).
Is check result OK?

6 DLC power and ground circuit check Go to Step 7. Repair or replace
1) Check DLC power supply and ground circuits as follows. defective wire harness.
• Voltage of “B1” circuit: 10 to 14 V
• Resistance between each of “C1” and “C2” circuits
and ground: less than 1 Ω
Is check result OK?

7 Scan tool operation check Scan tool is in good Replace VCI and
1) Check if communication is possible with other vehicles. condition, check recheck scan tool
intermittent trouble operation.
Is check result OK? referring to “Intermittent
Connection and Poor
Contact Inspection” in
Section 00 in related
manual.
DTC P0001
AENFL80B1134014
P0001: Fuel Volume Regulator Control Circuit / Open • Fuel flow actuator and/or its
• Measured voltage of fuel flow actuator drive circuit is higher than specified value. • ECM
• Measured voltage of fuel flow actuator drive circuit is lower than specified value.
Circuit Diagram
A1
YEL/BLK C01-4
2 A2
YEL C01-20
[A]
E01 C01
[a]
IDL10A110007-01
[A]: ECM connector (View: [a]) A2: Fuel flow actuator drive circuit 2. Fuel flow actuator
A1: Fuel flow actuator power supply circuit 1. ECM
NOTE
Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
DTC Troubleshooting
Step Action Yes No
in related manual.
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”: Diesel
(Page 1A-288).
Is check result OK?

3 Fuel flow actuator check Replace ECM and Replace fuel flow
1) Check fuel flow actuator. recheck DTC.  actuator.
Is check result OK?

DTC P0069 / P0107 / P0234

AENFL80B1134015
P0069: Manifold Absolute Pressure-Barometric Pressure • Boost pressure sensor and/or its circuit
Correlation • Air intake circuit
• Turbocharger
• Measured boost pressure is higher than barometric pressure by 23
• Vacuum system
kPa (0.23 kgf/cm2, 3.34 psi, 225 mbar) for 2 sec.
• Barometric pressure sensor (in ECM)
• Measured boost pressure is lower than barometric pressure by 23 kPa
(0.23 kgf/cm2, 3.34 psi, 225 mbar) for 2 sec. • ECM
P0107: Manifold Absolute Pressure / Barometric Pressure Circuit
Low
Difference between boost pressure and barometric pressure is lower
than 20 kPa (0.2 kgf/cm2, 2.90 psi, 0.2 bar).
P0234: Turbocharger / Supercharger “A” Overboost Condition
Boost pressure is higher than barometric pressure by 200 kPa (2.0 kgf/
cm2, 29.0 psi, 2.0 bar) for 1 sec.
Circuit Diagram
A1
RED/BLK C01-23
A2
2 YEL C01-41
A3
BLK C01-24
3 B1
WHT/GRN C01-37
[A]
E01 C01
[a]
IDL10A110008-01
[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

P0069 / P0234
NOTE

P0107
NOTE

2) Run engine at 2,000 rpm and keep the speed for 10 sec.
DTC Troubleshooting
Step Action Yes No
in related manual.
2 Boost pressure sensor power supply circuit, signal Go to Step 3. Repair or replace
circuit and ground circuit check defective wire harness.
1) Check “A1”, “A2” and “A3” circuits according to Step 5 –
8 of “Table B-3: Boost Pressure Sensor Check”: Diesel
(Page 1A-292).
Is check result OK?

3 Boost pressure sensor check Go to Step 4. Replace boost pressure
1) Check boost pressure sensor.  and IAT-2 sensor. 
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-289)
Is check result OK?

5 Vacuum system check Replace ECM and Repair or replace
1) Check the following parts: recheck DTC.  defective part(s).
• Check vacuum hoses and pipes.
• Check vacuum pump. 
Is check result OK?
DTC P0087 / P0089

AENFL80B1134016
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
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 YEL/BLK C01-38
A3
YEL/RED C01-6
[A]
E01 C01
[a]
IDL10A110009-01
[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
NOTE
DTC Troubleshooting
Step Action Yes No
in related manual.
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
6 of “Table A-4: Fuel Pressure Sensor Circuit Check”:
Diesel (Page 1A-286).
Is check result OK?

Is check result OK?

5 High fuel pressure circuit check Go to Step 6. Repair or replace
1) Check high fuel pressure circuit.  defective part(s).
Is check result OK?

Step Action Yes No

6 Fuel pressure sensor replacement Replace ECM and End.
1) Replace fuel pressure sensor.  recheck DTC. 
2) Clear DTC. (Page 1A-182)
(Page 1A-181)
DTC P0088
AENFL80B1134017
P0088: Fuel Rail / System Pressure-Too High • Fuel pressure sensor and/or its circuit
Measured fuel pressure in common rail is higher than 175 • Low fuel pressure circuit (fuel pressure regulator in fuel
MPa (1,784.5 kgf/cm2, 25,381 psi, 1,750 bar). pump, fuel pump and/or its circuit, fuel hose, fuel pipe)
• High fuel pressure circuit (high pressure pump,
common rail, high pressure pipe, fuel injector)
• ECM
Circuit Diagram
A1
GRN/YEL C01-8
A2
2 YEL/BLK C01-38
A3
YEL/RED C01-6
[A]
E01 C01
[a]
IDL10A110009-01
NOTE

DTC Troubleshooting
Step Action Yes No
in related manual.
circuit and ground circuit check defective wire harness
1) Check “A1”, “A2” and “A3” circuits according to Step 3 – and go to Step 3.
Is check result OK?

1) Check low fuel pressure circuit.  defective part(s) and go
to Step 5.
Is check result OK?
1) Check high fuel pressure circuit.  defective part and go to
Step 5.
Is check result OK?
4) Perform DTC confirmation procedure to check for DTC.
(Page 1A-181)
DTC P0095
AENFL80B1134018
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
• Measured voltage of IAT-2 sensor signal circuit is lower
Circuit Diagram
A1
RED/BLK C01-23
A2
2 YEL C01-41
A3
BLK C01-24
3 B1
WHT/GRN C01-37
[A]
E01 C01
[a]
IDL10A110008-01
[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 Troubleshooting
Step Action Yes No
in related manual.
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”: Diesel (Page 1A-305).
Is check result OK?

3 IAT-2 sensor check Replace ECM and Replace boost pressure
1) Check IAT-2 sensor.  recheck DTC.  and IAT-2 sensor. 
Is check result OK?
DTC P0100
AENFL80B1134019
P0100: Mass or Volume Air Flow “A” Circuit • MAF sensor and/or its circuit
• 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.
Circuit Diagram
IG1 1
A1
WHT
A2
2 RED E01-56
A3
YEL E01-34
3 B1
BLU E01-62
[A]
E01 C01
[a]
IDL10A110010-01
[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 Troubleshooting
Step Action Yes No
in related manual.
2 MAF sensor power supply circuit, signal circuit and Go to Step 3. Repair or replace
7 of “Table B-2: MAF Sensor Check”: Diesel (Page 1A-
290).
Is check result OK?

3 MAF sensor check Replace ECM and Replace MAF and IAT-1
1) Check MAF sensor.  recheck DTC.  sensor. 
Is check result OK?

DTC P0101
AENFL80B1134020
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
Circuit Diagram
IG1 1
A1
WHT
A2
2 RED E01-56
A3
YEL E01-34
3 B1
BLU E01-62
[A]
E01 C01
[a]
IDL10A110010-01
! WARNING
accident can occur.
NOTE
• Troubleshoot first unexpected DTCs previously detected in “DTC Confirmation Procedure”.
• Check that the following condition is met in this “DTC Confirmation Procedure”.
– Fuel cut < 50 times

2) Drive vehicle (with engine speed at 2,500 rpm or more) and gear at 4th for 10 sec.
3) Release accelerator pedal, and let vehicle coast to 1,500 rpm with engine brakes applied.
DTC Troubleshooting
Step Action Yes No
in related manual.
7 of “Table B-2: MAF Sensor Check”: Diesel (Page 1A-
290).
Is check result OK?

3 MAF sensor check Go to Step 4. Replace MAF and IAT-1
1) Check MAF sensor.  sensor. 
Is check result OK?

4 EGR valve operation check Go to Step 5. Repair or replace
1) Check EGR valve operation. (Page 1A-294) 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.  defective part(s).
Is check result OK?
DTC P0110
AENFL80B1134021
P0110: Intake Air Temperature Sensor 1 Circuit • IAT-1 sensor and/or its circuit
• Duty ratio of IAT-1 sensor signal is higher than specified value for 3 sec.
• Duty ratio of IAT-1 sensor signal is lower than specified value for 3 sec.
Circuit Diagram
IG1 1
A1
WHT
A2
2 RED E01-56
A3
YEL E01-34
3 B1
BLU E01-62
[A]
E01 C01
[a]
IDL10A110010-01

DTC Troubleshooting
Step Action Yes No
in related manual.
2 IAT-1 sensor signal circuit and MAF sensor ground Go to Step 3. Repair or replace
1) Check “B1” and “A3” circuits according to Step 2 of
“Table C-4: IAT-1 Sensor Check”: Diesel (Page 1A-304).
Is check result OK?

3 IAT-1 sensor check Replace ECM and Replace MAF and IAT-1
1) Check IAT-1 sensor.  recheck DTC.  sensor. 
Is check result OK?
DTC P0115
AENFL80B1134022
P0115: Engine Coolant Temperature Sensor 1 Circuit • ECT sensor and/or its circuit
• Measured voltage of ECT sensor signal circuit is higher than 4.85 V for 2 sec.
• Measured voltage of ECT sensor signal circuit is lower than 0.10 V for 2 sec.
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 Troubleshooting
Step Action Yes No
in related manual.
“Table C-3: ECT Sensor Check”: Diesel (Page 1A-302).
Is check result OK?

Is check result OK?
DTC P0120
AENFL80B1134023
P0120: Throttle / Pedal Position Sensor / Switch “A” Circuit • APP sensor and/or its circuit
• 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.
• Measured voltage of APP sensor (main) signal circuit is higher than 4.80 V.
• Both measured voltages of APP sensor (main) and APP sensor (sub) signal
circuits are lower than 0.05 V.
Circuit Diagram
1
A1
2 BRN E01-83
A2
LT BLU E01-65
A3
BLU E01-35
B1
3 BLK E01-15
B2
YEL E01-41
B3
WHT E01-32
[A]
E01 C01
[a]
IDL10A110011-01
[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 Troubleshooting
Step Action Yes No
in related manual.
2 APP sensor (main) power supply circuit, signal circuit Go to Step 3. Repair or replace
and ground circuit check defective wire harness.
6 of “Table C-6: Accelerator Pedal Check”: Diesel (Page
1A-307).
Is check result OK?

3 APP sensor (main) check Replace ECM and Replace APP sensor. 
1) Check APP sensor (main).  recheck DTC. 
Is check result OK?

DTC P0130 / P2244

AENFL80B1134024
P0130: O2 Sensor Circuit • A/F sensor and/or its circuit
Measured voltages of A/F sensor signal circuits are out of specified range. • ECM
P2244: O2 Sensor Reference Voltage Performance
A/F power supply voltage is out of specified range.
Circuit Diagram
2 1
A1
BLK E01-47
A2
LT GRN E01-44
A3
YEL E01-46
A4
MAIN
WHT E01-45
B1 B2
PINK E01-12
BLU
[A]
E01 C01
[a]
IDL10A110012-01
[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 Troubleshooting
Step Action Yes No
in related manual.
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”: Diesel (Page
1A-296).
Is check result OK?

Step Action Yes No

3 A/F sensor replacement Replace ECM and End.
1) Replace A/F sensor.  recheck DTC. 
(Page 1A-181)
DTC P0135
AENFL80B1134025
P0135: O2 Sensor Heater Circuit • A/F sensor heater and/or its
• Measured voltage of A/F sensor heater drive circuit is higher than specified value • ECM
for 3 sec. even when command signal of A/F sensor heater is ON.
• Measured voltage of A/F sensor heater drive circuit is lower than specified value
for 3 sec. even when command signal of A/F sensor heater is OFF.
(1 D/C detection logic but does not light up)
Circuit Diagram
2 1
A1
BLK E01-47
A2
LT GRN E01-44
A3
YEL E01-46
A4
MAIN
WHT E01-45
B1 B2
PINK E01-12
BLU
[A]
E01 C01
[a]
IDL10A110012-01
NOTE

DTC Troubleshooting
Step Action Yes No
in related manual.
2 A/F sensor heater power supply circuit and drive circuit Go to Step 3 Repair or replace
1) Check “B1” and “B2” circuits according to Step 1 – 2 of
“Table B-6: A/F Sensor Check”: Diesel (Page 1A-296).
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.  recheck DTC. 
Is check result OK?
DTC P0168 / P0180

AENFL80B1134026
P0168: Fuel Temperature Too High • Fuel temperature sensor and/or its circuit
Fuel temperature is higher than specified value. • ECM
P0180: Fuel Temperature Sensor “A” Circuit
• Measured voltage of fuel temperature sensor signal
circuit is higher than 4.85 V for 3 sec.
• Measured voltage of fuel temperature sensor signal
Circuit Diagram
2 A1
YEL E01-61
A2
BLU E01-13
[A]
E01 C01
[a]
IDL10A110013-01
[A]: ECM connector (View: [a]) A2: Fuel temperature sensor ground circuit 2. Fuel temperature sensor
A1: Fuel temperature sensor signal circuit 1. ECM

P0168
! WARNING
accident can occur.

2) Drive vehicle for 1 min.
P0180
DTC Troubleshooting
Step Action Yes No
in related manual.
2 Fuel temperature sensor signal circuit and ground Go to Step 3. Repair or replace
1) Check “A1” and “A2” circuits according to Step 2 of
“Table A-3: Fuel Temperature Sensor Check”: Diesel
(Page 1A-284).
Is check result OK?

3 Fuel temperature sensor check Replace ECM and Replace fuel filter
1) Check fuel temperature sensor.  recheck DTC.  assembly. 
Is check result OK?
DTC P0190
AENFL80B1134027
P0190: Fuel Rail Pressure Sensor “A” Circuit • Lack of fuel
Any of the following conditions is met. • Fuel pressure sensor and/or its circuit
• Measured voltage of fuel pressure sensor signal circuit is higher than • Low fuel pressure circuit (fuel pressure
4.85 V. regulator in fuel pump, fuel pump and/
• Measured voltage of fuel pressure sensor signal circuit is lower than or its circuit, fuel hose, fuel pipe)
0.15 V. • High fuel pressure circuit (high
• Difference between current fuel pressure and previous fuel pressure at pressure pump, common rail, high
specified vehicle condition is more than 10 MPa (102.0 kgf/cm2, 1,450 pressure pipe, fuel injector)
psi, 100 bar). • ECM
Circuit Diagram
A1
GRN/YEL C01-8
A2
2 YEL/BLK C01-38
A3
YEL/RED C01-6
[A]
E01 C01
[a]
IDL10A110009-01

DTC Troubleshooting
Step Action Yes No
in related manual.
1) Check fuel level by fuel gauge. DTC.
Does fuel gauge indicate “E” level (empty)?

Is check result OK?

Is check result OK?

1) Check high fuel pressure circuit.  defective part(s).
Is check result OK?

Step Action Yes No

(Page 1A-181)
DTC P0201 / P0202 / P0203 / P0204 / P2146

AENFL80B1134028
NOTE
For identification of each cylinder, refer to “Statement on Cleanliness and Care”: Diesel in related
manual.

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
• Measured voltage of relevant fuel injector drive circuit (high side) does not match
command signal.
• Measured voltage of relevant fuel injector drive circuit (low side) does not match
command signal.
P2146: Fuel Injector Group “A” Supply Voltage Circuit / Open
• Measured voltage of fuel injector drive circuit (high side) is higher than 50 V.
• Measured voltage of fuel injector drive circuit (high side) is lower than 30 V.
Circuit Diagram
A1
WHT C01-47
2 A2
GRY/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]
IDL10A110014-01
[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

P0201 / P0202 / P0203 / P0204
NOTE

2) Run engine at 3,000 rpm and keep the speed for 10 sec.
P2146
NOTE
DTC Troubleshooting
Step Action Yes No
in related manual.
2 Fuel injector drive circuit (high side) and (low side) Go to Step 3. Repair or replace
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”: Diesel (Page 1A-283).
Is check result OK?

3 Fuel injector check Replace ECM and Replace fuel injector. 
1) Check fuel injector.  recheck DTC. 
Is check result OK?
DTC P0217
AENFL80B1134029
P0217: Engine Coolant Over Temperature Condition • ECT sensor and/or its circuit
Measured voltage of ECT sensor signal circuit is higher than specified • Engine cooling system
value.
• Engine oil insufficient
• ECM
Circuit Diagram
1
A1
2
PPL/WHT C01-54
A2
GRN C01-29
[A]
E01 C01
[a]
IBL80A112017-01
! WARNING
accident can occur.

2) Drive vehicle for 1 min.
DTC Troubleshooting
Step Action Yes No
in related manual.
“Table C-3: ECT Sensor Check”: Diesel (Page 1A-302).
Is check result OK?

3 ECT sensor check Go to Step 4. Replace ECT sensor. 
1) Check ECT sensor. 
Is check result OK?

Step Action Yes No

4 Cooling system check Go to Step 5. Repair or replace
1) Check cooling system. defective part(s).
• Radiator cooling fan operation: (Page 1A-314)
• Coolant level: 
• Engine cooling system: 
Is check result OK?

5 Engine lubrication system check Go to Step 6. Repair or replace
1) Check that there is no engine oil leakage and check defective part(s).
engine oil level. (Page 1E-11)
Is check result OK?

6 Thermostat replacement Replace ECM and End.
1) Replace thermostat.  recheck DTC. 
2) Check DTC. (Page 1A-181)
DTC P0219
AENFL80B1134030
P0219: Engine Overspeed Condition • CKP sensor and/or its circuit
Engine speed exceeds 6,000 rpm for 2 sec. • ECM
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
! WARNING
accident can occur.

2) Drive vehicle for 5 min. (Engine speed at lower than 4,000 rpm.)
DTC Troubleshooting
Step Action Yes No
in related manual.
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?
“Table C-2: Engine Speed Check”: Diesel (Page 1A-
301).
Is check result OK?

4 CKP sensor check Go to Step 5. Replace CKP sensor. 
1) Check CKP sensor. 
Is check result OK?

5 CKP sensor teeth check Replace ECM and Replace flywheel.
1) Check CKP sensor teeth.  recheck DTC.  (Page 1D-41)
Is check result OK?
DTC P0220
AENFL80B1134031
P0220: Throttle / Pedal Position Sensor / Switch “B” Circuit • APP sensor and/or its
• Measured voltage of APP sensor (sub) signal circuit is lower than 0.3 V and output • ECM
voltage of APP sensor (main) signal circuit is higher than 0.86 V.
• Measured voltage of APP sensor (sub) signal circuit is higher than 4.9 V.
• Both measured voltages of APP sensor (main) and APP sensor (sub) signal circuits
are lower than 0.05 V.
Circuit Diagram
1
A1
2 BRN E01-83
A2
LT BLU E01-65
A3
BLU E01-35
B1
3 BLK E01-15
B2
YEL E01-41
B3
WHT E01-32
[A]
E01 C01
[a]
IDL10A110011-01
A3: APP sensor (main) ground circuit 1. ECM

DTC Troubleshooting
Step Action Yes No
in related manual.
2 APP sensor (sub) power supply circuit, signal circuit Go to Step 3. Repair or replace
1) Check “B1”, “B2” and “B3” circuits according to Step 3 –
1A-307).
Is check result OK?

3 APP sensor (sub) check Replace ECM and Replace APP sensor. 
1) Check APP sensor (sub).  recheck DTC. 
Is check result OK?
DTC P0230
AENFL80B1134032

P0230: Fuel Pump Primary Circuit • Fuel pump relay (coil side) and/or its
• 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.
Circuit Diagram
MAIN 1
A1 2 A3
BLU YEL E01-75

BLU PNK B1
4 B2
3
A2 BLK
[A]
E01 C01
[a]
IDL10A110015-04
[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
NOTE
DTC Troubleshooting
Step Action Yes No
in related manual.
2 Fuel pump relay (coil side) power supply circuit and Go to Step 3. Repair or replace
drive circuit check defective wire harness.
1) Check “A1” and “A3” circuits according to Step 2 – 3 of
“Table A-1: Fuel Pump Relay Operation Check”: Diesel
(Page 1A-281).
Is check result OK?

Step Action Yes No

3 Fuel pump relay check Replace ECM and Replace fuel pump
1) Check fuel pump relay for resistance.  recheck DTC.  relay. (Page 10B-8)
Is check result OK?
DTC P0235
AENFL80B1134033
P0235: Turbocharger / Supercharger Boost Sensor “A” Circuit • Boost pressure sensor and/or its circuit
• 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
Circuit Diagram
A1
RED/BLK C01-23
A2
2 YEL C01-41
A3
BLK C01-24
3 B1
WHT/GRN C01-37
[A]
E01 C01
[a]
IDL10A110008-01

DTC Troubleshooting
Step Action Yes No
in related manual.
Step Action Yes No

2 Boost pressure sensor power supply circuit, signal Go to Step 3. Repair or replace
8 of “Table B-3: Boost Pressure Sensor Check”: Diesel
(Page 1A-292).
Is check result OK?

3 Boost pressure sensor check Replace ECM and Replace boost pressure
1) Check boost pressure sensor.  recheck DTC.  and IAT-2 sensor. 
Is check result OK?
DTC P0243
AENFL80B1134034
P0243: Turbocharger / Supercharger Wastegate Solenoid “A” • Boost pressure control solenoid valve
• Measured voltage of boost pressure control solenoid valve drive • Boost pressure and IAT-2 sensor and/or
circuit does not match command signal of boost pressure control its circuit
solenoid valve. • Air intake system
• Difference between actual boost pressure and estimated boost • Turbocharger
pressure is more than specified value when turbocharger is
• Vacuum system
operated.
Circuit Diagram
+B
1
BLU/RED A1 A2
2 GRY/RED C01-15
B1 B2
YEL 3 YEL/GRN C01-30
[A]
E01 C01
[a]
IDL10A110016-02
[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
NOTE

2) Run engine at 2,500 rpm or more for 10 sec.
DTC Troubleshooting
Step Action Yes No
in related manual.
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-297)
Is check result OK?

3 Boost pressure sensor check Go to Step 4. Repair or replace
1) Check boost pressure sensor. (Page 1A-292) 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).
Is check result OK?

5 Vacuum system check Replace ECM and Repair or replace
1) Check the following parts: recheck DTC.  defective part(s).
• Vacuum hose and pipe
• Vacuum pump 
Is check result OK?
DTC P0335
AENFL80B1134035
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
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
NOTE
1) Crank engine for 5 sec.

2) Run engine at 2,000 rpm or more.
DTC Troubleshooting
Step Action Yes No
in related manual.
“Table C-2: Engine Speed Check”: Diesel (Page 1A-
301).
Is check result OK?

Is check result OK?

4 CKP sensor teeth check Replace ECM and Replace flywheel.
1) Check CKP sensor teeth.  recheck DTC.  (Page 1D-41)
Is check result OK?

DTC P0340
AENFL80B1134036
NOTE
manual.

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.
• Measured voltage of CMP sensor signal circuit is lower than specified value
when cylinder No.1 is at compression TDC.
• Measured voltage of CMP sensor signal circuit is higher than specified
value when cylinder No.4 is at compression TDC.
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

DTC Troubleshooting
Step Action Yes No
in related manual.
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.
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. 
Is check result OK?
4 CMP sensor power supply circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “C01” connector from recheck DTC.  defective wire harness.
ECM.
2) Check for proper terminal connection to “C01”
connector.
“ON”)
Is check result OK?

5 CMP sensor signal circuit check Go to Step 6. Repair or replace
“ON”)
Is check result OK?

6 CMP sensor check Go to Step 7. Replace CMP sensor.
1) Check CMP sensor.  
Is check result OK?

7 CMP sensor teeth check Replace ECM and Replace exhaust
1) Check CMP sensor teeth. (Page 1D-49) recheck DTC.  manifold side camshaft.
(Page 1D-47)
Is check result OK?
DTC P0380 / P0683

AENFL80B1134037
NOTE
manual.

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
• ECM
P0683: Glow Plug Control Module to PCM Communication
Circuit
Measured voltage of glow plug drive circuit does not match
command signal for 3 sec.
Circuit Diagram
+B IG1 1
A2 A1
B1
WHT PNK E01-70
B2
WHT 2
LT BLU E01-74
A3
GRY
C1 C2 C3 C4
BLU RED YEL GRN
3 4 5 6
[A]
E01 C01
[a]
IDL10A110017-02
[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

P0380
NOTE

P0683
NOTE
DTC Troubleshooting
Step Action Yes No
in related manual.
2 Glow plug control module power supply circuit, ground Go to Step 3. Repair or replace
circuit and drive circuit check defective wire harness.
1) Check “A1”, “A2”, “A3” and “B1” circuits according to
Step 2 – 5 of “Table C-8: Glow Plug Operation Check”:
Is check result OK?

3 Glow plug check Go to Step 4. Replace faulty glow
1) Check glow plugs.  plug. 
Is check result OK?

4 Glow plug circuit check Go to Step 5. Repair or replace
1) Check “C1”, “C2”, “C3” and “C4” circuits according to defective wire harness.
Step 7 of “Table C-8: Glow Plug Operation Check”:
Is check result OK?

5 Glow plug control module replacement Replace ECM and End.
1) Replace glow plug control module.  recheck DTC. 
(Page 1A-181)
DTC P0401 / P0402

AENFL80B1134038
P0401: Exhaust Gas Recirculation “A” Flow Insufficient Detected • MAF sensor and/or its circuit
Difference between measured intake air mass and estimated intake air • EGR valve and/or its circuit
mass is higher than specified value for 10 sec.
• Air intake circuit leakage or clog
P0402: Exhaust Gas Recirculation “A” Flow Excessive Detected • Turbocharger
Difference between measured intake air mass and estimated intake air • ECM
mass is out of specified range.
Circuit Diagram
IG1 1
A1
WHT
A2
2 RED E01-56
A3
YEL E01-34
3 B1
BLU E01-62
[A]
E01 C01
[a]
IDL10A110010-01
NOTE
– Barometric pressure > 90 kPa (675 mmHg, 26.6 in.Hg, 0.90 bar)
– IAT > 15 °C (59 °F)

2) Run engine at 1,400 to 3,000 rpm for 1 min.
DTC Troubleshooting
Step Action Yes No
in related manual.
1) Check “A1”, “A2” and “A3” circuit according to Step 5 – 7
of “Table B-2: MAF Sensor Check”: Diesel (Page 1A-
290).
Is check result OK?

3 MAF sensor check Go to Step 4. Replace MAF and IAT-1
1) Check MAF sensor.  sensor. 
Is check result OK?

Step Action Yes No

4 EGR valve operation check Go to Step 5. Repair or replace
1) Check EGR valve operation. (Page 1A-294) 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.  defective part(s).
Is check result OK?
DTC P0403
AENFL80B1134039
P0403: Exhaust Gas Recirculation “A” Control Circuit • EGR valve and/or its circuit
Measured voltage of EGR valve drive circuit does not match command signal for 2 • ECM
sec.
Circuit Diagram
+B
1
BLU/RED A1 A2
2 GRY/RED C01-15
B1 B2
[A]
E01 C01
[a]
IDL10A110016-02
[A]: ECM connector (View: [a]) B1: Boost pressure control solenoid valve power supply circuit 2. EGR valve
NOTE

DTC Troubleshooting
Step Action Yes No
in related manual.
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 defective wire harness.
of “Table B-5: EGR Valve Operation Check”: Diesel
(Page 1A-294).
Is check result OK?

3 EGR valve check Replace ECM and Replace EGR valve. 
1) Check EGR valve.  recheck DTC. 
Is check result OK?
DTC P0480
AENFL80B1134040
P0480: Fan1 Control Circuit • Radiator cooling fan relay No.1 (coil side)
• Measured voltage at drive circuit of radiator cooling fan relay No.1 • ECM
is higher than specified value 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 even though command signal of
radiator cooling fan relay No.1 is OFF.
Circuit Diagram
1
+B MAIN
A1 A3
3
BLU LT GRN E01-7
BLU/RED
4
2
A2 C1
BLK C2
B1 B3
6
BLU GRN E01-8
RED
7
5
B2 D1
BLK D2
[A]
E01 C01
[a]
IDL10A110018-01
A2: Radiator cooling fan relay No.1 power supply circuit (switch side) 1. ECM
NOTE

DTC Troubleshooting
Step Action Yes No
in related manual.
Step Action Yes No

(coil side) and radiator cooling fan relay No.1 drive defective wire harness.
circuit check
“Table C-9: Radiator Cooling Fan Operation Check”:
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.  recheck DTC.  fan relay No.1. (Page
10B-8)
Is check result OK?
DTC P0481
AENFL80B1134041
P0481: Fan2 Control Circuit • Radiator cooling fan relay No.2 (coil side)
• Measured voltage at drive circuit of radiator cooling fan relay No.2 is • ECM
higher than specified value even though command signal of radiator
cooling fan relay No.2 is ON.
• Measured voltage at drive circuit of radiator cooling fan relay No.2 is
lower than specified value even though command signal of radiator
cooling fan relay No.2 is OFF.
Circuit Diagram
1
+B MAIN
A1 A3
3
BLU LT GRN E01-7
BLU/RED
4
2
A2 C1
BLK C2
B1 B3
6
BLU GRN E01-8
RED
7
5
B2 D1
BLK D2
[A]
E01 C01
[a]
IDL10A110018-01
NOTE

DTC Troubleshooting
Step Action Yes No
in related manual.
Step Action Yes No

(coil side) and radiator cooling fan relay No.2 drive defective wire harness.
circuit check
1) Check “B1” and “B3” circuits according to Step 8 – 9 of
“Table C-9: Radiator Cooling Fan Operation Check”:
Is check result OK?

3 Radiator cooling fan relay No.2 check Replace ECM and Replace radiator cooling
1) Check radiator cooling fan relay No.2.  recheck DTC.  fan relay No.2. (Page
10B-8)
Is check result OK?
DTC P0500
AENFL80B1134042
P0500: Vehicle Speed Sensor “A” • VSS and/or its circuit (non-ABS model)
Non-ABS model • Wheel speed sensor and/or its circuit (ABS model)
• CAN communication line (ABS model)
• Vehicle speed is higher than 250 km/h (155 mile/h).
• ABS control module (ABS model)
• Vehicle speed is lower than 10 km/h (6 mile/h) for 2
• No vehicle variant data (including CAN vehicle
sec. even though engine speed is in 2,000 to 3,000 rpm
configuration data) (ABS model)
at fuel cut condition.
ABS model • ECM
Invalid vehicle speed signal is received from ABS control
module via CAN.
Circuit Diagram
[A]
MAIN 1
BLU A1
A2
2 PPL E01-89
GRY A3
[B] 3
4 GRN
BLK 1
GRN
5
BEG
8 RED E01-64
WHT E01-40 8
BRN
6
YEL
LT BLU
7
PNK
[C]
E01 C01
[a]
IDL10A110029-01
[A]: Non-ABS model A3: VSS ground circuit 5. Right-front wheel speed sensor
[B]: ABS model 1. ECM 6. Left-rear wheel speed sensor
[C]: ECM connector (View: [a]) 2. VSS 7. Right-rear wheel speed sensor
A1: VSS power supply circuit 3. ABS control module 8. CAN driver
A2: VSS signal circuit 4. Left-front wheel speed sensor
! WARNING
accident can occur.

2) Drive vehicle at engine speed of 2,000 to 3,000 rpm for 10 sec.
DTC Troubleshooting
Non-ABS model
Step Action Yes No
in related manual.
2 VSS power supply circuit and ground circuit check Go to Step 4. Go to Step 3.
4) Check that voltage between “A1” and “A3” circuits is
battery voltage.
Is check result OK?

3 VSS ground circuit check Repair “A3” circuit. Repair “A1” circuit.
voltage.
Is check result OK?

connectors.
terminal VSS connector: infinity
“ON”)
Is check result OK?

Is check result OK?
ABS model
Step Action Yes No
in related manual.
2 VSS (non-ABS model) or wheel speed sensor (ABS Go to Step 3. Repair or replace
model) check defective part(s).
1) Check that VSS (non-ABS model) or wheel speed
sensor (ABS model) is working properly. (Page 1A-
309)
Is check result OK?

Step Action Yes No

3 Vehicle variant data (including CAN vehicle Replace ECM and End.
configuration data) check recheck DTC. 
1) Check registered vehicle variant data (including CAN
vehicle configuration data). 
2) Perform DTC confirmation procedure, and check for
DTCs. (Page 1A-181)
DTC P0520
AENFL80B1134043
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.
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
NOTE

2) Set ignition “OFF” and wait for more than 30 sec.
DTC Troubleshooting
Step Action Yes No
in related manual.
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.
“ON”)
Is check result OK?

3 Oil pressure switch check Replace ECM and Replace oil pressure
1) Check oil pressure switch.  recheck DTC.  switch. 
Is check result OK?
DTC P0530
AENFL80B1134044
P0530: A/C Refrigerant Pressure Sensor “A” Circuit • A/C refrigerant pressure sensor and/or
Any of the following conditions is met. its circuit
• Measured voltage of A/C refrigerant pressure sensor signal circuit is • No vehicle variant data (including CAN
lower than 0.1 V for 2 sec. vehicle configuration data)
• Measured voltage of A/C refrigerant pressure sensor signal circuit is • ECM
Circuit Diagram
1
A1
PNK E01-37
A2
2 GRN E01-87
A3
GRY E01-10
[A]
E01 C01
[a]
IDL10A110020-01
[A]: ECM connector (View: [a]) A2: A/C refrigerant pressure sensor signal circuit 1. ECM
A1: A/C refrigerant pressure sensor power supply circuit A3: A/C refrigerant pressure sensor ground circuit 2. A/C refrigerant pressure sensor

DTC Troubleshooting
Step Action Yes No
in related manual.
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
2) Check for proper terminal connection to A/C refrigerant
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
Is check result OK?

4 A/C refrigerant pressure sensor power supply circuit Replace ECM and Repair or replace
check recheck DTC.  defective wire harness.
1) When ignition is “OFF”, disconnect “E01” connector from
ECM.
infinity
“ON”)
Is check result OK?

5 A/C refrigerant pressure sensor signal circuit check Go to Step 6. Repair or replace
infinity
“ON”)
Is check result OK?

Step Action Yes No

6 A/C refrigerant pressure sensor check Go to Step 7. Replace A/C refrigerant
1) Check A/C refrigerant pressure sensor. pressure sensor.
• Single A/C model:  • Manual A/C model:
• Dual A/C model:  
• Dual A/C model: 
Is check result OK?
DTC P0560
AENFL80B1134045
P0560: System Voltage • ECM backup power supply
• Measured voltage of backup power supply circuit is higher than 16 V. • ECM ground circuit
• Measured voltage of backup power supply circuit is lower than 6 V. • Charging system
Circuit Diagram
1
D1
YEL E01-50
A1 2 A3
YEL PNK E01-80
WHT BLU B1
A2 GRN E01-4
B2
GRN E01-5
B3
GRN E01-6
C1
BRN E01-1
C2
BRN E01-2
C3
BRN E01-3
[A]
E01 C01
[a]
IDL10A110031-01
[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 Troubleshooting
Step Action Yes No
in related manual.
2 ECM backup power supply circuit and ground circuit Go to Step 3. Repair or replace
ECM and “ECM” fuse.
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
• Voltage of “D1”, “C1”, “C2” and “C3” circuits: approx. 0
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-23)
Is check result OK?

4 DTC check Replace ECM and End.
1) Clear DTC. (Page 1A-182) recheck DTC. 
(Page 1A-181)

DTC P0571 / P1571

AENFL80B1134046
DTC Detecting Condition and Table Area
P0571: Brake Switch “A” Circuit • Brake light switch and/or its circuit
Any of the following conditions is met. • Brake switch and/or its circuit
• Vehicle speed increases from under 10 km/h (6 mile/h) to over 90 km/h • ECM
(56 mile/h) even though brake pedal is depressed.
• Brake light switch signal does not correlate with brake switch signal.
P1571: Brake Switch Circuit
• Vehicle speed increases from under 10 km/h (6 mile/h) to over 90 km/h
(56 mile/h) even though brake pedal is depressed.
• Brake switch signal does not correlate with brake light signal.
Circuit Diagram
+B IG1
B1 A1 1
A2
2
BLU E01-68
5 3
YEL GRN E01-20
4
B2
[A]
E01 C01
[a]
IDL10A110021-03
[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
! WARNING
accident can occur.
1) Drive vehicle at 90 km/h (56 mile/h) or more.

DTC Troubleshooting
Step Action Yes No
in related manual.
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.
4) Check that voltage between each of “A1” and “B1”
Is check result OK?

3 Brake switch signal circuit and brake light switch signal Go to Step 4. Repair or replace
ECM.
terminal at brake light switch / brake switch connector:
infinity
terminal at brake light switch / brake switch connector:
infinity
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.  recheck DTC.  switch / brake switch.
(Page 4A-3)
Is check result OK?
DTC P0600 / P0601 / P0604 / P060B / P2226

AENFL80B1134047
P0600: Serial Communication Link • ECM power supply circuit and/or
ECM internal failure is detected. ground circuit
P0601: Internal Control Module Memory Check Sun Error
ECM internal failure is detected.
P0604: Internal Control Module Random Access Memory (RAM) Error
P060B: Internal Control Module A/D Processing Performance

P2226: Barometric Pressure Sensor “A” Circuit • Barometric pressure sensor (in ECM)
• Measured voltage of barometric pressure sensor signal circuit is higher
• Measured voltage of barometric pressure sensor signal circuit is lower
Circuit Diagram
1
D1
YEL E01-50
A1 2 A3
YEL PINK E01-80
WHT BLU B1
A2 GRN E01-4
B2
GRN E01-5
B3
GRN E01-6
C1
BRN E01-1
C2
BRN E01-2
C3
BRN E01-3
[A]
E01 C01
[a]
IDL10A110022-02

DTC Troubleshooting
Step Action Yes No
in related manual
Step Action Yes No

(Page 1A-181)
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.  defective wire harness.
according to Step 3 – 4 of “Table C-1: Main Relay
Operation Check”: Diesel (Page 1A-299).
Is check result OK?
DTC P0641
AENFL80B1134048
P0641: Sensor Reference Voltage “A” Circuit / Open • Fuel pressure sensor and/or its circuit
Sensor power supply voltage “A” is higher than 5.3 V or • Boost pressure sensor and/or its circuit
lower than 4.7 V.
• ECM
Circuit Diagram
GRN/YEL C01-8
2 YEL/BLK C01-38
YEL/RED C01-6
RED/BLK C01-23
3 YEL C01-41
BLK C01-24
[A]
E01 C01
[a]
IDL10A110023-01
[A]: ECM connector (View: [a]) 2. Fuel pressure sensor

1. ECM 3. Boost pressure sensor

DTC Troubleshooting
Step Action Yes No
in related manual.
2 Sensor power supply circuit, signal circuit and ground Go to Step 3. Repair or replace
1) Check power supply circuit, signal circuit and ground
circuit of the following sensors.
• Fuel pressure sensor: According to Step 3 – 6 of
“Table A-4: Fuel Pressure Sensor Circuit Check”:
• Boost pressure sensor: According to Step 5 – 8 of
“Table B-3: Boost Pressure Sensor Check”: Diesel
(Page 1A-292).
Is check result OK?

3 DTC check Go to Step 4. Replace fuel pressure
1) When ignition is “OFF”, disconnect connector from fuel sensor. 
pressure sensor.
(Page 1A-181)

4 DTC check Replace ECM and Replace boost pressure
1) When ignition is “OFF”, disconnect connector from boost recheck DTC.  and IAT-2 sensor. 
pressure and IAT-2 sensor.
(Page 1A-181)
DTC P0645
AENFL80B1134049
P0645: A/C Clutch Relay Control Circuit • A/C compressor relay (coil side) and/or its
• Measured voltage of A/C compressor relay drive circuit is higher • No vehicle variant data (including CAN
than specified value for 2 sec. even when command signal of A/C vehicle configuration data)
compressor relay is ON. • ECM
• Measured voltage of A/C compressor relay drive circuit is lower
than specified value for 2 sec. even when command signal of A/C
compressor relay is OFF.
Circuit Diagram
+B MAIN 1
A1 2 A2
BLU GRY E01-79

LT BLU
WHT WHT
3
BLK BLK
[A]
E01 C01
[a]
IDL10A110024-01
[A]: ECM connector (View: [a]) A2: A/C compressor relay drive circuit 2. A/C compressor relay
A1: A/C compressor relay power supply circuit (coil side) 1. ECM 3. A/C compressor
NOTE

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
DTC Troubleshooting
Step Action Yes No
in related manual.
Step Action Yes No

2 A/C compressor relay power supply circuit (coil side) Go to Step 3. Repair or replace
1) When ignition is “OFF”, remove A/C compressor relay.
(Page 10B-8)
2) Check for proper terminal connection to A/C compressor
relay connector.
battery voltage.
Is check result OK?

3 A/C compressor relay drive circuit check Go to Step 4. Repair or replace
ECM.
• Resistance between “A2” circuit terminal and each
terminal at A/C compressor relay connector: infinity
“ON”)
Is check result OK?

4 A/C compressor relay check Go to Step 5. Replace A/C
1) Check A/C compressor relay for resistance. compressor relay.
(Page 10B-8)
• Single A/C model: 
Is check result OK?

DTC P0651
AENFL80B1134050
P0651: Sensor Reference Voltage “B” Circuit / Open • APP sensor (main) and/or its circuit
Sensor power supply voltage “B” is higher than 5.3 V or • CMP sensor and/or its circuit
lower than 4.7 V.
• ECM
Circuit Diagram
2 BRN E01-83
LT BLU E01-65
BLU E01-35
PNK C01-25
3 PNK/BLK C01-56
PPL C01-21
[A]
E01 C01
[a]
IDL10A110025-01
[A]: ECM connector (View: [a]) 2. APP sensor (main)

1. ECM 3. CMP sensor

DTC Troubleshooting
Step Action Yes No
in related manual.
• APP sensor (main) according to Step 3 – 6 of “Table
C-6: Accelerator Pedal Check”: Diesel (Page 1A-307).
• CMP sensor according to Step 2 – 5 of “DTC P0340”:

3 DTC check Go to Step 4. Replace APP sensor. 
1) When ignition is “OFF”, disconnect connector from APP
sensor.
(Page 1A-181)

Step Action Yes No

4 DTC check Replace ECM and Replace CMP sensor.
1) When ignition is “OFF”, disconnect connector CMP recheck DTC.  
sensor.
(Page 1A-181)
DTC P0657 / P0685

AENFL80B1134051
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.
P0685: ECM/PCM Power Relay Control Circuit / Open
• Measured voltage of main relay drive circuit is higher
main relay is ON.
• Measured voltage of main relay drive circuit is lower
main relay is OFF.
Circuit Diagram
1
D1
YEL E01-50
A1 2 A3
YEL PINK E01-80
WHT BLU B1
A2 GRN E01-4
B2
GRN E01-5
B3
GRN E01-6
C1
BRN E01-1
C2
BRN E01-2
C3
BRN E01-3
[A]
E01 C01
[a]
IDL10A110022-02
NOTE
DTC Troubleshooting
Step Action Yes No
in related manual.
2 Main relay power supply circuit (coil side) and main Go to Step 3. Repair or replace
relay drive circuit check defective wire harness.
“Table C-1: Main Relay Operation Check”: Diesel (Page
1A-299).
Is check result OK?

Step Action Yes No

3 Main relay check Replace ECM and Replace main relay.
1) Check main relay.  recheck DTC.  (Page 10B-8)
Is check result OK?
DTC P0697
AENFL80B1134052
P0697: Sensor Reference Voltage “C” Circuit / Open • A/C refrigerant pressure sensor and/or its circuit
Sensor power supply voltage “C” is higher than 5.3 V or • APP sensor (sub) and/or its circuit
lower than 4.7 V.
• ECM
Circuit Diagram
PINK E01-37
2 GRN E01-87
GRY E01-10
3
BLK E01-15
YEL E01-41
WHT E01-32
[A]
E01 C01
[a]
IDL10A110026-01
[A]: ECM connector (View: [a]) 2. A/C refrigerant pressure sensor

1. ECM 3. APP sensor (sub)

DTC Troubleshooting
Step Action Yes No
in related manual.
Step Action Yes No

• A/C refrigerant pressure sensor according to Step 2 –
5 of “DTC P0530”: Diesel (Page 1A-257).
• APP sensor (sub) according to Step 3 – 6 of “Table C-
6: Accelerator Pedal Check”: Diesel (Page 1A-307).
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-182) • Dual A/C model: 
(Page 1A-181)

4 DTC check Replace ECM and Replace APP sensor. 
1) When ignition is “OFF”, disconnect connector from APP recheck DTC. 
sensor.
(Page 1A-181)
DTC P0704
AENFL80B1134053
P0704: Clutch Switch Input Circuit • CPP No.2 switch and/or its circuit
CPP No.2 switch signal does not change even though gear is shifted • ECM
60 times.
Circuit Diagram
A2 A1
2
BLK PPL E01-27
[A]
E01 C01
[a]
IDL10A110027-02
[A]: ECM connector (View: [a]) A2: CPP No.2 switch power supply circuit 2. CPP No.2 switch
A1: CPP No.2 switch signal circuit 1. ECM
! WARNING
accident can occur.
1) Drive vehicle at 10 km/h (6 mile/h) or higher while engine keeps running at 1,000 rpm or higher.
2) In state of Step 1), repeat gear shift 60 times or more.
DTC Troubleshooting
Step Action Yes No
in related manual.
2 CPP No.2 switch power supply circuit check Go to Step 3. Repair or replace
1) When ignition is “OFF”, disconnect CPP No.2 switch defective wire harness.
connector.
2) Check for proper terminal connection to CPP No.2
switch connector.
battery voltage.
Is check result OK?

Step Action Yes No

3 CPP No.2 switch signal circuit check Go to Step 4. Repair or replace
ECM.
terminal at CPP switch connector: infinity
“ON”)
Is check result OK?

4 CPP No.2 switch check Replace ECM and Replace CPP No.2
Check CPP No.2 switch. (Page 5C-5) recheck DTC. (Page switch. (Page 5C-5)
5C-5)
Is check result OK?
DTC P1647
AENFL80B1134054
P1647: Vehicle Variant Not Programmed • No vehicle variant data
Vehicle variant data is not registered in ECM. • ECM

DTC Troubleshooting
Step Action Yes No
in related manual.
2 Registration data check Go to Step 3. Register correct vehicle
1) When ignition is “OFF”, connect SUZUKI scan tool to variant data to ECM,
DLC. referring to “Vehicle
Variant Data (Including
CAN Vehicle
3) Check registered vehicle variant data.  Configuration Data)
Registration”: Diesel in
Is registered vehicle variant data correct?
Section 1C in related
manual.

DTC P2135
AENFL80B1134055
P2135: Throttle / Pedal Position Sensor / Switch “A” / “B” Voltage Correlation • APP sensor and/or its circuit
• Measured voltage of APP sensor (main) signal circuit is higher than output voltage
of APP sensor (sub) by 0.22 V though output voltage of APP sensor (main) is
lower than 1.27 V.
• Measured voltage of APP sensor (main) signal circuit is higher than output voltage
of APP sensor (sub) by 0.32 V though output voltage of APP sensor (main) is
higher than 1.27 V.
Circuit Diagram
1
A1
2 BRN E01-83
A2
LT BLU E01-65
A3
BLU E01-35
B1
3 BLK E01-15
B2
YEL E01-41
B3
WHT E01-32
[A]
E01 C01
[a]
IDL10A110011-01
A3: APP sensor (main) ground circuit 1. ECM
NOTE

DTC Troubleshooting
Step Action Yes No
in related manual.
2 APP sensor (main) power supply circuit, signal circuit Go to Step 3. Repair or replace
1A-307).
Is check result OK?

3 APP sensor (sub) power supply circuit, signal circuit Go to Step 4. Repair or replace
1) Check “B1”, “B2” and “B3” circuits according to Step 3 –
1A-307).
Is check result OK?

4 APP sensor check Replace ECM and Replace APP sensor. 
1) Check APP sensor.  recheck DTC. 
Is check result OK?
DTC P2237 / P2297

AENFL80B1134056
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.
P2297: O2 Sensor Out of Range During Deceleration
A/F value at fuel cut is not as specified.
Circuit Diagram
2 1
A1
BLK E01-47
A2
LT GRN E01-44
A3
YEL E01-46
A4
MAIN
WHT E01-45
B1 B2
PINK E01-12
BLU
[A]
E01 C01
[a]
IDL10A110012-01
[A]: ECM connector (View: [a]) A3: A/F sensor signal circuit (VSIP) B2: A/F heater drive circuit
A2: A/F sensor signal circuit (VS) B1: A/F heater power supply circuit 2. A/F sensor

P2237
P2297
! WARNING
accident can occur.
NOTE
– 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
in related manual.
1) Check “A1”, “A2”, “A3” and “A4” circuits according to defective wire harness.
Step 3 of “Table B-6: A/F Sensor Check”: Diesel (Page
1A-296).
Is check result OK?

3 A/F sensor replacement Replace ECM and Repair or replace
1) Replace A/F sensor.  recheck DTC.  defective wire harness.
(Page 1A-181)
DTC P2264
AENFL80B1134057
P2264: Water in Fuel Sensor Circuit • Fuel filter water detection sensor and/or its circuit
Measured voltage of fuel filter water detection sensor is • ECM
higher than specified value even though the voltage is
controlled at low level by ECM during self test.
Circuit Diagram
IG1 1
A1
A2
WHT
2 RED E01-90
GRY
A3
[A]
E01 C01
[a]
IDL10A110028-01
[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

2) Set ignition “OFF” and wait for more than 30 sec.

DTC Troubleshooting
Step Action Yes No
in related manual
2 Drain water from fuel filter End. Go to Step 3.
1) Drain water. 
(Page 1A-181)
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.
4) Check voltage between “A1” and “A3” circuit is battery
voltage.
Is check result OK?

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
ECM.
“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.  recheck DTC.  detection sensor. 
Is check result OK?
DTC P268A
AENFL80B1134058
P268A: Fuel Injector Calibration Not Learned / Programmed • NO injector calibration code
Injector calibration code is not registered in ECM. • ECM

DTC Troubleshooting
Step Action Yes No
in related manual.
2 Injector calibration code check Go to Step 3. Register correct injector
1) When ignition is “OFF”, connect SUZUKI scan tool to calibration code to
DLC. ECM. 
3) Check registered injector calibration code with that of the
code mentioned on the injector with the help of SDT. 
Is registered injector calibration code correct?

(Page 1A-181)
Is DTC P268A still detected?
DTC U0073
AENFL80B1134059
Refer to “Troubleshooting for Communication Bus Off”: Diesel Model in Section 10H (Page 10H-45).
DTC U0121
AENFL80B1134060
Refer to “Troubleshooting for Lost Communication”: Diesel Model in Section 10H (Page 10H-38).
DTC U0140
AENFL80B1134061
DTC U0141
AENFL80B1134062
DTC U2101
AENFL80B1134063
U2101: CAN Vehicle Configuration List not Programmed • No Vehicle variant data
Vehicle variant data is not registered in ECM. • ECM

DTC Troubleshooting
Step Action Yes No
in related manual.
Step Action Yes No

2 Registration data check Go to Step 3. Register correct CAN
1) When ignition is “OFF”, connect SUZUKI scan tool to vehicle configuration
DLC. data to ECM, referring
to “Vehicle Variant Data
(Including CAN Vehicle
3) Check Vehicle variant data.  Configuration Data)
Registration”: Diesel in
Is registered Vehicle variant data correct?
Section 1C in related
manual.
Table A-1: Fuel Pump Relay Operation Check

AENFL80B1134064
Circuit Diagram
MAIN 1
A1 2 A3
BLU YEL E01-75

BLU PNK B1
4 B2
3
A2 BLK
[A]
E01 C01
[a]
IDL10A110015-04
[A]: ECM connector (View: [a]) B1: Fuel pump power supply circuit 3. Fuel pump
A1: Fuel pump relay power supply circuit (coil side) B2: Fuel pump ground circuit 4. “F/P” fuse
A2: Fuel pump relay power supply circuit (switch side) 1. ECM
A3: Fuel pump relay drive circuit 2. Fuel pump relay
Troubleshooting
Step Action Yes No
1 Fuel pump operation check End. Go to Step 2.
1) Check fuel pump operation. 
Is check result OK?

Step Action Yes No

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-8)
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.
ECM.
terminal at fuel pump relay connector: infinity
“ON”)
Is check result OK?

4 Fuel pump relay check Go to Step 5. Replace fuel pump
1) Check fuel pump relay.  relay. (Page 10B-8)
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. 
approx. 0 V for about 20 sec. after setting ignition “ON”.
Is check result OK?

6 Fuel pump power supply circuit and ground circuit Replace fuel pump.  Go to Step 7.
check
1) When ignition is “OFF”, install fuel pump relay.
2) Disconnect connector from fuel pump.
3) Check for proper connection to fuel pump.
4) If connections are OK, check that voltage between “B1”
and “B2” circuits is battery voltage for about 20 sec. after
setting ignition “ON”.
Is check result OK?

7 Fuel pump ground circuit check Repair “B2” circuit. Repair “B1” circuit.
battery voltage for about 20 sec. after setting ignition
“ON”.
Is check result OK?

Table A-2: Fuel Injector Circuit Check

AENFL80B1134065
NOTE
• This procedure is to troubleshoot only open, short to ground circuit and short to power supply
circuit of fuel injector circuit. If it is necessary to troubleshoot for injector operation, perform .
• For identification of each cylinder, refer to “Statement on Cleanliness and Care”: Diesel in related
manual.
Circuit Diagram
A1
WHT C01-47
2 A2
GRY/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]
IDL10A110014-01
[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
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.
and all fuel injector connectors.
• 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
terminal at fuel injector connector: infinity
• Resistance between “B1” circuit terminal and each
• Resistance between “C1” circuit terminal and each
• Resistance between “D1” circuit terminal and each
• 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. 
Is check result OK?
Table A-3: Fuel Temperature Sensor Check

AENFL80B1134066
Circuit Diagram
2 A1
YEL E01-61
A2
BLU E01-13
[A]
E01 C01
[a]
IDL10A110013-01
[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.
ECM and fuel temperature sensor connector.
2) Check for proper terminal connection to “E01” connector
and fuel temperature sensor connector.
• Resistance between each of “A1” and “A2” circuit and
ground: infinity
terminal at fuel temperature sensor connector: infinity
terminal at fuel temperature sensor connector: infinity
Is check result OK?

3 Fuel temperature sensor check Replace ECM and Replace fuel filter
1) Check fuel temperature sensor.  recheck parameter.  assembly. 
Is check result OK?

Table A-4: Fuel Pressure Sensor Circuit Check

AENFL80B1134067
Circuit Diagram
A1
GRN/YEL C01-8
A2
2 YEL/BLK C01-38
A3
YEL/RED C01-6
[A]
E01 C01
[a]
IDL10A110009-01
Troubleshooting
Step Action Yes No
DLC.
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 to 45
MPa.
Is check result OK?

1) With accelerator pedal depressed and engine speed at
3,500 rpm, check that “Fuel Rail Pressure” displayed on
SUZUKI scan tool is more than 60 MPa.
Is check result OK?

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.
approx. 5 V.
Is check result OK?

4 Fuel pressure sensor ground circuit check Repair “A3” circuit. Go to Step 5.
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.
connector.
terminal at fuel pressure sensor connector: infinity
“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. 
connector.
terminal at fuel pressure sensor connector: infinity
“ON”)
Is check result OK?

Table A-5: Fuel Flow Actuator Operation Check

AENFL80B1134068
Circuit Diagram
A1
YEL/BLK C01-4
2 A2
YEL C01-20
[A]
E01 C01
[a]
IDL10A110007-01
[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.
and fuel flow actuator connector.
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 1G-
24)
Is check result OK?
Table B-1: Air Intake / Turbocharger Circuit Check

AENFL80B1134069
Troubleshooting
Step Action Yes No
1 Preliminary check Go to Step 2. Repair replace defective
1) Check the following points. part(s).
• Check seal of turbocharger system hoses.
• Check intercooler for leakage.
• Check that hose clamps in air intake system are
correctly fitted and tightened.
• Check air intake hoses and pipes for obstructions,
damage, etc.
• Check that MAF 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. 
Is check result OK?

3 Air cleaner filter condition check Go to Step 4. Refit air cleaner filter
1) Check that air cleaner filter is correctly fitted. correctly.
Is check result OK?

4 Turbocharger check Go to Step 5. Repair or replace
1) Check turbocharger. (Page 1D-32) 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).
290)
Is check result OK?

Table B-2: MAF Sensor Check

AENFL80B1134070
Circuit Diagram
IG1 1
A1
WHT
A2
2 RED E01-56
A3
YEL E01-34
3 B1
BLU E01-62
[A]
E01 C01
[a]
IDL10A110010-01
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.
3) Check that engine stops and all electrical loads are
turned off.
4) Check that “MAF” parameter displayed on SUZUKI scan
tool is 0.0 to 1.0 g/sec. (0.0 to 0.13 Lb/min).
Is check result OK?

temperature.
tool is 3 to 8 g/sec. (0.40 to 1.06 Lb/min).
Is check result OK?

1) With all electrical loads turned off, depress accelerator
pedal several times and check that “MAF” parameter
displayed on SUZUKI scan tool is changed in a short
time.
Is check result OK?

Step Action Yes No

tool is 40.0 g/sec. (5.29 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.
battery voltage.
Is check result OK?

6 MAF sensor ground circuit check Repair “A3” circuit. Repair “A1” circuit.
battery voltage.
Is check result OK?

7 MAF sensor signal circuit check Go to Step 8. Repair or replace
ECM.
terminal at MAF and IAT-1 sensor connector: infinity
“ON”)
Is check result OK?

8 MAF sensor check Replace ECM and Replace MAF and IAT-1
1) Check MAF sensor.  recheck parameter.  sensor. 
Is check result OK?

Table B-3: Boost Pressure Sensor Check

AENFL80B1134071
Circuit Diagram
A1
RED/BLK C01-23
A2
2 YEL C01-41
A3
BLK C01-24
3 B1
WHT/GRN C01-37
[A]
E01 C01
[a]
IDL10A110008-01
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-289)
Is check result OK?

DLC.
turned off.
4) Check that “Boost Pressure” displayed on SUZUKI scan
tool is approximately equal to “Barometric Pressure”.
Is check result OK?

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?

Step Action Yes No

1) With accelerator pedal depressed and engine speed at
3,500 rpm, check that “Boost pressure” is 110 kPa (1.1
kgf/cm2, 16.0 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.
approx. 5 V.
Is check result OK?

6 Boost pressure sensor ground circuit check Repair “A3” circuit. Go to Step 7.
approx. 5 V.
Is check result OK?

7 Boost pressure sensor power supply circuit check Go to Step 8. Repair or replace
ECM.
connector.
terminal at boost pressure and IAT-2 sensor
connector: infinity
“ON”)
Is check result OK?

8 Boost pressure sensor signal circuit check Go to Step 9. Repair or replace
ECM.
connector.
connector: infinity
“ON”)
Is check result OK?

9 Boost pressure sensor check Replace ECM and Replace boost pressure
1) Check boost pressure sensor.  recheck parameter.  and IAT-2 sensor. 
Is check result OK?

Table B-4: Barometric Pressure Check

AENFL80B1134072
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.
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

AENFL80B1134073
Circuit Diagram
+B
1
BLU/RED A1 A2
2 GRY/RED C01-15
B1 B2
[A]
E01 C01
[a]
IDL10A110016-02
[A]: ECM connector (View: [a]) B1: Boost pressure control solenoid valve power supply circuit 2. EGR valve
Troubleshooting
Step Action Yes No

1 Active test End. Go to Step 2.
DLC.
2) Check condition of main and circuit fuses. If not, replace
fuse and check for short circuit to ground.
4) Select “EGR Valve” function in “Active Test” 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.
battery voltage.
Is check result OK?

3 EGR valve drive circuit check Go to Step 4. Repair or replace
ECM.
connector.
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.  recheck EGR valve
operation. 
Is check result OK?
Table B-6: A/F Sensor Check

AENFL80B1134074
Circuit Diagram
2 1
A1
BLK E01-47
A2
LT GRN E01-44
A3
YEL E01-46
A4
MAIN
WHT E01-45
B1 B2
PINK E01-12
BLU
[A]
E01 C01
[a]
IDL10A110012-01
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.
battery voltage.
Is check result OK?

2 A/F sensor heater drive circuit check Go to Step 3. Repair or replace
ECM.
terminal at A/F sensor connector: infinity
“ON”)
Is check result OK?

Step Action Yes No

• Resistance of “A1, “A2”, “A3” and “A4” circuits: less
than 1 Ω
• Resistance between each of “A1, “A2”, “A3” and “A4”
• Voltage of “A1, “A2”, “A3” and “A4” circuits: approx. 0
Is check result OK?

4 A/F sensor check Replace ECM and Replace A/F sensor. 
1) Check A/F sensor.  recheck parameter. 
Is check result OK?
Table B-7: Boost Pressure Control Solenoid Valve Operation Check

AENFL80B1134075
Circuit Diagram
+B
1
BLU/RED A1 A2
2 GRY/RED C01-15
B1 B2
[A]
E01 C01
[a]
IDL10A110016-02
[A]: ECM connector (View: [a]) B1: Boost pressure control solenoid valve power 2. EGR valve
supply circuit
Troubleshooting
Step Action Yes No

1 Preliminary check Go to Step 2. Repair or replace
1) Check the following parts. defective part(s).
• Check vacuum hoses and pipes.
• Check vacuum pump. 
Is check result OK?

2 Active check End. Go to Step 3.
DLC.
3) Select “Boost Pressure Control Solenoid Valve Duty”
function in “Active 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
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.
battery voltage.
Is check result OK?

4 Boost pressure control solenoid valve drive circuit Go to Step 5. Repair or replace
ECM.
terminal at boost pressure control solenoid valve
connector: infinity
“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.  recheck boost pressure control solenoid valve.
control solenoid valve. 
Is check result OK? 
Table C-1: Main Relay Operation Check

AENFL80B1134076
Circuit Diagram
1
D1
YEL E01-50
A1 2 A3
YEL PNK E01-80
WHT BLU B1
A2 GRN E01-4
B2
GRN E01-5
B3
GRN E01-6
C1
BRN E01-1
C2
BRN E01-2
C3
BRN E01-3
[A]
E01 C01
[a]
IEL10A112002-01
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.
Is check result OK?

Step Action Yes No

2 Main relay drive circuit check Go to Step 3. Repair or replace
ECM.
terminal at main relay connector: infinity
“ON”)
Is check result OK?

3 ECM power supply circuit Go to Step 4. Repair or replace
• Resistance of “B1”, “B2” and “B3” circuits: less than 1
Ω
• Resistance between each of “B1”, “B2” and “B3”
terminal at “E01” connector: infinity
• Voltage of “B1”, “B2” and “B3” circuits: approx. 0 V
Is check result OK?

4 ECM ground circuit check Go to Step 5. Repair or replace
• Resistance of “C1”, “C2” and “C3” circuits: less than 1
Ω
• Resistance between each of “C1”, “C2” and “C3”
• Voltage of “C1”, “C2” and “C3” circuits: approx. 0 V
Is check result OK?

5 Main relay check End. Replace main relay.
1) Check main relay.  (Page 10B-35)
Is check result OK?

Table C-2: Engine Speed Check

AENFL80B1134077
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
Troubleshooting
Step Action Yes No
DLC.
3) Check that “Engine Speed” is approx. 0 rpm with engine
stopped.
Is check result OK?

2 Idle speed check End. Go to Step 3.
temperature.
2) With engine running at specified idle speed, all electrical
loads turned off and accelerator pedal released, check
that “Engine Speed” is approx. 760 rpm.
Is check result OK?

Step Action Yes No

ECM and CKP sensor connector.
and CKP sensor connector.
terminal at CKP sensor connector: infinity
Is check result OK?

Is check result OK?

5 CKP sensor teeth check Replace ECM and Replace flywheel. 
1) Check CKP sensor teeth.  recheck parameter. 
Is check result OK?
Table C-3: ECT Sensor Check

AENFL80B1134078
Circuit Diagram
1
A1
2
PPL/WHT C01-54
A2
GRN C01-29
[A]
E01 C01
[a]
IBL80A112059-01
Troubleshooting
Step Action Yes No

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?

ECM and ECT sensor connector.
and ECT sensor connector.
terminal at ECT sensor connector: infinity
Is check result OK?

1) Check ECT sensor.  recheck parameter. 
Is check result OK?

Table C-4: IAT-1 Sensor Check

AENFL80B1134079
Circuit Diagram
IG1 1
A1
WHT
A2
2 RED E01-56
A3
YEL E01-34
3 B1
BLU E01-62
[A]
E01 C01
[a]
IDL10A110010-01
Troubleshooting
Step Action Yes No
DLC.
temperature.
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?

Step Action Yes No

2 IAT-1 sensor signal circuit and MAF sensor ground Go to Step 3. Repair or replace
ECM and MAF and IAT-1 sensor connector.
and MAF and IAT-1 sensor connector.
• Resistance of “B1” and “A3” circuits: less than 1 Ω
• Resistance between each of “B1” and “A3” circuits
• Voltage of “B1” and “A3” circuits: approx. 0 V (When
Is check result OK?

3 IAT-1 sensor check Replace ECM and Replace MAF and IAT-1
1) Check IAT-1 sensor.  recheck parameter.  sensor. 
Is check result OK?
Table C-5: IAT-2 Sensor Check

AENFL80B1134080
Circuit Diagram
A1
RED/BLK C01-23
A2
2 YEL C01-41
A3
BLK C01-24
3 B1
WHT/GRN C01-37
[A]
E01 C01
[a]
IDL10A110008-01
Troubleshooting
Step Action Yes No

DLC.
temperature.
loads turned off and accelerator pedal not depressed,
check that “IAT2” is between environmental temp. and
60 °C (108 °F) + environmental temp.
Is check result OK?

2 IAT-2 sensor signal circuit and boost pressure sensor Go to Step 3. Repair or replace
ECM and boost pressure and IAT-2 sensor connector.
and boost pressure and IAT-2 sensor connector.
• Resistance of “B1” and “A3” circuits: less than 1 Ω
• Resistance between each of “B1” and “A3” circuits
ground: infinity
connector: infinity
connector: infinity
• Voltage of “B1” and “A3” circuits: approx. 0 V (When
Is check result OK?

3 IAT-2 sensor check Replace ECM and Replace boost pressure
1) Check IAT-2 sensor.  recheck parameter.  and IAT-2 sensor. 
Is check result OK?

Table C-6: Accelerator Pedal Check

AENFL80B1134081
Circuit Diagram
1
A1
2 BRN E01-83
A2
LT BLU E01-65
A3
BLU E01-35
B1
3 BLK E01-15
B2
YEL E01-41
B3
WHT E01-32
[A]
E01 C01
[a]
IDL10A110011-01
[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)
A3: APP sensor (main) ground circuit 1 ECM
Troubleshooting
Step Action Yes No
DLC.
3) With all electrical loads turned off and accelerator pedal
not depressed, check that the following parameters
displayed on SUZUKI scan tool are as specified below.
• “Accel Position”: 0 to 5%
• “APP Sensor 1 Volt”: 0.50 to 0.90 V
• “APP Sensor 2 Volt”: 0.20 to 0.60 V
Is check result OK?

1) With accelerator pedal depressed fully, check that the
following parameters displayed on SUZUKI scan tool are
as specified below.
• “Accel Position”: 95 to 100%
• “APP sensor 1 volt”: 3.60 to 4.20 V
• “APP sensor 2 volt”: 1.70 to 2.30 V
Is check result OK?

Step Action Yes No

3 APP sensor power supply circuit and ground circuit Go to Step 6. Go to Step 4.
check
connector.
connector.
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.
Is check result OK?

6 APP sensor signal circuit check Go to Step 7. Repair or replace
ECM.
Is check result OK?

7 APP sensor check Replace ECM and Replace APP sensor. 
1) Check APP sensor.  recheck parameter. 
Is check result OK?

Table C-7: Speed Signal Check

AENFL80B1134082
Circuit Diagram
[A]
MAIN 1
BLU A1
A2
2 PPL E01-89
GRY A3
[B] 3
4 GRN
BLK 1
GRN
5
BEG
8 RED E01-64
WHT E01-40 8
BRN
6
YEL
LT BLU
7
PNK
[C]
E01 C01
[a]
IDL10A110029-01
[A]: Non-ABS model A3: VSS ground circuit 5. Right-front wheel speed sensor
[B]: ABS model 1. ECM 6. Left-rear wheel speed sensor
[C]: ECM connector (View: [a]) 2. VSS 7. Right-rear wheel speed sensor
A1: VSS power supply circuit 3. ABS control module 8. CAN driver
A2: VSS signal circuit 4. Left-front wheel speed sensor
Troubleshooting
Non-ABS model
! WARNING
accident can occur.
Step Action Yes No

DLC.
2) Carry out a road test and drive vehicle at constant speed
of 30 km/h (19 mile/h).
3) Check that “Vehicle Speed” displayed on SUZUKI scan
tool is approx. 30 km/h (19 mile/h).
Is check result OK?

2 VSS power supply circuit and ground circuit check Go to Step 5. Go to Step 3.
battery voltage.
Is check result OK?

3 VSS ground circuit check Repair “A3” circuit. Go to Step 4.
voltage.
Is check result OK?

4 VSS power supply circuit check Replace ECM and Repair or replace
1) When ignition is “OFF”, disconnect “E01” connector from recheck DTC.  defective wire harness.
ECM.
“ON”)
Is check result OK?

ECM.
“ON”)
Is check result OK?

Is check result OK?

ABS model
Step Action Yes No
DLC.
2) Perform a road test and drive vehicle at constant speed
of 30 km/h (19 mile/h).
3) Check that “Vehicle Speed” displayed on SUZUKI scan
tool is approx. 30 km/h (19 mile/h).
Is check result OK?

1) Check ABS control module for DTC. for applicable DTC.
Is there any DTC related to wheel speed sensor?

1) Check ECM and ABS control module for DTC. for applicable DTC.
Is there any DTC related to CAN?

4 ECM replacement End. Replace ABS control
1) Replace ECM.  module. 
2) Recheck parameter referring to “Step 1”.
Is check result OK?
Table C-8: Glow Plug Operation Check

AENFL80B1134083
NOTE
manual.
Circuit Diagram
+B IG1 1
A2 A1
B1
WHT PNK E01-70
B2
WHT 2
LT BLU E01-74
A3
GRY
C1 C2 C3 C4
BLU RED YEL GRN
3 4 5 6
[A]
E01 C01
[a]
IDL10A110017-02
[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
DLC.
2) Disconnect glow plug connector from glow plugs.
4) Select “Glow Plug” function in “Active Test” mode on
SUZUKI scan tool.
5) Check that voltage between each of glow plug connector
terminal and vehicle ground is higher than 12 V.
Is check result OK?

2 Glow plug control module power supply circuit and Go to Step 5. Go to Step 3.
ground circuit check
glow plug control module.
circuits and “A3” circuit is battery voltage.
Is check result OK?

3 Glow plug control module ground circuit check Repair “A3” circuit. Go to Step 4.
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 plug defective wire harness.
ECM. operation. 
connector.
terminal at glow plug control module connector:
infinity
infinity
Is check result OK?

Step Action Yes No

5 Glow plug control module drive circuit check Go to Step 6. Repair or replace
ECM.
infinity
“ON”)
Is check result OK?

6 Glow plug control module communication circuit check Go to Step 7. Repair or replace
infinity
“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”
infinity
infinity
infinity
infinity
• Voltage of “C1”, “C2”, “C3” and “C4” circuits: approx. 0
Is check result OK?

Step Action Yes No

8 Glow plug check Replace glow plug Replace glow plugs. 
1) Check all glow plugs.  control module and go
to Step 1. 
Is check result OK?
Table C-9: Radiator Cooling Fan Operation Check

AENFL80B1134084
! WARNING
The radiator cooling fan can come on whenever the ignition is “ON”. This electric fan starts
automatically anytime the ECT sensor senses a coolant temperature higher than a predetermined level
even when the engine is not running.
When the ignition is “ON”, keep hands, tools, clothing, and other items away from the radiator cooling
fan.
Circuit Diagram
1
+B MAIN
A1 A3
3
BLU LT GRN E01-7
BLU/RED
4
2
A2 C1
BLK C2
B1 B3
6
BLU GRN E01-8
RED
7
5
B2 D1
BLK D2
[A]
E01 C01
[a]
IDL10A110018-01
Troubleshooting
Step Action Yes No
1 Active test Go to Step 2. Go to Step 3.
DLC.
3) Select “Radiator Fan Low” function in “Active Test” mode
on SUZUKI scan tool.
4) Check that radiator cooling fan operates at low mode.
Is check result OK?

1) Select “Radiator Fan High” function in “Active Test”
mode on SUZUKI scan tool.
2) Check that radiator cooling fan operates at high mode.
Is check result OK?

1) When ignition is “OFF”, remove radiator cooling fan relay
No.1. (Page 10B-8)
Is check result OK?

4 Radiator cooling fan relay No.1 drive circuit check Go to Step 5. Repair or replace
ECM.
infinity
“ON”)
Is check result OK?

1) Check radiator cooling fan relay No.1.  fan relay No.1. (Page
10B-8)
Is check result OK?
Step Action Yes No

6 Radiator cooling fan power supply circuit Go to Step 7. Repair or replace
1) When ignition is “OFF”, disconnect radiator cooling fan defective wire harness.
connector.
fan connector.
• Resistance of “C1” circuit: less than 1 Ω
• Resistance between “C1” circuit and ground: infinity
terminal at radiator cooling fan connector: infinity
• Voltage of “C1” circuit: approx. 0 V (When ignition is
“ON”)
Is check result OK?

7 Radiator cooling fan ground circuit Go to Step 13. Repair or replace
• Resistance between “C2” circuit and ground: less
than 1 Ω
terminal at radiator cooling fan connector: infinity
“ON”)
Is check result OK?

1) When ignition is “OFF”, remove radiator cooling fan relay
No.2. (Page 10B-8)
4) Check that voltage between each of “B1” and “B2”
Is check result OK?

9 Radiator cooling fan relay No.2 drive circuit check Go to Step 10. Repair or replace
ECM.
infinity
“ON”)
Is check result OK?

1) Check radiator cooling fan relay No.2.  fan relay No.2. (Page
10B-8)
Is check result OK?
Step Action Yes No

11 Radiator cooling sub fan power supply circuit Go to Step 12. Repair or replace
1) When ignition is “OFF”, disconnect radiator cooling sub defective wire harness.
fan connector.
sub fan connector.
• Resistance of “D1” circuit: less than 1 Ω
• Resistance between “D1” circuit and ground: infinity
terminal at radiator cooling sub fan connector: infinity
• Voltage of “D1” circuit: approx. 0 V (When ignition is
“ON”)
Is check result OK?

12 Radiator cooling sub fan ground circuit Go to Step 14. Repair or replace
• Resistance of “D2” circuit: less than 1 Ω
• Resistance between “D2” circuit and ground: less
than 1 Ω
terminal at radiator cooling sub fan connector: infinity
• Voltage of “D2” circuit: approx. 0 V (When ignition is
“ON”)
Is check result OK?

13 Radiator cooling fan motor check Replace ECM and Replace radiator cooling
1) Check radiator cooling fan.  recheck radiator cooling fan motor. 
fan motor operation. 
Is check result OK?
14 Radiator cooling sub fan motor check Replace ECM and Replace radiator cooling
1) Check radiator cooling sub fan.  recheck radiator cooling sub fan motor. 
fan and sub fan motor
Is check result OK? operation. 

AENFL80B1134085
NOTE
• Voltage with asterisk (*) cannot be measured with voltmeter because it is pulse signal.
Use oscilloscope for its check.
• Before performing this inspection, read “Precautions of ECM Circuit Inspection” under .
[A]
E01 C01
[a]
IBL80A112066-01

Fuel injector No.4 drive circuit Refer to reference waveform.
C01-1* WHT/BLU
(low side) “Fuel injector signal”: Diesel (Page 1A-324)
C01-2 — — — —
C01-3 — — — —
Fuel flow actuator power
C01-4 YEL/BLK 10 to 14 V Ignition: “ON”
supply circuit
C01-5 BLU/RED ECM power supply circuit 10 to 14 V Ignition: “ON”
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
Oil pressure switch signal 0 to 1 V Ignition: “ON”
C01-9 GRY/YEL
circuit 10 to 14 V Engine: Idle speed after warming up
C01-10 — — — —
C01-11 — — — —
C01-12 — — — —
C01-13 — — — —
C01-14 — — — —
C01-15* GRY/RED EGR valve drive circuit
“EGR valve signal”: Diesel (Page 1A-325)
C01-16* GRY/WHT
C01-17* YEL/BLK
C01-18 — — — —
C01-19 — — — —
C01-20* YEL/BLK Fuel flow actuator drive circuit
“Fuel flow actuator signal”: Diesel (Page 1A-325)
C01-21 PPL CMP sensor ground circuit Below 0.3 V Ignition: “ON”

C01-22 — — — —
Boost pressure sensor power
C01-23 RED/BLK 4 to 6 V Engine: Idle speed after warming up
supply circuit
Boost pressure sensor ground
circuit
CMP sensor power supply
C01-25 PNK 4 to 6 V Engine: Idle speed after warming up
circuit
C01-26 — — — —
C01-27 — — — —
C01-28 — — — —
C01-29 GRN ECT sensor ground circuit Below 0.3 V Ignition: “ON”
Boost pressure control
C01-30* YEL/GRN “Boost pressure control solenoid valve signal”: Diesel
solenoid valve drive circuit
(Page 1A-326)
C01-31* WHT/GRN
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
Ignition: “ON”
Approx. 0.5 V
Approx. 1.1 V Reference rail pressure: 30 MPa (305.9
kgf/cm2, 4,350 psi, 300 bar)
Fuel pressure sensor signal
C01-38 YEL/BLK Engine: Running at 3,500 rpm after
circuit
warming up
Approx. 2.2 V
Reference rail pressure: 75 MPa (764.8
kgf/cm2, 10,900 psi, 750 bar)
Ignition: “ON”
Approx. 0 V
Blower motor signal circuit Ignition: “ON”
C01-39 GRY 5 to 7 V
(Manual A/C model) Blower speed switch: 1st
Ignition: “ON”
10 to 14 V
C01-40 — — — —
Approx. 1.6 V Reference boost pressure: 99 kPa
(1.01 kgf/cm2, 14.4 psi, 0.99 bar)
Boost pressure sensor signal
C01-41 YEL Engine: Running at 3,500 rpm after
circuit
warming up
Approx. 2.0 V
Reference boost pressure: 123 kPa
(1.25 kgf/cm2, 17.8 psi, 1.23 bar)
C01-42 — — — —
C01-43* GRY/BLK CKP sensor signal circuit (+) “CMP sensor signal and CKP sensor signal”: Diesel
(Page 1A-326)
C01-44 — — — —
C01-45 — — — —
C01-46* BLU
(high side) “Fuel injector signal”: Diesel (Page 1A-324)
C01-47* WHT

C01-48* GRN
C01-49* YEL
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
Ignition: “ON”
Approx. 0.7 V
C01-55 — — — —
C01-56* PNK/BLK CMP sensor signal circuit “CMP sensor signal and CKP sensor signal”: Diesel
(Page 1A-326)
C01-57 — — — —
C01-58 — — — —
C01-59* YEL/RED CKP sensor signal circuit (–) “CMP sensor signal and CKP sensor signal”: Diesel
(Page 1A-326)
C01-60 — — — —

E01-1 BRN ECM ground circuit Below 0.3 V Ignition: “ON”
E01-4 GRN ECM power supply circuit 10 to 14 V Ignition: “ON”
Radiator cooling fan relay 0 to 1 V Radiator cooling fan motor: Operate
E01-7 LT GRN
No.1 drive circuit 10 to 14 V Radiator cooling fan motor: Not operate
Radiator cooling sub fan motor:
0 to 1 V
Radiator cooling fan relay Operate
E01-8 GRN
No.2 drive circuit Radiator cooling sub fan motor: Not
10 to 14 V
operate
Ignition: “ON”
10 to 14 V
ENG A-STOP OFF switch ENG A-STOP OFF switch: Pushed
E01-9 BLU
Approx. 0 V
ENG A-STOP OFF switch: Released
Brake stroke sensor ground
E01-11 GRY Approx. 0 V Ignition: “ON”
circuit
E01-12* PNK A/F sensor heater drive circuit “A/F sensor heater relay drive signal”: Diesel (Page 1A-
327)
Fuel temperature sensor
ground circuit
E01-14 — — — —
E01-15 BLK 4 to 6 V Ignition: “ON”
supply circuit
E01-16 — — — —
Ignition: “ON”
Approx. 0 V
Hood latch switch 2 signal Hood latch: Latch released
E01-17 GRY
circuit Refer to reference waveform.
“Hood latch switch 2 signal”: Diesel (Page 1A-327)

E01-18 — — — —
DC/DC converter diagnosis 10 to 14 V Ignition: ACC
E01-19 LT BLU
output signal circuit Approx. 0 V Ignition: “ON”
Ignition: “ON”
0 to 1 V
Brake light switch signal Brake pedal: Not depressed
E01-20 GRN
10 to 14 V
Ignition: “ON”
Approx. 0 V Brake pedal: Fully depressed after
Brake booster switch signal
E01-21 GRY depressing several times
circuit
Engine: Running
10 to 14 V
E01-22 — — — —
E01-23 WHT Ignition signal circuit 10 to 14 V Ignition: “ON”
Ignition: “ON”
10 to 14 V
Hood latch switch 1 signal Hood latch: Latch released
E01-24 GRN
Approx. 0 V
Hood latch: Fully latched
E01-25 — — — —
Ignition: “ON”
Approx. 0 V
Neutral position switch signal Gear position: Other than Neutral
E01-26 YEL
circuit (–) Ignition: “ON”
Approx. 3 V
Gear position: Neutral
Ignition: “ON”
10 to 14 V
Clutch pedal: Not depressed
E01-27 PPL CPP No.2 switch signal circuit
Ignition: “ON”
0 to 1 V
E01-28 — — — —
E01-29 — — — —
E01-30 — — — —
E01-31 — — — —
APP sensor (sub) ground
circuit
E01-33 — — — —
E01-34 YEL MAF sensor ground circuit Below 0.3 V Ignition: “ON”
APP sensor (main) ground
circuit
E01-36 — — — —
E01-37 PNK 4 to 6 V Engine: Idle speed after warming up
sensor power supply circuit
Brake stroke sensor power
E01-38 GRN 4 to 6 V Ignition: “ON”
supply circuit
E01-39 — — — —
CAN (low) communication Refer to reference waveform.
E01-40* WHT
circuit “CAN communication signal”: Diesel (Page 1A-327)
Ignition: “ON”
1.70 to 2.30 V
APP sensor (sub) signal Accelerator pedal: Fully depressed
E01-41 YEL
0.20 to 0.60 V
E01-42 — — — —
E01-43 — — — —
E01-44 LT GRN A/F sensor signal circuit (VS) 2 to 6 V Engine: Idle speed after warming up
E01-45 WHT A/F sensor signal circuit (IP) 2 to 6 V Engine: Idle speed after warming up
A/F sensor signal circuit
E01-46 YEL 2 to 6 V Engine: Idle speed after warming up
(VSIP)
E01-47 BLK A/F sensor signal circuit (RC) 2 to 6 V Engine: Idle speed after warming up
E01-48 — — — —
E01-49 — — — —

ECM backup power supply
E01-50 YEL 10 to 14 V —
circuit
• “ISG wake-up signal and ISG inhibitor signal”: Diesel
E01-51 BRN ISG inhibition signal circuit
(Page 1A-328)
• “ISG wake-up signal, ISG inhibition signal and DC/DC
converter activation signal”: Diesel (Page 1A-328)
E01-52 — — — —
E01-53 — — — —
E01-54 — — — —
E01-55 — — — —
E01-56* RED MAF sensor signal circuit
“MAF sensor signal”: Diesel (Page 1A-327)
E01-57 — — — —
E01-58 — — — —
• “ISG wake-up signal and ISG inhibitor signal”: Diesel
E01-59 PPL ISG wake-up signal circuit (Page 1A-328)
• “ISG wake-up signal, ISG inhibition signal and DC/DC
E01-60 — — — —
Approx. 2.54 V
Fuel temperature: 25 °C (77 °F)
Fuel temperature sensor Engine: Idle speed after warming up
E01-61 YEL Approx. 1.14 V
signal circuit Fuel temperature: 60 °C (140 °F)
Approx. 0.43 V
Fuel temperature: 100 °C (212 °F)
E01-62* BLU IAT-1 sensor signal circuit
“IAT-1 sensor signal”: Diesel (Page 1A-328)
E01-63 — — — —
CAN (high) communication Refer to reference waveform.
E01-64* RED
circuit “CAN communication signal”: Diesel (Page 1A-327)
Ignition: “ON”
3.60 to 4.20 V
APP sensor (main) signal Accelerator pedal: Fully depressed
E01-65 LT BLU
0.50 to 0.90 V
E01-66* PPL Serial communication circuit
“Serial communication signal”: Diesel (Page 1A-329)
E01-67 — — — —
Ignition: “ON”
10 to 14 V
E01-68 BLU Brake switch signal circuit
Ignition: “ON”
0 to 1 V
E01-69 — — — —
Ignition: Within 20 sec. after setting
Glow plug control module 0 to 1 V
E01-70 PNK ignition “ON”
drive circuit
10 to 14 V Ignition: After 20 sec. from ignition “ON”
E01-71 — — — —
E01-72 — — — —
E01-73 — — — —
Glow plug control module 10 to 14 V
E01-74 LT BLU ignition “ON”
communication circuit
0 to 1 V
ignition “ON”
E01-75 YEL Fuel pump relay drive circuit

E01-76 — — — —
E01-77 — — — —
E01-78 — — — —
0 to 1 V
A/C compressor relay drive A/C compressor: ON
E01-79 GRY
circuit Engine: Idle speed after warming up
10 to 14 V
A/C compressor: OFF
10 to 14 V Ignition: “OFF”
E01-81 — — — —
E01-82 — — — —
APP sensor (main) power
E01-83 BRN 4 to 6 V Ignition: “ON”
supply circuit
Starting motor control relay Approx. 0 V Ignition: “ON”
E01-84 LT GRN
signal circuit 6 to 12 V Ignition: “Start”
DC/DC converter activation
E01-85 PPL “ISG wake-up signal, ISG inhibition signal and DC/DC
signal circuit
E01-86 — — — —
A/C switch: OFF
0.9 to 1.3 V
A/C refrigerant pressure: 600 kPa (6.1
A/C refrigerant pressure kgf/cm2, 87 psi, 6.0 bar)
E01-87 GRN
sensor signal circuit Engine: Idle speed after warming up
A/C switch: ON
1.3 to 2.2 V
A/C refrigerant pressure: 1,200 kPa
(12.2 kgf/cm2, 174 psi, 12 bar)
E01-88 — — — —
E01-89* PPL VSS signal circuit
“VSS signal”: Diesel (Page 1A-329)
Ignition: After 5 sec. from ignition “ON”
10 to 14 V Amount of water in fuel filter: Below
Fuel filter water detection
E01-90 RED specified level
sensor signal circuit
Amount of water in fuel filter: Specified
0 to 1 V
level or more
E01-91 — — — —
Ignition: “ON”
Approx. 0 V
E01-92 GRN CPP No.1 switch signal circuit
Ignition: “ON”
10 to 14 V
Ignition: “ON”
10 to 14 V
Neutral position switch signal Gear position: Other than Neutral
E01-93 PNK
circuit (+) Ignition: “ON”
Approx. 3 V
Gear position: Neutral
Ignition: “ON”
Approx. 1.0 V
Brake stroke sensor signal Brake pedal: Released
E01-94 PPL
1.5 to 2.5 V
Reference Waveform Fuel injector No.3 signal (high side) (3):

NOTE + C01-48
3
• Display includes the following types of – E01-1
data:
Fuel injector No.3 signal (low side) (4):
+ C01-31
4
– E01-1
I8T401111066-01


Fuel injector signal IAY40A110011-02
5. Signal is outputted, but fuel is not injected. 7. Crankshaft angle at 360°

Fuel injector No.1 signal (high side) (1): 6. Fuel is injected.
+ C01-47
1
– E01-1

+ C01-16
2
– E01-1
Fuel injector No.4 signal (high side) (3):

+ C01-46
3
– E01-1

+ C01-1 IAY40A110019-01
4
– E01-1 5. Signal is outputted, but fuel is not injected. 6. Fuel is injected.
Fuel injector No.2 signal (high side) (1):

+ C01-49
1
– E01-1

+ C01-17
2
– E01-1
Fuel flow actuator signal EGR valve signal

+ C01-20 + C01-15
1 1
– E01-1 – E01-1

Ignition: “ON” • Engine: Running after warming up
EGR valve duty: 50%
I7N20A112003-02
• Engine: Running after warming up
• EGR valve duty: 2.0%
IAY40A110034-01
I7N20A112004-02
IAY40A110035-01
Boost pressure control solenoid valve signal CMP sensor signal and CKP sensor signal
+ C01-30 CMP sensor signal (1):
– E01-1
+ C01-56
1
Measurement condition – E01-1
Ignition: “ON”
CKP sensor signal (+) (2):
+ C01-43
2
– E01-1
CKP sensor signal (–) (3):

+ C01-59
3
– E01-1
IAY40A110036-01
I9P60A112043-01
I9P60A112044-01
IAY40A110037-01
A/F sensor heater relay drive signal CAN communication signal

+ E01-12 CAN (high) communication (1):
– E01-1
+ E01-40
1
Measurement condition – E01-1
CAN (low) communication (2):
+ E01-64
2
– E01-1
I7V10A112001-01
Hood latch switch 2 signal

+ E01-17
1
– E01-1
I7N20A112011-03
• Ignition: “ON” MAF sensor signal
• Hood latch: Fully latched Channel Probe Terminal No.
+ E01-56
1
– E01-1
IFL10A110004-01
I7N20A112012-02
ISG wake-up signal and ISG inhibitor signal Measurement condition

Engine auto stop control → Engine auto start control →
ISG wake-up signal (1): Engine running
+ E01-59
1
– E01-1
ISG inhibition signal (2):

+ E01-51
2
– E01-1
• Vehicle: Running
• Engine power assist: OFF → ON → OFF
IFL10A110006-01
4. Engine auto stop control 6. Engine running

5. Engine auto start control
IAT-1 sensor signal

+ E01-62
1
– E01-1
IFL10A110005-01
3. Engine power assist: ON
ISG wake-up signal, ISG inhibition signal and DC/DC

converter activation signal
ISG wake-up signal (1):

+ E01-59
1
– E01-1
ISG inhibition signal (2):

Channel Probe Terminal No. I7N20A112013-02
+ E01-51
2
– E01-1
DC/DC converter activation signal (3):

+ E01-85
3
– E01-1
Serial communication signal VSS signal

+ E01-66 + E01-89
1 1
– E01-1 – E01-1

Ignition: “ON” Vehicle: Running at 40 km/h (25 mile/h)
I7N20A112014-02
IBP80A112067-01
Repair Instructions
Idle Speed Inspection Special tool
AENFL80B1136001 : SUZUKI scan tool (Suzuki SDT-II)
1) Shift transaxle into neutral.
Engine idle speed
A/C OFF: Approx. 800 rpm
temperature.
A/C ON: Approx. 850 rpm
3) Turn all electrical loads off.
5) If engine idle speeds are not as specified, go to
4) Using SUZUKI scan tool, check that idle speed is
“Improper Engine Idling or Engine Stops at Idle”
within specification.
under “Engine Symptom Diagnosis”: Diesel in
related manual.

Special Tool
AENFL80B1138002
SDT-II)
—
//
1B-1 Aux. Emission Control Devices: Petrol and Bi-Fuel CNG
Aux. Emission Control Devices

Engine
Petrol and Bi-Fuel CNG

EVAP Canister Purge System Inspection
AENFL80B1214001
! WARNING
Do not use your mouth to apply vacuum to
EVAP canister purge valve. Fuel vapor is
harmful.
! CAUTION
1
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 2
damaged.
(A)
1) Prepare to operate EVAP canister purge valve as
follows.
• Using SUZUKI scan tool:
a. Connect SUZUKI scan tool to DLC (1) with
IFL80B111018-04
ignition “OFF”.
2. VCI
b. Set ignition “ON”, clear DTC and select
“Engine / Active Test” mode on SUZUKI scan • Using service wire:
tool.
a. Connect service wire (2) between EVAP
Special tool canister purge valve and EVAP canister purge
(A): SUZUKI scan tool (Suzuki SDT-II) valve connector with ignition “OFF”.
NOTE b. Set ignition “ON”.
EVAP canister purge valve is operated using NOTE
scan tool as follows. EVAP canister purge valve (1) is operated
• EVAP canister purge valve is off: 0% using service wire as follows.
• EVAP canister purge valve is on: 100% • EVAP canister purge valve is off:
Disconnect “BLU/BLK” harness side of
EVAP canister purge valve and ground [a]
• EVAP canister purge valve is on:
Connect “BLU/BLK” harness side of EVAP
canister purge valve and ground [b]
[a]
[b]
1
I8C50B120002-01
Aux. Emission Control Devices: Petrol and Bi-Fuel CNG 1B-2
2) Set ignition “OFF”. • Vacuum hoses: 

3) Disconnect vacuum hose (2) from intake manifold
and purge hose from EVAP canister purge valve (1). [A]
(A)
4) Install special tool to vacuum hose.
Special tool
(A): 09917M47011
1 2
6) Check EVAP canister purge valve operation as
follows.
a) Check that vacuum of –60 kPa (–0.6 kgf/cm2, – [B]
(A)
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
EVAP canister purge valve is turned on [B].
1 2
7) If faulty condition is found, check the following
points.
• Wire harness and connections
IEL10A121001-01
• EVAP canister purge valve: (Page 1B-2)
Repair Instructions
EVAP System Components
AENFL80B1216001
(a)
1 3
IEL10A121002-01
1. EVAP canister purge valve 3. EVAP canister bracket 5. To fuel tank

2. EVAP canister 4. To intake manifold : 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
EVAP Canister Purge Valve Inspection ! WARNING

AENFL80B1216002
Do not use mouth to apply vacuum to EVAP

canister purge valve. Fuel vapor is harmful.
Use a hand vacuum pump to apply vacuum.
1B-3 Aux. Emission Control Devices: Petrol and Bi-Fuel CNG
! CAUTION b) With 12 V battery connected to purge valve

terminals, check that vacuum (–60 kPa, –0.6 kgf/
If excessive vacuum is applied, the EVAP cm2, –8.7 psi, –0.6 bar) cannot be applied to
canister purge valve may be damaged. purge valve.
Do not exceed a vacuum of –66 kPa (–0.67
c) With no 12 V battery connected to purge valve
kgf/cm2, –9.57 psi, –0.66 bar).
terminals, check that vacuum (–60 kPa, –0.6 kgf/
cm2, –8.7 psi, –0.6 bar) can be applied to purge
1) With ignition “OFF”, disconnect connector and hoses
valve.
from EVAP canister purge valve (1).
2) Remove purge valve from air cleaner assembly. [A]
3) Check resistance between two terminals of purge
valve.
If faulty condition is found, replace EVAP canister
purge valve. 2
EVAP canister purge valve resistance (A)

1
30 to 34 Ω at 20 °C (68 °F)
[B]
2
1
IBP80A121005-01 (A)
4) Check EVAP canister purge valve operation as 1
follows.
If faulty condition is found, replace EVAP canister
purge valve.
IDAA0A121003-01
a) Install special tool and vacuum hose (2) to purge
valve (1). [A]: EVAP canister purge valve ON [B]: EVAP canister purge valve OFF
Special tool
(A): 09917M47011
Specifications
Tightening Torque Specifications
AENFL80B1217002
Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“EVAP System Components”: Petrol and Bi-Fuel CNG
“Fasteners Information” in Section 0A in related manual

Special Tool
AENFL80B1218002
09917M47011 SUZUKI scan tool (Suzuki
SDT-II)
Vacuum pump gauge —
/ 
Engine Electrical Devices: Petrol and Bi-Fuel CNG 1C-1
Engine Electrical Devices

Engine

Repair Instructions
CNG Cylinder Pressure-and-Temperature

Sensor Inspection (Bi-Fuel CNG Model)
AENFL80B1316026
3
CNG/LPG Temperature Sensor Inspection

1) Remove CNG pressure-and-temperature sensor. 
2) Check O-ring (1) for damage and deterioration. If "1"
"2"
faulty condition is found, replace CNG pressure-and- 5
temperature sensor. 1
3) Measure resistance between sensor terminals “1” 4
and “2” while blowing hot air to temperature sensing 2
part (2) of CNG pressure-and-temperature sensor
(3) using hot air drier (4). If measured resistance is
not as specified, replace CNG pressure-and-
temperature sensor.
! CAUTION [A]
Do not heat up CNG pressure-and-

temperature sensor more than 100 °C (212
°F). Otherwise, CNG pressure-and-
temperature sensor will be damaged.
CNG temperature sensor resistance 2.24 - 2.75

0 °C (32 °F): 5.30 – 6.48 kΩ
20 °C (68 °F): 2.24 – 2.75 kΩ
40 °C (104 °F): 1.05 – 1.29 kΩ 1.05 - 1.29
0.535 - 0.655
60 °C (140 °F): 0.535 – 0.655 kΩ
0 20 40 60 80 [B]
32 68 104 140 176 F
I9R90A130009-02
[A]: Resistance 5. Temperature gauge

[B]: Temperature
CNG Cylinder Pressure Sensor Inspection

1) Relieve fuel pressure in CNG fuel line. 
2) Disconnect fuel hose between CNG fuel delivery
pipe and CNG cylinder pressure regulator.
3) Install pressure gauge between CNG cylinder
pressure regulator and CNG fuel delivery pipe,
referring to “Fuel Pressure Basic Check”: Bi-Fuel
CNG in Section 1G (Page 1G-13).
4) Connect SUZUKI scan tool (2) to DLC (1).
Special tool
1C-2 Engine Electrical Devices: Petrol and Bi-Fuel CNG
If electric load current sensor circuits and charging

system are in good condition, replace electric load
current sensor (1).
(A)
IEL10A131019-01
IFL80B111018-04 Without using SUZUKI scan tool

5) Turn ignition switch to ON position and select “CNG 1) With ignition “OFF”, disconnect electric load current
Cylinder Pressure” under “Data List” mode on scan sensor connector.
tool. Check CNG pressure displayed on scan tool. 2) Using service wires (1), connect electric load current
6) Check that fuel pressure on pressure gauge and sensor (2) and electric load current sensor connector
“CNG Cylinder Pressure” on SUZUKI scan tool are (3).
similarly decreased, when fuel pressure is relieved. 3) With ignition “ON”, check that voltage varies
If check result is not as specified, replace CNG depending on electric load referring to “Inspection of
pressure-and-temperature sensor. ECM and Its Circuits”: Petrol in Section 1A (Page
1A-107)
Electric Load Current Sensor On-Vehicle
Inspection 2
AENFL80B1316032 3
1
Battery Current
Using SUZUKI scan tool
1) With ignition “OFF”, connect SUZUKI scan tool to
DLC.
Special tool
: SUZUKI scan tool (Suzuki SDT-II)
2) Check that battery current value displayed on
SUZUKI scan tool changes to values given below as
electric load increases.
I9P60A131022-01
Battery current (Reference) If check result is not as specified, check the following
Ignition “ON”: 2 to 8 A parts and circuits.
Ignition “ON” and headlight ON: 10 to 24 A • Electric load current sensor circuits (power, ground
Ignition “ON”, headlight ON and blower speed and output)
selector in MAX position: 24 to 33A
• Battery negative (–) cable
If check result is not as specified, check the following • The following charging system components:
points.
– Battery 
• Electric load current sensor circuits (power,
– Generator (Page 1J-3)
ground and output)
– Generator LIN communication circuit according to
• Battery negative (–) cable
Step 2 under (Page 1A-105)
• The following charging system components: If electric load current sensor circuits and charging
– Battery  system are in good condition, replace electric load
– Generator (Page 1J-3) current sensor.
– Generator LIN communication circuit according
to Step 2 under (Page 1A-105)
Engine Electrical Devices: Petrol and Bi-Fuel CNG 1C-3
Temperature 3) Check that resistance varies depending on battery

1) With ignition “OFF”, disconnect electric load current temperature as shown in graph below.
sensor connector. If check result is not as specified, replace electric
load current sensor.
2) Connect ohmmeter to electric load current sensor
(1)1 as shown in figure.
[a]
2 1
0 20 40 60 80 90 [b]
4 3 68 104 140 176 194
I8C50B130012-03
[a]: Resistance [b]: Temperature
IEL10A131020-01

Special Tool
AENFL80B1318002
SDT-II)
—
/
1C-4 Engine Electrical Devices: Diesel
Diesel
General Description
Description of ECM Registration
AENFL80B1321001
The following vehicle information are registered in ECM.
• Injector calibration code
• Vehicle variant data (including CAN vehicle configuration data)
• Flywheel data
• A/F sensor data
• MAF sensor data
• Rail pressure sensor data
• Immobilizer ID code
• Brake stroke sensor zero point
If any one of the following parts is replaced, register / initialize the necessary information in ECM as table below.
Part Registered / initialized data Reference
• Injector calibration code
• Vehicle variant data (including
CAN vehicle configuration data)
• Flywheel data Go to “Registration for ECM
ECM
• A/F sensor data Replacement”: Diesel in related manual.
• MAF sensor data
• Rail pressure sensor data
• Immobilizer ID code
Go to “Injector Calibration Code
Fuel injector(s) Injector calibration code
Registration”: Diesel in related manual.
Go to “Flywheel Data Initialization”:
Flywheel Flywheel data
Diesel in related manual.
Go to “A/F Sensor Data Initialization”:
A/F sensor A/F sensor data
Go to “MAF Sensor Data Initialization”:
MAF sensor MAF sensor data
• Common rail Go to “Rail Pressure Sensor
Rail pressure sensor data
• Rail pressure sensor Initialization”: Diesel in related manual.
Ignition switch model:
Go to “ECM Registration”: Ignition Switch
Ignition switch model:
Model in Section 10C in related manual.
BCM
Immobilizer ID code Keyless push start model:
Keyless push start model:
Go to “ECM Registration”: Keyless Push
Keyless start control module
Start Model in Section 10C (Page 10C-
14).
Go to “Brake Stroke Sensor Zero Point
Brake stroke sensor Brake stroke sensor zero point
Reset”: Diesel (Page 1C-7).
Engine Electrical Devices: Diesel 1C-5
Repair Instructions
Brake Stroke Sensor On-Vehicle Inspection Removal
AENFL80B1326016
1) Disconnect negative (–) cable at battery.
DLC. 2) Remove steering column hole cover. (Page 9C-24)
3) Remove brake light switch. (Page 4A-3)
Special tool
: SUZUKI scan tool (Suzuki SDT-II) 4) Disconnect brake stroke sensor connector (1).
2) Set ignition “ON” and select “Data List” mode.

3) Check that “Brake Stroke” and “Brake Stroke Sensor
Voltage” parameters displayed on SUZUKI scan tool
varies according to depressed amount of brake
pedal.
If check result is not as specified, check the following
points.
1
• Brake stroke sensor circuits
• Brake stroke sensor (Page 1C-6)
Brake stroke sensor specification
Brake pedal Brake Stroke Brake Stroke
depressed amount Sensor Voltage
0 mm (0 in.) 0% Approx. 1.0 V
Fully depressed 20 to 30% 1.5 to 2.5 V IFL10A130002-01
5) Remove brake stroke sensor (1) from brake pedal

Brake Stroke Sensor Removal and Installation assembly (2).
AENFL80B1326017
NOTICE
Failure to take proper precautions when
1
handling the brake stroke sensor may lead to
malfunction of the sensor.
• Do not disassemble the sensor.
• Do not drop or otherwise expose the
sensor to large shock. Any brake stroke
2
sensor that has received large shock must
be replaced. IFL10A130003-01
• Keep the sensor section of the brake

stroke sensor away from water and/or oil.
Installation (New Part) Installation (Reused Part)

1) Insert lever (1) of brake stroke sensor (2) into
NOTE
opening (3) in brake pedal (4).
Do not break the pin (1) that holds the lever
2) Install brake stroke sensor and tighten brake stroke
(2) in place before tightening the brake stroke
sensor bolts (5) temporarily.
sensor bolts (3). If the pin is broken by
mistake, follow the installation procedure for 3
a reused part to install the brake stroke
5
sensor (4).
1) Insert lever of brake stroke sensor into opening (5) in

brake pedal (6). 2
1
2) Install brake stroke sensor and tighten brake stroke
sensor bolts to specified torque. 4
Tightening torque
5
Brake stroke sensor bolt (a): 9.0 N·m (0.92 kgf-
m, 7.0 lbf-ft) IFL10A130005-02
3) Connect brake stroke sensor connector.

4) Adjust installation position of brake stroke sensor
referring to “Adjustment” under “Brake Stroke
Sensor Inspection and Adjustment”: Diesel (Page
1C-6).
1 5) Install brake light switch. (Page 4A-3)
6) Install steering column hole cover. (Page 9C-24)
5 2
3, (a) Brake Stroke Sensor Inspection and
Adjustment
AENFL80B1326018
Inspection
4
2 1) Remove brake stroke sensor. (Page 1C-5)
6
2) Check brake stroke sensor output voltage as follows.
If faulty condition is found, replace brake stroke
sensor.
3, (a)
a) Arrange 3 new 1.5 V batteries (1) in series, and
IFL10A130004-01
check that total voltage is 4.5 to 5.0 V.
3) Break the pin that holds lever by depressing brake
b) Connect voltmeter (2) and batteries to brake
pedal.
stroke sensor as shown in figure.
4) Check that pin comes off lever and that brake pedal
can be operated smoothly.
5) Connect brake stroke sensor connector. 4 3 2 1
2
6) Perform “Brake Stroke Sensor Zero Point Reset”:
Diesel (Page 1C-7).
7) Install brake light switch. (Page 4A-3)
8) Install steering column hole cover. (Page 9C-24)
1
IEV00P130005-01
Engine Electrical Devices: Diesel 1C-7
c) While moving lever (1) manually, check that 5) Tighten brake stroke sensor bolts to specified
voltage varies depending on lever position as torque.
shown in the following graph.
Tightening torque
Brake stroke sensor bolt (a): 9.0 N·m (0.92 kgf-
m, 7.0 lbf-ft)
1, (a)
1
“b”
“c” “a”
2
IFL10A130006-01
IFL10A130009-01
[b] 6) Perform “Brake Stroke Sensor Zero Point Reset”:
4.55 - 4.65
Diesel (Page 1C-7).
[a] Brake Stroke Sensor Zero Point Reset

AENFL80B1326019
NOTE
0.94 - 1.06 In the ECM memory, the released position of
0.35 - 0.45 brake pedal is defined as the zero point,
“b”
which serves as a benchmark of the brake
[c]
“a” “c”
[d] stroke amount. Since this zero point will
change if any of the following service is
2
IEV00P130007-01 performed, a zero point initialization must be
2. Reference line (lever pivot [a]: Brake stroke sensor voltage
performed.
point-connector center) • Removal/installation or replacement of
“a”: 39.7° ± 3.0° [b]: Output voltage (V) brake stroke sensor
“b”: 30.0° ± 3.0° [c]: Counterclockwise turn of lever
“c”: 28.3° ± 3.0° [d]: Clockwise turn of lever
DLC.
Adjustment
Special tool
DLC.
2) Set ignition “ON” and execute “Brake Stroke Sensor
Special tool
Zero Point Reset” in “Utility” mode of SUZUKI scan
tool.
2) Set ignition “ON” and select “Brake Stroke Sensor 3) When ignition is “OFF”, disconnect SUZUKI scan
Voltage” in “Data List” mode. tool from DLC.
3) Loosen brake stroke sensor bolts (1). 4) Be sure that brake pedal is fully released. Turn
4) Adjust position of brake stroke sensor until output ignition “ON” and wait 5 seconds or more. The zero
voltage is within specified range. point is stored in ECM.
Brake stroke sensor output voltage
Brake pedal released: 0.94 – 1.06 V
Specifications
AENFL80B1327002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Brake stroke sensor bolt 9.0 0.92 7.0 /
Reference:

Special Tool
AENFL80B1328002
SDT-II)
—
//
Engine Mechanical: Petrol and Bi-Fuel CNG 1D-1
Engine Mechanical
Engine

General Description
Engine Construction Description
AENFL80B1411001
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.
The cylinder block is equipped with a water jacket spacer (1) in the water jacket for effective cylinder head cooling.
[a]
IEL10A141001-01
[a]: Crankshaft pulley side

Compression Check 7) Install special tools into spark plug hole.
AENFL80B1414001
1) Warm up engine to normal operating temperature. Special tool
(A): 09915M64512
2) Stop engine after warming up.
(B): 09915M64530
3) For M/T model, place gear shift lever in “Neutral” and (C): 09915M64550
For A/T model, place select lever in “P” and apply
parking brake. (A)
4) Remove air cleaner assembly with air suction pipe. (B)

(Page 1D-4)
5) Remove all ignition coil assemblies and all spark
plugs. 
6) Disconnect all fuel injector connectors.
(C)
I7V20A141002-01
1D-2 Engine Mechanical: Petrol and Bi-Fuel CNG
8) Disengage clutch (1) (to lighten starting load on Engine Vacuum Check
engine) for M/T model, and depress accelerator AENFL80B1414002
pedal (2) all the way to make throttle fully open. 1) Warm up engine to normal operating temperature.
2) For M/T model, place gear shift lever in “Neutral” and
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
I2RH0B140005-01
6) Close PCV valve (2) using tape (3) or the like.
9) Crank engine with fully charged battery, and read the
highest pressure on special tool.
(A)
NOTE
3
• For measuring compression pressure,
crank engine at least 200 rpm with fully 2
charged battery.
• Check installation condition of special tool 1
if measured compression pressure is
lower than the limit.
• If the measured compression pressure of
particular cylinder is lower than the limit,
add a bit of engine oil into the cylinder
through the spark plug hole, and then IEL10A141002-02
repeat the compression check. 7) Run engine at specified idle speed. (Page 1A-121)
– If the compression pressure increases 8) Read vacuum gauge. Vacuum should be within
after adding engine oil, the following specification.
may be the cause:
Vacuum specification (at sea level)
– Pressure leakage due to worn piston
–50 kPa (–0.50 kgf/cm2, –7.25 psi, –0.5 bar) or
rings or worn cylinder
less at specified idle speed
– If the compression pressure does not
increase, one of the following may be 9) Disconnect special tool from PCV hose.
the cause: 10) Pull off tape from PCV valve.
– Incorrect valve timing
– Pressure leakage from the valve or
valve seats
– Pressure leakage from the cylinder
head gasket
Compression pressure
Standard: 1,475 kPa (15.0 kgf/cm2, 214 psi)
Limit: 1,200 kPa (12.2 kgf/cm2, 174 psi)
Max. difference between any two cylinders: 100
kPa (1.0 kgf/cm2, 14.5 psi)
10) Carry out Step 7) – 9) on each cylinder to obtain 4
readings.
11) Install spark plugs and ignition coil assemblies. 
12) Connect fuel injector connectors.
13) Install air cleaner assembly with air suction pipe.
(Page 1D-4)
Repair Instructions
Air Cleaner Components
AENFL80B1416001
4
4
2
1
(a)
8
7
11
6
10
(a)
IFL80B141004-03
1. Air cleaner assembly 5. Air cleaner outlet hose 9. To cylinder head cover
2. Air cleaner suction pipe joint 6. Air cleaner bracket 10. To throttle body assembly
3. Air cleaner suction pipe 7. IAT sensor 11. To intake manifold
4. Suction pipe grommet 8. EVAP canister purge valve : 1.3 Nm (0.13 kgf-m, 1.0 lbf-ft)
Air Cleaner Assembly Removal and Installation

AENFL80B1416004
Removal
2) Remove EVAP canister purge valve (1).
3) Disconnect engine harness clamps (2).
(a)
4) Loosen air cleaner outlet hose clamp bolt, and then
remove air cleaner assembly (3).
5) Remove air cleaner outlet hose (4) according to the
following procedure if necessary.
a) Disconnect breather hose (5) from air cleaner
outlet hose.
IEL10A141006-01
b) Disconnect IAT sensor connector.
c) Remove air cleaner outlet hose.
2 1
3 4
IFL80B141005-03
Installation
Reverse removal procedure noting the following point.
• Tighten air cleaner outlet hose clamp bolts to
specified torque.
Tightening torque
Air cleaner outlet hose clamp bolt (a): 1.3 N·m (0.13
kgf-m, 1.0 lbf-ft)
Throttle Body and Intake Manifold Components

AENFL80B1416005
Petrol model
7 5
IEL10A141007-02
1. Intake manifold 4. Electric throttle body gasket 7. Air cleaner bracket

2. Intake manifold gasket 5. MAP sensor 8. To PCV valve
3. Electric throttle body assembly 6. PCV hose : Do not reuse.
: Do not disassemble.
Electric Throttle Body Assembly Removal and 4) Remove electric throttle body assembly and air
Installation cleaner bracket (3) from intake manifold.
AENFL80B1416007
NOTICE 3
The electric throttle body will lose its original

performance if it is disassembled.
Do not disassemble the electric throttle body. 1
If any faulty condition is found, replace the
electric throttle body with a new one.
Removal
2
2) Remove air cleaner assembly. (Page 1D-4)
3) Disconnect connector (1) from electric throttle body
assembly (2).
IEL10A141008-01
Installation
1) Clean mating surfaces and install new throttle body
gasket (1) to intake manifold.
1
I7V20A141038-01
2) Install electric throttle body assembly (1) and air

IEL10A141010-01
cleaner bracket (2) to intake manifold.
3) Connect connector (3) to electric throttle body 5) Remove heater hose bracket (1).
assembly.
1
IEL10A141011-01
6) Disconnect MAP sensor connector (1) and clamp

IEL10A141009-01
(2).
4) Install air cleaner assembly. (Page 1D-4) 7) Remove intake manifold (3) and its gasket.
5) Connect negative (–) cable at battery.
Intake Manifold Removal and Installation (Petrol

Model)
AENFL80B1416009
Removal
2) Remove air cleaner assembly. (Page 1D-4) 3 1
3) Remove electric throttle body assembly from intake

manifold. (Page 1D-5)
4) Disconnect the following hoses:
• Brake booster hose (1) from brake booster 2
IEL10A141012-01
• PCV hose (2) from PCV valve
Installation
Reverse removal procedure noting the following points.
• Use new gasket.
• Check that all removed parts are back in place.
Cylinder Head Cover Components

AENFL80B1416010
3 (a)
2 1217G
IEL10A141013-01
1. Cylinder head cover 5. Oil filler cap

2. Cylinder head cover gasket : 3.0 Nm → 5.0 Nm → 7.5 Nm (0.31 kgf-m → 0.51
: Apply sealant 99000-31260 referring to “Cylinder Head Cover Removal and kgf-m → 0.76 kgf-m, 2.5 lbf-ft → 4.0 lbf-ft → 5.5 lbf-ft)
Installation”: Petrol and Bi-Fuel CNG (Page 1D-7).
3. Cylinder head cover bolt : Do not reuse.
: For tightening order, refer to “Cylinder Head Cover Removal and Installation”:
Petrol and Bi-Fuel CNG (Page 1D-7).
4. PCV valve
Cylinder Head Cover Removal and Installation

AENFL80B1416011 5 6
“7” “10” “13” “12”
Removal “3” “5”
2) Remove air cleaner assembly. (Page 1D-4) 7 4 2
3) Remove ignition coil assemblies.  “1”

1 “2”
4) Disconnect clamps of the following harnesses.
• Engine harness (1) 3
• HO2S-1 and HO2S-2 harness (2) “4”
“6” “11” “14” “9” “8”
• Ignition coil harness (3) IEL10A141014-01
5) Remove oil level gauge (4).

6) Disconnect PCV hose (5) from PCV valve and
breather hose (6) from cylinder head cover.
7) Remove PCV valve (7) from cylinder head cover, if
necessary.
8) Loosen cylinder head cover mounting bolts in
numerical order (“1” – “14”) evenly and gradually.
9) Remove cylinder head cover (1) with gasket (2). 4) Install cylinder head cover to cylinder head.
NOTE
When installing cylinder head cover, use care
so that cylinder head cover gasket will not
get out of place or fall off.
1 5) Tighten cylinder head cover bolts according to the
following procedure:
a) Tighten cylinder head cover bolts to 3.0 Nm
(0.31 kgf-m, 2.5 lbf-ft) in numerical order (“1” –
“14”) evenly and gradually.
2 b) Retighten them to 5.0 Nm (0.51 kgf-m, 4.0 lbf-ft)
in the same manner as in Step a).
c) Retighten them to 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)
IEL10A141015-01 in the same manner as in Step a).
Tightening torque
Installation Cylinder head cover bolt* (a): 3.0 Nm → 5.0
1) Remove oil, old sealant and dust from sealing Nm → 7.5 Nm (0.31 kgf-m → 0.51 kgf-m→
surfaces on cylinder head and cover. 0.76 kgf-m, 2.5 lbf-ft → 4.0 lbf-ft → 5.5 lbf-ft)
2) Install new gasket (2) to cylinder head cover (1).
6) Install PCV valve (1) to cylinder head cover if
removed.
7) Connect PCV hose (2) to PCV valve.
8) Connect breather hose (3) to cylinder head cover.
9) Install oil level gauge (4).
1
10) Install following harness clamps.
• Engine harness (5)
• HO2S-1 and HO2S-2 harness (6)
• Ignition coil harness (7)
2 2 3
“8” “5” “2” “3”
“12” “10”
IEL10A141015-01
1 4 6
3) Apply sealant “A” to mating surfaces of timing chain
“14”
cover (1) and cylinder head (2). 5 “17”
“A”: Sealant 99000–31260 (SUZUKI Bond

No.1217G) 7
“11”
“9” “4” “1”, (a) “6” “7”
“A” IEL10A141016-03
2
11) Install ignition coil assemblies. 
12) Connect engine harness clamps.
13) Install air cleaner assembly. (Page 1D-4)
1
“A”
I9P60A141027-01
Engine Mounting Components

AENFL80B1416016
(a)
(a)
(a) (a)
[A]
2
(b) 1
(a)
(a)
(a)
[A]
4
(a)
(a)
3 (a)
6
(a)
[B]
5
(a)
(b)
[B] (a)
(a)
4
(a)
(a)
(a)
IFL80B141003-04
[A]: M/T model 3. Engine left mounting 7. Engine rear mounting No.2 bracket
[B]: A/T model 4. Engine left mounting bracket : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
1. Engine right mounting 5. Engine rear mounting : 93 Nm (9.5 kgf-m, 68.5 lbf-ft)
2. Engine right mounting stiffener 6. Engine rear mounting No.1 bracket
Engine Assembly Removal and Installation 11) For A/T model, disconnect TCM connectors, and
(Petrol Model) then pull out engine harness into engine
AENFL80B1416017 compartment.
Removal
12) Disconnect the following cables.
1) Relieve fuel pressure. (Page 1G-5)
• Gear select control cable (1) (M/T model)
2) Remove battery. 
• Gear shift control cable (2) (M/T model)
3) Disconnect ECM connectors. 
• A/T select cable (3) (A/T model)
4) Remove battery bracket with ECM.
5) Remove right and left side engine undercovers. [A]
6) Drain the following oils and fluid if necessary.
2
• Engine oil: (Page 1E-2)
• Manual transaxle oil (M/T model): (Page 5B-4) 1
• ATF (A/T model): (Page 5A-104) 4
7) Drain coolant. 
9) With hose connected, detach A/C compressor.
• Single A/C model: (Page 7B-18)
! CAUTION
Suspend removed A/C compressor at a place [B]
where no damage will be caused during
removal and installation of engine assembly.
10) Disconnect the following electric wires/connectors

and each clamp.
• Battery ground cable (1)
• Connectors (2) in main fuse box
• Electric load current sensor connector (3)
• Connector (4) in individual circuit fuse box No.1 3
I9P60A141044-01
1 13) For M/T model, remove the clutch operating cylinder

assembly (4) from transaxle. 
3
4
I9P60A141043-01
14) Disconnect the following hoses. 22) Remove engine left mounting bracket bolt (1) and
• Brake booster hose (1) nuts (2).
• Radiator inlet and outlet hoses (2)
[A] 1 2
• Heater inlet and outlet hoses (3)
• Fuel feed hose (4)
• ATF cooler hoses (5) (A/T model)
1
3
1 2
[B]
4
IEL10A141022-01
[A]: M/T model [B]: A/T model
23) Remove engine right mounting bracket bolt (1) and

5
nuts (2).
I9P60A141045-01
15) Disconnect steering lower shaft from pinion shaft.

(Page 6B-7) 1
16) Remove stabilizer bar joints from stabilizer bar. 

17) Disconnect tie-rod end from steering knuckle. 
2
18) Disconnect right and left drive shaft joints from
steering knuckle. (Page 3A-3)
19) Remove exhaust No.1 pipe and exhaust center pipe.
(Page 1K-1)
20) Support front suspension frame (1), transaxle case
(2) and cylinder block (3) using jack.
IAP70A140006-01
21) Remove front suspension frame bolts (4). 24) Before removing engine, check that all hoses,
electric wires and cables are disconnected from
2 engine.
3
25) Lower engine with transaxle, front suspension frame,
drive shafts and steering gear case assembly all
together.
! CAUTION
Before lowering engine, in order to avoid
4
damage to A/C compressor, make clearance
4
between A/C compressor and engine by
suspending A/C compressor.
1
I9P60A141047-01
26) Remove front drive shaft assembly, if necessary. 5) For A/T model, install drive intermediate shaft
(Page 3A-3) assembly, if removed. (Page 3A-9)
27) For A/T model, remove drive intermediate shaft 6) Install front drive shaft assembly, if removed.
assembly, if necessary. (Page 3A-9) (Page 3A-3)
28) Remove the following components from engine 7) Install engine harness to engine and transaxle, and
assembly, if necessary. then tighten engine harness ground bolt (1) to
• Engine harness specified torque, if removed.
• Front suspension frame Tightening torque
• Transaxle Engine harness ground bolt (a): 11 N·m (1.1 kgf-
m, 8.5 lbf-ft)
– M/T model: 
– A/T model: (Page 5A-127)
NOTE
When lifting engine assembly, use engine
hook (1) and engine hook bolt.
• Engine hook: 11851M60B01
1, (a)
• Engine hook bolt: 09103M08451
I9P60A141049-01
8) Lift up engine with transaxle, front suspension frame,

drive shafts and P/S gear case assembly all
together.
NOTICE
Before lifting engine, in order to avoid
1
9) Tighten engine right mounting bracket bolt (1) and

nuts (2) to specified torque.
Tightening torque
IEL10A141029-01
Engine right mounting bracket bolt and nut (a):
55 N·m (5.6 kgf-m, 40.5 lbf-ft)
29) Remove clutch cover and clutch disc, if necessary.

30) For M/T model, remove flywheel, if necessary.
(Page 1D-14) 1, (a)
For A/T model, remove drive plate, if necessary.
(Page 1D-14)
2, (a)
Installation
1) For M/T model, install flywheel, if removed. (Page
1D-14)
For A/T model, install drive plate, if removed.
(Page 1D-14)
2) For M/T model, install clutch cover and clutch disc, if
removed.  IAP70A140008-01
3) Install transaxle to engine, if removed.

• M/T model: 
• A/T model: (Page 5A-127)
4) Install front suspension frame, if removed. (Page
1D-9)
10) Tighten engine left mounting bracket bolts (1) and

nuts (2) to specified torque.
Tightening torque
Engine left mounting bracket bolt and nut (a): 1
55 N·m (5.6 kgf-m, 40.5 lbf-ft)
[A] 1, (a)
2, (a)
I9P60A141052-02
2, (a)
1, (a) 19) For M/T model, install clutch operating cylinder
assembly. 
[B] 20) For M/T model, connect gear shift and select control
cables. 
For A/T model, connect A/T select cable. (Page
1, (a)
5A-107)
21) Install A/C compressor to its bracket.
2, (a)
22) Install A/C compressor drive belt.
23) Install air cleaner assembly. (Page 1D-4)
IEL10A141026-01
24) Check to ensure that all removed parts are back in
[A]: M/T model [B]: A/T model
place. Reinstall any necessary parts which have not
been reinstalled.
11) Tighten suspension frame bolts to specified torque.
 25) Refill the following oils and fluid if necessary.
12) Install exhaust No.1 pipe and exhaust center pipe. • Engine oil: (Page 1E-2)
(Page 1K-1) • Manual transaxle oil (M/T model): (Page 5B-4)
13) Connect right and left drive shaft joints to steering • ATF (A/T model): (Page 5A-104)
knuckle. (Page 3A-3) 26) Install battery and battery tray with ECM. 
14) Connect tie-rod end from steering knuckle.  27) Connect ECM wire harness. 
15) Install stabilizer bar joints to stabilizer bar.  28) Connect positive (+) and negative (–) cables at
16) Connect steering lower shaft from pinion shaft. battery.
(Page 6B-7) 29) Refill cooling system with coolant. 
17) Install all other removed electric wires, connectors 30) Check any leakage of fuel, coolant, oil and exhaust
and hoses to original positions. gas.
18) Tighten battery ground terminal bolt (1). • Fuel leakage: 
• Coolant leakage: 
31) Install right and left side engine undercovers.
Timing Chain Cover Components

AENFL80B1416018
OIL
5
(a)
10 (b)
9
6
8 (b)
OIL
1 1217G 4
2
OIL
(c) 3
8 (b)
IDP70A142003-02
1. Timing chain cover 6. Dowel pin : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: Apply sealant 99000-31260.
For details, refer to “Timing Chain Cover
Removal and Installation”: Petrol and Bi-Fuel
2. Crankshaft pulley 7. OCV : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
3. Oil seal 8. Timing chain cover bolt : 150 Nm (15.3 kgf-m, 111.0 lbf-ft)
: Apply engine oil to oil seal lip. : For tightening order, refer to “Timing Chain
Cover Removal and Installation”: Petrol and
Bi-Fuel CNG in related manual.
4. O-ring 9. Timing chain cover plug gasket : Do not reuse.
: Apply engine oil.
5. Gasket 10. Timing chain cover plug
: Apply engine oil.
Flywheel / Drive Plate Removal and Installation

AENFL80B1416022
Removal
1) For M/T model, remove clutch cover and clutch disc.

2) For A/T model, remove transaxle assembly. (Page
5A-127)
3) Install special tool to ring gear teeth to lock flywheel
or drive plate as shown in figure.
Special tool I8C50A140045-01
(A): 09924M17811
4) Remove flywheel (M/T model) or drive plate (A/T
model) from crankshaft.
Installation
• Install new flywheel bolts (M/T model) or drive plate
bolts (A/T model).
• Install special tool in ring gear teeth to lock flywheel
(M/T model) or drive plate (A/T model) as shown in
figure.
Special tool
(A): 09924M17811
• Tighten flywheel bolts (M/T model) or drive plate bolts
(A/T model) to specified torque.
Tightening torque
Flywheel bolt (a): 83 N·m (8.5 kgf-m, 61.0 lbf-ft)
Drive plate bolt (a): 83 N·m (8.5 kgf-m, 61.0 lbf-ft)
IBP50A140022-02

Cylinder Disassembly and Reassembly
AENFL80B1416036
Disassembly
1) Using a piston ring expander, remove two
compression rings (1st and 2nd) and oil ring from
piston.
I8C50A140046-01
2) Remove piston pin from connecting rod as follows.
a) Remove piston pin circlips (1), as shown.
Flywheel / Drive Plate Inspection
AENFL80B1416023
Visual Inspection
• If ring gear is damaged, cracked or worn, replace
flywheel (M/T model) or drive plate (A/T model).
• If the surface contacting clutch disc is damaged or
excessively worn, replace flywheel (M/T model).
Flywheel / Drive Plate Face Runout

Check flywheel (M/T model) or drive plate (A/T model)
face runout with a dial gauge.
If runout exceeds its limit, replace flywheel or drive plate.
I2RH0B140113-01
Flywheel / drive plate face runout b) Remove piston pin.
Limit: 0.2 mm (0.0079 in.)
I2RH0B140114-01
Reassembly 3) Install piston rings to piston noting the following.

• As shown in figure, 1st and 2nd rings have top
NOTICE
mark (1) respectively. When installing these piston
The engine will seize up if it is operated when rings to piston, top mark side of each ring upward.
the parts listed below are not properly
• 1st ring (2) differs from 2nd ring (3) in thickness,
lubricated.
shape and color of surface contacting cylinder
Lubricate all the friction surfaces of these
wall.
parts with engine oil before installing them.
Refer to the figure to distinguish 1st ring from 2nd
• Cylinder wall ring.
• Piston • When installing oil ring (4), install spacer first and
• Piston pin then two rails.
• Piston ring
• Connecting rod small-end bore
1) Remove carbon deposits from piston head and ring

grooves using a suitable tool. 1
2) Install piston pin to piston (1) and connecting rod (2)

as follows.
a) Apply engine oil to piston pin and piston pin
1
holes in piston and connecting rod.
2
b) Fit connecting rod as shown in figure.
NOTE 3
Position front mark (4) on piston and oil hole
(5) of connecting rod at specified position as 4
shown in figure.
I8T401142098-02
c) Insert piston pin to piston and connecting rod. 4) After installing three rings (1st, 2nd and oil rings),
d) Install new piston pin circlips (3). distribute their end gaps as shown in figure.
NOTE
Circlip should be installed with its end gap
facing as shown in figure. Install so that
circlip end gap comes within such range as
indicated by arrow (6).
I9P60A141080-02
4
1. Front mark 4. 2nd ring end gap and oil ring spacer gap
2. Oil ring upper rail gap 5. Oil ring lower rail gap
1
6 3. 1st ring end gap “a”: 45°
“a”
2 3
5
IEL10A141031-01
“a”: 45°
Cylinder, Piston and Piston Ring Inspection Piston diameter

AENFL80B1416037 As shown in figure, piston diameter should be measured
at specified position “a” 9.0 mm (0.3543 in.) from piston
Cylinder skirt end in the direction perpendicular to piston pin.
Visual inspection
Check cylinder walls for scratches, roughness or ridges Piston diameter specification
which indicate excessive wear. If cylinder bore is very Standard size (used piston): 72.978 – 72.990 mm
rough, deeply scratched or ridged, replace cylinder (2.8732 – 2.8736 in.)
block, piston rings and/or pistons. Standard size (new piston with coating): 72.984 –
73.016 mm (2.8734 – 2.8746 in.)
Cylinder bore diameter, taper and out-of-round
Using a cylinder gauge, measure cylinder bore in thrust
and axial directions at two positions (“a” and “b”) and
cylinder taper (“c” and “d”) as shown in figure.
If any of the following conditions is found, replace
cylinder block.
“a”
• Cylinder bore diameter exceeds limit.
IEL10A141032-01
• Difference of measurements at two positions exceeds
“a”: 9.0 mm (0.3543 in.)
taper limit.
• Difference between thrust and axial measurements Piston clearance
exceeds out-of-round limit. Measure cylinder bore diameter and piston diameter to
Cylinder bore diameter find their difference which is piston clearance. Piston
Standard: 73.000 – 73.014 mm (2.8740 – 2.8746 in.) clearance should be within specification. If it is not as
Limit: 73.056 mm (2.876 in.) specified, replace cylinder block, piston rings and/or
pistons.
Cylinder taper and out-of-round
Limit: 0.010 mm (0.0004 in.) NOTE
Cylinder bore diameters used here are
measured in thrust direction at two positions.
Piston clearance
Limit: 0.139 mm (0.0055 in.)
I7V20A141095-01
“e” “f”
“c”
I7V20A141095-01
“d”
“b”
“a”
I9P60A141081-01
“e”: 50 mm (1.96 in.) “f”: 100 mm (3.94 in.)

“a”
Piston IEL10A141032-01
Visual inspection
“a”: 9.0 mm (0.3543 in.)
Check piston for faults, cracks or other damages.
Damaged or faulty piston should be replaced. Ring groove clearance
1) Before checking, piston grooves must be clean, dry
and free from carbon deposits.
2) Fit new piston ring (1) into piston groove, and Piston Pin and Connecting Rod Inspection
measure clearance between ring and ring land using AENFL80B1416038
feeler gauge (2). If clearance is out of limit, replace

Piston Pin
piston.
Visual inspection
Ring groove clearance Check piston pin, connecting rod small-end bore and
Standard Limit piston pin hole in piston for wear or damage, paying
0.03 – 0.07 mm particular attention to condition of small-end bore
1st ring 0.12 mm (0.0047 in.)
(0.0012 – 0.0028 in.) bushing. If piston pin, connecting rod small end bore or
0.02 – 0.06 mm piston pin hole in piston is badly worn or damaged,
2nd ring 0.10 mm (0.0039 in.)
(0.0008 – 0.0023 in.) replace pin, connecting rod and/or piston.
0.03 – 0.13 mm
Oil ring —
(0.0012 – 0.0051 in.) Piston pin clearance
Check piston pin clearance in small-end and piston.
Replace connecting rod and/or piston if its small end is
badly worn or damaged or if measured clearance
exceeds limit.
1
Piston pin clearance in connecting rod small-end
Standard: 0.003 – 0.018 mm (0.00012 – 0.00070 in.)
Limit: 0.018 mm (0.00070 in.)
2
Piston pin clearance in piston
Standard: 0.006 – 0.016 mm (0.00024 – 0.00062 in.)
Limit: 0.016 mm (0.00062 in.)
Small-end bore
IEL10A141033-01 18.003 – 18.013 mm (0.7088 – 0.7091 in.)
Piston Ring Piston pin outside diameter

Piston ring end gap 17.995 – 18.000 mm (0.70847 – 0.70866 in.)
To measure end gap, insert piston ring (1) into cylinder Diameter of piston pin hole in piston
bore and then measure the gap using feeler gauge (2). 18.006 – 18.011 mm (0.70890 – 0.70909 in.)
If measured gap exceeds limit, replace ring.
NOTE
Remove carbon deposit from top of cylinder
bore before inserting piston ring.
Piston ring end gap

Item Standard Limit
0.15 – 0.27 mm
Top ring 0.7 mm (0.0276 in.)
(0.0059 – 0.0106 in.)
0.28 – 0.41 mm
2nd ring 1.0 mm (0.0394 in.)
(0.0110 – 0.0161 in.)
0.10 – 0.40 mm
Oil ring 1.2 mm (0.0472 in.)
(0.0039 – 0.0157 in.)
I4RS0A140023-01
"a"
1
I7V20A141096-02
“a”. 50 mm (1.97 in.)

Connecting Rod
Big-end side clearance 1 “c” “d”
Check big-end of connecting rod for side clearance, with

rod fitted and connected to its crankshaft pin in a normal
manner. If measured clearance exceeds its limit, replace
connecting rod.
“a”
Big-end side clearance
Standard: 0.1 – 0.3 mm (0.0039 – 0.0118 in.) “b”
Limit: 0.55 mm (0.0217 in.)
I9P60A141082-01
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.)
I4RH01140053-01
Connecting rod bolt deformation

Measure each thread diameter of connecting rod bolt (1)
at “c” on 12 mm (0.47 in.) from bolt mounting surface
and “d” on 32 mm (1.26 in.) from bolt mounting surface
using a micrometer (3).
Calculate difference in diameters (“c” – “d”). If it exceeds
limit, replace connecting rod bolt (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.)
Main Bearing, Crankshaft and Cylinder Block Components

AENFL80B1416040
(c) 2
16
OIL
3
[A]
(d)
17
(b)
4 18
14
7
OIL
6 (a)
14 5 1217G
OIL
12 13
(b)
OIL
OIL
8 9
OIL
10
15
11
(b)
IEL10A141028-01
[A]: M/T model 12. Crankshaft timing sprocket key

1. CKP sensor 13. Rear oil seal
: For removal and installation, refer to “CKP Sensor Removal and Installation”: : Apply engine oil to oil seal lip.
Petrol and Bi-Fuel CNG in Section 1C in related manual.
2. Knock sensor 14. Dowel pin
: For removal and installation, refer to “Knock Sensor Removal and Installation”:
Petrol and Bi-Fuel CNG in Section 1C in related manual.
3. Cylinder block 15. Spring pin
: Do not apply engine oil to main bearing seating face.
: Apply engine oil to sliding surface
4. Timing chain oil jet 16. Water jacket spacer
5. Engine rear crankshaft oil seal housing 17. Flywheel
: Apply sealant 99000-31260 referring to “Main Bearing, Crankshaft and Cylinder
Block Removal and Installation”: Petrol and Bi-Fuel CNG (Page 1D-21).
6. Main bearing cap bolt 18. Pilot bearing
: Check main bearing cap bolt for deformation to reuse. 
: Apply engine oil to bolt thread and seat.
: For tightening order, refer to “Main Bearing, Crankshaft and Cylinder Block
Removal and Installation”: Petrol and Bi-Fuel CNG (Page 1D-21).
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 : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: Install thrust bearing with oil grooves facing out.
: Apply engine oil to sliding surface.
10. Main bearing : 70 Nm (7.1 kgf-m, 52.0 lbf-ft)
: For applying engine oil, refer to “Main Bearing, Crankshaft and Cylinder Block
Removal and Installation”: Petrol and Bi-Fuel CNG (Page 1D-21).
11. Sensor plate : Do not reuse.

Removal and Installation
AENFL80B1416041
Removal
1) Remove engine assembly from vehicle. (Page 1D-
10)
2) Remove water jacket spacer (1) from cylinder block
(2).
1
1
I7V20A141105-01
2 6) Remove main bearing cap bolts in numerical order

gradually as shown in figure.
“7” “9” “5”
“3” “1”
IDP70P141022-01
3) Remove flywheel (M/T model) or drive plate (A/T

model). (Page 1D-14)
“4” “2”
4) Remove pistons and connecting rods. 
5) Remove engine rear crankshaft oil seal housing (1). “8” “10” “6”
I9P60A141012-01
7) Remove crankshaft from cylinder block.

8) Remove sensor plate from crankshaft, if necessary.
Installation 2) Install main bearings to cylinder block and main

bearing cap.
NOTICE
NOTE
• The engine will seize up if it is operated
when the parts listed below are not • Install main bearing halves with oil groove
properly lubricated. to cylinder block.
Lubricate all the friction surfaces of these • Install other main bearing halves to main
parts with engine oil before installing bearing cap.
them.
– Crankshaft journal a) Fit the tab (1) on each bearing into recess (2) in
– Main bearing cylinder block and main bearing cap.
– Thrust bearing b) Press bearing end (3) until it fully seats in
cylinder block and main bearing cap.
• Using main bearing cap bolts that are
deformed exceeding the service limit could c) Apply engine oil to sliding surface (4) of main
lead to engine problems. bearing halves.
When main bearing cap bolts are reused, NOTICE
check that main bearing cap bolts are not
deformed exceeding the service limit If oil is present between the bearing’s outside
referring to “Main Bearing Cap Bolt” under surface (5) and the cylinder block or main
“Main Bearing Inspection”: Petrol and Bi- bearing cap surface, the bearing could heat
Fuel CNG in related manual. up to very high temperature, resulting in
seizure.
1) Install sensor plate (1) using the following procedure, Thoroughly wipe off any trace of oil that is
if removed. present between the bearing’s outside
surface and the cylinder block or main
a) Attach spring pin (2) to crankshaft (3).
bearing cap surface.
b) Install sensor plate to crankshaft, spring pin into
hole (4) and facing inside edge (5) outward as
shown in figure.
c) Tighten bolts to specified torque.
Tightening torque 1 3
4
Sensor plate bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-
ft)
2
6 5
3 I8T401142036-01
3) Install thrust bearings (1) to cylinder block between

5 1 No.2 and No.3 cylinders.
(a) NOTE
Face oil groove (2) side to crank web.
(a)
2 4) Check that dowel pins (3) are installed to intake side
4 of each journal.
1
(a)
IAP70B140038-01
6. Crankshaft side
2
1 3
I7V20A141108-01
5) Install crankshaft to cylinder block.

6) Install bearing cap to cylinder block, pointing arrow 11) Install dowel pin (2) to engine rear crankshaft oil seal
mark (on each cap) to crankshaft pulley side. Fit housing (1) as shown in figure.
them in numerical order (1 – 4 and R), starting from 12) Apply sealant to mating surface of engine rear
pulley side. crankshaft oil seal housing (1).
7) After applying engine oil to main bearing cap bolts
(“1” – “10”), tighten them as follows.
No.1217G)
a) Tighten bolts to 20 Nm (2.0 kgf-m, 15.0 lbf-ft) in
numerical order as shown in figure using a 12- Sealant amount for rear oil seal housing
point socket wrench. Width: “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
b) In the same manner as in Step a), tighten them
to 40 Nm (4.0 kgf-m, 29.5 lbf-ft).
“a”
c) In the same manner as in Step a), retighten them “A” “b”
to 60°.
Tightening torque
“A”
Main bearing cap bolt*: 20 Nm → 40 Nm →
+60° (2.0 kgf-m → 4.0 kgf-m →+60°, 14.5 lbf-ft 1
→ 29.0 lbf-ft →+60°)
“4” “2” “6” 2
“8” “10”
I7V20A141111-01
13) Apply engine oil to oil seal lip, and then install engine
rear crankshaft oil seal housing (1) using special
tool.
“7” “9”
14) Tighten new engine rear crankshaft oil seal housing
bolts (2) to specified torque.
NOTE
“3” “1” “5”
I9P60A141013-01 Check that engine rear crankshaft oil seal lip
8) Check that crankshaft rotates smoothly when turning is not turned over after engine rear
it by 12 Nm (1.2 kgf-m, 9.0 lbf-ft) torque or below. crankshaft oil seal housing is installed.
9) Clean sealing surface between engine rear
crankshaft oil seal housing (2) and cylinder block. Special tool
(A): 09911M97720
10) Apply engine oil to new rear oil seal (1) and install it
to engine rear crankshaft oil seal housing (2) using Tightening torque
special tool. Engine rear crankshaft oil seal housing bolt (a):
11 N·m (1.1 kgf-m, 8.5 lbf-ft)
Special tool
(A): 09914M87110
(A)
Engine rear crankshaft oil seal installing position 3
(depth)
“a”: 1.0 mm (0.04 in.)
1
(A)
(A)
2,(a)
(A) 1
“a” I7V20A141112-01
3: Crankshaft side
2
15) Install flywheel (M/T model) or drive plate (A/T
2 1 model). (Page 1D-14)
16) Install pistons and connecting rods. 
I7V20A141110-01
17) Install water jacket spacer to cylinder block.
18) Install cylinder head. 
19) Install camshafts and tappets.  Replace water jacket spacer if defective.
20) Install timing chain. 
21) Install timing chain cover. 
22) Install cylinder head cover. (Page 1D-7)
23) Install oil pan. (Page 1E-4)
24) Install engine assembly to vehicle. (Page 1D-10)
Water Jacket Spacer Inspection

AENFL80B1416047
IDP70P141023-01
Check water jacket spacer for crack, deformation or
other damage.
Specifications
AENFL80B1417002
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
Air cleaner outlet hose clamp bolt 1.3 0.13 1.0 
Cylinder head cover bolt* 3.0 Nm → 5.0 Nm → 7.5 Nm (0.31 kgf-m 
→ 0.51 kgf-m→ 0.76 kgf-m, 2.5 lbf-ft → 4.0
lbf-ft → 5.5 lbf-ft)
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 
Flywheel bolt 83 8.5 61.0 
Drive plate bolt 83 8.5 61.0 
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 
Reference:
“Air Cleaner Components”: Petrol and Bi-Fuel CNG
“Cylinder Head Cover Components”: Petrol and Bi-Fuel CNG
“Engine Mounting Components”: Petrol and Bi-Fuel CNG
“Timing Chain Cover Components”: Petrol and Bi-Fuel CNG
“Main Bearing, Crankshaft and Cylinder Block Components”: Petrol and Bi-Fuel CNG

AENFL80B1418003
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 /
NOTE
Required service material(s) is also described in:
“Cylinder Head Cover Components”: Petrol and Bi-Fuel CNG
“Timing Chain Cover Components”: Petrol and Bi-Fuel CNG
“Main Bearing, Crankshaft and Cylinder Block Components”: Petrol and Bi-Fuel CNG
Special Tool
AENFL80B1418004
09911M97720 09914M87110
Oil seal installer Oil seal installer
 
09915M64512 09915M64530
Compression gauge Compression gauge hose
 
09915M64550 09915M67311
Compression gauge Vacuum gauge
attachment (B)
 
09924M17811
Flywheel holder
/
1D-26 Engine Mechanical: Diesel
Diesel
Timing Check
AENFL80B1424002
Check timing between camshafts and crankshaft as
follows.
2) Remove right side engine undercover.
3) Remove common rail. (Page 1G-23)
4) Remove engine hook (1) and common rail bracket
(2) from camshaft housing.
(A)
I9P60A142001-01
2
[A] [B]
“a” 2 2
“b”
1 1
I3RB0A143007-01
5) Disconnect wiring harness connectors of injectors,

(A)
CMP sensor and glow plugs.
(A)
6) Remove camshaft housing plugs (1).
7) Align camshaft housing plug hole (2) with camshaft I7V20A142002-01
gap (3) by turning crankshaft pulley clockwise as [A]: Proper position “a”: 2 mm (0.079 in.)
shown in figure. [B]: Improper position “b”: 10 mm (0.394 in.)
8) Lock camshafts (4) by inserting special tools (A) to 2. Flywheel
plug holes.
10) After checking, remove all special tools inserted in
Special tool Step 8) – 9).
(A): 09917M68610
11) Apply thread lock compound to thread part of
camshaft housing plugs (1), and tighten camshaft
2
(A) housing plugs to specified torque.
“A”: Thread lock cement (Loctite omnifit 100M
spezial®)
4
3
(A)
Tightening torque
1
(A) Camshaft housing plug (a): 18 N·m (1.8 kgf-m,
13.5 lbf-ft)
1
1, “A”, (a)
I3RB0A143010-01
9) Insert special tool to hole of transaxle case (1) while

lightly swing crankshaft pulley by hand.
Check that special tools can be inserted in proper
position as shown in figure.
1, “A”, (a)
Special tool
(A): 09912M46310
I3RB0A143031-03
If not, adjust timing by reinstalling timing chain.
(Page 1D-41) 12) Connect wiring harness connectors of injectors,
CMP sensor and glow plugs.
Engine Mechanical: Diesel 1D-27
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): 22 N·m (2.2 kgf-
m, 16.5 lbf-ft)
1 (a)
(a)
I3RB0A143034-01
14) Install common rail. (Page 1G-23)

15) Install right side engine undercover.
17) Check for fuel leakage: 
Repair Instructions
Air Cleaner Components
AENFL80B1426001
10
12
(a)
7 (b)
3
6 2
[A] 1
13
(a) 11
5
IFL80B142001-06
[A]: ISG model 6. Air cleaner outlet hose 12. To engine

1. Air cleaner assembly 7. Hose clamp 13. Air cleaner filter
:Be sure to position clamp screw in
specified place as shown in the
figure.
2. Air cleaner mounting bolt 8. Breather hose : 1.5 Nm (0.15 kgf-m, 1.1 lbf-ft)
3. MAF sensor 9. Breather hose clip : 3.5 Nm (0.36 kgf-m, 2.5 lbf-ft)
:Be sure to position clip in specified
direction as shown in the figure.
4. MAF sensor O-ring 10. Breather pipe : Do not reuse.
5. Air cleaner bracket 11. To turbocharger
Intercooler Components
AENFL80B1426005
11 (a)
8
11 (a)
14
9 13
11 (a)
11 (a)
11 (a)
3
12
5
11 (a)
2 10
11 (a)
IFL80B142002-03
1. Intercooler 7. Intercooler outlet No.1 hose 13. To intake manifold

2. Intercooler bolt 8. Intercooler outlet No.2 hose 14. Air intake joint
3. Intercooler inlet No.1 hose 9. Intercooler outlet pipe : 4.0 Nm (0.41 kgf-m, 3.0 lbf-ft)
4. Intercooler inlet No.2 hose 10. Intercooler mounting : Do not reuse.
5. Intercooler inlet pipe 11. Hose clamp
: Position clamp screw in specified position
as shown in figure
6. Cross member 12. To turbocharger
Turbocharger and Exhaust Manifold Components

AENFL80B1426009
IDL10A140012-02
1. Turbocharger 7. Catalytic converter : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)

2. Gasket 8. Exhaust manifold gasket : 30 Nm (3.1 kgf-m, 22.5 lbf-ft)
3. Lock plate 9. Exhaust manifold cover : 15 Nm → +30° (1.5 kgf-m → +30°, 11.0
: Bend lock part to prevent catalytic converter bolt lbf-ft → +30°)
from loosening.
4. Turbocharger lubrication pipe 10. Spacer : 45 Nm (4.6 kgf-m, 33.5 lbf-ft)
5. Oil return pipe : 25 Nm (2.5 kgf-m, 18.5 lbf-ft) : Do not reuse.
6. Exhaust manifold : 22 Nm (2.2 kgf-m, 16.5 lbf-ft)
Turbocharger Inspection 4) Measure stroke of boost pressure control valve rod

AENFL80B1426011 “a” (3) when applying vacuum of –60 kPa (–0.61 kgf/
cm2, –8.70 psi, –0.60 bar).
Visual Inspection
Rotate turbine shaft (1) by hand and check that it turns Boost pressure control valve rod stroke:
smoothly without any abnormal noise and excessive “a”: 6.7 to 7.7 mm (0.264 to 0.303 in.) when
runout. pressure is changed from –30 kPa (–0.31 kgf/
If a malfunction is found, replace the turbocharger. cm2, –4.35 psi, –0.30 bar) to –60 kPa (–0.61 kgf/
cm2, –8.70 psi, –0.60 bar)
2
3
1 1
I7V20A142024-01
Boost Pressure Control Valve

1) Set magnetic base with dial gauge (1) as shown in [a]
figure.
2) Connect special tool to boost pressure control valve [b]
(2). “a”
Special tool IDL10A140024-01
(A): 09917M47011 [a]: Boost pressure control valve rod position at –30 kPa (–0.31 kgf/cm2, –
4.35 psi, –0.30 bar)
3) Apply vacuum of –30 kPa (–0.31 kgf/cm2, –4.35 psi, [b]: Boost pressure control valve rod position at –60 kPa (–0.61 kgf/cm2, –
–0.30 bar). 8.70 psi, –0.60 bar)
Intake Manifold Components

AENFL80B1426013
6
6
(b)
1
7 (a)
IDL10A140029-01
1. Intake manifold 5. Harness bracket : 2.0 Nm (0.20 kgf-m, 1.5 lbf-ft)
2. Boost Pressure Sensor with IAT Sensor-2 6. Intake manifold gasket : Do not reuse.
3. EGR pipe 7. Intake manifold bolt
: For tightening order, refer to “Intake Manifold Removal
and Installation (ISG Model)”: Diesel (Page 1D-33).
4. EGR pipe gasket : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
Intake Manifold Removal and Installation (ISG

2 1
Model)
AENFL80B1426014
Removal
2) Remove ISG. (Page 1J-27)
3) Remove ECM. 
4) Remove cowl top panel. 
5) Remove engine cover.
6) Remove intercooler outlet pipe. (Page 1D-29) I9P60A142038-01
7) Remove EGR valve assembly.  12) Remove intake manifold (1) and gasket from cylinder
8) Remove harness clamp (1) with wire harness from head.
intake manifold.
1
1
I5RS0B140019-01
9) Remove oil separator bolt (1) from intake manifold.
I9P60A142040-01
Installation
• Clean mating surfaces of intake manifold and cylinder
head.
• Use new gasket for intake manifold, air intake joint
and EGR pipe.
• Tighten intake manifold bolts in numerical order
evenly and gradually to specified torque.
I9P60A142025-01
Tightening torque
10) Remove oil level gauge guide (2) with level gauge. Intake manifold bolt* (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)
11) Disconnect connector from boost pressure sensor
(3).
Crankshaft Oil Seal Replacement (ISG Model)

“9”,(a) “5”,(a) “1”,(a) “4”,(a) “8”,(a) AENFL80B1426015
1) Remove front-right wheel. (Page 2D-1)
2) Remove right engine undercover.
3) Remove ISG drive belt. (Page 1J-25)
4) Remove crank pulley (1).
“7”,(a) “3”,(a) “2”,(a) “6”,(a)

I9P60A142041-01
• Tighten oil level gauge guide mounting bolt to

specified torque.
1
Tightening torque IFL10A140009-02
Oil level gauge guide mounting bolt (a): 9.0 N·m ( 5) Remove engine cover. (Page 1D-29)
0.92 kgf-m, 7.0 lbf-ft)
6) Lock camshaft and flywheel referring to Steps 4) – 8)
1
under “Timing Check”: Diesel (Page 1D-26).
7) Install special tool to crankshaft pulley flange.
NOTE
Use bolt (1) that comes with special tool.
Special tool
(A): 09910M95020
(a)
I9P60A142042-01
• Tighten oil separator bolts to specified torque.

Tightening torque
Oil separator bolt (a): 9.0 N·m (0.92 kgf-m, 7.0 lbf-
ft)
(A)
IEL10A142002-02
(a)
IFL10A140008-01
• Check that all removed parts are back in place.

Reinstall any necessary parts which have not been
reinstalled.
8) Loosen crankshaft pulley flange bolt (1) by turning it 10) Install new oil seal (1) using special tool.
clockwise, and then remove crankshaft pulley flange.
Special tool
NOTE (A): 09913M75510
Turn crankshaft pulley flange bolt clockwise
to loosen it.
(A)
IEL10A142005-01
11) Apply engine oil to oil seal lip.

12) Install crankshaft pulley flange and special tool.
IEL10A142003-01 13) Tighten new crankshaft pulley flange bolt (1) to
9) Using flat-bladed screwdriver (1) or the like, remove specified torque by turning it counterclockwise.
crankshaft oil seal (2).
Tightening torque
NOTICE Crankshaft pulley flange bolt* (a): 50 Nm →
+90° (5.1 kgf-m → +90°, 37.0 lbf-ft → +90°)
Damage to timing chain cover may result in
oil leakage.
When removing the crankshaft oil seal, wrap
the tip of flat-bladed screwdriver or the like 1, (a)
with protective tape (3) to prevent the timing
chain cover from being damaged.
3 2
IEL10A142004-02 IEL10A142006-01
4. Wooden block or like

14) Remove special tool from crankshaft pulley flange. 10) Drain transaxle oil, if necessary. (Page 5B-32)
11) Drain cooling system. 
NOTE
12) Take out clutch fluid from brake master reservoir (1)
Install removed bolts (1) to special tool.
in space (A) as shown in the figure with syringe or
such.
! WARNING
Do not allow fluid to get on painted surface. It
1 may cause painted surface damage.
IEL10A142007-01
1
15) Remove special tools installing Step 6), and then
install removed parts referring to Steps 10) – 11) “A”
under “Timing Check”: Diesel (Page 1D-26).
16) Install engine cover. (Page 1D-29)
2
17) Install crankshaft pulley (1) and tighten crankshaft
pulley bolts (2) to specified torque.
Tightening torque
Crankshaft pulley bolt (a): 30 N·m (3.1 kgf-m, I5RS0B140024-01
22.5 lbf-ft)
13) Remove right and left side engine undercovers.
14) Remove turbocharger oil intake pipe. (Page 1D-
30)
1 15) Remove water pump drive belt. (Page 1F-10)
2, (a) 16) With A/C hose connected, detach A/C compressor
from its bracket. Using a rope, hold A/C compressor
in a place where no damage will be caused.
• Auto A/C model: 
IFL10A140010-01
! CAUTION
18) Install ISG drive belt. (Page 1J-25) Suspend removed A/C compressor at a place
19) Start engine and check for oil leakage. If leakage is where no damage will be caused during
found, repair leaky point. removal and installation of engine assembly.
20) Install right engine undercover.
17) Disconnect the following pipes and hoses:
21) Install front-right wheel. (Page 2D-1)
• Brake booster hose (1)
• Fuel feed hose (2)
Engine Assembly Removal and Installation (ISG
Model) • Fuel return hose (3)
AENFL80B1426017 • Radiator inlet hose (4) and outlet hose (5)
Removal
• Heater inlet hose (6) and outlet hose (7)
1) Disconnect negative (–) and positive (+) cable at
battery. • Clutch hose and pipe (8)
2) Remove battery and battery tray from vehicle. 18) Disconnect the following cables from transaxle.
(Page 1J-24) • Gear select control cable (9)
3) Remove coolant reservoir. • Gear shift control cable (10)
4) Remove engine cover. (Page 1D-29)
5) Remove air cleaner assembly with MAF sensor with
IAT sensor-1. 
6) Remove intercooler. 
7) Remove ECM. 
8) Remove cowl top panel. 
9) Drain engine oil. (Page 1E-11)
7 1 6 2 1 3
4 8
5 4 8 10
I9P60A142044-02
19) Disconnect the following electric wires and clamps:

• Ground wire (1)
• Electric load current sensor connector (2)
6
• Individual circuit fuse box No. 1 (3)
• Main fuse box (4)
7
• Magnet clutch switch of A/C compressor (if
equipped)
• Main harness (5) 5
• Each wire harness clamps (6) I9P60A142045-03
• Glow plug control module (7)  20) Remove exhaust No.1, No. 2 and center pipes. 
21) Disconnect steering lower shaft from pinion shaft.
(Page 6B-7)
22) Remove stabilizer joints from stabilizer bar. 
23) Disconnect tie-rod end from steering knuckle. 
24) Disconnect right and left drive shaft joints from
steering knuckle. (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).
3 2 2
4
4
1
I9P60A142063-01
27) Remove engine left mounting bracket nuts (1) and

bolts (2).
1
I9P60A142047-01
2
29) Before removing engine, make sure all hoses,
electric wires and cables are disconnected from
engine.
30) Lower engine with transaxle, front suspension frame,
drive shafts and P/S gear case assembly all
together.
! CAUTION
Before lowering the engine, in order to avoid
31) Disconnect engine harness from engine and

1
transaxle, if necessary.
2 1
32) Remove front drive shaft assembly, if necessary.
(Page 3A-3)
33) Remove front suspension frame, if necessary.
34) Disconnect transaxle from engine, if necessary.
(Page 5B-33)
35) Remove clutch cover and clutch disc. 
I9P60A142046-01
28) Remove engine right mounting bracket nuts (1).

Installation
2, (b)
1) Install clutch cover and clutch disc. 
2) Connect transaxle to engine, if removed. (Page
5B-33)
3) Install front suspension frame, if removed. 
4) Install front drive shaft assembly, if removed.
(Page 3A-3)
5) 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-
m, 8.5 lbf-ft)
1, (a)
2, (b) 1, (a)
1, (a)
I9P60A142064-01
3, (c)
6) Lift up engine with transaxle into engine
compartment using chain hoist.
! CAUTION
Before lowering the engine, in order to avoid
7) Install engine left mounting bracket nuts (1), bolts (2)

and engine right mounting bracket nuts (3). Tighten
them to specified torque.
Tightening torque
Engine left mounting bracket nut (a): 55 N·m (
5.6 kgf-m, 40.5 lbf-ft)
Engine left mounting bracket bolt (b): 55 N·m ( I9P60A142049-03
5.6 kgf-m, 40.5 lbf-ft) 8) Tighten suspension frame bolts to specified torque.
Engine right mounting bracket nut (c): 55 N·m ( 
5.6 kgf-m, 40.5 lbf-ft)
9) Connect right and left drive shaft joints to steering
knuckle. (Page 3A-3)
10) Connect tie-rod end to steering knuckle. 
11) Install stabilizer joints to stabilizer bar. 
12) Connect steering lower shaft to pinion shaft. (Page
6B-7)
13) Install exhaust pipe No.1 and No. 2. 
14) Install A/F sensor. 
15) Reinstall disconnected hoses, cables and electric
wires.
Tightening torque 23) Install air cleaner assembly with MAF sensor with
Engine rear mounting bush bolt: 55 N·m (5.6 IAT sensor-1. 
kgf-m, 40.5 lbf-ft) 24) Install engine cover.
16) Install A/C compressor to its bracket. 25) Refill engine with engine oil. (Page 1E-11)
• Single A/C model: (Page 7B-18) 26) Refill transaxle with transaxle oil. (Page 5B-32)
• Dual A/C model:  27) Refill cooling system with coolant. 
17) Install water pump drive belt. (Page 1F-10) 28) Refill clutch system with clutch fluid and bleed the
18) Install right and left side engine undercovers. system. 
19) Install intercooler.  29) Install battery tray and battery. (Page 1J-24)
20) Install front bumper. (Page 9H-1) 30) Connect positive (+) and negative (–) cables at
battery.
21) Install cowl top panel. 
31) Check any leakage of fuel, coolant, oil and exhaust.
22) Install ECM. 
• Fuel leakage: 
• Coolant leakage: 
Timing Chain Cover and Timing Chain Components (ISG Model)

AENFL80B1426018
14
13 (b)
(e)
OIL
7 (a)
(a)
17
3
11
(a)
OIL
10
(d) 12
OIL
4 15
6
4 8
OIL
5 2
(c)
1
(a)
16 (f)
IFL10A140012-01
1. Crankshaft pulley 9. Timing chain guide 17. Crankshaft timing sprocket

2. Crankshaft pulley side crankshaft oil seal 10. Timing chain tensioner : 9.0 Nm (0.92 kgf-m, 7.0 lbf-
: Apply engine oil to oil seal lip. : Apply engine oil to sliding surface. ft)
3. Timing chain cover 11. Timing chain tensioner adjuster : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
4. Crankshaft sprocket shim 12. Flywheel : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
5. Crankshaft pulley flange 13. Camshaft housing plug : 30 Nm (3.1 kgf-m, 22.5 lbf-ft)
: Apply Loctite omnifit 100M spezial® to thread parts.
6. Timing chain cover gasket 14. Ventilation connector : 44 Nm (4.5 kgf-m, 32.5 lbf-ft)
7. Timing chain 15. Camshaft housing / cylinder head / cylinder block : 50 Nm → +90° (5.1 kgf-m →
: Apply engine oil. : Apply sealant 99000-85E11 to mating surfaces. +90°, 37.0 lbf-ft → +90°)
8. Crankshaft timing sprocket 16. Crankshaft pulley flange bolt : Do not reuse.
:Turn crankshaft pulley flange bolt clockwise to loosen it.
Timing Chain Cover and Timing Chain Removal 9) Remove water pump. 
and Installation (ISG Model) 10) Remove engine right mounting bracket (1).
AENFL80B1426019
Removal
1) Remove engine assembly from engine
compartment. (Page 1D-36)
1
2) Remove oil pan. (Page 1E-13)
3) Remove ventilation connector (1) and O-ring (2)
from timing chain cover (3).
IFL10A140014-01
11) Remove crankshaft pulley (1).
I7V20A142036-01
1
4) Remove common rail. (Page 1G-23)
5) Remove engine hook (1) and common rail bracket
(2) from camshaft housing.
IFL10A140015-01
2 12) Remove camshaft housing plugs (1).

13) Align camshaft housing plug holes (2) with camshaft
gap (3) by turning crankshaft clockwise as shown in
figure.
14) Lock camshafts (4) by inserting special tools (A) into
I3RB0A143007-01
plug holes.
6) Remove ISG. (Page 1J-27) Special tool
7) Remove ISG drive belt idler pulley. (Page 1J-27) (A): 09917M68610
8) Remove ISG drive belt idler bracket (1).
2
(A)
4
3
1 (A)
(A)
1
I3RB0A143010-01
15) Lock flywheel (1) using special tool (B).

Special tool
(B): 09916M98610
IFL10A140013-01
(C)
(B)
1 2 1
I3RB0A143011-01 I3RB0A143014-01
16) Remove special tools (A) installed in Step 14). 21) Remove timing chain cover (1) and its gasket.
17) Loosen crankshaft pulley flange bolt (1) by turning it
clockwise and remove crankshaft pulley flange (2).
1
NOTE
Turn crankshaft pulley flange bolt clockwise
to loosen it.
I3RB0A143015-01
22) Remove crankshaft pulley side crankshaft oil seal (1)

from timing chain cover (2) using flat-bladed
I3RB0A143012-01 screwdriver (3) or the like, if necessary.
18) Reinstall special tools (A) removed in Step 16).
19) Remove flywheel (1), and then special tool (B)
installed in Step 15). 3 1
I3RB0A143016-01
23) Remove timing chain tensioner adjuster (1).

(B)
24) Remove timing chain tensioner (2).
I3RB0A143013-01 25) Remove timing chain guide (3).
20) Lock crankshaft (1) by installing special tool (C) as 26) Remove timing chain (4) with crankshaft timing
shown in figure. sprocket (5).
NOTE
Align hole (2) of special tool with knock pin
securely.
Special tool
(C): 09912M38300
4
1
1
3
3
2
5
4
5
5 I3RB0A143019-01
6) Insert crankshaft timing sprocket with timing chain

I3RB0A143017-01 into crankshaft.
27) Remove crankshaft sprocket shim, if necessary. 7) Apply engine oil to sliding surface of timing chain
guide (1) and tighten chain guide mounting bolts to
Installation specified torque.
1) Clean mating surfaces on timing chain cover,
Tightening torque
cylinder block, cylinder head, camshaft housing and
Chain guide mounting bolt (a): 9.0 N·m (0.92
flywheel.
kgf-m, 7.0 lbf-ft)
2) Check that special tools (A) and (B) are installed. If
special tool(s) is removed, install special tool(s)
referring to Step 14) and Step 20) of “Removal” in
this procedure. 1
Special tool (a)

(A): 09917M68610
(B): 09912M38300
(A)
I3RB0A143020-01
8) Apply engine oil to sliding surface of timing chain

tensioner (1) and tighten chain tensioner mounting
(A) bolts to specified torque.
(A)
Tightening torque
Chain tensioner mounting bolt (a): 25 N·m (2.5
kgf-m, 18.5 lbf-ft)
(B)
I3RB0A143018-01
3) Install crankshaft sprocket shim, if removed.

4) Install timing chain (1) to camshaft timing sprocket
(2).
(a)
5) Install crankshaft timing sprocket (5) to timing chain
with its long taper side (3) facing outside (4) as I3RB0A143021-01
shown in figure.
9) Push plunger (1) into timing chain tensioner adjuster “A”: Sealant 99000–85E11 (Three Bond TB
body (2) till plunger is held in place as shown in 1227®)
figure.
Sealant amount for timing chain cover
Width “a”: 3 – 4 mm (0.12 – 0.15 in.)
Height “b”: 1.5 – 2 mm (0.06 – 0.07 in.)
2 1
I3RB0A143022-01
10) Install timing chain tensioner adjuster (1) as follows. “a”

a) Tighten upper chain tensioner adjuster mounting
“b”
bolt (2) by hand.
“A”
b) Push tensioner adjuster assembly in arrow
direction as shown in figure, and then tighten
tensioner adjuster bolts to specified torque.
Tightening torque
Chain tensioner adjuster bolt (a): 9.0 N·m (
0.92 kgf-m, 7.0 lbf-ft) IDL10A140048-01
“a”: 3 – 4 mm (0.12 – 0.15 in.) “b”: 1.5 – 2 mm (0.06 – 0.07 in.)
2,(a)
14) Install timing chain cover (1) as follows.
a) Fit timing chain cover and new timing chain
1 cover gasket (2).
b) Install crankshaft pulley flange (3).
c) Tighten timing chain cover bolts and nuts to
specified torque.
Tightening torque
(a) Timing chain cover bolt (a): 9.0 N·m (0.92
I3RB0A143025-01
kgf-m, 7.0 lbf-ft)
11) Apply engine oil to timing chain. Timing chain cover nut (b): 9.0 N·m (0.92
12) Install new crankshaft pulley side crankshaft oil seal kgf-m, 7.0 lbf-ft)
(1) to timing chain cover (2) using special tool (C) as
shown in figure, if removed.
Special tool
(C): 09913M75510
(C)
1
2
I3RB0A143023-01
13) Apply sealant to crankcase side of timing chain

cover gasket as shown in figure.
18) Remove special tools (A) checked in Step 2).

19) Tighten new crankshaft pulley flange bolt (1) to
specified torque by turning it counterclockwise.
1 Tightening torque
2 Crankshaft pulley flange bolt* (a): 50 Nm →
+90° (5.1 kgf-m → +90°, 37.0 lbf-ft → +90°)
(a)
1, (a)
(b)
3 4
I3RB0A143028-01
20) Install crankshaft pulley (1) and tighten crankshaft

pulley bolts (2) to specified torque.
Tightening torque
1
Crankshaft pulley bolt (a): 30 N·m (3.1 kgf-m,
I9P60A142051-01
22.5 lbf-ft)
4. Oil seal
15) Install knock pin (1) to crankshaft (2), if removed.

1
16) Remove special tool (B) checked in Step 2). 2, (a)
17) Install flywheel (3) as follows.
NOTE
If flywheel is replaced, initialize flywheel data
in ECM.
For details, refer to “Flywheel Data
Initialization”: Diesel in Section 1C in related IFL10A140010-01
manual. 21) Remove special tool (D) installed in Step 17).

22) Turn crankshaft clockwise two revolutions.
a) Tighten new flywheel bolts (4) by hand.
23) Lock camshafts (3) by inserting special tools (A) to
b) Lock flywheel using special tool (D). camshaft housing plug holes after aligning camshaft
Special tool housing plug holes (1) with camshaft gaps (2) as
(D): 09916M98610 shown in figure.
c) Tighten flywheel bolts to specified torque. Special tool

(A): 09917M68610
Tightening torque
Flywheel bolt (a): 44 N·m (4.5 kgf-m, 32.5 lbf-
1
ft) (A)
2 3
2
3 (A)
(A)
I3RB0A143029-01
24) Check that special tool (B) can be inserted in holes

4, (a)
of flywheel and cylinder block smoothly.
1 (D) If not, remove timing chain and flywheel and repeat
I3RB0A143027-01
Step 2) – 23).
Special tool 29) Install ISG drive belt idler bracket (1) and tighten ISG
(B): 09912M38300 drive belt idler bracket bolts to specified torque.
Tightening torque
(B)
ISG drive belt idler bracket bolt (a): 55 N·m (5.6
kgf-m, 40.5 lbf-ft)
1
(a)
IBP80A142006-01
25) Remove special tools (A) installed in Step 23) and

(B) installed in Step 24).
26) Apply thread lock cement to thread part of camshaft
housing plugs (1) and tighten camshaft housing
plugs to specified torque.
“A”: Thread lock cement (Loctite omnifit 100M
spezial®)
IFL10A140017-01
Tightening torque 30) Install ISG drive belt idler pulley. (Page 1J-27)
Camshaft housing plug (a): 18 N·m (1.8 kgf-m,
31) Install ISG. (Page 1J-27)
13.5 lbf-ft)
1, “A”, (a) 33) Install common rail bracket (2) and engine hook (1)
to camshaft housing and tighten common rail
bracket bolts to specified torque.
Tightening torque
Common rail bracket bolt (a): 22 N·m (2.2 kgf-
m, 16.5 lbf-ft)
1, “A”, (a)
1 (a)
I3RB0A143031-03 2
27) Install engine right mounting bracket (1) and tighten
engine right mounting bracket No.2 bolts to specified
(a)
torque.
Tightening torque
Engine right mounting bracket No.2 bolt (a): 60
N·m (6.1 kgf-m, 44.5 lbf-ft)
I3RB0A143034-01
34) Install common rail. (Page 1G-23)

35) Install ventilation connector with new O-ring.
1 36) Install engine assembly to engine compartment.
(Page 1D-36)
(a)
(a)
IFL10A140016-01
28) Install water pump. 

Camshaft Housing Components

AENFL80B1426021
(d)
OIL
11 (a) 7
12 (b)
OIL
5
OIL
8
OIL
6
(c)
10
IDL10A140057-01
1. Camshaft housing 7. Intake manifold side camshaft gear : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
: Apply engine oil to gear.
2. Camshaft timing sprocket 8. Exhaust manifold side camshaft gear : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: Apply engine oil to gear.
3. Washer 9. Cylinder head : 150 Nm (15.3 kgf-m, 111.0 lbf-ft)
4. Camshaft housing gasket 10. Knock pin : 15 Nm → 150 Nm (1.5 kgf-m →
: “TOP” mark provided on gasket facing upward. 15.3 kgf-m, 11.0 lbf-ft → 111.0 lbf-ft)
5. Intake manifold side camshaft 11. Camshaft housing bolt : Do not reuse.
: Apply engine oil to sliding surface. : For tightening order, refer to “Camshaft
Housing Assembly Removal and
Installation”: Diesel in related manual.
6. Exhaust manifold side camshaft 12. Camshaft housing stud bolt
: Apply engine oil to sliding surface. : For tightening order, refer to “Camshaft
Housing Assembly Removal and
Camshaft Housing Assembly Disassembly and Special tool

Reassembly (A): 09917M68610
AENFL80B1426023
Disassembly
1) Remove camshaft housing assembly. 
2) Remove vacuum pump. 
3) Remove high pressure pump. (Page 1G-24)
4) Remove CMP sensor. 
5) Remove special tools from camshaft housing.
e) Remove camshafts and camshaft gears.
Reassembly
(A) 1) Apply engine oil to sliding surface of each camshaft
and camshaft housing, and then install intake
manifold side camshaft (1) and exhaust manifold
side camshaft (2) to camshaft housing (3).
NOTE
(A) Identify intake manifold side and exhaust
I3RB0A143049-01 manifold side camshafts by marks shown in
6) Remove camshafts (1), camshaft timing sprocket the figure.
and camshaft gears (2) from camshaft housing as
follows. 1
7 2 3
6
1 1 4
2
I3RB0A143050-01
a) Lock camshaft timing sprocket (1) using special

tool. 5
Special tool
(A): 09917M68222
b) Loosen camshaft gear bolt (2) of intake manifold 2
side. I3RB0A143052-01
c) Loosen camshaft gear bolt (3) of exhaust 4. “LH” mark 6. Crankshaft pulley side
5. “RH” mark 7. Flywheel side
manifold side.
d) Loosen camshaft timing sprocket bolt (4) and
2) Install special tools (A) as follows.
remove camshaft timing sprocket (1).
a) Align camshaft housing plug holes (1) with
camshaft gaps (2) by turning intake manifold
side and exhaust manifold side camshafts as
1 shown in figure.
b) Lock camshafts (3) by inserting special tools (A)
4 into plug holes.
Special tool
(A): 09917M68610
(A)
3 2
I3RB0A143051-01
Tightening torque
1
Camshaft timing sprocket bolt (a): 150 N·m (
(A) 15.3 kgf-m, 111.0 lbf-ft)
c) Tighten exhaust manifold side camshaft gear
3 bolt (3) and intake manifold side camshaft gear
2
bolt (4) to 15 Nm (1.5 kgf-m, 11.0 lbf-ft).
d) Retighten exhaust manifold side camshaft gear
bolt and intake manifold side camshaft gear bolt
to 150 Nm (15.3 kgf-m, 111.0 lbf-ft).
(A) Tightening torque
Camshaft gear bolt* (b): 15 Nm → 150 Nm
3
(A) (1.5 kgf-m → 15.3 kgf-m, 11.0 lbf-ft → 111.0
lbf-ft)
3
I3RB0A143053-01
1
3) Install intake manifold side camshaft gear (1) and
exhaust manifold side camshaft gear (2) to camshaft
2, (a)
housing and tighten camshaft gear bolts (3) by hand.
NOTE
Identify intake and exhaust side camshaft
gears by punched marks shown in figure.
(A)
4 5
2 3, (b) 4, (b)
I3RB0A143055-01
5) Install CMP sensor. 

6) Install high pressure pump. (Page 1G-24)
3 7) Install vacuum pump. 
8) Install camshaft housing assembly. 
Camshaft Inspection
1 AENFL80B1426024
IDL10A140049-02
4. “IN” mark 5. “EX” mark Camshaft

• Check journals and cam faces for wear or damage.
4) Tighten camshaft timing sprocket bolt and camshaft If any defect is found, replace camshaft.
gear bolts as follows. • Check CMP sensor pickup for missing, damage or
a) Lock camshaft timing sprocket (1) using special deformation.
tool. If any defect is found, replace camshaft.
Special tool
(A): 09917M68222
b) Install camshaft timing sprocket and tighten
camshaft timing sprocket bolt (2) to specified
torque.
If measured diameter is not as specified, 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.)
I3RB0A143056-01
Camshaft Journal
Check camshaft journal diameter using micrometer.
If measured diameter is not as specified, replace
camshaft. 3 2 1
Camshaft journal diameter

No.1: 38.500 – 38.515 mm (1.5158 – 1.5163 in.)
No.2: 38.000 – 38.015 mm (1.4961 – 1.4966 in.)
4
No.3: 30.000 – 30.015 mm (1.1812 – 1.1816 in.)
I3RB0A143059-01
1. Camshaft journal bore No.1 3. Camshaft journal bore No.3

2. Camshaft journal bore No.2 4. Crankshaft pulley side
Camshaft Timing Sprocket

Check camshaft timing sprocket for pitting, scratch or
damage.
If any defect is found, replace camshaft timing sprocket.
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
I3RB0A143060-01
• Check camshaft journals and camshaft housings for
pitting, scratch, wear or damage.
If any defect is found, replace camshaft housing. Intake Manifold Side Camshaft Gear and Exhaust
Manifold Side Camshaft Gear
Check intake manifold side and exhaust manifold side
camshaft gears for pitting, scratch or damage.
If any defect is found, replace intake manifold side and/
or exhaust manifold side camshaft gear.
I3RB0A143058-01
• Check camshaft journal bore diameter using bore

gauge.
I3RB0A143061-01
Valve and Cylinder Head Components

AENFL80B1426025
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
IDL10A140058-01
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°,
: For tightening order, refer to “Valve and 29.5 lbf-ft → +90°→ +90°)
Cylinder Head Assembly Removal and
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 Disassembly

Disassembly and Reassembly 1) Using special tools (A) and (B), compress valve
AENFL80B1426027
spring and then remove valve cotters (1) using
special tool (C).
Special tool
(A): 09916M14510
(B): 09916M14522 (B): 09917M98221

(C): 09916M84511
(A)
(B)
I3RB0A143073-01
2) Release special tools, 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 I3RB0A143075-01
special tool, and then remove valve spring seat (2). 3) Apply engine oil to valve stem seal, valve guide bore
and valve stem, and then install valve to valve guide.
Special tool
(A): 09917M98610
(A)
I3RB0A143076-01
4) Install valve spring and valve spring retainer.

I3RB0A143074-01
5) Using special tools (A) and (B), compress valve
spring. Then, fit two valve cotters (1) into groove in
Reassembly valve stem using special tool (C).
1) Install valve spring seats to cylinder head. Special tool
2) Install new valve stem seal (1) to valve guide. (A): 09916M14510
After applying engine oil to seal and spindle of (B): 09916M14522
special tool (valve guide installer handle), fit stem (C): 09916M84511
seal to spindle, and then install seal to valve guide
by pushing special tool by hand.
After installation, check that seal is properly installed
to valve guide.
NOTICE
If the valve stem seal is installed by striking
the special tool with a hammer or other
similar tool, the valve stem seal may be
damaged, causing oil to leak past the seal.
Push the special tool only by hand to force
the valve stem seal into position. I3RB0A143077-01
NOTE
Do not reuse removed seal. Install new seal.
Special tool
(A): 09916M58210
Piston, Piston Ring, Connecting Rod and Cylinder Components

AENFL80B1426031
OIL
1
OIL
7
OIL
2
OIL
3
OIL
8
OIL
4 6
OIL
5
10 (a)
OIL
9
6
I9P60A142059-01
1. Top ring 8. Connecting rod bearing

: For assembly, refer to “Piston, Piston Ring, Connecting Rod and Cylinder
Disassembly and Reassembly”: Diesel in related manual.
2. 2nd ring 9. Connecting rod bearing cap
: For assembly, refer to “Piston, Piston Ring, Connecting Rod and Cylinder : Do not apply oil to mating surface between connecting rod bearing
Disassembly and Reassembly”: Diesel in related manual. and connecting rod bearing cap.
3. Oil ring 10. Connecting rod bearing cap bolt
: For assembly, refer to “Piston, Piston Ring, Connecting Rod and Cylinder : For tightening order, refer to “Piston, Piston Ring, Connecting Rod
Disassembly and Reassembly”: Diesel in related manual. and Cylinder Removal and Installation”: Diesel (Page 1D-53).
4. Piston : 20 Nm → +40° (2.0 kgf-m → +40°, 15.0 lbf-ft → +40°)
: For assembly, refer to “Piston, Piston Ring, Connecting Rod and Cylinder
Removal and Installation”: Diesel (Page 1D-53).
5. Piston pin : Do not reuse.
6. Piston pin circlip : Apply engine oil to sliding surface.
7. Connecting rod
: Do not apply oil to mating surface between connecting rod and
connecting rod bearing.
Piston, Piston Ring, Connecting Rod and Special tool

Cylinder Removal and Installation (A): 09912M38300
AENFL80B1426032
Removal
1) Remove engine assembly from engine
2) Remove cylinder head. 
(A)
3) Remove oil pan. (Page 1E-13)
4) Remove oil pan baffle plate (1) from lower
crankcase.
1
I3RB0A143084-01
6) Mark cylinder numbers on all pistons using silver

pencil or quick drying paint.
7) Remove connecting rod bearing caps (1).
I3RB0A143083-01
5) Remove special tool.

1
(A)
I3RB0A143085-01 I3RB0A143087-01
8) Remove carbon deposits from top of each cylinder 4) Install connecting rod bearing cap (1) to applicable
bore before removing piston from cylinder. cylinder matching cylinder number (2) on bearing
9) Push piston and connecting rod assembly out from cap and connecting rod, and then tighten new
the top of cylinder bore. connecting rod bearing cap bolts as follows.
a) Tighten all connecting rod bearing cap bolts (3)
Installation to 20 Nm (2.0 kgf-m, 15.0 lbf-ft).
1) Apply engine oil to pistons, rings, cylinder walls, b) Retighten them 40°.
connecting rod bearings and crankshaft pins. Tightening torque
NOTICE Connecting rod bearing cap bolt* (a): 20 Nm
→ +40° (2.0 kgf-m → +40°, 15.0 lbf-ft → +40°)
If oil is present between the bearing’s outside
surface and the connecting rod surface, the 3, (a) 3, (a)
bearing could heat up to very high
temperature, resulting in seizure.
Thoroughly wipe off any trace of oil that is
present between the bearing’s outside
surface and the connecting rod surface.
2) When installing piston and connecting rod assembly

into cylinder bore, point arrow mark (1) on piston
head to crankshaft pulley side (2).
1
I3RB0A143088-01
5) Lock crankshaft (1) using special tool.

2
I3RB0A143086-01
NOTE
3) Install piston and connecting rod assembly into Align hole (2) of special tool with knock pin
cylinder bore matching cylinder number marked in securely.
removal. Use special tool (piston ring compressor) to
compress rings. Guide connecting rod into place on Special tool
crankshaft. (A): 09912M38300
Using a hammer handle, tap piston head to install
piston into bore. Hold ring compressor firmly against
cylinder block until all piston rings enter the cylinder
bore.
Special tool
(A): 09916M77310
• Difference between thrust and axial measurements

exceeds out-of-roundness limit.
Cylinder bore diameter
(A)
Cylinder bore diameter specification
Category (2) Cylinder bore diameter
69.600 – 69.610 mm
A
(2.74016 – 2.74054 in.)
69.610 – 69.620 mm
1 B
2 (2.74055 – 2.74093 in.)
69.620 – 69.630 mm
I3RB0A143089-01 C
(2.74094 – 2.74133 in.)
6) Install oil pan baffle plate (1) to lower crankcase and
tighten oil pan baffle plate bolts to specified torque. Cylinder taper difference
Tightening torque Limit: 0.01 mm (0.00040 in.)
Oil pan baffle plate bolt (a): 9.0 N·m (0.92 kgf-m, Out-of-roundness difference
7.0 lbf-ft) Limit: 0.005 mm (0.00020 in.)
2
1
(a)
I3RB0A143090-02

8) Install cylinder head. 
9) Install camshaft housing assembly. 
3
10) Install timing chain and timing chain cover. (Page
1D-41)
11) Install engine assembly to engine compartment.
(Page 1D-36)
Cylinder, Piston and Piston Ring Inspection

AENFL80B1426034
I7V20A142048-02
Cylinder
3. Crankshaft pulley side
Visual inspection
Check cylinder walls for scratches, roughness or ridges
Piston
which indicate excessive wear.
Visual inspection
If cylinder bore is very rough, deeply scratched or ridged,
Check piston for crack or other damages.
replace cylinder block with new one.
Damaged or faulty piston should be replaced.
Cylinder bore diameter, taper and out-of-roundness
Piston diameter
Using a cylinder gauge (1), measure cylinder bore in
As shown in figure, piston diameter should be measured
thrust and axial directions at any positions as shown in
at a position 7.00 mm (0.28 in.) (“a”) from piston skirt end
figure.
in the direction perpendicular to piston pin.
If any of the following conditions is found, replace
cylinder block. Piston diameter specification
• Cylinder bore diameter exceeds specification. Index (1) on piston
Piston diameter with coating
• Difference of measurements at two positions exceeds head
taper limit. 69.546 – 69.556 mm
A
(2.7381 – 2.7384 in.)
Index (1) on piston

Piston diameter with coating
head
69.556 – 69.566 mm 1
B
(2.7384 – 2.7388 in.)
69.566 – 69.576 mm
C
(2.7388 – 2.7392 in.)
I3RB0A143097-01
Piston Ring
Piston ring end gap
To measure end gap, insert piston ring (1) into cylinder
bore and then measure the gap using feeler gauge (2).
If measured gap is not as specified, replace piston ring.
NOTE
I7V20A142049-01 Remove all carbon deposits from top of
cylinder bore before inserting piston ring.
Piston clearance
Measure cylinder bore diameter and piston diameter to Piston ring end gap
find their difference which is piston clearance. If it is not Top ring: 0.18 – 0.30 mm (0.0071 – 0.0118 in.)
as specified, rebore cylinder and use oversize piston. 2nd ring: 1.00 – 1.50 mm (0.0394 – 0.0590 in.)
Oil ring: 0.25 – 0.50 mm (0.0099 – 0.0196 in.)
NOTE
Cylinder bore diameters used here are
measured in thrust direction at two positions.
Piston clearance:
Standard: 0 – 0.036 mm (0 – 0.0014 in.)
Limit: 0.064 mm (0.0025 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 using feeler gauge
(2). If clearance is not as specified, replace piston ring
and/or piston. I3RB0A143099-01
Ring groove clearance Honing or Reboring Cylinder

Top ring: 0.105 – 0.150 mm (0.0042 – 0.0059 in.)
2nd ring: 0.075 – 0.120 mm (0.0030 – 0.0047 in.) 1) When any of the cylinders needs reboring, all other
Oil ring: 0.025 – 0.070 mm (0.0001 – 0.0002 in.) cylinders must also be rebored at the same time.
2) Use oversized piston according to amount of
cylinder wear.
Oversize piston diameter
Size Piston diameter with coating
Oversize 0.40 69.946 – 69.956 mm
(2.7537 – 2.7542 in.)
I2RH01140157-01
“a”: 7 mm (0.276 in.)
3) Using micrometer, measure piston diameter.

4) Rebore and hone cylinder to the following
dimension.
Cylinder bore diameter to be rebored:
70.000 – 70.010 mm (2.75590 – 2.75629 in.)
NOTE
Before reboring, install all main bearing caps
in place and tighten to specification to avoid I3RB0A143098-01
distortion of bearing bores.
Connecting Rod
5) Measure piston clearance after honing. If clearance Check connecting rod big-end bore and length.
is out of specification, replace cylinder block and all
pistons. 1) Install connecting rod bearing cap (2) to connecting
rod (1).
Piston clearance: 2) Measure connecting rod big-end bore using bore
0.054 mm (0.00212 in.) gauge (3).
If measured bore is not as specified, replace
Piston Pin and Connecting Rod Inspection connecting rod and bearing cap as a set.
AENFL80B1426035
Piston Pin Visual Inspection Big-end bore:
Check piston pin, connecting rod small-end bore and 45.734 – 45.744 mm (1.8006 – 1.8009 in.)
piston pin hole in piston for wear or damage, paying
particular attention to condition of small-end bore
bushing. If piston pin, connecting rod small-end pin hole
in piston or piston bore is badly worn or damaged,
replace pin, connecting rod and/or piston.
Piston Pin Clearance

Check piston pin clearance in small-end and piston. 3
Replace connecting rod and/or piston, if its small-end is
badly worn or damage.
Piston pin clearance in connecting rod small-end: 1
0.019 – 0.030 mm (0.00075 – 0.00118 in.)

Piston pin clearance in piston: 2
I3RB0A143100-01
0.004 – 0.014 mm (0.00016 – 0.00055 in.)
Piston pin diameter: Crankshaft Pin and Connecting Rod Bearing
22.982 – 22.987 mm (0.90481 – 0.90500 in.) Inspection
AENFL80B1426036
Connecting rod small-end bore: Connecting Rod Bearing General Information
23.006 – 23.012 mm (0.90575 – 0.90598 in.)
• Cap side connecting rod bearing half (1) has oil hole
Piston bore: (2) as shown in figure.
22.991 – 22.996 mm (0.90516 – 0.90535 in.) Install this half with oil hole to connecting rod bearing
cap.
• Connecting rod side connecting rod bearing half (3)
does not have oil hole.
Connecting rod bearing clearance
2 NOTE
Do not rotate crankshaft while gauging
plastic is fitted.
1) Before checking bearing clearance, clean bearing

1
and crankshaft pin.
2) Install bearing in connecting rod and bearing cap.
3 3) Place a piece of gauging plastic (1) to full width of
I3RB0A143101-01
crankshaft pin so it is in contact with bearing (parallel
to crankshaft), avoiding oil hole.
Crankshaft Pin Diameter
Check crankshaft pin for uneven wear or damage.
Measure crankshaft pin for out-of-roundness or taper
1
with a micrometer (1).
If crankshaft pin is damaged or out-of-roundness or
taper is not as specified, regrind or replace crankshaft.
Crankshaft pin diameter:
42.582 – 42.600 mm (1.6765 – 1.6771 in.)
I3RB0A143102-01
4) Install connecting rod and connecting rod bearing

cap. (Page 1D-53)
NOTE
It is not necessary to use new bearing cap
bolts for measuring procedure.
5) Using scale (1) on gauging plastic (2) envelope,

I5RS0B140032-01 measure gauging plastic width at the widest point
(clearance) after removing connecting rod bearing
Big-End Side Clearance cap.
Check big-end of connecting rod for side clearance, with If clearance exceeds its specification, use a new
rod fitted and connected to its crankshaft pin in normal standard size bearing and/or crankshaft.
manner. After selecting new connecting rod bearing, recheck
If measured clearance is not as specified, replace clearance.
connecting rod.
Connecting rod bearing clearance:
Big-end side clearance: 0.030 – 0.062 mm (0.0012 – 0.0024 in.)
0.12 – 0.45 mm (0.0048 – 0.0177 in.)
2
1
I3RB0A143103-01
I2RH0B140148-01
Connecting Rod Bearing Visual Inspection

Check bearing shells for signs of fusion, pitting, burn or
flaking and observe contact pattern. Defective bearing
shells must be replaced.
Selection of Connecting Rod Bearing 3) There are two kinds of standard bearings differing in
thickness. To distinguish them, they are painted in
NOTE the following colors at the position shown in figure.
• If bearing is defective or bearing clearance Each color indicates the following thickness at the
is not as specified, select a new standard center of bearing.
bearing according to the following Standard size of connecting rod bearing
procedure and install it. thickness
• When replacing crankshaft or connecting Color painted Bearing thickness
rod and its bearings due to any reason, 1.546 – 1.552 mm
select new standard bearings to be Red
(0.06087 – 0.06110 in.)
installed referring to alphabets stamped on 1.550 – 1.556 mm
crank web No.4. Blue
(0.06103 – 0.06125 in.)
Standard size of connecting rod bearing

1) Check connecting rod big-end inside diameter.
If measured big-end inside diameter is not as
specified, 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. I5RS0B140031-01
For example, stamped “A” indicates that 1. Paint
corresponding crankshaft pin diameter is 42.591 –
42.600 mm (1.6769 – 1.66771 in.). 4) From alphabet stamped on crank web No.4,
Crankshaft pin diameter determine new standard bearing to be installed to
Class Crankshaft pin diameter connecting rod big-end inside, referring to the table.
42.591 – 42.600 mm For example, if number stamped on crank web No.4
A is “A“, install a new standard bearing painted in
(1.6769 – 1.6771 in.)
42.582 – 42.591 mm “Red” to its connecting rod big-end inside.
B
(1.6765 – 1.6768 in.) Specification of new standard connecting rod
bearing size
Alphabet stamped on crank web
Color painted
No.4 (Crankshaft pin diameter)
A Red
B Blue
1 5) Check bearing clearance with newly selected

standard bearing referring to “Connecting Rod
Bearing Visual Inspection”: Diesel (Page 1D-58).
If clearance is not as specified, use next thicker
bearing and recheck clearance.
2
1
I7V20A142050-01
I5RS0B140033-01
1. Scale 2. Gauging plastic

Undersize bearing (0.127 mm (0.0050 in.))

• 0.127 mm (0.00500 in.) undersize bearing is available
in two kinds varying in thickness. To distinguish them,
each bearing is painted in the following colors at the
position shown in figure. Each color indicates the
following thickness at the center of bearing.
Undersize connecting rod bearing thickness
Color painted Bearing thickness
1.609 – 1.615 mm
Brown
(0.06335 – 0.06358 in.)
1.613 – 1.619 mm
Green I5RS0B140032-01
(0.06351 – 0.06374 in.)
I5RS0B140031-01
1. Paint
• If necessary, regrind crankshaft pin and select

undersize bearing to use with it as follows.
1) Regrind crankshaft pin to the following finished
diameter.
Finished diameter
42.455 – 42.473 mm (1.6715 – 1.6721 in.)
2) Using micrometer (1), measure reground crankshaft
pin diameter. Measurement should be taken in two
directions perpendicular to each other to check for
out-of-roundness.
3) Using crankshaft pin diameter measured above,
select an undersize bearing, referring to table given
below. Check bearing clearance with newly selected
undersize bearing.
Specification of new undersize connecting rod
bearing
Measured crankshaft
Color painted
pin diameter
42.464 – 42.473 mm
Brown
(1.6719 – 1.6721 in.)
42.455 – 42.464 mm
Green
(1.6715 – 1.6718 in.)
Main Bearing, Crankshaft and Cylinder Block Components

AENFL80B1426037
OIL
1 3
OIL
11
5
OIL
2
(a)
OIL
4
OIL
10 5
OIL
6 5
8 (d)
(b)
11
7 (c)
I9P60A142054-04
1. Cylinder block 9. Oil jet

: Apply sealant 99000-85E11. (Page 1D-61)
: Do not apply oil to main bearing seating face.
2. Crankshaft 10. Timing chain oil jet
3. Main bearing (with thrust bearing) 11. Knock pin
4. Flywheel side crankshaft oil seal : 6.0 Nm (0.61 kgf-m, 4.5 lbf-ft)
: Apply engine oil-to-oil seal lip.
5. Main bearing : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
: Apply engine oil to bearing inside surfaces.
6. Lower crankcase : 20 Nm → +80° (2.0 kgf-m → +80°, 15.0 lbf-ft → +80°)
: Do not apply oil to main bearing seating face.
7. Crankcase bolt No.1 : 15 Nm → 30 Nm (1.5 kgf-m → 3.1 kgf-m, 11.0 lbf-ft →
: For tightening order, refer to “Main Bearing, Crankshaft and Cylinder Block 22.5 lbf-ft)
Removal and Installation (ISG Model)”: Diesel (Page 1D-61).
8. Crankcase bolt No.2 : Do not reuse.
: For tightening order, refer to “Main Bearing, Crankshaft and Cylinder Block
Removal and Installation (ISG Model)”: Diesel (Page 1D-61).
Main Bearing, Crankshaft and Cylinder Block Removal

Removal and Installation (ISG Model) 1) Remove engine assembly from engine
AENFL80B1426038
NOTE 2) Remove cylinder head assembly. 
• All parts to be installed must be perfectly 3) Remove CKP sensor. 
clean. 4) Remove oil cooler. 
• Apply oil to crankshaft journals, main 5) Remove ISG. (Page 1J-27)
bearings, main bearing (with thrust 6) Remove starting motor. (Page 1I-8)
bearing), crankpins, connecting rod
7) Remove A/C compressor bracket (1).
bearings, pistons, piston rings and
cylinder bores.
“1” “3”
“6”
“10” “7”
“15” “12” “14”
“17” “20”
“19” “18”
“13” “11” “16”

IFL10A140018-01
“8”
8) Remove timing chain oil jet (1) from cylinder block. “5” “9”
“4” “2”
I3RB0A143108-01
13) Remove lower crankcase (1) from cylinder block

using special tool.
Special tool
1
(A): 09921M96510
I3RB0A143106-01
9) Remove ISG bracket (1) from cylinder block.
(A)
I3RB0A143109-01
14) Remove crankshaft (1) and flywheel side crankshaft

oil seal (2) from cylinder block.
15) Remove main bearings (3) and main bearing (with
thrust bearing) (4) from cylinder block and lower
1 crankcase.
1
IFL10A140019-01
10) Remove crank ventilation cover from cylinder block.

3
11) Remove piston and connecting rod. (Page 1D-53)
12) Loosen crankcase bolt No.1 and crankcase bolt
No.2 in numerical order evenly and gradually as
shown in figure, and remove them.
4
3
I3RB0A143110-01
16) Remove oil jet (1) from cylinder block, if necessary.

17) Remove knock pin (2) from cylinder block, if
necessary.
NOTE
One of two main bearing halves has an oil
2
groove (5).
Install the one half to cylinder block, and the
other half without oil groove to lower
crankcase.
1 2
Check that two halves are painted in the
same color.
I3RB0A143111-01 1
2
Installation 5
1) Install knock pin (1) to cylinder block, if removed.
2) Install oil jet (2) to cylinder block and tighten new oil
jet bolt to specified torque, if removed.
Tightening torque 3
Oil jet bolt (a): 9.0 N·m (0.92 kgf-m, 7.0 lbf-ft)
(a) 3
1
2 1
4
I3RB0A143113-01
4) Install knock pin (1) to crankshaft, if removed.
I3RB0A143112-01
3) Install main bearings (3) and main bearings (with

thrust bearing) (4) to cylinder block and lower
crankcase aligning tab (1) with gap (2).
NOTICE
• The engine will seize up if it is operated
when the parts listed below are not
1
properly lubricated.
Lubricate all the friction surfaces of these
parts with engine oil before installing I3RB0A143114-01
them. 5) Install crankshaft (1) to cylinder block.

– Crankshaft journals
– Main bearings
– Thrust bearings
• If oil is present between the bearing’s
outside surface and the cylinder block /
1
lower crankcase surface, the bearing could
heat up to very high temperature, resulting
in seizure.
Thoroughly wipe off any trace of oil that is
present between the bearing’s outside I3RB0A143115-01
surface and the cylinder block / lower 6) Apply sealant to cylinder block (1) as shown in
crankcase surface. figure.
“A”: Sealant 99000–85E11 (Three Bond TB
1227®)
9) Using special tools, install flywheel side crankshaft

1
oil seal (1) as follows.
Special tool
“A” “A” (A): 09913M58620
(B): 09924M74510
“a” Crankshaft rear oil seal Installing position
“A” (depth)
“a”: 1.0 mm (0.04 in.)
a) Fit crankshaft oil seal to special tool (A).
I3RB0A143116-01 b) Install special tool (B) to special tool (A), and
“a”: 3.0 mm (0.118 in.) install crankshaft oil seal by tapping special tool
(B) lightly with a plastic hammer.
7) Install lower crankcase to cylinder block. c) Remove special tools (A) and (B).
8) Tighten new crankcase bolts No.1 (“1” – “10”) and
new crankcase bolts No.2 (“11” – “20”) as follows. “a” 3
1
NOTE
Tighten these bolts in numerical order as
shown in figure in this procedure. 2
a) Tighten crankcase bolts No.1 to 20 Nm (2.0 kgf-

m, 15.0 lbf-ft). 1
b) Retighten them 80°. (A)

c) Tighten crankcase bolts No.2 to 15 Nm (1.5 kgf-
m, 11.0 lbf-ft). (B)
d) Retighten them to 30 Nm (3.1 kgf-m, 22.5 lbf-ft).
Tightening torque
Crankcase bolt No.1*: 20 Nm → +80° (2.0
kgf-m → +80°, 15.0 lbf-ft → +80°)
IDL10A140050-01
Crankcase bolt No.2*: 15 Nm → 30 Nm (1.5
2. Crankshaft 3. Cylinder block
kgf-m → 3.1 kgf-m, 11.0 lbf-ft → 22.5 lbf-ft)
NOTE 10) Install timing chain oil jet (1) to cylinder block and
After tightening lower crankcase bolts, check tighten oil jet union bolts to specified torque.
that crankshaft rotates smoothly. Tightening torque
Oil jet union bolt (a): 6.0 N·m (0.61 kgf-m, 4.5 lbf-
ft)
“20” “18”
“15”
“11” “14”
“6” “9” “7”
1
“1”
“4”
(a)
“2” “3”
I3RB0A143119-01
11) Install pistons and connecting rods. (Page 1D-53)

“8” “10” “5” 12) Install crank ventilation cover to cylinder block.
“13” 13) Install ISG bracket (1) to cylinder block and tighten
“17” “19” “16” “12” ISG bracket bolts to specified torque.
I3RB0A143117-01
Tightening torque
ISG bracket bolt (a): 22 N·m (2.2 kgf-m, 16.5 lbf-
ft)
(a) 2
I3RB0A143123-01
Visual inspection
Check bearings for pitting, scratches, wear or damage.
If any defect is found, replace both upper and lower
IFL10A140020-01
halves.
14) Install A/C compressor bracket (1) and tighten A/C Never replace either half without replacing the other half.
compressor bracket bolts in numerical order (“1” –
“4”), if removed. Main bearing clearance
NOTE
“3” “4” Do not rotate crankshaft while gauging
plastic is placed.
1) Before checking bearing clearance, clean bearing

and crankshaft journal.
2) Install bearing to cylinder block and main bearing
cap. (Page 1D-61)
3) Place a piece of gauging plastic (1) to full width of
crankshaft journal so it is in contact with bearing
(parallel to crankshaft), avoiding oil hole.
1
“1” “2”
IFL10A140021-01
15) Install starting motor. (Page 1I-8)

16) Install ISG. (Page 1J-27)
17) Install oil cooler. 
18) Install CKP sensor. 
19) Install cylinder head assembly.  1
20) Install engine assembly to engine compartment. I3RB0A143124-01

(Page 1D-36) 4) Install lower crankcase. (Page 1D-61)
Main Bearing Inspection (ISG Model) NOTE

AENFL80B1426040
It is not necessary to use new crankcase
General Information
bolts for measuring procedure.
• Service main bearings are available in standard size
and 0.127 mm (0.00500 in.) undersize, and both 5) Remove cap and using a scale (1) on gauging
standard size and undersize bearings have three plastic (2) envelope, measure gauging plastic width
kinds varying in thickness. at the widest point (clearance).
• Bearing upper half (1) has oil groove (2) as shown in If clearance is not as specified, replace bearing.
figure. Always replace both upper and lower bearings as a
Install this half with oil groove to cylinder block. set.
• Bearing lower half does not have oil groove. Main bearing clearance:
0.026 – 0.050 mm (0.0011 – 0.0019 in.)
2) Check journal bore diameter. On mating surface of

cylinder block, three numbers are stamped as shown
in figure.
1 Three kinds of numbers (“1”, “2” and “3”) represent
the following journal bore diameters.
Stamped numbers on cylinder block represent
journal bore diameter marked with an arrow in figure
respectively.
For example, stamped “1” indicates that
corresponding journal bore diameter is 54.710 –
2 54.714 mm (2.15394 – 2.15409 in.).
I3RB0A143125-01
Crankshaft journal bore
Selection of Main Bearing Stamped number Journal bore diameter
Standard bearing 54.710 – 54.714 mm
1
If bearing is defective, or bearing clearance is not as (2.15394 – 2.15409 in.)
specified, select a new standard bearing according to 54.714 – 54.718 mm
2
the following procedure and install it. (2.15410 – 2.15425 in.)
1) Check journal diameter. As shown in figure, crank 54.718 – 54.722 mm
3
web No.4 has stamped alphabets. (2.15426 – 2.15440 in.)
Three kinds of alphabets (“A”, “B” and “C”) represent
the following journal diameters.
Stamped alphabets on crank web No.4 represent
journal diameters marked with an arrow in figure
respectively. For example, stamped alphabet “A”
indicates that corresponding journal diameter is
50.994 – 51.000 mm (2.0077 – 2.0078 in.).
Crankshaft journal diameter
Stamped alphabet Journal diameter
50.994 – 51.000 mm
A
(2.0077 – 2.0078 in.)
50.988 – 50.994 mm
B
(2.0074 – 2.0076 in.)
50.982 – 50.988 mm
C
(2.0072 – 2.0074 in.)
1
1
I7V20A142055-01
3) There are 3 kinds of standard bearings differing in

thickness. To distinguish them, they are painted in
the following colors at the position shown in figure.
Each color indicates the following thickness at the
center of bearing.
I7V20A142054-01
Standard size of crankshaft main bearing without
thrust bearing thickness
Color painted Bearing thickness
1.836 – 1.841 mm
Red
(0.07229 – 0.07248 in.)
Color painted Bearing thickness Color painted

1.841 – 1.846 mm With standard
Blue With oversize Bearing thickness
(0.07249 – 0.07267 in.) size thrust
thrust bearing
1.846 – 1.851 mm bearing
Yellow
(0.07268 – 0.07287 in.) 1.846 – 1.851 mm
Yellow Yellow / Black (0.07268 – 0.07287
Standard size of crankshaft main bearing with in.)
thrust bearing thickness (non-ISG model)
Color painted
With standard
With oversize Bearing thickness
size thrust
thrust bearing
bearing
1.836 – 1.841 mm
Red Red / White (0.07229 – 0.07248
in.)
1.841 – 1.846 mm
Blue Blue / White (0.07249 – 0.07267
in.)
1.846 – 1.851 mm
Yellow Yellow / White (0.07268 – 0.07287
in.)
Standard size of crankshaft main bearing with

thrust bearing thickness (ISG model)
Color painted
With standard
With oversize Bearing thickness
size thrust
thrust bearing
bearing
1.836 – 1.841 mm I7V20A142056-02
Red Red / Black (0.07229 – 0.07248
[A]: Without thrust bearing 1. Paint
in.) [B]: With thrust bearing
1.841 – 1.846 mm
Blue Blue / Black (0.07249 – 0.07267
in.)
4) From alphabet stamped on crank web No.4 and numbers stamped on cylinder block, determine new standard
bearing to be installed to journal, referring to the table below.
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 / Black” for upper and “Red” for lower to its journal.
Main bearing cross-reference table for non-ISG model (standard size)
Alphabet stamped on crank web No.4 (Journal diameter)
A B C
Upper Red or Red / White Red or Red / White Blue or Blue / White
1
Lower Red Blue Blue
Number stamped on Upper Red or Red / White Blue or Blue / White Blue or Blue / White
2
cylinder block (Cap bore Lower Blue Blue Yellow
diameter) Upper Blue or Blue / White Blue or Blue / White Yellow or Yellow /
3 White
Lower Blue Yellow Yellow
Main bearing cross-reference table for ISG model (standard size)

A B C
Upper Red or Red / Black Red or Red / Black Blue or Blue / Black
1
Lower Red Blue Blue
Number stamped on Upper Red or Red / Black Blue or Blue / Black Blue or Blue / Black
2
cylinder block (Cap bore Lower Blue Blue Yellow
diameter) Upper Blue or Blue / Black Blue or Blue / Black Yellow or Yellow /
3 Black
Lower Blue Yellow Yellow
2
I5RS0B140036-01
1. Scale 2. Gauging plastic
Undersize bearing 0.127 mm (0.0050 in.) Undersize of crankshaft main bearing with thrust
• 0.127 mm (0.0050 in.) undersize bearing is available bearing thickness (ISG model)
in three kinds varying in thickness. To distinguish Color painted
them, each bearing is painted in the following colors at With
the position shown in figure. Each color represents standard With oversize Bearing thickness
the following thickness at the center of bearing. size thrust thrust bearing
bearing
Undersize of crankshaft main bearing without
1.899 – 1.904 mm
thrust bearing thickness Brown Brown / Black
(0.07477 – 0.07496 in.)
Color painted Bearing thickness 1.904 – 1.909 mm
1.899 – 1.904 mm Green Green / Black
Brown (0.07497 – 0.07515 in.)
(0.07477 – 0.07496 in.) 1.909 – 1.914 mm
1.904 – 1.909 mm Black Black / Black
Green (0.07516 – 0.07535 in.)
(0.07497 – 0.07515 in.)
1.909 – 1.914 mm
Black
(0.07516 – 0.07535 in.)
Undersize of crankshaft main bearing with thrust

bearing thickness (non-ISG model)
Color painted
With
standard With oversize Bearing thickness
size thrust thrust bearing
bearing
1.899 – 1.904 mm
Brown Brown / White
(0.07477 – 0.07496 in.)
1.904 – 1.909 mm
Green Green / White
(0.07497 – 0.07515 in.)
1.909 – 1.914 mm
Black Black / White
(0.07516 – 0.07535 in.)
• If necessary, regrind crankshaft journal and select

undersize bearing to use with crankshaft as follows.
I7V20A142056-02
[A]: Without thrust bearing 1. Paint

[B]: With thrust bearing
1) Regrind journal to the following finished diameter.

Finished diameter
50.855 – 50.873 mm (2.00216 – 2.00287 in.)
2) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions
perpendicular to each other to check for out-of-roundness.
3) Using journal diameter measured above, select an undersize bearing, referring to table below. Check bearing
clearance with newly selected undersize bearing.
Main bearing cross-reference table for non-ISG model (undersize)
50.867 – 50.873 mm 50.861 – 50.867 mm 50.855 – 50.861 mm
(2.0027 – 2.0028 in.) (2.0024 – 2.0026 in.) (2.0022 – 2.0024 in.)
Brown or Brown / Brown or Brown /
Upper Green or Green / White
1 White White
Lower Brown Green Green
Number stamped on Brown or Brown / Green or Green /
Upper Green or Green / White
cylinder block (Cap bore 2 White White
diameter) Lower Green Green Black
Green or Green / Green or Green /
Upper Black or Black / White
3 White White
Lower Green Black Black
Main bearing cross-reference table for ISG model (undersize)

50.867 – 50.873 mm 50.861 – 50.867 mm 50.855 – 50.861 mm
(2.0027 – 2.0028 in.) (2.0024 – 2.0026 in.) (2.0022 – 2.0024 in.)
Brown or Brown / Brown or Brown /
Upper Green or Green / Black
1 Black Black
Lower Brown Green Green
Number stamped on Brown or Brown / Green or Green /
Upper Green or Green / Black
cylinder block (Cap bore 2 Black Black
diameter) Lower Green Green Black
Green or Green / Green or Green /
Upper Black or Black / Black
3 Black Black
Lower Green Black Black
Flywheel side crankshaft oil seal

Carefully check flywheel side crankshaft oil seal (1) for wear or damage.
If its lip is worn or damaged, replace oil seal.
I3RB0A143126-01
Cylinder Block Inspection

AENFL80B1426041
Distortion of Gasket Surface

Using straightedge and feeler gauge, check gasket
surface for distortion. If distortion exceeds specified limit,
repair it.
If repair is not possible, replace cylinder block.
Cylinder block flatness
Limit: 0.03 mm (0.0012 in.)
IDL10A140053-01
IDL10A140052-01
Specifications
AENFL80B1427002
NOTE
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Camshaft housing plug 18 1.8 13.5 /
Common rail bracket bolt 22 2.2 16.5 /
Intake manifold bolt* 25 2.5 18.5 
Oil level gauge guide mounting bolt 9.0 0.92 7.0 
Oil separator bolt 9.0 0.92 7.0 
Crankshaft pulley flange bolt* 50 Nm → +90° (5.1 kgf-m → +90°, 37.0 lbf- /
ft → +90°)
Crankshaft pulley bolt 30 3.1 22.5 /
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 7.0 
Chain tensioner mounting bolt 25 2.5 18.5 
Chain tensioner adjuster bolt 9.0 0.92 7.0 
Timing chain cover bolt 9.0 0.92 7.0 
Timing chain cover nut 9.0 0.92 7.0 
Flywheel bolt 44 4.5 32.5 
Engine right mounting bracket No.2 bolt 60 6.1 44.5 
ISG drive belt idler bracket bolt 55 5.6 40.5 
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Camshaft timing sprocket bolt 150 15.3 111.0 
Camshaft gear bolt* 15 Nm → 150 Nm (1.5 kgf-m → 15.3 kgf- 
m, 11.0 lbf-ft → 111.0 lbf-ft)
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 7.0 
Oil jet bolt 9.0 0.92 7.0 
Crankcase bolt No.1* 20 Nm → +80° (2.0 kgf-m → +80°, 15.0 lbf- 
ft → +80°)
Crankcase bolt No.2* 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 
ISG bracket bolt 22 2.2 16.5 
Reference:
“Air Cleaner Components”: Diesel
“Intercooler Components”: Diesel
“Turbocharger and Exhaust Manifold Components”: Diesel
“Intake Manifold Components”: Diesel
“Timing Chain Cover and Timing Chain Components (ISG Model)”: Diesel
“Camshaft Housing Components”: Diesel
“Valve and Cylinder Head Components”: Diesel
“Piston, Piston Ring, Connecting Rod and Cylinder Components”: Diesel
“Main Bearing, Crankshaft and Cylinder Block Components”: Diesel

AENFL80B1428003
Sealant Three Bond TB 1227® P/No.: 99000–85E11 /
Thread lock cement Loctite omnifit 100M spezial® — /
NOTE
“Timing Chain Cover and Timing Chain Components (ISG Model)”: Diesel
“Camshaft Housing Components”: Diesel
“Valve and Cylinder Head Components”: Diesel
“Piston, Piston Ring, Connecting Rod and Cylinder Components”: Diesel
“Main Bearing, Crankshaft and Cylinder Block Components”: Diesel
Special Tool
AENFL80B1428004
09910M95020 09912M38300
Oil pump drive flange holder Crankshaft locking tool
 ////
09912M46310 09913M58620
TDP definition pin Oil seal installer
EN-46785 
09913M75510 09916M14510
Bearing installer Valve lifter
/ /
09916M14522 09916M58210
Valve spring compressor Valve guide installer handle
attachment
/ 
09916M77310 09916M84511
Piston ring compressor (50 - Forceps
125 mm)
 /
09916M98610 09917M47011
Flywheel locking tool Vacuum pump gauge
KM-652 /  
09917M68222 09917M68610
Crankshaft pulley holder Camshaft locking tool
/ EN-46781 /  /  /  / 
/
09917M98221 09917M98610
Valve guide stem Valve stem seal pliers
attachment
 KM-840
09921M96510 09924M74510
Oil pan seal cutter Bearing and oil seal handle
 
1E-1 Engine Lubrication System: Petrol and Bi-Fuel CNG
Engine Lubrication System

Engine

Oil Pressure Check
AENFL80B1514001
! CAUTION
2
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.
NOTE
1
Before checking oil pressure, check the
I7V20A151002-01
following points.
4) Install special tools to threaded hole where oil
• Oil level in oil pan
pressure switch was removed.
If oil level is low, add oil up to FULL level
mark (hole) (1) on oil level gauge. (Page Special tool
1E-2) (A): 09915M77311
(B): 09915M78211
(B)
(A)
IYSQ01020012-01
2. LOW level mark (hole)
I7V20A151003-01
• Oil quality
5) Start engine and warm engine up to normal
If oil is discolored or deteriorated, change
operating temperature.
it. (Page 1E-2)
6) After warming up, raise engine speed to 4,000 rpm
• Oil leakage
and measure oil pressure.
If leak is found, repair leaky point.
Oil pressure specification
1) For M/T model, place gear shift lever in “Neutral” and More than 300 – 500 kPa (3.1 – 5.1 kgf/cm2, 43.5 –
apply parking brake. 72.5 psi) at 4,000 rpm.
parking brake. 7) Stop engine and remove special tools.
2) Disconnect oil pressure switch lead wire (1). 8) Apply sealant to thread portion of oil pressure switch
(1), and then tighten oil pressure switch to specified
3) Remove oil pressure switch (2) from cylinder block.
torque.
NOTICE
If sealant is applied to the hole when
applying sealant to thread portion of the oil
pressure switch, the engine oil pressure light
will not operate properly due to clogging.
Avoid applying sealant to the oil pressure
switch hole.
Engine Lubrication System: Petrol and Bi-Fuel CNG 1E-2
“A”: Thread lock cement 99000–32110 (Thread

Lock Cement Super 1322)
1
Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
lbf-ft)
“A” 1
1, (a)
I7V20A151005-01
10) Start engine and check oil pressure switch for oil
leakage. If oil leakage is found, install oil pressure
switch correctly to prevent leakage.
11) Check DTC. If any DTC is displayed, clear DTC.
I9R90A150004-01 • DTC check: (Page 1A-16)
9) Connect oil pressure switch lead wire (1). • DTC clearance: (Page 1A-16)
Repair Instructions
Engine Oil and Filter Change
AENFL80B1516001
! CAUTION
There is an increased risk of severe personal
injury or health problems if the procedure
described below is performed without taking
proper precautions.
• Engine oil has an adverse health effect.
Read and understand the instructions in
(Page 00-1) and follow all the 1, (a)
instructions.
I8C50B150002-01
• Check that the engine is not running when 3) Loosen oil filter using special tool and remove oil
performing Steps 1) – 7) of the procedure. filter.
• Adequately ventilate the working area
when starting the engine in Step 8). Special tool
(A): 09915M47341
Before draining engine oil, check engine for oil leakage.
If any evidence of leakage is found, correct defective
part before proceeding to the following procedure.
1) Drain engine oil by removing drain plug (1). (A)
2) Wipe drain plug clean. Reinstall drain plug with new
gasket and tighten drain plug to specified torque.
Tightening torque
Engine oil drain plug (a): 35 N·m (3.6 kgf-m, 26.0
lbf-ft)
I7V20A151009-02
4) Wipe clean oil filter mounting surface on oil pan.

5) Apply engine oil to new oil filter gasket.
cover. It is recommended to use engine oil of SG,

SH, SJ, SL or SM grade. Select appropriate oil
viscosity according to following engine oil viscosity
chart [A].
SAE 0W-20 oil is the best choice for good fuel
economy and good starting in cold weather.
NOTE
• Engine oil capacity is as specified below.
However, note that actual amount of oil
required during oil change may somewhat
IYSQ01020009-01 differ from that indicated below depending
6) Install the oil filter in the following manner. on such factors as temperature, viscosity,
Using a torque wrench etc.
a) Fit the oil filter (1) with the oil pan, and then • Engine oil specification and viscosity chart
tighten it to the specified torque using the special [A] indicated in this manual are typical
tool. ones.
Special tool For the specific information on the engine
(A): 09915M47341 oil and proper engine oil viscosity, refer to
“Engine Oil and Filter” section of the
Tightening torque Owner's Manual.
Oil filter (a): 14 N·m (1.4 kgf-m, 10.5 lbf-ft)
Engine oil specification
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 /
(A) Imp pt.)
1, (a) Others: About 0.3 liter (0.63 / 0.53 US / Imp pt.)
Total: About 3.4 liters (7.19 / 5.98 US / Imp pt.)
20W-40
[A] 15W-40
10W-40
10W-30
IAV10P150001-01
5W-30
Not using a torque wrench
0W-20
a) Tighten the oil filter (1) by hand until its gasket o
C -30 -20 -10 0 10 20 30 40
touches the oil pan. o
F -22 -4 14 32 50 68 86 104
IAW10A150001-01
b) Using the special tool, rotate the oil filter three-
quarters of one turn (2) to tighten it. 8) Start engine and run it for 5 minutes. Stop it and wait
for 5 minutes before checking oil level. Add oil, if
Special tool necessary, to bring oil level to FULL level mark (hole)
(A): 09915M47341 (1) on oil level gauge.
(A)
1
IYSQ01020012-01
2. LOW level mark (hole)

IEL10A151006-01
7) Replenish oil until oil level is brought to FULL level 9) Check oil filter and drain plug for oil leakage.
mark (hole) on oil level gauge (oil pan and oil filter
capacity). Oil filler port is at top of cylinder head
Oil Pan and Oil Pump Strainer Components

AENFL80B1516003
OIL
1
3 1217G
11 (a)
OIL
10 (a)
2
9 (a)
(e)
5 7 (c)
(a)
OIL (a)
OIL
(d) 8 (b)
IEL10A151001-02
1. O-ring 7. Oil filter stand : 14 Nm (1.4 kgf-m, 10.5 lbf-ft)

: Apply engine oil.
2. Strainer 8. Oil filter : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
: For tightening order, refer to “Engine Oil and
Filter Change”: Petrol and Bi-Fuel CNG (Page
1E-2).
: Apply engine oil to oil filter gasket.
3. Oil pan 9. Oil pump strainer bolt : 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
: Apply sealant 99000-31260 to mating : For tightening order, refer to “Oil Pan and Oil
surface. Pump Strainer Removal and Installation”: Petrol
and Bi-Fuel CNG (Page 1E-4).
4. Dowel pin 10. 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”: Petrol
and Bi-Fuel CNG (Page 1E-4).
5. Gasket 11. Oil pan baffle plate stud bolt : Do not reuse.
6. Drain plug : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
: Apply engine oil to mating surface.
Oil Pan and Oil Pump Strainer Removal and

Installation
AENFL80B1516004
Removal
2
1) Remove oil level gauge.
2) Remove right engine undercover.
3) Drain engine oil by removing drain plug.
4) Remove exhaust pipe No.1. (Page 1K-1)
5) Remove oil filter. (Page 1E-2) 1
6) Remove transaxle bolts (1) and oil pan bolts (2). I7V20A151012-01
7) Remove oil pan (1) from cylinder block using special 4) Install dowel pins (1) to oil pan and cylinder block.
tool and hammer.
Special tool
(A): 09921M96510
(A)
I7V20A151013-02 1
IEL10A151003-01
8) Remove oil pump strainer and oil pan baffle plate
stud bolt, if necessary. 5) Apply engine oil to new O-ring (1), and then install O-
ring to position as shown in figure.
Installation 6) Apply sealant to mating surface of oil pan as shown
1) Install oil pan baffle plate stud bolt (1) if removed, in figure.
and then tighten oil pan baffle plate stud bolt to
NOTE
specified torque.
• Before applying sealant, check that mating
Tightening torque
surface is clean and dry.
Oil pan baffle plate stud bolt (a): 11 N·m (1.1 kgf-
m, 8.5 lbf-ft) • Wipe off excessive sealant.
• Install oil pan within 2 minutes after
2) Apply engine oil to new O-ring (2) and then install O-
applying sealant.
rings to oil pump strainer (3).
3) Install oil pump strainer with O-ring and washer (4), “A”: Sealant 99000–31260 (SUZUKI Bond
tighten bolt (5) first, and then tighten nut (6) to No.1217G)
specified torque.
Sealant amount for oil pan
Tightening torque Width “a”: 3 mm (0.12 in.)
Oil pump strainer bolt* (b): 11 N·m (1.1 kgf-m, Height “b”: 2 mm (0.08 in.)
8.5 lbf-ft)
Oil pump strainer bracket nut* (c): 11 N·m (1.1 1
kgf-m, 8.5 lbf-ft)
2
“A” “a”
“A”
1, (a) “b”
4
I7V20A151017-01
7) Install oil pan to cylinder block and then tighten oil

5, (b) 3 6, (c) pan bolts in numerical order (“1” – “17”) evenly and
IEL10A151002-02 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” 1, (a)
I9P60A151006-01
“17” 9) Install oil filter. (Page 1E-2)

10) Install exhaust pipe No.1. (Page 1K-1)
“9” “5” “1 ”, (a) “3” “7” “11” 11) Install right engine undercover.
I9P60A151005-01
12) Install drain plug and refill engine with engine oil.
8) Tighten transaxle bolts (1) to specified torque.
(Page 1E-2)
Tightening torque 13) Install oil level gauge.
Transaxle bolt (a): 55 N·m (5.6 kgf-m, 40.5 lbf-ft)
14) Check that there is no engine oil or exhaust gas
leakage at each connection.
Oil Pump Assembly Components

AENFL80B1516005
(b)
4
9
8
1
OIL
5
OIL
3
OIL
2
OIL
7 (a)
IFRA0A151007-01
1. Timing chain cover 5. Relief valve 9. O-ring

:Apply engine oil
2. Inner rotor 6. Spring : 28 Nm (2.9 kgf-m 21.0 lbf-ft)
:Apply engine oil. :Apply engine oil.
3. Outer rotor 7. Retainer : 11 Nm (1.1 kgf-m 8.5 lbf-ft)
:Apply engine oil.
4. Rotor plate 8. Oil gallery pipe : Do not reuse.
Oil Pump Assembly Disassembly and • Outer rotor

Reassembly • Inside surfaces of oil pump case
AENFL80B1516007
3) Install outer rotor (1) and inner rotor (2) to timing
Disassembly chain cover.
1) Remove rotor plate (1) by removing rotor plate NOTE
mounting bolts.
When installing the outer rotor and inner
rotor, face the marks (3) toward cylinder
block.
IFRA0A151009-01
2) Remove outer rotor (1) and inner rotor (2). 2
IFRA0A151011-01
4) Apply engine oil to relief valve (1) and relief valve

spring (2), and install them to rotor plate (4).
1 5) Tighten retainer (3) to specified torque.
Tightening torque
Oil relief valve retainer (a): 28 N·m (2.9 kgf-m,
21.0 lbf-ft)
2
IFRA0A151010-01 1
3) Remove relief valve (1) and spring (2) by removing
retainer (3) from rotor plate (4).
4 2
3,(a)
I7V20A151023-01
6) Install rotor plate and tighten rotor plate bolts to

specified torque. After installing plate, check that
4
rotors can be turned smoothly by hand (Torque: 0.3
Nm (0.03 kgf-m, 0.25 lbf-ft) or less).
1 Tightening torque
Oil pump rotor plate bolt (a): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)
2
I8C50A150023-02
Reassembly
(a)
1) Clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to the following parts.
I8C50A150024-02
• Inner rotor
Oil Pump Inspection If clearance is out of specification, replace oil pump

AENFL80B1516008 assembly.
Oil Seal Radial clearance between outer rotor and case of oil
Check oil seal lip for defects and damage. Replace oil pump
seal if necessary. Standard: 0.12 – 0.19 mm (0.0048 – 0.0074 in.)
Limit: 0.21 mm (0.0083 in.)
I2RH0B150023-01
2
IFRA0A151013-01
Oil Pump
Side clearance
• Check outer (1) and inner rotors (2), rotor plate and oil Using straightedge (1) and feeler gauge (2), measure
pump case for excessive wear or damage. side clearance.
If side clearance is out of specification, replace oil pump
assembly.
Side clearance of oil pump inner rotor
3 Standard: 0.024 – 0.069 mm (0.0010 – 0.0027 in.)
Limit: 0.0089 mm (0.0035 in.)
1
Side clearance of oil pump outer rotor
Standard: 0.038 – 0.083 mm (0.0015 – 0.0032 in.)
Limit: 0.103 mm (0.0040 in.)
2
1
IFRA0A151011-01
3. Front mark
• Check that relief valve (1) is not excessively worn or

damaged and operates smoothly.
2
IEL10A151005-01
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.
1
Relief valve spring free length and load
Standard Limit
32.7 mm
Free length —
(1.29 in.)
Load at spring 48.3 N
54.5 N
I8C50A150029-01 length (4.9 kgf, 10.9
(5.6 kgf, 12.3 lbf)
26.0 mm (1.02 in.) lbf)
Radial clearance
Check radial clearance between outer rotor (1) and case
(2) using feeler gauge.
I2RH01150023-01
Specifications
AENFL80B1517002
NOTE
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 pump strainer bolt* 11 1.1 8.5 
Oil pump strainer bracket nut* 11 1.1 8.5 
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 bolt 11 1.1 8.5 
Reference:
“Oil Pan and Oil Pump Strainer Components”: Petrol and Bi-Fuel CNG
“Oil Pump Assembly Components”: Petrol and Bi-Fuel CNG

AENFL80B1518003
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 
Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 
NOTE
“Oil Pan and Oil Pump Strainer Components”: Petrol and Bi-Fuel CNG
“Oil Pump Assembly Components”: Petrol and Bi-Fuel CNG
Special Tool
AENFL80B1518004
09915M47341 09915M77311
Oil filter wrench socket Oil pressure gauge
// 
09915M78211 09921M96510
Oil pressure gauge Oil pan seal cutter
attachment
 
1E-11 Engine Lubrication System: Diesel
Diesel
Repair Instructions
Engine Oil Level Check
AENFL80B1526001
1) Check engine oil level as follows:
a) Place vehicle on a level surface. 1
b) Warm up engine to normal operating

temperature.
c) Stop engine and wait for 10 min.
d) Remove dipstick and wipe it with a clean lint-free
cloth.
e) Reinsert dipstick fully.
f) Remove dipstick again and check oil level. IBP80A152001-01
2) If oil level is above upper limit mark on the dipstick, 2) Drain engine oil by removing drain plug (1).
adjust oil level to upper limit. 3) Wipe drain plug clean and replace seal ring with a
3) If engine oil level is near lower limit mark on dipstick, new one. Reinstall drain plug, and tighten it to
add engine oil to upper level mark. (Page 1E-11) specified torque.
Tightening torque
Engine Oil and Filter Change Engine oil drain plug (a): 24 N·m (2.4 kgf-m, 17.7
AENFL80B1526002
lbf-ft)
! WARNING
There is an increased risk of severe personal
injury or health problems if the procedure
described below is performed without taking
proper precautions.
• Engine oil has an adverse health effect.
Read and understand the instructions in 1, (a)
“General Precautions” in Section 00 (Page
00-1) and follow all the instructions. I5RS0B020001-01
• Check that the engine is not running when 4) Install oil filter.
performing Step 1) – 6) of the procedure.
a) Replace O-ring (1) of oil filter housing cover (2)
• Adequately ventilate the working area with new one and apply engine oil to O-ring.
when starting the engine in Step 7).
Before draining engine oil, check engine for oil leakage.

If any evidence of leakage is found, correct defective
part before proceeding to the following procedure. 1
1) Remove oil filter element.
a) Place oil collecting basin under oil filter.
b) Loosen and remove oil filter housing cover (1). 2
IBP80A152003-01
b) Install new oil filter to housing.

c) Install oil filter housing cover and tighten it to
specified torque.
1
Tightening torque
Oil filter housing cover (a): 25 N·m (2.5 kgf-
m, 18.5 lbf-ft)
I3RM0B020002-01
c) Pull out oil filter (1) from oil filter housing cover.
Engine Lubrication System: Diesel 1E-12
NOTE
Note that the amount of oil actually required
when changing oil may somewhat differ from
the data depending on various conditions
(a) (temperature, viscosity, etc.).
6) Check oil filter and drain plug for oil leakage.

7) Start engine and run it for 5 minutes. Stop it and wait
for 5 minutes before checking oil level. Add oil, if
necessary, to bring oil level to upper limit mark (1) on
I3RM0B020006-01
dipstick.
5) Replenish oil until oil level is brought to upper limit
mark on dipstick.
Engine oil specifications
Oil pan and oil filter capacity: About 3.2 liters
(6.76 / 5.63 US / Imp pt.) 1 2
The filler inlet is close to the engine oil filter.

Use specified synthetic engine oil.
Engine oil grade: ACEA A5/B5-10
Engine oil viscosity: SAE 5W-30 I3RM0B020008-01
2. LOW level mark
Oil Cooler Components

AENFL80B1526005
4 (a)
1
(b)
5
7
3
(b)
IDL10A150001-02
1. Filler cap 5. Oil filter : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
2. O-ring 6. Coolant feed pipe : Do not reuse.
3. Gasket 7. Oil cooler assembly
: Never disassemble oil cooler assembly.
4. Oil filter housing cover : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
Oil Pan Components

AENFL80B1526007
(b) (b)
3
2 (a)
I9P60A152011-01
1. Oil pan 3. O-ring : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)

: Apply sealant 99000-85E11 to mating surface.
2. Drain plug : 20 Nm (2.0 kgf-m, 15.0 lbf-ft) : Do not reuse.
Oil Pan Removal and Installation NOTE

AENFL80B1526008
Be careful not to damage stud bolt (4)
Removal between oil pan and crankcase when cutting
sealant.
1) Remove dipstick.
2) Hoist vehicle. 8) Remove oil pan (2) from lower crankcase (3).
3) Drain engine oil. (Page 1E-11)
3
4) Remove exhaust No.1 pipe. 
5) Remove transaxle stiffener (1).
1 (A)
I9P60A152019-01
6) Remove oil pan bolts (1) and nuts (2).
1
2
4
I5RS0B150010-01
Installation
1) Clean mating surfaces of oil pan and lower
I9P60A152020-01
crankcase.
7) Cut sealant at hatched part shown in the figure using
special tool and hammer (1).
Special tool
(A): 09921M96510
(a)
1, (b)
I5RS0B150013-01
5) Install transaxle stiffener and tighten transaxle

stiffener bolts (1) to specified torque.
Tightening torque
Transaxle stiffener bolt (a): 34 N·m (3.5 kgf-m,
25.0 lbf-ft)
6) Tighten transaxle-engine bolts (2) to specified
torque. 
I5RS0B150011-01
2) Apply continuous bead of sealant to oil pan mating 7) Tighten catalytic converter brace bolt (3) to specified
surface as shown in figure. torque. 
“A”: Sealant 99000–85E11 (Three Bond TB 1, (a)

1227®)
“A”
3
2
I5RS0B150012-01
3) Fit oil pan to lower crankcase and lightly tighten oil 1, (a)
pan bolts and nuts. I9P60A152021-01
Then, starting from the central bolt at either side of 8) Install exhaust No.1 pipe. 
oil pan, tighten oil pan bolts and nuts diagonally to 9) Install dipstick.
specified torque. 10) Refill engine with engine oil. (Page 1E-11)
Tightening torque 11) Check that there is no engine oil leakage and
Oil pan bolt and nut (a): 9.0 N·m (0.92 kgf-m, 7.0 exhaust gas leakage at each connection.
lbf-ft)
4) Install new O-ring and drain plug (1) to oil pan.
Tighten drain plug to specified torque.
Tightening torque
Drain plug (b): 20 N·m (2.0 kgf-m, 15.0 lbf-ft)
Oil Pump / Oil Pump Strainer Components

AENFL80B1526009
3
2
(a) 1
I9P60A152014-01
2
Installation
3 Reverse removal procedure noting the following points.
• Clean mating surfaces of rotor plate (3) and oil pump
strainer (1).
• Install oil pump strainer with new gasket (2) to timing
I9P60A152013-01 chain cover.
1. Timing chain cover : 9.0 Nm (0.92 kg-m, 7.0 • Tighten oil strainer bolts to specified torque.
: Oil pump is incorporated in lbf-ft)
timing chain cover. Tightening torque
2. Oil pump strainer gasket : Do not reuse.
Oil strainer bolt (a): 9.0 N·m (0.92 kgf-m, 7.0 lbf-ft)
3. Oil pump strainer
Oil Pump / Oil Pump Strainer Removal and 3
Installation
AENFL80B1526010
(a)
Removal
1) Remove timing chain cover. (Page 1D-41)
2) Remove oil pump strainer (1) and gasket (2) from
rotor plate (3). 2
1
I9P60A152015-01
Specifications
AENFL80B1527002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Engine oil drain plug 24 2.4 17.7 
Oil filter housing cover 25 2.5 18.5 
Oil pan bolt and nut 9.0 0.92 7.0 
Drain plug 20 2.0 15.0 
Transaxle stiffener bolt 34 3.5 25.0 
Oil strainer bolt 9.0 0.92 7.0 
Reference:
“Oil Cooler Components”: Diesel
“Oil Pan Components”: Diesel
“Oil Pump / Oil Pump Strainer Components”: Diesel

AENFL80B1528003
Sealant Three Bond TB 1227® P/No.: 99000–85E11 
NOTE
“Oil Pan Components”: Diesel
Special Tool
AENFL80B1528004
09921M96510
Oil pan seal cutter

1F-1 Engine Cooling System: Petrol and Bi-Fuel CNG
Engine Cooling System

Engine

Radiator Cooling Fan Control System Circuit Diagram
AENFL80B1612002
9
GRN WHT E01-6
1 6
10
YEL YEL PNK E01-49
WHT YEL BLU E01-56 12V

5V
BLU E01-55
BLK BLU
2
12 LT GRN E01-46
11
GRY
E1 A1 RED
GRN
3 D1 B1 D1 4 GRN E01-36
L+
H+ L-
LT BLU 5 BLK
E1 C01-51 BLK
A2 H- C1 C2 C01-50 BLK
B2
WHT
8 5V
A3
LT GRN C01-20
GRY/BLU C01-45
[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
IFL80B161006-04
[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. “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
Engine Cooling System: Petrol and Bi-Fuel CNG 1F-2

Radiator Cooling Fan System Check
AENFL80B1614002
Circuit Diagram
9
GRN WHT E01-6
1 6
10
YEL YEL PNK E01-49
WHT YEL BLU E01-56 12V

5V
BLU E01-55
BLK BLU
2
12 LT GRN E01-46
11
GRY
E1 A1 RED
GRN
3 D1 B1 D1 4 GRN E01-36
L+
H+ L-
LT BLU 5 BLK
E1 C01-51 BLK
A2 H- C1 C2 C01-50 BLK
B2
WHT
8 5V
A3
LT GRN C01-20
GRY/BLU C01-45
[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
IFL80B161006-04
[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
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. “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”.
NOTE
• For details of engine cooling fan operation, refer to “Cooling Fan Operation Description”: Petrol and
Bi-Fuel CNG in related manual.
• Before beginning troubleshooting, be sure to read “Precautions for Engine (K14B)” in Section 1 in
related manual.
• When measuring circuit voltage, resistance and/or pulse signal of ECM, refer to:
– For Petrol model: (Page 1A-107)
– For Bi-fuel CNG model: (Page 1A-17)
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-6)
Is check result OK?

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-6)
Is check result OK?

4 Radiator cooling fan relay No.1 power supply circuit Go to Step 5. Repair “A1” circuit.
(switch side) check
1) Set ignition “OFF” and remove radiator cooling fan relay
No.1 from individual circuit fuse box No.1.
2) Check for proper connection to radiator cooling fan relay
No.1 at each terminal.
3) If OK, measure voltage between “A1” circuit and ground.
Is it 10 – 14 V?
Is check result OK?

6 Radiator cooling fan motor drive circuit (low speed) Go to Step 7. Repair “B1” circuit.
check
1) Set ignition “OFF” and disconnect ECM connector. 
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
• Voltage of “B1” circuit: approx. 0 V (with ignition “ON”)

7 Radiator cooling fan motor ground circuit check Go to Step 16. Repair “C1” circuit.
1) Measure resistance between “C1” circuit and ground.
Step Action Yes No

(switch side) check
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?
Is check result OK?

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
• Voltage of “B2” circuit: approx. 0 V (with ignition “ON”)
Is check result OK?

(switch side) check
• Resistance of “A3” circuit: 1 Ω or less
• Voltage of “A3” circuit: approx. 0 V (with ignition “ON”)
Is check result OK?

Is check result OK?

13 Radiator cooling fan relay No.3 ground circuit check Go to Step 14. Repair “C2” circuit.
1) Measure resistance between “C2” circuit and ground.
14 Radiator cooling fan relay No.2 and No.3 power supply Go to Step 15. Repair “D1” circuit.
circuit (coil side) check
• 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 check result OK?

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.
• 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 check result OK?

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 check result OK?
Repair Instructions
Cooling System Components
AENFL80B1616001
(a)
[D]
(b)
2 [C]
1 2
9 1207F 10
1
5 7
11
6
[A]
13
8
3
12
3 11
15 13
[B]
15 [C]
4 13
[D]
14
14
IFL80B161003-03
[A]: Petrol model 5. Radiator cooling fan assembly 13. To heater core
[B]: Bi-fuel CNG model 6. Thermostat assembly (incorporating with ECT sensor) 14. To CNG cylinder pressure
regulator
[C]: M/T model 7. Gasket 15. To ATF cooler
[D]: A/T model 8. O-ring : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
1. Radiator 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”: Petrol and Bi-Fuel CNG in related manual
2. Radiator cap 10. Water pump pulley : Do not reuse.
3. Drain plug 11. To throttle body
4. Reservoir 12. To cylinder head
Radiator Cooling Fan Assembly On-Vehicle

[A] [B]
Inspection
AENFL80B1616009
Radiator Cooling Fan Operation
1) Connect scan tool to DLC (1) with ignition “OFF”.
Special tool
IAP70A160002-01
[A]: Low speed [B]: High speed
3) Check that radiator cooling fan motors rotate

smoothly and properly.
1
If any abnormality is found, replace radiator cooling
fan motor.
Reference: Fan motor specified current at 12 V
Low speed: 4.8 – 7.8 A
(A)
High speed: 7.4 – 10.9 A
Radiator Removal and Installation

AENFL80B1616014
IFL80B180001-01 Removal
2) Set ignition “ON” and clear DTC. (Page 1A-16) 1) Remove cooling fan assembly. 
3) Select “Radiator Fan” function in “Active Test”. 2) Remove condenser assembly.
4) Check radiator cooling fan operation at low and high • Single A/C Model: 
modes. • Dual A/C model: 
If any abnormality is found, check cooling fan control 3) Remove radiator outlet hose from radiator.
system. (Page 1F-2)
Radiator cooling fan operation 5) For A/T model, disconnect ATF cooler inlet and
Radiator cooling fan motor outlet hoses (2) from radiator.
OFF OFF
Low mode Low speed
High mode High speed
Radiator Cooling Fan Motor

1) Disconnect radiator cooling fan motor connector (1).
IFL80B161005-02
1 6) Remove radiator upper brackets (1).

IAP70P160004-01
7) Remove radiator (2) from vehicle.
2) Using service wire, connect radiator cooling fan
motor connector and battery as shown in figure.
• Check cooling system for leakage. 

1
• For A/T model, refill transaxle with ATF. (Page 5A-
104)
2 • For A/T model, check ATF leakage.
IAP70P160007-01
Installation
• Refill cooling system with coolant. 
Specifications
AENFL80B1617002
Reference:
“Cooling System Components”: Petrol and Bi-Fuel CNG

Special Tool
AENFL80B1618003
SDT-II)
—

Engine Cooling System: Diesel 1F-8
Diesel
General Description
Water Pump Drive Belt Description (ISG Model)
AENFL80B1621004
The water pump drive belt is a low modulus belt. It stretches itself to maintain the belt tension. Therefore, a tension
pulley, which is used to adjust the belt tension, or components for adjusting the clearance between the crankshaft
pulley and the water pump pulley are not necessary. When removing or installing the low modulus belt, use the special
tool to prevent the belt from being damaged.
1F-9 Engine Cooling System: Diesel

Engine Cooling Symptom Diagnosis
AENFL80B1624001
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 (without ISG model) drive belt tensioner.
operates) Accessory drive belt: 
Accessory drive belt tensioner: 
Loose or broken water pump drive belt Replace water pump drive belt. (Page 1F-
(with ISG model) 10)
Not enough coolant Check coolant level and add coolant as
necessary. 
Faulty thermostat Replace thermostat assembly. 
Faulty water pump Replace water pump.
• Without ISG model: 
• With ISG model: (Page 1F-12)
Dirty or bent radiator fins Clean or repair radiator. 

Coolant leakage Repair cooling system.
Clogged radiator Check and replace radiator as necessary.
Check: 
Replace: 
Faulty degassing tank cap Replace degassing tank cap.
Dragging brakes Check brake. 
Slipping clutch Replace clutch cover and clutch disc. 
Poorly charged battery Check and replace battery as necessary.
Check (without ISG): 
Replace (without ISG): 
Check (with ISG): (Page 1J-22)
Replace (with ISG): (Page 1J-24)
Poor electricity generated by generator Check and replace generator if necessary.
Check (without ISG): (Page 1J-13)
Replace (without ISG): 
Check (with ISG): (Page 1J-23)
Replace (with ISG): (Page 1J-27)
Faulty ECT sensor Check and replace ECT sensor if necessary.
Check: 
Replace: 
Faulty radiator cooling fan motor Check and replace radiator cooling fan motor if
necessary.
Check: 
Replace: 
Faulty radiator cooling fan relay Check and replace radiator cooling fan relay if
necessary. (Page 10B-35)
Faulty ECM Check and replace ECM if necessary.
Faulty wiring or grounding Repair wiring.
Equipped with too much electric load Dismount.
part(s)

Engine overheats (It is in Blown fuse Check fuse of relay/fuse box and check for
case that radiator fan short circuit to ground.
won’t operate) Faulty radiator cooling fan relay Check and replace radiator cooling fan relay if
necessary. (Page 10B-35)
Faulty ECT sensor Check and replace ECT sensor if necessary.
Check: 
Replace: 
Faulty radiator cooling fan motor Check and replace radiator cooling fan motor if
necessary.
Check: 
Replace: 
Faulty wiring or grounding Repair wiring.
Faulty ECM Check and replace ECM if necessary.
Repair Instructions
• For the setting of the belt tension meter,
Water Pump Drive Belt Inspection (ISG Model) follow the operation manual of the belt
AENFL80B1626016
tension meter.
1) Check water pump drive belt (1) for wear, crack,
deformation and contamination. If any defect is
found, replace water pump drive belt with new one.
(Page 1F-10)
2) Hoist vehicle and remove right side front wheel. 1
(Page 2D-1)
4) When engine is cool, with the belt tension meter,
measure water pump drive belt tension at the
midpoint between crankshaft pulley (2) and magnet
clutch pulley (3). If water pump drive belt tension is
less than limit, replace water pump drive belt with
new one.
2
3
Water pump drive belt tension
Standard: 286 – 834 N (29.2 – 85.0 kgf or 64.3 –
187.5 lbf) IFL10A160001-01
Limit: 240 N (24.5 kgf or 54.0 lbf) 5) Install right side engine undercover.
Recommended belt tension meter specification 6) Install right side front wheel. (Page 2D-1)
Gates Corporation “507C” or equivalent
Setting value for belt tension meter “507C” Water Pump Drive Belt Removal and Installation
(ISG Model)
AENFL80B1626017
MASS 58 Removal
WIDTH 1.0
SPAN 170 1) Hoist vehicle and remove right side front wheel.
(Page 2D-1)
NOTE 2) Remove right side engine undercover.
• For using general belt tension meter (other 3) Place special tool between crankshaft pulley (1) and
than Gates Corporation “507C”), refer to water pump drive belt (2) as shown in figure.
the following belt specification values. NOTE
– Length: 884 mm (34.8 in.) Place special tool while positioning it along
– Weight: 49.6 g (1.8 oz) wall “a” of crankshaft pulley.
– Distance between the contact points of
belt and pulley: 170.1 mm (6.696 in.) Special tool
(A): 09991M07410
(A)
“a” (A)
(A)
“d”
5
“b”
“c”
“a”
1 IFL10A160004-01
2
IFL10A160002-01
4) Remove water pump drive belt (1) by turning 4 2

crankshaft pulley (2) clockwise.
(A) 1
2 (A)
1 1
IFL10A160003-01
Installation 4
1) Fit ribs of water pump drive belt (1) into grooves of

water pump pulley (2) and magnet clutch pulley (3).
2) Install water pump drive belt and special tool to 5
crankshaft pulley (4) as shown in figure. IFL10A160005-01
Special tool 3) Turn crankshaft pulley (1) clockwise until ribs of

(A): 09991M07460 water pump drive belt (2) fit into grooves of
crankshaft pulley, magnet clutch pulley (3) and water
NOTICE pump pulley (4) completely.
Installing water pump drive belt using special NOTICE
tool without its protective cover attached
may cause damage to crankshaft pulley or Turning crankshaft pulley with water pump
peeling of its surface coating. Always use drive belt improperly attached to magnet
special tool with its protective cover (5) clutch pulley and water pump pulley may
attached. If designated protective cover is cause scratch on water pump drive belt.If
not available, cut PVC (soft polyvinyl water pump drive belt is not installed
chloride) hose to specified dimension as properly, remove and then reinstall it
shown below and attach it to special tool. properly.
Protective cover dimensions Outside
diameter “a”: 18 mm (0.70 in.)Inside diameter
“b”: 15 mm (0.59 in.) Length “c”: 15 mm (0.59
in.) Thickness “d”: 1.5 mm (0.059 in.)
NOTE
When installing water pump drive belt, push
water pump drive belt at a location closer to
crankshaft pulley than water pump pulley
toward timing chain cover to prevent
misalignment between water pump drive belt
and water pump pulley.
IFL10A160008-01
Installation
• Use new seal (1).
IFL10A160006-02 • Tighten water pump nuts to specified torque.
Tightening torque
4
1 Water pump nut (a): 9.0 N·m (0.92 kgf-m, 7.0 lbf-
ft)
2
IFL10A160007-01
1
4) Turn crankshaft clockwise 720° and check that all (a)
ribs of belt fit into grooves of pulleys.
5) Start engine and stabilize water pump drive belt
tension. (a)
6) Stop engine, and then inspect water pump drive belt
IFL10A160009-01
tension. (Page 1F-10)
7) Install right side engine undercover. Water Pump Inspection (ISG Model)
8) Install right side front wheel. (Page 2D-1) AENFL80B1626019
Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
Water Pump Removal and Installation (ISG abnormal noise, replace it.
Model)
AENFL80B1626018
Removal
2) Drain coolant. 
3) Remove water pump drive belt. (Page 1F-10)
4) Remove water pump (1).
IFL10A160010-01
Specifications
AENFL80B1627002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Water pump nut 9.0 0.92 7.0 
Reference:

Special Tool
AENFL80B1628002
09991M07410 09991M07460
Drive belt remover Low modulus belt installer
 
Fuel System: Petrol 1G-1
Fuel System
Engine
Petrol
Precautions
Precautions for Fuel System Service
AENFL80B1710001
! 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.
• Have CO2 fire extinguisher handy.
• 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 immediately may cause dangerous spout of fuel. Before loosening or
disconnecting fuel feed line, make sure to relieve fuel pressure. (Page 1G-5)
• 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. 
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 it 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.

Fuel Delivery System Diagram
AENFL80B1712001
1G-2 Fuel System: Petrol
13 10
11 12 15
14
6 7
2
8 3
9
1
5
IEP80A171001-01
1. Fuel tank 6. Fuel feed line 11. Intake manifold

2. Fuel pump assembly 7. Fuel filter 12. EVAP canister
3. Fuel pressure regulator 8. Fuel level sensor 13. EVAP canister purge valve
4. Delivery pipe 9. Fuel pump 14. Vapor control valve
5. Fuel injector 10. Fuel vapor line 15. Fuel return line
Fuel Injector Control System Circuit Diagram

AENFL80B1712002
10
A1 6 A2
C01-11 BLU/YEL
B1 7 B2
C01-12 BLU/WHT
C1 8 C2
C01-10 BLU/RED
D1 9 D2
C01-22 LT GRN/BLK
5
E01-49 PNK
4
E01-56 BLU
12V
5V E01-55 BLU
3.3V
E01-6 WHT
3
2
C01-50 BLK
C01-51 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
IFL80B171004-01
[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

AENFL80B1712003
B1 A1
6
E01-54 YEL
BLK 7 PNK
B3 B2 A2
5
E01-49 PNK
4
E01-56 BLU
12V
5V E01-55 BLU
3.3V
E01-6 BLK/WHT
3
2
C01-50 BLK
C01-51 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
IFL80B171005-01
[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

Power Balance Test For A/T model, place select lever in “P” and apply
AENFL80B1714002 parking brake.
NOTICE
2) Connect SUZUKI scan tool to DLC (1) with ignition
When performing power balance test, do not “OFF”.
increase engine speed higher than set idling
speed. Doing so may damage engine. Special tool
1) For M/T model, place gear shift lever in “Neutral” and

5) Using SUZUKI scan tool, select “Fuel Injector” in
“Active Test” and turn off each fuel injector.
6) With each fuel injector turned off, check that engine
speed decreases from specified idle speed.
7) If decreasing rates of engine speed are not in scale,
check the following items.
1
• Spark plug: (Page 1H-2)
• Ignition coil circuit: 
(A)
• Ignition coil: 
• Engine compression: (Page 1D-1)
IFL80B180001-01
Repair Instructions
Fuel System Components
AENFL80B1716001
20 (b)
17
18
(d)
19 14
8
10 9
11 (a) 5
23
7
24 (c)
6
4
2 21 1
22
(a) 11
15
12
16
13
IFL80B171001-03
1. Fuel tank 11. Fuel tank bolt 21. To EVAP canister

2. Fuel pump assembly 12. Fuel feed line (pump to filter) 22. To fuel pump assembly
3. O-ring (fuel pump) 13. Fuel feed line (filter to 3 way) 23. To fuel feed line
4. Fuel pump lock nut: For tightening 14. Fuel feed line (3 way to delivery pipe) 24. From 3 way
procedure, refer to “Fuel Pump Assembly
Removal and Installation”: Petrol in related
manual.
5. Breather hose 15. Fuel vapor line : 45 Nm (4.6 kgf-m, 33.5 lbf-ft)
6. Fuel tank filter hose 16. Fuel filter : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
7. Fuel filter neck 17. Fuel delivery pipe : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
8. Fuel filter cap 18. Fuel injector : 3.0 Nm (0.31 kgf-m, 2.5 lbf-ft)
9. Fuel tank belt 19. Injector cushion : Do not reuse
10. Heat insulator 20. Fuel delivery pipe bolt
Fuel Pressure Relief Procedure

AENFL80B1716003
! CAUTION
Never perform this work when engine is hot.
Doing so may cause adverse effect to
catalyst.
1) For M/T model, place shift lever in “Neutral” and

parking brake.
I2RH0B170007-01
2) Remove individual circuit fuse box No.1 cover. 2) Disconnect connector (1) from injector, connect
3) Remove fuel pump relay (1) from individual circuit ohmmeter between terminals of injector and check
fuse box No.1 (2). resistance.
4) Remove fuel filler cap in order to release fuel vapor If resistance is out of reference value greatly, replace
pressure from fuel tank, and then reinstall fuel filler injector.
cap.
Reference resistance of fuel injector
5) Start engine and run it until engine stops for lack of 12.2 Ω at 25 °C (77 °F)
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.
6) After servicing, install fuel pump relay (1) to
individual circuit fuse box No.1 and install individual
circuit fuse box No.1 cover.
1
2
I2RH0B170008-01
3) Connect connector to injector securely.
Fuel Injector Removal and Installation

AENFL80B1716008
I9P60A171005-02
! WARNING
Fuel Injector On-Vehicle Inspection When performing the following procedure, be
AENFL80B1716007
1) Using sound scope (1) or the like, check operating sure to observe “Precautions for Fuel
sound of injector (2) when engine is running or System Service”: Petrol (Page 1G-1) in order
cranking. to reduce the risk of fire and personal injury.
Cycle of operating sound should vary according to
engine speed. Removal
If no sound or unusual sound is heard, check injector 1) Relieve fuel pressure. (Page 1G-5)
circuit (wire or connector) or injector. 2) Disconnect negative (–) cable at battery.

4) Disconnect fuel injector connectors.
5) Disconnect fuel feed hose (4) from fuel delivery pipe
(1).
6) Remove fuel delivery pipe nuts (2).
7) Remove fuel injector(s) (3).
3
4
IEL10A171012-02
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. IEL10A171013-02
• Tighten fuel delivery pipe nuts (5) to specified torque • After completing installation, check fuel line
and make sure that injectors can be rotated smoothly. connections for leaks with engine not running and
Tightening torque ignition “ON”. 
Fuel delivery pipe nut (a): 25 N·m (2.5 kgf-m, 18.5
lbf-ft) Fuel Injector Inspection
AENFL80B1716009
! WARNING
• When performing the following procedure,

be sure to observe “Precautions for Fuel
System Service”: Petrol (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-5)

2) Set special tools as follows.
Special tool
(A): 09912M58421
(B): 09912M57610
(C): 09930M86310
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).
(B)
1
(A)
(A)
2 (C)
IFL80B180001-01
1
Not using SUZUKI scan tool:
a) Remove fuel pump relay from connector.
b) Connect two terminals of relay connector using
(A)
service wire (1) as shown in figure.
! CAUTION
Check that connection is made between
I6RW0B170014-01
correct terminals. Wrong connection can
3) Install suitable vinyl tube onto injector nozzle to cause damage to ECM, wire harness, etc.
prevent fuel from splashing out during injection.
4) Put graduated cylinder under injector. c) Set ignition “ON”.
5) Connect one of terminal of special tool (C) to battery
positive (+) terminal. 1
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
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 2) Remove fuel tank inlet valve (1) using flat-bladed
Less than 1 drop/min. screwdriver (2) or the like.
NOTICE
Failure to take adequate precautions when
removing the fuel tank inlet valve, the valve
may be damaged.
Be careful not to damage the fuel tank inlet
valve when using the flat-bladed screwdriver
or the like.
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. IDL10A170016-01
1. Stop operation of fuel pump.

Installation
2. Put graduated cylinder under injector.
1) Install fuel tank inlet valve (1) to fuel tank.
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.
I2RH0B170018-01
12) Install fuel injectors to cylinder head. (Page 1G-5)
2) Install fuel tank filler hose to fuel tank. 
13) Connect fuel feed hose to delivery pipe.
14) Check for fuel leaks. 
Fuel Tank Inlet Valve Inspection
AENFL80B1716021
Fuel Tank Inlet Valve Removal and Installation Check fuel tank inlet valve for the following points.
AENFL80B1716020 If any damage or malfunction is found, replace fuel tank
Removal inlet valve.
1) Remove fuel tank filler hose from fuel tank.  • No damage or deformation
• Smooth opening and closing
I2RH0B170019-01
Specifications
AENFL80B1717002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Fuel delivery pipe nut 25 2.5 18.5 
Reference:
“Fuel System Components”: Petrol

Special Tool
AENFL80B1718002
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
SDT-II)
Injector test harness —
 /
1G-10 Fuel System: Bi-Fuel CNG
Bi-Fuel CNG
Precautions
AENFL80B1720001
! WARNING
Before servicing on fuel system, the following points should be always observed to reduce the risk of
fire and personal injury.
• Disconnect negative (–) cable at battery.
• Do not smoke, and place no smoking signs near working area.
• Keep CO2 fire extinguisher handy.
• Perform work in a well-ventilated area. If necessary, install equipment such as a gas leak alarm in
the working area.
• Do not perform any actions that will spark, if gas leak is detected.
• Be sure to perform work away from any open flames such as gas heater.
• Wear safety glasses.
• To relieve fuel (petrol) 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 immediately may cause dangerous spout of fuel. Before loosening or
disconnecting fuel feed line, relieve fuel pressure. 
• A small amount of fuel may be released when the petrol fuel line is disconnected. To reduce the risk
of personal injury, cover the fitting to be disconnected with shop cloth.
• Never perform service work when engine and exhaust system are hot.
• Turn the manual shut off valve to “OFF” position prior to commencement of the repair work.
• Never remove the CNG cylinder valve from the cylinder assembly.
• Even if the CNG from CNG cylinder is consumed till the engine stops, some amount of CNG will be
left out in the tank under pressure.
NOTICE
Use unleaded fuel only.
Leaded or low lead fuel can result in engine damage and reduce the effectiveness of the emission
control system.
Fuel System: Bi-Fuel CNG 1G-11

Fuel Injector Control System Circuit Diagram
AENFL80B1722002
NOTE
For identification of each cylinder, refer to “Bi-Fuel CNG System Component Description”: Bi-Fuel
CNG in Section 1A in related manual.
Circuit Diagram
4 17
3
6
GRN WHT E01-6 C01-8 BLK
C01-28 BLK
7 C01-29 BLK
WHT
BLK/YEL BLK/YEL GRN/YEL E01-12
BLK/YEL BLU BLU E01-1

5 BLU E01-11
B1 9 A1 C1
1 2 BLU/YEL C12-6 C12-8 BRN/YEL C01-11
B2 10 A2 C2
BLU/WHT C12-14 C12-16 BRN C01-12
B3 11 A3 C3
BLU/RED C12-5 C12-7 WHT/GRN C01-10
1
B4 12 A4 C4
8 LT GRN/ C12-13
BLK C12-15 BLK/RED C01-22
1
RED/WHT
13
WHT/BLK C12-1
14
GRY C12-10
15
WHT/BLU C12-18
16
WHT/BLU C12-27
[A]
E23 C12
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10 A
26 25 24 23 22 21 20 19 18 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 34 33 32 31 30 29 28 27
[B] C01 E01
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
IFL80B172001-01
[A]: ECM connector (View: [a]) C2: Fuel injector No.2 control circuit 9. Petrol fuel injector No.1
[B]: CNG control module connector (View: [a]) C3: Fuel injector No.3 control circuit 10. Petrol fuel injector No.2
A1: Petrol fuel injector No.1 drive circuit C4: Fuel injector No.4 control circuit 11. Petrol fuel injector No.3
A2: Petrol fuel injector No.2 drive circuit 1. Main fuse box 12. Petrol fuel injector No.4
A3: Petrol fuel injector No.3 drive circuit 2. “Ignition Switch” fuse 13. CNG fuel injector No.1
A4: Petrol fuel injector No.4 drive circuit 3. Ignition switch 14. CNG fuel injector No.2
B1: Petrol fuel injector No.1 power supply circuit 4. Junction box 15. CNG fuel injector No.3
B2: Petrol fuel injector No.2 power supply circuit 5. CNG control module 16. CNG fuel injector No.4
B3: Petrol fuel injector No.3 power supply circuit 6. “IG” fuse 17. ECM
B4: Petrol fuel injector No.4 power supply circuit 7. Main Relay
C1: Fuel injector No.1 control circuit 8. “CNG” fuse

Power Balance Test 7) With each fuel injector turned off, confirm that engine
AENFL80B1724002 speed decreases from specified idle speed.
NOTICE
8) If decreasing rates of engine speed are not in scale,
When performing the power balance test, do check the following items.
not increase engine speed higher than set
idling speed. Doing so may damage the
engine. • Petrol fuel injector: 
• CNG fuel injector: 
Using SUZUKI Scan Tool • Spark plug: (Page 1H-2)
1) Place gear shift lever in “Neutral” and apply parking • Ignition coil circuit: 
brake.
2) Connect scan tool to DLC (1) with ignition switch
turned OFF. • Engine compression: (Page 1D-1)
Special tool Not Using SUZUKI Scan Tool

(A): SUZUKI scan tool (Suzuki SDT-II) 1) Place gear shift lever in “Neutral” and apply parking
brake.
temperature.
4) For checking petrol system, select “Petrol MODE”
with selector switch.
For checking CNG system, select “Forced CNG
1
MODE” with selector switch.
5) For checking petrol system, disconnect petrol fuel
injector connector (1) for cylinder No.1.
For checking CNG system, disconnect CNG fuel
injector connector (2) for cylinder No.1.
(A)
IFL80B180001-01
3) Clear DTC. 
4) For checking petrol system, select “Petrol MODE”
with selector switch.
For checking CNG system, select “Forced CNG
MODE” with selector switch.
temperature.
6) Using SUZUKI scan tool, select “Fuel Injector” in
“Active Test” and turn off each fuel injector.
Fuel System: Bi-Fuel CNG 1G-13
(A)
IFL80B180001-01
IDL80A173003-01
4) Clear DTC. 
6) Check that engine speed decreases from specified
idle speed. 5) Select “Forced CNG MODE” with selector switch.
7) Repeat Step 5) and 6) for all cylinders, compare 6) Start engine and warm it up to normal operating
decreasing rates of engine speed. temperature.
8) If decreasing rates of engine speed are not in scale, 7) Using SDT, check CNG low pressure at idling.
check the following items. • If measured pressure is out of specification, there
• Fuel injector circuit  is possibility of the following cause.
• Petrol fuel injector  – CNG low pressure filter choke. Check CNG fuel
filter for evidence of dirt and contamination. 
• CNG fuel injector 
– CNG fuel leakage. 
• Spark plug: (Page 1H-2)
– Vacuum hose fault.
• Ignition coil circuit: 
– CNG cylinder pressure regulator fault.
• Engine compression: (Page 1D-1) CNG fuel pressure specification
At specified idle speed: 200 kPa (2.0 kg/cm2, 29.0
9) Clear DTC. 
psi)
Fuel Pressure Basic Check
AENFL80B1724006
Petrol System
Refer to “Fuel Pressure Basic Check”: Petrol in related
manual.
CNG System
NOTICE
Do not use special tools that were used for a
petrol fuel line. If petrol mixes in the CNG fuel
line, it could damage the CNG fuel injector.
1) Check that CNG cylinder pressure is more than 1

MPa (10.2 kgf/cm2, 145 psi) using SUZUKI scan tool.
Otherwise, refill CNG tank.
2) Place gear shift lever in “Neutral” and apply parking
brake.
3) Connect scan tool to DLC (1) with ignition switch
turned OFF.
Special tool
Repair Instructions
CNG Cylinder Pressure Regulator On-Vehicle
Inspection
AENFL80B1726011
1) Check CNG cylinder pressure regulator for coolant
leakage, deformation and damage. If any faulty
condition is found, replace CNG cylinder pressure
regulator.
2) Check CNG cylinder pressure regulator for CNG fuel
leakage. If faulty condition is found, replace CNG 1
cylinder pressure regulator. 
3) Check the shut-off valve operation sound as follows.
a) Turn ignition switch to ON position.
b) Select “Forced CNG MODE” with selector switch
(A)
and check the shut-off valve operation sound. If
operating sound of shut-off valve is not heard,
replace CNG cylinder pressure regulator.
4) Inspect the CNG cylinder pressure sensor as
follows. IFL80B180001-01
a) Turn ignition switch to OFF position and then b) Turn ignition switch to ON position and select
connect SUZUKI scan tool to DLC (1). “Forced CNG MODE” with selector switch.
Special tool c) Select “CNG Cylinder Pressure” under “Data
(A): SUZUKI scan tool (Suzuki SDT-II) List” mode on scan tool. Check CNG fuel
pressure displayed on scan tool.
d) Check that CNG fuel pressure on CNG pressure
gauge and “CNG Cylinder Pressure” on SUZUKI
scan tool similarly decrease, when CNG fuel
pressure is relieved. If check result is not
satisfactory, replace CNG cylinder pressure
regulator.

Special Tool
AENFL80B1728002
SDT-II)
—
//
Fuel System: Diesel 1G-15
Diesel
Precautions
AENFL80B1730001
! 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.
– Have CO2 fire extinguisher handy.
– Perform work in a well-ventilated area and away from any open flames (such as gas 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-18)
– 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.

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. 
• Fuel system is very sensitive to contamination. Problems caused by introduction of contamination into the system
include:
– Damage to or destruction of high pressure injection system and engine.
1G-16 Fuel System: Diesel
– 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. 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
(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 return collector
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.
• Follow the instructions below before opening the fuel circuit.

– Use new thinner from clean receptacle every time connection is cleaned (used thinner contains impurities).
– Use only clean brush in good condition (without loose bristles) for applying thinner.
– Use brush and thinner to clean connections to be opened.
– Blow compressed air over cleaned parts (connections and injection system area including tools). Check that no
bristles remain on cleaned surfaces.
– Wash your hands before and during the operation if necessary.
– When wearing leather gloves, cover them with latex gloves.
• Follow the instructions below during operation.
– As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system using
plug caps. Do not reuse removed plugs.
– Close plastic bag every time it is opened, even if it has to be reopened shortly afterwards.
Ambient air carries contamination.
– All removed components of injection system must be kept in a plastic bag with hermetically closing fastener once
openings are closed with plugs.
– The use of brush, thinner, bellows, sponge or normal cloth is strictly forbidden once fuel system circuit has been
opened. These items are likely to allow impurities to enter the system.
– Open package of replacement part only immediately before installation.
Repair Instructions
Fuel Pressure Relief Procedure
AENFL80B1736002
1) Check that engine is cold.
2) Connect SUZUKI scan tool to DLC (1) with ignition
“OFF”.
Special tool
(A)
IFL80B180001-01

4) Confirm that fuel pressure line is not under pressure
using “Fuel Rail Pressure” parameter of SUZUKI
scan tool.
Fuel System Components

AENFL80B1736006
! WARNING
Before starting the following procedure, be sure to observe “Precautions for Fuel System Service”:
Diesel (Page 1G-15) in order to reduce the risk or fire and personal injury.
Low-Pressure Fuel Supply Circuit
(d)
4 5
7 (a)
3 3
(c)
(b)
13
F
11
10
12
12 10
IFL80B173003-04
F: Forward 7. Fuel filter fastener : 30 N.m (3.1 kgf-m, 22.5 lbf-ft)

1. Fuel tank 8. Fuel filter bracket : 45 N.m (4.6 kgf-m, 33.5 lbf-ft)
2. Fuel pump 9. To fuel filter : 5.5 N.m (0.56 kgf-m, 4.0 lbf-ft)
3. O-ring 10. To fuel tank : 3.0 N.m (0.31 kgf-m, 2.5 lbf-ft)
4. Fuel pump lock nut 11. To dash panel : Do not reuse
5. Fuel filter 12. To high pressure pump
6. Fuel filter element 13. To fuel return collector
High-Pressure Fuel Supply Circuit
(b)
(g)
5 (c)
9 (d)
7
11
12
(b)
(c)
(f)
(e)
8
(b) (a)
(f)
12 4
1
(e)
1 6
(a)
4 11
2
7 10 3
2
3
IFL80B173001-04
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 : 24 Nm (2.4 kgf-m, 18.0 lbf-ft)
4. Washer 11. Engine side hook : 15 Nm (1.5 kgf-m, 11.0 lbf-ft)
5. Common rail 12. High pressure pipe : : 9 Nm (0.9 kgf-m, 7.0 lbf-ft)
: For tightening order, refer to “High Pressure Pipe
Removal and Installation”: Diesel (Page 1G-22)
6. High pressure pump : 20 Nm (2.0 kgf-m, 15.0 lbf-ft) : Do not reuse.
7. Fuel return collector : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
High Pressure Pipe Removal and Installation • For high pressure pipes between fuel injector and
AENFL80B1736007 common rail.
! WARNING a. Loosen high pressure pipe union nuts (1) from
Before servicing fuel system, be sure to fuel injectors.
observe “Precautions for Fuel System b. Loosen high pressure pipe union nuts (2) from
Service”: Diesel (Page 1G-15). common rail (3), and remove high pressure
pipes (4).
NOTICE
2
If the union nut of the high pressure pipe
connecting to the high pressure pump / fuel 3
injectors is loosened and tightened without 4
holding the union nuts (1), the high pressure

pump / fuel injectors may be damaged.
Hold the union nuts whenever loosening and
tightening the union nut of the high pressure
pipe.
1
IBL80A172022-02
• For high pressure pipe between high pressure

pump and common rail.
a. Loosen high pressure pipe union nuts (1), and
remove high pressure pipe (2).
! CAUTION
When loosing union nut on high pressure
pump side, hold union nut (3) with wrench.
1
IDP60A173006-01
1
Removal 2
! CAUTION
As small amount of fuel may come out during
removal of high pressure pipes, cover high 3
pressure pipes with plug caps.
1) Release fuel pressure. (Page 1G-18)

3) Remove engine cover and engine cover bracket.
(Page 1D-29)
4) Remove intercooler outlet pipe bolts (1) and then
detach intercooler outlet pipe (2).
IBL80A172025-02
Installation
! CAUTION
• Do not touch pipes with wrench when

1
tightening union nuts to avoid damage to
1 high pressure pipe.
• When using the special tool with torque
wrench, torque wrench reading should be
smaller than specified tightening torque.
2 Correct reading value should be calculated
IBL80A172024-07
according to the formula below.
5) Remove high pressure pipes as follows.
• When tightening union nuts on high

(b)
pressure pump side and injector side, hold
each union nut with wrench.
Tightening torque formula.

M = T x L / (L + “a”)
M: Value indicated on torque wrench
T: Specified tightening torque
L: Length of torque wrench (a)
“a”: Length of special tool
IBL80A172036-01
Special tool
• Tighten engine cover bolts to specified torque.
(A): 09911M75420
(Page 1D-29)
(B): 09950M76510
• Check for fuel leakage. 
“a” Common Rail Removal and Installation

AENFL80B1736010
! WARNING
L
Before starting the following procedure, be
sure to observe “Precautions for Fuel
System Service”: Diesel (Page 1G-15) in
(A) order to reduce the risk or fire and personal
injury.
Removal
(A) “a” (B)
“b” 1) Release fuel pressure. (Page 1G-18)
3) Remove engine cover and engine cover bracket.
(Page 1D-29)
4) Remove high pressure pipes. (Page 1G-22)
IDL10A170038-01
5) Disconnect connectors from fuel pressure sensor as
follows.
• Use new high pressure pipe.
a) Move connector lock pin (1) in arrow direction as
• Tighten injector side union nuts and high pressure shown in figure.
pump side union nut to specified torque.
b) Push connector lock lever (2) and disconnect
Special tool each connector from fuel pressure sensor (3).
: 09950M76510 6) Remove common rail (4) from its bracket (5).
Tightening torque
High pressure pipe union nut (fuel injector side
1 2
and high pressure pump side) (a): 24 N·m (2.4
3
kgf-m, 18.0 lbf-ft)
• Tighten common rail side union nuts to specified 4
torque.
Special tool
: 09911M75420
Tightening torque
High pressure pipe union nut (common rail side)*
(b): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)
5
IDP60A173008-01
Installation
1
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.
NOTICE
Do not reuse high pressure pipe.
3) Tighten common rail bolts to specified torque.

Tightening torque
Common rail bolt (a): 25 N·m (2.5 kgf-m, 18.0 lbf-
ft) IBP80A172020-01
5) Remove intercooler outlet pipe bolts (1) and then

detach intercooler outlet pipe (2).
3(a)
1
2
IBL80A172031-02
4) Tighten high pressure pipe union nuts to specified

torque. (Page 1G-22) 2
IBL80A172024-07
5) Connect connectors to fuel pressure sensor. 6) Disconnect fuel feed hose (2) from high pressure
6) Install engine cover bracket and engine cover, and pump.
then tighten engine cover bolts to specified torque. 7) Remove high pressure pipe (1) between common
(Page 1D-29) rail and high pressure pump. (Page 1G-22)
7) Connect negative (–) cable at battery. 8) Disconnect fuel return hose (3) from high pressure
8) Check for fuel leakage.  pump.
High Pressure Pump Removal and Installation

AENFL80B1736011
! WARNING
2
Before starting the following procedure, be
System Service”: Diesel (Page 1G-15) in 1
order to reduce the risk of fire and personal
injury.
Removal
1) Release fuel pressure. (Page 1G-18)
2) Remove battery from vehicle.
• ISG model: (Page 1J-24)
• Non-ISG model: 
3) Remove engine cover. (Page 1D-29) 3
4) With hose connected, move degassing tank (1) in IDL10A170011-01
arrow direction to release it from stay. 9) Remove vacuum pump. 

10) Remove high pressure pump (1) from camshaft
housing.
IBL80A172039-01
Installation
1) Clean mating surfaces of high pressure pump and 3
camshaft housing. IDL10A170011-01
2) Install new gasket (1) to high pressure pump. NOTICE

3) Install high pressure pump (2) to camshaft housing.
Do not reuse high pressure pipe.
Fit dogs (3) of high pressure pump coupling into the
grooves (4) in camshaft. 7) Install intercooler outlet pipe bolts (1) and intercooler
4) Tighten high pressure pump bolts to specified outlet pipe (2).
torque.
Tightening torque
High pressure pump bolt (a): 15 N·m (1.5 kgf-m,
11.0 lbf-ft)
2 1
2
IBL80A172024-07
8) Install degassing tank to degassing tank bracket.

9) Install engine cover, and then tighten engine cover
bolts to specified torque. (Page 1D-29)
3 10) Connect negative (–) cable at battery.
11) Check for fuel leakage. 
IBL80A172041-01
5) Install new high pressure pipe (1) between high

pressure pump and common rail. (Page 1G-22)
6) Connect fuel feed hose (2) and return hose (3) to
high pressure pump.
Fuel Pipe Removal and Installation ! CAUTION

AENFL80B1736015
When connecting joint, clean outside
! WARNING surfaces of pipe where joint is to be inserted,
push joint into pipe till joint lock clicks and
• Before starting the following procedure, be
check to ensure that pipes are connected
securely, or fuel leak may occur.
System Service”: Diesel (Page 1G-15) in
order to reduce the risk of fire and
4) Check for fuel leakage. 
personal injury.
• A small amount of fuel may be released
Fuel Level Sensor Inspection
after fuel hose is disconnected. In order to AENFL80B1736024
reduce the chance of personal injury, Check resistance between terminals “3” and “4” at each
cover hose and pipe to be disconnected float position indicated below.
with a lint-free cloth. If check result is not as specified, replace fuel pump.
Be sure to put the used cloth in an
Fuel level sensor specifications
approved container when disconnection is
completed. Float position Resistance (Ω)
“a” 92.8 mm 51.6 – 55.0
“b” 56.7 mm 158.0 – 162.0
Removal
“c” 16.3 mm 264.0 – 269.4
2) Disconnect fuel pipe joints from fuel pipes at both
front and rear ends of each fuel pipe.  3 4
3) Mark the location of clamps on fuel pipes, so that the

clamps can be reinstalled to original positions.
(Page 1G-19)
4) Remove fuel pipes together with clamps from vehicle 1
underbody.
5) 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. “a”
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel pipes to respective pipes. 
2 “b”
“c”
I9P60A172037-02
1. Fuel pump 2. Float
Specifications
AENFL80B1737002
NOTE
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
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 
25 2.5 18.5
side)*
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Common rail bolt 25 2.5 18.0 
High pressure pump bolt 15 1.5 11.0 
Reference:
“Fuel System Components”: Diesel

Special Tool
AENFL80B1738002
09911M75420 09919M46310
Crowfoot flare-nut wrench Fuel system, plug set
18.17 /  

SDT-II)
Pipe spanner —
OUT0000148 /  
1H-1 Ignition System:
Ignition System
Engine

Ignition System Circuit Diagram
AENFL80B1802001
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
WHT E01-6
2 3
16
BLK YEL PNK E01-49
12V
WHT YEL BLU E01-56
5V
BLU E01-55
5V
1 4
RED/YEL C01-28
C01-50 BLK
5V
C01-51 BLK
5
PNK C01-31
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
IFL80B180002-01
[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
Ignition System: 1H-2
Repair Instructions
Spark Plug Inspection
AENFL80B1806002
Inspect spark plug for:
• Electrode wear
• Carbon deposits
• Insulator damage
If any abnormality is found, adjust air gap, clean with
spark plug cleaner or replace it with new plug.
1
Spark plug air gap “a”
: 0.95 to 1.05 mm (0.037 to 0.041 in.)
Spark plug type
NGK: LKR6F-10 (Nickel)
(A)
“a”
IFL80B180001-01

temperature.
3) Check that all electrical loads except ignition system
are switched off.
4) Check that idle speed is within specification referring
to “Idle Speed and IAC Throttle Valve Opening
Inspection”: Petrol in Section 1A (Page 1A-121).
5) Fix ignition timing by using “Fixed Spark” under
I8T401182005-01
“Active Test” mode on SUZUKI scan tool.
6) Set timing light (1) to ignition coil harness for No.1
Ignition Timing Inspection cylinder and check that ignition timing is within
AENFL80B1806005
NOTE specification.
• Ignition timing is not adjustable. If ignition Ignition timing

timing is not as specified, check Fixed with SUZUKI scan tool: 5° ± 3° BTDC (at
components related to ignition system. specified idle speed)
• Before starting engine, place transmission Ignition order
gear shift lever in neutral (M/T model) or 1–3–4–2
transmission select lever in “P” position
(A/T model) and set parking brake. Special tool
(A): 09930M76420
• For identification of each cylinder, refer to
“Statement on Cleanliness and Care”: 1, (A)
Petrol in Section 1A in related manual.
1) Connect scan tool to DLC (1) with ignition “OFF”.

Special tool
I7V20A180007-01
7) If ignition timing is out of specification, check the

following points.
• CKP sensor
• CKP sensor plate
1H-3 Ignition System:
• ECM and its circuit 9) With engine idling, check that ignition timing is about
• CMP sensor 5° – 15° BTDC (constant variation within a few
degrees from 5° – 15° BTDC indicates no
• CMP sensor rotor teeth of camshaft
abnormality and proper functioning of electronic
• Crankshaft timing control system). Also, check that increasing
• Crankshaft pulley engine speed advances ignition timing.
• Crankshaft pulley key If check result is not as specified, check the following
8) After checking initial ignition timing, release ignition points.
timing fixation using scan tool. • ECM and its circuit: (Page 1A-107)
• TP sensor: 
• APP sensor: 

Special Tool
AENFL80B1808002
SDT-II)
Timing light (dry cell type) —
 
Starting System: Petrol and Bi-Fuel CNG 1I-1
Starting System
Engine

General Description
Cranking System Description
AENFL80B1911001
The cranking circuit consists of the battery, starting motor, starting motor control relay, ignition switch (ignition switch
model), engine switch (keyless push start model), transmission range sensor (A/T model) or CPP No. 1 switch (if
equipped) and related electrical wiring.

Cranking System Circuit Diagram
AENFL80B1912001
Ignition switch model
10
7 GRN
5 6
RED/WHT C01-16
WHT/BLU 4 8
RED BLU/YEL C01-52
WHT 3 YEL 9
M
1
IFL80B191002-01
1. Battery 5. Ignition switch 9. ECM

2. Main fuse box 6. “ST SIG” fuse 10. Transmission Range Sensor (A/T model) or CPP No. 1 switch (M/T model) (if
equipped)
3. Starting motor 7. Starting motor control relay
4. “ST” fuse 8. “ST SIG2” fuse
1I-2 Starting System: Petrol and Bi-Fuel CNG
Keyless push start model
E01-92
9
E484-4 11
E484-8 11
10
BLK
PNK GRN
9
4 8
RED LT GRN E01-84
WHT 3 YEL 11
LT GRN E484-6
M
1
IFL80B191001-02
1. Battery 5. Ignition switch 9. ECM

2. Main fuse box 6. “ST SIG” fuse 10. Transmission Range Sensor (A/T model) or CPP No. 1 switch (M/T model) (if
equipped)
3. Starting motor 7. Starting motor control relay 11. Keyless start control module
4. “ST” fuse 8. “ST SIG2” fuse

Cranking System Symptom Diagnosis
AENFL80B1914001
Possible symptoms of starting system trouble are as follows:
• Starting motor does not run (or runs slowly).
• Starting motor runs but fails to crank engine.
• Abnormal noise is heard.
Proper diagnosis must be made to determine in which of the battery, wiring harness, starting motor (including
magnetic switch) and engine the cause of each trouble lies.
Before removing the starting motor, check the following items to identify most possible cause of trouble.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine) and starting motor terminals
3) Discharge of battery
4) Mounting of starting motor
Starting System: Petrol and Bi-Fuel CNG 1I-3

Starting motor not Malfunction of transmission range Check transmission range sensor. (Page 5A-
running (No operating sensor (A/T model) 109)
sound of magnetic Malfunction of CPP No.1 switch (if Check CPP No.1 switch. (Page 5C-1)
switch) equipped)
Battery voltage is too low Check battery. 
Improper charging due to deteriorated Replace battery. 
battery
Poor battery terminal connection Check terminal connection or replace battery.

Poor ground cable connection Tighten ground cable.
Blown fuse Replace fuse and check its circuit.
Faulty magnetic switch Check magnetic switch. 
Poor magnetic switch lead wire Check connector connection. 
connector connection
Open circuit in pull-in coil Check pull-in coil circuit. 
Defective brushes and/or brush springs Check brushes and brush springs. 
Poor sliding of plunger and/or pinion Check plunger and pinion. 
Faulty starting motor control relay Check starting motor control relay. (Page 1I-
4)
Faulty keyless push start system Check keyless push start system. (Page
(keyless push start model) 10E-43)
Faulty ignition switch (ignition switch Check ignition switch. 
model)
Starting motor not Battery voltage is too low Check battery. 
running (Operating sound Impossible charging due to deteriorated Replace battery. 
of magnetic switch heard) battery

Poor ground terminal connection Tighten ground cable.
Defective brush holder Check brush holder. 
Burnt commutator Check commutator. 
Short circuit between commutator and Check commutator. 
armature
Poor starting motor cable connection Check starting motor cable connection. 
Open circuit between battery and Repair circuit.
magnetic switch
Obstructed crankshaft rotation Repair engine assembly.
Starting motor running Faulty magnetic switch Check magnetic switch. 
but too slow (small Low battery voltage Check battery. 
torque) Impossible charging due to deteriorated Replace battery. 
battery

armature
Defective rear bracket bushing Check rear bracket bushing. 
Starting motor running, Worn pinion tip Replace overrunning clutch. 
but not cranking engine Poor sliding of overrunning clutch Check overrunning clutch. 
Slipping overrunning clutch Replace overrunning clutch. 
Worn teeth of ring gear Replace flywheel. (Page 1D-14)
Noise Abnormally worn bushing Replace bushing. 
Worn teeth of pinion Replace overrunning clutch. 
1I-4 Starting System: Petrol and Bi-Fuel CNG
Repair Instructions
Starting Motor Control Relay Inspection
AENFL80B1916004
Refer to “Control Relay Inspection” in Section 10B (Page 10B-35).
Starting System: Diesel 1I-5
Diesel
General Description
Cranking System Description
AENFL80B1921001
Cranking Circuit
The cranking circuit consists of the battery, starting motor, starting motor control relay, ignition switch (ignition switch
model), engine switch (keyless push start model) or CPP No.1 switch (keyless push start model), and related electrical
wiring.
Starting Motor Circuit

In the circuit shown in “Cranking System Circuit Diagram”: Diesel (Page 1I-5), the coil of the magnetic switch in
starting motor is energized when ignition is set to “START”. The resulting movement of the plunger and pinion drive
lever causes the pinion to engage with the engine flywheel gear while closing the contacts of the magnetic switch. This
causes the starting motor to rotate to crank the engine.
When the engine starts, the pinion overrunning clutch protects the armature from excessive speed until the switch is
opened, at which time the return spring causes the pinion to disengage.

Cranking System Circuit Diagram
AENFL80B1922001
8
6 7 9
BRN PNK GRN
WHT/BLU
4
WHT RED
5 11
BLK E01-92
BLK
YEL
3 10
E01-84
2
1
M
IFL80B192002-01
1. Battery 4. “ST” fuse 7. “ST SIG” fuse 10. “ST SIG” fuse
2. Main fuse box 5. “IG2 SIG” fuse 8. Starting motor control relay 11. ECM
3. Starting motor 6. Ignition switch 9. CPP No.1 switch (ISG model)
1I-6 Starting System: Diesel
E01-92
9
E484-4 10
E484-8 10
11
BLK
PNK GRN
9
4 8
RED LT GRN E01-84
BLK 3 YEL 10
LT GRN E484-6
M
1
IFL80B192001-02
1. Battery 5. “IG2 SIG” fuse 9. ECM

2. Main fuse box 6. Ignition switch 11. Keyless start control module
3. Starting motor 7. “ST SIG” fuse 10. Transmission Range Sensor (A/T model) or CPP No.
1 switch (M/T model) (if equipped)
4. “ST MOT” fuse 8. Starting motor control relay

Cranking System Symptom Diagnosis
AENFL80B1924001
Possible symptoms of starting system trouble are as follows:
• Starting motor does not run (or runs slowly).
• Starting motor runs but fails to crank engine.
• Abnormal noise is heard.
• Starting motor does not stop running.
Proper diagnosis must be made to determine in which of the battery, wiring harness, starting motor (including
magnetic switch) and engine the cause of each trouble lies.
Before removing the starting motor, check the following items to identify most possible causes of trouble.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine) and starting motor terminals
3) Discharge of battery
4) Mounting of starting motor

Starting motor not Malfunction of CPP No.1 switch (keyless Check CPP No.1 switch. (Page 5C-5)
running (No operating push start model)
sound of magnetic Battery voltage is too low Check battery.
switch) ISG model: (Page 1J-22)
Non-ISG model: 
Impossible charging due to deteriorated Replace battery.
battery ISG model: (Page 1J-24)
Non-ISG model: 
ISG model: (Page 1J-24)
Non-ISG model: 
Poor ground cable connection Tighten ground cable.
Blown fuse Replace fuse and check its circuit.
Poor magnetic switch lead wire Check connector connection. (Page 1I-8)
connector connection
Open circuit in pull-in coil Check pull-in coil circuit. 
Poor sliding of plunger and/or pinion Check plunger and pinion. 
Faulty starting motor control relay Check starting motor control relay. 
Faulty keyless push start system Check keyless push start system. (Page
model)
Starting motor not Battery voltage is too low Check battery.
running (Operating sound ISG model: (Page 1J-22)
of magnetic switch heard) Non-ISG model: 
Non-ISG model: 
Non-ISG model: 
Poor ground terminal connection Tighten ground cable.
Defective magnetic switch Check magnetic switch. 
Faulty brush holder Check brush holder. 
armature
Poor starting motor cable connection Check starting motor cable connection.
(Page 1I-8)
Open circuit between battery and Repair circuit.
magnetic switch
Obstructed crankshaft rotation Repair engine assembly.

Starting motor running Faulty magnetic switch Check magnetic switch. 
but too slow (small Low battery voltage Check battery.
torque) ISG model: (Page 1J-22)
Non-ISG model: 
Non-ISG model: 
Non-ISG model: 
armature
Defective rear bracket bushing Check rear bracket bushing. 
Starting motor running, Worn pinion tip Replace overrunning clutch. 
but not cranking engine Poor sliding of overrunning clutch Replace overrunning clutch. 
Slipping overrunning clutch Replace overrunning clutch. 
Noise Abnormally worn bushing Replace starter housing or rear bracket. 
Worn teeth of pinion Replace overrunning clutch. 
Starting motor does not Faulty magnetic switch Check magnetic switch. 
stop running Faulty keyless push start system Check keyless push start system. (Page
model)
Faulty starting motor control relay Check starting motor control relay. 
Repair Instructions
Starting Motor Removal and Installation
AENFL80B1926002
Removal
1) Remove battery and battery tray.
Non-ISG model: 
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).
1 2
4
IBP80A192002-01
Installation
• 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)
1,(a)
1,(a) 2,(b)
3,(c)
IBP80A192003-01
Specifications
AENFL80B1927003
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 
Reference:
Charging System: Petrol and Bi-Fuel CNG 1J-1
Charging System
Engine

General Description
Generator Description
AENFL80B1A11002
The generator is of a small and high performance type with an IC regulator incorporated. The internal components are
connected electrically as shown in figure.
LIN is used for communication between generator and ECM. (For petrol model, refer to “Electronic Control System
Description”: Petrol in Section 1A (Page 1A-5) for more information on generator control system. For bi-fuel CNG
model, refer to “Electronic Control System Description”: Bi-Fuel CNG in Section 1A in related manual for more
information on generator control system).
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 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
8
2
3
LIN
6
7
IEL10A1A1001-02
1. Generator 4. Diode 7. Battery

2. IC regulator 5. Field coil (rotor coil) 8. Electric load
3. Stator coil 6. ECM
1J-2 Charging System: Petrol and Bi-Fuel CNG
IEL10A1A1002-03
1. Pulley 5. Bearing retainer 9. Rear end cover

2. Pulley nut 6. Rotor 10. Generator output (“B” terminal)
3. Rotor fan 7. Stator assembly 11. LIN terminal
4. Bearing 8. Brush holder assembly 12. Drive end frame

Generator Symptom Diagnosis
AENFL80B1A14002
Trouble in charging system will show up as one or more of the following conditions.
Charging Warning Light Operation

Charge warning light Blown fuse Replace fuse.
does not light with Faulty combination meter Replace combination meter. (Page 9C-24)
ignition “ON” and engine Faulty BCM Check BCM.
off For ignition switch model, refer to “Inspection
of BCM and Its Circuits (Ignition Switch
Model)” in Section 10B (Page 10B-20).
For keyless push start model, refer to
“Inspection of BCM and Its Circuits (Keyless
Push Start Model)” in Section 10B (Page 10B-
27).
Faulty CAN communication line Repair or replace CAN communication line.
(Page 10H-10)
Faulty wiring Repair or replace wiring.
Faulty IC regulator or field coil Repair or replace generator. (Page 1J-5)
Charge warning light Loose or worn drive belt Adjust or replace drive belt. 
does not go out with Faulty combination meter Replace combination meter. (Page 9C-24)
engine running (battery Faulty BCM Check BCM.
requires frequent For ignition switch model, refer to “Inspection
recharging) of BCM and Its Circuits (Ignition Switch
27).
Faulty IC regulator or generator Repair or replace generator. (Page 1J-5)
Faulty wiring Repair or replace wiring.
Battery Charge Failure

Undercharged battery Loose or worn drive belt Adjust or replace drive belt. 
Loose or corroded battery terminal Tighten battery terminal or replace battery. 
Faulty rectifier, rotor and/or IC regulator Repair or replace generator. (Page 1J-5)
Overcharged battery Faulty IC regulator Repair or replace generator. (Page 1J-5)
Noise
Noisy generator Loose mounting bolts Tighten mounting bolts. 
Dirty, worn and/or faulty bearings Repair or replace generator. (Page 1J-5)
Faulty rotor, diode and/or stator Repair or replace generator. (Page 1J-5)
Generator Test
AENFL80B1A14003
This condition, as evidenced by slow cranking or low
specific gravity, can be caused by one or more of the
following conditions even though warning light operates
normally. The following procedure also applies to cars
with voltmeter and ammeter.
• Check that undercharged condition has not been
caused by accessories being left on for extended
period of time.
• Check generator drive belt for wear and tension. 
I9P60A1A1018-01
• If battery defect is suspected, refer to “Battery
1. Generator 6. Switch
Description”: Petrol and Bi-Fuel CNG in related
4. Battery 7. “B” terminal
manual.
• Check wiring for defects. Check all connections for 5) Run engine around 2,000 rpm and read meters.
tightness and cleanliness, battery cable connections
• If voltage is higher than standard value, check
at battery, starting motor and ignition ground cable.
ground circuit of brushes. (Page 1J-8)
If brushes are not grounded, replace IC regulator.
No-Load Check
• If voltage is lower than standard value, inspect
NOTE rotor, stator, rectifier, bushings and regulator.
Use fully charged battery. (Page 1J-8)
Specification for undercharged battery (No-load
1) Check for DTC. check)
Petrol model: (Page 1A-16) Current: 10 A
Bi-Fuel CNG model: (Page 1A-133) Regulated voltage: 10.4 – 16.3 V (at 25 °C, 77 °F)
If there is any DTC, perform troubleshooting for
applicable DTC and then clear DTC. Load Check
• Troubleshooting:
Petrol model: (Page 1A-17) NOTE
Bi-Fuel CNG model: (Page 1A-134) Use fully charged battery.
• DTC clearance:
Petrol model: (Page 1A-16) 1) Connect ammeter in the same way as “No-Load
Bi-Fuel CNG model:  Check”: Petrol and Bi-Fuel CNG (Page 1J-3).
2) Turn off all electrical loads (5). 2) Run engine around 2,000 rpm and turn on the
following electrical loads.
3) Connect voltmeter (3) and ammeter (2) as shown in
figure. • Headlight (High beam)
4) Start engine and warm it up to normal operating • Rear window defogger
temperature. • 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 7) Attach one end of the remaining negative (–) cable
AENFL80B1A16001 to negative (–) terminal of booster battery, and other
With Booster Battery
end to solid engine ground (such as exhaust
NOTICE manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
Starting an M/T vehicle equipped with a
catalytic converter by pushing or towing may 8) Start engine of vehicle with booster battery and turn
cause damage to emission control system off its electrical loads. Then try to start engine of
and/or other components. vehicle with discharged battery.
Do not start an M/T vehicle by pushing or 9) Disconnect jumper cables in exact reverse order.
towing it.
With Charging Equipment
Both booster and discharged battery should be treated
carefully when using jumper cables. Follow the ! CAUTION
procedure outlined as follows, being careful not to cause When jump-starting engine with charging
sparks. equipment, be sure that equipment is for 12-
volt and negative (–) ground system. Do not
! WARNING use 24-volt charging equipment. Using such
Failure to take proper precautions when jump equipment can cause serious damage to
starting a vehicle may result in serious electrical system or electronic parts.
personal injury and/or damage to electronic
components of either the vehicle with a dead
battery or the vehicle used for jump starting.
• Never expose the battery to open flame or
electric spark. A battery generates highly
flammable and explosive hydrogen gas.
• Remove rings, watches and other jewelry.
Wear approved eye protector.
• Battery fluid is a corrosive acid. Do not
allow it to contact eyes, skin, fabrics or
painted surfaces of the vehicle. If the fluid
contacts any of them, immediately and
thoroughly flush the affected area with
water.
• To avoid a danger of short circuit, do not
allow a metal tool or jumper cable to touch
the positive terminal of the battery (or a
metal piece in contact with it) and any
metal part of the vehicle at the same time.
1) For M/T model, place gear shift lever in “Neutral”.

For A/T model, place select lever in “P”.
2) Apply parking brake.
4) Turn off lights and all other electrical loads.
5) For battery with cell caps, check electrolyte level. If it
is below low level line, add distilled water.
6) Attach end of one jumper cable to positive (+)
terminal of booster battery and other end of the
same cable to positive (+) terminal of discharged
battery (Use 12-volt battery only to jump-start
engine).
Generator Components
AENFL80B1A16007
1 (a)
4
5
(b)
9 6
7
8
(d)
(c)
(e)
10
IEL10A1A1005-01
1. Pulley nut 6. Rotor : 133 Nm (13.6 kgf-m, 98.5 lbf-ft)

2. Pulley 7. Stator assembly : 2.3 Nm (0.23 kgf-m, 2.0 lbf-ft)
3. Drive end frame 8. Brush holder assembly : 5.9 Nm (0.60 kgf-m, 4.5 lbf-ft)
4. Bearing 9. Bushing : 1.8 Nm (0.18 kgf-m, 1.5 lbf-ft)
5. Bearing retainer 10. Rear end cover : 4.6 Nm (0.47 kgf-m, 3.5 lbf-ft)
Generator Disassembly and Reassembly

AENFL80B1A16008
3
Disassembly
1) To facilitate reinstallation, provide matchmarks (1)
1
on drive end frame (2) and stator assembly (3) as
shown.
3 2
2
IDAA0A1A1019-01
4) Remove brush holder assembly (1) from stator

assembly.
IDAA0A1A1018-02
2) Remove rear end cover bolts (1), and then remove

rear end cover (2) from stator assembly.
3) Remove bushing (3) from “B” terminal.
NOTICE
The rotor may be damaged if it is not held in a
vise in the specified method and at the
indicated parts when loosening the pulley
1 nut.
Be sure to hold the rotor in the vise via a
clean cloth (3) at the iron parts (4). Never hold
the rotor at other parts (5).
b) Remove pulley (6).
IEL10A1A1006-01 5
5) Remove rear end frame bolts (1).
3 4 1
1 2
IEL10A1A1009-01
1
8) Remove rotor (1) from drive end frame (2) by tapping
shaft (3) lightly using plastic hammer.
IEL10A1A1007-01
6) Remove stator assembly (1) from drive end frame

(2).
2
IEL10A1A1010-01
9) If necessary, remove bearing retainer screws and

bearing retainer (1), and then remove bearing (2)
from drive end frame (3) using special tool.
NOTE
If necessary, when removing bearing heat
drive end frame to a temperature of 80 – 100
°C (176 – 212 °F) so that it will not be
2 distorted.
Special tool
IEL10A1A1008-01
(A): 09925M96710
7) Remove pulley as follows.
a) Hold rotor (1) using vise (2).
2
1
1
2
3
(a)
IEL10A1A1016-01
IDAA0A1A1023-01
3) Install rotor (1) to stator assembly (2).
(A)
ICV00P1A0018-01
2
IEL10A1A1011-01
Reassembly
1) Using special tool, install new bearing to drive end 4) Install pulley as follows.
frame. Check the bearing for smooth rotation, if a) Hold rotor (1) using vise (2).
removed.
NOTICE
NOTICE The rotor may be damaged if it is not held in a
When installing the bearing, the bearing and vise in the specified method and at the
the drive end frame may become damaged if specified parts when tightening the pulley
pressing any section other than the outer nut.
race. Be sure to hold the rotor in the vise via a
Press the outer race of the bearing when clean cloth (3) at the iron parts (4). Never hold
installing it. the rotor at other parts (5).
Special tool b) Tighten pulley nut (6) to specified torque.

(A): 09913M76010 Tightening torque
Pulley nut (a): 133 N·m (13.6 kgf-m, 98.5 lbf-
ft)
6, (a)
(A) 5
ICV00P1A0021-01
2) Install bearing retainer (1) to drive end frame (2), and 3 4 1

2
then tighten bearing retainer screws to specified IEL10A1A1012-01
torque. 5) Install bearing bush to stator assembly.

Tightening torque 6) Install stator assembly (1) to drive end frame (2).
Bearing retainer screw (a): 2.3 N·m (0.23 kgf-m, 7) Tighten rear end frame bolts to specified torque.
2.0 lbf-ft)
Tightening torque
Rear end frame bolt (a): 5.9 N·m (0.60 kgf-m, 4.5
lbf-ft) 1
1
3, (a)
(a)
2
IEL10A1A1013-01 IDAA0A1A1028-01
8) Install brush holder assembly (1) using the following

procedure: Generator Inspection
AENFL80B1A16009
a) Push brushes (2) in arrow direction.
b) Hold brushes in compressed position, by Rotor
inserting a pin (3) into stopper hole (4). 1) Using ohmmeter (1), check for continuity between
slip rings (2) of rotor. If there is no continuity, replace
NOTE
rotor.
Recommended pin diameter: About 1.0 mm
(0.04 in.) Standard resistance between slip rings of rotor
1.7 – 2.3 Ω
c) Install brush holder assembly to stator assembly
(5), and then tighten brush holder assembly
screws (6) to specified torque.
Tightening torque
Brush holder assembly screw (a): 1.8 N·m (
0.18 kgf-m, 1.5 lbf-ft)
6,(a)
2
5 1 4
I4RS0B1A0005-01
2) Using ohmmeter (1), check that there is no continuity

between slip ring (2) and rotor core (3). If there is
4 continuity, replace rotor.
1
3
IEL10A1A1014-02
d) Remove pin from brush holder assembly.

9) Install bushing (1) to “B” terminal.
10) Install rear end cover (2) to stator assembly, and
then tighten rear end cover bolts (3) to specified
torque.
I4RS0B1A0008-01
Tightening torque 3) Check slip rings and fan blades for damage. If any
Rear end cover bolt (a): 4.6 N·m (0.47 kgf-m, 3.5 abnormality is found, replace rotor.
lbf-ft)
Bearing
Check bearing for smooth rotation.
If any abnormality is found, replace bearing.
NOTE NOTE
Bearing (1) shown in figure is combined with For diode test, refer to the instruction manual
rotor (2) and check it as it is. If any of circuit tester.
abnormality is found, replace rotor.
1
A4
A1
2 1
2
A3
ICV00P1A0016-01
A6
Stator A5
A2
• Using ohmmeter, check continuity between each of
stator coil terminals (A1 / A2 / A3). If there is no
continuity, replace stator assembly. 1

stator coil terminals (A1 / A2 / A3) and corresponding
terminals (A4 / A5 / A6). If there is no continuity, A1 A4
replace stator assembly.
• Using diode range of circuit tester, check continuity A2 A5
between “B” terminal (1) and stator coil terminals (A4 /

A3 A6
A5 / A6), and ground (2) and stator coil terminals (A4 /
A5 / A6).
Check both directions by reversing probes of circuit
tester and, if there is continuity in both directions or
there is no continuity in both directions, replace stator 2
assembly. IEL10A1A1015-01
Brush
Check each brush for wear by measuring its length as
shown. If brush has worn down to service limit, replace
brush holder assembly.
Exposed brush length “a”
Standard: 10.5 mm (0.41 in.)
Limit: 1.5 mm (0.06 in.)
“a”
I8T4011A0022-01
Rectifier
NOTE
Rectifiers are combined with stator assembly
and inspection for individual rectifier is not
possible.
Specifications
Charging System Specifications
AENFL80B1A17001
Battery
Battery specification
: 38B20L (28AH/5HR)
Generator
Type 80 A type
Rated voltage 12 V
Nominal output 80 A
Permissible max. speed 18,000 rpm
No-load speed 1,250 rpm
Regulated voltage 10.7 – 16.3 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

AENFL80B1A17003
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Bearing retainer screw 2.3 0.23 2.0 
Pulley nut 133 13.6 98.5 
Rear end frame bolt 5.9 0.60 4.5 
Brush holder assembly screw 1.8 0.18 1.5 
Rear end cover bolt 4.6 0.47 3.5 
Reference:
“Generator Components”: Petrol and Bi-Fuel CNG

Special Tool
AENFL80B1A18002
09913M76010 09925M96710
Bearing installer Bearing installer
 
Charging System: Diesel (without ISG) 1J-11
Diesel (without ISG)

General Description
AENFL80B1A21002
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 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 9
FR
IEP80A1A2002-01
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-12 Charging System: Diesel (without ISG)
10 11
3 4 5
6
12
2
9 8 13
IEP80A1A2001-01
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

AENFL80B1A24002
Charging Warning Light Operation Failure

Charge warning light Blown fuse Check fuse.
off For ignition switch model, refer to “Inspection
27)
(Page 10H-36)
Faulty wiring Repair wiring.
Faulty IC regulator or field coil Repair or replace generator. (Page 1J-14)

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: 
requires frequent Accessory drive belt tensioner: 
recharging) Faulty combination meter Replace combination meter. (Page 9C-24)
Faulty BCM Check BCM.
For ignition switch model, refer to “Inspection
27)
Faulty IC regulator or generator Repair or replace generator. (Page 1J-14)
Battery Charging Failure

Undercharged battery Loose or worn accessory drive belt Replace accessory drive and/or accessory
drive belt tensioner.
Accessory drive belt: 
Accessory drive belt tensioner: 
Faulty one way clutch pulley Replace one way clutch pulley. (Page 1J-14)
Loosen or corroded battery terminals Tighten battery terminals or replace battery. 
Faulty rectifier, rotor or IC regulator Repair or replace generator. (Page 1J-14)
Overcharged battery Faulty IC regulator Repair or replace generator. (Page 1J-14)
Noise
Noisy generator Loosen mounting bolts Tighten mounting bolts. 
Faulty rotor, diode or stator Repair or replace generator. (Page 1J-14)
Dirty, worn or faulty bearings Repair or replace generator. (Page 1J-14)
Faulty one way clutch pulley Replace one way clutch pulley. (Page 1J-14)
Generator Test If there is any DTC, perform troubleshooting for

AENFL80B1A24003 applicable DTC and then clear DTC.
specific gravity, can be caused by one or more of the • Troubleshooting: (Page 1A-182)
following conditions even though charge warning light • DTC clearance: (Page 1A-182)
operates normally. 2) Turn off all electrical loads (5).
• Check that undercharged condition has not been 3) Connect voltmeter (3) and ammeter (2) as shown in
caused by accessories being left on for extended figure.
period of time. 4) Start engine and warm it up to normal operating
• Check generator drive belt for wear and tension.  temperature.
Description”: Diesel (without ISG) in related manual.
• Check 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-181)

• If voltage is lower than standard value, inspect

rotor, stator, rectifier, brush and regulator. (Page
1J-17)
Specification for undercharged battery (No-load
check)
Current: 10 A
Regulated voltage: 11.7 – 15.3 V (at 25 °C, 77 °F)
Load Check
NOTE
I2RH011A0006-01
1) Connect ammeter in the same way as “No-Load
1. Generator 6. Switch
4. Battery
Check”: Diesel (without ISG) (Page 1J-13).
2) Run engine around 2,000 rpm and turn on the
5) Run engine around 2,000 rpm and read meters. following electrical loads.
• If voltage is higher than standard value, check • Headlight (High beam)
ground circuit of brushes. (Page 1J-17) • Rear window defogger (If equipped)
If brushes are not grounded, replace IC regulator. • Blower motor (Maximum speed)
3) Read ammeter. If meter reading is less than 20 A,
repair or replace generator.
Repair Instructions
Generator Disassembly and Reassembly

AENFL80B1A26008 1
Disassembly
1) To facilitate reinstallation, provide matchmarks (1)
on drive end frame (2) and stator assembly (3) as
shown in figure.
2 3
IDL10A1A0013-01
3) Remove brush holder (1).
IDL10A1A0012-01
2) Remove rear end cover (1).

6) Remove pulley as follows.

1 a) Remove pulley cap.
b) Hold rotor (1) using vise (2).
NOTICE
The rotor may be damaged if it is not held in a
vise in the specified method and at the
indicated parts when loosening the pulley.
clean cloth (3) at the iron parts (4). Never hold
the rotor at other parts (5).
c) Remove pulley (6) using special tool.

Special tool
(A): 09932M96510
IDL10A1A0014-01
4) Remove stator assembly (1) from drive end fame (2).

(A) 6
1
5
3 4 1
2
IDL10A1A0018-01
7) Remove rotor (1) from drive end frame (2) by tapping

shaft (3) lightly using plastic hammer.
2
1
IDL10A1A0015-01
5) Remove bearing bush (1).
2
IDL10A1A0019-01
8) If necessary, remove bearing retainer screws and

bearing retainer (1), and then remove drive end
1 bearing (2) from drive end frame (3) using special
tool.
NOTE
If necessary, heat drive end frame to a
IDL10A1A0016-01 temperature of 80 – 100 °C (176 – 212 °F) so
that it will not be distorted, and remove
bearing.
Special tool
(A): 09943M88211
2) Check that drive end bearing (1) turns smoothly.

1
3) Install bearing retainer (2), and then tighten bearing
retainer screws to specified torque.
Tightening torque
Bearing retainer screw (a): 2.3 N·m (0.23 kgf-m,
2.0 lbf-ft)
1 2
(a)
IDL10A1A0020-01
(a)
(A)
2 IDL10A1A0024-01
4) Install rotor (1) to drive end frame (2).
IDL10A1A0021-01
Reassembly
1) Install new drive end bearing (1) to drive end frame
2
using special tool and hydraulic press, if removed.
IDL10A1A0025-01
NOTICE 5) Install pulley as follows.

When installing the drive end bearing to drive a) Hold rotor (1) using vise (2).
end frame, the drive end bearing may be
damaged if pressing on any section other NOTICE
than the outer race of drive end bearing. The rotor may be damaged if it is not held in a
Press on the outer race of drive end bearing vise in the specified method and at the
when installing it to the drive end frame. indicated parts when loosening the pulley.
Special tool clean cloth (3) at the iron parts (4). Never hold
(A): 09913M76010 the rotor at other parts (5).
b) Tighten pulley (6) to specified torque.

Special tool
(A) (A): 09932M96510
Tightening torque
Pulley (a): 133 N·m (13.6 kgf-m, 98.5 lbf-ft)
IDL10A1A0023-01
10) Install brush holder (1), and then tighten brush

holder screws to specified torque.
(A) 6, (a) Tightening torque
Brush holder screw (a): 1.8 N·m (0.18 kgf-m, 1.5
5
lbf-ft)
3 4 1
2
IDL10A1A0026-01
c) Install pulley cap.

6) Install bearing bush to stator assembly. (a)
7) Install stator assembly (1) to drive end frame (2).
8) Tighten rear end frame bolts to specified torque.
Tightening torque
Rear end frame bolt (a): 5.9 N·m (0.60 kgf-m, 4.5 IDL10A1A0029-01
lbf-ft) 11) Remove wire.

12) Install rear end cover (1) and tighten rear end cover
1
bolts (2) to specified torque.
Tightening torque
Rear end cover bolt (a): 4.6 N·m (0.47 kgf-m, 3.5
lbf-ft)
1
(a)
2
IDL10A1A0027-01
9) Push brushes (1) into brush holder, and then support

brushes by inserting appropriate wire (2).
2, (a)
IDL10A1A0030-01
Generator Inspection
1 AENFL80B1A26009
2
Rotor
1) Using ohmmeter (1), check for continuity between
slip rings (2) of rotor. If there is no continuity, replace
IDL10A1A0028-01
rotor.
Standard resistance between slip rings of rotor
Approx, 2.9 Ω at 20 – 25 °C (68 °F – 77 °F)
• Using diode range of circuit tester, check continuity

2 between “B” terminal (1) and stator coil terminals (A4 /
A5 / A6), and ground (2) and stator coil terminals (A4 /
1
A5 / A6).
Check both directions by reversing probes of circuit
tester and, if there is continuity in both directions or
there is no continuity in both directions, replace stator
assembly.
NOTE
I8G0011A0010-01
For diode test, refer to the instruction manual
2) Using ohmmeter (1), check that there is no continuity
of circuit tester.
between slip ring (2) and rotor core (3). If there is
continuity, replace rotor.
2
A4
1 1
A1
2
A3
I8G0011A0011-01
A6
3) Check slip rings for roughness or score. If they are
A2
rough or scored, replace rotor.
Using a vernier caliper, measure the slip ring A5
diameter. If the diameter is less than service limit,

replace the rotor. 1
Slip ring diameter

Standard: 14.4 mm (0.566 in.)
Limit: 14.0 mm (0.551 in.) A1 A4
A2 A5
A3 A6
2
IEP80A1A2005-01
Brush
Check each brush for wear by measuring its length as
IYSQ011A0044-01
shown. If brush has worn down to service limit, replace
brush holder.
Bearing
Check bearing for smooth rotation. Exposed brush length “a”
If defective condition is found, replace it. Standard: 10.5 mm (0.413 in.)
Limit: 4.5 mm (0.177 in.)
Stator
stator coil terminals (A1 / A2 / A3). If there is no
continuity, replace stator assembly.
stator coil terminals (A1 / A2 / A3) and corresponding
terminals (A4 / A5 / A6). If there is no continuity,
replace stator assembly.
2) Using multimeter or ohmmeter, check continuity

between terminal “E” (1) and terminal “F” (2). Check
that the state of continuity is in the following
condition. If not, replace regulator (3).
• When positive and negative probes between
terminal “E” and terminal “F” are exchanged, there
is continuity in one direction but no continuity in
the other direction.
IDL10A1A0003-01 B
B IG
Rectifier L
P
3
NOTE FR
1
Rectifiers are combined with stator assembly 2 C
F
and inspection for individual rectifier is not E
possible.
E
IEP80A1A2004-01
Regulator
Pulley
NOTE
• Check pulley for wear, damage or other abnormal
If multimeter is used, choose its diode range conditions. Replace pulley if necessary.
for this check
• Check pulley according to the following procedure.
1) Using multimeter or ohmmeter, check continuity a. Hold center of pulley.
between terminal “F” (1) and terminal “B” (2). Check b. Check that pulley locks up when turned clockwise
that the state of continuity is in the following [b] and rotates smoothly when turned
condition. If not, replace regulator (3). counterclockwise [a].
• When positive and negative probes between If any faulty condition is found, replace pulley.
terminal “F” and terminal “B” are exchanged, there
is continuity in one direction but no continuity in [a]
the other direction.
B
B IG
L
P
3
FR [b]
1 C
F
E
2 IAW1011A0030-01
E
IEP80A1A2003-01
Specifications
AENFL80B1A27001
Battery type: DIN50LMF
Generator
Type 80 A type
Rated voltage 12 V
Nominal output 80 A
Permissible max. speed 18,000 r/min.
No-load speed 1,100 r/min.
Regulated voltage 11.7 – 15.3 V at 25 °C (77 °F)


AENFL80B1A27003
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Bearing retainer screw 2.3 0.23 2.0 
Pulley 133 13.6 98.5 
Rear end frame bolt 5.9 0.60 4.5 
Brush holder screw 1.8 0.18 1.5 
Rear end cover bolt 4.6 0.47 3.5 
Reference:

Special Tool
AENFL80B1A28002
09913M76010 09932M96510
Bearing installer Pulley remover attachment
 /
09943M88211
Pinion bearing installer

Charging System: Diesel (with ISG) 1J-21
Diesel (with ISG)

Precautions
Precautions for Handling Battery
AENFL80B1A30001
! WARNING
Failure to take proper precautions when handling the battery may cause severe personal injury.
• Never expose the battery to an open flame or electric spark. A battery generates highly flammable
and explosive hydrogen gas.
• Battery fluid is a corrosive acid. Do not allow it to contact eyes, skin, fabrics or painted surfaces of
the vehicle. If the fluid contacts any of them, immediately and thoroughly flush the affected area
with a large quantity of water.
• Keep the battery out of reach of children.
1) The battery is a very reliable component, but needs periodical attentions.

• Keep the battery tray clean.
• Prevent rust formation on the terminal posts.
• Keep electrolyte up to the upper level uniformly in all cells. (If cell caps are equipped)
• When keeping battery on vehicle over a long period, follow instructions given below.
– Weekly, start the engine and run it until it reaches normal operating temperature with engine speed of 2,000
to 3,000 rpm. Check that all electric switches are turned off before storing the vehicle.
– Recharge the battery twice a month to prevent it from discharging excessively. This is especially important
when ambient temperature is low.
The battery discharges even when it is not used, while vehicles are stored. Battery electrolyte can freeze and
battery case can crack in cold ambient condition if the battery is not properly charged.
2) Keep the battery cable connections clean.
The cable connections, particularly at the positive (+) terminal post, tend to corrode. The corrosion or rust on the
mating faces of conductors resists the flow of current.
Clean the terminals and fittings periodically to ensure good metal-to-metal contact, and grease the connections
after each cleaning to protect them against rusting.
3) Periodically check the state of charge of the battery. The simplest way to tell the state of charge is to carry out a
hydrometer test. The hydrometer is an instrument for measuring the specific gravity of the battery electrolyte. The
specific gravity of the electrolyte is indicative of the state of charge. (Page 1J-22)
Precautions for Replacing Battery

AENFL80B1A30002
Use SUZUKI genuine battery specified for SHVS system. (Page 1J-29)
General Description
Battery Description
AENFL80B1A31001
Refer to “Battery Description”: Diesel (without ISG) in related manual.
AENFL80B1A31002
For the details on electricity generating mechanism, refer to “SHVS System Description” in Section 11A (Page 11A-1).
1J-22 Charging System: Diesel (with ISG)

Battery Inspection
AENFL80B1A34001
Refer to “Battery Inspection”: Diesel (without ISG) in related manual.

AENFL80B1A34002
Charging Warning Light Operation Failure

Charge warning light Blown fuse Replace fuse and check its circuit.
off • Ignition switch model: (Page 10B-20)
• Keyless push start model: (Page 10B-27)
Faulty ECM Check ECM. (Page 1A-318)
Faulty gateway control module Check gateway control module. (Page 11A-
51)
(Page 10H-36)
Faulty LIN communication line Repair or replace LIN communication line.
Faulty ISG Replace ISG. (Page 1J-27)
Charge warning light Malfunctioning charging system Perform generator test. (Page 1J-23)
does not go out with Loose or worn ISG drive belt Replace ISG drive belt. (Page 1J-25)
engine running (battery Faulty ISG drive belt tensioner and idler Replace ISG drive belt tensioner and idler
requires frequent pulley pulley. (Page 1J-27)
recharging) Faulty combination meter Replace combination meter. (Page 9C-24)
Faulty BCM Check BCM.
• Ignition switch model: (Page 10B-20)
• Keyless push start model: (Page 10B-27)
Faulty ECM Check ECM. (Page 1A-318)
Faulty gateway control module Check gateway control module. (Page 11A-
51)
Battery Charging Failure

Undercharged battery Loose or worn ISG drive belt Replace ISG drive belt. (Page 1J-25)
Faulty ISG drive belt tensioner and idler Replace ISG drive belt tensioner and idler
pulley pulley. (Page 1J-27)
Loosen or corroded battery terminals Tighten battery terminals or replace battery.
(Page 1J-24)
Overcharged battery Faulty ISG Replace ISG. (Page 1J-27)
Noise
Noisy ISG Loose mounting bolts Tighten mounting bolts. (Page 1J-27)
Faulty rotor, stator or inverter Replace ISG. (Page 1J-27)
Dirty, worn or faulty bearings Replace ISG. (Page 1J-27)
Generator Test 5) Run engine around 2,000 rpm and read meters.
AENFL80B1A34003 If voltage is out of specified range, replace ISG.
(Page 1J-27)
specific gravity, can be caused by one or more of the
following conditions even though warning light operates Specification for undercharged battery (No-load
normally. The following procedure also applies to cars check)
with voltmeter and ammeter. Current: 10.2 A
• Check that undercharged condition has not been Regulated voltage: 14.2 – 14.8 V (at 25 °C, 77 °F)
caused by accessories being left on for an extended
period. Load Check
• Check ISG drive belt for wear and tension. (Page NOTE
1J-25)
Description”: Diesel (with ISG) (Page 1J-21). 1) Connect ammeter in the same way as “No-Load
• Check wiring for defects. Check all connections for Check”: Diesel (with ISG) (Page 1J-23).
tightness and cleanliness, battery cable connections 2) Run engine around 2,000 rpm and turn on the
at battery, starting motor and ignition ground cable. following electrical loads.
• Headlight (High beam)
No-Load Check
• Rear window defogger
NOTE • Blower motor (Maximum speed)
Use fully charged battery. 3) Read ammeter.
If meter reading is less than 20 A, replace ISG.
1) Check for DTC. (Page 11A-11) (Page 1J-27)
If there is any DTC, perform troubleshooting for
applicable DTC and then clear DTC.
• Troubleshooting: (Page 11A-12)
• DTC clearance: (Page 11A-12)
2) Turn off all electrical loads (5).
3) Connect voltmeter (3) and ammeter (2) as shown in
figure.
temperature.
I9P60A1A1018-01
1. ISG 6. Switch
4. Battery 7. “B” terminal
Repair Instructions
Jump-Starting in Case of Emergency 7) Attach one end of the remaining negative (–) cable
AENFL80B1A36001 to negative (–) terminal of booster battery, and the
With Booster Battery
other end to a solid engine ground (such as exhaust
NOTICE manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
Trying to start a vehicle equipped with a
catalytic converter by pushing or towing it 8) Start engine of vehicle with booster battery and turn
may cause damage to the emission control off its electrical loads. Then try to start engine of
system and/or other components. vehicle with discharged battery.
Do not start a vehicle by pushing or towing it. 9) Disconnect jumper cables in the exact reverse order.
Both booster and discharged battery should be treated With Charging Equipment
carefully when using jumper cables. Follow the
procedure outlined as follows, being careful not to cause NOTICE
sparks. Using 24-volt charging equipment to jump-
start the engine will cause serious damage to
! WARNING electric and electronic system components.
Failure to take proper precautions when jump Use only 12-volt charging equipment to
starting a vehicle may result in serious jump-start the engine.
personal injury and/or damage to electronic
components of either the vehicle with a dead Battery Removal and Installation
battery or the vehicle used for jump starting. AENFL80B1A36002
Removal
• Never expose the battery to open flame or
electric spark. A battery generates highly 1) Disconnect negative (–) cable (1) at battery.
flammable and explosive hydrogen gas. 2) Disconnect positive (+) cable (2) at battery.
• Remove rings, watches and other jewelry. 3) Remove battery band (3).
Wear approved eye protector. 4) Remove battery (4).
• Battery fluid is a corrosive acid. Do not
allow it to contact eyes, skin, fabrics or 1
painted surfaces of the vehicle. If the fluid
contacts any of them, immediately and
thoroughly flush the affected area with
2
water. 4
• To avoid a danger of short circuit, do not
allow a metal tool or jumper cable to touch
the positive terminal of the battery (or a
metal piece in contact with it) and any
3
metal part of the vehicle at the same time.
• Keep the battery out of the reach of
children.
1) Place gear shift lever in “Neutral”.

IFL10A1A0001-02
2) Apply parking brake.
5) Remove battery tray (1).
6) Remove degassing tank (2).
4) Turn off lights and all other electrical loads.
7) Remove battery bracket (3) together with degassing
5) For battery with cell caps, check electrolyte level. If it
tank bracket (4), if necessary.
is below low level line, add distilled water.
6) Attach end of one jumper cable to positive (+)
terminal of booster battery and the other end of the
same cable to positive (+) terminal of discharged
battery (Use 12-volt battery only to jump-start
engine).
2
(A)
4
3
[A] [B]
3
IFL10A1A0002-01 (A) 3
(A)
Installation
• Tighten battery cables securely.
2 4 2 2 4 2
• Initialize electrical devices if necessary.
IFL10A1A0003-03
ISG Drive Belt Inspection [A]: OK [B]: NG

AENFL80B1A36003
1) Check ISG drive belt (1) for crack, cuts, deformation,
ISG Drive Belt Removal and Installation
wear and cleanliness. If any defect exists, replace AENFL80B1A36004
belt. (Page 1J-25) Removal
2) Check that engine is cold. 1) Hoist vehicle and remove right side front wheel.
3) Place special tool onto pulleys (2) of ISG drive belt (Page 2D-1)
tensioner as shown in figure and check that width (3) 2) Remove right side engine undercover.
is smaller than width (4). 3) Remove water pump drive belt. (Page 1F-10)
If check result is not OK, replace ISG drive belt.
4) Turn pulley (1) of ISG drive belt tensioner
Special tool counterclockwise until protrusion (2) passes holes
(A): 09932M97650 (3).
5) Pass pin through holes in ISG drive belt tensioner to
secure it.
1 5
3 6
2
IFL10A1A0013-01 IFL10A1A0014-01
6) Remove ISG drive belt. 4) Turn crankshaft clockwise 720° and check that all
ribs of belt fit into grooves of pulleys.
Installation 5) Start engine and stabilize ISG drive belt tension.
1) Fit ribs of ISG drive belt (1) into grooves of 6) Stop engine, and then inspect ISG drive belt.
crankshaft pulley (2), ISG pulley (3), and idler pulleys (Page 1J-25)
(4).
7) Install water pump drive belt. (Page 1F-10)
2) Turn pulley (5) of ISG drive belt tensioner
8) Install right side engine undercover.
counterclockwise to remove pin (6).
9) Install right side front wheel. (Page 2D-1)
3) Turn pulley of ISG drive belt tensioner clockwise to
remove any slack in belt while ensuring that ribs on
ISG drive belt and grooves in crankshaft pulley, ISG
pulley, and idler pulleys are not misaligned.
ISG Drive Belt Tensioner and Idler Pulley ISG Drive Belt Tensioner and Idler Pulley
Removal and Installation Inspection
AENFL80B1A36005 AENFL80B1A36006
Removal Check the following points. If check result is not OK,
1) Remove ISG drive belt. (Page 1J-25) replace ISG drive belt tensioner and/or idler pulley.
2) Remove ISG drive belt tensioner (1) and idler pulleys • With bracket (1) of ISG drive belt tensioner secured in
(2). place, turn spring (2) and check that there is no
abnormal noise and that spring turns smoothly.
• Turn pulleys (3) of ISG drive belt tensioner or idler
pulleys (4) and check that there is no abnormal noise
and that pulleys turn smoothly.
• Check that there is no damage or scratch on surfaces
of ISG drive belt tensioner and idler pulleys.
1
3
2
2 4
1
IFL10A1A0004-01
Installation
IFL10A1A0006-01
• Tighten ISG drive belt tensioner bolts (1) and ISG ISG Removal and Installation
drive belt idler pulley bolts (2) to specified torque. AENFL80B1A36007
Removal
Tightening torque
ISG drive belt tensioner bolt (a): 10 N·m (1.0 kgf- 1) Disconnect negative (–) cable at battery.
m, 7.5 lbf-ft) 2) Remove exhaust No.1 pipe. 
ISG drive belt idler pulley bolt (b): 55 N·m (5.6 3) Remove vacuum tank (1).
kgf-m, 40.5 lbf-ft)
1, (a)
IFL10A1A0007-02
2, (b) 4) Remove drive intermediate shaft assembly. (Page

3A-9)
IFL10A1A0005-01
5) Remove ISG drive belt. (Page 1J-25)
• Check ISG drive belt. (Page 1J-25)
6) Remove cowl upper panel. 
7) Disconnect boost pressure sensor connector (1) and
harness clamp (2).
2, (b)
1 1, (a)
IFL10A1A0008-01 IFL10A1A0010-01
8) Disconnect “B” terminal wire (1) and connector (2) • Tighten vacuum tank bolts (1) to specified torque.
from ISG (3).
Tightening torque
9) Remove ISG and take ISG out of engine Vacuum tank bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
compartment between suspension frame member
and engine assembly.
1, (a)
1 IFL10A1A0011-01
IFL10A1A0009-01
ISG Inspection
10) Remove ISG drive belt tensioner from ISG, if AENFL80B1A36008
necessary. (Page 1J-27) Check the following points. If check result is not OK,
replace ISG.
Installation • Turn pulley (1) of ISG and check that there is no
Reverse removal procedure noting the following points. abnormal noise and that pulley turns smoothly.
• Tighten ISG bolts (1) and “B” terminal nut (2) to • Check that there is no damage or scratch on surface
specified torque. of ISG.
Tightening torque
ISG bolt (a): 50 N·m (5.1 kgf-m, 37.0 lbf-ft)
1
“B” terminal nut (b): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
IFL10A1A0012-01
Specifications
AENFL80B1A37001
Battery
: CCA 630A (70AH/20H, 60AH/5H) 12 V
ISG
Rated voltage 12 V
Permissible max. speed 18,000 rpm
Starting speed 1,500 rpm MAX.
Nominal output 200 A
Electricity generating mode
Regulated voltage 10.6 to 16.0 V
Max. output 1.7 kW
Driving mode
Max. torque 60 Nm (6.1 kgf-m, 44.5 lbf-ft)

AENFL80B1A37003
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
ISG drive belt tensioner bolt 10 1.0 7.5 
ISG drive belt idler pulley bolt 55 5.6 40.5 
ISG bolt 50 5.1 37.0 
“B” terminal nut 11 1.1 8.5 
Vacuum tank bolt 11 1.1 8.5 
Reference:

Special Tool
AENFL80B1A38002
09932M97650
Belt tensioner gauge

1K-1 Exhaust System: Petrol and Bi-Fuel CNG
Exhaust System
Engine

Repair Instructions
Exhaust System Components
AENFL80B1B16001
12
11
12
1 15
2
3 14 (a)
9 8
(b) (d) (e)
(b) 5 5
4 13
6 4
10
13
7 (a)
16
IFL80B1B1006-01
1. Exhaust manifold cover 9. Exhaust No.1 pipe : 45 Nm (46 kgf-m, 33.5 lbf-ft)
2. Exhaust manifold gasket 10. Exhaust center pipe : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
3. Exhaust manifold 11. Muffler : 43 Nm (4.4 kgf-m, 32.0 lbf-ft)
4. Exhaust manifold stiffener 12. Mounting No.1 : 2.4 Nm (0.24 kgf-m, 2.0 lbf-ft)
5. Exhaust manifold stiffener nut 13. O-ring : 50 Nm (5.1 kgf-m, 37.0 lbf-ft)
: For tightening order, refer to “Exhaust Manifold
Removal and Installation”: Petrol and Bi-Fuel CNG
(Page 1K-2).
6. Exhaust manifold stiffener bolt 14. HO2S-1 : Do not reuse.
: For tightening order, refer to “Exhaust Manifold
Removal and Installation”: Petrol and Bi-Fuel CNG
(Page 1K-2).
7. HO2S-2 15. Heat insulator
8. Gasket 16. Mounting No.2
Exhaust System: Petrol and Bi-Fuel CNG 1K-2
Exhaust Manifold Removal and Installation

AENFL80B1B16002 3
Removal
! CAUTION
Be careful not to drop exhaust manifold. If it 4
is dropped, inside of catalytic converter may
be damaged by impact.
1

2) Disconnect HO2S-1 connector (1) and HO2S-2
connector (2), and then detach them from their stay.
1 2
2
5
IFL80B1B1007-01
Installation
• Use new gasket.
2 • Tighten exhaust manifold bolts and nuts to specified
torque.
Tightening torque
IAP70P1B0002-01 Exhaust manifold bolt (a): 60 N·m (6.1 kgf-m, 44.5
3) Disconnect exhaust No.1 pipe (1) from exhaust lbf-ft)
manifold. Exhaust manifold nut (b): 60 N·m (6.1 kgf-m, 44.5
lbf-ft)
(a) (b) (a)
(b)
I7V20A1B1003-01
4) Remove exhaust manifold stiffeners (2). IFL80B1B1008-01
5) Remove exhaust manifold cover (3) from exhaust • Install HO2S-1 and HO2S-2 if removed. 
manifold. • Install exhaust manifold stiffeners as follows.
6) Remove HO2S-1 (4) and HO2S-2 (5) from exhaust a. Install exhaust manifold stiffeners (1), and then
manifold, if necessary.  tighten exhaust manifold stiffener nuts (2) by
7) Remove exhaust manifold (1) and its gasket from hand.
cylinder head. b. Tighten exhaust manifold stiffener bolts (3), and
then tighten exhaust manifold stiffener nuts (2).
1K-3 Exhaust System: Petrol and Bi-Fuel CNG
Tightening torque
Exhaust No.1 pipe bolt (a): 43 N·m (4.4 kgf-m,
32.0 lbf-ft)
1 2
IFL80B1B1009-01 (a)
I9P60A1B1004-01
• Tighten exhaust No.1 pipe bolts to specified torque.
• Run engine and check for exhaust gas leakage.
Specifications
AENFL80B1B17002
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 
Reference:
“Exhaust System Components”: Petrol and Bi-Fuel CNG
Exhaust System: Diesel 1K-4
Diesel
Repair Instructions
Exhaust System Components
AENFL80B1B26001
10
8
5
3 1
2
IBL80A1B2003-02
1. Catalytic converter cover 6. Heat insulator : 50 Nm (5.1 kgf-m, 37.0 lbf-ft)
2. Catalytic converter 7. Exhaust pipe No.2 : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
3. Catalytic converter 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
Specifications
AENFL80B1B27002
Reference:
“Exhaust System Components”: Diesel
1K-5 Exhaust System: Diesel
Section 2
Suspension
CONTENTS
NOTE
Precautions ................................................. 2-* Special Tools and Equipment ............................. 2B-*

Recommended Service Material ......................... 2B-* 2
Precautions.............................................................. 2-*
Precautions for Suspension ................................... 2-* Special Tool ........................................................ 2B-*
Suspension General Diagnosis...............2A-* Rear Suspension ......................................2C-*

Diagnostic Information and Procedures............ 2A-* General Description ............................................. 2C-*
Suspension, Wheel and Tire Symptom Rear Suspension Description.............................. 2C-*
Diagnosis ...........................................................2A-* Repair Instructions .............................................. 2C-*
Repair Instructions .............................................. 2A-* Rear Wheel Alignment Inspection....................... 2C-*
Suspension System Check ..................................2A-* Rear Suspension Components ........................... 2C-*
Rear Shock Absorber Removal and
Front Suspension .....................................2B-* Installation ......................................................... 2C-*
General Description ............................................. 2B-* Rear Shock Absorber Inspection ........................ 2C-*
Front Suspension Description ..............................2B-* Rear Coil Spring and Spring Seat Removal
Front Wheel Alignment Description......................2B-* and Installation .................................................. 2C-*
Rear Coil Spring and Spring Seat Check............ 2C-*
Repair Instructions .............................................. 2B-*
Rear Axle Removal and Installation .................... 2C-*
Front Wheel Alignment Inspection and
Rear Axle Check ................................................. 2C-*
Adjustment .........................................................2B-*
Rear Suspension Fastener Inspection ................ 2C-*
Front Strut Assembly Components ......................2B-*
Front Strut Assembly Removal and Specifications....................................................... 2C-*
Installation..........................................................2B-* Tightening Torque Specifications........................ 2C-*
Front Strut Assembly Disassembly and
Reassembly .......................................................2B-*
Wheels and Tires ..................................... 2D-1
Front Strut Inspection...........................................2B-* Precautions........................................................... 2D-*
Coil Spring, Strut Bearing and Strut Support Precautions for Servicing Wheel and Tire........... 2D-*
Check.................................................................2B-* General Description .............................................2D-1
Suspension Arm Components .............................2B-* Tire Description ................................................... 2D-*
Suspension Arm Removal and Installation ..........2B-* Replacement Tire Description............................. 2D-*
Suspension Arm Check .......................................2B-* Wheel Description ............................................... 2D-*
Suspension Arm Front Bushing Removal and Replacement Wheel Description......................... 2D-*
Installation..........................................................2B-* Wheel-Tire Assembly Description (for Vehicle
Suspension Arm Joint Dust Cover Removal Equipped with Steel Wheels) ............................ 2D-*
and Installation...................................................2B-* Tire Placard Description......................................2D-1
Front Suspension Frame and Stabilizer Bar Repair Instructions ..............................................2D-1
Components.......................................................2B-* Wheel (with Tire) Removal and Installation.........2D-1
Front Suspension Frame, Stabilizer Bar and Tire Inspection..................................................... 2D-*
Bushing Removal and Installation......................2B-* Wheel Inspection................................................. 2D-*
Stabilizer Bar Bushing Removal and Wheel Balance Inspection and Adjustment......... 2D-*
Installation..........................................................2B-* Tire Rotation........................................................ 2D-*
Front Suspension Frame Check ..........................2B-* Tire Mounting and Dismounting .......................... 2D-*
Front Stabilizer Bar, Bushing and Joint Check .....2B-* Tire Repair .......................................................... 2D-*
Front Suspension Fastener Check ......................2B-* Specifications.......................................................2D-2
Specifications....................................................... 2B-* Tightening Torque Specifications........................2D-2
Tightening Torque Specifications.........................2B-*
2D-1 Wheels and Tires:
Wheels and Tires

Suspension
General Description
Tire Placard Description The “Tire Placard” is located on the driver’s side door
AENFL80B2401006 lock pillar and should be referred to for tire information.
The placard lists the tire size, rim size and cold tire
pressure.
Repair Instructions
Wheel (with Tire) Removal and Installation NOTE
AENFL80B2406001
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
“A” – “B” – “C” – “D” – “E”
Tightening torque
Wheel nut (a): 100 N·m (10.2 kgf-m, 74 lbf-ft)
(a)
“D”
IFL80B240002-01
2) Hoist vehicle. “A”
3) Remove wheel with tire. “B”
NOTE “C”
“E”
Never use heat to loosen tight wheel because
application of heat to wheel can shorten life
of wheel and damage wheel bearings.
Installation
Wheel nuts must be tightened in sequence and to proper IFL80B240003-01
torque to avoid bending wheel or brake disc as shown in
the figure.
Wheels and Tires: 2D-2
Specifications
AENFL80B2407002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Wheel nut 100 10.2 74 
Reference:
2D-3 Wheels and Tires:
Section 3
Driveline / Axle
CONTENTS
NOTE
Precautions ................................................. 3-* Drive Intermediate Shaft Assembly

Precautions.............................................................. 3-* Disassembly and Reassembly ........................3A-10
Precautions for Driveline / Axle .............................. 3-* Front Wheel Hub and Steering Knuckle
Components...................................................... 3A-*
Drive Shaft / Axle ..................................... 3A-1 Front Wheel Bearing Check ................................ 3A-*
Front .........................................................................3A-1 Front Wheel Hub, Steering Knuckle and 3
General Description ............................................. 3A-* Wheel Bearing Removal and Installation .......... 3A-*
Front Drive Shaft Construction.............................3A-* Specifications.....................................................3A-15
Diagnostic Information and Procedures............ 3A-* Tightening Torque Specifications......................3A-15
Front Drive Shaft Symptom Diagnosis .................3A-* Special Tools and Equipment ...........................3A-15
Repair Instructions ..............................................3A-1 Recommended Service Material .......................3A-15
Front Drive Shaft Components ........................... 3A-1 Special Tool ......................................................3A-15
Front Drive Shaft Assembly On-Vehicle Rear .......................................................................... 3A-*
Inspection...........................................................3A-* Repair Instructions .............................................. 3A-*
Front Drive Shaft Assembly Removal and Rear Axle Components ....................................... 3A-*
Installation......................................................... 3A-3 Rear Wheel Bearing Check................................. 3A-*
Front Drive Shaft Disassembly and Rear Wheel Hub Assembly Removal and
Reassembly ...................................................... 3A-5 Installation ......................................................... 3A-*
Drive Intermediate Shaft Assembly Removal Specifications....................................................... 3A-*
and Installation.................................................. 3A-9 Tightening Torque Specifications........................ 3A-*
3A-1 Drive Shaft / Axle: Front
Drive Shaft / Axle

Driveline / Axle
Front
Repair Instructions
Front Drive Shaft Components
AENFL80B3116001
Drive Shaft / Axle: Front 3A-2
[B]
2
[A] 3
4 5
6 7
7
8
10 (a)
7 8
9 5
5 9
7
10 (a) [A]
5
3
2
6 12 (c)
[D]
1 4
[C] 11
19
3
2
5
4
[A] 7
6
[F]
7
8 8
10 (a)
5
7
9 9
5 10 (a)
[A]
[E] 5
4
3
[H] [G]
15
[A]
1
12 (c)
17
11
13
16
15
14
IFL80B311001-05
[A]: Wheel side 9. Wheel side joint assembly

: Never disassemble.
: Apply black grease in the service kit to wheel side boot.
[B]: Diesel model - Left side 10. Drive shaft nut

: After tightening nut to specified torque, caulk nut securely.
[C]: Diesel model - Right side 11. Drive intermediate shaft
[D]: Petrol model - Left side 12. Intermediate support bolt
: For tightening order, refer to (Page 3A-9).
[E]: Petrol model - Right side 13. Intermediate shaft bearing support
[F]: Diesel model - Right side differential side joint assembly and 14. Intermediate shaft bearing
drive intermediate shaft assembly : Apply grease 99000-25011 to side space.
[G]: Petrol model - M/T - Drive intermediate shaft assembly 15. Dust seal
[H]: Petrol model - A/T - Drive intermediate shaft assembly 16. Dust cover
1. Circlip 17. Bearing support circlip
2. Differential side (or drive intermediate shaft side) joint housing 18. Bearing shield
3. Snap ring 19. Deflector
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) : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
6. Differential side (or drive intermediate shaft side) boot : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: 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) : Do not reuse.
8. Wheel side boot
: Apply black grease in the service kit to wheel side boot.
Front Drive Shaft Assembly Removal and NOTE

Installation Turning drive shaft joint while pulling out
AENFL80B3116003
drive shaft may facilitate release of the circlip
Removal fitting of joint spline.
1) Hoist vehicle and remove front wheel. (Page 2D-1)
2) Release caulking (1) and remove drive shaft nut (2) [A] 2 [B]
2
with brake pedal depressed.
1
I9P60A311003-02
2 [A]: Left side shaft (Petrol and [B]: Right side shaft (Petrol
Diesel Model) Model)
IBP80A311002-01
3) Drain transaxle oil. • For Diesel model: For right side, remove
• Diesel model: (Page 5B-32) intermediate shaft support bolts (1), disconnect
• Petrol model M/T: (Page 5B-4) drive intermediate shaft assembly (3) from
transaxle and then remove the drive intermediate
• Petrol model A/T: (Page 5A-104)
shaft assembly, intermediate support and right
4) For vehicle with ABS, remove front wheel speed side drive shaft assembly (2) all together.
sensor from steering knuckle. 
5) Disconnect suspension arm joint from steering
knuckle. 
6) Pull out drive shaft joint (2) using tire lever (1) or
plastic hammer (3).
NOTICE NOTICE
Right side drive shaft and intermediate shaft Take care not to spray the cleaner on the
assembly are jointed to each other with intermediate shaft oil seal area. Use the
adhesive at their spline portions. If the cleaner to clean only the spline area of the
adhesion is split by force, the spline and intermediate shaft.
peripheral part may be damaged.Remove /
install the right side drive shaft and Three Bond Super Cleaner
intermediate shaft assembly as an assembly
without separating it in two shafts.
1
[A]
[B]
IEAD0A311002-01
7) Remove drive shaft assembly.
Installation
! CAUTION IFL80B311018-01
[A] Drive shaft

• Before inserting drive shaft, confirm that [B] Drive intermediate shaft
there is no foreign materials around
encoder (1) on wheel bearing. 2. Apply loctite 638 on internal surface of driveshaft
spline.
NOTICE
1
Spray the loctite uniformly on the internal
surface of the drives haft.
Loctite 638: 99000M24120-907

1 Quantity: Minimum 0.3 g
IBP80A311003-01
• Be careful not to damage oil seals and

boots.
• Do not hit joint boot with hammer.
Inserting joint only by hand is allowed.
• Make sure that differential side joint is
inserted fully and its circlip is seated as it IFL80B311019-01
was installed. 3. Fuse drive intermediate shaft (1) with drive shaft (2)
and leave the shafts in fused condition for 90 minutes.
Reverse removal procedure, noting the following points.
• Use new differential side (or drive intermediate shaft
side) joint circlip.
• For Diesel model:
1. Clean the spline area of the intermediate shaft and
mating area of the drive shaft with “Three Bond Super
Cleaner”.
1 1,(a)
2
IBP80A311004-01
IFL80B311017-03
4. Install intermediate shaft and drive shaft together • Connect suspension arm joint. 
on the vehicle. Tighten intermediate shaft support • For vehicle with ABS, install front wheel speed sensor.
bolts (1) in numerical order according to the following 
procedure. • Install front wheel. (Page 2D-1)
a. Temporarily tighten intermediate shaft support bolts • Fill transaxle with transaxle oil as specified.
in numerical order (“1” – “3”).
b. Tighten intermediate shaft support bolts to specified – Diesel model: (Page 5B-32)
torque in numerical order (“4” – “6”). – Petrol model: (Page 5B-4)
• Check front wheel alignment. 
Tightening torque
Intermediate shaft support bolt* (a): 23 N·m (2.3
kgf-m, 17.0 lbf-ft) Front Drive Shaft Disassembly and Reassembly
AENFL80B3116004
1,“3”,“6”,(a)
1,“1”,“4”,(a) Disassembly
! CAUTION
1,“2”,“5”,(a)
• 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.
• Do not disassemble tripod joint. If any
defect is found in tripod joint, replace
tripod joint assembly.
IEAD0A311003-01 NOTE
• Tighten new drive shaft nut (1) to specified torque. On diesel model with welded type boot band,
Tightening torque use nippers to cut boot band. Take care not
Drive shaft nut (a): 200 N·m (20.4 kgf-m, 148.0 lbf- to damage boot while cutting band.
ft)
Differential side joint
• Caulk drive shaft nut (1) as shown. 1) Remove boot big band (1) of differential side (or
! CAUTION drive intermediate shaft side) as follows.
To disengage hook, pinch band as shown in figure
Be sure not to crack caulking part (2) of drive and remove band.
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
I9P60A311023-02
6) Pull out differential side boot (or drive intermediate

shaft side boot) from shaft.
I7RW01311003-01
7) Remove damper from shaft. (petrol model-right side)
4) Remove tripod joint (1) using 3-arm puller (2).
! CAUTION Wheel side joint

1) Remove boot big band (1) of wheel side as follows.
To prevent any problem caused by washing
To disengage hook, pinch band as shown in figure
solution, do not wash tripod joint except its
and remove band.
housing. Degreasing of tripod joint with shop
cloth is allowed.
I9P60A311005-01 I9P60A311025-02
5) Remove boot small band of differential side (or drive 2) Use flat-bladed screwdriver (1) or the like to release
intermediate shaft side) boot as follows. caulking (2) of wheel side boot small band (3).
Diesel model
Use flat-bladed screwdriver (1) or the like to release
caulking (2) of boot small band (3).
2
1
2
1 3
I8V101311031-01
3) Pull out wheel side boot from shaft.

3
I8V101311031-01 Reassembly
Petrol model Judging from abnormality noted before disassembly and
To disengage hook, pinch band (1) as shown in what is found through visual check of component parts
figure and remove band. after disassembly, prepare replacing parts and proceed
to reassembly.
Make sure that wheel side joint assembly (1) and
housing of tripod joint (2) are washed thoroughly and air-
dried.
! CAUTION
2
• 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 I9P60A311028-01
gasoline or kerosene, etc. Washing in 7) Place new boot big band (3) and small band (4) onto
degreaser causes boot deterioration. wheel side boot so that outer end (1) of each band
• To ensure full performance of joint as faces in the direction opposite to the forward rotating
originally designed, apply the specified direction (2) as shown in figure.
amount of grease to respective joint
according to the following procedure.
4
I9P60A311006-02
8) Fasten boot band noting the following points.
! CAUTION
2
Do not squeeze or distort boot when
fastening boot with boot bands. Squeezing
boot to force air out may distort boot and
reduce its durability.
a) Fasten boot big band (1) by pinching hooks (2)

I9P60A311027-01
with special tool and engage hook (3) as shown
[A]: Wheel side in figure.
[B]: Differential side
Special tool
Wheel side joint (A): 09943M57021
1) Wash disassembled parts (except boots). After
washing parts, air-dry them completely.
2) Clean boots with shop cloth.
3) Apply grease in the service kit to wheel side joint. (A)
Grease specification for front drive shaft wheel

side joint
Grease Grease
Model
color amount
Diesel model Black 70 – 90 g (2.82
– 3.53 oz)
Petrol model M/T model Black 60 – 80 g (2.12 1
– 2.82 oz)
A/T model Yellowis 60 – 80 g (2.12
h Brown – 2.82 oz)
3 2
4) Install wheel side boot on shaft.
5) Fill boot inside with specified grease. I8C50A311034-01
6) Insert flat-bladed screwdriver into boot (2) and allow b) Fasten boot small band (5) using special tool as
air to enter boot so that air pressure in boot becomes shown in figure.
the same as the atmospheric pressure.
Special tool 6) Using specified grease included in service kit, apply

(B): 09943M57011 grease “A” to tripod joint, differential side joint
housing (1) and boot.
Grease specification for front drive shaft
differential side (or drive intermediate shaft side)
“a”
joint
Model Grease color Grease amount
Diesel model Brown 85 – 105 g (2.99 –
3.70 oz)
5
Petrol M/T Dark gray 70 – 90 g (2.47 –
model 3.17 oz)
A/T: LH Yellowish 100 – 120 g (3.53
(B)
I8C50A311004-02
Brown – 4.23 oz)
A/T: RH Yellowish 105 – 125 g (3.71
Install each boot band using the appropriate Brown – 4.41 oz)
method referring to the following table
Model Band Method
Diesel model Big band a
Small band b
Petrol model Big band a
Small band b
Differential side joint

1) Wash disassembled parts (except boots) and air-dry
them completely.
I4RS0B310003-01
2) Clean boots with shop cloth.
7) Fit boot (1) to grooves of shaft and differential side
3) For diesel model, install boot insert on differential (or drive intermediate shaft side) joint housing (2).
side (or drive intermediate shaft side) joint housing.
8) Insert flat-bladed screwdriver or the like into boot (1)
4) Install differential side (or drive intermediate shaft and allow air to enter boot so that air pressure in
side) boot on shaft. boot becomes the same as atmospheric pressure.
5) Install tripod joint (1) on shaft using special tool with
Drive shaft boot fixing position (distance
hammer, directing its chamfered spline (3) toward
between differential side joint end and boot small
wheel side, and then fasten tripod joint with new
band center)
snap ring (2) using snap ring pliers (4).
Model Drive shaft Fixing position “a”
Special tool Diesel RH 178.8 – 180.8 mm (7.04 – 7.12
(A): 09925M98221 model in.)
LH 162.7 – 165.2 mm (6.40 – 6.50
in.)
Petrol M/T: RH 176.0 – 178.0 mm (6.93 – 7.00
3 model in.)
M/T: LH 160.4 – 162.9 mm (6.31 – 6.41
in.)
A/T: RH 185.0 – 187.0 mm (7.28 – 7.36
I8G001311014-01
in.)
A/T: LH 169.9 – 172.4 mm (6.69 – 6.78
in.)
I8C50A311007-01
Model Band Method

Petrol model Big band a
Small band a
a) Fasten boot band (1) by pinching hooks (2) with

special tool and engage hook (3) as shown in
figure.
Special tool
“a” (A): 09943M57021
(A)
I9P60A311029-01
2
I8C50A311008-01
3 2
[A]: Drive shaft inserted into differential side
[B]: Drive shaft inserted into drive intermediate shaft side I8C50A311034-01
b) Fasten boot band (5) using special tool as shown

9) Place new boot big band (3) and small band (4) onto in figure
differential side (or drive intermediate shaft side)
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
“a”
I9P60A311006-02
(B)
10) Fasten boot big band and boot small band noting the I8C50A311004-02
following points.
! CAUTION Drive Intermediate Shaft Assembly Removal

and Installation
Do not squeeze or distort boot when AENFL80B3116005
fastening boot with boot bands. Squeezing ! CAUTION
boot to force air out may distort boot and
Be careful not to damage differential side oil
reduce its durability.
seal when removing and installing drive
intermediate shaft assembly.
Install each boot band using the appropriate
method referring to the following table Removal
Model Band Method 1) Drain transaxle oil. (Page 5B-32)
Diesel model Big band b
Small band b
2) Remove right side front drive shaft assembly. Petrol Model - A/T
(Page 3A-3)
1,“2”,“5”,(a) 1,“1”,“4”,(a) 1,“3”,“6”,(a)
3) Remove intermediate support bolts (1) and drive
intermediate shaft assembly (2) from transaxle.
Petrol Model - A/T
1
IFL80B311011-01
Petrol Model - M/T

1,“3”,“6”,(a)
2 1,“2”,“5”,(a) 1,“1”,“4”,(a)
IFL80B311009-01
Petrol Model - M/T

1
IFL80B311012-01
Drive Intermediate Shaft Assembly

2 Disassembly and Reassembly
AENFL80B3116006
IFL80B311010-01
Disassembly
Installation 1) Remove circlip (1) from drive intermediate shaft (2).
• Use new circlip.
• Tighten intermediate support bolts (1) in numerical
order as shown in figure.
1) Temporarily tighten intermediate support bolts in
numerical order (“1” – “3”). 1
2) Tighten intermediate support bolts to specified 2

torque in numerical order (“4” – “6”).
Tightening torque
Intermediate support bolt (a): 55 N·m (5.6 kgf-
m, 40.5 lbf-ft)
IBP80A311034-03
2) Using hydraulic press (1), remove drive intermediate

shaft (2) from intermediate shaft bearing.
NOTICE
For A/T model, bearing shield is pushed
together with drive intermediate shaft out of
support (2) by press. If shaft is pushed with
base put just under bearing shield, bearing
shield will interfere with base and bearing 1
shield can damage. Do not put bases of (A)
hydraulic unit just under bearing shield (1).
IBP80A311033-01
4) Remove bearing support circlip (1) using snap ring

pliers (2).
I6RS0B310006-03
IFL80B311002-01
5) Using hydraulic press and special tool, remove
intermediate shaft bearing from intermediate shaft
bearing support (1) by pushing the bearing from
transaxle side.
Special tool
(A): 09913M75810
(A)
IBP80A311008-01
3) Remove dust seals (1) from intermediate shaft 1

bearing support using special tool.
Special tool
(A): 09913M50121 IBP80A311012-01
6) Remove dust cover (1) from drive intermediate shaft

using flat-bladed screwdriver or the like, if necessary.
IBP80A311025-01
Reassembly
1) Install new dust cover (1) onto drive intermediate
shaft, if removed, by tapping flat-surface of dust IFL80B311004-01
cover indicated by arrow in figure, along the circle 3) Using hydraulic press and special tool, install new
little by little using flat-end rod covered with cloth (2) intermediate shaft bearing to intermediate shaft
so as not to warp it. bearing support (1) by pushing the bearing from
drive shaft side.
! CAUTION
Special tool
• Denting or scratching the oil seal contact (A): 09913M75520
surface of drive intermediate shaft will (B): 09940M51710
cause oil leakage. (C): 09944M68510
Do not damage the contact surface when
installing the dust cover.
M/T Model
• Incomplete installation of the dust cover
will damage the oil seal and result in oil
leakage.
Check that the dust cover end (3) contacts
the shoulder (4) of the shaft evenly.
(A)
1 1
IBP80A311010-01
2
A/T Model
3
1
IBP80A311026-02
2) For A/T model, install new bearing shield (1) to

intermediate shaft using special tool, if removed.
Special tool
(A): 09940M51710
IFL80B311005-01
4) Install new bearing support circlip (1) in groove (2) of

intermediate shaft bearing support.
“A”: Grease 99000–25011 (SUZUKI Super

Grease A)
1
M/T Model
IBP80A311027-02
5) For M/T model, apply grease to space on bearing as

shown in figure.
Grease A) IFL80B311006-01
A/T Model
“A” “A”
IBP80A311028-02
6) For M/T model, install new dust seal (1) to specified

position on transaxle side of intermediate shaft
bearing support in specified direction as shown in
figure using special tool.
Special tool
(A): 09925M15410
Distance
IFL80B311007-01
“a”: 4 – 5 mm (0.16 – 0.19 in.)
8) Install new dust seal (1) to specified position on drive
1 shaft side of intermediate shaft bearing support in
(A) specified direction as shown in figure using special
tools.
Special tool
(A): 09926M27610
(B): 09924M74510
(C): 09924M07720
(D): 09913M70123
Distance
“a”: 0.5 – 1.5 mm (0.02 – 0.05 in.)
“a”: 0.5 – 2.5 mm (0.02 – 0.10 in.)
“a”
IBP80A311029-01
7) Apply grease to seal lip of new dust seal on drive

shaft side and space on bearing indicated in the
figures.
M/T Model
(A)
(B) 2 1
(A)
“a”
IBP80A311032-02
(A)
A/T Model IBP80A311030-02
10) Install new circlip (1) to drive intermediate shaft (2).
IBP80A311035-02
IFL80B311008-01
9) Press-fit drive intermediate shaft (2) into inner race

(1) of intermediate shaft bearing from transaxle side
using hydraulic press and special tool.
Special tool
(A): 09913M84510
Specifications
AENFL80B3117002
NOTE
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Intermediate shaft support bolt* 23 2.3 17.0 
Drive shaft nut 200 20.4 148.0 
Intermediate support bolt 55 5.6 40.5 
Reference:
“Front Drive Shaft Components”: Front

AENFL80B3118003
Grease SUZUKI Super Grease A P/No.: 99000–25011 /
NOTE
“Front Drive Shaft Components”: Front
Special Tool
AENFL80B3118004
09913M50121 09913M70123
Oil seal remover Bearing installer
 
09913M75520 09913M75810
 
09913M84510 09924M07720
Bearing installer Synchronizer hub installer
 
09924M74510 09925M15410
Bearing and oil seal handle Oil seal installer
 
09925M98221 09926M27610
Bearing installer Oil seal installer
 
09940M51710 09943M57011
Bearing installer Band compressor
/ /
09943M57021 09944M68510
Low-profile clamp pliers Bearing installer attachment
/ 
Section 4
Brakes
CONTENTS
NOTE
Precautions .................................................4-1 Brake Booster Switch Inspection (ISG Model) ....4A-9

Precautions............................................................. 4-1 Specifications.....................................................4A-10
Precautions for Brakes.......................................... 4-1 Tightening Torque Specifications......................4A-10
Special Tools and Equipment ...........................4A-11
Brake Control System and Diagnosis ... 4A-1 Recommended Service Material .......................4A-11
Precautions........................................................... 4A-* Special Tool ......................................................4A-11
Precautions for Brake Service .............................4A-*
General Description .............................................4A-1 Front Brakes .............................................4B-*
Brake System Description................................... 4A-1 Repair Instructions .............................................. 4B-*
Brake Pedal Foot Protection Mechanism Front Disc Brake Components ............................ 4B-* 4
Construction (If Equipped) ................................ 4A-1 Front Brake Pad On-Vehicle Inspection.............. 4B-*
Diagnostic Information and Procedures............ 4A-* Front Brake Pad Removal and Installation.......... 4B-*
Brake Symptom Diagnosis...................................4A-* Front Brake Pad Inspection................................. 4B-*
Front Brake Caliper Removal and Installation..... 4B-*
Repair Instructions ..............................................4A-2
Front Brake Caliper Disassembly and
Brake Fluid Level Inspection ................................4A-*
Reassembly ...................................................... 4B-*
Brake Fluid Level Switch Inspection ....................4A-*
Front Brake Caliper Inspection............................ 4B-*
Brake Fluid Replacement.....................................4A-*
Front Brake Disc Removal and Installation ......... 4B-*
Air Bleeding of Brake System ..............................4A-*
Brake Pedal Components ................................... 4A-2 Front Brake Disc Inspection ................................ 4B-*
Brake Pedal Assembly Removal and Specifications....................................................... 4B-*
Installation (ISG Model) .................................... 4A-2 Tightening Torque Specifications........................ 4B-*
Brake Pedal Assembly Disassembly and Special Tools and Equipment ............................. 4B-*
Reassembly .......................................................4A-* Recommended Service Material ......................... 4B-*
Brake Pedal Free Height Inspection ....................4A-* Special Tool ........................................................ 4B-*
Brake Pedal Play Inspection ................................4A-*
Excessive Pedal Travel Inspection ......................4A-* Rear Brakes...............................................4C-*
Brake Light Switch Removal and Installation ...... 4A-3 Repair Instructions .............................................. 4C-*
Brake Light Switch Inspection ..............................4A-* Rear Drum Brake Components........................... 4C-*
Brake Hose and Pipe Components......................4A-* Rear Brake Drum Removal and Installation........ 4C-*
Brake Flexible Hose and Pipe Removal and Rear Brake Drum and Shoe Inspection .............. 4C-*
Installation..........................................................4A-* Rear Brake Shoe On-Vehicle Inspection ............ 4C-*
Brake Flexible Hose and Pipe Inspection ............4A-* Rear Brake Shoe Removal and Installation ........ 4C-*
Brake Master Cylinder Components ....................4A-* Rear Brake Shoe Inspection ............................... 4C-*
Brake Master Cylinder Assembly On-Vehicle Wheel Cylinder Removal and Installation ........... 4C-*
Inspection...........................................................4A-* Wheel Cylinder Inspection .................................. 4C-*
Brake Master Cylinder Assembly Removal Brake Back Plate Removal and Installation ........ 4C-*
and Installation...................................................4A-* Specifications....................................................... 4C-*
Brake Master Cylinder Reservoir Removal Tightening Torque Specifications........................ 4C-*
and Installation...................................................4A-* Special Tools and Equipment ............................. 4C-*
Brake Master Cylinder Assembly Inspection........4A-* Recommended Service Material ......................... 4C-*
Brake Booster Components ................................ 4A-4
Brake Booster Function Check ............................4A-* Parking Brake ...........................................4D-*
Brake Booster Removal and Installation (ISG General Description ............................................. 4D-*
model or A/T model) ......................................... 4A-5 Parking Brake Description................................... 4D-*
Brake Booster Inspection .....................................4A-*
Repair Instructions .............................................. 4D-* EBD Warning Light (Brake Warning Light)
Parking Brake Components ................................ 4D-* Comes ON Steady ............................................4E-9
Parking Brake Inspection .................................... 4D-* DTC C1021 / C1022 / C1025 / C1026 / C1031
Parking Brake Adjustment................................... 4D-* / C1032 / C1033 / C1035 / C1036...................4E-11
Parking Brake Cable Removal and DTC C1041 / C1042 / C1045 / C1046 / C1051
Installation ......................................................... 4D-* / C1052 / C1055 / C1056 / C1063...................4E-13
Parking Brake Lever Removal and Installation .... 4D-* DTC C1057 .......................................................4E-14
Parking Brake Switch Inspection......................... 4D-* DTC C1061 .......................................................4E-15
Specifications....................................................... 4D-* DTC C1062 ......................................................... 4E-*
Tightening Torque Specifications........................ 4D-* DTC C1071 ......................................................... 4E-*
DTC C1090 / C1091 / C1094 .............................. 4E-*
ABS............................................................4E-1 DTC U0073 ......................................................... 4E-*
Precautions........................................................... 4E-1 DTC U0100 ......................................................... 4E-*
Precautions for ABS............................................ 4E-1 ABS Control Module Power Supply and
Precautions for Diagnosing Troubles .................. 4E-1 Ground Circuit Check......................................4E-17
General Description ............................................. 4E-* Repair Instructions ............................................4E-18
ABS Description .................................................. 4E-* ABS Hydraulic Unit Operation Check................4E-18
OBD System Description .................................... 4E-* ABS Hydraulic Unit / Control Module
Warning Light Description ................................... 4E-* Assembly Components ..................................... 4E-*
DLC Description .................................................. 4E-* ABS Hydraulic Unit / Control Module
CAN Communication System Description........... 4E-* Assembly On-Vehicle Inspection ...................... 4E-*
Schematic and Routing Diagram........................ 4E-1 ABS Hydraulic Unit / Control Module
ABS Diagram ...................................................... 4E-* Assembly Removal and Installation .................. 4E-*
ABS Input / Output Diagram................................ 4E-* Front and Rear Wheel Speed Sensor On-
ABS Circuit Diagram ........................................... 4E-2 Vehicle Inspection ............................................. 4E-*
Component Location ........................................... 4E-* Front Wheel Speed Sensor Removal and
ABS Component Location................................... 4E-* Installation ......................................................... 4E-*
Rear Wheel Speed Sensor Removal and
Diagnostic Information and Procedures............ 4E-3
Installation ......................................................... 4E-*
ABS Check.......................................................... 4E-*
Front and Rear Wheel Speed Sensor
Visual Inspection ................................................. 4E-*
Inspection.......................................................... 4E-*
ABS Symptom Diagnosis .................................... 4E-*
Front Wheel Speed Sensor Encoder Removal
Warning Light Check........................................... 4E-*
and Installation .................................................. 4E-*
DTC Check.......................................................... 4E-3
Rear Wheel Speed Sensor Encoder Removal
DTC Clearance ................................................... 4E-4
and Installation .................................................. 4E-*
DTC Table........................................................... 4E-*
Front and Rear Wheel Speed Sensor
Fail-Safe Table.................................................... 4E-*
Encoder Inspection ........................................... 4E-*
Scan Tool Data ................................................... 4E-*
ABS Warning Light Does Not Come ON after Specifications ....................................................... 4E-*
Setting Ignition “ON” ......................................... 4E-5 Tightening Torque Specifications........................ 4E-*
ABS Warning Light Comes ON Steady............... 4E-7 Special Tools and Equipment ...........................4E-19
EBD Warning Light (Brake Warning Light) Special Tool ......................................................4E-19
Does Not Come ON after Setting Ignition
“ON” .................................................................. 4E-*
Precautions: 4-1
Precautions
Brakes
Precautions
Precautions for Brakes
AENFL80B4000001
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 in related manual.
Fastener Caution
Refer to “Fastener Caution” in Section 00 in related manual.
Wheel and Brake Caution

Refer to “Wheel and Brake Caution” in Section 00 in related manual.
Air Bag Warning

Refer to “Air Bag Warning” in Section 00 in related manual.
Reassembling Note for Wiring Harness

Observe “Reassembling Note for Wiring Harness” in Section 9A (Page 9A-110) whenever installing wiring harness.
Otherwise, electrical trouble may occur.
Precautions for CAN Communication System

Refer to “Precautions for CAN Communication System” in Section 00 in related manual.
4A-1 Brake Control System and Diagnosis:
Brake Control System and Diagnosis

Brakes
General Description
Brake System Description
AENFL80B4101001
• 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.
• Brake pedal is equipped with brake pedal foot protection mechanism (if equipped).
[A]
5
3
4 7
1
6
2
7
8
IDL10A410020-01
[A]: Vehicle forward 3. Secondary side 6. Parking brake lever

1. Brake booster 4. Primary side 7. Parking brake cable
2. Brake master cylinder 5. ABS hydraulic unit / control module assembly (ABS model) or 8. Brake 4-way joint
proportioning valve (Non-ABS model)
Brake Pedal Foot Protection Mechanism Construction (If Equipped)

AENFL80B4101002
Should a frontal crash occur, the engine pushes the dash panel towards the interior and the brake pedal bracket (5) is
also pushed rearward. In this case, the brake pedal lever (3) comes off from the brake pedal (1), to prevent the brake
pedal from moving rearward.
[A] [B]
5 2 5
2
3
3
I9P60A410002-01
[A]: Before crash 2. Brake booster

[B]: After crash 4. Booster push clevis rod
Brake Control System and Diagnosis: 4A-2
Repair Instructions
Brake Pedal Components
AENFL80B4106005
[C] [A]
6 (a)
6 (a)
5 (a) 5 (a)
8 (b) 3
12
8 (b) 7
(c)
7
10
3 4 (a) 4 (a)
9
9
10 9
9
11 4 (a)
11
1
1
2
[B]
2 2
IFL80B410001-02
[A]: K14B model and D13A (without ISG) model 4. Brake booster nut 10. Pedal shaft spacer
: Tighten brake booster nut, brake
pedal bracket nut and cowl upper
stiffener bolt in this order.
[B]: A/T model 5. Brake pedal bracket nut 11. Pedal spring
: Tighten brake booster nut, brake : Apply grease 99000-25011 to inside of
pedal bracket nut and cowl upper pedal spring.
stiffener bolt in this order.
[C]: D13A (with ISG) model 6. Cowl upper stiffener bolt 12. Brake stroke sensor
:Tighten brake booster nut, brake : For installation, refer to “Brake Stroke
pedal bracket nut and steering support Sensor Removal and Installation”: Diesel in
member bolt in this order. Section 1C (Page 1C-5).
1. Brake pedal assembly 7. Pedal shaft : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
: Do not disassemble for model equipped
with brake pedal foot protection mechanism.
2. Pedal pad 8. Brake pedal shaft nut : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
3. Brake light switch 9. Pedal bushing : 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
: Apply grease 99000-25011 to outside
of bushing.
Brake Pedal Assembly Removal and Installation 5) Remove clip, clevis pin and brake booster nuts from
(ISG Model) brake pedal bracket. (Page 4A-5)
AENFL80B4106006
6) Remove steering column reinforcement (1).
Removal
1) Remove combination meter cluster panel. (Page
9C-24)
2) Remove steering column hole cover. (Page 6B-3)
3) Remove brake light switch. (Page 4A-3)
4) Remove brake stroke sensor. (Page 1C-5)
(a)
(b)
I9P60A410010-01
4) Install clevis pin and new clip. (Page 4A-5)

IBP80A410007-01
5) Tighten steering column reinforcement bolt and nut
7) Remove brake pedal bracket nut and brake booster to specified torque.
nuts. Remove cowl upper stiffener bolt. (Page 4A-
2) Tightening torque
Steering column reinforcement bolt (a): 5.5 N·m
NOTE (0.56 kgf-m, 4.0 lbf-ft)
Have someone slightly pull brake booster Steering column reinforcement nut (b): 5.5 N·m (
towards engine compartment to facilitate 0.56 kgf-m, 4.0 lbf-ft)
removal of brake pedal assembly.
(b)
1) Remove brake pedal assembly.
Installation
1) Install brake pedal assembly and install brake
booster.
2) Tighten brake booster nuts (1) to specified torque.
Tightening torque
(a)
Brake booster nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf-
ft)
IBP80A410008-01
6) Check brake pedal free height and play.

• Brake pedal free height: 
• Brake pedal play: 
7) Install brake stroke sensor. (Page 1C-5)
8) Install brake light switch. (Page 4A-3)
9) Check all connections for fluid leakage and check
1,(a) that brake system operates properly.
IBP80A410052-01
3) Tighten brake pedal bracket nut and cowl upper 10) Install steering column hole cover. (Page 6B-3)
stiffener bolt to specified torque. 11) Install combination meter cluster panel. (Page 9C-
24)
Tightening torque
Brake pedal bracket nut (a): 13 N·m (1.3 kgf-m,
9.5 lbf-ft) Brake Light Switch Removal and Installation
AENFL80B4106011
Cowl upper stiffener bolt (b): 13 N·m (1.3 kgf-m, Removal
9.5 lbf-ft) 1) Disconnect brake light switch connector (1).
2) Remove brake light switch (2) from brake pedal Petrol and Bi-Fuel CNG: 0.8 to 1.8 mm (0.032
assembly. to 0.070 in.)
Diesel model: 1.0 to 2.0 mm (0.039 to 0.078
1 in.)
“a”
IBP80A410012-01
IBP80A410014-01
Installation 2) Connect brake light switch connector (3).

1) While pulling up brake pedal (2) fully, install brake
light switch (1) pressing it to pedal bracket so that 3
the switch stroke becomes 0 (zero) and turning it
clockwise viewed from above by approx. 90°.
NOTE
While installing brake light switch turning it
clockwise, the switch body rises from the
1
pedal bracket.
This movement automatically creates
specified clearance “a” between switch
screw end and the pedal bracket. 2
Clearance “a”:
IDL10A410007-01
Brake Booster Components

AENFL80B4106021
ISG model or A/T model
3 4 2
9
1 8
10
(a)
5
6
(b)
IFL80B410002-02
1. Brake master cylinder 6. Hose clamp : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
2. Gasket 7. Vacuum hose : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
3. Clevis pin 8. O-ring : Apply grease to piston rod included in spare part for brake
master cylinder or brake booster.
4. Clip 9. Brake booster : Do not reuse.
5. Check valve 10. Brake booster switch
Brake Booster Removal and Installation (ISG 8) Pull out oil level gauge guide a little to facilitate brake
model or A/T model) booster removal.
AENFL80B4106023
9) Wrap the oil level gauge guide end (5) with adhesive
plaster or the like to protect brake booster from
Removal
scratching.
1) Disconnect brake pipes (1) from ABS hydraulic unit/
10) Disconnect engine harness (1) and crankcase
control module assembly (2) (ABS model) or
ventilation connector (2).
proportioning valve (3) (Non-ABS model) using
special tool. 11) Remove engine hook (3) and intake manifold bolt(4).
Special tool 5 2
1
: 09950M78220
[A] [B]
4
2 3
1 3
IDL10A410017-01 IBP80A410036-01
[A]: ABS model [B]: Non-ABS model 12) Remove actuator bracket bolt (1) (with ABS) or
proportioning valve bracket bolt (2) (without ABS).
2) Disconnect brake booster switch connector.
[A] [B]
3) Remove brake master cylinder assembly from brake
booster. 
1
4) Recover refrigerant from A/C system.  2
1
5) Remove A/C suction hose and A/C liquid pipe from
HVAC unit. 
6) Disconnect vacuum hose from brake booster.
7) Pull out oil level gauge (1) and remove oil level
gauge guide mounting bolt (2).
IBP80A410037-02
1 [A]: ABS model [B]: Non-ABS model
13) Remove clip (2) and clevis pin (1).
2
IBP80A410057-01
NOTE
2 Instead of step 14), engine can be supported
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
1
hoist, bring hood up to upright position and
hold it at the position with rope.
16) Remove engine right mounting bracket nuts (1) and

then lower engine carefully until end of stud bolts
(2)are flush with surface of mounting.
1
2
IBP80A410058-01
1
14) Remove brake booster nuts (1).
IBP80A410039-01
17) Moving oil level gauge aside, remove brake booster

from dash panel.
1
18) Remove vacuum check valve (1) from brake
IBP80A410059-01 booster(2).
15) Support engine with a chain hoist or an engine crane
as follows.
a) Remove engine right mounting bracket bolt (2). 2
b) Install the removed engine hook (1) with engine
right mounting bracket bolt (2) to support engine 1
steady.
IBP80A410040-01
Installation
1) Remove combination meter. (Page 9C-24)
2) Loosen brake pedal bracket nut (1) and cowl upper
stiffener bolt (2).
2
1
IBP80A410038-01
2 (a)
1
IAP70B410011-01
3) Install vacuum check valve (1) to brake booster (2). IBP80A410044-01
6) After removing a chain hoist or an engine crane and

engine hook, tighten engine right mounting bracket
2
bolt (1) to specified torque.
Tightening torque
Engine right mounting bracket bolt (a): 60 N·m (
6.1 kgf-m, 44.5 lbf-ft)
(a)
1
IDL10A410018-01
4) Hold brake booster (1) in a position as illustrated

carefully and install it to dash panel.
! CAUTION
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
IDL10A410006-01
surface from scratching.
7) Connect clevis (3) to brake pedal arm with clevis
pin(2) and new clip (1).
1
3
1
IBP80A410043-01
5) Lift up engine and tighten engine right mounting

bracket nuts to specified torque. IBP80A410062-01
Tightening torque 8) Tighten brake booster nuts (1) to specified torque.

Engine right mounting bracket nut (a): 55 N·m ( Tightening torque
5.6 kgf-m, 40.5 lbf-ft) Brake booster nut (a): 13 N·m (1.3 kgf-m, 9.5 lbf-
ft)
16) Install engine harness and crankcase ventilation

connector (3).
2,(a)
1,(a)
IBP80A410063-01
9) Tighten brake pedal bracket nut to specified torque.

Tightening torque
Brake pedal booster nut (a): 13 N·m (1.3 kgf-m, 4,(b) 1
IBP80A410048-02
9.5 lbf-ft)
17) Push oil level gauge guide (1), pulled out before,
10) Tighten cowl upper stiffener bolt to specified torque. back to original position and tighten oil level gauge
Tightening torque guide mounting bolt to specified torque. And then,
Cowl upper stiffener bolt (a): 13 N·m (1.3 kgf-m, insert oil level gauge.
9.5 lbf-ft) Tightening torque
11) Install combination meter cluster panel. (Page 9C- Oil level gauge guide mounting bolt (b): 9.0 N·m
24) (0.92 kgf-m, 7.0 lbf-ft)
12) Connect vacuum hose to brake booster. 1
13) Tighten actuator bracket bolt (with ABS) or
proportioning valve bracket bolt (without ABS) to
specified torque.
Tightening torque
Actuator bracket bolt (a): 26 N·m (2.7 kgf-m,
19.5 lbf-ft)
[A] [B]
(a) (b)
(a)
(a)
IBP80A410064-01
18) Install brake master cylinder assembly to brake

booster.
IBP80A410047-01 19) Connect brake pipes (1) to ABS hydraulic unit /
[A]: ABS model [B]: Non-ABS model
control module assembly (2) (with ABS) or
proportioning valve (3) (without ABS) using special
14) Tighten intake manifold bolt (2) to specified torque. tool.
Tightening torque Tightening torque

Intake manifold bolt (a): 25 N·m (2.5 kgf-m, 18.5 Brake pipe flare nut (b): 16 N·m (1.6 kgf-m, 12.0
lbf-ft) lbf-ft)
15) Install engine hook (1) and tighten engine hook Special tool
bolt(4) to specified torque. : 09950M78220
Tightening torque
Engine hook bolt (b): 25 N·m (2.5 kgf-m, 18.5 lbf-
ft)
Special tool
[A] [B] (A): SUZUKI scan tool (Suzuki SDT-II)
2 3
1,(a)
1,(a)
IBP80A410050-01
[A]: ABS model [B]: Non-ABS model 1
20) After installation, bleed brake system. 

21) Check installed parts for brake fluid leakage. 2
22) Check brake pedal for play. 

23) Make sure that brake system operates properly
without brake fluid leakage.
24) Install A/C suction hose and A/C liquid pipe. 
25) Connect brake booster switch connector.
26) Evacuate and charge the A/C system.  (A)
IDL10A722005-01
Brake Booster Switch Inspection (ISG Model)
AENFL80B4106025 2. VCI
! CAUTION
4) Set ignition “ON”, and select “Brake Booster
Do not remove brake booster switch. Condition” in “Data list” mode on SUZUKI scan tool.
Removal and reinstallation will spoil its
5) Check data displayed on SUZUKI scan tool at each
original performance.
negative pressure specified.
If faulty condition is observed, replace brake
If the data displayed is not as shown in the table,
booster assembly with new one.
replace brake booster assembly with new one.
Using SUZUKI Scan Tool Brake booster switch reference value
1) Disconnect vacuum hose from brake booster (2). Negative pressure Scan tool display
2) Connect special tool (A) to brake booster. 30.7 kPa (0.3 kgf/cm2, 4.45 psi) Value Lo
38.7 kPa (0.4 kgf/cm2, 5.61 psi) Value Hi
Special tool
(A): 09917M47011 Using Circuit Tester
1) Disconnect connector from brake booster switch (1).
2
2) Disconnect vacuum hose from brake booster (2).
3) Connect special tool (A) to brake booster.
(A)
Special tool
(A): 09917M47011
(A)
1
IEL10A410007-01
1. Brake booster switch
3) Connect SUZUKI scan tool to DLC (1) located

around bottom of instrument panel on driver’s seat
side.
1
IEL10A410008-01
4) Apply vacuum to brake booster (2) by special tool

and check for continuity between switch terminal and 2
ground at each specified negative pressure in the

following table.
5) If the tester reading is not as shown in the table,
3
replace brake booster assembly with new one.
Brake booster switch continuity
Negative pressure Scan tool display
30.7 kPa (0.3 kgf/cm2, 4.45 psi) Continuity exists
38.7 kPa (0.4 kgf/cm2, 5.61 psi) No continuity
1
IEL10A410009-01
1. Brake booster switch 3. Circuit tester
Specifications
AENFL80B4107002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Brake booster nut 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 
Engine right mounting bracket nut 55 5.6 40.5 
Engine right mounting bracket bolt 60 6.1 44.5 
Brake pedal booster nut 13 1.3 9.5 
Actuator 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 
Brake pipe flare nut 16 1.6 12.0 
Reference:
“Brake Pedal Components”:
“Brake Booster Components”:

AENFL80B4108003
NOTE
“Brake Pedal Components”:
“Brake Booster Components”:
Special Tool
AENFL80B4108004
09917M47011 09950M78220
Vacuum pump gauge Flare nut wrench (10 x 12
mm)
/ /

SDT-II)
—

ABS: 4E-1
ABS
Brakes
Precautions
Precautions for ABS • When disconnecting ABS control module connector
AENFL80B4500002 (1), pull up the lock lever (2) of connector.
When disconnecting ABS control module connector,
When connecting the connector, set the connector in
disconnect the negative (–) cable at battery since the
position on ABS hydraulic unit / control module
battery voltage is constantly applied to ABS hydraulic
assembly and pull down the lock lever (2) until it locks.
unit / control module assembly.
1
[C] [D]
Precautions for Diagnosing Troubles
AENFL80B4500001 2
To check that the trouble diagnosis is done accurately
and smoothly, observe the following and follow “ABS [B] [E]
Check” in related manual.
• Before using scan tool, read its Operator’s Manual to
[A]
know how to use it.
• If the vehicle was operated in any of the following
conditions, ABS warning light may light momentarily
but this does not indicate any fault in ABS.
IEAD0A450001-01
– The vehicle is driven with parking brake applied. [A]: Press at this point before pulling up as [D]: Connect
– The vehicle is driven with brake dragging. explained in [B]
[B]: Pull up to unlock [E]: Pull down to lock
– The vehicle is stuck in mud, sand, etc.
[C]: Disconnect
– Wheel spins while driving.
– Wheels are rotated while the vehicle is jacked up. • Communication of ABS control module and other
• Follow trouble diagnosis procedure described in “ABS control module is established by CAN.
Check” in related manual. If trouble diagnosis Therefore, be sure to read “Precautions for Installing
procedure is not followed properly, incorrect diagnosis Mobile Communication Equipment” in Section 00 in
may result. (If incorrect procedure is performed, other related manual before inspection and handling CAN
DTC may be stored in the ABS hydraulic unit / control communication line.
module assembly.)

4E-2 ABS:
ABS Circuit Diagram

AENFL80B4502003
2
GRN
31
RED
32
[B] 3
4
21
34
WHT BEG E24-4
33 [C] 37
35
36
WHT E24-14 BLK
E24-38 BLK
PNK
RED
E24-1
E24-26
6
7 8
1
9
BLK
5
25
30
RED M
24
WHT 22
11 WHT 20
RED
23
GRN
10 26
14
GRN BLK
15
LT GRN
4
RED
12
WHT
27
RED E24-2
5 5
WHT E24-15
13 28
GRN
RED E24-3
5
WHT E24-16
[A] E24
26 1
2
27 15
3 GRN E24-20
28 16 16
4 BLK E24-33
29 17
5
30 18
6 GRN E24-17
31 19 17
7 BEG E24-29
32 20
8
33 21 29
9 BRN E24-7
34 22 18
10 YEL E24-19
35 23
11
36 24
12 [a] LT BLU E24-18
37 25 19
13 PNK E24-5
38 14
: 38 : 39
: 5V : 12V
IFL80B450001-01
ABS: 4E-3
[A]: ABS control module connector (View: [a]) 12. Brake light 26. Solenoid valve power supply relay
[B]: Ignition switch model 13. ECM 27. Solenoid valve
[C]: Keyless push start model 14. Brake fluid level switch 28. Solenoid valve relay
1. Battery 15. Parking brake switch 29. Wheel speed sensor driver
2. Individual circuit fuse box No.1 16. Left-front wheel speed sensor 30. P/S control module
3. Ignition switch 17. Right-front wheel speed sensor 31. “ABS1” fuse
4. J/B 18. Left-rear wheel speed sensor 32. “ABS2” fuse
5. CAN driver 19. Right-rear wheel speed sensor 33. “IGN” fuse
6. Combination meter 20. DLC 34. “ABS” fuse
7. ABS warning light 21. ABS hydraulic unit / control module assembly 35. “MTR” fuse
8. EBD warning light (Brake warning light) 22. CPU 36. “STOP” fuse
9. CPU (combination meter) 23. Internal memory 37. IG1 relay
10. BCM 24. Pump motor relay 38. Engine ground
11. Brake light switch 25. Pump motor 39. Ground
Terminal Wire color Circuit

1 RED Solenoid valve power supply circuit
2 RED CAN communication line (high) for BCM
3 RED CAN communication line (high) for ECM
4 BEG Ignition power supply circuit
5 PNK Right-rear wheel speed sensor signal circuit
7 BRN Left-rear wheel speed sensor 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 GRN Right-front wheel speed sensor power supply circuit
18 LT BLU Right-rear wheel speed sensor power supply circuit
19 YEL Left-rear wheel speed sensor signal circuit
20 GRN Left-front wheel speed sensor power supply circuit
26 GRN Pump motor power supply circuit
29 BEG Right-front wheel speed sensor signal circuit
33 BLK Left-front wheel speed sensor signal circuit
38 BLK ABS control module ground circuit 2

DTC Check NOTE
AENFL80B4504005
If communication between SUZUKI scan tool
and ABS control module is not possible,
2) Connect SUZUKI scan tool to DLC (1). perform the following checks:
Special tool • Check communication condition between
(A): SUZUKI scan tool (Suzuki SDT-II) PC and VCI (2) using SUZUKI scan tool
function.
circuit.
SUZUKI scan tool and print it or write it down. Refer
to Operator's Manual of SUZUKI scan tool for further • Check DLC cable. If necessary, check DLC
details. cable by substituting a known-good DLC
cable.
• Check CAN communication system.
(“Control Module Communication Bus Off”
is detected in any control module.)
4E-4 ABS:
– K14B model: (Page 10H-19) NOTE

– D13A model: (Page 10H-45) If communication between SUZUKI scan tool
• Check ABS control module power circuit and ABS control module is not possible,
and ground circuit. (Page 4E-17) perform the following checks:
• Check communication condition between
PC and VCI (2) using SUZUKI scan tool
function.
circuit.
cable.
1 (“Control Module Communication Bus Off”
2 – K14B model: (Page 10H-19)
– D13A model: (Page 10H-45)
(A) • Check ABS control module power circuit
and ground circuit. (Page 4E-17)
IFL80B450002-04

disconnect SUZUKI scan tool from DLC.
DTC Clearance
AENFL80B4504006
! WARNING 1
If you do not select a suitable route and take

proper precautions when performing a road 2
test, an accident can occur.
• Select a level road with no traffic to
(A)
minimize the risk of accident.
• Perform the road test with 2 persons, a
driver and an assistant.
IFL80B450002-04
1) Set ignition “OFF”. 5) After completing the clearance, set ignition “OFF”
2) Connect SUZUKI scan tool to DLC (1). and disconnect SUZUKI scan tool from DLC.
Special tool
4) Clear DTC according to instructions displayed on
SUZUKI scan tool and print it or write it down. Refer
to Operator's Manual of SUZUKI scan tool for further
details.
ABS: 4E-5
ABS Warning Light Does Not Come ON after Setting Ignition “ON”
AENFL80B4504010
Circuit Diagram
2
GRN
15
RED
16
[A] 20
14
4
18
WHT GRY E24-4
17 [B] 3
19
E24-1
E24-26
A1 RED
E24-14 BLK
G240-3 E24-38 BLK [C] E24
6
7 8
26 1
A2
2
9 G240-5 27 15
BLK 3
1 5 28 16
4
29 17
5
RED 30 18
6
WHT 31 19
7
[a] 32 20
WHT 8
13 33 21
RED 9
34 22
10
35 23
10 11
B1 11 36 24
[A] E04-10 12
GRN BLK 37 25
[B] E05-18 13
12
[A] L01-22 LT GRN
[B] L02-21 38 14
B2
RED
WHT
[D] G240
RED E24-2
5 5 1 2 3 4 5 6 7 8 9 10 11 12
WHT E24-15
13 14 15 16 17 18 19 20 21 22 23 24
IFL80B450003-03
[A]: Ignition switch model 3. IG1 relay 13. DLC

[B]: Keyless push start model 4. J/B 14. ABS control module
[C]: ABS control module connector (View: [a]) 5. CAN driver 15. “ABS1” fuse
[D]: Combination meter connector (View: [a]) 6. Combination meter 16. “ABS2” fuse
A1: Combination meter power supply circuit 7. ABS warning light 17. “IGN” fuse
A2: Combination meter ground circuit 8. EBD warning light 18. “ABS” fuse
B1: Brake fluid level switch signal circuit 9. CPU (combination meter) 19. “MTR” fuse
B2: Parking brake switch signal circuit 10. BCM 20. Ignition switch
1. Battery 11. Brake fluid level switch
2. Individual circuit fuse box No.1 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 with 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
4E-6 ABS:
Step Action Yes No

1 Warning light check Go to Step 2. Go to Step 4.
Do other indicator lights light up?

2 DTC check • K14B model: Go to Go to Step 3.
1) Check DTC. (Page 4E-3) “Troubleshooting for
Communication Bus
Is DTC U0073 detected? Off”: Petrol and Bi-
Fuel CNG Model in
Section 10H (Page
10H-19)
• D13A model: Go to
“Troubleshooting for
Communication Bus
Off”: Diesel Model in
Section 10H (Page
10H-45)
3 Combination meter check Replace ABS hydraulic End.
1) Replace combination meter. (Page 9C-24) unit / control module
assembly and recheck
warning light operation.
Does warning light stay OFF? 
4 Fuse check Go to Step 5. Replace “MTR” fuse
and check for short
Is “MTR” fuse in good condition? circuit to ground.
5 Combination meter power supply circuit check Replace combination Go to Step 6.
1) Remove combination meter. (Page 9C-24) meter and recheck
2) Check for proper connection to “G240” connector.
(Page 9C-24)
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.
2) Measure resistance between “G240-5” terminal and
ground.
Is it 1 Ω or less?
ABS: 4E-7
ABS Warning Light Comes ON Steady

AENFL80B4504011
Circuit Diagram
2
GRN
15
RED
16
[A] 20
14
4
18
WHT GRY E24-4
17 [B] 3
19
E24-1
E24-26
A1 RED
E24-14 BLK
G240-3 E24-38 BLK [C] E24
6
7 8
26 1
A2
2
9 G240-5 27 15
BLK 3
1 5 28 16
4
29 17
5
RED 30 18
6
WHT 31 19
7
[a] 32 20
WHT 8
13 33 21
RED 9
34 22
10
35 23
10 11
B1 11 36 24
[A] E04-10 12
GRN BLK 37 25
[B] E05-18 13
12
[A] L01-22 LT GRN
[B] L02-21 38 14
B2
RED
WHT
[D] G240
RED E24-2
5 5 1 2 3 4 5 6 7 8 9 10 11 12
WHT E24-15
13 14 15 16 17 18 19 20 21 22 23 24
IFL80B450003-03

Circuit Description
Refer to “Circuit Description” under “ABS Warning Light Does Not Come ON after Setting Ignition “ON”” (Page 4E-5).
4E-8 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-3). troubleshooting.
Is there any DTC(s)?

3 ABS control module power supply and ground circuit Go to Step 4. Repair or replace
1) Check ABS control module power supply circuit and
ground circuit. (Page 4E-17)
Are the circuits in good condition?

Does warning light stay on? 
ABS: 4E-9
EBD Warning Light (Brake Warning Light) Comes ON Steady

AENFL80B4504013
Circuit Diagram
2
GRN
15
RED
16
[A] 20
14
4
18
WHT GRY E24-4
17 [B] 3
19
E24-1
E24-26
A1 RED
E24-14 BLK
G240-3 E24-38 BLK [C] E24
6
7 8
26 1
A2
2
9 G240-5 27 15
BLK 3
1 5 28 16
4
29 17
5
RED 30 18
6
WHT 31 19
7
[a] 32 20
WHT 8
13 33 21
RED 9
34 22
10
35 23
10 11
B1 11 36 24
[A] E04-10 12
GRN BLK 37 25
[B] E05-18 13
12
[A] L01-22 LT GRN
[B] L02-21 38 14
B2
RED
WHT
[D] G240
RED E24-2
5 5 1 2 3 4 5 6 7 8 9 10 11 12
WHT E24-15
13 14 15 16 17 18 19 20 21 22 23 24
IFL80B450003-03

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.
Also, the warning light is turned ON continuously by light driver module when the connector of ABS control module is
disconnected.
4E-10 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.

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. 
Is check result OK?

3 ABS warning light operation check Perform “ABS Warning Go to Step 4.
1) Set ignition “ON”. Light Comes ON
Steady” (Page 4E-7).
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 following connectors. If OK, check parking
• Ignition switch model: “E04” and “L01” brake switch and/or
brake fluid level
• Keyless push start model: “E05” and “L02” switch.
– Parking brake
• Resistance between “B1” circuit and ground: infinity switch: 
• Resistance between “B2” circuit and ground: infinity – Brake fluid level
Is check result OK? switch: 
5 CAN communication circuit check • K14B model: Go to Go to Step 6.
1) Connect following connector. “Troubleshooting for
Communication Bus
• Ignition switch model: “E04”
Off”: Petrol and Bi-
• Keyless push start model: “E05” Fuel CNG Model in
2) Perform “DTC Check” (Page 4E-3). Section 10H (Page
10H-19)
Is DTC U0073 detected?
Communication Bus
Section 10H (Page
10H-45)
6 DTC check for BCM • K14B model: Go to Go to Step 7.
1) Check BCM for DTC. (Page 10B-10) “Troubleshooting for
Communication Bus
Is DTC U0073 detected? Off”: Petrol and Bi-
Fuel CNG Model in
Section 10H (Page
10H-19)
Communication Bus
Section 10H (Page
10H-45)
ABS: 4E-11
Step Action Yes No

Does EBD warning light stay on? 
DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1033 / C1035 / C1036
AENFL80B4504014
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-4) and check
whether any abnormality exists or not by performing road test as described in Step 3 of “ABS Check”
in related manual.
• Vehicle was driven with parking brake lever pulled.
• Wheel spins while driving.
• Wheel(s) is rotated while vehicle was jacked up.
Circuit Diagram
5
[A] E24
A1
GRN E24-20 [a] 26 1
1
BLK E24-33 2
27 15
A2 3
28 16
B1 4
GRN E24-17 29 17
5
2 30 18
BEG E24-29 6
31 19
B2 7
32 20
C1 8
6 33 21
BRN E24-7 9
3 34 22
YEL E24-19 10
35 23
C2 11
36 24
12
D1 37 25
LT BLU E24-18 13
4
PNK E24-5 38 14
D2
IFL80B450004-01
[A]: ABS control module connector (View: [a]) C1: Left-rear wheel speed sensor power supply circuit 2. Right-front wheel speed sensor
A1: Left-front wheel speed sensor power supply circuit C2: Left-rear wheel speed sensor signal circuit 3. Left-rear wheel speed sensor
A2: Left-front wheel speed sensor signal circuit D1: Right-rear wheel speed sensor power supply circuit 4. Right-rear wheel speed sensor
B1: Right-front wheel speed sensor power supply circuit D2: Right-rear wheel speed sensor signal circuit 5. ABS control module
B2: Right-front wheel speed sensor signal circuit 1. Left-front wheel speed sensor 6. Wheel speed sensor driver
4E-12 ABS:
NOTE
• DTC C1057 is not detected.

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” in
related manual.
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
2) Disconnect “E24” and each of wheel speed sensor
connectors.
3) Check for proper connection to “E24” and each of wheel
speed sensor connectors.
• 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
terminal at left-front wheel speed sensor connector:
infinity
terminal at right-front wheel speed sensor connector:
infinity
terminal at left-rear wheel speed sensor connector:
infinity
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.  assembly and recheck
DTC. 
Is check result as specified?
ABS: 4E-13
Step Action Yes No

5 Wheel speed sensor check Go to Step 6. • Clean, repair or
1) Check applicable wheel speed sensor.  replace wheel speed
sensor.
Is check result OK?
– Front wheel speed
sensor: 
– Rear wheel speed
sensor: 
6 Wheel speed sensor encoder check Replace ABS hydraulic • Clean, repair or
1) Check applicable wheel speed sensor encoder.  unit / control module replace wheel speed
assembly and recheck sensor encoder.
Is check result OK? DTC.  – Front wheel speed
sensor encoder: 
– Rear wheel speed
sensor encoder: 
DTC C1041 / C1042 / C1045 / C1046 / C1051 / C1052 / C1055 / C1056 / C1063
AENFL80B4504015
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-14 ABS:
Circuit Diagram
2 A1 4
3
1 RED E24-1
[a]
5V
[A] E24
6
26 1
6 2
27 15
3
28 16
6 4
29 17
7 5
30 18
6 6
31 19
7
6 32 20
8
33 21
9
34 22
6 10
35 23
11
36 24
B1 12
6 37 25
13
BLK E24-14
E24-38 38 14
BLK 6
B2
IFL80B450005-01
[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” in
related manual.
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. 
Circuit Check” (Page 4E-17).
Is check result OK?
DTC C1057
AENFL80B4504016
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-15
Circuit Diagram
4 [A] E24
2 A1
[a]
7 26 1
GRN E24-26 5
1 8 2
RED E24-1 6 27 15
3
A2 28 16
C1 4
BLK E24-14 29 17
5
BLK 30 18
E24-38 6
31 19
C2 7
3 B1 32 20
8
9 33 21
10 BEG E24-4 9
34 22
10
35 23
11
36 24
12
37 25
13
38 14
IFL80B450006-02
[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” in
related manual.
2 ABS control module power supply and ground circuits Go to Step 3. Repair or replace
1) Check ABS control module power supply circuit and
ground circuit. (Page 4E-17)

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 1J-3)
Is voltage between 9.3 V and 16.8 V?
– D13A model:
– with ISG model:
(Page 1J-23)
– without ISG
model: (Page
1J-13)
DTC C1061
AENFL80B4504017
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-16 ABS:
Circuit Diagram
1
[A] E24
[a]
A1 26 1
7
6 2
5 GRN E24-26 27 15
3
28 16
4
5V 29 17
5
30 18
6
31 19
7
2 3 32 20
8
33 21
9
34 22
B1 10
35 23
M 11
BLK E24-14 36 24
4 12
BLK E24-38 37 25
13
B2
38 14
IFL80B450007-01
[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

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” in
related manual.
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”
“E24-38” terminals and ground. assembly and recheck circuit.
DTC. 
Is resistance less than 1 Ω?
ABS: 4E-17
ABS Control Module Power Supply and Ground Circuit Check

AENFL80B4504023
Circuit Diagram
4 [A] E24
2 A1
[a]
7 26 1
GRN E24-26 5
1 8 2
RED E24-1 6 27 15
3
A2 28 16
C1 4
BLK E24-14 29 17
5
BLK 30 18
E24-38 6
31 19
C2 7
3 B1 32 20
8
9 33 21
10 BEG E24-4 9
34 22
10
35 23
11
36 24
12
37 25
13
38 14
IFL80B450006-02
[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”
5) Measure voltage between “E24-4” 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”
2) Measure voltage between each of “E24-26” and “E24-1”
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”
“E24-38” terminals and ground. ground circuits are in circuit.
good condition.
Is resistance less than 1 Ω?
4E-18 ABS:
Repair Instructions
ABS Hydraulic Unit Operation Check 6) Perform the following checks with help of another
AENFL80B4506001 person.
NOTE
• Depressurization check
• A false diagnosis may result if operation Step on brake pedal and then select testing wheel
check of the ABS hydraulic unit is by SUZUKI scan tool and the wheel should be
performed without satisfying all of the turned by another person’s hand. At this time,
specified condition below. check whether the wheel rotates freely due to
Check that all the following conditions are brake depressurization.
met before performing operation check of
the ABS hydraulic unit. NOTE
– Battery voltage is 12 V or more. Depressurization by SUZUKI scan tool is
– No air is trapped in the brake system. available for 0.5 seconds.
– Brakes do not drag.
– No DTC is stored in ABS hydraulic unit /
control module.
• Operation check must be performed by 2
persons.
• Lighting or blinking of warning light stops
when ignition is set “ON” after completing
ABS hydraulic unit operation check.
I8G001460007-01
1) Check that ignition is “OFF”.
7) Check all 4-wheels respectively.
2) Connect SUZUKI scan tool (PC and VCI (2)) to DLC
8) Check that ABS warning light is turned off after
(1) located around bottom of instrument panel on
switching ignition from “OFF” to “ON”. Check for
driver’s seat side.
DTC and repair problem if lights are still lit.
Special tool 9) If any faulty condition is found in Step 6) - 7), replace
(A): SUZUKI scan tool (Suzuki SDT-II) ABS hydraulic unit /control module assembly.
10) After completing the check, confirm that ignition is
“OFF” and then disconnect SUZUKI scan tool from
DLC.
(A)
IFL80B450002-04
3) Hoist vehicle until tire can be rotated.

4) Set transmission to neutral and release parking
brake.
5) Set ignition “ON”, and select “Depressurization
check” in “Hydraulic control test” under “Utility” mode
of SUZUKI scan tool.
Refer to Operator’s Manual of SUZUKI scan tool for
further details.
ABS: 4E-19

Special Tool
AENFL80B4508002
SDT-II)
—
//
4E-20 ABS:
Section 5
Transmission / Transaxle
CONTENTS
NOTE
Precautions ................................................. 5-* P Range Test ....................................................5A-40

Precautions.............................................................. 5-* A/T Symptom Diagnosis....................................5A-42
Precautions for Transmission / Transaxle.............. 5-* MIL Does Not Come ON with Ignition “ON”
and Engine Stopped (but Engine Can Be
Automatic Transmission/Transaxle....... 5A-1 Started) ...........................................................5A-43
Precautions...........................................................5A-1 MIL Remains ON after Engine Starts................5A-43
Precautions for Diagnosing Trouble.................... 5A-1 Transmission Warning Light Does Not Come
Precautions for OBD System .............................. 5A-1 ON with Ignition ON ........................................5A-43
Precautions for Disassembly and Transmission Warning Light Remains ON
Reassembly ...................................................... 5A-1 with Ignition ON...............................................5A-43
DTC P0562 / P0563 ..........................................5A-43
General Description .............................................5A-2
DTC P0602 .......................................................5A-45
A/T Description ................................................... 5A-2
DTC P0604 / P062F / P1702 ............................5A-45
Description of Clutch / Brake / Planetary Gear
DTC P0705 .......................................................5A-45
Functions .......................................................... 5A-4 5
DTC P0707 .......................................................5A-48
Operation Table of A/T Component .................... 5A-5
DTC P0711 .......................................................5A-50
Electronic Shift Control System Input / Output
DTC P0712 .......................................................5A-51
Table ................................................................. 5A-7
DTC P0713 .......................................................5A-52
A/T Diagnosis General Description ..................... 5A-7
DTC P0717 .......................................................5A-53
OBD System Description .................................... 5A-7
DTC P0722 .......................................................5A-55
Schematic and Routing Diagram........................5A-9
DTC P072A .......................................................5A-57
Electronic Shift Control System Input / Output
DTC P0731 .......................................................5A-58
Diagram ............................................................ 5A-9
DTC P0741 .......................................................5A-60
Electronic Shift Control System Circuit
DTC P0742 .......................................................5A-62
Diagram .......................................................... 5A-10
DTC P0746 / P0747 ..........................................5A-64
Component Location .........................................5A-12 DTC P0751 .......................................................5A-66
Electronic Shift Control System Component DTC P0776 .......................................................5A-68
Location .......................................................... 5A-12 DTC P0777 .......................................................5A-69
Diagnostic Information and Procedures..........5A-13 DTC P0796 / P0797 ..........................................5A-71
A/T Control System Check................................ 5A-13 DTC P0961 .......................................................5A-73
MIL Check ......................................................... 5A-15 DTC P0962 .......................................................5A-74
Transmission Warning Light Check .................. 5A-15 DTC P0963 .......................................................5A-76
DTC Check ....................................................... 5A-15 DTC P0965 .......................................................5A-77
DTC Clearance ................................................. 5A-16 DTC P0966 .......................................................5A-78
DTC Table......................................................... 5A-16 DTC P0967 .......................................................5A-80
Fail-Safe Table.................................................. 5A-19 DTC P0969 .......................................................5A-81
Scan Tool Data ................................................. 5A-25 DTC P0970 .......................................................5A-83
Visual Inspection ............................................... 5A-28 DTC P0971 .......................................................5A-84
A/T Basic Check ............................................... 5A-29 DTC P0973 .......................................................5A-85
Road Test ......................................................... 5A-29 DTC P0974 .......................................................5A-87
Manual Road Test............................................. 5A-35 DTC P1706 .......................................................5A-88
Engine Brake Test ............................................ 5A-35 DTC P1736 .......................................................5A-89
Stall Test ........................................................... 5A-36 DTC P1737 .......................................................5A-90
Time Lag Test ................................................... 5A-37 DTC P1738 .......................................................5A-91
Line Pressure Test ............................................ 5A-38 DTC P1739 .......................................................5A-92
DTC P2762 ....................................................... 5A-93 Forward and Reverse Clutch Assembly

DTC P2763 ....................................................... 5A-95 Components..................................................5A-141
DTC P2764 ....................................................... 5A-96 Forward and Reverse Clutch Assembly
DTC U0073 ....................................................... 5A-97 Preliminary Check .........................................5A-141
DTC U0100 ....................................................... 5A-97 Forward and Reverse Clutch Assembly
Inspection of TCM and Its Circuits .................... 5A-97 Disassembly and Reassembly ......................5A-142
TCM Power and Ground Circuit Check........... 5A-102 Forward and Reverse Clutch Assembly
Repair Instructions ..........................................5A-103 Inspection......................................................5A-145
TCM Learning Control Initialization ................. 5A-103 Transaxle Rear Cover (O/D and 2nd Coast
ATF Level Check............................................. 5A-103 Brake Piston) Assembly Components...........5A-146
ATF Change.................................................... 5A-104 Transaxle Rear Cover (O/D and 2nd Coast
Select Lever Assembly Components .............. 5A-105 Brake Piston) Assembly Disassembly and
Select Lever Assembly Removal and Reassembly ..................................................5A-146
Installation ..................................................... 5A-105 Transaxle Rear Cover (O/D and 2nd Coast
Select Lever Assembly Inspection .................. 5A-105 Brake Piston) Assembly Inspection...............5A-147
O/D Off Switch Inspection ............................... 5A-105 Countershaft Assembly Components..............5A-148
Shift Lock Solenoid Inspection ........................ 5A-106 Countershaft Assembly Disassembly and
Manual Release of Shift Lock ......................... 5A-106 Reassembly ..................................................5A-148
Select Cable Components .............................. 5A-107 Differential Assembly Components .................5A-149
Select Cable Removal and Installation ........... 5A-108 Differential Assembly Disassembly and
Select Cable Adjustment................................. 5A-108 Reassembly ..................................................5A-149
Transmission Range Sensor Removal and Differential Assembly Inspection .....................5A-151
Installation ..................................................... 5A-109 Torque Converter Housing Disassembly and
Transmission Range Sensor Inspection and Reassembly ..................................................5A-151
Adjustment .................................................... 5A-109 Transaxle Case Disassembly and
Key Interlock Cable Removal and Installation. 5A-110 Reassembly ..................................................5A-153
Key Interlock Cable Inspection........................ 5A-112 A/T Assembly Inspection and Adjustment.......5A-155
Output Shaft Speed Sensor Removal and A/T Assembly Reassembly .............................5A-157
Installation ..................................................... 5A-113 Specifications ...................................................5A-169
Output Shaft Speed Sensor Inspection........... 5A-113 Tightening Torque Specifications....................5A-169
Input Shaft Speed Sensor Removal and Special Tools and Equipment .........................5A-170
Installation ..................................................... 5A-113 Recommended Service Material .....................5A-170
Input Shaft Speed Sensor Inspection.............. 5A-114 Special Tool ....................................................5A-170
A/T Oil Strainer Assembly Removal and
Installation ..................................................... 5A-114 Manual Transmission/Transaxle ............ 5B-1
A/T Oil Pan and Oil Strainer Assembly Petrol and Bi-Fuel CNG Model ...............................5B-1
Inspection...................................................... 5A-115 General Description .............................................5B-1
ATF Temperature Sensor Removal and Manual Transaxle Construction ..........................5B-1
Installation ..................................................... 5A-116 Diagnostic Information and Procedures ............ 5B-*
ATF Temperature Sensor Inspection .............. 5A-116 Manual Transaxle Symptom Diagnosis............... 5B-*
Valve Body Assembly Removal and
Installation ..................................................... 5A-117
Manual Transaxle Oil Level Check ..................... 5B-*
Solenoid Valve On-Vehicle Inspection ............ 5A-120
Manual Transaxle Oil Change.............................5B-4
Solenoid Valve Inspection............................... 5A-120
Differential Side Oil Seal Replacement ...............5B-5
TCM Removal and Installation ........................ 5A-121
Gear Shift Control Lever and Cable
Differential Side Oil Seal Replacement ........... 5A-122
Components...................................................... 5B-*
ATF Cooler Hose Inspection ........................... 5A-123
Gear Shift Control Lever and Cable Removal
ATF Cooler Hose Replacement ...................... 5A-123
and Installation .................................................. 5B-*
A/T Assembly Components............................. 5A-124
Gear Select Control Cable Adjustment ............... 5B-*
A/T Assembly Dismounting and Remounting.. 5A-127
Back Up Light Switch Removal and
A/T Assembly Disassembly............................. 5A-128
Installation ......................................................... 5B-*
Oil Pump Assembly Components ................... 5A-135
Back Up Light Switch Inspection......................... 5B-*
Oil Pump Assembly Disassembly and
Manual Transaxle Unit Components................... 5B-*
Reassembly .................................................. 5A-136
Manual Transaxle Unit Dismounting and
Oil Pump Assembly Inspection ....................... 5A-136
Remounting....................................................... 5B-*
Direct Clutch Assembly Components.............. 5A-137
Gear Shift and Select Shaft Assembly
Direct Clutch Assembly Preliminary Check..... 5A-137
Components......................................................5B-6
Direct Clutch Assembly Disassembly and
Gear Shift and Select Shaft Assembly
Reassembly .................................................. 5A-138
Removal and Installation...................................5B-6
Direct Clutch Assembly Inspection.................. 5A-139
Manual Transaxle Assembly Components.......... 5B-8 Differential Components....................................5B-51

Fifth Gear Disassembly and Reassembly ........... 5B-9 Differential Disassembly and Reassembly........5B-52
Manual Transaxle Assembly Disassembly Specifications.....................................................5B-53
and Reassembly ............................................. 5B-12 Tightening Torque Specifications......................5B-53
Transaxle Right Case Disassembly and Special Tools and Equipment ...........................5B-54
Reassembly .......................................................5B-* Recommended Service Material .......................5B-54
Transaxle Left Case Disassembly and Special Tool ......................................................5B-54
Reassembly .......................................................5B-*
Input Shaft and Countershaft Components....... 5B-18 Clutch ....................................................... 5C-1
Input Shaft Disassembly and Reassembly........ 5B-19 Petrol and Bi-Fuel CNG Model ...............................5C-1
Countershaft Disassembly and Reassembly .... 5B-21 General Description ............................................. 5C-*
Gear Shift Shaft Components ........................... 5B-25 Clutch Construction............................................. 5C-*
Gear Shift Shaft and Fork Inspection ...................5B-*
Diagnostic Information and Procedures ............ 5C-*
Differential Components ................................... 5B-25
Clutch System Symptom Diagnosis .................... 5C-*
Differential Disassembly and Reassembly........ 5B-25
Repair Instructions ..............................................5C-1
Specifications.....................................................5B-27
CPP (Clutch Pedal Position) No.1 Switch
Tightening Torque Specifications...................... 5B-27
Removal and Installation (Keyless Push
Special Tools and Equipment ...........................5B-28 Start Model).......................................................5C-1
Recommended Service Material ....................... 5B-28 CPP (Clutch Pedal Position) No.1 Switch
Special Tool ...................................................... 5B-28 Inspection and Adjustment (Keyless Push
Diesel Model ..........................................................5B-30 Start Model).......................................................5C-1
General Description ...........................................5B-30 CPP (Clutch Pedal Position) No.2 Switch
Manual Transaxle Construction ........................ 5B-30 Removal and Installation...................................5C-2
Diagnostic Information and Procedures............ 5B-* CPP (Clutch Pedal Position) No.2 Switch
Manual Transaxle Symptom Diagnosis................5B-* Inspection and Adjustment................................5C-2
Repair Instructions ............................................5B-32 Clutch Pedal Inspection ...................................... 5C-*
Manual Transaxle Oil Level Check ......................5B-* Clutch Fluid Level Inspection .............................. 5C-*
Manual Transaxle Oil Change .......................... 5B-32 Air Bleeding of Clutch System............................. 5C-*
Differential Side Oil Seal Replacement ................5B-* Clutch Fluid Pipe and Hose Components ........... 5C-*
Gear Shift Control Lever and Cable Clutch Fluid Pipe and Hose Removal and
Components.......................................................5B-* Installation ......................................................... 5C-*
Gear Shift Control Lever and Cable Removal Clutch Fluid Pipe and Hose Inspection ............... 5C-*
and Installation...................................................5B-* Clutch Master Cylinder Removal and
Gear Select Control Cable Adjustment ................5B-* Installation ......................................................... 5C-*
Neutral Position Switch On-Vehicle Clutch Master Cylinder Inspection ...................... 5C-*
Inspection........................................................ 5B-33 Clutch Operating Cylinder Assembly
Back Up Light Switch Removal and Removal and Installation................................... 5C-*
Installation..........................................................5B-* Clutch Operating Cylinder Assembly
Back Up Light Switch Inspection..........................5B-* Inspection.......................................................... 5C-*
Manual Transaxle Unit Components....................5B-* Clutch Pedal Assembly Components..................5C-3
Manual Transaxle Unit Dismounting and Clutch Pedal Assembly Removal and
Remounting..................................................... 5B-33 Installation ......................................................... 5C-*
Gear Shift and Select Shaft Assembly Clutch Cover and Clutch Disc Components........ 5C-*
Components.................................................... 5B-34 Clutch Cover and Clutch Disc Removal and
Gear Shift and Select Shaft Assembly Installation ......................................................... 5C-*
Removal and Installation................................. 5B-34 Clutch Cover and Clutch Disc Inspection............ 5C-*
Manual Transaxle Assembly Components........ 5B-36 Input Shaft Bearing Removal and Installation ..... 5C-*
Fifth Gear Disassembly and Reassembly ......... 5B-37 Input Shaft Bearing Inspection ............................ 5C-*
Manual Transaxle Assembly Disassembly Specifications.......................................................5C-3
and Reassembly ............................................. 5B-40 Tightening Torque Specifications........................5C-3
Transaxle Right Case Disassembly and Special Tools and Equipment .............................5C-4
Reassembly .......................................................5B-* Recommended Service Material .........................5C-4
Transaxle Left Case Disassembly and Special Tool ........................................................ 5C-*
Reassembly .......................................................5B-* Diesel Model ............................................................5C-5
Input Shaft and Countershaft Components..........5B-* General Description ............................................. 5C-*
Input Shaft Disassembly and Reassembly........ 5B-45 Clutch (Hydraulic Type) Construction ................. 5C-*
Countershaft Disassembly and Reassembly .... 5B-47
Diagnostic Information and Procedures ............ 5C-*
Gear Shift Shaft Components ........................... 5B-51
Clutch System Symptom Diagnosis .................... 5C-*
Gear Shift Shaft and Fork Inspection ...................5B-*
Repair Instructions ..............................................5C-5
CPP (Clutch Pedal Position) No.1 Switch Clutch Operating Cylinder Assembly
Removal and Installation (Keyless Push Removal and Installation................................... 5C-*
Start Model) ......................................................5C-5 Clutch Operating Cylinder Assembly
CPP (Clutch Pedal Position) No.1 Switch Inspection.......................................................... 5C-*
Inspection and Adjustment (Keyless Push Clutch Pedal Assembly Components..................5C-5
Start Model) ......................................................5C-5 Clutch Pedal Assembly Removal and
CPP (Clutch Pedal Position) No.2 Switch Installation ......................................................... 5C-*
Removal and Installation...................................5C-5 Clutch Cover and Clutch Disc Components ........ 5C-*
CPP (Clutch Pedal Position) No.2 Switch Clutch Cover and Clutch Disc Removal and
Inspection and Adjustment................................5C-5 Installation ......................................................... 5C-*
Clutch Pedal Inspection ...................................... 5C-* Clutch Cover and Clutch Disc Inspection ............ 5C-*
Clutch Fluid Level Inspection .............................. 5C-* Specifications .......................................................5C-6
Air Bleeding of Clutch System............................. 5C-* Tightening Torque Specifications........................5C-6
Clutch Fluid Pipe and Hose Components ........... 5C-* Special Tools and Equipment .............................5C-6
Clutch Fluid Pipe Removal and Installation......... 5C-* Recommended Service Material .........................5C-6
Clutch Fluid Pipe Inspection................................ 5C-* Special Tool ........................................................ 5C-*
Clutch Master Cylinder Removal and
Installation ......................................................... 5C-*
Automatic Transmission/Transaxle: 5A-1
Automatic Transmission/Transaxle
Precautions
Precautions for Diagnosing Trouble Communication System Diagnosis General
AENFL80B5100001 Description”: Petrol and Bi-Fuel CNG Model in
NOTE
Section 10H (Page 10H-2)). Therefore, handle CAN
For distinction of types A and B of OBD communication line with care referring to “Precautions
system, refer to “Discrimination for OBD for CAN Communication System” in Section 00 in
System” under “OBD System Description” related manual.
(Page 5A-7).
Precautions for OBD System
• Diagnostic information stored in TCM memory can be AENFL80B5100002
cleared and checked using SUZUKI scan tool or CAN NOTE
communication OBD generic scan tool (type A). For distinction of types A and B of OBD
Before using scan tool, read its “Operator’s system, refer to “Discrimination for OBD
(Instruction) Manual” for how to use it. System” under “OBD System Description”
• When replacing TCM with used one, all learned (Page 5A-7).
values which are stored in TCM memory should be
erased after installation of used TCM referring to There are two types of OBD system, type A and B,
“TCM Learning Control Initialization” (Page 5A-103). depending on the vehicle specification. As the diagnosis
Neglecting this initialization may cause excessive shift function is different between these two types, fully
shock. understand the OBD system. (Page 5A-7)
• Read “Precautions for Electrical Circuit Service” in
Section 00 in related manual before inspection, and Warning method to driver
understand well what is written there. Transmission
MIL
warning light
• TCM replacement
Type A *
– When substituting a known-good TCM, check that Type B ×
all actuators have resistance of specified value.
Neglecting this check may result in damage to the *: Lit when a trouble that affects exhaust gas has
known-good TCM. occurred.
• Communication of TCM and other control module is
established by CAN. (For more detail of CAN
communication for TCM, refer to “CAN
Precautions for Disassembly and Reassembly

AENFL80B5100003
When repairing Automatic Transaxle (A/T), it is necessary to conduct the on-vehicle test to investigate where the
cause of the trouble lies first.
Then whether overhaul should be done or not is determined. If the transaxle is disassembled without such preliminary
procedure, not only the cause of the trouble would be unknown, but also a secondary trouble may occur and often
time would be wasted.
As the A/T consists of high precision component, the following cautions should be strictly observed when handling its
parts in disassembly and reassembly.
• Never disassemble valve body assembly. Otherwise, disassembly will spoil its original performance.
• When component part of forward clutch, direct clutch and/or O/D and 2nd coast brake, namely clutch disc, brake
disc, retaining plate and/or separator plate, have been replaced, all learned contents, which have been stored in
TCM memory by executing learning control should be initialized. (Page 5A-103)
• Wash dirt off from the transaxle so that no such dirt will enter the transaxle during dismounting and remounting.
• When overhauling, select a clean place free from dust and dirt.
• Place a rubber mat on a workbench to protect parts from damage.
• When wiping internal parts of A/T, use lint-free paper, not cloth rags.
• When separating the case joint, do not pry with a flat-bladed screwdriver or the like but tap with a plastic hammer
lightly.
• Wash the disassembled parts in ATF or kerosene (with care not to allow ATF or kerosene to get on your face, etc.)
and check that each fluid passage is not clogged by blowing air into it. Use kerosene to wash the discs, resin
washers and rubber parts.
5A-2 Automatic Transmission/Transaxle:
• Replace each gasket, oil seal and O-ring with a new one.
• Apply ATF to sliding or rotating parts before reassembly.
• Keep component parts in group for each subassembly and avoid mixing them up.
• Clean all parts with cleaning solvent thoroughly and air-dry them.
• Keep face and eyes away from solvent spray while air blowing parts.
• Check mating surface for irregularities and remove them, if any, and clean it again.
• Apply ATF to all O-rings.
• When installing seal ring, be careful so that it is not expanded excessively, extruded or caught.
• Replace oil seals that are removed and apply grease to their lips.
• Always use torque wrench when tightening bolts.
• A new disc should be soaked in ATF at least 2 hours before use.
General Description
A/T Description
AENFL80B5101001
This transaxle is electronic control full automatic transaxle with forward 3-speed plus overdrive (O/D) and reverse 1-
speed.
The torque converter is of a 3-element, 1-step and 2-phase type and is equipped with an automatically controlled lock-
up mechanism.
The gear change device consists of a Ravigneaux type planetary gear unit, 3 multiple disc type clutches, 2 multiple
disc type brakes and 1 one-way clutch.
The hydraulic pressure control device consists of a valve body assembly, 3 pressure control solenoid valves (linear
solenoid), shift solenoid valve and TCC solenoid valve (linear solenoid).
Employing the ravigneaux type planetary gear unit and this clutch-to-clutch control system greatly simplifies the
construction to make possible a lightweight and compact transaxle.
A line pressure learning control is conducted to provide optimum shifting time at every upshifting with engine throttle
opened. If long upshifting time is detected, the subsequent line pressure applied during upshifting is intensified. On the
contrary, if short upshifting time is detected, the subsequent line pressure applied during upshifting is weakened.
Lock up control:
When the vehicle speed exceeds the specified value, the TCC solenoid valve completely engages the TCC upon
control signal from TCM. This control helps to improve the power transaxle efficiency.
Slip controlled lock-up function:
Even at a lower speed than when the TCC is completely engaged, control over the TCC solenoid valve works to cause
the TCC to slip (be engaged slightly), thereby improving the transaxle efficiency. While such slip control is being
executed, the oil pressure applied to the TCC is controlled by the TCC solenoid valve so that the difference between
the engine speed and the input shaft speed becomes close to the specified value.
Also, during deceleration, the TCC is made to slip (be engaged slightly) to raise the engine speed and enlarge the fuel
cut operation range so that better fuel consumption is achieved.
Due to this reason, it is absolutely necessary for the A/T to use ATF suitable for slip control. Use of any fluid other than
the specified ATF may cause juddering or some other faulty condition to occur.
Reverse control:
On the reverse control, if the shift lever is shifted to R range while the vehicle is running forward, TCM shifts the gear
to neutral to guard A/T inside parts from damage.
Slope shift control:
TCM distinguishes uphill according to vehicle speed and accelerator position, and limits gear shift up.
Garage shift control:
The garage shift control adjusts the oil pressure applied to the forward clutch or the reverse clutch to reduce garage
shift shock when shifting gear from N range to D or R range with vehicle stopped.
ICL80C510001-01
1. Drive plate 10. Output shaft speed sensor 19. Forward clutch (C1)
2. Torque converter clutch (TCC) 11. Reduction drive gear 20. Reverse clutch (C3)
3. Torque converter 12. Planetary carrier 21. Rear planetary sun gear
4. Input shaft 13. 1st and reverse brake (B3) 22. Front planetary sun gear
5. Oil pump 14. Planetary ring gear 23. Short planetary pinion gear
6. Direct clutch drum (double as sensor rotor for input shaft speed sensor) 15. Long planetary pinion gear 24. Countershaft
7. Direct clutch (C2) 16. One-way clutch No.2 (F2) 25. Reduction driven gear
8. Input shaft speed sensor 17. O/D and 2nd coast brake (B1) 26. Differential case assembly
9. Parking lock gear 18. Intermediate shaft 27. Final gear
Specifications
Item Specifications
3-element, 1-step, 2-phase type (with TCC (lock-up)
Type
Torque converter mechanism)
Stall torque ratio 1.85 to 2.05
Item Specifications
Type Internal involute gear type oil pump (non crescent type)
Oil pump
Drive system Engine driven
Type Forward 4-step, reverse 1-step planetary gear type
P range Gear in neutral, output shaft fixed, engine start
R range Reverse
N range Gear in neutral, engine start
D range Forward 1st ↔ 2nd ↔ 3rd ↔ 4th automatic gear
(O/D ON) change
Shift position
D range Forward 1st ↔ 2nd ↔ 3rd ← 4th automatic gear
(O/D OFF) change
2 range Forward 1st ↔ 2nd ← 3rd automatic gear change
Forward 1st ← 2nd ← 3rd reduction, and fixed at 1st
Gear change L range
gear
device
1st 2.875 Number of Front planetary sun gear: 24
2nd 1.568 teeth Rear planetary sun gear: 30
Gear
3rd 1.000 Long planetary pinion gear: 20
ratio
4th (overdrive gear) 0.697 Short planetary pinion gear: 19
Reverse (reverse gear) 2.300 Planetary ring gear: 69
Wet type multiple-disc clutch... 3 sets
Control elements Wet type multiple-disc brake... 2 sets
One-way clutch... 1 set
Reduction gear ratio 1.023
Final gear reduction ratio 4.444
Lubrication Lubrication system Force feed system by oil pump
Cooling Cooling system Radiator assisted cooling (water-cooled)
Fluid used SUZUKI ATF AW-1
Description of Clutch / Brake / Planetary Gear Functions

AENFL80B5101002
7
9
8
2 4 6 10 11
15
3 12 13 14
16
17
ICL80C510002-01
1. Input shaft and intermediate shaft 6. Long planetary pinion gear 11. Forward clutch (C1) 16. Reduction driven gear
2. Direct clutch (C2) 7. 1st and reverse brake (B3) 12. Planetary ring gear 17. Final driven gear
3. Reduction drive gear 8. One-way clutch No.2 (F2) 13. Front planetary sun gear
4. Planetary carrier 9. O/D and 2nd coast brake (B1) 14. Rear planetary sun gear
5. Short planetary pinion gear 10. Reverse clutch (C3) 15. Final drive gear
Functions
Part name Function
Forward clutch (C1) Meshes intermediate shaft and front planetary sun gear
Direct clutch (C2) Meshes input shaft and planetary carrier
Reverse clutch (C3) Meshes intermediate shaft and rear planetary sun gear
O/D and 2nd coast brake (B1) Fixes rear planetary sun gear
1st and reverse brake (B3) Fixes planetary carrier
One-way clutch No.2 (F2) Prevents planetary carrier from turning counterclockwise
Operation Table of A/T Component

AENFL80B5101003
Part
Selector Gear O/D and 1st and One-way
Forward Direct Reverse Condition
position position 2nd coast reverse clutch
clutch (C1) clutch (C2) clutch (C3)
brake (B1) brake (B3) No.2 (F2)
P Parking × × × × × ×
When vehicle is
traveling forwards at
× × × ×
9 km/h (6 mile/h) or
less
R Reverse
When vehicle is
traveling forwards at
× × × × ×
more than 9 km/h (6
mile/h)
N Neutral × × × × × ×
When engine brake
× × × ×
is not applied
1st
When engine brake
× × ×
is applied
D 2nd × × × ×
2nd↔3rd ×→ × →× × ×
3rd × × × ×
3rd↔4th →× × ×→ × ×
4th × × × ×
1st × × × ×
2
2nd × × × ×
L 1st × × × ×
: Applied
×: Release
Operation Table of Shift Solenoid Valve, Pressure Control Solenoid Valve and TCC Solenoid Valve
Solenoid valve
Pressure Pressure Pressure
Selector Gear TCC Shift
control control control Condition
position position solenoid solenoid
solenoid solenoid solenoid
valve valve “A”
valve “A” valve “B” valve “C”
P Parking × ×
When vehicle is traveling forwards
× ×
at 9 km/h (6 mile/h) or less
R Reverse
×
at more than 9 km/h (6 mile/h)
N Neutral × ×
Solenoid valve
Pressure Pressure Pressure
Selector Gear TCC Shift
control control control Condition
position position solenoid solenoid
solenoid solenoid solenoid
valve valve “A”
valve “A” valve “B” valve “C”
( ) × × at 12 km/h (8 mile/h) or less and
engine brake is applied
1st When vehicle is traveling forwards
( ) × × × at more than 12 km/h (8 mile/h)
and engine brake is applied
( ) × When engine brake is applied
When vehicle is Lock-up
( )
traveling forwards at ON
12 km/h (8 mile/h) or Lock-up
( ) ×
less OFF
2nd
D When vehicle is Lock-up
( ) ×
more than 12 km/h (8 Lock-up
( ) × ×
mile/h) OFF
( ) → →× × Lock-up ON
2nd↔3rd
( ) → →× × × Lock-up OFF
( ) × × Lock-up ON
3rd
( ) × × × Lock-up OFF
→ ( ) ×→ × Lock-up ON
3rd↔4th
→ ( ) ×→ × × Lock-up OFF
( ) × Lock-up ON
4th
( ) × × Lock-up OFF
( ) × ×
1st
( ) × × ×
( )
2
12 km/h (8 mile/h) or Lock-up
( ) ×
less OFF
2nd
( ) ×
more than 12 km/h (8 Lock-up
( ) × ×
mile/h) OFF
( ) × ×
L 1st
( ) × × ×
: ON (Power ON)
×: OFF (Power OFF)
: Controlled
: Controlled (line pressure)
Valve status
Power ON Power OFF
Pressure control solenoid valve “A” Close Open
Pressure control solenoid valve “B” Close Open
Pressure control solenoid valve “C” Open Close
TCC solenoid valve Open Close
Shift solenoid valve “A” Open Close
Electronic Shift Control System Input / Output Table

AENFL80B5101004
ICL80C510003-04
A/T Diagnosis General Description Difference in OBD system type

AENFL80B5101005 Type A Type B
This vehicle is equipped with TCM, which controls the
Freeze frame data Available Available
automatic shift up and shift down timing, TCC operation,
SUZUKI scan tool
etc. suitably to vehicle driving conditions. Available Available
(SUZUKI SDT)
TCM has an OBD system which detects a malfunction in
CAN communication
this system. Available Not available
OBD generic scan tool
When diagnosing a trouble in transaxle including this
system, have full understanding of the outline of “OBD General Description (Type A)
System Description” (Page 5A-7) and each item in For A/T control system, TCM has the following functions.
“Precautions for Diagnosing Trouble” (Page 5A-1) and
execute diagnosis according to “A/T Control System • When ignition is “ON” with no malfunction in A/T
Check” (Page 5A-13) to obtain correct result smoothly. control system detected, transmission warning light
(1) lights for about 2 seconds and then goes OFF for
bulb check.
AENFL80B5101006 • When TCM detects a malfunction in A/T control
Discrimination for OBD System system, it indicates transmission warning light and
There are two types of OBD system, type A and B in stores DTC in its memory.
accordance with regulations in each country. And TCM detects a malfunction which gives an
Vehicle equipped with the OBD system of Type A: adverse effect to vehicle emission in A/T control
Market code E14 system while the engine is running, TCM requires
ECM to make the MIL (2) in the combination meter of
Vehicle equipped with the OBD system of Type B: the instrument panel turn ON.
Market code E12
• TCM stores the malfunction area (DTC according to

SAE J2012) in TCM memory. (If it judges that the 1
system is normal for 3 driving cycles continuously
after detecting a malfunction, it makes transmission
warning light turn off although DTC stored in its
memory will remain.)
• It is possible to communicate with vehicle through
DLC (3) using not only SUZUKI scan tool (4) but also
CAN communication OBD generic scan tool which are
in compliance with SAE J1978. (Diagnostic
information can be accessed using a scan tool.)
1 2
ICL80C510005-01
• For information about the following items, refer to

4 “OBD System Description”: Petrol in Section 1A (Page
1A-1).
3 – Warm-up cycle
– Driving cycle
– 2 driving cycle detection logic
– Pending DTC
– Freeze frame data
ICL80C510004-01
• For information about the following items, refer to

“OBD System Description”: Petrol in Section 1A (Page
1A-1).
– Warm-up cycle
– Driving cycle
– 2 driving cycle detection logic
– Pending DTC
– Freeze frame data
General Description (Type B)

• When ignition is “ON” with no malfunction in A/T
control system detected, transmission warning light
(1) lights for about 2 seconds and then goes OFF for
bulb check.
• When TCM detects a malfunction in A/T control
system, it indicates transmission warning light and
stores DTC in its memory.
• It is possible to communicate with vehicle through
DLC (2) using SUZUKI scan tool (3). Diagnostic
information can be checked and cleared using
SUZUKI scan tool.

Electronic Shift Control System Input / Output Diagram
AENFL80B5102001
ICL80C510006-02
Electronic Shift Control System Circuit Diagram

AENFL80B5102002
12V 20
5V
21
2
WHT C07-16 C06-11 LT GRN
BLK C07-6 C06-12 BEG
12V
12V
22
3
PPL C07-14 C06-16 BRN
GRY C07-5 12V
23
4 P C06-22 RED
PNK/BLK C07-20
5 C06-9 BLK
R
RED C07-1 12V
RED/BLK 24
N 6 C06-21 BLK/YEL
BEG C07-8
D C06-19 BLU/BLK
BLU C07-7 12V
25
2 C06-4 GRY/RED
GRN/YEL C07-19
C06-2 LT GRN/BLK
L
LT GRN/BLK C07-18 12V
26
C06-5 WHT/BLU
12V
C06-3 WHT/BLK
7
8
GRN C07-21
GRY 9 27
GRN 10 C06-6 YEL/BLK
BLK
16 28
C06-24 LT GRN/BLK
29
11 WHT C06-7
5
RED C06-17
WHT
RED 30 31
P
BLK GRN/BLK
34
WHT/BLK N
YEL
15 33
32
12 16
RED/BLK C06-1 BLK
14
WHT
RED 12V C06-23 BLK
17 18
19
WHT
16
13 RED
16
ICL80C510007-02
1. TCM 13. BCM 25. Pressure control solenoid valve “C”

2. Input speed sensor 14. Combination meter 26. TCC solenoid valve
3. Output speed sensor 15. DLC 27. “AT” fuse
4. Transmission range sensor 16. CAN driver 28. “IG1 SIG” fuse
5. To ignition power supply 17. MIL 29. Ignition switch
6. Back-up light 18. Transmission warning light 30. Transmission range sensor
7. Select lever 19. Meter driver 31. Starting motor control relay
8. O/D off switch 20. A/T 32. Starting motor
9. Shift lock solenoid 21. ATF temperature sensor 33. “ST” fuse
10. To BCM 22. Shift solenoid valve “A” 34. Main fuse box
11. ECM 23. Pressure control solenoid valve “A”
12. ABS control module (ABS model) 24. Pressure control solenoid valve “B”
Terminal Arrangement of TCM Connector (Viewed from Harness Side)
NOTE
For circuit name and terminal voltage, refer to “Inspection of TCM and Its Circuits” (Page 5A-97).
[A]
C06 C07
[a]
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
I8C50B510011-01
[A]: TCM connector (View: [a])

Component Location
Electronic Shift Control System Component Location
AENFL80B5103001
3 4
18
19
17
20
1
2 7
11
12
15
16
14 10
13
9
ICL80C510008-02
1. Engine 8. Output shaft speed sensor 15. Pressure control solenoid valve “C”
2. Transaxle 9. Input shaft speed sensor 16. ATF temperature sensor
3. Transmission warning light 10. Solenoid connector 17. Transmission range sensor
4. MIL 11. Shift solenoid “A” 18. BCM
5. Select lever 12. TCC solenoid valve 19. ECM
6. O/D off switch 13. Pressure control solenoid valve “A” 20. Shift lock solenoid
7. TCM 14. Pressure control solenoid valve “B”

A/T Control System Check
AENFL80B5104001
Refer to the following items for the details of each step.
Step Action Yes No
1 Customer complaint analysis Go to Step 2. Perform customer
1) Perform customer complaint analysis. (Page 5A-13) complaint analysis.
Was customer complaint analysis performed?

2 DTC / freeze frame data check, record and clear Print DTC and freeze Go to Step 4.
1) Check for DTC (current and pending DTC). (Page 5A- frame data or write them
14) down and clear them
referring to “DTC
Is there any DTC(s)? Clearance” (Page 5A-
16), and go to Step 3.
3 Visual inspection Repair or replace faulty Go to Step 5.
1) Perform visual inspection. (Page 5A-14) part, and go to Step 11.
Is there any faulty condition?

4 Visual inspection Repair or replace faulty Go to Step 8.
1) Perform visual inspection. (Page 5A-14) part, and go to Step 11.

5 Trouble symptom confirmation Go to Step 6. Go to Step 7.
1) Check trouble symptom. (Page 5A-14)
Is trouble symptom identified?

6 Recheck and record DTC / freeze frame data Go to Step 9. Go to Step 8.
1) Recheck for DTC (current and pending DTC) and freeze
frame data. (Page 5A-15)

7 Recheck and record DTC / freeze frame data Go to Step 9. Go to Step 10.
1) Recheck for DTC (current and pending DTC) and freeze
frame data. (Page 5A-15)

8 A/T basic check and A/T symptom diagnosis Check and repair faulty Go to Step 10.
1) Perform A/T basic check and A/T symptom diagnosis. part(s), and go to Step
(Page 5A-15) 11.

9 Troubleshooting for DTC Go to Step 11. Check and repair faulty
1) Perform troubleshooting for applicable DTC. (Page part(s), and go to Step
5A-15) 11.
Are check and repair complete?

10 Intermittent problem check Repair or replace faulty Go to Step 11.
1) Check for intermittent problems. (Page 5A-15) part(s), and go to Step
11.
11 Final confirmation test Go to Step 6. End.
1) Perform final confirmation test. (Page 5A-15)
Is there any problem symptom, DTC or abnormal condition?
Step 1. Customer Complaint Analysis

Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such an inspection form will facilitate collecting information required for proper analysis and
diagnosis.
NOTE
The form is a standard sample. It should be modified according to conditions of each market.
Customer questionnaire form (Example)
I8C50B510014-01
Step 2. DTC / Freeze Frame Data Check, Record and Step 5. Trouble Symptom Confirmation
Clearance In case that there is no DTC at Step 2:
First, check DTC (current and pending DTC). If DTC is Based on information obtained in “Step 1. Customer
indicated, print DTC and freeze frame data or write them Complaint Analysis” (Page 5A-13) and “Step 2. DTC /
down and then clear them. (Page 5A-16) Freeze Frame Data Check, Record and Clearance”
(Page 5A-14), check trouble symptoms.
Step 3 and 4. Visual Inspection
As a preliminary step, perform visual check of the items In case that there is any DTC at Step 2:
that support proper function of engine and A/T. (Page Recheck DTC according to “DTC Confirmation
5A-28) Procedure” described in each DTC troubleshooting.
Step 6 and 7. Rechecking and Record of DTC and DTC Check

Freeze Frame Data AENFL80B5104004
NOTE
Refer to “DTC Check” (Page 5A-15) for checking
procedure. • For distinction of types A and B of OBD
system, refer to “Discrimination for OBD
Step 8. A/T Basic Check and A/T Symptom System” under “OBD System Description”
Diagnosis (Page 5A-7).
1) Perform A/T basic check. (Page 5A-29) • For type A, in case that MIL turns on, the
2) In case there is no faulty part found in inspection malfunction(s) is detected in either ECM or
procedure of “A/T Basic Check”, perform “A/T TCM and it stores the trouble information
Symptom Diagnosis” (Page 5A-42) based on (DTC, freeze frame data, etc.) in its
symptom found in vehicle checking in the following memory. According to the varieties of scan
items. tool, check the trouble information as
• Customer complaint analysis follows.
• Trouble symptom confirmation – SUZUKI scan tool:
It is necessary to check both ECM and
Step 9. Troubleshooting for DTC TCM separately because the trouble
Perform applicable DTC troubleshooting and repair or information of both modules cannot be
replace faulty parts. read and displayed at once.
– CAN communication OBD-II generic
Step 10. Intermittent Problem Check scan tool:
In case that there is no DTC at Step 2: It is not necessary to check both ECM
Check for intermittent problem.  and TCM separately because the trouble
information of both modules can be read
In case that there is any DTC at Step 2: and displayed at once.
Check parts related to detected DTC (e.g. wire harness,
connector, etc.).  1) Prepare SUZUKI scan tool.
Step 11. Final Confirmation Test 3) Connect SUZUKI scan tool to DLC (1).
Check that the problem symptom has gone and the
vehicle is free from any abnormal conditions. If what has Special tool
been repaired is related to DTC, clear DTC once, (A): SUZUKI scan tool (SUZUKI-SDT)
perform DTC confirmation procedure and check that no
DTC is indicated.
MIL Check
AENFL80B5104002
Refer to “MIL Check”: Petrol in Section 1A (Page 1A-16).
(A)
Transmission Warning Light Check
AENFL80B5104003
1
2) Check that transmission warning light (1) lights for
about 2 sec. and then goes OFF. If anything faulty is
found, refer to “Transmission Warning Light Does
Not Come ON with Ignition ON” (Page 5A-43) or
“Transmission Warning Light Remains ON with
Ignition ON” (Page 5A-43). ICL80C510009-01

1 5) Read DTC, pending DTC and freeze frame data
according to instructions displayed on scan tool and
print it down. Refer to Operator’s Manual of SUZUKI
scan tool for further details.
If communication between scan tool and TCM is not
possible, go to (Page 10H-10).
6) After completing check, set ignition “OFF” and
IAP70B510007-02
DTC Clearance NOTE

AENFL80B5104005
Pending and confirmed DTC and freeze frame
data stored in TCM memory are also cleared
2) Connect SUZUKI scan tool to DLC. (Page 5A-15) in the following cases. Be careful not to clear
3) Set ignition “ON”. them before recording them.
4) Clear DTC and pending DTC according to • When the same malfunction (DTC) is not
instructions displayed on scan tool. Refer to detected again for 40 engine warm-up
Operator’s Manual of SUZUKI scan tool for further cycles.
details. • Even though the pending and confirmed
If communication between scan tool and TCM is not DTCs are cleared, the permanent DTC will
possible, go to (Page 10H-10). not be cleared.
5) After completing DTC clearance, set ignition “OFF”
and disconnect SUZUKI scan tool from DLC.
DTC Table
AENFL80B5104006
NOTE
• For distinction of types A and B of OBD system, refer to “Discrimination for OBD System” under
“OBD System Description” (Page 5A-7).
• With OBD system of type A, DTC with in the following table cannot be read with CAN
communication OBD-II generic scan tool.
• For details of D/C (driving cycle), refer to “OBD System Description”: Petrol in Section 1A (Page 1A-
1).
• *1: MIL operation is applicable to type A only.
DTC
Transmission
DTC DTC name DTC detecting condition detection MIL*1
warning light
logic
P0562 Main power supply circuit voltage
(Page System Voltage Low is lower than specified value for 20 1 D/C Lights up Lights up
5A-43) sec.
P0563 Main power supply circuit voltage
(Page System Voltage High is higher than specified value for 1 D/C Lights up Lights up
5A-43) 20 sec.
P0602
Control Module Programming TCM internal failure (data
(Page — Off Off
Error programming error).
5A-45)
P0604 Internal Control Module
(Page Random Access Memory TCM internal failure (RAM error). 1 D/C Lights up Lights up
5A-45) (RAM) Error
P062F
Internal Control Module TCM internal failure (EEPROM
(Page 1 D/C Lights up Lights up
EEPROM Error error).
5A-45)
P0705
Transmission Range Sensor Multiple signals are input
“A” Circuit (PRNDL Input) simultaneously for 4 sec.
5A-45)
P0707
Transmission Range Sensor No sensor signal is input for 28
“A” Circuit Low sec.
5A-48)
ATF temperature sensor signal
P0711 Transmission Fluid
circuit voltage is unchanged for
(Page Temperature Sensor “A” 2 D/C Lights up Lights up
600 sec., after drive vehicle at 40
5A-50) Circuit Range / Performance
km/h (25 mile/h).
P0712 Transmission Fluid ATF temperature sensor signal
(Page Temperature Sensor “A” circuit voltage is lower than 2 D/C Lights up Lights up
5A-51) Circuit Low specified value for 5 sec.
DTC
Transmission
warning light
logic
P0713 Transmission Fluid ATF temperature sensor signal
(Page Temperature Sensor “A” circuit voltage is higher than 2 D/C Lights up Lights up
5A-52) Circuit High specified value for 5 sec.
P0717 Input shaft speed sensor signal is
Input / Turbine Speed Sensor
(Page not input even if output shaft 1 D/C Lights up Lights up
“A” Circuit No Signal
5A-53) speed sensor signal is input.
P0722 Output shaft speed sensor signal
Output Speed Sensor Circuit
(Page is not input even if input shaft 1 D/C Lights up Lights up
No Signal
5A-55) speed sensor signal is input.
Difference between engine speed
and input shaft speed is less than
P072A
specified value, and the gear
(Page Stuck in Neutral 1 D/C Lights up Lights up
commanded by TCM does not
5A-57)
match the actual gear when
driving.
P0731 The gear commanded by TCM
(Page Gear 1 Incorrect Ratio does not match the actual gear 2 D/C Lights up Lights up
5A-58) when driving.
P0741 Torque Converter Clutch
and input shaft speed is more than
(Page Circuit Performance / Stuck 2 D/C Lights up Lights up
specified value even if TCC
5A-60) Off
solenoid valve is turned on.
P0742
Torque Converter Clutch and input shaft speed is less than
Circuit Stuck On specified value even if TCC
5A-62)
solenoid valve is turned off.
Pressure Control Solenoid “A”
(Page does not match the actual gear 2 D/C Lights up Lights up
Performance / Stuck Off
Stuck On
Shift Solenoid “A”
Pressure Control Solenoid “B”
Stuck On
Pressure Control Solenoid “C”
Stuck On
Difference between target electric
P0961 Pressure Control Solenoid “A” current and measured current of
(Page Control Circuit Range / pressure control solenoid valve “A” 1 D/C Lights up Lights up
5A-73) Performance drive circuit (+) is more than
Measured electric current of
P0962
Pressure Control Solenoid “A” pressure control solenoid valve “A”
Control Circuit Low drive circuit (+) is lower than
5A-74)
specified value.
DTC
Transmission
warning light
logic
P0963
Pressure Control Solenoid “A” pressure control solenoid valve “A”
Control Circuit High drive circuit (+) is higher than
5A-76)
specified value.
P0965 Pressure Control Solenoid “B” current and measured current of
(Page Control Circuit Range / pressure control solenoid valve “B” 1 D/C Lights up Lights up
5A-77) Performance drive circuit (+) is more than
P0966
Pressure Control Solenoid “B” pressure control solenoid valve “B”
Control Circuit Low drive circuit (+) is lower than
5A-78)
specified value.
P0967
Pressure Control Solenoid “B” pressure control solenoid valve “B”
Control Circuit High drive circuit (+) is higher than
5A-80)
specified value.
P0969 Pressure Control Solenoid “C” current and measured current of
(Page Control Circuit Range / pressure control solenoid valve 1 D/C Lights up Lights up
5A-81) Performance “C” drive circuit (+) is more than
P0970
Pressure Control Solenoid “C” pressure control solenoid valve
Control Circuit Low “C” drive circuit (+) is higher than
5A-83)
specified value.
P0971
Pressure Control Solenoid “C” pressure control solenoid valve
Control Circuit High “C” drive circuit (+) is lower than
5A-84)
specified value.
Shift solenoid valve “A” drive
P0973
Shift Solenoid “A” Control circuit voltage is lower than
Circuit Low specified value even if shift
5A-85)
solenoid valve “A” is turned on.
Shift solenoid valve “A” drive
P0974
Shift Solenoid “A” Control circuit voltage is higher than
Circuit High specified value even if shift
5A-87)
solenoid valve “A” is turned off.
P1702
Internal Control Module TCM internal failure (check sum
Memory Check Sum Error error).
5A-45)
P1706 Torque Request ECM detects abnormality of CAN
(Page Communication Error from communication data which TCM 1 D/C Off Off
5A-88) TCM transmits.
(Page circuit voltage is lower than 1 D/C Lights up Lights up
Low
5A-89) specified value.
(Page circuit voltage is higher than 1 D/C Lights up Lights up
High
P1738 Input shaft speed sensor signal
(Page circuit voltage is higher than 1 D/C Lights up Lights up
“A” Circuit Low
P1739 Input shaft speed sensor signal
(Page circuit voltage is lower than 1 D/C Lights up Lights up
“A” Circuit High
DTC
Transmission
warning light
logic
Torque Converter Clutch
P2762 current and measured current of
Pressure Control Solenoid
(Page TCC solenoid valve drive circuit 1 D/C Lights up Lights up
Control Circuit Range /
5A-93) (+) is more than specified value for
Performance
3 sec.
P2763 Torque Converter Clutch Measured electric current of TCC
(Page Pressure Control Solenoid solenoid valve drive circuit (+) is 1 D/C Lights up Lights up
5A-95) Control Circuit High higher than specified value.
P2764 Torque Converter Clutch Measured electric current of TCC
(Page Pressure Control Solenoid solenoid valve drive circuit (+) is 1 D/C Lights up Lights up
5A-96) Control Circuit Low lower than specified value.
U0073
Control Module Refer to “CAN DTC (Lost
Communication Bus Off Communication and
5A-97)
Communication Bus Off) Table”:
U0100
Lost Communication With Petrol and Bi-Fuel CNG Model in
ECM Section 10H (Page 10H-10).
5A-97)
Fail-Safe Table
AENFL80B5104007
This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sensor or
its circuit fails. The following table shows the fail-safe function for each fail condition of sensor, solenoid or its circuit.
• Torque limitation is activated.
• Gear shifts to 3rd.
• Gear remains in R range when the failure occurs in R
range.
P0562 • Reverse control is disabled.
(Page System Voltage Low • TCM stops following control / function.
5A-43) – Slip controlled lock-up function
– Lock-up function
– Learning control
– Garage shift control
– Slope shift control
P0563 • Torque limitation is activated
(Page System Voltage High • Remains in gear when the failure occurs, shifts to 2nd after
5A-43) the vehicle has stopped.
range.
• TCM stops following control / function.
P0604
Internal Control Module Random Access – Slip controlled lock-up function
(Page
Memory (RAM) Error – Lock-up function
5A-45)
P062F
(Page Internal Control Module EEPROM Error TCM controls with default value.
5A-45)

• Selected range is set in priority order shown below.
D> 2> L> R> N> P
• Remains in gear when the failure occurs, shifts to 2nd after
the vehicle has stopped.
P0705 • Gear remains in R range when the failure occurs in R
Transmission Range Sensor “A” Circuit range.
(Page
(PRNDL Input) • TCM stops following control / function.
5A-45)
– Slip controlled lock-up function
• TCM controls actuators assuming that selected range is D
range.
Transmission Range Sensor “A” Circuit range.
(Page
Low • TCM stops following control / function.
5A-48)
P0711
Transmission Fluid Temperature Sensor
(Page
“A” Circuit Range / Performance • TCM controls actuators assuming that ATF temperature is
5A-50)
P0712 80 °C (176 °F).
(Page • TCM stops following control / function.
“A” Circuit Low
P0713 – Learning control
(Page
“A” Circuit High
5A-52)
range.
P0717 • TCM calculates input shaft speed by output shaft speed
Input / Turbine Speed Sensor “A” Circuit sensor.
(Page
No Signal • TCM stops following control / function.
5A-53)

• Remains in gear when the failure occurs, shifts to 4th after
• TCM calculates vehicle speed by input shaft speed sensor.
P0722 • TCM stops following control / function.
(Page Output Speed Sensor Circuit No Signal – Slip controlled lock-up function
5A-55) – Lock-up function
– Reverse control
P072A – Slip controlled lock-up function
(Page Stuck in Neutral – Lock-up function
5A-57) – Slope shift control
– Gear shifting
(Page Gear 1 Incorrect Ratio – Learning control
5A-58) – Slope shift control
P0741 – Slip controlled lock-up function
Torque Converter Clutch Circuit
(Page
Performance / Stuck Off – Lock-up function
5A-60)
• Torque limitation is activated in R range.
(Page Torque Converter Clutch Circuit Stuck On
5A-62) – Learning control
• Remains in gear when the failure occurs, shifts to 2nd or
4th after the vehicle has stopped.
(Page – Slip controlled lock-up function
(Page Pressure Control Solenoid “A” Stuck On
5A-64)
– Multiplex shifting
• During L range, shifts to 2nd.
(Page Shift Solenoid “A” Performance / Stuck Off
5A-66) – Learning control

• Remains in gear when the failure occurs, shifts to 3rd after
(Page Pressure Control Solenoid “B” Stuck On
5A-69)
• Remains in gear when failure occurs, shifts to 3rd after the
vehicle has stopped.
(Page Pressure Control Solenoid “C” Stuck On
5A-71)

P0961
Pressure Control Solenoid “A” Control
(Page
Circuit Range / Performance
5A-73)
P0962
(Page
Circuit Low
5A-74)
P0963
(Page
Circuit High • Power supply for all solenoid valve is cut off (3rd).
5A-76)
Pressure Control Solenoid “B” Control range.
(Page
5A-77) • Reverse control is disabled.
Pressure Control Solenoid “B” Control
(Page
Circuit Low – Slip controlled lock-up function
5A-78)
P0967 – Lock-up function
Pressure Control Solenoid “B” Control
(Page – Learning control
Circuit High
5A-80) – Garage shift control
P0969
Pressure Control Solenoid “C” Control – Slope shift control
(Page
5A-81)
P0970
Pressure Control Solenoid “C” Control
(Page
Circuit Low
5A-83)
P0971
Pressure Control Solenoid “C” Control
(Page
Circuit High
5A-84)
P0973 • Torque limitation is activated.
(Page Shift Solenoid “A” Control Circuit Low • If failure occurs in 1st or 2nd, remains in the same gear
5A-85) when failure occurs, shifts to 2nd when the vehicle has
stopped.
• If failure occurs in 3rd or 4th, shifts to 3rd, and then shifts to
2nd when the vehicle has stopped.
P0974 range.
(Page Shift Solenoid “A” Control Circuit High • TCM stops following control / function.
range.
P1702
Internal Control Module Memory Check • TCM stops following control / function.
(Page
Sum Error

(Page Output Speed Sensor Circuit Low • Remains in gear when the failure occurs, shifts to 2nd after
range.
• TCM calculates vehicle speed by input shaft speed sensor.
P1737
(Page Output Speed Sensor Circuit High
– Reverse control
Input / Turbine Speed Sensor “A” Circuit
(Page • Remains in gear when the failure occurs, shifts to 2nd after
Low
range.
• TCM calculates input shaft speed by output shaft speed
sensor.
P1739
Input / Turbine Speed Sensor “A” Circuit • TCM stops following control / function.
(Page
High – Slip controlled lock-up function
5A-92)
• Power supply for all solenoid valve is cut off (3rd).
range.
• Reverse control is disabled.
P2762 Torque Converter Clutch Pressure Control • TCM stops following control / function.
(Page Solenoid Control Circuit Range /
5A-93) Performance
P2763 • Torque limitation is activated in R range.
Torque Converter Clutch Pressure Control
(Page • TCM stops following control / function.
Solenoid Control Circuit High
5A-95)
P2764 – Lock-up function
Torque Converter Clutch Pressure Control
(Page – Learning control
Solenoid Control Circuit Low
5A-96)

U0073 • TCM controls actuators assuming that engine speed is
(Page Control Module Communication Bus Off 7000 rpm.
5A-97) • TCM controls actuators assuming that ECT is 80 °C (176
°F).
• TCM controls actuators assuming that throttle position is
0%.
• TCM controls actuators assuming that accelerator pedal
position is 0%.
• TCM controls actuators assuming that engine torque is
maximum.
U0100 • Remains in gear when the failure occurs, shifts to 2nd after
(Page Lost Communication With ECM the vehicle has stopped.
5A-97)
range.
Scan Tool Data

AENFL80B5104008
As the data values given in the following table 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, condition in the following table that can be checked by the scan tool are those detected by TCM and output from
TCM as commands and there may be cases where the automatic transaxle or actuator is not operating (in the
condition) as indicated by the scan tool.
NOTE
The following scan tool data related to A/T can be checked only by communication with TCM.
Normal condition / reference

values
Ignition ON and engine stopped 0 rpm
Input Shaft Revolution
At 60 km/h (37 mile/h) constant speed, D (O/D OFF) 2300 rpm
(Page 5A-27)
range, 20% or less throttle opening and in 3rd gear (displayed in increments of 50 rpm)
Output Shaft At vehicle stop 0 rpm
Revolution (Page 5A- At 60 km/h (37 mile/h) constant speed, D (O/D OFF) 2300 rpm
27) range, 20% or less throttle opening and in 3rd gear (displayed in increments of 50 rpm)
After driving at 60 km/h (37 mile/h) for 15 minutes or
ATF Temperature
more, and ATF temperature around sensor reaches 70 to 80 °C
(Page 5A-27)
70 to 80 °C (158 to 176 °F)
Battery Voltage Ignition: “ON” Battery voltage is displayed
(Page 5A-27) Engine: stopped (8 to 16 V)
Engine Speed (Page Engine: Running at idle speed
Engine idle speed is displayed.
5A-27) Select lever: P range
Ignition: “ON” 0 to 100% (Varies depending on
Accel Actual Position Accelerator pedal: Depressed depressed value)
0%
Accelerator pedal: Released

values
Ignition: “ON”
1
Accel Effective Position Accelerator pedal: Depressed
0%
Accelerator pedal: Released
Engine coolant temperature is
ECT (Page 5A-27) Ignition: “ON”
displayed.
Ignition: “ON”
P
Select lever: P range
Ignition: “ON”
R
Select lever: R range
Ignition: “ON”
N
Gear Position (Page Select lever: N range
D
Select lever: D range
Ignition: “ON”
2nd
Select lever: 2 range
Ignition: “ON”
1st
Select lever: L range
Lock-up: Off Release
Torque Converter
Lock-up: Off ↔ On Slip
Clutch (Page 5A-27)
Lock-up: On Connect
Engine: Running at idle speed
15 to 40 rpm
Slip RPM (Page 5A-
Engine: Running at idle speed
28)
Vehicle: Stopped Engine speed is displayed.
Vehicle: Running The same value as speedometer
5A-28)
Ignition: “ON”
P
Ignition: “ON”
R
Select lever: R range
Ignition: “ON”
N
Transaxle Range Select lever: N range
D
Ignition: “ON”
2
Select lever: 2 range
Ignition: “ON”
L
Select lever: L range
Ignition: “ON”
ON
P Range (Page 5A- Select lever: P range
28) Ignition: “ON”
OFF
Select lever: P, R, D, 2, L range
Ignition: “ON”
ON
R Range (Page 5A- Select lever: R range
OFF
Select lever: P, N, D, 2, L range
Ignition: “ON”
ON
N Range (Page 5A- Select lever: N range
OFF
Select lever: P, R, D, 2, L range
Ignition: “ON”
ON
D Range (Page 5A- Select lever: D range
OFF
Select lever: P, R, N, 2, L range

values
Ignition: “ON”
ON
2 Range (Page 5A- Select lever: 2 range
OFF
Select lever: P, R, N, D, L range
Ignition: “ON”
ON
L Range (Page 5A- Select lever: L range
OFF
Select lever: P, R, N, D, 2 range
Ignition: “ON”
ON
3 Pos (O/D OFF) State Select lever: D (O/D OFF) range
OFF
Select lever: D (O/D ON) range
Shift Solenoid A (Com) Vehicle: Stopped ON
(Page 5A-28) Select lever: P, R, N, D, 2 or L range
Gear position: 2nd, 3rd or 4th OFF
Shift Solenoid A (Mon) Vehicle: Stopped ON
(Page 5A-28) Select lever: P, R, N, D, 2 or L range
Gear position: 2nd, 3rd or 4th OFF
Ignition: “ON”
ON
Brake Switch (Page Brake pedal: Fully depressed
OFF
Air Conditioner Signal Magnet clutch: ON ON
(Page 5A-28) Magnet clutch: OFF OFF
Ignition: “ON”
OFF
Transaxle Warning Transaxle warning light: OFF
Light (Page 5A-28) Ignition: “ON”
ON
Transaxle warning light: Lights up
Ignition: “ON”
OFF
MIL Request (Page MIL: OFF
ON
MIL: Lights up
Scan Tool Data Definitions: Accel Actual Position (Accelerator Actual Position,
Input Shaft Revolution (rpm) %)
Input shaft revolution computed by reference pulses Accelerator pedal opening ratio detected by signal
coming from input shaft speed sensor on transmission through CAN communication line fed from ECM.
case.
Accel Effective Position (Accelerator Effective
Output Shaft Revolution (rpm) Position, %)
Output shaft revolution computed by reference pulses This parameter indicates accelerator pedal position
coming from output shaft speed sensor on transmission calculated by accelerator pedal position sensor input
case. and cruise control.
ATF Temperature (°C) ECT (Engine Coolant Temperature, °C)

ATF temperature decided by signal from transmission Engine coolant temperature detected by signal through
fluid temperature sensor installed in valve body. CAN communication line fed from ECM.
Battery Voltage (V) Gear Position (1st, 2nd, R, N, P, D)

Battery voltage read by TCM as analog input signal by This parameter indicates the gear position of A/T.
TCM.
Torque Converter Clutch (Release, Slip, Connect)
Engine Speed (rpm) This parameter indicates the state of lock-up clutch
Engine speed computed by signal through CAN which is output from ECU.
communication line fed from ECM.
Slip RPM (rpm) 3 Pos (O/D OFF) State (OFF, ON)

This parameter indicates slipping rotation in the torque This parameter indicates the state of O/D OFF which is
converter (difference between input shaft rotation and output from TCM.
engine rotation)
Shift Solenoid A (Com) (Shift Solenoid Valve A
Vehicle Speed (km/h) (Command), OFF, ON)
Vehicle speed computed by duty signal from ECM. ON: ON command is being outputted to shift solenoid
valve “A”.
Transaxle Range (P, R, N, D, 2, L) OFF: ON command not being outputted to shift solenoid
Transmission range detected by signal fed from valve “A”.
transmission range sensor.
Shift Solenoid A (Mon) (Shift Solenoid Valve A
P Range (OFF, ON) (Monitor), OFF, ON)
This parameter indicates the state of P range switch in ON: Electricity being passed to shift solenoid-A
transmission range sensor. OFF: Electricity not being passed to shift solenoid-A
R Range (OFF, ON) Brake Switch (OFF, ON)

This parameter indicates the state of R range switch in Brake light switch position detected by signal through
transmission range sensor. CAN communication line fed from ECM.
ON: Brake pedal depressed
N Range (OFF, ON) OFF: Brake pedal released
This parameter indicates the state of N range switch in
transmission range sensor. Air Conditioner Signal (ON/OFF)
ON: Signal which inform that air conditioner compressor
D Range (OFF, ON) is turned ON.
This parameter indicates the state of D range switch in OFF: Signal which inform that air conditioner
transmission range sensor. compressor is turned OFF.
2 Range (OFF, ON) Transaxle Warning Light (OFF, ON)

This parameter indicates the state of 2 range switch in This parameter indicates the state of transmission
transmission range sensor. warning light.
L Range (OFF, ON) MIL Request (OFF, ON)

This parameter indicates the state of L range switch in This parameter indicates the state of MIL.
transmission range sensor.
Visual Inspection
AENFL80B5104009
NOTE
There are two types of OBD system depending on the vehicle specification. For identification, refer to
“OBD System Description” (Page 5A-7).
Visually check the following parts and systems.

Inspection item Referring
• ATF ----- level, leakage, color “ATF Level Check” (Page 5A-103)
• ATF hoses ----- disconnection, looseness, deterioration “ATF Cooler Hose Replacement” (Page 5A-123)
• A/T select cable ----- installation “Select Cable Removal and Installation” (Page 5A-
108)
• Engine oil ----- level, leakage (Page 1E-2)
• Engine coolant ----- level, leakage 
• Engine mountings ----- play, looseness, damage (Page 1D-10)
• Suspension ----- play, looseness 
• Drive shafts ----- damage 
• Battery ----- indicator condition, corrosion of terminal 
• Connectors of electric wire harness ----- disconnection, friction “Electronic Shift Control System Component
Location” (Page 5A-12)
• Fuses ----- burning
• Parts ----- installation, damage
• Bolts ----- looseness
• Other parts that can be checked visually
Inspection item Referring

Also check the following items at engine start, if possible.
• Malfunction indicator lamp ----- Operation (type A) “MIL Check” (Page 5A-15)
• Transmission warning light ----- Operation “Transmission Warning Light Check” (Page 5A-15)
• Charge warning light ----- Operation (Page 1J-2)
• Engine oil pressure warning light ----- Operation “Combination Meter Diagnosis” in Section 9C
(Page 9C-24)
• Other parts that can be checked visually “Combination Meter Diagnosis” in Section 9C
(Page 9C-24)
A/T Basic Check

AENFL80B5104010
This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in
“Visual Inspection” (Page 5A-28). Follow the flow carefully.
Step Action Yes No
1 Was “A/T Control System Check” performed? Go to Step 2. Go to “A/T Control
System Check” (Page
5A-13).
2 Road test Go to Step 3. Repair or replace
1) Perform road test. (Page 5A-29) defective part.
Is test result OK?

3 Manual road test Go to Step 4. Repair or replace
1) Perform manual road test. (Page 5A-35) defective part.
Is test result OK?

4 Engine brake test Go to Step 5. Repair or replace
1) Perform engine brake test. (Page 5A-35) defective part.
Is test result OK?

5 Stall test Go to Step 6. Repair or replace
1) Perform stall test. (Page 5A-36) defective part.
Is test result OK?

6 Time lag test Go to Step 7. Repair or replace
1) Perform time lag test. (Page 5A-37) defective part.
Is test result OK?

7 Line pressure test Proceed to “A/T Repair or replace
1) Perform line pressure test. (Page 5A-38) Symptom Diagnosis” defective part.
(Page 5A-42).
Is test result OK?
Road Test
AENFL80B5104011
This test is to check if upshift, downshift and lock-up take place at specified speeds while actually driving vehicle on a
level road.
! WARNING

• Road test should be performed with two persons, a driver and a tester, on a level road.
1) Warm up engine.
2) With engine running at idle, shift select lever to D range.
3) Accelerate by depressing accelerator pedal gradually.
4) While driving in D range, check if gear shift and lock-up occur properly as shown in “Automatic Gear Shift Table”
(Page 5A-30).
Automatic Gear Shift Table

Automatic gear shift schedule is shown in the following table. Test-drive the vehicle on a level road in the D (O/D ON),
D (O/D OFF) or 2 range.
1. Shift point in D (O/D ON), D (O/D OFF) or 2 range

Vehicle speed (km/h
Throttle opening Shift Remark
(mile/h))
1st → 2nd 44 – 49 (28 – 30) D (O/D ON), D (O/D OFF), 2 range
Over 88% 2nd → 3rd 87 – 92 (55 – 57) D (O/D ON), D (O/D OFF) range
3rd → 4th 147 – 152 (92 – 94) D (O/D ON) range
UP shift 50% 2nd → 3rd 61 – 66 (38 – 41) D (O/D ON), D (O/D OFF) range
3rd → 4th 97 – 102 (61 – 63) D (O/D ON) range
10% 2nd → 3rd 28 – 33 (18 – 20) D (O/D ON), D (O/D OFF) range
3rd → 4th 37 – 42 (23 – 26) D (O/D ON) range
4th → 3rd 135 – 140 (84 – 86) D (O/D ON) range
Over 95%
3rd → 2nd 78 – 83 (49 – 51) D (O/D ON), D (O/D OFF) range
Over 90% (4th → 3rd)
2nd → 1st 36 – 41 (23 – 25) D (O/D ON), D (O/D OFF), 2 range
4th → 3rd 58 – 63 (37 – 39) D (O/D ON) range
DOWN
50% 3rd → 2nd 25 – 30 (16 – 18) D (O/D ON), D (O/D OFF) range
shift
4th → 3rd 27 – 32 (17 – 19) D (O/D ON) range
10% 3rd → 2nd 19 – 24 (12 – 14) D (O/D ON), D (O/D OFF) range
2. Lock-up point in D (O/D ON), D (O/D OFF) or 2 range

Lock-up Throttle Vehicle speed (km/h
Remark
clutch status opening (mile/h))
Over 88% — D (O/D ON), D (O/D OFF), 2 range
ON 50% — D (O/D ON), D (O/D OFF), 2 range
10% — D (O/D ON), D (O/D OFF), 2 range
2nd gear lock-up
Over 88% — D (O/D ON), D (O/D OFF), 2 range
OFF 50% — D (O/D ON), D (O/D OFF), 2 range
10% — D (O/D ON), D (O/D OFF), 2 range
Over 88% 87 – 92 (55 – 57) D (O/D ON), D (O/D OFF) range
ON 50% 61 – 66 (38 – 41) D (O/D ON), D (O/D OFF) range
10% 33 – 38 (21 – 23) D (O/D ON), D (O/D OFF) range
3rd gear lock-up
Over 88% 78 – 83 (49 – 51) D (O/D ON), D (O/D OFF) range
OFF 50% 49 – 54 (31 – 33) D (O/D ON), D (O/D OFF) range
10% 28 – 33 (18 – 20) D (O/D ON), D (O/D OFF) range
Over 88% 147 – 152 (92 – 94) D (O/D ON) range
ON 50% 97 – 102 (61 – 63) D (O/D ON) range
10% 65 – 70 (41 – 43) D (O/D ON) range
4th gear lock-up
Over 90% 135 – 140 (84 – 86) D (O/D ON) range
OFF 50% 76 – 81 (48 – 50) D (O/D ON) range
10% 62 – 67 (39 – 41) D (O/D ON) range
3. Slip lock-up point in D (O/D ON), D (O/D OFF) or 2 range

Slip lock-up Throttle Vehicle speed (km/h
Remark
D (O/D ON), D (O/D OFF), 2 range and
Slip ON 15% 17 – 22 (11 – 13)
not locked-up
2nd gear
D (O/D ON), D (O/D OFF), 2 range and
Slip OFF 15% 14 – 19 (9 – 11)
not locked-up
D (O/D ON), D (O/D OFF) range and not
Slip ON 15% 31 – 36 (20 – 22)
locked-up
3rd gear
D (O/D ON), D (O/D OFF) range and not
Slip OFF 15% 27 – 32 (17 – 19)
locked-up
Slip lock-up Throttle Vehicle speed (km/h

Remark
Slip ON 15% 40 – 45 (25 – 27) D (O/D ON) range and not locked-up
4th gear
Slip OFF 15% 35 – 40 (22 – 24) D (O/D ON) range and not locked-up
Troubleshooting
Unable to run in D range Damaged drive plate (Page 1D-15)
Malfunction of shift solenoid valve “A” “Solenoid Valve Inspection” (Page 5A-120)
Malfunction of pressure control solenoid “Solenoid Valve Inspection” (Page 5A-120)
valve “A”
Malfunction of ATF “ATF Level Check” (Page 5A-103)
Faulty valve body component “Valve Body Assembly Removal and
Installation” (Page 5A-117)
Faulty oil pump “Oil Pump Assembly Inspection” (Page 5A-
136)
Seized or broken planetary gear Check planetary gear referring to “A/T
Assembly Reassembly” (Page 5A-157).
Faulty one-way clutch No.2 Check one-way clutch No.2 referring to “A/T
Assembly Disassembly” (Page 5A-128).
Faulty forward clutch “Forward and Reverse Clutch Assembly
Preliminary Check” (Page 5A-141)
Faulty reverse clutch “Forward and Reverse Clutch Assembly
Faulty 1st and reverse brake Check 1st and reverse brake referring to “A/T
Damaged drive plate (Page 1D-15)
Faulty torque converter Replace torque converter referring to “A/T
Unable to run in R range Damaged drive plate (Page 1D-15)
valve “B”
136)
Seized or broken planetary gear Check planetary gear referring to “A/T
Damaged drive plate (Page 1D-15)

1 → 2 upshift fails Battery voltage is too low Check battery. 
Malfunction of input shaft speed sensor “Input Shaft Speed Sensor Inspection” (Page
5A-114)
Malfunction of output shaft speed “Output Shaft Speed Sensor Inspection” (Page
sensor 5A-113)
Malfunction of ATF temperature sensor “ATF Temperature Sensor Inspection” (Page
5A-116)
valve “A”
valve “B”
valve “C”
Malfunction of APP sensor 
Malfunction of transmission range “Transmission Range Sensor Inspection and
sensor Adjustment” (Page 5A-109)
Faulty O/D and 2nd coast brake Check O/D and 2nd coast brake referring to “A/
T Assembly Reassembly” (Page 5A-157).
5A-114)
sensor 5A-113)
5A-116)
valve “A”
valve “B”
valve “C”
Faulty direct clutch “Direct Clutch Assembly Preliminary Check”
(Page 5A-137)

5A-114)
sensor 5A-113)
5A-116)
valve “A”
valve “B”
valve “C”
T Assembly Reassembly” (Page 5A-157)
Gear shift point is Abnormal engine condition 
incorrect Malfunction of pressure control solenoid “Solenoid Valve Inspection” (Page 5A-120)
valve “A”
valve “B”
4 → 3 downshift fails Malfunction of O/D off switch “O/D Off Switch Inspection” (Page 5A-105)
Battery voltage is too low Check battery. 
5A-114)
sensor 5A-113)
5A-116)
valve “A”
valve “B”
valve “C”

3 → 2 downshift fails Battery voltage is too low Check battery. 
5A-114)
sensor 5A-113)
5A-116)
valve “A”
valve “B”
valve “C”
Valve body component “Valve Body Assembly Removal and
T Assembly Reassembly” (Page 5A-157)
2 → 1 downshift fails Battery voltage is too low Check battery. 
5A-114)
sensor 5A-113)
5A-116)
valve “A”
valve “B”
valve “C”
Installation” (Page 5A-117).
TCC (lock-up) function Battery voltage is too low Check battery. 
pressure control does not Malfunction of input shaft speed sensor “Input Shaft Speed Sensor Inspection” (Page
operate 5A-114)
sensor 5A-113)
5A-116)
Malfunction of TCC solenoid valve “Solenoid Valve Inspection” (Page 5A-120)
Malfunction of brake light switch 
Assembly Reassembly” (Page 5A-157)
Valve body component “Valve Body Assembly Removal and
Manual Road Test

AENFL80B5104012
! WARNING
• Perform road test in a place where there is 1

no traffic to prevent an accident.
• Road test should be performed with two
persons, a driver and a tester, on a level
road.
This test checks the gears being used in L, 2, D (O/D

OFF) or D (O/D ON) range when driven with deactivated ICL80C510010-01
gear shift control system. Test drive vehicle on a level
3) With select lever in L range, start vehicle and check
road.
that 3rd gear is being used referring to the following
NOTE table.
Before this test, check DTC. Vehicle speed at 1000 rpm in engine speed
Gear position Vehicle speed
1) With select lever in P range, start engine and warm it 1st 8.6 km/h (5.3 mile/h)
up. 2nd 15.8 km/h (9.8 mile/h)
2) After warming up engine, set ignition “OFF” and 3rd 24.7 km/h (15.3 mile/h)
disconnect solenoid connector (1). 4th 35.4 km/h (22.0 mile/h)
Reverse 10.8 km/h (6.7 mile/h)
4) While vehicle is running, shift select lever to 2 range

and check that 3rd gear is being used.
5) While vehicle is running, shift select lever to D range
and check that 3rd gear is being used.
6) After the checks, stop vehicle then set ignition
“OFF”, and reconnect solenoid connector.
Troubleshooting
Operated gear is not Faulty valve body component “Valve Body Assembly Removal and
correct Installation” (Page 5A-117)
Faulty clutch or brake Check clutch and brake referring to “A/T
Engine Brake Test

AENFL80B5104013
! WARNING
Before test, check that there is no vehicle behind to prevent rear-end collision.
1) While driving vehicle in 3rd gear of D range, shift down to 2 range and check if engine brake operates.
2) In the same way as in Step 1), check engine brake for operation when shifted down to L range.
3) Engine brake should operate.
Troubleshooting
Failure to operate when Faulty valve body component “Valve Body Assembly Removal and
shifted down to 2 range Installation” (Page 5A-117)
T Assembly Reassembly” (Page 5A-157).

Failure to operate when Faulty valve body component “Valve Body Assembly Removal and
shifted down to L range Installation” (Page 5A-117)
Stall Test
AENFL80B5104014
This test is to check overall performance of A/T and
engine by measuring stall speed in D and R ranges.
Perform this test only when ATF is at normal operating
temperature and its level is between FULL and LOW
marks.
(A)
! CAUTION
1
• Do not run engine at stall for more than 5
seconds continuously, or fluid temperature
may rise excessively.
• After performing stall test, be sure to leave
engine running at idle for longer than 1
minute before another stall test.
ICL80C510009-01
NOTE 3) Display “Data list” mode on scan tool.
Repeat test 3 times and take average of those 4) Start engine with select lever in P range.
data for final time lag data. 5) Depress brake pedal fully.
1) Apply parking brake and block wheels. 6) Shift select lever to D range and depress accelerator
pedal fully while watching tachometer. Read engine
2) Connect SUZUKI scan tool to DLC (1).
rpm quickly when it has become constant (stall
Special tool speed).
(A): SUZUKI scan tool (SUZUKI-SDT) 7) Release accelerator pedal immediately after stall
speed is checked.
8) In the same way, check stall speed in R range.
9) Stall speed should be within the following
specification.
Engine stall speed
Standard: 2,100 – 2,500 rpm
Troubleshooting
Lower than standard level Engine output torque failure 
in both D and R ranges Faulty torque converter Replace torque converter referring to “A/T
Higher than standard Malfunction of pressure control solenoid “Solenoid Valve Inspection” (Page 5A-120)
level in D range valve “A” (Low line pressure)
Slippery forward clutch “Forward and Reverse Clutch Assembly

level in R range valve “B” (Low line pressure)
Slippery reverse clutch “Forward and Reverse Clutch Assembly
Slippery 1st and reverse brake Check 1st and reverse brake referring to “A/T
level in both D and R valve “A” (Low line pressure)
ranges Malfunction of pressure control solenoid “Solenoid Valve Inspection” (Page 5A-120)
valve “B” (Low line pressure)
Clogged oil strainer “A/T Oil Strainer Assembly Removal and
136)
Time Lag Test Gear shifting time lag

AENFL80B5104015 N → D: Less than 0.7 sec.
This test is to check conditions of clutch, brake and fluid
N → R: Less than 1.2 sec.
pressure. “Time lag” means time elapsed since select
lever is shifted with engine idling till shock is felt. NOTE
1) With chocks placed before and behind front and rear
• When repeating this test, be sure to wait at
wheels respectively, depress brake pedal.
least one minute after select lever is
2) Start engine. shifted back to N range.
3) With a stopwatch ready, shift select lever from N to D • Engine should be warmed up fully for this
range and measure time from that moment till shock test.
is felt.
• Repeat test 3 times and take average of
4) Similarly measure time lag by shifting select lever those data for final time lag data.
from N to R range.
Troubleshooting
N → D time lag exceeds Malfunction of pressure control solenoid “Solenoid Valve Inspection” (Page 5A-120)
specification valve “A”
valve “B”
136)
Faulty forward clutch “Forward and Reverse Clutch Assembly

N → R time lag exceeds Malfunction of pressure control solenoid “Solenoid Valve Inspection” (Page 5A-120)
specification valve “A”
valve “B”
136)
Line Pressure Test

AENFL80B5104016
Purpose of this test is to check operating conditions of
each part by measuring fluid pressure in fluid pressure
line.
Line pressure test requires the following conditions.
• ATF is at normal operating temperature (70 to 80 °C /
158 to 176 °F).
• ATF is replenished to proper level (between FULL and
LOW on dipstick).
1
• A/C OFF
1) Hoist vehicle.
2) Remove left side engine undercover.
(A)
3) Remove fluid pressure check hole bolt (1).
4) Attach oil pressure gauge to fluid pressure check
hole (2) in transaxle rear cover.
2
! CAUTION
After attaching oil pressure gauge, check
that no fluid leakage exists.
Special tool ICL80C510013-02
(A): 09925M37811M001 5) Start engine and run at idle.

6) Shift to D range and check fluid pressure.
NOTE
Repeat test 3 times and take average of those
data for final time lag data.
A/T line pressure

D range
At idle 240 – 350 kPa (2.4 – 3.6 kgf/cm2,
speed 35 – 50 psi, 2.4 – 3.5 bar)
1
7) Stop engine and disconnect special tool.
8) After applying ATF to new O-ring, fit it to fluid
(A)
pressure check hole bolt (1). Then install fluid
pressure check hole bolt to transaxle rear cover (2)
by tightening it to specified torque.
Tightening torque 2
Fluid pressure check hole bolt (a): 7.5 N·m (0.76
kgf-m, 5.5 lbf-ft)
ICL80C510011-01
11) Start engine and run at idle.

12) Shift to R range and check fluid pressure.
NOTE
Repeat test 3 times and take average of those
data for final time lag data.
2 1, (a)
ICL80C510014-01
A/T line pressure
9) Remove fluid pressure check hole bolt (1).
10) Attach oil pressure gauge to fluid pressure check R range
hole (2) in transaxle case. At idle 420 – 560 kPa (4.3 – 5.7 kgf/cm2,
speed 61 – 81 psi, 4.2 – 5.6 bar)
! CAUTION
After attaching oil pressure gauge, check
13) Stop engine and disconnect special tool.
that no fluid leakage exists.
14) After applying ATF to new O-ring, fit it to fluid
Special tool pressure check hole bolt (1). Then install fluid
(A): 09925M37811M001 pressure check hole bolt to transaxle rear cover (2)
by tightening it to specified torque.
Tightening torque
Fluid pressure check hole bolt (a): 7.5 N·m (0.76
kgf-m, 5.5 lbf-ft)
15) Install left side engine undercover.
2 1, (a)
ICL80C510012-01
Troubleshooting
level in each range valve “A”
valve “B”
Lower than standard level Malfunction of pressure control solenoid “Solenoid Valve Inspection” (Page 5A-120)
in each range valve “A”
valve “B”
136)
Lower than standard level Faulty forward clutch Inspect forward clutch. If NG, replace forward
only in D range clutch.
Lower than standard level Faulty reverse clutch Inspect reverse clutch. If NG, replace reverse
only in R range clutch.
Faulty 1st and reverse brake Inspect 1st and reverse brake. If NG, replace
1st and reverse brake.
level only in D range valve “A”
valve “B”
level only in R range valve “A”
valve “B”
P Range Test 1) Stop vehicle on a slope of 5 degrees or more, shift to

AENFL80B5104017 P range and apply parking brake.
! WARNING 2) Stop engine, depress brake pedal and release
Before test, make sure no one is around parking brake.
vehicle or down on a slope and keep watchful 3) Then, release brake pedal gradually and check that
for safety during test. vehicle remains stationary.
4) Depress brake pedal and shift select lever to N 5) Then, release brake pedal gradually and check that
range. vehicle moves.
Troubleshooting
Vehicle moves in P range Defective parking lock pawl or spring Check parking lock pawl and/or spring
or remains stationary in N referring to “A/T Assembly Reassembly” (Page
range 5A-157).
A/T Symptom Diagnosis

AENFL80B5104018
Engine Chassis Electrical system CAN ATF A/T

Diagnostic item
Wear, looseness, scratches, large deflection on drive
Water intrusion or different type of fluid in ATF

Drive system and body interference
Pressure control solenoid valve "C"

Pressure control solenoid valve "A"
Pressure control solenoid valve “B”
Engine coolant temperature signal

Resonant exhaust pipe system
Suspension play, looseness
Transmission range sensor

Output shaft speed sensor
Accelerator position signal

Input shaft speed sensor
ATF temperature sensor

Shift solenoid valve "A"
Throttle position signal

Engine torque signal
Engine speed signal
TCC solenoid valve
Drive plate runout
Brake light switch
Torque converter
Engine mounting
Battery voltage
Tire unbalance
ATF low level

ATF burning
Valve body
Oil seal
Gasket
Engine
O-ring
TCM
A/T
Symptom
Impossible or Impossible to go
start out forward or slippage ● ●● ● ●●● ●●●
slippage in D range
Impossible or Impossible to go
start out backward or ● ● ● ● ●●● ●●●
slippage slippage in R
Impossible or Slippage during
start out shifting or ●●●●● ● ●●● ●●●
slippage acceleration
Excessive N → D time lag ● ● ● ● ●●● ●●
Excessive N → R time lag ● ● ●●● ●●
Starting motor does not operate in
P or N range ●
N→D
N→R ● ● ● ● ●●●
Engine stalls
During
acceleration ● ● ● ● ●●●
Poor acceleration ● ● ● ● ● ● ● ● ● ●●●
Poor 1st → 2nd
shift ● ●●●●● ● ● ● ● ● ● ● ● ● ●●
Poor 2nd → 3rd
No gear shift
shift ● ●●●●●●● ● ● ● ● ● ● ● ● ●●
Poor 3rd → 4th
shift
● ●●●●● ● ● ● ● ● ● ● ● ● ●●
Non operate TCC (lock-up) system ●●● ● ●●● ● ● ●●●
Poor engine brake ● ●● ●●● ● ● ●●
No kickdown ● ● ● ●●
Incorrect gear shift point ● ● ● ●●
Shift lever movement hard /
too loose ●
Breather ●
Engine to T/A
housing mating ●● ● ●●
surface
Differential oil seal ●
Manual shaft oil
Oil leakage seal ●
T/A housing
Oil pan
Rear case ●
T/A case
O-ring ●
Oil cooler hose ●
N→D ● ● ●● ●● ● ● ●● ● ● ● ● ● ●
N→R ● ● ●● ●● ● ● ●● ● ● ● ● ● ●
Shift up ● ● ● ● ● ●●● ● ● ● ● ● ● ●
Excessive shift During coastdown ● ● ● ● ●●● ● ● ● ● ● ● ●
shock
During kickdown ● ● ● ● ●●● ● ● ● ● ● ● ●
When depressing
or releasing
accelerator (with ● ● ● ●
no shifting)
Abnormal During idling ●●●●● ● ●
vibration During driving ●●●●●●● ●
During idling ● ●● ● ● ● ●
During garage shift ● ●●● ● ● ●
Abnormal noise During driving ● ●●●●● ● ●
During shifting ● ●● ●● ● ● ● ●
When depressing
or releasing ● ●● ●●● ●
accelerator
●: Applicable)
(
ICL80C510225-01
MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)
AENFL80B5104019
Refer to “MIL Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine Can Be Started)”: Petrol in
Section 1A in related manual.
MIL Remains ON after Engine Starts

AENFL80B5104020
Refer to “MIL Remains ON after Engine Starts”: Petrol in Section 1A in related manual.
Transmission Warning Light Does Not Come ON with Ignition ON

AENFL80B5104021
Troubleshooting
Step Action Yes No
1) Check DTC related to CAN communication. for applicable DTC.
Is there CAN-DTC(s) detected?

2 DTC check Go to troubleshooting Substitute a known-
1) Check combination meter for DTC. for applicable DTC. good TCM and recheck
transmission warning
Is there any DTC(s)? light operation. (Page
5A-121)
Transmission Warning Light Remains ON with Ignition ON

AENFL80B5104022
Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting Substitute a known-
1) Check DTC. (Page 5A-15) for applicable DTC. good combination meter
and recheck
Is there any DTC(s)? transmission warning
light operation. (Page
9C-24)
If transmission warning
light still remains ON,
substitute a known-
good TCM and recheck
transmission warning
light operation. (Page
5A-121)
DTC P0562 / P0563

AENFL80B5104023
P0562: System Voltage Low • TCM power supply circuit and/or ground circuit
Main power supply circuit voltage is lower than specified • Charging system
value for 20 sec.
• TCM
P0563: System Voltage High
Main power supply circuit voltage is higher than specified
value for 20 sec.
Circuit Diagram
1
A1
2
C06-6 YEL/BLK
A2
3
C06-24 LT GRN/BLK
4
B1
C06-1 BLK
B2
C06-23 BLK
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510015-01
[A]: TCM connector (View: [a]) A3: Ground circuit 2. “AT” fuse 5. Main fuse box
A1: Main power supply circuit A4: Ground circuit 3. “IG1 SIG” fuse
A2: Ignition on signal circuit 1. TCM 4. Ignition switch
NOTE
• Be sure to troubleshoot first unexpected DTCs previously detected in “DTC Confirmation
Procedure”.
• Check that the following conditions are satisfied in this procedure.
– ECM: DTC P0335, P0340 is not detected.
– TCM: DTC P0717, P1738, P1739, U0073, U0100 is not detected.
1) Start engine at idle for 30 sec.
DTC Troubleshooting
Step Action Yes No
5A-13).
2 TCM power supply and ground circuits check Go to Step 3. Repair TCM power
1) Check TCM power supply and ground circuits. (Page supply or ground circuit.
5A-102)
Is check result OK?

3 TCM power supply voltage check Substitute a known- Check charging system.
1) Check power supply voltage following conditions. good TCM and recheck (Page 1J-3)
DTC. (Page 5A-121)
• Ignition ON
• Engine running at 3,000 rpm
Is voltage 10 to 15 V?
DTC P0602
AENFL80B5104024
P0602: Control Module Programming Error TCM
TCM internal failure (data programming error).
(1 D/C detection logic but transmission warning light and MIL
do not light up)

1) Start engine and run it at idle if possible.
DTC Troubleshooting
Step Action Yes No
1 DTC check Go to Step 2. Check for intermittent
3) Set ignition “ON” and check DTC.
Is DTC P0602 still indicated?

2 TCM power and ground circuit check Substitute a known- Repair TCM power or
1) Check TCM power supply circuit and ground circuit. good TCM and recheck ground circuit.
(Page 5A-102) DTC. (Page 5A-121)
Is check result OK?
DTC P0604 / P062F / P1702

AENFL80B5104025
P0604: Internal Control Module Random Access Memory (RAM) TCM
Error
TCM internal failure (RAM error).
P062F: Internal Control Module EEPROM Error
TCM internal failure (EEPROM error).
P1702: Internal Control Module Memory Check Sum Error
TCM internal failure (check sum error).

DTC Troubleshooting
Step Action Yes No
1 Is DTC P0604, P062F or P1702 detected after performing Substitute a known- Check for intermittent
“DTC Confirmation Procedure”? good TCM and recheck trouble. 
DTC P0705
AENFL80B5104026
P0705: Transmission Range Sensor “A” Circuit (PRNDL Input) • Select cable
Multiple signals are input simultaneously for 4 sec. • Transmission range sensor and/or its circuit
• TCM
Circuit Diagram
2 P A1
C166-6 PNK/BLK C07-20
IG1 R A2
C166-1 RED C07-1
RED/BLK 3
B1 N
C166-9 BEG C07-8
A3
D A4
C166-7 BLU C07-7
2 A5
C166-3 GRN/YEL C07-19
L A6
C166-8 LT GRN/BLK C07-18
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510016-02
[A]: TCM connector (View: [a]) A6: Transmission range sensor (L range) circuit
A1: Transmission range sensor (P range) circuit B1: Transmission range sensor power supply circuit
A2: Transmission range sensor (R range) circuit 1. TCM
A3: Transmission range sensor (N range) circuit 2. Transmission range sensor
A4: Transmission range sensor (D range) circuit 3. Back-up light
A5: Transmission range sensor (2 range) circuit
NOTE
Check that the following condition is satisfied in this procedure.
• 10.2 V < Battery voltage <15.5 V
1) Shift select lever to each of L, 2, D, N, R and P ranges for 10 seconds each.
DTC Troubleshooting
Step Action Yes No
5A-13).
2 Do you have SUZUKI scan tool? Go to Step 3. Go to Step 4.
3 Transmission range sensor circuit check Check for intermittent Go to Step 5.
1) Connect SUZUKI scan tool to DLC with ignition OFF. trouble. 
2) Set ignition “ON” and check transmission range signal
(P, R, N, D, 2 or L) on scan tool when shifting select lever
to each range.
Is applicable range indicated?

Step Action Yes No

1) Set ignition “ON”. trouble. 
2) Check that voltage between each transmission range
sensor circuit and ground respectively with select lever
shifted to each range.
Taking transmission range sensor (2 range) circuit as an
example, check that battery voltage is indicated only
when select lever is shifted to 2 range and 0 V is
indicated when shifted to other ranges as shown in the
following table.
Check voltage at other circuits likewise, referring to the
following table.
Is check result OK?

5 Select cable adjustment check Go to Step 6. Adjust select cable and
1) Check select cable for adjustment. (Page 5A-108) recheck DTC.
Is it adjusted correctly?
6 Transmission range sensor adjustment check Go to Step 7. Adjust transmission
1) Check transmission range sensor for adjustment. range sensor and
(Page 5A-109) recheck DTC.
7 Transmission range sensor circuit check Go to Step 8. Repair or replace
2) Disconnect “C166” and “C07” connectors.
3) Check for proper terminal connection to “C166” and
“C07” connectors.
• Resistance between each of “A1”, “A2”, “A3”, “A4”,
“A5” and “A6” circuit terminals and other terminal at
“C166” connector: infinity
• Voltage of “A1”, “A2”, “A3”, “A4”, “A5” and “A6”
circuits: approx. 0 V (When ignition is “ON”)
Is check result OK?

8 Transmission range sensor check Substitute a known- Replace transmission
1) Check transmission range sensor. (Page 5A-109) good TCM and recheck range sensor. (Page
DTC. (Page 5A-121) 5A-109)
Is check result OK?
Table for Step 4

Terminal
C07-20 C07-1 C07-8 C07-7 C07-19 C07-18
P 8.4 to 14 V 0V 0V 0V 0V 0V
R 0V 8.4 to 14 V 0V 0V 0V 0V
N 0V 0V 8.4 to 14 V 0V 0V 0V
Select lever position
D 0V 0V 0V 8.4 to 14 V 0V 0V
2 0V 0V 0V 0V 8.4 to 14 V 0V
L 0V 0V 0V 0V 0V 8.4 to 14 V
DTC P0707
AENFL80B5104027
P0707: Transmission Range Sensor “A” Circuit Low • Select cable
No sensor signal is input for 28 sec. • Transmission range sensor and/or its circuit
• TCM
Circuit Diagram
2 P A1
C166-6 PNK/BLK C07-20
IG1 R A2
C166-1 RED C07-1
RED/BLK 3
B1 N
C166-9 BEG C07-8
A3
D A4
C166-7 BLU C07-7
2 A5
C166-3 GRN/YEL C07-19
L A6
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510016-02
[A]: TCM connector (View: [a]) A6: Transmission range sensor (L range) circuit
A1: Transmission range sensor (P range) circuit B1: Transmission range sensor power supply circuit
A2: Transmission range sensor (R range) circuit 1. TCM
A3: Transmission range sensor (N range) circuit 2. Transmission range sensor
A4: Transmission range sensor (D range) circuit 3. Back-up light
A5: Transmission range sensor (2 range) circuit
! WARNING

NOTE
Procedure”.
– 10.2 V Battery voltage 15.5 V
– DTC P0562, P0563, P0604, P0705, P0717, P0722, P0746, P0747, P0776, P0777, P0796, P0797,
P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
P1737, P1738, P1739, P2762, U0073, U0100 is not detected.
1) Drive vehicle at 35 km/h (22 mile/h) or more in D (O/D ON) range for 1 min.
DTC Troubleshooting
Step Action Yes No
5A-13).
Step Action Yes No

2 Do you have SUZUKI scan tool? Go to Step 3. Go to Step 4.
1) Connect SUZUKI scan tool to DLC with ignition OFF. trouble. 
2) Set ignition “ON” and check transmission range signal
(P, R, N, D, 2 or L) on scan tool when shifting select lever
to each range.
Is applicable range indicated?

1) Set ignition “ON”. trouble. 
2) Check that voltage between each transmission range
sensor circuit and ground respectively with select lever
shifted to each range.
Taking transmission range sensor (2 range) circuit as an
example, check that battery voltage is indicated only
when select lever is shifted to 2 range and 0 V is
indicated when shifted to other ranges as shown in the
following table.
Check voltage at other circuits likewise, referring to the
following table.
Is check result OK?

5 Select cable adjustment check Go to Step 6. Adjust select cable and
1) Check select cable for adjustment. (Page 5A-108) recheck DTC.
6 Transmission range sensor adjustment check Go to Step 7. Adjust transmission
1) Check transmission range sensor for adjustment. range sensor and
(Page 5A-109) recheck DTC.
7 Transmission range sensor power supply voltage check Go to Step 8. Repair or replace
1) With ignition “OFF”, disconnect “C166” connector. defective wire harness.
connector.
battery voltage.
Is check result OK?

8 Transmission range sensor circuit check Go to Step 9. Repair or replace
connector.
• Resistance of “A1”, “A2”, “A3”, “A4”, “A5” and “A6”
circuits: less than 1 Ω
• Resistance between each of “A1”, “A2”, “A3”, “A4”,
“A5” and “A6” circuits and ground: infinity
Is check result OK?

9 Transmission range sensor check Substitute a known- Replace transmission
1) Check transmission range sensor. (Page 5A-109) good TCM and recheck range sensor. (Page
DTC. (Page 5A-121) 5A-109)
Is check result OK?
Table for Step 4

Terminal
C07-20 C07-1 C07-8 C07-7 C07-19 C07-18
P 8.4 to 14 V 0V 0V 0V 0V 0V
R 0V 8.4 to 14 V 0V 0V 0V 0V
N 0V 0V 8.4 to 14 V 0V 0V 0V
Select lever position
D 0V 0V 0V 8.4 to 14 V 0V 0V
2 0V 0V 0V 0V 8.4 to 14 V 0V
L 0V 0V 0V 0V 0V 8.4 to 14 V
DTC P0711
AENFL80B5104028
P0711: Transmission Fluid Temperature Sensor “A” • ATF temperature sensor and/or its circuit
Circuit Range / Performance • TCM
ATF temperature sensor signal circuit voltage is unchanged
for 600 sec., after drive vehicle at 40 km/h (25 mile/h).
Circuit Diagram
1
3
5V 4
A1
2
C06-11 LT GRN C139-1
C06-12 BEG C139-7
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510226-01
[A]: TCM connector (View: [a]) 1. TCM 4. Solenoid connector

A1: ATF temperature sensor signal circuit 2. ATF temperature sensor
A2: ATF temperature sensor ground circuit 3. A/T
! WARNING

NOTE
Procedure”.
– 10.2 V < Battery voltage < 15.5 V
– TCM: DTC P0562, P0563, P0604, P0705, P0707, P0712, P0713, P0717, P0722, P0746, P0747, P0776,
P0777, P0796, P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973,
P0974, P1702, P1736, P1737, P1738, P1739, P2762, U0073, U0100 is not detected.

2) Drive vehicle at 45 km/h (28 mile/h) or more in D range.

3) Keep select lever position at D range for 12 min.
DTC Troubleshooting
Step Action Yes No
5A-13).
2 ATF temperature sensor signal circuit and ground Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “C06”
connectors.
terminal at “C139” connector: infinity
Is check result OK?

3 ATF temperature sensor check Substitute a known- Replace ATF
1) Check ATF temperature sensor. (Page 5A-116) good TCM and recheck temperature sensor.
DTC. (Page 5A-121) (Page 5A-116)
Is check result OK?
DTC P0712
AENFL80B5104029
P0712: Transmission Fluid Temperature Sensor “A” Circuit Low • ATF temperature sensor and/or its circuit
ATF temperature sensor signal circuit voltage is lower than specified • TCM
value for 5 sec.
Circuit Diagram
1
3
5V 4
A1
2
C06-11 LT GRN C139-1
C06-12 BEG C139-7
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510226-01

NOTE
• 10.2 V < Battery voltage < 15.5 V

DTC Troubleshooting
Step Action Yes No
5A-13).
2 ATF temperature sensor signal circuit check Go to Step 3. Replace defective wire
1) With ignition “OFF”, disconnect “C139” and “C06” harness.
connectors.
Is check result OK?

3 ATF temperature sensor check Substitute a known- Repair or replace ATF
DTC. (Page 5A-121) (Page 5A-116)
Is check result OK?
DTC P0713
AENFL80B5104030
P0713: Transmission Fluid Temperature Sensor “A” • ATF temperature sensor and/or its circuit
Circuit High • TCM
ATF temperature sensor signal circuit voltage is higher than
Circuit Diagram
1
3
5V 4
A1
2
C06-11 LT GRN C139-1
C06-12 BEG C139-7
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510226-01

NOTE
Procedure”.
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702,
P1736, P1737, P1738, P1739, P2762, U0073, U0100 is not detected.

DTC Troubleshooting
Step Action Yes No
5A-13).
2 ATF temperature sensor signal circuit and ground Go to Step 3. Repair or replace
1) With ignition “OFF”, disconnect “C139” and “C06”
connectors.
Is check result OK?

3 ATF temperature sensor check Substitute a known- Replace ATF
DTC. (Page 5A-121) (Page 5A-116)
Is check result OK?
DTC P0717
AENFL80B5104031
P0717: Input / Turbine Speed Sensor “A” Circuit No signal • Input shaft speed sensor and/or its circuit
Input shaft speed sensor signal is not input even if output shaft • Direct clutch
speed sensor signal is input.
• TCM
Circuit Diagram
1
12V
2 A1
C44-1 WHT C07-16

C44-2 BLK C07-6
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510017-03
[A]: TCM connector (View: [a]) A2: Input shaft speed sensor signal circuit 2. Input shaft speed sensor
A1: Input shaft speed sensor power supply circuit 1. TCM
! WARNING

NOTE
Procedure”.
P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
1) Drive vehicle at 30 km/h (19 mile/h) or more in D (O/D ON) range for 5 min. (keep throttle valve opening constant
in this step.)
DTC Troubleshooting
Step Action Yes No
5A-13).
2 Input shaft speed sensor power supply circuit check Go to Step 3. Repair or replace
connector.
battery voltage.
Is check result OK?

Step Action Yes No

3 Input shaft speed sensor signal circuit check Go to Step 4. Repair or replace
connector.
“ON”)
Is check result OK?

4 Input shaft speed sensor check Go to Step 5. Replace input shaft
1) Check input shaft speed sensor. (Page 5A-114) speed sensor. (Page
5A-113)
Is check result OK?
5 Input shaft speed sensor visual check Go to Step 6. Clean, repair or replace
1) Remove input shaft speed sensor. (Page 5A-113) input shaft speed
sensor.
2) Check input shaft speed sensor visually as follows.
• No damage
• No foreign material attached
• Correct installation
ICL80C510241-01
Is check result OK?

6 Input shaft speed sensor teeth visual check Check for intermittent Replace direct clutch.
1) Check input shaft speed sensor teeth (1) visually. trouble.  • Removal: (Page
If OK, substitute a 5A-128)
1 known-good TCM and • Installation: (Page
recheck DTC. (Page 5A-157)
5A-121)
ICL80C510227-01
Is check result OK?
DTC P0722
AENFL80B5104032
P0722: Output Speed Sensor Circuit No Signal • Output shaft speed sensor and/or its circuit
Output shaft speed sensor signal is not input even if input • Reduction drive gear
shaft speed sensor signal is input.
• TCM
Circuit Diagram
1
12V
2 A1
C44-1 WHT C07-16

C44-2 BLK C07-6
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510017-03
[A]: TCM connector (View: [a]) A2: Output shaft speed sensor signal circuit 2. Output shaft speed sensor
A1: Output shaft speed sensor power supply circuit 1. TCM
! WARNING

NOTE
Procedure”.
P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
1) Drive vehicle at 15 km/h (9 mile/h) or more in D (O/D ON) range for 5 min.
DTC Troubleshooting
Step Action Yes No
5A-13).
2 Output shaft speed sensor power supply circuit check Go to Step 3. Repair or replace
connector.
battery voltage.
Is check result OK?

Step Action Yes No

3 Output shaft speed sensor signal circuit check Go to Step 4. Repair or replace
connector.
“ON”)
Is check result OK?

4 Output shaft speed sensor check Go to Step 5. Replace output shaft
1) Check output shaft speed sensor. (Page 5A-113) speed sensor. (Page
5A-113)
Is check result OK?
5 Output shaft speed sensor visual check Go to Step 6. Clean, repair or replace
1) Remove output shaft speed sensor. (Page 5A-113) output shaft speed
sensor.
2) Check output shaft speed sensor visually as follows.
• No damage
• No foreign material attached
• Correct installation
ICL80C510241-01
Is check result OK?

6 Output reduction drive gear visual check Check for intermittent Replace reduction drive
1) Check reduction drive gear (1) visually. trouble.  gear.
If OK, substitute a • Removal: (Page
1 known-good TCM and 5A-128)
recheck DTC. (Page • Installation: (Page
5A-121) 5A-157)
ICL80C510228-01
Is check result OK?
DTC P072A
AENFL80B5104033
P072A: Stuck in Neutral • Valve body assembly
Difference between engine speed and input shaft speed is less than • A/T (clutch, brake or gear etc.)
specified value, and the gear commanded by TCM does not match the
• TCM
actual gear when driving.
! WARNING

NOTE
Procedure”.
• ATF temperature ≥ 20 °C (68 °F)
P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738, P1739, P2762,
U0073, U0100 is not detected.

2) Drive vehicle with 1st gear for 10 sec.
3) Drive vehicle with 2nd gear for 10 sec.
4) Drive vehicle with 3rd gear for 10 sec.
5) Drive vehicle with 4th gear for 10 sec.
DTC Troubleshooting
Step Action Yes No
5A-13).
2 Valve body assembly replacement Check A/T mechanical End.
1) Replace valve body assembly. (Page 5A-117) systems (clutch, brake
or gear etc.)
2) Check DTC.
If OK, substitute a
Is DTC P072A still indicated? known-good TCM and
recheck DTC. (Page
5A-121)
DTC P0731
AENFL80B5104034
P0731: Gear 1 Incorrect Ratio • Pressure control solenoid valve “A” and/
The gear commanded by TCM does not match the actual gear when or its circuit
driving. • Pressure control solenoid valve “B” and/
(2 D/C detection logic) or its circuit
• TCC solenoid valve and/or its circuit
• Valve body assembly
• A/T (clutch, brake or gear etc.)
• TCM
Circuit Diagram
1 5
12V 6
A1 2
C06-22 RED C139-6
A2
C06-9 BLK C139-13
12V
3
B1
C06-21 BLK/YEL C139-5
B2
C06-19 BLU/BLK C139-12
12V
4
C1
C06-5 WHT/BLU C139-3
C2
C06-3 WHT/BLK C139-9
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510019-02
[A]: TCM connector (View: [a]) 1. TCM

A1: Pressure control solenoid valve “A” drive circuit (+) 2. Pressure control solenoid valve “A”
A2: Pressure control solenoid valve “A” drive circuit (–) 3. Pressure control solenoid valve “B”
B1: Pressure control solenoid valve “B” drive circuit (+) 4. TCC solenoid valve
B2: Pressure control solenoid valve “B” drive circuit (–) 5. A/T
C1: TCC solenoid valve drive circuit (+) 6. Solenoid connector
C2: TCC solenoid valve drive circuit (–)
! WARNING

NOTE
Procedure”.
– ATF temperature ≥ 20 °C (68 °F)
P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737,
1) Drive vehicle at more than 35 km/h (22 mile/h) in “L” range.

2) Release accelerator pedal, and keep vehicle coasting for 20 sec. with engine brakes applied.
DTC Troubleshooting
Step Action Yes No
5A-13).
Step Action Yes No

2 Solenoid valve drive circuit check Go to Step 3. Repair or replace
1) Check following circuits. defective wire harness.
• Pressure control solenoid valve “A” drive circuit (+)
and (–): (Page 5A-73)
• Pressure control solenoid valve “B” drive circuit (+)
and (–): (Page 5A-77)
• TCC solenoid valve drive circuit (+) and (–): (Page
5A-93)
Is check result OK?

3 Solenoid valve circuit check Go to Step 5. Go to Step 4.
1) Check following circuits. (Page 5A-120)
• Pressure control solenoid valve “A”
• Pressure control solenoid valve “B”
• TCC solenoid valve drive
Is check result OK?

4 Solenoid valve check for resistance Replace solenoid Replace valve body
1) Check following solenoid valve for resistance. (Page harness. (Page 5A- assembly. (Page 5A-
5A-120) 116) 117)
Is check result OK?

5 Solenoid valve check for operation Go to Step 6. Replace valve body
1) Check following solenoid valve for operation. (Page assembly. (Page 5A-
5A-120) 117)
Is check result OK?

or gear etc.)
2) Check DTC.
If OK, substitute a
Is DTC P0731 still indicated? known-good TCM and
5A-121)
DTC P0741
AENFL80B5104035
P0741: Torque Converter Clutch Circuit Performance / Stuck Off • Shift solenoid valve “A” and/or its circuit
Difference between engine speed and input shaft speed is more than • TCC solenoid valve and/or its circuit
specified value even if TCC solenoid valve is turned on.
• TCM
Circuit Diagram
1
4
5
12V
A1 2
C06-16 BRN C139-10
12V
3
B1
B2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510240-01
[A]: TCM connector (View: [a]) 2. Shift solenoid valve “A”

A1: Shift solenoid valve “A” drive circuit 3. TCC solenoid valve
B1: TCC solenoid valve drive circuit (+) 4. A/T
B2: TCC solenoid valve drive circuit (–) 5. Solenoid connector
1. TCM
! WARNING

NOTE
Procedure”.
P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738, P1739, P2762,
P2763, P2764, U0073, U0100 is not detected.
1) Drive vehicle with 4th gear in D range for 1 min. (keep throttle valve opening constant in this step.)
DTC Troubleshooting
Step Action Yes No
5A-13).
Step Action Yes No

• Shift solenoid valve “A” drive circuit
– Short to ground: (Page 5A-85)
– Open and short to power supply circuit: (Page
5A-87)
• TCC solenoid valve drive circuit (+) and (–): (Page
5A-93)
Is check result OK?

• Shift solenoid valve “A”
Is check result OK?

1) Check following solenoid valve for operation. (Page harness. (Page 5A- assembly. (Page 5A-
5A-120) 116) 117)
Is check result OK?

5A-120) 117)
Is check result OK?

or gear etc.)
2) Check DTC.
If OK, substitute a
5A-121)
DTC P0742
AENFL80B5104036
P0742: Torque Converter Clutch Circuit Stuck On • TCC solenoid valve and/or its circuit
Difference between engine speed and input shaft speed is less than • Valve body assembly
specified value even if TCC solenoid valve is turned off.
• TCM
Circuit Diagram
1 3
4
12V
2
A1
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510020-04
[A]: TCM connector (View: [a]) 2. TCC solenoid valve

A1: TCC solenoid valve drive circuit (+) 3. A/T
A2: TCC solenoid valve drive circuit (–) 4. Solenoid connector
1. TCM
! WARNING

NOTE
Procedure”.
P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738, P1739, P2762,
1) Drive vehicle and increase vehicle speed to 80 km/h (50 mile/h) with 50% throttle opening.
2) Close throttle and decrease vehicle speed to 30 km/h (18 mile/h).
3) Repeat steps 1) to 2) 5 times or more.
DTC Troubleshooting
Step Action Yes No
5A-13).
2 TCC solenoid valve drive circuit check Go to Step 3. Repair or replace
1) Check TCC solenoid valve drive circuit (+) and (–). defective wire harness.
(Page 5A-93)
Is check result OK?

3 TCC solenoid valve circuit check Go to Step 5. Go to Step 4.
1) Check TCC solenoid valve drive circuit. (Page 5A-120)
Is check result OK?

Step Action Yes No

4 TCC solenoid valve check for resistance Replace solenoid Replace valve body
1) Check TCC solenoid valve for resistance. (Page 5A- harness. (Page 5A- assembly. (Page 5A-
120) 116) 117)
Is check result OK?

5 TCC solenoid valve check for operation Go to Step 6. Replace valve body
1) Check TCC solenoid valve for operation. (Page 5A- assembly. (Page 5A-
120) 117)
Is check result OK?

or gear etc.)
2) Check DTC.
If OK, substitute a
5A-121)
DTC P0746 / P0747

AENFL80B5104037
P0746: Pressure Control Solenoid “A” Performance / Stuck Off • Pressure control solenoid valve “A” and/
driving. • Valve body assembly
P0747: Pressure Control Solenoid “A” Stuck On
The gear commanded by TCM does not match the actual gear when • TCM
driving
Circuit Diagram
1
3
4
12V
2
A1
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510020-04
[A]: TCM connector (View: [a]) 2. Pressure control solenoid valve “A”
A1: Pressure control solenoid valve “A” drive circuit (+) 3. A/T
A2: Pressure control solenoid valve “A” drive circuit (–) 4. Solenoid connector
1. TCM
! WARNING

P0746:
NOTE
Procedure”.
P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738,

P0747:
NOTE
Procedure”.
– ATF temperature ≥ –20 °C (–4 °F)
P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738, P1739,
P2762, U0073, U0100 is not detected.

2) Drive vehicle with 4th gear in D range for 20 sec. (keep throttle valve opening constant in this step.)
DTC Troubleshooting
Step Action Yes No
5A-13).
2 Pressure control solenoid valve “A” drive circuit check Go to Step 3. Repair or replace
1) Check pressure control solenoid valve “A” circuit (+) and defective wire harness.
(–). (Page 5A-73)
Is check result OK?

3 Pressure control solenoid valve “A” circuit check Go to Step 5. Go to Step 4.
1) Check pressure control solenoid valve “A” circuit.
(Page 5A-120)
Is check result OK?

4 Pressure control solenoid valve “A” check for Replace solenoid Replace valve body
resistance harness. (Page 5A- assembly. (Page 5A-
1) Check pressure control solenoid valve “A” for resistance. 116) 117)
(Page 5A-120)
Is check result OK?

Step Action Yes No

5 Pressure control solenoid valve “A” check for operation Go to Step 6. Replace valve body
1) Check pressure control solenoid valve “A” for operation. assembly. (Page 5A-
(Page 5A-120) 117)
Is check result OK?

or gear etc.)
2) Check DTC.
If OK, substitute a
Is DTC P0746 / P0747 still indicated? known-good TCM and
5A-121)
DTC P0751
AENFL80B5104038
P0751: Shift Solenoid “A” Performance / Stuck Off • Shift solenoid valve “A” and/or its circuit
The gear commanded by TCM does not match the actual gear when • Valve body assembly
driving.
• TCM
Circuit Diagram
1
3
4
12V
A1 2
C06-16 BRN C139-10
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510025-02
[A]: TCM connector (View: [a]) 1. TCM 3. A/T

A1: Shift solenoid valve “A” drive circuit 2. Shift solenoid valve “A” 4. Solenoid connector
! WARNING

NOTE
Procedure”.
P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738, P1739,
1) Repeat acceleration at 50% throttle opening and deceleration between 10 and 35 km/h (6 and 22 mile/h) in L
range for more than 5 times.
DTC Troubleshooting
Step Action Yes No
5A-13).
2 Shift solenoid valve “A” drive circuit check Go to Step 3. Repair or replace
1) Check shift solenoid valve “A” drive circuit. defective wire harness.
• Short to ground: (Page 5A-85)
• Open and short to power supply circuit: (Page 5A-
87)
Is check result OK?

3 Shift solenoid valve “A” circuit check Go to Step 5. Go to Step 4.
1) Check shift solenoid valve “A” circuit. (Page 5A-120)
Is check result OK?

4 Shift solenoid valve “A” check for resistance Replace solenoid Replace valve body
1) Check shift solenoid valve “A” for resistance. (Page harness. (Page 5A- assembly. (Page 5A-
5A-120) 116) 117)
Is check result OK?

5 Shift solenoid valve “A” check for operation Go to Step 6. Replace valve body
1) Check shift solenoid valve “A” for operation. (Page 5A- assembly. (Page 5A-
120) 117)
Is check result OK?

or gear etc.)
2) Check DTC.
If OK, substitute a
5A-121)
DTC P0776
AENFL80B5104039
P0776: Pressure Control Solenoid “B” Performance / Stuck Off • Shift solenoid valve “A” and/or its circuit
The gear commanded by TCM does not match the actual gear when • Pressure control solenoid valve “B” and/
driving. or its circuit
• TCM
Circuit Diagram
1 4
5
12V
A1 2
C06-16 BRN C139-10
12V
3
B1
C06-21 BLK/YEL C139-5
B2
C06-19 BLU/BLK C139-12
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510021-02
[A]: TCM connector (View: [a]) 2. Shift solenoid valve “A”

A1: Shift solenoid valve “A” drive circuit 3. Pressure control solenoid valve “B”
B1: Pressure control solenoid valve “B” drive circuit (+) 4. A/T
B2: Pressure control solenoid valve “B” drive circuit (–) 5. Solenoid connector
1. TCM
! WARNING

NOTE
Procedure”.
P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738,

DTC Troubleshooting
Step Action Yes No
5A-13).
• Shift solenoid valve “A” drive circuit
– Short to ground: (Page 5A-85)
– Open and short to power supply circuit: (Page
5A-87)
• Pressure control solenoid valve “B” drive circuit (+)
and (–): (Page 5A-77)
Is check result OK?

Is check result OK?

1) Check following solenoid valve for resistance. (Page harness. (Page 5A- assembly. (Page 5A-
5A-120) 116) 117)
Is check result OK?

5A-120) 117)
Is check result OK?

or gear etc.)
2) Check DTC.
If OK, substitute a
5A-121)
DTC P0777
AENFL80B5104040
P0777: Pressure Control Solenoid “B” Stuck On • Pressure control solenoid valve “B” and/
• TCM
Circuit Diagram
1 3
4
12V
2
A1
C06-21 BLK/YEL C139-5
A2
C06-19 BLU/BLK C139-12
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510022-02
[A]: TCM connector (View: [a]) 2. Pressure control solenoid valve “B”
A1: Pressure control solenoid valve “B” drive circuit (+) 3. A/T
A2: Pressure control solenoid valve “B” drive circuit (–) 4. Solenoid connector
1. TCM
! WARNING

NOTE
Procedure”.
– TCM: DTC P0562, P0563, P0604, P0705, P0707 P0711, P0712, P0713, P0717, P0722, P0746, P0747,
P0776, P0796, P0797, P0961, 0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973,
P0974, P1702, P1736, P1737, P1738, P1739, P2762, U0073, U0100 is not detected.
2) Drive vehicle in 2 range for 1 min. (keep throttle valve opening constant in this step.)
DTC Troubleshooting
Step Action Yes No
5A-13).
2 Pressure control solenoid valve “B” drive circuit check Go to Step 3. Repair or replace
1) Check pressure control solenoid valve “B” circuit (+) and defective wire harness.
(–). (Page 5A-77)
Is check result OK?

3 Pressure control solenoid valve “B” circuit check Go to Step 5. Go to Step 4.
1) Check pressure control solenoid valve “B” circuit.
(Page 5A-120)
Is check result OK?

Step Action Yes No

4 Pressure control solenoid valve “B” check for Replace solenoid Replace valve body
1) Check pressure control solenoid valve “B” for resistance. 116) 117)
(Page 5A-120)
Is check result OK?

5 Pressure control solenoid valve “B” check for operation Go to Step 5. Replace valve body
1) Check pressure control solenoid valve “B” for operation. assembly. (Page 5A-
(Page 5A-120) 117)
Is check result OK?

or gear etc.)
2) Check DTC.
If OK, substitute a
5A-121)
DTC P0796 / P0797

AENFL80B5104041
P0796: Pressure Control Solenoid “C” Performance / Stuck Off • Pressure control solenoid valve “C” and/
P0797: Pressure Control Solenoid “C” Stuck On
The gear commanded by TCM does not match the actual gear when • TCM
driving.
Circuit Diagram
1
3
4
12V
2
A1
C06-4 GRY/RED C139-4
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510023-02
[A]: TCM connector (View: [a]) 2. Pressure control solenoid valve “C”
A1: Pressure control solenoid valve “C” drive circuit (+) 3. A/T
A2: Pressure control solenoid valve “C” drive circuit (–) 4. Solenoid connector
1. TCM
! WARNING

P0796
NOTE
Procedure”.
P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738,

P0797
NOTE
Procedure”.
• Check that the following conditions are satisfied in this procedure
P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1736, P1737, P1738, P1739,
2) Drive vehicle with 3rd gear for 1 min.
DTC Troubleshooting
Step Action Yes No
5A-13).
2 Pressure control solenoid valve “C” drive circuit check Go to Step 3. Repair or replace
1) Check pressure control solenoid valve “C” circuit (+) and defective wire harness.
(–). (Page 5A-81)
Is check result OK?

Step Action Yes No

3 Pressure control solenoid valve “C” circuit check Go to Step 5. Go to Step 4.
1) Check pressure control solenoid valve “C” circuit.
(Page 5A-120)
Is check result OK?

4 Pressure control solenoid valve “C” check for Replace solenoid Replace valve body
1) Check pressure control solenoid valve “C” for resistance. 116) 117)
(Page 5A-120)
Is check result OK?

5 Pressure control solenoid valve “C” check for operation Go to Step 6. Replace valve body
1) Check pressure control solenoid valve “C” for operation. assembly. (Page 5A-
(Page 5A-120) 117)
Is check result OK?

or gear etc.)
2) Check DTC.
If OK, substitute a
Is DTC P0796 / P0797 still indicated? known-good TCM and
5A-121)
DTC P0961
AENFL80B5104042
P0961: Pressure Control Solenoid “A” Control Circuit • Pressure control solenoid valve “A” and/or its circuit
Range / Performance • TCM
Difference between target electric current and measured
current of pressure control solenoid valve “A” drive circuit (+)
is more than specified value for 3 sec.
Circuit Diagram
1
3
4
12V A1 2
C06-22 RED C139-6
C06-9 BLK C139-13
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510024-02

A2: Pressure control solenoid valve “A” drive circuit (–) 3. A/T
NOTE
Procedure”.
– 10.5 V < Battery voltage <15.5 V
P0797, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
DTC Troubleshooting
Step Action Yes No
5A-13).
1) With ignition “OFF”, disconnect “C139” and “C06” defective wire harness.
connectors.
Is check result OK?

3 Pressure control solenoid valve “A” circuit check Substitute a known- Go to Step 4.
1) Check resistance of pressure control solenoid valve “A” good TCM and recheck
circuit. (Page 5A-120) DTC. (Page 5A-121)
Is check result OK?

4 Pressure control solenoid valve “A” check Replace solenoid Replace valve body
1) Check pressure control solenoid valve “A”. (Page 5A- harness. (Page 5A- assembly. (Page 5A-
120) 116) 117)
Is check result OK?
DTC P0962
AENFL80B5104043
P0962: Pressure Control Solenoid “A” Control Circuit Low • Pressure control solenoid valve “A” and/or its
Measured electric current of pressure control solenoid valve “A” circuit
drive circuit (+) is lower than specified value. • TCM
Circuit Diagram
1
3
4
12V A1 2
C06-22 RED C139-6
C06-9 BLK C139-13
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510024-02

NOTE
Procedure”.
P0797, P0961, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
DTC Troubleshooting
Step Action Yes No
5A-13).
connectors.
Is check result OK?

Is check result OK?

Step Action Yes No

120) 116) 117)
Is check result OK?
DTC P0963
AENFL80B5104044
P0963: Pressure Control Solenoid “A” Control Circuit High • Pressure control solenoid valve “A” and/or its
Measured electric current of pressure control solenoid valve “A” circuit
drive circuit (+) is higher than specified value. • TCM
Circuit Diagram
1 3
4
12V A1 2
C06-22 RED C139-6
C06-9 BLK C139-13
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510024-02

NOTE
Procedure”.
P0797, P0961, P0962, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
DTC Troubleshooting
Step Action Yes No
5A-13).
Step Action Yes No

connectors.
Is check result OK?

Is check result OK?

120) 116) 117)
Is check result OK?
DTC P0965
AENFL80B5104045
P0965: Pressure Control Solenoid “B” Control Circuit Range / • Pressure control solenoid valve “B” and/
Performance or its circuit
Difference between target electric current and measured current of • TCM
pressure control solenoid valve “B” drive circuit (+) is more than
Circuit Diagram
1
3
4
12V
2
A1
C06-21 BLK/YEL C139-5
A2
C06-19 BLU/BLK C139-12
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510022-02
1. TCM
NOTE
Procedure”.
P0797, P0961, P0962, P0963, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
DTC Troubleshooting
Step Action Yes No
5A-13).
connectors.
Is check result OK?

3 Pressure control solenoid valve “B” circuit check Substitute a known- Go to Step 4.
1) Check resistance of pressure control solenoid valve “B” good TCM and recheck
Is check result OK?

4 Pressure control solenoid valve check Replace solenoid Replace valve body
1) Check pressure control solenoid valve “B”. (Page 5A- harness. (Page 5A- assembly. (Page 5A-
120) 116) 117)
Is check result OK?
DTC P0966
AENFL80B5104046
P0966: Pressure Control Solenoid “B” Control Circuit Low • Pressure control solenoid valve “B” and/
Measured electric current of pressure control solenoid valve “B” drive or its circuit
circuit (+) is lower than specified value. • TCM
Circuit Diagram
1 3
4
12V
2
A1
C06-21 BLK/YEL C139-5
A2
C06-19 BLU/BLK C139-12
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510022-02
1. TCM
NOTE
Procedure”.
P0797, P0961, P0962, P0963, P0965, P0967, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
DTC Troubleshooting
Step Action Yes No
5A-13).
connectors.
Is check result OK?

Is check result OK?

Step Action Yes No

120) 116) 117)
Is check result OK?
DTC P0967
AENFL80B5104047
P0967: Pressure Control Solenoid “B” Control Circuit High • Pressure control solenoid valve “B” and/
Measured electric current of pressure control solenoid valve “B” drive or its circuit
circuit (+) is higher than specified value. • TCM
Circuit Diagram
1 3
4
12V
2
A1
C06-21 BLK/YEL C139-5
A2
C06-19 BLU/BLK C139-12
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510022-02
1. TCM
NOTE
Procedure”.
• Check that the following conditions are satisfied in this procedure
P0797, P0961, P0962, P0963, P0965, P0966, P0969, P0970, P0971, P0973, P0974, P1702, P1736,
DTC Troubleshooting
Step Action Yes No
5A-13).
Step Action Yes No

connectors.
Is check result OK?

Is check result OK?

120) 116) 117)
Is check result OK?
DTC P0969
AENFL80B5104048
P0969: Pressure Control Solenoid “C” Control Circuit Range / • Pressure control solenoid valve “C” and/
Performance or its circuit
Difference between target electric current and measured current of • TCM
pressure control solenoid valve “C” drive circuit (+) is more than
Circuit Diagram
1 3
4
12V
2
A1
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510023-02
1. TCM
! WARNING

NOTE
Procedure”.
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0970, P0971, P0973, P0974, P1702, P1736,
1) Drive vehicle in D range at 2nd for 10 sec.

2) Drive vehicle in D range at 4th for 10 sec.
DTC Troubleshooting
Step Action Yes No
5A-13).
connectors.
Is check result OK?

3 Pressure control solenoid valve “C” circuit check Substitute a known- Go to Step 4.
1) Check resistance of pressure control solenoid valve “C” good TCM and recheck
Is check result OK?

1) Check pressure control solenoid valve “C”. (Page 5A- harness. (Page 5A- assembly. (Page 5A-
120) 116) 117)
Is check result OK?

DTC P0970
AENFL80B5104049
P0970: Pressure Control Solenoid “C” Control Circuit Low • Pressure control solenoid valve “C” and/
Measured electric current of pressure control solenoid valve “C” drive or its circuit
circuit (+) is higher than specified value. • TCM
Circuit Diagram
1 3
4
12V
2
A1
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510023-02
1. TCM
NOTE
Procedure”.
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0971, P0973, P0974, P1702, P1736,
DTC Troubleshooting
Step Action Yes No
5A-13).
Step Action Yes No

connectors.
Is check result OK?

Is check result OK?

120) 116) 117)
Is check result OK?
DTC P0971
AENFL80B5104050
P0971: Pressure Control Solenoid “C” Control Circuit High • Pressure control solenoid valve “C” and/
Measured electric current of pressure control solenoid valve “C” drive or its circuit
circuit (+) is lower than specified value. • TCM
Circuit Diagram
1 3
4
12V
2
A1
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510023-02
1. TCM
NOTE
Procedure”.
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0973, P0974, P1702, P1736,
DTC Troubleshooting
Step Action Yes No
5A-13).
connectors.
Is check result OK?

Is check result OK?

120) 116) 117)
Is check result OK?
DTC P0973
AENFL80B5104051
P0973: Shift Solenoid “A” Control Circuit Low • Shift solenoid valve “A” and/or its circuit
Shift solenoid valve “A” drive circuit voltage is lower than • TCM
specified value even if shift solenoid valve “A” is turned on.
Circuit Diagram
1 3
4
12V
A1 2
C06-16 BRN C139-10
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510025-02

NOTE
Procedure”.
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0974, P1702, P1736,
DTC Troubleshooting
Step Action Yes No
5A-13).
connectors.
Is check result OK?

3 Shift solenoid valve “A” circuit check Substitute a known- Go to Step 4.
1) Check resistance of shift solenoid valve “A” circuit. good TCM and recheck
(Page 5A-120) DTC. (Page 5A-121)
Is check result OK?

4 Shift solenoid valve “A” check Replace solenoid Replace valve body
1) Check shift solenoid valve “A”. (Page 5A-120) harness. (Page 5A- assembly. (Page 5A-
116) 117)
Is check result OK?
DTC P0974
AENFL80B5104052
P0974: Shift Solenoid “A” Control Circuit High • Shift solenoid valve “A” and/or its circuit
Shift solenoid valve “A” drive circuit voltage is higher than • TCM
specified value even if shift solenoid valve “A” is turned off.
Circuit Diagram
1 3
4
12V
A1 2
C06-16 BRN C139-10
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510025-02

! WARNING

NOTE
Procedure”.
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P1702, P1736,
1) Drive vehicle at 15 km/h (9 mile/h) or more in D range for 10 sec.
DTC Troubleshooting
Step Action Yes No
5A-13).
Step Action Yes No

connectors.
“ON”)
Is check result OK?

3 Shift solenoid valve “A” circuit check Substitute a known- Go to Step 4.
1) Check resistance of shift solenoid valve “A” circuit. good TCM and recheck
(Page 5A-120) DTC. (Page 5A-121)
Is check result OK?

4 Shift solenoid valve “A” check Replace solenoid Replace valve body
1) Check shift solenoid valve “A”. (Page 5A-120) harness. (Page 5A- assembly. (Page 5A-
116) 117)
Is check result OK?
DTC P1706
AENFL80B5104053
P1706: Torque Request Communication Error from TCM • TCM
ECM detects abnormality of CAN communication data which TCM transmits. • ECM
(1 D/C detection logic but transmission warning light and MIL do not light up)
NOTE
Procedure”.
– TCM: DTC U0073, U0100 is not detected.
1) Start engine at idle for 30 sec.
DTC Troubleshooting
Step Action Yes No
troubleshooting.
Is there any DTC(s) other than P1706?
2 DTC check of ECM Go to applicable DTC Substitute a known-
1) Check DTC of ECM. (Page 1A-16) troubleshooting. good TCM and recheck
DTC P1736
AENFL80B5104054
P1736: Output Speed Sensor Circuit Low • Output shaft speed sensor and/or its circuit
Output shaft speed sensor signal circuit voltage is lower than • TCM
specified value.
Circuit Diagram
1
12V
A1
2
PPL C07-14
GRY C07-5
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510018-01
NOTE
DTC Troubleshooting
Step Action Yes No
5A-13).
connector.
battery voltage.
Is check result OK?

Step Action Yes No

3 Output shaft speed sensor signal circuit check Go to Step 4. Repair or replace
connector.
Is check result OK?

4 Output shaft speed sensor check Check for intermittent Replace output shaft
1) Check output shaft speed sensor. (Page 5A-113) trouble.  speed sensor. (Page
Is check result OK? known-good TCM and
5A-121)
DTC P1737
AENFL80B5104055
P1737: Output Speed Sensor Circuit High • Output shaft speed sensor and/or its circuit
Output shaft speed sensor signal circuit voltage is higher • TCM
than specified value.
Circuit Diagram
1
12V
A1
2
PPL C07-14
GRY C07-5
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510018-01
NOTE

DTC Troubleshooting
Step Action Yes No
5A-13).
connector.
Is check result OK?

3 Output shaft speed sensor check Check for intermittent Replace output shaft
1) Check output shaft speed sensor. (Page 5A-113) trouble.  speed sensor. (Page
Is check result OK?
known-good TCM and
5A-121)
DTC P1738
AENFL80B5104056
P1738: Input/Turbine Speed Sensor “A” Circuit Low • Input shaft speed sensor and/or its circuit
Input shaft speed sensor signal circuit voltage is higher than • TCM
specified value.
Circuit Diagram
1
12V
2 A1
C44-1 WHT C07-16

C44-2 BLK C07-6
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510017-03
NOTE
10.2 V < Battery voltage <15.5 V

DTC Troubleshooting
Step Action Yes No
5A-13).
connector.
battery voltage.
Is check result OK?

3 Input shaft speed sensor signal circuit check Go to Step 4. Repair or replace
connector.
Is check result OK?

4 Input shaft speed sensor check Check for intermittent Replace input shaft
1) Check input shaft speed sensor. (Page 5A-114) trouble.  speed sensor. (Page
Is check result OK? known-good TCM and
5A-121)
DTC P1739
AENFL80B5104057
P1739: Input/Turbine Speed Sensor “A” Circuit High • Input shaft speed sensor and/or its circuit
Input shaft speed sensor signal circuit voltage is lower than • TCM
specified value.
Circuit Diagram
1
12V
2 A1
C44-1 WHT C07-16

C44-2 BLK C07-6
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510017-03
NOTE
DTC Troubleshooting
Step Action Yes No
5A-13).
connector.
“ON”)
Is check result OK?

3 Input shaft speed sensor check Check for intermittent Replace input shaft
1) Check input shaft speed sensor. (Page 5A-114) trouble.  speed sensor. (Page
Is check result OK?
known-good TCM and
5A-121)
DTC P2762
AENFL80B5104058
P2762: Torque Converter Clutch Pressure Control • TCC solenoid valve and/or its circuit
Solenoid Control Circuit Range / Performance • TCM
Difference between target electric current and measured
current of TCC solenoid valve drive circuit (+) is more than
Circuit Diagram
1 3
4
12V
2
A1
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510020-04

A1: TCC solenoid valve drive circuit (+) 2. TCC solenoid valve
A2: TCC solenoid valve drive circuit (–) 3. A/T
NOTE
Procedure”.
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702,

DTC Troubleshooting
Step Action Yes No
5A-13).
connectors.
Is check result OK?

3 TCC solenoid valve circuit check Substitute a known- Go to Step 4.
1) Check resistance of TCC solenoid valve circuit. (Page good TCM and recheck
5A-120) DTC. (Page 5A-121)
Is check result OK?

4 TCC solenoid valve check Replace solenoid Replace valve body
1) Check TCC solenoid valve. (Page 5A-120) harness. (Page 5A- assembly. (Page 5A-
116) 117)
Is check result OK?
DTC P2763
AENFL80B5104059
P2763: Torque Converter Clutch Pressure Control • TCC solenoid valve and/or its circuit
Solenoid Control Circuit High • TCM
Output voltage of TCC solenoid valve control circuit (+) is
higher than specified value.
Circuit Diagram
1 3
4
12V
2
A1
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510020-04

NOTE
Procedure”.
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702,
DTC Troubleshooting
Step Action Yes No
5A-13).
Step Action Yes No

connectors.
Is check result OK?

5A-120) DTC. (Page 5A-121)
Is check result OK?

4 TCC solenoid valve check Replace solenoid Replace TCC solenoid
1) Check TCC solenoid valve. (Page 5A-120) harness. (Page 5A- valve. (Page 5A-117)
116)
Is check result OK?
DTC P2764
AENFL80B5104060
P2764: Torque Converter Clutch Circuit Pressure • TCC solenoid valve and/or its circuit
Control Solenoid Control Circuit Low • TCM
Measured electric current of TCC solenoid valve drive circuit
(+) is lower than specified value.
Circuit Diagram
1 3
4
12V
2
A1
A2
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510020-04

NOTE
Procedure”.
P0797, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P1702,
DTC Troubleshooting
Step Action Yes No
5A-13).
connectors.
Is check result OK?

5A-120) DTC. (Page 5A-121)
Is check result OK?

4 TCC solenoid valve check Replace solenoid Replace valve body
1) Check TCC solenoid valve. (Page 5A-120) harness. (Page 5A- assembly. (Page 5A-
116) 117)
Is check result OK?
DTC U0073
AENFL80B5104061
Refer to “CAN DTC (Lost Communication and Communication Bus Off) Table”: Petrol and Bi-Fuel CNG Model in
Section 10H (Page 10H-10).
DTC U0100
AENFL80B5104062
Refer to “CAN DTC (Lost Communication and Communication Bus Off) Table”: Petrol and Bi-Fuel CNG Model in
Section 10H (Page 10H-10).
Inspection of TCM and Its Circuits

AENFL80B5104063
TCM and its circuits can be checked at TCM wiring connectors by measuring voltage, pulse signal and resistance.
! CAUTION
TCM cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to TCM with
connector disconnected from it.
1) Remove TCM (1) from vehicle. (Page 5A-121)

2) Connect TCM connectors (2) to TCM.
3) Check voltage and/or pulse signal using voltmeter (3) and oscilloscope (4).
NOTE
• As each terminal voltage is affected by battery voltage, check that it is 12 V or more when ignition is
“ON”.
• Voltage with asterisk(*) cannot be measured by voltmeter because it is pulse signal. Check it with
oscilloscope if necessary.
[A] [B]
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
[a]
2
I8C50B510028-01
[A]: TCM connector “C06” (View: [a]) [B]: TCM connector “C07” (View: [a])
Connector “C06”
Terminal Normal
Wire color Circuit Condition
No. voltage
C06-1 BLK Ground circuit Approx. 0 V Constantly
LT GRN/ Pressure control solenoid valve “C” drive
C06-2 Approx. 0 V Constantly
BLK circuit (–)
C06-3 WHT/BLK TCC solenoid valve drive circuit (–) Approx. 0 V Constantly
Pressure control solenoid valve “C” drive
C06-4* GRY/RED “Pressure Control Solenoid Valve “A”, “B”, “C” and
circuit (+)
TCC Solenoid Valve Signal” (Page 5A-100)
C06-5* WHT/BLU TCC solenoid valve drive circuit (+) “Pressure Control Solenoid Valve “A”, “B”, “C” and
C06-6 YEL/BLK Main power supply circuit 10 to 14 V Constantly
C06-7* WHT CAN communication line (Low) circuit
“CAN Communication Signal” (Page 5A-101)
C06-8 — — — —
Pressure control solenoid valve “A” drive
C06-9 BLK Approx. 0 V Constantly
circuit (–)
C06-10 — — — —
Ignition: “ON”
2.9 to 3.1 V
ATF temperature: 20 °C (68 °F)
C06-11 LT GRN ATF temperature sensor signal circuit
Ignition: “ON”
0.3 to 0.5 V
ATF temperature: 100 °C (212 °F)
Terminal Normal
No. voltage
C06-12 BEG ATF temperature sensor ground circuit Approx. 0 V Constantly
C06-13 — — — —
C06-14 — — — —
C06-15 — — — —
Ignition: “ON”
C06-16 BRN Shift solenoid valve “A” circuit 9.5 to 14 V
Select lever position: P range
C06-17* RED CAN communication line (High) circuit
“CAN Communication Signal” (Page 5A-101)
C06-18 — — — —
Pressure control solenoid valve “B” drive
C06-19 BLU/BLK Approx. 0 V Constantly
circuit (–)
C06-20 — — — —
Pressure control solenoid valve “B” drive
C06-21* BLK/YEL “Pressure Control Solenoid Valve “A”, “B”, “C” and
circuit (+)
Pressure control solenoid valve “A” drive
C06-22* RED “Pressure Control Solenoid Valve “A”, “B”, “C” and
circuit (+)
C06-23 BLK Ground circuit Approx. 0 V Constantly
LT GRN/ 10 to 14 V Ignition: “ON”
C06-24 Ignition ON signal circuit
BLK Approx. 0 V Other than above condition
Connector “C07”
Terminal Normal
No. voltage
Ignition: “ON”
Transmission range sensor (R range) 8.4 to 14 V
C07-1 RED Select lever position: R range
circuit
Approx. 0 V Other than above condition
C07-2 — — — —
C07-3 — — — —
C07-4 — — — —
C07-5* GRY Output shaft speed sensor signal circuit “Output Shaft Speed Sensor Signal” (Page 5A-
101)
C07-6* BLK Input shaft speed sensor signal circuit
“Input Shaft Speed Sensor Signal” (Page 5A-101)
Ignition: “ON”
Transmission range sensor (D range) 8.4 to 14 V
C07-7 BLU Select lever position: D range
circuit
Ignition: “ON”
Transmission range sensor (N range) 8.4 to 14 V
C07-8 BEG Select lever position: N range
circuit
C07-9 — — — —
C07-10 — — — —
C07-11 — — — —
C07-12 — — — —
C07-13 — — — —
Output shaft speed sensor power supply 8.4 to 14 V Ignition: “ON”
C07-14 PPL
circuit Approx. 0 V Ignition: 5 sec. after ignition “OFF”
C07-15 — — — —
Input shaft speed sensor power supply 8.4 to 14 V Ignition: “ON”
C07-16 WHT
circuit Approx. 0 V Ignition: 5 sec. after ignition “OFF”
C07-17 — — — —
Ignition: “ON”
LT GRN/ Transmission range sensor (L range) 8.4 to 14 V
C07-18 Select lever position: L range
BLK circuit
Terminal Normal
No. voltage
Ignition: “ON”
Transmission range sensor (2 range) 8.4 to 14 V
C07-19 GRN/YEL Select lever position: 2 range
circuit
Ignition: “ON”
Transmission range sensor (P range) 8.4 to 14 V
C07-20 PNK/BLK Select lever position: P range
circuit
Ignition: “ON”
8.4 to 14 V
O/D off switch: Released
C07-21 GRN O/D off switch signal circuit
Ignition: “ON”
Approx. 0 V
O/D off switch: Pushed
C07-22 — — — —
C07-23 — — — —
C07-24 — — — —
C07-25 — — — —
C07-26 — — — —
Reference Waveform Pressure control solenoid valve “B” signal (3):

NOTE + C06-21
3
• How to read waveforms is shown below. – C06-1
Pressure control solenoid valve “A” signal (4):

+ C06-22
4
– C06-1
• Select lever position: P range
I8T401111066-01


Pressure Control Solenoid Valve “A”, “B”, “C” and ICL80C510026-01
TCC Solenoid Valve Signal

Pressure control solenoid valve “C” signal (1): • Engine: Idle speed after warming up
Channel Probe Terminal No. • Select lever position: L range
+ C06-4
1
– C06-1
TCC solenoid valve signal (2):

+ C06-5
2
– C06-1
ICL80C510028-01
ICL80C510027-01
CAN Communication Signal Input Shaft Speed Sensor Signal

CAN communication signal (Low) (1): + C07-6
1
Channel Probe Terminal No. – C06-1
+ C06-7
2 Measurement condition
– C06-1
CAN communication signal (High) (2): • Select lever position: P range
+ C06-17
1
– C06-1
• Engine: Stop
ICL80C510029-01
I9P60A510016-01
Output Shaft Speed Sensor Signal

+ C07-5
1
– C06-1
• Vehicle: Drive vehicle at 40 km/h (25 mile/h)
TCM Power and Ground Circuit Check

AENFL80B5104064
Circuit Diagram
1
A1
2
C06-6 YEL/BLK
A2
3
C06-24 LT GRN/BLK
4
B1
C06-1 BLK
B2
C06-23 BLK
[A]
[a]
C06 C07
6 5 4 3 2 1 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8 7
24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18
ICL80C510015-01
[A]: TCM connector (View: [a]) A3: Ground circuit 2. “AT” fuse 5. Main fuse box
A1: Main power supply circuit A4: Ground circuit 3. “IG1 SIG” fuse
A2: Ignition ON signal circuit 1. TCM 4. Ignition switch
Troubleshooting
Step Action Yes No
1 Main power supply circuit check Go to Step 2. Repair or replace
1) Set ignition “OFF” and disconnect connectors from TCM. defective wire harness.
2) Check for proper terminal connection to TCM
connectors.
3) If connections are OK, check that voltage between main
power supply circuit (A1) and ground is battery voltage.
Is check result OK?

2 Ignition ON signal circuit check Go to Step 3. Repair or replace
3) Check that voltage between Ignition ON signal circuit
(A2) and ground is battery voltage.
Is check result OK?

3 TCM ground circuit check TCM power supply and Repair or replace
1) Set ignition “OFF”. ground circuits are in defective wire harness.
good condition.
2) Check that resistance between each TCM ground circuit
1 (B1) and ground circuit 2 (B2) and ground is less than
1 Ω.
Is check result OK?

Repair Instructions
TCM Learning Control Initialization NOTE
AENFL80B5106001
! CAUTION • Perform ATF level check before checking
any service on A/T.
When TCM or A/T unit is replaced, initialize
• Do not replenish or drain ATF before each
learning control.
test.
1) With ignition “OFF”, connect SUZUKI scan tool to Level Check at Normal Operating (Hot) Temperature
DLC (1). – Hot Check
Special tool 1) Drive vehicle so that ATF temperature reaches
(A): SUZUKI scan tool (SUZUKI-SDT) normal operating temperature (70 to 80 °C (158 to
176 °F)).
NOTE
Engine coolant temperature can be raised by
racing engine in P or N range, but ATF
temperature cannot be raised in P or N range.
(A) Drive vehicle to raise ATF temperature.
2) Stop vehicle on a level place with engine running.

1
3) With select lever in P range, apply parking brake and
block wheels.
4) Connect SUZUKI scan tool to DLC and confirm “ATF
Temperature” is 70 to 80 °C (158 to 176 °F).
5) Keep engine idling, depress brake pedal fully and
shift select lever slowly to L and back to P range.
ICL80C510009-01
6) With engine idling and A/C switch turned off, pull out
2) Display “Data List” mode on SUZUKI scan tool. fluid level gauge (1), wipe it off with clean paper
3) Drive vehicle until A/T fluid temperature reaches towel and put it back into place.
normal operating temperature (65 to 110 °C (149 to 7) Pull out fluid level gauge (1) again and check fluid
230 °F)). level indicated on it. Lowest fluid level should be
4) Stop vehicle with engine running and apply parking between “FULL HOT” (2) and “LOW HOT” (3). If it is
brake. below “LOW HOT”, add specified ATF up to “FULL
5) Depress brake pedal fully. HOT”.
6) Shift select lever to N range, and wait for 3 sec. ATF specification
7) Shift select lever to D range, and wait for 3 sec. : SUZUKI ATF AW-1
8) Repeat Step 6) through 7) 4 times. NOTE
9) Shift select lever to N range, and wait for 3 sec.
• Do not race engine while checking fluid
10) Shift select lever to R range, and wait for 3 sec. level, even after engine start.
11) Repeat Step 9) through 10) 4 times. • Do not overfill. Overfilling can cause
12) Open throttle 25 to 35% and accelerate vehicle to 80 foaming and loss of fluid through breather.
km/h (50 mile/h). Then slippage and transaxle failure can
13) Release accelerator pedal, and keep vehicle result.
coasting for 60 sec. in engine braking condition. • Bringing level from “LOW HOT” to “FULL
14) Repeat Step 12) through 13) 9 times. HOT” requires 0.4 liters (0.85 / 0.70 US/Imp.
pt).
ATF Level Check • If vehicle was driven under high load such
AENFL80B5106002 as pulling trailer, fluid level should be
! CAUTION checked about half an hour after it is
Do not use any fluid other than specified ATF. stopped.
Use of any other fluid may cause juddering or • Check lower position of fluid on both sides
some other faulty condition to occur. of level gauge.
ATF Change
AENFL80B5106003
1 ! WARNING
Spilling the ATF on the exhaust system
components may cause fire and personal
injury.
When changing the ATF, observe the
following precautions.
• Check the engine is at a stop.
• Do not carry out the ATF filling operation
over the exhaust system components so
as not to adhere the ATF on the exhaust
5 4 3 2 1
system components even if you spill the
ATF.
ICL80C510030-01
• Be sure to remove the ATF on the exhaust
4. “FULL COLD” mark 5. “LOW COLD” mark system components thoroughly after the
exhaust manifold cools down if you spill
Level Check at Room (Cold) Temperature – Cold the ATF on the exhaust system
Check components.
Fluid level can be checked temporarily at room (cold)
temperature which corresponds to 20 to 30 °C (68 to 86 ! CAUTION
°F). This level check is considered as preparation before
performing level check under normal operating (hot) Do not use any fluid other than specified ATF.
temperature. Checking procedure itself is the same as Use of any other fluid may cause juddering or
that described in “Level Check at Normal Operating some other faulty condition to occur.
(Hot) Temperature – Hot Check” (Page 5A-103). If fluid
level is between “FULL COLD” (4) and “LOW COLD” (5), 1) Hoist vehicle.
proceed to test drive. And when ATF temperature has 2) Remove left side engine undercover.
reached 70 to 80 °C (158 to 176 °F), check fluid level 3) When engine is cool, remove ATF drain plug (1) from
again and adjust it if necessary. A/T oil pan (2) and drain ATF.
! CAUTION NOTE
Fluid level check at room (cold) temperature ATF does not drain completely from drain
is recommended only for preparation of level plug.
check under normal (hot) operating
condition. 4) Install ATF drain plug (1) with new gasket (3) and
Failure to perform fluid level check under then tighten it to specified torque.
normal (hot) operating temperature may
Tightening torque
result in damage to transaxle.
ATF drain plug (a): 17 N·m (1.7 kgf-m, 12.5 lbf-ft)
1 3
2
1, (a)
ICL80C510031-01
5 4 3 2 1
5) Install left side engine undercover.
6) Lower vehicle and replenish proper amount of
specified ATF.
ICL80C510030-01
7) Check fluid level. (Page 5A-103)
1. Fluid level gauge 2. “FULL HOT” mark 3. “LOW HOT” mark
ATF specification
: SUZUKI ATF AW-1
ATF capacity 2) Disconnect adjuster case (select cable end) from

When draining from drain plug hole: 2.7 liters select lever assembly. (Page 5A-107)
(5.71 / 4.75 US/Imp. pt.) 3) Disconnect key interlock cable end and detach cable
When overhauling: 5.0 liters (10.57 / 8.80 US/Imp. casing cap from select lever assembly (ignition
pt.) switch model). (Page 5A-110)
4) Disconnect select lever connector.
5) Remove select lever assembly from floor panel after
1
removing nuts.
Installation
• Tighten select lever nuts to specified torque. (Page
5A-105)
• After installing select lever assembly, adjust select
cable. (Page 5A-108)
5 4 3 2 1 Select Lever Assembly Inspection

AENFL80B5106006
Check select lever for smooth and clear-cut movement
ICL80C510030-01 respectively. Replace select lever assembly if
1. Fluid level gauge 3. “LOW HOT” mark 5. “LOW COLD” mark malfunction is found. (Page 5A-105)
2. “FULL HOT” mark 4. “FULL COLD” mark
O/D Off Switch Inspection
AENFL80B5106007
Select Lever Assembly Components
AENFL80B5106004 1) Remove console box. (Page 9H-7)
2) Disconnect select lever connector.
3) Check for continuity between terminals “3” and “8” of
select lever connector (1).
2 If check result is not as specified, replace select
4 lever assembly.
O/D off switch specification
Condition Specification
With O/D off switch (2) pressed Continuity
(a)
exists
With O/D off switch (2) released No continuity
exists
(a)
ICL80C510032-01
1. Shift lock solenoid 4. O/D off switch

2. Select lever assembly : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
3. Select lever connector
Select Lever Assembly Removal and

Installation
AENFL80B5106005
Removal
1) Remove center console box. (Page 9H-7)
5 4 3 2 1
10 9 8 7 6
1 5 4 3 2 1
10 9 8 7 6
ICP50A510007-01
ICP50A510005-01
Manual Release of Shift Lock
AENFL80B5106009
Shift Lock Solenoid Inspection 1) Set ignition switch to ACC.
AENFL80B5106008
! CAUTION 2) Open cap (1) at select lever assembly using a flat-
bladed screwdriver.
Reverse connection of the polarity may
damage the shift lock solenoid.
1) Remove console box. (Page 9H-7)

2) Disconnect select lever connector (1).
3) Check that shift lock solenoid rod moves smoothly
and returns when positive terminal of battery is
connected to terminal “5” and negative terminal of
battery is connected to terminal “10”.
Replace select lever assembly, if solenoid rod does 1
not move smoothly.
ICP50A510008-01
3) While pushing down shift lock solenoid release plate

(1) at inside of cap using a flat-bladed screwdriver
(2), press the select lever button (3). Check that
select lever (4) can be shifted to other than P range.
If faulty condition is found, replace select lever
assembly.
4
3
1
ICP50A510009-01
Select Cable Components

AENFL80B5106010
8 11
9 A
10
(d)
(c) (b)
(a)
(a)
3
A
ICL80C510033-02
1. Select lever assembly 6. Select cable clip 11. Lock

: Insert clip so that the claw is positioned toward
the vehicle upside.
2. Select cable 7. Manual select lever pin : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: After completing installation, adjust select : Apply lithium grease 99000-25011
cable. (Page 5A-108)
3. Clip 8. Casing cap : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
: Check that claw of the casing cap fit completely
to the select lever assembly.
4. Select cable bracket 9. Select lever pin : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
: Apply lithium grease 99000-25011
5. Manual select lever 10. Adjuster case : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
Select Cable Removal and Installation 8) Check that needle direction shaped on manual
AENFL80B5106011 select lever (2) and N reference line (1) on
transmission range sensor are aligned.
Removal
1) Disconnect select cable from select lever assembly
and then detach from bracket. (Page 5A-105)
2) Remove select cable clip and disconnect select
cable from manual select lever.
1
3) Remove select cable from dash panel.
2
Installation
Reverse removal procedure noting the following.
• Apply grease to pin and cable joint. (Page 5A-107)
• Use new clip.
• Tighten bolts and nuts to specified torque. (Page ICL80C510034-01
5A-107) 9) Apply grease to select lever pin (1), and then install
• Adjust select cable. (Page 5A-108) adjuster case (2) into select lever pin securely.
Select Cable Adjustment Grease A)
AENFL80B5106012
1) Apply parking brake and block wheels. 10) Push lock piece (3) in arrow direction [a] as shown in
2) Set ignition “ON”, shift select lever to N range. figure.
3) Remove console box. (Page 9H-7) 11) Slide lock plate (4) in arrow direction [b] as shown in
4) Remove adjuster case (cable end) from select lever figure until it gets over the claw (5).
pin of select lever assembly. (Page 5A-107)
5) Release lock plate (1) which restricts moving of lock
piece (2).
6) Pull out lock piece (2) from adjuster case (3) using
pliers to disengage cable. 1, “A”
2 5 4
[b]
3 3 [a] 4
1
I9P60A510030-02
2
12) After installing select cable, check the following.
• Perform “P Range Test” (Page 5A-40).
• Check back-up light turns ON when shifting select
lever to R range.
• Check shift position indicated information display
is consistent with select lever range.
3 2
• Check engine can start in P and N ranges and
cannot start in other ranges.
I8C50B510062-01
7) Shift select lever to N range.

Transmission Range Sensor Removal and ! CAUTION

Installation
AENFL80B5106013 Do not reuse transmission range sensor.
Removal Reusing of transmission range sensor may
1) Disconnect negative (–) cable at battery. affect the performance of A/T system.
2) Remove select cable clip and disconnect select
• Adjust select cable. (Page 5A-108)
cable from manual select lever. (Page 5A-107)
• Tighten transmission range sensor mounting bolts
3) Shift manual select lever (1) to N position.
and manual select lever nut to specified torque.
“R” “N”
“D” “2” Tightening torque
“L”
“P” Transmission range sensor bolt (a): 5.4 N·m (0.55
kgf-m, 4.0 lbf-ft)
Manual select lever nut (b): 12 N·m (1.2 kgf-m, 9.0
lbf-ft)
(a)
ICL80C510035-01
4) Disconnect transmission range sensor connector

(1).
(a)
(b)
ICL80C510038-01
1
Transmission Range Sensor Inspection and

Adjustment
AENFL80B5106014
1) Apply parking brake and block wheels.
2) With ignition “ON”, shift select lever to N range.
3) Check that needle direction shaped (2) on manual
ICL80C510036-01 select lever (2) and N reference line (1) on
5) Remove manual select lever nut (1) and manual transmission range sensor are aligned. If not, loosen
select lever (2). sensor bolts (3) and align them.
6) Remove transmission range sensor mounting bolts 4) Tighten sensor bolts to specified torque.
(3) and transmission range sensor (4). Tightening torque
Transmission range sensor bolt (a): 5.4 N·m (
0.55 kgf-m, 4.0 lbf-ft)
3, (a)
4
3
1 2 4
ICL80C510037-01
Installation
Reverse removal procedure noting the following points. 3, (a)
ICL80C510039-01
5) Check that engine can start with select lever in N or

P ranges but not D, 2, L or R range. Also, check that
back-up light lights in R range.
If faulty condition cannot be corrected by adjustment, 5) Remove console box. (Page 9H-7)
disconnect transmission range sensor connector 6) Detach cable end (1) from interlock cam (2) while
and check that continuity exists as shown by moving pressing claws (3) of interlock cam boss.
manual select lever. At this time, be careful not to cause damage to its
claws.
Detach cable casing cap (4) from selector bracket
4 3 2 1 (5) while pressing check hook.
9 8 7 6 5
7) Remove interlock cable.
1 2 3 4 5 6 7 8 9 2
4
P
1
D
3 4
2
L 5
I9P60A510070-01 I9P60A510034-03
6) Check transmission range sensor for the following.

• Vehicle should not move in P range even when
pushed.
• Check engine can start in P and N ranges, and
cannot start in other ranges.
• Check back-up light turns ON only when shifting
select lever to R range.
Key Interlock Cable Removal and Installation

AENFL80B5106015
NOTE
Do not bend interlock cable excessively
when removing and installing it, or system
will not operate correctly.
Removal
1) Remove steering column cover. (Page 6B-1)
2) Turn ignition switch to ACC position.
3) Pull out key interlock cable (1) from key cylinder
cover (2) while pressing check hook with a flat-
bladed screwdriver or the like (3).
3
I7V10A510031-02
4) Turn ignition switch to LOCK position.

Installation
1) Lay interlock cable to its original cabling route.
ICL80C510040-01
1. Key interlock cable 3. Steering lock assembly 5. Select cable

2. Clamp 4. Select lever assembly
2) Turn ignition switch to ACC position.

3) Insert cable casing cap (1) into key cylinder cover (2) securely.
I7V10A510033-02
4) Pull out lock button (1) of selector side cable end (2).
2
1
1
I2RH01510086-01
5) Shift select lever to N range.

6) Install cable casing cap (3) to selector bracket (4).
7) Connect cable end (1) to interlock cam (2) with ignition switch turned to ACC position.
8) Drive lock button (5) in cable end until it locks cable expansion and contraction.
4
1
4
I9P60A510036-03
9) Check key interlock cable (Ignition switch model). (Page 5A-112)

10) Install console box. (Page 9H-7)
11) Install steering column cover. (Page 6B-1)
Key Interlock Cable Inspection

AENFL80B5106016
3
1) Shift select lever to P range and set ignition switch to
ACC.
2) Open cap (1) at select lever assembly using a flat-
bladed screwdriver.
2
1
ICP50A510012-01
4) At the condition in Step 3), check that ignition switch

cannot be turned from ACC to LOCK position.
1
ICP50A510008-01
3) While pushing shift lock solenoid release plate (1) at

inside of cap using a flat-bladed screwdriver (2), I9P60A510071-01
press the select lever button (3). 5) Release the select lever button. Check that ignition
switch can be turned from ACC to LOCK position.
If faulty condition is found, adjust key interlock cable. Output Shaft Speed Sensor Inspection
(Page 5A-110) AENFL80B5106018
! CAUTION
Incorrect voltage and/or wrong connection
cause damage to output shaft speed sensor.
I9P60A510072-01
1) Check the following points:
• O-ring is free of damage.
Output Shaft Speed Sensor Removal and • End face of sensor is free of any metal particles
Installation and damage.
AENFL80B5106017
Removal 2) Set up measuring devices as shown in figure.
1) Disconnect negative (–) cable at battery. 3) Using ammeter, check that outlet shaft speed sensor
current is as specified below both when iron (5) is
2) Disconnect output shaft speed sensor connector.
brought in front of and away from output shaft speed
3) Remove output shaft speed sensor (1) by removing sensor.
its bolt. If current is not as specified, replace output shaft
speed sensor.
NOTE
Be sure to keep approximately 5 mm (0.2 in.)
gap “a” between magnetic substance (iron)
and end face of output shaft speed sensor.
Output shaft speed sensor current

Low current: 0.4 to 0.8 mA
High current: 1.2 to 1.6 mA
1
ICL80C510043-01
1
5
Installation
1) Apply ATF to output shaft speed sensor O-ring.
3
2) Install output shaft speed sensor (1) to A/T case and
“a”
tighten bolt to specified torque.
Tightening torque 2
Output shaft speed sensor bolt (a): 5.4 N·m (
0.55 kgf-m, 4.0 lbf-ft)
4
3) Connect output shaft speed sensor connector to
output shaft speed sensor (1). ICL80C510044-04
1. Output shaft speed sensor 3. Power supply (12 V)

2. Resistance (100 Ω) 4. Ammeter
Input Shaft Speed Sensor Removal and

Installation
AENFL80B5106019
Removal
2) Disconnect input shaft speed sensor connector.
3) Remove input shaft speed sensor (1) by removing its
bolt.
1
(a)
ICL80C510045-01

3) Using ammeter, check that outlet shaft speed sensor

1 current is as specified below both when iron (5) is
brought in front of and away from input shaft speed
sensor.
If current is not as specified, replace input shaft
speed sensor.
NOTE
Be sure to keep approximately 5 mm (0.2 in.)
gap “a” between magnetic substance (iron)
and end face of input shaft speed sensor.
Input shaft speed sensor current

Low current: 0.4 to 0.8 mA
ICL80C510041-01 High current: 1.2 to 1.6 mA
Installation
1) Apply ATF to input shaft speed sensor O-ring.
1
2) Install input shaft speed sensor (1) to A/T case and 5
tighten bolt to specified torque.
Tightening torque 3
Input shaft speed sensor bolt (a): 5.4 N·m (0.55 “a”
kgf-m, 4.0 lbf-ft)
3) Connect input shaft speed sensor connector to input 2
shaft speed sensor (1).
4
(a) 1
ICL80C510044-04
1. Input shaft speed sensor 3. Power supply (12 V)

2. Resistance (100 Ω) 4. Ammeter
A/T Oil Strainer Assembly Removal and

Installation
AENFL80B5106021
Removal
2) Hoist vehicle.
3) Remove left side engine undercover.
ICL80C510042-01
4) Drain A/T fluid. (Page 5A-104)
4) Connect negative (-) cable at battery. 5) Remove A/T oil pan (1) and oil pan gasket (2).
NOTE
Input Shaft Speed Sensor Inspection
AENFL80B5106020 When removing A/T oil pan, tap around it
lightly with plastic hammer. Do not force it off
! CAUTION using flat-bladed screwdriver or the like.
Incorrect voltage and/or wrong connection
cause damage to input shaft speed sensor. 6) Remove oil strainer assembly (3) and O-ring (4).
1) Check the following points:

• O-ring is free of damage.
• End face of sensor is free of any metal particles
and damage.
2) Set up measuring devices as shown in figure.
3 1
1
2 3
1 4
ICL80C510046-01 (a)
ICL80C510048-01
Installation • Replenish ATF. (Page 5A-104)

Reverse removal procedure noting the following points. • Check fluid level. (Page 5A-103)
• When overhauling A/T, replace oil strainer (1) and its • Check for fluid leakage after warming up A/T.
O-ring (2) with new one.
• Use new oil pan gasket (3) for A/T oil pan (4). A/T Oil Pan and Oil Strainer Assembly
• Tighten oil pan bolts to specified torque. Inspection
AENFL80B5106022
Tightening torque • Check that the oil cleaner magnets (1) are free from
Oil pan bolt (a): 7.0 N·m (0.71 kgf-m, 5.5 lbf-ft) metal particles. If not, clean.
• Check A/T oil pan (2) for crack, deformation, and
damage.
• Check oil strainer assembly for crack, deformation,
and damage.
ICL80C510049-01
ATF Temperature Sensor Removal and

Installation
AENFL80B5106023
Removal
2) Hoist vehicle.
3) Drain A/T fluid. (Page 5A-104)
4) Install ATF drain plug. (Page 5A-104)
5) Remove A/T oil pan and oil strainer assembly.
(Page 5A-114) (a)
6) Remove valve body assembly. (Page 5A-117)

7) Lower vehicle.
8) Remove battery tray, if necessary. 
9) Remove solenoid connector (1) with solenoid ICL80C510051-01
harness (2).
• For details of A/T oil pan installation, refer to “A/T Oil
! CAUTION Strainer Assembly Removal and Installation” (Page
5A-114).
When pulling solenoid harness out of Use new oil pan gasket.
transaxle case, take care not to damage ATF
• Apply ATF to new solenoid harness O-ring.
temperature sensor at narrow exit of case.
Careless sensor treatment might cause • Tighten solenoid connector bolt to specified torque.
sensor malfunction. Tightening torque
Solenoid connector bolt (a): 5.4 N·m (0.55 kgf-m,
4.0 lbf-ft)
1
(a)
ICL80C510050-02
ICL80C510052-01
• Replenish ATF and check fluid level. (Page 5A-104)

• Check for fluid leakage after warming up A/T.
ATF Temperature Sensor Inspection

AENFL80B5106024
1) Warm up ATF temperature sensor (2).
2) Check resistance between terminals of solenoid
2 connector (1). Make sure its resistance decreases
ICL80C510229-02 as its temperature increases.
If measured resistance is out of specified resistance,
Installation replace ATF temperature sensor.
ATF temperature sensor resistance
• For details of valve body assembly and solenoid valve 10 °C (50 °F): 5.63 – 7.30 kΩ
connectors installation, refer to “Valve Body Assembly 110 °C (230 °F): 224 – 271 Ω
Removal and Installation” (Page 5A-117). 145 °C (293 °F): 102 – 121 Ω
• Tighten ATF temperature sensor plate bolt to
specified torque.
Tightening torque
ATF temperature sensor plate bolt (a): 6.8 N·m (
0.69 kgf-m, 5.0 lbf-ft)
NOTE
There are two kinds of bolts (bolts A (1) and
B (2)) for fixing valve body assembly.
6 5 4 3 2 1
13 12 11 10 9 8 7
1
1
1
1 2
2
2 2
3
2
2
2
2
ICL80C510055-02
ICL80C510053-01
5) Remove valve body assembly (1).
3. ATF
Valve Body Assembly Removal and Installation

AENFL80B5106025
Removal
1) Remove A/T oil pan and oil strainer assembly.
(Page 5A-114)
2) Disconnect each connector (1) from solenoid valves.
3) Remove ATF temperature sensor (2).
1 1 1
1
1 ICL80C510056-01
6) Remove solenoid connector (1) with harness.
! CAUTION
2
When pulling solenoid harness (2) out of
transaxle case, take care not to damage ATF
temperature sensor at narrow exit of case.
Careless sensor treatment might cause
sensor malfunction.
ICL80C510054-01
4) Remove valve body assembly bolts.
! CAUTION
Be careful not to let manual valve fall off
when removing valve body assembly.
ICL80C510050-02
Accumulator O-ring dimension

Inside Section
O-ring name
diameter diameter
Large C3 accumulator 24.6 mm 2.62 mm
O-ring (1) (0.968 in.) (0.103 in.)
Small C3 accumulator 21.8 mm 2.62 mm
O-ring (2) (0.853 in.) (0.103 in.)
2) Install new O-rings to accumulator piston and apply

2 A/T fluid to them.
ICL80C510229-02
NOTE
7) Remove governor No.1 gasket (1).
Check that O-rings are not twisted or caught
1 when installing.
3) Install C3 accumulator piston and spring referring to

the following table.
Accumulator piston identification
Identification as
Piston name embossed letters on
piston
C3 accumulator piston (3) SC-3A
ICL80C510058-01
Accumulator spring identification
8) Remove C3 accumulator piston (1) and No.1 spring Color of
(2), position rag on piston to catch piston. To remove Spring name Length “a” identification
piston, force low-pressure compressed air (100 kPa, paint
1.0 kgf/cm2, 14.5 psi max) into hole (3) as shown in C3 accumulator No.1 65.40 mm
Yellow
figure, and pop piston into rag. spring (4) (2.575 in.)
NOTE
“a”
Do not push accumulator piston with fingers
or anything when removing them.
Pushing them may cause compressed fluid
in accumulator to spew out of hole and get to I7V10A510047-02
your face and clothes.
1
3
2
1
3 4
ICL80C510060-01
4) After applying ATF to new governor No.1 gasket (1),

ICL80C510059-01
install it to transaxle case.
Installation
1) Select new O-rings referring to the following table.
1 1
1
1
2
2
2 2
ICL80C510058-01
5) Install solenoid harness to transaxle case. (Page 2

5A-116) 2
2
6) Install manual valve rod (1) to manual valve lever (3)
and then install valve body assembly (2) to transaxle
case. “a”
ICL80C510230-02
8) Connect solenoid connectors identifying their

installing positions by wire color.
Solenoid valve Wire color
Shift solenoid valve “A” (1) RED
TCC solenoid valve (2) BLU, YEL
Pressure control solenoid valve “C” (3) GRY, LT BLU
Pressure control solenoid valve “B” (4) GRN, BRN
Pressure control solenoid valve “A” (5) WHT, BLK
ICL80C510061-01
7) Tighten valve body bolts to specified torque, 9) Install ATF temperature sensor (6).
referring to the following table and figure. Tightening torque
Tightening torque ATF temperature sensor plate bolt (a): 6.8 N·m (
Valve body bolt: 11 N·m (1.1 kgf-m, 8.5 lbf-ft) 0.69 kgf-m, 5.0 lbf-ft)
Valve body bolt length 3 4 5
2
Bolt Length “a” Pieces 1
1 20 mm (0.79 in.) 3
2 36 mm (1.4 in.) 8
6
(a)
ICL80C510063-01
10) Install A/T oil pan and oil strainer assembly. (Page
5A-114)
11) Lower vehicle.
12) Replenish proper amount of specified ATF. (Page
5A-2)
Solenoid Valve On-Vehicle Inspection

AENFL80B5106026 [A] [B]
Resistance Check 1 1

2) Remove battery tray. 
3) Disconnect solenoid connector from A/T.
4) Check for proper terminal connection to solenoid
connector (1).
5) Check resistance of each solenoid valve circuit as
follows. [C] [D]
1 1
Shift solenoid valve “A” resistance: [A]
Between (10) terminal of solenoid connector and
transaxle: 11 to 15 Ω at 20 °C (68 °F)
Pressure control solenoid valve “A” resistance: [B]
Between (6) and (13) terminals of solenoid
connector: 5.0 to 5.6 Ω at 20 °C (68 °F)
transaxle: Infinity [E]
1
Pressure control solenoid valve “B” resistance: [C]
Between (5) and (12) terminals of solenoid
transaxle: Infinity
Pressure control solenoid valve “C” resistance: [D]
Between (4) and (11) terminals of solenoid ICL80C510064-01

Between (4) terminal of solenoid connector and Solenoid Valve Inspection
transaxle: Infinity AENFL80B5106027
Shift Solenoid Valve “A” Inspection
TCC solenoid valve resistance: [E] Resistance check
Between (3) and (9) terminals of solenoid connector: Check shift solenoid valve “A”.
5.0 to 5.6 Ω at 20 °C (68 °F)
Between (3) terminal of solenoid connector and Shift solenoid valve “A” resistance
transaxle: Infinity Standard: 11 to 15 Ω at 20 °C (68 °F)
ICL80C510050-02
ICL80C510067-01
Operation check
Check that shift solenoid valve “A” (1) makes a clicking
sound when voltage is applied to each terminal as
shown in figure.
4
3
5
ICL80C510068-01
2. 12 V battery
Pressure control solenoid valve “A”, “B”, “C” and

6
TCC solenoid valve inspection
! CAUTION
ICL80C510231-01
Be very careful not to make dust etc. enter 5. 12 V- 21 W bulb 6. 12 V battery
pressure control solenoid valves during
inspection.
TCM Removal and Installation
AENFL80B5106028
Resistance check ! CAUTION
Measure resistance pressure control solenoid valve “A”
(1), “B” (2), “C” (3) and TCC pressure control solenoid • TCM consists of highly precise parts.
valve (4). When handling, be careful not to expose to
excessive shock.
Pressure control solenoid valve “A”
Standard: 5.0 to 5.6 Ω at 20 °C (68 °F) • When replacing TCM with used one, all
learned contents, which have been stored
Pressure control solenoid valve “B” in TCM memory by learning control,
Standard: 5.0 to 5.6 Ω at 20 °C (68 °F) should be initialized after replacement.
Pressure control solenoid valve “C”
Standard: 5.0 to 5.6 Ω at 20 °C (68 °F) Removal
TCC pressure control solenoid valve
Standard: 5.0 to 5.6 Ω at 20 °C (68 °F) 2) For air bag model, disable air bag system. 
3) Remove glove box. (Page 9C-24)
4
3
4) Disconnect connectors from TCM (1).
2
5) Remove TCM with bracket by removing bracket nuts
(2).
1
2
1
2
ICL80C510069-01 ICL80C510070-01
6) Remove TCM (1) from bracket (2) by removing TCM

Operation check mounting bolts (3).
Check that pressure control solenoid valve “A” (1), “B”
(2), “C” (3) and TCC pressure solenoid valve (4)
operates with click sound when voltage is applied to
each terminal as shown in figure.
ICL80C510071-01
Installation
• Tighten bolts and nuts to specified torque.
Tightening torque
TCM mounting bolt: 8.8 N·m (0.89 kgf-m, 6.5 lbf-
ft)
Bracket nut: 14 N·m (1.4 kgf-m, 10.5 lbf-ft)
• Connect TCM connectors securely.
• For air bag model, enable air bag system after TCM is
back in place.  I7V10A510055-02
[a]: Forward
Differential Side Oil Seal Replacement
AENFL80B5106029
5) Apply grease to new differential side oil seal lips.
1) Hoist vehicle and drain ATF. (Page 5A-104)
2) Remove intermediate shaft. : Grease 99000–25030 (SUZUKI Super Grease C)
Refer to “Drive Intermediate Shaft Assembly 6) Using special tool, install new differential side oil
Removal and Installation”: Front in Section 3A (Page seals (1) at specified position as shown in figure.
3A-9).
Special tool
3) Remove left drive shaft joints from differential gear of
(C): 09944M88220
transaxle. Refer to “Front Drive Shaft Assembly
(D): 09924M74510
Removal and Installation”: Front in Section 3A (Page
(E): 09951M16091
3A-3) for procedure to disconnect drive shaft joints.
For differential side oil seal removal, it is not Differential side oil seal installing depth
necessary to remove drive shafts from steering “a”: 2.6 to 3.6 mm (0.11 to 0.14 in.)
knuckle.
4) Remove differential side oil seal (1) using flat-bladed
screwdriver or the like.
ICL80C510073-01
ATF Cooler Hose Replacement

AENFL80B5106031
Rubber hoses for ATF cooler should be checked at
specified interval. If replacing them, be sure to note the
following.
• Replace clamps at the same time
• Insert hose as far as its limit mark
• Clamp clamps securely
1
2
ICL80C510074-01
1. Inlet hose (Inlet to ATF cooler)

2. Outlet hose (Outlet from ATF cooler)
ICL80C510072-01
[A]: Right side [B]: Left side
7) Install intermediate shaft. (Page 3A-9).

8) Install left drive shaft and right drive shaft. (Page
3A-3)
9) Replenish proper amount of ATF. (Page 5A-104)
ATF Cooler Hose Inspection

AENFL80B5106030
Check ATF cooler hoses (1) for fluid leakage, crack,
damage and deterioration. Replace hose and/or clamp if
any faulty condition is found.
A/T Assembly Components

AENFL80B5106032
ICL80C510075-03
[A]: Positioning type 2. Taper : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)

[B]: Standard type 3. Drive plate : 69 Nm (7.0 kgf-m, 51.0 lbf-ft)
1-1. Drive plate to torque converter No.1 bolt: For 4. Drive plate bolt : 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
tightening order, refer to “Remounting” under “A/T : Apply sealant 99000-31230 to thread.
Assembly Dismounting and Remounting” (Page
5A-127).
1-2. Drive plate to torque converter No.2 bolt: For 5. Torque converter
tightening order, refer to “Remounting” under “A/T : Apply grease 99000-25011 to mating
Assembly Dismounting and Remounting” (Page surface to drive plate.
5A-127).
Inner Parts
(d) 30
(d) 29 FLD 19 FLD
23 18 FLD
24
22 27 15 FLD
13 FLD
26 FLD
25 FLD
12 21 FLD
28 20
9 FLD 10
25 FLD 17 FLD
16 61 FLD
7 FLD
(c)
4 (a) 14 FLD 63 FLD
59 FLD
11 FLD
FLD
3 FLD 57 FLD
3
55 FLD 62 FLD
3 FLD 52 FLD
1 A
8
48 FLD 60 FLD
5 FLD 49
6 FLD 58 FLD
3 FLD 56 FLD
46 FLD
2
(d) 44 FLD 54 FLD
3 FLD 53 FLD
32 (b)
42 FLD 51 FLD
31 50
(d) 127 91 93 FLD
33 35 36
87 FLD 89
(f) 47 FLD 85 FLD
34
FLD
FLD
40 45
39 1216B 92 FLD
3 FLD 83 FLD
81 FLD 90 FLD
(e) 43 FLD
79 FLD
FLD 88 FLD
41 FLD 78 FLD 86
38 76 84 100 1216B
3 FLD
37 (d)
3 FLD
74 82 FLD
3 FLD 126 (a)
75 80 99 FLD
(e) (g)
70 98 FLD
64 FLD 71 125 (a) 77 FLD
LD
96
72 (c) 73 (c)
(c)
113 FLD 94
101 FLD
3 FLD
77 FLD
3 FLD 3 FLD
65 3 FLD
(l) 3 FLD 126 (a)

95 97 FLD
3 FLD 104 FLD
66
67
106
114 117 FLD
68 102 FLD 118 119
(h) 115
103
69 (j)
104 FLD
108 FLD 116 121 122
102 FLD
107 FLD 123
111
(k)
109 112 (i) 105 FLD
120 FLD
110 (m) 124 FLD
103
ICL80C510077-02
1. Torque converter 49. One-way clutch outer race retainer 97. O/D and 2nd coast brake piston
: Apply grease 99000-25011 to mating front O-ring
surface of drive plate.
2. Torque converter housing 50. O/D and 2nd coast brake retaining plate 98. O/D and 2nd coast brake piston rear
snap ring O-ring
3. O-ring 51. O/D and 2nd coast brake retaining plate 99. Rear cover seal ring
4. Torque converter housing plug 52. O/D and 2nd coast brake disc 100. Transaxle rear cover
: Apply sealant 99000-31230 to
mating surface to transaxle case.
5. Oil seal 53. O/D and 2nd coast brake separator 101. Governor gasket No.1
plate
6. Input shaft seal ring 54. O/D and 2nd coast brake rear plate 102. Differential side oil seal
7. Input shaft front thrust bearing 55. Planetary gear thrust bearing 103. Side bearing shim
8. Input shaft subassembly 56. Front sun gear thrust bearing race 104. Side bearing cup
9. Direct clutch piston 57. Front planetary sun gear 105. Differential side right bearing
10. Direct clutch return spring subassembly 58. Rear planetary sun gear subassembly 106. Differential case subassembly
11. Direct clutch balancer 59. Rear sun gear thrust bearing 107. Final driven gear
12. Shaft snap ring 60. Forward clutch hub 108. Differential side left bearing
13. Direct clutch separator plate 61. Intermediate shaft thrust bearing front 109. Over flow plug gasket
race
14. Direct clutch disc 62. Intermediate shaft thrust bearing 110. Over flow plug
15. Direct clutch retaining plate 63. Intermediate shaft thrust bearing rear 111. ATF drain plug gasket
race
16. Direct clutch retaining plate snap ring 64. Governor gasket No.2 112. ATF drain plug
17. Input shaft rear thrust bearing 65. Valve body assembly 113. Reverse clutch separator plate
18. Input shaft rear thrust bearing race 66. A/T oil strainer assembly 114. Parking lock pawl rod
19. Direct clutch hub 67. Oil pan gasket 115. Parking lock pawl bracket
20. Reduction drive gear nut 68. Oil cleaner magnet 116. Manual detent spring
: Tighten reduction drive gear nut gradually
so as rotational torque of reduction drive
gear to be in specified value. (Page 5A-
157)
21. Reduction drive gear 69. A/T oil pan 117. Parking lock pawl shaft
22. Fluid reservoir plate 70. C3 accumulator No.1 spring 118. Parking lock pawl
23. Lubrication tube clamp 71. C3 accumulator piston 119. Parking lock pawl spring
24. Lubrication tube 72. Fluid filler tube union 120. Manual valve lever
25. Bearing cap 73. Fluid cooler pipe union 121. Manual valve lever pin
26. Countershaft right bearing 74. Transmission range sensor 122. Manual shift shaft spacer
27. Countershaft 75. Manual select lever 123. Manual shift shaft
28. Reduction driven gear 76. Reverse clutch plate snap ring 124. Manual shift shaft oil seal
29. Countershaft left bearing 77. Reverse clutch retaining plate 125. Transaxle case plug
30. Countershaft bearing shim 78. Reverse clutch disc 126. Transaxle rear cover plug
31. Solenoid harness 79. Reverse clutch cushion plate 127. ATF temperature sensor plate
32. Breather hose plug 80. Forward clutch plate snap ring : Do not reuse.
33. Breather hose 81. Forward clutch retaining plate : Apply ATF.
34. Breather union 82. Forward clutch disc : 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)
35. Input shaft speed sensor 83. Forward clutch separator plate : 29 Nm (3.0 kgf-m, 21.5 lbf-ft)
36. Output shaft speed sensor 84. Balancer snap ring : 25 Nm (2.6 kgf-m, 18.5 lbf-ft)
37. Fluid reservoir left plate No.1 85. Forward clutch balancer : 5.4 Nm (0.55 kgf-m, 4.0 lbf-ft)
38. Fluid reservoir left plate No.2 86. Forward clutch return spring : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
subassembly
39. Transaxle case 87. Forward clutch piston : 6.8 Nm (0.69 kgf-m, 5.0 lbf-ft)
: Apply sealant 99000-31230 to mating
surface to torque converter housing.
40. 1st and reverse brake piston 88. Forward clutch piston O-ring : 12 Nm (1.2 kgf-m, 9.0 lbf-ft)
41. 1st and reverse brake spring subassembly 89. Forward clutch drum : 78 Nm (8.0 kgf-m, 57.5 lbf-ft)
42. 1st and reverse brake separator plate 90. Forward clutch drum O-ring : 17 Nm (1.7 kgf-m, 12.5 lbf-ft)
43. 1st and reverse brake disc 91. Forward and reverse clutch assembly : 7.4 Nm (0.75 kgf-m, 5.5 lbf-ft)
44. 1st and reverse brake retaining plate 92. Intermediate shaft seal ring : 9.8 Nm (1.0 kgf-m, 7.5 lbf-ft)
45. 1st and reverse brake retaining plate snap 93. Reverse clutch drum thrust bearing : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
ring
46. Planetary ring gear subassembly 94. O/D and 2nd coast brake return spring : 24 Nm (2.4 kgf-m, 18.0 lbf-ft)
subassembly snap ring
47. Planetary gear assembly 95. O/D and 2nd coast brake return spring
subassembly
48. One-way clutch No.2 assembly 96. O/D and 2nd coast brake piston
A/T Assembly Dismounting and Remounting

AENFL80B5106033
! WARNING
Be sure to keep transaxle with torque
converter horizontal or facing up throughout
work. Should it be tilted with torque
converter down, converter may fall off and
cause personal injury.
Dismounting
1) Dismount transaxle with engine. Refer to “Engine
Assembly Removal and Installation (Petrol Model)”:
Petrol and Bi-Fuel CNG in Section 1D (Page 1D-10).
2) Remove starting motor. 
3) Lock drive plate by engaging flat-bladed screwdriver
or the like (1) with drive plate ring gear.
ICL80C510080-01
Remounting
1) Check that torque converter is installed correctly to
transaxle. (Page 5A-157)
2) Attach transaxle to engine.
3) Tighten bolts and nuts to specified torque. (Page
5A-124)
1 4) Check that there is one different bolt (No.1 bolt) in
drive plate to torque converter bolts.
ICL80C510078-02
• Drive plate to torque converter No.1 bolt (1):
4) Remove drive plate to torque converter bolts through Positioning bolt with taper
installation hole of starting motor.
• Drive plate to torque converter No.2 bolt (2):
Standard bolt
1 2
I9P60A510074-01
3. Taper
5) Lock drive plate by engaging flat-bladed screwdriver

or the like (1) with drive plate gear.
ICL80C510079-01
5) Remove bolts and nuts fastening engine and

transaxle, and then detach transaxle from engine.
NOTE
When detaching transaxle from engine, move
it in parallel with crankshaft and use care so
as not to apply excessive force to drive plate
and torque converter.
ICL80C510078-02
6) Align a bolt hole of drive plate with that of torque

converter.
7) Engage the drive plate and torque converter by

tightening the drive plate to torque converter No.1
bolt through installation hole of starting motor.
1
Tightening torque
Drive plate to torque converter No.1 bolt: 23
N·m (2.3 kgf-m, 17.0 lbf-ft)
8) Tighten drive plate to torque converter No.2 bolts in
the same manner.
Tightening torque
Drive plate to torque converter No.2 bolt: 23
N·m (2.3 kgf-m, 17.0 lbf-ft)
ICL80C510081-01
3) Remove harness bracket with select cable clamp.

(Page 5A-124)
4) Remove engine hook (1).
ICL80C510079-01
9) Install starting motor. 

10) Remount engine with transaxle assembly to vehicle.
Refer to “Engine Assembly Removal and Installation ICL80C510082-01
(Petrol Model)”: Petrol and Bi-Fuel CNG in Section
5) Remove transmission range sensor. (Page 5A-
1D (Page 1D-10) for its procedure.
109)
6) Remove output shaft speed sensor (1) and input
A/T Assembly Disassembly
AENFL80B5106034 shaft speed sensor (2).
! CAUTION
2
• Thoroughly clean transaxle exterior before
overhauling it.
• Keep working table, tools and hands clean
while overhauling.
• Use special care to handle aluminum parts 1
so as not to damage them.

• Do not expose removed parts to dust.
Keep them always clean.
ICL80C510083-01
1) Drain ATF. (Page 5A-104) 7) Remove fluid cooler pipe (1), gaskets (2), fluid cooler
2) Remove torque converter (1). pipe unions (3) and O-rings (4).
! CAUTION 8) Remove fluid level gauge (5), fluid filler tube (6) and
O-ring (7).
Remove torque converter as straight as 9) Remove fluid filler tube union (8) and O-ring (9).
possible. Leaning it may cause to damage oil
seal lip.
NOTE
6 Do not push accumulator piston with fingers
or anything before removing them. Pushing
5 7 them may cause compressed fluid in
6
accumulator to spew out of hole and get to
8 your face and clothes.
1
3
2
2
1
2
1 3
ICL80C510084-02
10) Remove A/T oil pan, oil pan gasket and oil strainer
assembly. (Page 5A-114)
NOTE ICL80C510059-01
For removal of A/T oil pan, do not turn 15) Remove torque converter housing bolts (2).
transaxle over as this will contaminate valve 16) Remove torque converter housing (1) while tapping
body with foreign materials in bottom of A/T around it lightly with plastic hammer.
oil pan.
11) Remove valve body assembly. (Page 5A-117)

12) Remove solenoid connector. (Page 5A-116)
13) Remove governor gasket No.1 (1).
ICL80C510085-01
17) Remove breather hose (1) and breather union (2).
ICL80C510058-01
1
14) Remove C3 accumulator piston (1) and No.1 spring
2
(2), position rag on piston to catch piston. To remove
piston, force low-pressure compressed air (100 kPa,
1.0 kgf/cm2, 14.5 psi, max) into hole (3) as shown in
figure, and pop piston into rag.
ICL80C510086-01
18) Remove oil pump bolts (2) then remove oil pump
assembly (1).
ICL80C510087-01
ICL80C510090-01
19) Remove direct clutch assembly (1). 23) Remove differential assembly (1) and countershaft
assembly (2).
1
ICL80C510088-01
ICL80C510091-01
20) Remove input shaft front thrust bearing (1). 24) Remove governor gasket No.2 (1).
NOTE
1
If input shaft front thrust bearing is not
found, it may have been taken out with oil
pump assembly.
1
1
ICL80C510092-01
25) Remove bolts (1) then remove fluid reservoir left

plate No.1 (2) and No.2 (3).
3
1
ICL80C510089-02
21) Remove input shaft rear thrust bearing (1) and thrust
bearing race (2). 2
1
NOTE ICL80C510093-01
If input shaft rear thrust bearing is not found, 26) Turn over transaxle and remove bolts (1) then
it may have been taken out with direct clutch remove rear cover assembly (2).
assembly.
22) Remove direct clutch hub (3).

2 1
1
ICL80C510094-01
27) Remove 2nd brake gaskets (1). I2RH0B510112-01
31) Remove forward clutch hub (1).
1
ICL80C510095-01
28) Remove reverse clutch drum thrust bearing (1).
NOTE
If reverse clutch drum thrust bearing is not
found, it may have been taken out with rear
ICL80C510098-01
cover assembly.
32) Remove rear sun gear thrust bearing (1) from
29) Remove forward and reverse clutch assembly (2). forward clutch hub (2).
NOTE
If rear sun gear thrust bearing is not found on
forward clutch hub, it may have been left in
transaxle.
ICL80C510096-01
30) Remove intermediate shaft thrust bearing front race

(1), thrust bearing (2) and rear race (3) from forward
and reverse clutch assembly (4).
NOTE
ICL80C510099-01
If intermediate shaft thrust bearing and/or
races are not found on forward and reverse 33) Remove rear sun gear thrust bearing race (1).
clutch assembly, they may have been left in 34) Remove rear planetary sun gear subassembly (2).
transaxle.
ICL80C510102-01
38) Remove front planetary sun gear (1).
ICL80C510100-01
35) Remove planetary gear thrust bearing (1).
NOTE
If planetary gear thrust bearing is not found
on rear planetary sun gear assembly, it may
have been left in transaxle.
ICL80C510103-01
1
39) Remove front sun gear thrust bearing race (2) from
front planetary sun gear (1).
2
ICL80C510101-01
36) Remove O/D and 2nd coast brake rear plate (1),
discs (2), separator plates (3) and retaining plate (4).
1
ICL80C510104-01
40) Remove one-way clutch outer race retainer (1).
1
ICL80C510105-01
41) Check one-way clutch No.2 as follows.

ICL80C510097-01
37) Remove O/D and 2nd coast brake retaining plate • Ensure planetary carrier (1) rotates only
snap ring (1). counterclockwise direction [a], never clockwise
direction [b].
If planetary carrier rotates both ways or does not

rotate either way, one-way clutch No.2 assembly
will need to be replaced with new one-way clutch
No.2 assembly.
ICL80C510110-01
! CAUTION
ICL80C510106-01
• It is recommended that this operation
42) Remove planetary gear assembly (1) with one-way should be carried out on rubber mat to
clutch No.2 assembly (2). prevent damaging transaxle case.
• Never reuse removed nut.
Special tool
(A): 09927M26010
ICL80C510107-01
43) Remove one-way clutch No.2 assembly (1).
ICL80C510111-01
46) Screwing in bolts of 30 mm (1.2 in.) in length (1),

remove reduction drive gear (2).
! CAUTION
Screw 3 bolts into reduction drive gear
uniformly, or reduction drive gear, bearing
and transaxle case may be damaged.
ICL80C510108-01 Reduction drive gear screwing bolt length

44) Turn over transaxle and uncaulk reduction drive gear 40 to 80 mm (1.6 to 3.1 in.)
nut (1).
I2RH0B510136-01
45) Secure reduction drive gear (1) with parking lock

pawl (2), then remove reduction drive gear nut.
ICL80C510109-01
50) Blowing compressed air from oil hole (1) of oil pump,
remove 1st and reverse brake piston (2).
ICL80C510113-01
47) Remove snap ring while 1st and reverse brake

piston return springs are compressed using special
tool and hydraulic press. 1
! CAUTION
Do not push in 1st and reverse brake return
spring subassembly more than 0.8 mm (0.03
in.).
Excessive compression may cause damage
to return spring subassembly, discs, plates ICL80C510114-01
and/or piston.
51) Remove inner O-ring (1) and outer O-ring (2) from
1st and revered brake piston.
Special tool
(A): 09926M97620
ICL80C510116-01
52) Remove bolts (1), and then remove parking lock

I2RH0B510134-01 pawl bracket (2).
48) Remove 1st and reverse brake retaining plate (1),
discs (2) and separator plates (3).
49) Remove 1st and reverse brake return spring
subassembly (4).
1
ICL80C510115-01
53) Remove parking lock pawl shaft, and then remove

spring (2) and parking lock pawl (1).
ICL80C510120-01
ICL80C510112-01 58) Remove parking lock pawl rod (2) from manual valve
54) Remove manual detent spring (1). lever (1).
ICL80C510121-01
59) Remove manual shift shaft oil seal (1).
ICL80C510117-01
55) With chisel (1), brake manual valve lever spacer (2)
and remove it.
ICL80C510122-01
Oil Pump Assembly Components

AENFL80B5106035
ICL80C510118-01
56) Using spring pin remover (1) with 3 mm (0.1 in.) in

diameter and hammer, remove manual valve lever
pin.
3
2 FLD
1 C
ICL80C510123-01
ICL80C510119-01
1. Oil seal
57) Remove manual shift shaft (1). : Apply grease 99000-25030 to oil seal lip.
2. O-ring
3. Oil pump assembly
: Apply ATF.
: Do not reuse.
Oil Pump Assembly Disassembly and

Reassembly
AENFL80B5106036
Disassembly 1
1) Remove O-ring from oil pump body.
2) Remove oil seal (1) using special tool. I4RS0A510043-01
Special tool
(A): 09913M50121 Oil Pump Assembly Inspection
AENFL80B5106037
1) Using special tool, measure inside diameter of stator
shaft bushing (1).
If check result is not as specified, replace oil pump
assembly.
Special tool
(A): 09900M20605
Stator shaft bushing inside diameter “a”
Standard: 18.424 to 18.450 mm (0.7254 to 0.7263
in.)
I2RH0B510150-01
2. Oil pump assembly
Reassembly
1) Install new oil seal (1) to oil pump body (2).
Use special tool and hammer to install it, and then
apply grease to its lip portion.
Special tool
(A): 09913M85210
Grease C) ICL80C510125-01
2) Install direct clutch assembly (1) to stator shaft

assembly, then ensure that direct clutch assembly
turns smoothly.
If unsmooth rotation or noise are found in oil pump
assembly (2), replace oil pump assembly with new
one. This check should also be done to input shaft
assembly and replace input shaft assembly if
necessary.
I2RH0B510151-01
2) After applying ATF to new O-ring, install it to oil

pump body.
3) Check drive gear for smooth rotation using torque
converter (1).
I2RH0B510158-01
3) Using special tool, measure inside diameter of oil

pump body bushing (1).
If check result is not as specified, replace oil pump
assembly. Torque converter also needs to be
checked. Replace torque converter, if necessary.
Special tool
(A): 09900M20605
Oil pump body bushing inside diameter “a”
Standard: 38.113 to 38.138 mm (1.5006 to 1.5014
in.)
ICL80C510127-01
Direct Clutch Assembly Components

AENFL80B5106038
ICL80C510126-01
1. Input shaft front thrust bearing 6. Direct clutch piston 11. Direct clutch disc
2. Input shaft seal ring 7. Direct clutch return spring subassembly 12. Direct clutch retaining plate
3. Input shaft subassembly 8. Direct clutch balancer 13. Plate snap ring
4. Inner O-ring 9. Shaft snap ring : Apply ATF.
5. Outer O-ring 10. Direct clutch separator plate : Do not reuse.
Direct Clutch Assembly Preliminary Check 2) Install special tools to upper surface of direct clutch
AENFL80B5106039 piston. Blow in air (400 to 800 kPa, 4.1 to 8.1 kgf/
1) Install direct clutch assembly (1) to oil pump cm2, 58.1 to 116 psi) through oil hole (3) of oil pump
assembly (2). assembly, and measure piston stroke of direct
clutch.
If piston stroke exceeds specified value,

disassemble, check and replace inner parts. (A)
Special tool
(A): 09900M20607 1
(B): 09900M20701
Direct clutch piston stroke
0.4 to 0.7 mm (0.016 to 0.027 in.)
ICL80C510131-01
3) Remove clutch No.2 balancer (1) and direct clutch

return spring subassembly (2).
ICL80C510128-01
Direct Clutch Assembly Disassembly and

Reassembly
AENFL80B5106040
Disassembly
1) Remove plate snap ring (1), and then remove direct
clutch retaining plate, discs and separator plates. ICL80C510130-01
4) Using finger to block an oil hole (1), apply

compressed air (400 to 800 kPa, 4.1 to 8.2 kgf/cm2,
58.0 to 116 psi) to opposite oil hole, to assist removal
of clutch piston.
ICL80C510129-01
2) Using special tool and hydraulic press, compress

direct clutch return spring subassembly, and remove
shaft snap ring (1).
Special tool
(A): 09926M95420 I2RH0B510164-01
! CAUTION 5) Remove outer O-ring (1) from direct clutch piston (2).
Do not press in direct clutch return spring

subassembly more than 0.7 mm (0.03 in.).
to direct clutch return spring subassembly
and/or piston.
ICL80C510132-01
6) Remove inner O-ring (2) from input shaft

subassembly (1).
4
1
2
ICL80C510133-01
7) Remove input shaft seal rings (1) from input shaft

subassembly. ICL80C510136-01
• Install new plate snap ring so that its both ends would
be positioned in correct location as shown in figure.
ICL80C510134-01
Reassembly
Reverse disassembly procedure noting the following
points.
• Use new seal rings and O-rings. Apply ATF before
installation.
• Apply ATF to direct clutch balancer
• Use new shaft snap ring.
• Do not damage direct clutch balancer (1) and piston
by pressing in direct clutch balancer passing through
its original installing position over 0.7 mm (0.03 in.).
Special tool
(A): 09926M95420
I2RH0B510170-01
(A) [A]: Correct [B]: Incorrect
• Measure direct clutch piston stroke. (Page 5A-137)

When piston stroke is out of specification, select direct
1 clutch retaining plate with suitable thickness from
among the following table and replace it.
Available direct clutch retaining plate thickness
Thickness Identification mark
2.8 mm (0.110 in.) 1
3.0 mm (0.118 in.) 2
3.2 mm (0.126 in.) 3
ICL80C510135-01
• Apply ATF to direct clutch separator plates (4), discs Direct Clutch Assembly Inspection
AENFL80B5106041
(3) and retaining plate (2).
• Before assembling discs, soak them in ATF for at Clutch Disc, Separator Plate and Retaining Plate
least two hours. Check that sliding surfaces of clutch discs, separator
• Install direct clutch separator plates, discs, retaining plates and retaining plate are not worn hard or burnt.
plate and new plate snap ring (1) to input shaft If necessary, replace.
subassembly.
NOTE
If disc lining is exfoliated or discolored,
replace all discs.
I2RH0B510172-01
Direct Clutch Return Spring Subassembly

Measure free length of direct clutch return spring.
If measured length is out of reference value greatly,
replace direct clutch assembly.
NOTE
• Do not apply excessive force when
measuring spring free length.
• Perform measurement at several points.
Reference free length of direct clutch return spring

“a”: 23.74 mm (0.9346 in.)
ICL80C510137-01
Forward and Reverse Clutch Assembly Components

AENFL80B5106042
ICL80C510138-02
1. Forward clutch balancer 8. Intermediate shaft seal ring 15. Forward clutch retaining plate
2. Forward clutch return spring subassembly 9. Reverse clutch plate snap ring 16. Forward clutch disc
3. Forward clutch piston 10. Reverse clutch retaining plate 17. Forward clutch separator plate
4. Forward clutch piston O-ring 11. Reverse clutch separator plate 18. Balancer snap ring
5. Forward clutch drum 12. Reverse clutch disc : Apply ATF.
6. Forward clutch drum O-ring 13. Reverse clutch cushion plate : Do not reuse.
7. Intermediate shaft subassembly 14. Forward clutch plate snap ring
Forward and Reverse Clutch Assembly If piston stroke exceeds specified value,
Preliminary Check disassemble, check and replace inner parts.
AENFL80B5106043
1) Install forward and reverse clutch assembly (1) to Special tool
transaxle rear cover (2). (A): 09900M20607
(B): 09900M20701
2) Install special tools to upper surface of reverse
clutch retaining plate (3). Reverse clutch piston stroke
Blow in compressed air (400 to 800 kPa, 4.1 to 8.2 0.52 to 1.12 mm (0.0205 to 0.0440 in.)
kgf/cm2, 58.0 to 116 psi) through oil hole (4) of
transaxle rear cover and measure reverse clutch
piston stroke.
I7V10A510075-01
3) Remove forward clutch plate snap ring (1).

ICL80C510139-01
4) Remove forward clutch retaining plate, discs and
3) Blow in compressed air (400 – 800 kPa, 4.1 – 8.2 separator plates from forward clutch drum.
kgf/cm2, 58.0 – 116 psi) through oil hole (1) of
transaxle rear cover with special tool attached on
upper surface of forward clutch retaining plate, and
measure forward clutch piston stroke.
disassemble, check and replace inner parts.
Special tool
(A): 09900M20607
(B): 09900M20701
(C): 09952M06020
I7V10A510076-01
Forward clutch piston stroke
5) Using special tool and hydraulic press, compress
0.8 to 1.0 mm (0.032 to 0.039 in.)
forward clutch balancer (1) and remove balancer
snap ring.
Special tool
(A): 09926M97610
! CAUTION
Do not press in forward clutch return spring
subassembly more than 1.0 mm (0.039 in.).
to return spring subassembly and/or
balancer.
ICL80C510140-01
Forward and Reverse Clutch Assembly

Disassembly and Reassembly
AENFL80B5106044
Disassembly
1) Remove reverse clutch plate snap ring (1).
2) Remove reverse clutch retaining plates, discs,
separator plate and clutch cushion plate from
intermediate shaft subassembly.
I2RH0B510180-01
6) Remove forward clutch balancer (1).

7) Remove forward clutch return spring subassembly
(2) from intermediate shaft subassembly (3).
11) Remove forward clutch drum O-ring (1) from forward

clutch drum (2).
ICL80C510141-01
8) Install intermediate shaft subassembly (1) to

transaxle rear cover (2). Apply compressed air (400 ICL80C510145-01
to 800 kPa, 4.1 to 8.2 kgf/cm2, 58.0 to 116 psi) to oil 12) Remove intermediate shaft seal ring (1) from
hole (3) of transaxle rear cover to remove forward intermediate shaft subassembly (2).
clutch piston (4).
I2RH0B510186-01
Reassembly
ICL80C510142-01
Reverse disassembly procedure noting the following
9) Apply compressed air (400 to 800 kPa, 4.1 to 8.2 points.
kgf/cm2, 58.0 to 116 psi) to oil hole (1) of transaxle
rear cover to remove forward clutch drum (2). • Use new O-rings and seal ring. Apply ATF before
installation.
• Use new balancer snap ring.
• Apply ATF to forward clutch piston and forward clutch
balancer.
• Do not damage forward clutch return spring
subassembly and balancer (1) by pressing forward
clutch return spring subassembly passing through its
original installing position over 1.0 mm (0.039 in.).
Special tool
(A): 09926M97610
ICL80C510146-01
10) Remove forward clutch piston O-ring (1) from

intermediate shaft subassembly (2).
I2RH0B510180-01
• Apply ATF to forward clutch separator plates (1), discs

(2) and retaining plate (3).
ICL80C510144-01
• Before assembling discs, soak them in ATF for two Thickness Identification mark
hours or more. 3.7 mm (0.146 in.) 8
• Install forward clutch separator plates, discs and 3.8 mm (0.150 in.) 9
retaining plate, then new forward clutch plate snap
ring (4) to forward clutch drum. • Install reverse clutch cushion plate (1) in correct
direction as shown in figure.
4 • Apply ATF to reverse clutch cushion plate, reverse
3 clutch separator plate (2), discs (3) and retaining
2 plates (4).
1 • Before assembling discs, soak them in ATF for two
hours or more.
• Install reverse clutch cushion plate, reverse clutch
separator plate, discs, retaining plate and then snap
ring (5) to intermediate shaft subassembly.
ICL80C510147-01
• Install new forward clutch plate snap ring so that its

both ends would be positioned in correct location as
shown in figure.
ICL80C510149-01
• Install new reverse clutch plate snap ring so that its

both ends would be positioned in correct location as
shown in figure.
ICL80C510148-01
[A]: Correct [B]: Incorrect
• Measure forward clutch piston stroke. (Page 5A-

141)
When piston stroke is out of specification, select
forward clutch retaining plate with suitable thickness
from among the following table and replace it.
I2RH0B510190-01
Available forward clutch retaining plate thickness
3.0 mm (0.118 in.) 1
• Measure reverse clutch piston stroke. (Page 5A-
3.1 mm (0.122 in.) 2
141)
3.2 mm (0.126 in.) 3
When piston stroke is out of specification, select
3.3 mm (0.130 in.) 4
reverse clutch retaining plate with suitable thickness
3.4 mm (0.134 in.) 5
from among the following table and replace it.
3.5 mm (0.138 in.) 6
3.6 mm (0.142 in.) 7
Available reverse clutch retaining plate thickness Forward Clutch Piston Lip and Forward Clutch
Thickness Identification mark Balancer Lip
3.0 mm (0.118 in.) 1 Check each lip for wear, deformation, cut and/or
3.2 mm (0.126 in.) 2 hardening. If necessary, replace.
3.4 mm (0.134 in.) 3
3.6 mm (0.142 in.) 4
Forward and Reverse Clutch Assembly

Inspection
AENFL80B5106045
Clutch Disc, Separator Plate and Retaining Plate

ICL80C510151-01
Check that sliding surfaces of clutch discs, separator
plate and retaining plates are not worn hard or burnt.
Forward Clutch Drum Lip
If necessary, replace.
Check its lip for wear, deformation, cut and/or hardening.
NOTE If necessary, replace.
If disc lining is exfoliated or discolored,
replace all discs.
I2RH0B510195-01
I2RH0B510192-01
Forward Clutch Return Spring Subassembly

Measure free length of forward clutch return spring.
If measured length is out of reference value greatly,
replace forward and reverse clutch assembly.
NOTE
Reference free length of forward clutch return spring

“a”: 20.88 mm (0.8220 in.)
ICL80C510150-01
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components
AENFL80B5106046
ICL80C510152-02
1. Snap ring 5. O/D and 2nd coast brake piston 9. Rear cover plug O-ring
2. O/D and 2nd coast brake return spring 6. Rear cover seal ring : Apply ATF.
subassembly
3. O/D and 2nd coast brake piston front O-ring 7. Transaxle rear cover : Do not reuse.
: Apply sealant 99000-31230 to mating surface to
transaxle case.
4. O/D and 2nd coast brake piston rear O-ring 8. Rear cover plug : 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)
Transaxle Rear Cover (O/D and 2nd Coast Brake

Piston) Assembly Disassembly and
Reassembly
AENFL80B5106047
Disassembly
1) Remove O/D and 2nd coast brake return spring
subassembly snap ring (1).
2) Remove O/D and 2nd coast brake return spring
subassembly (2).
ICL80C510153-01
4) Remove O/D and 2nd coast brake piston front O-ring

(1) and rear O-ring (2) from O/D and 2nd coast brake
piston.
ICL80C510232-01 ICL80C510154-01
3) Apply compressed air (400 to 800 kPa, 4.1 to 8.2 5) Remove rear cover seal rings (1) from rear cover.
kgf/cm2, 58.0 to 116 psi) to oil hole (2) of transaxle
rear cover (1) to remove O/D and 2nd coast brake
piston.
[A]
“a” “a”
[B]
ICL80C510155-01
6) Remove rear cover plugs (1) from rear cover.
ICL80C510158-01
Transaxle Rear Cover (O/D and 2nd Coast Brake

Piston) Assembly Inspection
AENFL80B5106048
O/D and 2nd Coast Brake Return Spring

1 1
1 Subassembly
ICL80C510157-01
Measure free length of O/D and 2nd coast brake return
Reassembly spring.
Reverse disassembly procedure noting the following If measured length is out of specified length, replace
points. transaxle rear cover.
• Use new seal rings and O-rings. Apply ATF to seal NOTE
rings and O-rings before installation.
• Tighten rear cover plugs to specified torque. (Page measuring spring free length.
5A-146)
• First, tighten seal ring to 5 mm (0.2 in.), and then
install seal ring. O/D and 2nd coast brake return spring free length
• Do not open rear cover seal ring too wide to attach. “a”: 12.63 mm (0.4972 in.)
ICL80C510156-01
ICL80C510159-01
1. Transaxle rear cover
• Install new O/D and 2nd coast brake return spring

subassembly snap ring so that its both ends are
positioned in correct location as shown in figure.
Snap ring installation position
“a”: More than 3 mm (0.12 in.)
Countershaft Assembly Components

AENFL80B5106049
I2RH0B510211-01
Reassembly
1) Press-fit new countershaft right bearing (1) using
special tool and hydraulic press.
NOTE
Replace countershaft right bearing together
ICL80C510233-01
with bearing cup as a set.
1. Countershaft right bearing 5. Bearing cup
2. Countershaft 6. Countershaft bearing shim
Special tool
3. Countershaft left bearing : Apply ATF.
(A): 09913M84510
4. Reduction driven gear : Do not reuse.
Countershaft Assembly Disassembly and

Reassembly
AENFL80B5106050
Disassembly
1) Remove countershaft left bearing (1) and reduction
driven gear (2) together using special tool and
hydraulic press.
Special tool
(A): 09925M98221 I2RH0B510212-01
2) Press-fit reduction driven gear (1) using special tools

and hydraulic press.
Special tool
(A): 09913M84510
(B): 09925M88210
I7V10A510080-01
2) Remove countershaft right bearing (1) using special

tools.
Special tool I2RH0B510213-01
(A): 09913M61510 3) Press-fit countershaft left bearing (1) using special

(B): 09926M58010 tools and hydraulic press.
Special tool
(A): 09913M84510
(B): 09925M88210
I2RH0B510214-01
Differential Assembly Components

AENFL80B5106051
ICL80C510160-02
1. Differential side right bearing 4. Differential side left bearing : Apply ATF.
2. Differential case subassembly 5. Side bearing cup : Do not reuse.

3. Final driven gear 6. Side bearing shim : 78 Nm (8.0 kgf-m, 57.5 lbf-ft)
Differential Assembly Disassembly and Special tool

Reassembly (A): 09926M37610
AENFL80B5106052 (B): 09926M37610M001
(C): 09926M37610M003
Disassembly (D): 09926M37610M002
1) Remove final gear bolts (1) and final driven gear (2).
ICL80C510161-01
2) Remove differential side right bearing using special ICL80C510162-01

tools.
3) Remove differential side left bearing using special

tools.
Special tool
(A): 09926M37610
(B): 09926M37610M001
(C): 09926M37610M003
(D): 09926M37610M002
ICL80C510163-01
3) Tighten final gear bolts (1) to specified torque.
NOTE
To avoid rust, apply ATF to final driven gear
after installation.
Tightening torque
Final gear bolt (a): 78 N·m (8.0 kgf-m, 57.5 lbf-ft)
I2RH0B510228-01
Reassembly
! WARNING
• When taking heated final driven gear out of

vessel, use tongs or the like. Taking it out
with bare hands will cause severe burn.
• While installing heated final driven gear,
use oven gloves such as leather gloves. I2RH0B510231-01
Picking it up with bare hand may cause
2. Final driven gear
burn.
4) After applying ATF to new differential side right
! CAUTION bearing (1), press-fit it to differential case
Do not leave final driven gear in boiling water subassembly using special tool and hydraulic press.
for longer than 5 min. Overheating the gear
NOTE
may cause strength reduction of gear.
Replace differential side right bearing
1) Put final driven gear in water vessel, heat and together with bearing cup as a set.
remove when it boils, and then remove moisture.
Special tool
NOTE (A): 09913M70123
After removing moisture on final driven gear,
install final driven gear to differential case as
quickly as possible.
ICL80C510164-01
5) After applying ATF to new differential side left

bearing (1), install it to differential case subassembly
I2RH0B510229-01
using special tool and hydraulic press.
2) Facing groove (2) side upward, install final driven
gear (1) to differential case as shown in figure.
NOTE NOTE
Replace differential side left bearing together Do not bend lubrication tube with excessive
with bearing cup as a set. force.
Special tool
(A): 09913M70123 2
I2RH0B510234-01 ICL80C510165-01
3) Remove differential side oil seal (1) using a flat-

Differential Assembly Inspection bladed screwdriver or the like.
AENFL80B5106053
1) Hold differential case subassembly with soft jawed
vise and set special tools as shown.
Special tool
(A): 09900M20607
(B): 09900M20701
2) Measure differential side gear thrust play.
Differential side gear thrust play
Standard: 0.06 to 0.22 mm (0.0024 to 0.0087 in.)
I7V10A510084-01
4) Remove countershaft right bearing cup using special

tools.
Special tool
(A): 09944M96012
(B): 09942M15511
(C): 09921M26010
(B) (C)
I2RH0B510235-01 (A)
3) If check result is not as specified, replace differential
case subassembly.
Torque Converter Housing Disassembly and

Reassembly
AENFL80B5106054
ICL80C510166-02
Disassembly 5) Remove differential side right bearing cup using
1) Remove fluid reservoir plate (1) and lubrication tube special tools.
clamp (2).
Special tool
2) Remove lubrication tube (3).
(A): 09925M16510
(B): 09924M74510
(a)
(B)
(A)
ICL80C510171-01
2) Using special tools, install shim and differential side

ICL80C510234-01
right bearing cup.
6) Remove torque converter housing plugs (1). NOTE
Use shim with the same thickness as
removed one.
Special tool
(A): 09924M74510
1 (B): 09944M88220
(A)
1
ICL80C510168-01
(B)
ICL80C510172-01
3) Using special tool, install new countershaft right

bearing cup.
1
Special tool
ICL80C510169-01 (A): 09924M74510
(B): 09944M68510
Reassembly
1) After applying ATF to new O-rings, fit them to
housing plugs. Then install plugs to torque converter
housing.
(A)
Tightening torque
(B)
Torque converter housing plug (a): 7.5 N·m (
0.76 kgf-m, 5.5 lbf-ft)
ICL80C510173-01
4) Using special tools, install new differential side oil

(a)
seal to torque converter housing evenly at specified
position shown in figure.
Special tool
(A): 09924M74510
(a) (B): 09944M88220
ICL80C510170-01
Differential side oil seal installing depth

“a”: 2.6 to 3.6 mm (0.11 to 0.14 in.)
5) Apply grease to oil seal lip.

: Grease 99000–25030 (SUZUKI Super Grease C)
(A)
(B)
I7V10A510085-01
2) Remove countershaft left bearing cup and shim

using special tools.
Special tool
(A): 09944M96012
(B): 09942M15511
(C): 09921M26010
“a”
ICL80C510174-01
6) Install lubrication tube (1).

7) Install fluid reservoir plate (2) and lubrication tube
clamp (3) by tightening their mounting bolts to
specified torque.
ICL80C510235-01
Tightening torque 3) Remove differential side left bearing cup and shim
Fluid reservoir plate bolt (a): 5.4 N·m (0.55 kgf- using special tools.
m, 4.0 lbf-ft)
Lubrication tube clamp bolt (b): 5.4 N·m (0.55 Special tool
kgf-m, 4.0 lbf-ft) (A): 09913M75520
(b) (A)
3
(a)
(a)
ICL80C510175-01
ICL80C510176-02
Transaxle Case Disassembly and Reassembly 4) Remove transaxle case plugs (1).
AENFL80B5106055
Disassembly
1) Remove differential side oil seal (1) using a flat-
bladed screwdriver or the like.
1 (a)
ICL80C510239-01
2) Using special tools, assemble shim and differential

side left bearing cup.
1
ICL80C510236-01 NOTE
1
removed one.
Special tool
(A): 09924M74510
(B): 09944M88220
(A)
(B)
ICL80C510237-01
Reassembly
1) After applying ATF to new O-rings, fit them to
transaxle case plugs. Then install plugs to transaxle
case.
Tightening torque
Transaxle case plug (a): 7.5 N·m (0.76 kgf-m, 5.5 ICL80C510177-01
lbf-ft)
3) Using special tools, install shim and countershaft left
bearing cup.
(a)
NOTE
removed one.
Special tool
(A): 09924M74510
(B): 09944M88220
(A)
(B)
(a)
ICL80C510238-01
ICL80C510178-01
4) Using special tools, install new differential side oil NOTE

seal to transaxle case evenly at specified position
shown in figure. • If disc lining is exfoliated or discolored,
replace all discs.
Special tool • Before assembling new discs, soak them
(A): 09924M74510 in ATF for at least two hours.
(B): 09951M16091
Differential side oil seal installing depth
“a”: 2.6 to 3.6 mm (0.11 to 0.14 in.)
5) Apply grease to oil seal lip.
: Grease 99000–25030 (SUZUKI Super Grease C)
I2RH01510147-01
Brake separator plate and retaining plate

Dry plates and check for discoloration. If plate surface is
smooth and even color smear is indicated, plate should
be reused. If severe heat spot discoloration or surface
scuffing is indicated, plate must be replaced.
I2RH0B510253-01
Brake return spring subassembly

ICL80C510179-01
Measure brake return springs.
Evidence of extreme heat or burning in area of clutch
A/T Assembly Inspection and Adjustment may have caused springs to take heat set and would
AENFL80B5106056
require their replacement.
Inspection 1st and reverse brake return spring free length
Brake disc “a”: 22.57 mm (0.8886 in.)
Dry and check them for pitting, burn, flaking, significant
wear, glazing, cracking, charring and chips or metal NOTE
particles embedded in lining.
If discs show any of above conditions, replacement is
required.
ICL80C510180-01
Adjustment NOTE
Differential side bearing preload Record measured differential side bearing,
1) After applying ATF to differential assembly, fit it to because it is necessary to adjust
transaxle case. countershaft bearing preload.
2) Install torque converter housing to transaxle case,
then tighten torque converter housing bolts (1) to Available shim thickness
specified torque. Thickness Identification mark
1.80 mm (0.0709 in.) A
Tightening torque 1.85 mm (0.0728 in.) B
Torque converter housing bolt (a): 29 N·m (3.0 1.90 mm (0.0748 in.) C
kgf-m, 18.5 lbf-ft) 1.95 mm (0.0768 in.) D
2.00 mm (0.0787 in.) E
2.05 mm (0.0807 in.) F
2.08 mm (0.0819 in.) G
2.11 mm (0.0831 in.) H
2.14 mm (0.0843 in.) J
2.17 mm (0.0854 in.) K
2.20 mm (0.0866 in.) L
2.23 mm (0.0878 in.) M
2.26 mm (0.0890 in.) N
2.29 mm (0.0902 in.) P
2.32 mm (0.0913 in.) Q
2.35 mm (0.0925 in.) R
ICL80C510181-01 2.40 mm (0.0945 in.) S
3) Turn differential assembly more than 3 revolutions 2.45 mm (0.0965 in.) T
using special tool. 2.50 mm (0.0984 in.) U
2.55 mm (0.1004 in.) V
Special tool
2.60 mm (0.1024 in.) W
(A): 09928M06050
2.65 mm (0.1043 in.) X
4) Measure bearing preload at a speed of 100 rpm 2.70 mm (0.1063 in.) Y
using a small torque wrench and special tool.
6) Remove differential assembly.
Special tool
(A): 09928M06050
Countershaft bearing preload
Differential side bearing preload (a) measured as 1) After applying ATF to countershaft assembly (1) and
starting torque differential assembly (2), fit them.
In case of new bearing: 0.78 to 1.37 Nm (8.0 to
13.9 kgf-cm, 0.58 to 1.01 lbf-ft) 2
In case of reused bearing: 0.39 to 0.69 Nm (4.0 to
7.0 kgf-cm, 0.29 to 0.50 lbf-ft) 1
ICL80C510182-01
2) Install torque converter housing to transaxle case,

then tighten torque converter housing bolts (1) to
I2RH0B510256-01 specified torque.
5) If check result is not as specified, select shim with Tightening torque
suitable thickness from among the following table Torque converter housing bolt (a): 29 N·m (3.0
and replace it. Then adjust differential side bearing kgf-m, 18.5 lbf-ft)
preload within specification.

2.11 (0.0831 in.) E
2.14 (0.0843 in.) F
2.17 (0.0854 in.) G
2.20 (0.0866 in.) H
2.25 (0.0886 in.) K
2.30 (0.0906 in.) L
2.35 (0.0925 in.) M
2.40 (0.0945 in.) N
2.45 (0.0965 in.) P
2.50 (0.0984 in.) Q
2.55 (0.1004 in.) R
ICL80C510181-01 2.60 (0.1024 in.) S
3) Turn differential assembly more than 3 revolutions 2.65 (0.1043 in.) U
using special tool. 2.70 (0.1063 in.) W
Special tool 6) Remove differential assembly and countershaft
(A): 09928M06050 assembly.
4) Measure bearing preload at a speed of 100 rpm
using a small torque wrench and special tool. A/T Assembly Reassembly
AENFL80B5106057
Special tool
(A): 09928M06050 ! CAUTION
Countershaft bearing (b) – Differential side bearing • A/T consists of highly precise parts. As
=
preload preload (a) even flaw in small part may cause oil
leakage or decrease in function, check
Countershaft bearing preload (b) measured as each part carefully before installation.
starting torque
In case of new bearing: 0.33 to 0.76 Nm (3.4 to • Clean all parts with compressed air. Never
7.7 kgf-cm, 0.25 to 0.56 lbf-ft) use wiping cloths or rags.
In case of reused bearing: 0.17 to 0.38 Nm (1.8 to • Before assembling new clutch or brake
3.8 kgf-cm, 0.13 to 0.28 lbf-ft) discs, soak them in ATF for at least 2
hours.
• Lubricate O-rings with ATF.
• Apply ATF on sliding or rotating surfaces
of parts before assembly.
• Use SUZUKI Super Grease C to retain parts
in place.
• Be sure to install thrust bearings and races
in correct direction and position.
I3RM0B510067-01 • Check that snap ring ends are not aligned
5) If check result is not as specified, select shim with with one of cut outs and are installed in
suitable thickness from among the following table groove correctly.
and replace it. Then adjust countershaft bearing • Do not use adhesive cements on gaskets
preload within specification. and similar parts.
Available shim thickness • Be sure to torque each bolt and nut to
specification.
1.70 (0.0669 in.) 1
1) Install new manual shift shaft oil seal to transaxle
1.75 (0.0689 in.) 2
case evenly at specified position as shown in figure.
1.80 (0.0709 in.) 3
Use special tool and hammer it to install oil seal,
1.85 (0.0728 in.) 4
then apply ATF to its lip portion.
1.90 (0.0748 in.) 5
1.93 (0.0760 in.) 6 Special tool
1.96 (0.0772 in.) 7 (A): 09925M98210
1.99 (0.0783 in.) A
Manual shift shaft oil seal installing depth
2.02 (0.0795 in.) B
“a”: 0.75 to 1.25 mm (0.030 to 0.0492 in.)
2.05 (0.0807 in.) C
2.08 (0.0819 in.) D
“a”
(A)
ICL80C510242-01
2) Install manual detent spring (1) to transaxle case

and tighten manual detent spring bolt to specified ICL80C510184-01
torque.
Tightening torque
Manual detent spring bolt (a): 9.8 N·m (1.0 kgf-
m, 7.5 lbf-ft)
ICL80C510185-01
6) Install parking lock pawl bracket (1) to transaxle case

by tightening its mounting bolt to specified torque.
Tightening torque
ICL80C510183-01 Parking lock pawl bracket bolt (a): 7.4 N·m (0.75
3) Install parking lock pawl rod (2) to new manual valve kgf-m, 5.5 lbf-ft)
lever (1).
ICL80C510121-01 (a)
ICL80C510186-01
4) After applying ATF to new manual valve lever (1),
install new manual shift shaft (4), new spacer (3) and 7) After applying ATF to new O-rings, install them to 1st
manual valve lever to transaxle case. and reverse brake piston (3).
5) After installing new manual valve lever pin (2) using
spring pin remover with 3 mm (0.1 in.) in diameter (5)
and hammer, turn spacer to set position as shown in
figure. Then caulk spacer with punch (6).
I2RH0B510263-01
1. Inner O-ring 2. Outer O-ring
8) Install 1st and reverse brake piston (1) to transaxle

case (2).
NOTE Special tool

Be careful not to damage O-ring when (A): 09926M97620
installing 1st and reverse brake piston.
I2RH0B510267-01
12) Install new 1st and reverse brake snap ring so that
its both ends would be positioned in correct location
I2RH0B510264-01 as shown in figure.
9) After applying ATF to 1st and reverse brake return
spring subassembly (1), install it to transaxle case
(2).
I2RH0B510265-01
10) Apply ATF to 1st and reverse brake discs (2),

separator plates (3) and retaining plate (1), and then
install them to transaxle case.
I2RH0B510268-01
13) Measure 1st and reverse brake piston stroke.

disassemble, check and replace discs and plates.
I2RH0B510266-01
• Using special tool, measure 1st and reverse brake
11) Compress 1st and reverse brake return spring piston stroke when compressed air (400 – 800
subassembly using special tool and hydraulic press, kPa, 4.1 – 8.2 kgf/cm2, 58.0 – 116 psi) is blown
then attach new snap ring. through oil hole.
! CAUTION Special tool
(A): 09900M20607
Do not damage 1st and reverse brake return
(B): 09900M20701
spring subassembly, discs, plates and piston
(C): 09952M06020
by pressing in 1st and reverse brake return
spring subassembly passing its original 1st and reverse brake piston stroke
installing position more than 0.8 mm (0.03 Standard: 0.791 to 1.489 mm (0.03115 to 0.05862
in.). in.)
ICL80C510112-01
16) Press-fit new planetary ring gear subassembly (1) to

ICL80C510187-01 reduction drive gear (3) using special tools and
14) Press-fit reduction drive gear (1) to transaxle case hydraulic press as shown in figure.
(3) using special tools and hydraulic press as shown
in figure. ! CAUTION
! CAUTION • Do not reuse planetary ring gear

subassembly. Otherwise it may cause
• Do not use transaxle case as groundwork damage to planetary gear unit and/or
to press-fit reduction drive gear. reduction gears.
• Do not give load more than 20 kN (2039.4 • Do not use transaxle case as groundwork
kgf, 4496.2 lbf) with hydraulic press. to press-fit planetary ring gear
Otherwise, it may result in damaging subassembly.
reduction drive gear bearing. • Do not give load more than 20 kN (2039.4
kgf, 4496.2 lbf) with hydraulic press.
NOTE Otherwise, it may result in damaging
When replacing reduction drive gear, replace reduction drive gear bearing.
it together with reduction driven gear as a
set. Special tool
(A): 09951M18211
Special tool (B): 09944M78210
(A): 09951M18211
(B): 09944M78210
I2RH0B510272-01
2. Stand that can slightly lift transaxle case.
I2RH0B510270-01
17) Install new reduction drive gear nut.
2. Stand that can slightly lift transaxle case.
18) Measure preload by turning counter drive gear at a
speed of 100 rpm using a small torque wrench.
15) Install parking lock pawl (1) and spring (2). Apply
If measured preload is out of specification preload,
ATF to parking lock pawl shaft, then insert it into
replace the following parts.
transaxle case.
• A/T case
• Reduction drive gear
• Planetary ring gear sub assembly Measure distance “a” using vernier caliper (1) and
• Reduction drive gear nut straightedge (2). If check result is not as specified,
remove planetary gear assembly and reinstall it
! CAUTION properly.
• Do not tighten nut over specified torque. Distance between planetary gear assembly and
mating surface of transaxle case
• Carry out this procedure on rubber mat in
“a”: 30.3 to 32.3 mm (1.20 to 1.27 in.)
order not to damage transaxle case.
Special tool
(A): 09927M26010
Reduction drive gear bearing preload measured
as starting torque
Standard: 0.05 to 0.35 Nm (0.5 to 3.5 kgf-cm, 0.04
to 0.25 lbf-ft)
ICL80C510188-01
19) Using chisel or the like, caulk planetary ring gear

subassembly (1).
ICL80C510191-01
22) Apply ATF to one-way clutch No.2 assembly (1), and

install it to planetary gear assembly. After that,
ensure that planetary carrier (2) rotates only
counterclockwise direction [a], not clockwise
direction [b].
ICL80C510189-01
20) Apply ATF to planetary gear assembly (1), and fit it

to planetary ring gear assembly.
ICL80C510192-01
23) Install one-way clutch outer race retainer (1).
ICL80C510190-01
21) Check for correct installation of planetary gear

assembly as follows.
1
ICL80C510105-01
24) Install new O/D and 2nd coast brake retaining plate
snap ring (1). ICL80C510193-01
27) After applying ATF to O/D and 2nd coast brake

! CAUTION retaining plate (4), separator plates (3), discs (2) and
Be sure to install new O/D and 2nd coast rear plate (1), install them to transaxle case (5).
brake retaining plate snap ring correctly in
groove of transaxle case.
ICL80C510201-01
ICL80C510102-01
28) After applying ATF to planetary gear thrust bearing
25) After applying ATF to front sun gear thrust bearing
(1), install it to rear planetary sun gear subassembly
race (2), install it to front planetary sun gear (1) in
(2) in direction shown in figure.
direction shown in figure.
2 1
1
2 2
ICL80C510104-01
26) After applying ATF to front planetary sun gear (1),

install it to planetary gear assembly (2).
ICL80C510194-01
29) After applying ATF to rear planetary sun gear

subassembly (1), install them in transaxle case (2).
ICL80C510198-01
ICL80C510195-01 33) After applying ATF to intermediate shaft thrust

30) After applying ATF to rear sun gear thrust bearing bearing rear race (3), thrust bearing (2) and front
race (1), install it to rear planetary sun gear (2) in race (1), install them to forward and reverse clutch
direction shown in figure. assembly (4) referring to the following table.
ICL80C510196-01 I2RH0B510294-01
31) After applying ATF to rear sun gear thrust bearing 34) Apply ATF to forward and reverse clutch assembly
(1), install it to forward clutch hub (2) in direction (1).
shown in figure. Install forward and reverse clutch assembly while
rotating clockwise and counterclockwise frequently
to fit clutch discs to mating hubs.
NOTE
Before installation, align teeth of forward and
reverse clutch discs to facilitate installation.
ICL80C510197-01
32) After applying ATF to forward clutch hub (1), install it

in transaxle case.
ICL80C510199-01
35) Check for correct installation of forward and reverse

clutch assembly as follows.
Measure distance “a” using vernier caliper (1) and

straightedge (2). If check result is not as specified,
remove forward and reverse clutch assembly,
forward clutch hub, rear planetary sun gear
subassembly, and reinstall them properly.
Distance between forward and reverse clutch
assembly and mating surface of transaxle case
“a”: 32.9 to 36.3 mm (1.30 to 1.42 in.)
ICL80C510202-01
ICL80C510209-01
37) After applying ATF to new 2nd brake gaskets (1),

install them to transaxle case (2).
ICL80C510200-01
36) Measure O/D and 2nd coast brake piston stroke.

2
• Measure dimension “a” from end face of transaxle 1
ICL80C510204-01
case to O/D and 2nd coast brake rear plate (1)
using straightedge and vernier caliper. 38) After applying ATF to reverse clutch drum thrust
• Measure dimension “b” from O/D and 2nd coast bearing (1), install it to forward and reverse clutch
brake piston (2) to rear cover assembly mating assembly (2) in direction shown in figure.
surface using straightedge and vernier caliper.
• Calculate piston stroke from measured value of
dimensions “a” and “b”.
• Piston stroke = “a” – “b”
O/D and 2nd coast brake piston stroke
Standard: 0.65 – 1.05 mm (0.026 – 0.0413 in.)
If check result is not as specified, select O/D and 2nd
coast brake rear plate with suitable thickness from
among the following table and replace it.
ICL80C510210-01
Available O/D and 2nd coast brake rear plate
thickness 39) Remove sealant attached to mating surface of
transaxle rear cover (1) completely.
1.8 mm (0.071 in.) 1 40) Apply sealant to mating surface of transaxle rear
2.0 mm (0.079 in.) 2 cover (1) as shown in figure.
2.2 mm (0.087 in.) 3 “A”: Sealant 99000–31230 (SUZUKI Bond
2.4 mm (0.094 in.) 4 No.1216B)
2.6 mm (0.102 in.) 5
“a”
“a”
“A”
1
ICL80C510092-01
44) After applying ATF to differential assembly (1) and

ICL80C510206-01 countershaft assembly (2), install them to transaxle
a: 1.2 mm (0.047 in.) case.
41) Install transaxle rear cover assembly (1) on 1
transaxle case (2) and tighten rear cover bolts (3) to

specified torque. 2
Tightening torque
Rear cover bolt (a): 25 N·m (2.6 kgf-m, 18.5 lbf-
ft)
1
3, (a)
ICL80C510091-01
45) After applying ATF to direct clutch hub (1), install it to

planetary gear assembly.
3, (a)
2
3, (a)
ICL80C510207-01
42) Install fluid reservoir left plate No.1 (2) and No.2 (3)
and then tighten fluid reservoir left plate No.1 bolt
and No.2 bolt to specified torque.
Tightening torque
Fluid reservoir left plate bolt No.1 (a): 10 N·m ( ICL80C510211-01
1.0 kgf-m, 7.5 lbf-ft)
46) After applying ATF to input shaft rear thrust bearing
Fluid reservoir left plate bolt No.2 (b): 10 N·m (
(1) and thrust bearing race (2), install them into
1.0 kgf-m, 7.5 lbf-ft)
direct clutch hub (3) in direction shown in figure.
2
(b)
1
(a)
ICL80C510208-01
ICL80C510212-01
43) After applying ATF to new governor gasket No.2 (1),
47) After applying ATF to direct clutch assembly (1),
install it while rotating clockwise and
counterclockwise frequently to fit clutch discs to
mating hub.
NOTE Tightening torque

Before installation, align teeth of direct Oil pump assembly bolt (a): 25 N·m (2.6 kgf-m,
clutch discs to facilitate installation. 18.5 lbf-ft)
1
48) After applying ATF to input shaft front thrust bearing
(2), install it to direct clutch assembly (1) in direction (a)
shown in figure.
2 2
ICL80C510205-02
51) Check that input shaft (1) turns smoothly.
ICL80C510203-02
49) Check for correct installation of direct clutch

assembly as follows.
Measure distance “a” using vernier caliper (1) and
straightedge (2). If check result is not as specified,
remove direct clutch assembly, direct clutch hub and
ICL80C510214-02
reinstall them properly.
52) Measure input shaft thrust play by applying dial
Distance between direct clutch assembly and gauge onto input shaft end (1).
mating surface of transaxle case
“a”: 10.4 to 12.2 mm (0.410 to 0.480 in.) Special tool
(A): 09900M20607
(B): 09900M20701
Input shaft thrust play
0.3 to 0.9 mm (0.02 to 0.03 in.)
(A)
1 (B)
ICL80C510215-01
53) After applying ATF to new O-ring, fit it to breather

union (2). Then install breather union to transaxle
case.
54) Install breather hose (1).
ICL80C510213-01
50) Install oil pump assembly (1) to transaxle case and

tighten oil pump assembly bolts to specified torque.
NOTE
Check that O-rings are not twisted or caught
when installing.
1
2 Accumulator O-ring dimension

Inside Section
O-ring name
diameter diameter
Large C3 accumulator 24.6 mm 2.62 mm
O-ring (1) (0.968 in.) (0.103 in.)
Small C3 accumulator 21.8 mm 2.62 mm
O-ring (2) (0.858 in.) (0.103 in.)
ICL80C510086-01
55) Wipe off and clean mating surface between 59) Install C3 accumulator piston and spring referring to
transaxle case (1) and torque converter housing. the following table.
56) Apply sealant to transaxle case as shown in figure. Accumulator piston identification
“A”: Sealant 99000–31230 (SUZUKI Bond Identification as
No.1216B) Piston name embossed letters on
piston
C3 accumulator piston (3) SC-3A
Accumulator spring identification

Color of identification
Spring name
paint
C3 accumulator No.1
Yellow
spring (4)
1
3
2
ICL80C510217-01
4
“a”: 1.2 mm (0.047 in.)
57) Install torque converter housing to transaxle case.

a) Apply sealant to threads of four bolts (1).
No.1216B)
b) Tighten bolts to specified torque.
Tightening torque
Torque converter housing bolt (a): 29 N·m (3.0 ICL80C510060-01
kgf-m, 21.5 lbf-ft)
60) After applying ATF to new governor gasket No.1 (1),
ICL80C510218-01
ICL80C510058-01
58) Install new O-rings to accumulator piston and apply
ATF to them referring to the following table. 61) Install solenoid connector and valve body assembly.
(Page 5A-117)
62) Install A/T oil pan and oil strainer assembly. (Page Tightening torque
5A-114) Input shaft speed sensor bolt (a): 5.4 N·m (0.55
63) After applying ATF to new O-rings (1), fit it to fluid kgf-m, 4.0 lbf-ft)
cooler pipe unions (2). Then install fluid cooler pipe Output shaft speed sensor bolt (b): 5.4 N·m (
unions to transaxle case by tightening to specified 0.55 kgf-m, 4.0 lbf-ft)
torque.
Tightening torque 1 (a)
Fluid cooler pipe union (a): 25 N·m (2.6 kgf-m, (b)
18.5 lbf-ft)
64) After applying ATF to new O-ring (1), fit it to fluid filler 2
tube union (3). Then install fluid filler union to
transaxle case by tightening to specified torque.
Tightening torque
Fluid filler tube union (b): 25 N·m (2.6 kgf-m,
18.5 lbf-ft)
ICL80C510221-01
65) Install fluid cooler pipe (4) and new gaskets (5) by 68) Install transmission range sensor. (Page 5A-109)
tightening fluid cooler union bolts and fluid cooler
69) Install hook (1) and tightening hook nut to specified
pipe bracket bolt to specified torque.
torque.
Tightening torque
Tightening torque
Fluid cooler pipe union bolt (c): 35 N·m (3.6 kgf-
Hook nut (a): 25 N·m (2.6 kgf-m, 18.5 lbf-ft)
m, 26.0 lbf-ft)
Fluid cooler pipe bracket bolt (d): 11 N·m (1.1 (a)
kgf-m, 8.5 lbf-ft) 1
66) After applying ATF to new O-ring (6), fit it to fluid filler
tube (7). Then install fluid filler tube to transaxle case
and tightening fluid filler tube bolt to specified torque.
Tightening torque
Fluid filler tube bolt (e): 11 N·m (1.1 kgf-m, 8.5
lbf-ft)
ICL80C510222-01
70) Install harness brackets and select cable clamp.

(Page 5A-124)
71) Install torque converter (3) noting the following
6 points.
7
! CAUTION
3, (b)
• Before installing converter, check that its
1 pump hub portion is free from nicks, burrs
or damage which may cause oil seal to
(c)
leak.
(e)
• Do not drop converter on oil pump gear.
5
Damage in gear may cause a critical
(d) 4 trouble.
5
• Install torque converter while aligning grooves (1)
2, (a)
of torque converter with projections (2) of oil pump
drive gear.
1
ICL80C510220-02 • Install torque converter using care not to damage
67) After applying ATF to O-rings of each sensor, install oil seal of oil pump.
input shaft speed sensor (1) (color of marking: • After installing torque converter check that
green) and output shaft speed sensor (2) (color of distance “a” is within specification.
marking: white) by tightening its mounting bolts to
Torque converter installing position
specified torque.
“a”: More than 29.9 mm (1.18 in.)
• Check torque converter for smooth rotation.
• Apply grease around cup (6) at the center of

torque converter.
Grease A)
ICL80C510224-01
ICL80C510223-01
4. Flange nut 5. Torque converter housing
Specifications
AENFL80B5107002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Fluid pressure check hole bolt 7.5 0.76 5.5 /
ATF drain plug 17 1.7 12.5 
Transmission range sensor bolt 5.4 0.55 4.0 /
Manual select lever nut 12 1.2 9.0 
Output shaft speed sensor bolt 5.4 0.55 4.0 /
Input shaft speed sensor bolt 5.4 0.55 4.0 /
Oil pan bolt 7.0 0.71 5.5 
ATF temperature sensor plate bolt 6.8 0.69 5.0 /
Solenoid connector bolt 5.4 0.55 4.0 
Valve body bolt 11 1.1 8.5 
TCM mounting bolt 8.8 0.89 6.5 
Bracket nut 14 1.4 10.5 
Drive plate to torque converter No.1 bolt 23 2.3 17.0 
Drive plate to torque converter No.2 bolt 23 2.3 17.0 
Final gear bolt 78 8.0 57.5 
Torque converter housing plug 7.5 0.76 5.5 
Fluid reservoir plate bolt 5.4 0.55 4.0 
Lubrication tube clamp bolt 5.4 0.55 4.0 
Transaxle case plug 7.5 0.76 5.5 
Torque converter housing bolt 29 3.0 18.5 /
Manual detent spring bolt 9.8 1.0 7.5 
Parking lock pawl bracket bolt 7.4 0.75 5.5 
Rear cover bolt 25 2.6 18.5 
Fluid reservoir left plate bolt No.1 10 1.0 7.5 
Fluid reservoir left plate bolt No.2 10 1.0 7.5 
Oil pump assembly bolt 25 2.6 18.5 
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Torque converter housing bolt 29 3.0 21.5 
Fluid cooler pipe union 25 2.6 18.5 
Fluid filler tube union 25 2.6 18.5 
Fluid cooler pipe union bolt 35 3.6 26.0 
Fluid cooler pipe bracket bolt 11 1.1 8.5 
Fluid filler tube bolt 11 1.1 8.5 
Hook nut 25 2.6 18.5 
Reference:
“Select Lever Assembly Components”:
“Select Cable Components”:
“A/T Assembly Components”:
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components”:
“Differential Assembly Components”:

AENFL80B5108003
Grease SUZUKI Super Grease A P/No.: 99000–25011 /
SUZUKI Super Grease C P/No.: 99000–25030 ///
Sealant SUZUKI Bond No.1216B P/No.: 99000–31230 //
NOTE
“Select Cable Components”:
“A/T Assembly Components”:
“Oil Pump Assembly Components”:
“Direct Clutch Assembly Components”:
“Forward and Reverse Clutch Assembly Components”:
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components”:
“Countershaft Assembly Components”:
“Differential Assembly Components”:
Special Tool
AENFL80B5108004
09900M20605 09900M20607
Dial calipers (1/100 mm, 10 - Dial gauge
34 mm)
/ /////
09900M20701 09913M50121
Magnetic stand Oil seal remover
///// 
09913M61510 09913M70123
Bearing puller Bearing installer
 /
09913M75520 09913M84510
 //
09913M85210 09921M26010
Bearing installer Bearing outer race remover
collar
 /
09924M74510 09925M16510
/////// 

09925M37811M001 09925M88210
Oil pressure gauge Bearing puller attachment
/ /
09925M98210 09925M98221
Input shaft bearing installer Bearing installer
 
09926M37610 09926M37610M001
Bearing remover Bearing puller
/ /
09926M37610M002 09926M37610M003
Bearing puller attachment Bearing remover attachment
/ /
09926M58010 09926M95420
Bearing remover attachment Clutch spring compressor
 /
09926M97610 09926M97620
Spring compressor Spring compressor
/ /
09927M26010 09928M06050
Counter drive gear socket Differential preload adapter
/ ///
09942M15511 09944M68510
Sliding hammer Bearing installer attachment
/ 
09944M78210 09944M88220
Bearing installer support Oil seal installer
/ ////
09944M96012 09951M16091
Bearing outer race remover Oil seal installer
/ /
09951M18211 09952M06020
Oil seal remover & installer Dial gauge plate No.2
No. 2
/ /
SUZUKI scan tool (SUZUKI- 6

SDT)
— 1 2
This kit includes the
4
following items. 1. SUZUKI- 3
SDT 2. DLC cable 3. USB 5
cable 4. AC/DC power
supply 5. Voltage meter
probe 6. Storage case / 
/
5B-1 Manual Transmission/Transaxle: Petrol and Bi-Fuel CNG Model
Manual Transmission/Transaxle
Petrol and Bi-Fuel CNG Model

General Description
Manual Transaxle Construction
AENFL80B5211001
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
inhibited from being lapped with respective gear cones using lapping compound before they are assembled.
Manual Transmission/Transaxle: Petrol and Bi-Fuel CNG Model 5B-2
15
14
13 12
11
1
2
3
5 4
7
6
9
8
10
IFL80B521002-00
1. 5th speed sleeve &hub 6. Left case 11. Side cover

2. Input shaft 5th gear 7. Reverse gear shaft 12. 5th and reverse gear shift shaft
3. Input shaft 4th gear 8. Reverse idler gear 13. High speed gear shift shaft
4. High speed synchronizer sleeve & 9. Input shaft 14. Low speed gear shift shaft
hub
5. Input shaft 3rd gear 10. Right case 15. 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.
13
8 12
5
9 7 11
10
IFL80B521019-01
1. Gear shift control cable 6. Reverse gear shift lever 11. High speed gear shift shaft
2. Gear select control cable 7. 5th & reverse gear shift shaft 12. 5th and reverse gear shit shaft
3. Select cable lever 8. Gear shift & select shaft assembly 13. Gear shift control assembly
4. Shift cable lever 9. Gear shift interlock bolt
5. 5th gear shift fork 10. Low speed gear shift shaft
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.
2) 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
Repair Instructions
Manual Transaxle Oil Change 4) Remove drain plug (1), and drain oil.
AENFL80B5216002
5) Apply sealant to thread of drain plug (1), and tighten
1) Before changing oil, be sure to stop engine and keep
it to specified torque.
the vehicle horizontal.
2) With vehicle hoisted, check leakage. “A”: Sealant 99000–31260 (SUZUKI Bond
If leakage exists, correct it. No.1217G)
3) Remove oil level / filler plug (2).
Tightening torque Differential Side Oil Seal Replacement

Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m, AENFL80B5216003
15.5 lbf-ft) 1) Hoist vehicle and drain transaxle oil.

2) Remove left drive shaft assembly. “Front Drive Shaft
6) Add new specified oil until oil level reaches lower
Assembly Removal and Installation”: Front in
end of oil filler plug hole (3) as shown in figure.
Section 3A (Page 3A-3)
NOTE 3) Remove oil seal (1) using special tool.
It is highly recommended to use “SUZUKI Special tool
GEAR OIL 75W-80”. (A): 09913M50121
Transaxle oil specification
: API GL-4 (For SAE classification, refer to
viscosity chart.)
Transaxle oil capacity
Reference: 2.6 liters (5.5/4.6 US/Imp. pt.)
Viscosity chart
75W - 80, 75W - 85, 75W - 90

(A)
C - 30 - 20 - 10 0 10 20 30 40 1
F - 22 -4 14 32 50 68 86 104 I9P60A522004-01
[a] 4) Install new oil seal (1) using special tool.

IAP70A520004-01
[a]: Temperature NOTE

• Be sure to install oil seal facing its spring
7) Apply sealant to thread of level / filler plug, and then
side inward.
tighten it to specified torque.
• Be sure to install oil seal to surface of left
“A”: Sealant 99000–31260 (SUZUKI Bond case (2) in parallel.
No.1217G)
Special tool
Tightening torque
(A): 09944M88220
Transaxle oil level / filler plug (b): 21 N·m (2.1
(B): 09924M74510
kgf-m, 15.5 lbf-ft)
Distance between case surface and oil seal “a”
2, (b), “A”
LH side: 0 – 1.0 mm (0 – 0.04 in.)
RH side: 9.5 – 10.5 mm (0.37 – 0.41 in.)
5) Apply grease to oil seal lip and check drive shaft
where oil seal contacts for smoothness.
1, (a), “A”
Grease A)
“a”
IAP70A520005-01
(B)
(A) 1, “A”
I9P60A522005-02
6) Insert left drive shaft assembly. “Front Drive Shaft

Assembly Removal and Installation”: Front in
Section 3A (Page 3A-3)
IAP70A320006-01 7) Add transaxle oil. (Page 5B-4)
Gear Shift and Select Shaft Assembly Components

AENFL80B5216011
3 (a)
2 (a)
3 (a)
5 (a)
2 (a)
1 1217G
4 (a)
4 (a) 3 (a)
IFL80B521022-01
1. Gear shift & select shaft assembly 5. Gear shift interlock bolt
: Apply sealant 99000-31260 to mating surface.
2. Gear shift guide case No.1 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”: Petrol and Bi-Fuel CNG Model (Page 5B-6).
3. Gear shift guide case No.2 bolt : Do not reuse.
4. Gear shift guide case No.3 bolt
Gear Shift and Select Shaft Assembly Removal

and Installation
AENFL80B5216012
3
Removal 3
1) Remove battery and battery tray with ECM. “Battery 2
Removal and Installation”: Petrol and Bi-Fuel CNG in

Section 1J in related manual
2) Disconnect gear shift and gear select control cables
from transaxle.
3) Remove gear shift interlock bolt (1) and washer from
transaxle case. 1
4) Remove gear shift guide case bolts (3) and gear shift
& select shaft assembly (2).
IFL80B521023-01
Installation
(b)
NOTICE
(c)
Be sure to use new bolt with pre-coated
adhesive. Otherwise, bolt may loosen.
1) Install gear shift & select shaft assembly in the

1
following procedure. (a)
a) Clean sealing surface between gear shift &

select shaft assembly and transaxle. Remove oil,
old sealant and dust from sealing surface.
(d)
b) Apply sealant “A” to left case as shown in figure.
No.1217G) “A” (e)
Sealant amount for side cover

“a”: 1.5 mm (0.059 in.) “a”
“a”
c) Install gear shift & select shaft assembly (1).
d) Tighten gear shift guide case No.1, No.2 and
No.3 bolts by hand. IFL80B521024-01
NOTICE
Be sure to use new gear shift guide case No.2
and No.3 bolts with pre-coated adhesive.
Otherwise, bolt may loosen.
e) Tighten gear shift guide case No.1 bolt to

specified torque.
Tightening torque
Gear shift guide case No.1 bolt* (a): 23 N·m (
2.3 kgf-m, 17.0 lbf-ft)
f) Tighten gear shift guide case No.2 and No.3
bolts to specified torque.
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.
NOTICE
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)
3) Connect gear shift and gear select control cables to 5) Connect ECM connectors. “ECM Removal and
transaxle. Installation”: Petrol and Bi-Fuel CNG in Section 1C in
4) Install battery tray and battery. “Battery Removal and related manual
Installation”: Petrol and Bi-Fuel CNG in Section 1J in
related manual
Manual Transaxle Assembly Components

AENFL80B5216013
1217G 3
10 1217G (a)
6 (e)
39
40
OIL
[B] [A] 7
47 (g)
45 (c)
33 A
43
2 1217G
44 46
35
8 34
14 (b)
38 (f)
5 1217G
34
41
9 1217G (a)
36
42 (c) 21 (d)
20
11 (c)
13 (c)
OIL
15
23
32
OIL
24 18
23
17
4 22 (c)
OIL
1 16
25
14 (b) 19
32 12 (b)
OIL
29 28
31 (b)
37 30
27 (b)
26
IFL80B521004-03
[A]. Non-ABS model 29. Washer

[B]. ABS model 30. Reverse idler gear
1. Transaxle right case 31. Reverse gear shaft bolt
2. Transaxle left case 32. Inputshaft nut washer
: Apply sealant 99000-31260 to mating surface of left case and right case.
Gear shift & select shaft assembly 33. Oil seal
3. : For details, refer to “Gear Shift and Select Shaft Assembly Removal and : Apply grease 99000-25011 to oil seal lip.
:Apply sealant 99000-31260 to mating surface of gear shift & select shaft
assembly and left case.
4. Transaxle left case plate 34. Outer race

5. Transaxle side cover 35. Shim
: Apply sealant 99000-31260 to mating surface of side cover and left case.
6. Back up light switch 36. Input oil gutter
7. O-ring 37. Input shaft & countershaft assembly
: Apply transaxle oil to O-ring : For details, refer to “Input Shaft and Countershaft
Components”: Petrol and Bi-Fuel CNG Model (Page
5B-18).
8. Differential assembly 38. Gear shift locating bolt
: For details, refer to “Differential Disassembly and Reassembly”: Petrol and Bi-
Fuel CNG Model (Page 5B-25).
9. Oil level / filler plug 39. Breather plug
: Apply sealant 99000-31260 to threads.
10. Oil drain plug 40. Breather hose
11. Oil gutter bolt 41. Breather cover plate
12. Left case plate bolt 42. Breather cover plate bolt
13. Side cover bolt 43. Breather union
14. Transaxle case bolt 44. Cap
15. 5th speed synchronizer ring 45. Cap bolt
16. 5th speed synchronizer lever 46. Vehicle speed sensor
17. 5th speed synchronizer sleeve & hub 47. Vehicle speed sensor bolt
18. Inputshaft nut : 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)
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 : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
25. Input shaft 5th gear : Do not reuse.
26. Reverse gear shift lever : Apply transaxle oil.
27. Reverse gear shift lever bolt

28. Reverse gear shaft
Fifth Gear Disassembly and Reassembly

AENFL80B5216014
Disassembly 1
1) Remove gear shift & select shaft assembly. (Page
5B-6)
2) Remove side cover bolts and take off transaxle side
cover (1) using special tool.
NOTICE
Be sure not to distort side cover when it is
removed from transaxle left case. 1
Special tool
(A): 09921M96510 (A)
I9P60A522015-01
3) Unfasten caulking of input shaft nut (3).

4) Arrange a double-gear-engagement shifting both low
speed gear shift shaft (1) and high speed gear shift
shaft (2) in arrow direction, and then remove input
shaft nut (3) and washer.
8) Remove input shaft 5th gear, needle bearing and

then countershaft 5th gear (1). Gear puller (2) is
2
necessary if spline fitting of countershaft 5th gear is
tight.
IDAA0A521019-01
I9P60A522016-01
5) Remove 5th gear shift fork bolt (1).
6) Remove 5th gear shift fork (2) and 5th gear all Reassembly
together. Use gear puller for removal if spline fitting 1) Install countershaft 5th gear (1) to countershaft as
of hub is tight. shown in figure.
2
1
[c]
[b]
[a]
IAP70A520014-01
IDAA0A521020-01
7) Unfasten caulking of countershaft nut (2), install [a]: Countershaft side [c]: Short flange (Outside)
[b]: Long flange (Inside)
input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2). 2) Apply transaxle oil to needle bearing (3), and install it
to input shaft.
Special tool
3) Install input shaft 5th gear (1) to input shaft.
(A): 09927M76060
4) Install special tool to stop shaft rotation.
(A) Special tool
(A): 09927M76060
5) Tighten countershaft nut (2) to specified torque, and
2
caulk nut securely.
! CAUTION
• Be sure to use new countershaft nut.

1
• Be sure not to crack caulking part (4) of
I4RH01520016-01
countershaft nut while caulking it. Replace
it with new one if it is cracked.
Tightening torque
Countershaft nut (a): 100 N·m (10.2 kgf-m, 74.0
lbf-ft)
1
3
I9P60A522047-01
c) Install 5th speed synchronizer ring (1) to 5th

speed synchronizer hub (2) in specified direction
as shown in figure.
IAP70A520015-01
6) Assemble 5th speed synchronizer sleeve (1), 5th

speed synchronizer hub (2), 5th speed synchronizer
levers (3) and 5th speed synchronizer ring (4) as 2
follows.
I4RH01520055-01
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 groove (5)
on input shaft.
5
4
I4RH01520054-01
a) Install 5th speed synchronizer hub (1) to 5th

speed synchronizer sleeve (2) in specified
[b] 1
2
3
[a]
2
IAP70A520016-02 1
[a]: Chamfered side [b]: Long boss 3
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).
IFL80B521025-01
8) Tighten 5th gear shift fork bolt (2) to specified torque. d) Tighten side cover bolts to specified torque.
! CAUTION Tightening torque

Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
Be sure to use new 5th gear shift fork bolt
with pre-coated adhesive. Otherwise, bolt 1
may loosen.
“A”
Tightening torque
5th gear shift fork bolt (a): 10 N·m (1.0 kgf-m, 7.5
“A”
lbf-ft)
9) Arrange a double-gear-engagement shifting both low (a)
IAP70A520017-01
shaft (2) in arrow direction.
13) Install gear shift & select shaft assembly. (Page
10) Install washer and new input shaft nut (4).
5B-6)
11) Tighten input shaft nut to specified torque, and then
caulk nut securely.
Manual Transaxle Assembly Disassembly and
NOTICE Reassembly
AENFL80B5216015
• Once input shaft nut is removed, it will no
longer have necessary fastening Disassembly
performance. 1) Remove gear shift & select shaft assembly. (Page
Never reuse the input shaft nut. 5B-6)
• If caulking part of input shaft nut is 2) Remove input shaft 5th gear and countershaft 5th
cracked while caulking, the nut will spoil gear. (Page 5B-9)
locking performance. Replace the nut with 3) Remove left case plate bolts (3).
new one again.
4) Remove left case plate (1) and bearing set shim (2).
Tightening torque 5) Remove snap ring (6) using snap ring pliers (4).
Inputshaft bolt (a): 100 N·m (10.2 kgf-m, 74.0 lbf-
3
ft)
1, (a)
2 3
4, (b) 3
I9P60A522018-02
IDAA0A521022-01 2
5 4
12) Install side cover (1) to left case as follows.
7
a) Clean mating surfaces of left case and side
cover.
b) Apply specified amount of sealant to side cover
as shown in figure.
6
No.1217G)
“a”: 1.5 mm (0.059 in.) I9P60A522019-01
c) Mate side cover with left case. 5. Input shaft 7. Input shaft left bearing
6) Remove back up light switch. 

7) Remove reverse gear shaft bolt (1) with gasket.
1
(A)
I9P60A522021-01
8) Remove transaxle case bolts (1).
(a
((a) 2
1a
a))
IAP70A520019-01
10) Remove reverse gear shift lever bolts (4) and

reverse gear shift lever (5).
11) Pull out reverse gear shaft (1) with washer (2), and
then take off reverse idler gear (3).
12) Pull out 5th & reverse gear shift shaft (6).
NOTE
When removing 5th & reverse gear shift shaft
(6), push up high speed gear shift shaft and
shift it to 4th to facilitate removal of 5th &
reverse shift shaft.
1
1
2
3
5
IAP70A520018-02
9) Remove transaxle left case (1) from transaxle right

case (2) using special tool.
IFL80B521018-06
Special tool
(A): 09912M34510 13) Remove countershaft left bearing outer race (1) from
transaxle left case (2) using special tool.
Special tool
(A): 09913M70123
2
(A)
I2RH01520080-01
3) Install 5th & reverse gear shift shaft (1) into transaxle
right case (4). Reverse gear shift arm (3) has to be
I9P60A522025-01 joined with reverse gear shift lever (2) at the same
14) By tapping input shaft end with plastic hammer, push time
it out as assembly from case a little, and then
remove input shaft assembly (1), countershaft
1
assembly (2), high speed gear shift shaft (3) and low
speed gear shift shaft (4) all together. 3
NOTE
• Be sure not to damage countershaft right 2
bearing during the removal.
4
IFL80B521013-01
4) Mate reverse idler gear (1) with reverse gear shift

I2RH01520035-01
lever (2), insert reverse gear shaft (3) and washer (6)
15) Remove differential assembly from transaxle right into case (4) through idler gear and then align bolt
case. hole (7) on shaft with notch (8) on case.
5) Tighten new reverse gear shift lever bolts (5) to
Reassembly specified torque.
! CAUTION ! CAUTION
Be sure to use new bolt with pre-coated Be sure to use new reverse gear shift lever
adhesive. Otherwise, bolt may loosen. bolt with pre-coated adhesive. Otherwise,
bolt may loosen.
1) Install differential assembly into transaxle right case.
2) Join input shaft (5), countershaft (4), low speed gear Tightening torque
shift shaft (2) and high speed gear shift shaft (3) Reverse gear shift lever bolt (a): 23 N·m (2.3 kgf-
assemblies all together, and then install them into m, 17.0 lbf-ft)
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.
• Be sure not to damage countershaft right
bearing during the installation.
7
(a)
3
6
1
2
(a)
(a)
IFL80B521021-01
6) Install right case to left case as follows.

a) Clean mating surfaces of right case and left
case.
b) Apply specified amount of sealant to left case (1)
as shown in figure.
IAP70A520021-02
No.1217G) 8) Install new reverse gear shaft bolt (1) and new
gasket, and tighten it to specified torque.
Sealant amount for left case
“a”: 1.5 mm (0.059 in.) Tightening torque
Reverse gear shaft bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)
1,(a)
IAP70A520020-01
c) Mate right case with left case. I9P60A522030-01
7) Tighten transaxle case bolts to specified torque. 9) Install new snap ring (1) using snap ring pliers (4).
Tightening torque
Transaxle case bolt (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)
Available shim thickness

2 4
Clearance Applicable shim
3 0.42 – 0.47 mm
0.65 mm (0.0256 in.)
(0.0166 – 0.0185 in.)
0.48 – 0.52 mm
0.70 mm (0.0276 in.)
(0.0189 – 0.0204 in.)
0.53 – 0.57 mm
0.75 mm (0.0295 in.)
(0.0209 – 0.0224 in.)
1 0.58 – 0.62 mm
0.80 mm (0.0315 in.)
(0.0229 – 0.0244 in.)
0.63 – 0.67 mm
0.85 mm (0.0335 in.)
I7RW01520006-01 (0.0249 – 0.0263 in.)
2. Input shaft 3. Input shaft left bearing 0.68 – 0.72 mm
0.90 mm (0.0354 in.)
(0.0268 – 0.0283 in.)
10) To seat countershaft left bearing outer race (1) to 0.73 – 0.77 mm
0.95 mm (0.0374 in.)
bearing cone, tap countershaft left bearing outer (0.0288 – 0.0303 in.)
race (1) using special tool and plastic hammer (3). 0.78 – 0.82 mm
1.00 mm (0.0394 in.)
(0.0308 – 0.0322 in.)
Special tool 0.83 – 0.87 mm
(A): 09913M70123 1.05 mm (0.0413 in.)
(0.0327 – 0.0342 in.)
0.88 – 0.92 mm
1.10 mm (0.0433 in.)
(0.0347 – 0.0362 in.)
0.93 – 0.97 mm
3 1.15 mm (0.0453 in.)
(0.0367 – 0.0381 in.)
0.98 – 1.02 mm
1.20 mm (0.0472 in.)
2
(0.0386 – 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.
e) Turn countershaft (3) 10 times or more.
a) Push down bearing outer race and measure
clearance between transaxle right case and 1, (a)
bearing outer race using straightedge (1) and
feeler gauge (2).
1, (a)
1
1, (a)
2 IFL80B521026-01
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).
Clearance between case surface and 14) Install gear shift & select shaft assembly. (Page
straightedge 5B-6)
“a”: 0.18 – 0.22 mm (0.0071 – 0.0087 in.) 15) Install back up light switch. 
h) If clearance “a” is out of specification, select 16) Check input shaft for rotation in each gear position.
suitable shim which adjusts clearance “a” to 17) Also confirm continuity of back up light switch with
specification and put it on bearing outer race. gears in reverse position using ohmmeter.
NOTE
Insert 0.2 mm (0.008 in.) feeler to check
whether or not a shim fulfills specification.
I9P60A521048-02
12) Install left case plate (2) and then tighten new left
case plate bolts (1) to specified torque.
NOTE
After tightening bolts, make sure that
countershaft (3) can be rotated by hand with
certain load.
Tightening torque
Left case plate bolt (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)
1, (a)
1, (a)
1, (a)
IFL80B521027-01
4. Input shaft
13) Install input shaft 5th gear and countershaft 5th gear.
(Page 5B-9)
Input Shaft and Countershaft Components

AENFL80B5216018
32
31
30
29 26
21
23
28
21
27 25
24
OIL
19
18
OIL
22
OIL
20
IFL80B521028-01
1. Input shaft 13. Circlip 25. 2nd gear synchronizer center cone
2. Oil seal 14. 5th gear spacer 26. 2nd gear synchronizer inner ring
: Apply grease 99000-25011 to oil seal lip.
3. Input shaft right bearing 15. Countershaft right bearing 27. Circlip
4. Input shaft 3rd gear 16. Countershaft 28. Countershaft 2nd gear
5. Needle bearing 17. Countershaft 1st gear 29. Countershaft 3rd gear
6. High speed synchronizer ring 18. Low speed synchronizer inner ring 30. 3rd & 4th gear spacer
7. High speed synchronizer spring 19. Low speed synchronizer inner cone 31. Countershaft 4th gear
8. High speed synchronizer sleeve & hub 20. Low speed synchronizer outer ring 32. Countershaft left bearing
9. High speed synchronizer key 21. Low speed synchronizer spring : Do not reuse.
10. Circlip 22. Low speed synchronizer sleeve & hub : Apply transaxle oil.
11. Input shaft 4th gear 23. Low speed synchronizer key
12. Input shaft left bearing 24. 2nd gear synchronizer outer ring
Input Shaft Disassembly and Reassembly

AENFL80B5216019
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 1) Clean all components thoroughly, inspect them for
2) Remove 5th gear spacer (2), left bearing (3) and 4th any abnormality and replace them with new ones if
gear (4) all together using puller (5) and hydraulic necessary.
press. 2) Check clearance “a” between synchronizer ring (2)
and gear (1), key slot width “b” in synchronizer ring
! CAUTION
and replace with new one, if necessary. Also, check
To avoid gear teeth from damage, support gear teeth for damage.
4th gear with flat side of bearing puller.
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 from damage, support
3rd gear with flat side of bearing puller.
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 6) Install 3rd gear needle bearing (4), apply oil to it, and
specified position (1) as shown in figure. then install 3rd gear (1) and synchronizer ring (2).
7) Install high speed sleeve & hub assembly (3) using
NOTE
special tool and hydraulic press.
• Be sure to assemble sleeve and hub in
correct direction. (No direction is specified NOTE
to each key.) • Make sure that synchronizer ring key slots
• High speed synchronizer sleeve, hub, keys are aligned with keys (5) in sleeve & hub
and springs are smaller in size than low assembly.
speed ones. • Check free rotation of 3rd gear after press-
fitting sleeve & hub assembly.
Synchronizer key installation position
• Make sure that groove of hub assembly is
“a” = “b”
aligned with the oil hole of the shaft.
Special tool
(A): 09913M84510
[c]
3 [a]
(A)
IAP70A520026-01
[a]: 4th gear side [c]: Projecting end 5
[b]: Short flange side
5) Install right bearing (1) to input shaft (2) using

special tool and hydraulic press. 4 [b] 2
Special tool IAP70A520027-01
(A): 09913M80113 [a]: 3rd gear side [c]: Long flange

[b]: Key way
8) Install new circlip (1) to groove securely.

NOTE ! CAUTION
• Make sure that taper side of circlip is To avoid gear teeth damage, support 4th gear
facing downwards while the flat side is (3) on flat side of puller.
facing upward.
9) Install needle bearing (2), apply oil to it and then

install synchronizer ring (3) and 4th gear.
I2RH01520054-01
1. Countershaft
I2RH01520052-01
2) Apply puller (5) to 2nd gear (4), and remove 3rd &
4th gear spacer (2) and 3rd gear (3) together with
5. Input shaft
2nd gear using hydraulic press. Needle bearing
would come out with 2nd gear.
10) Press-fit left bearing (2) using special tool and
hydraulic press. ! CAUTION
Special tool To avoid gear teeth from damage, support
(A): 09913M80113 2nd gear with flat side of bearing puller.
11) Using the same special tool at step 10), install 5th
gear spacer (1).
! 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.
I3RH0A520020-01
Countershaft Disassembly and Reassembly

AENFL80B5216020
Disassembly
1) Remove left bearing cone (2) with 4th gear (3) using
puller (4) and hydraulic press. I7RW01520008-01
2. Low speed synchronizer sleeve

5) Apply puller (3) to 1st gear (2) and remove low • Difference between outer ring (1) and inner ring
speed synchronizer sleeve & hub assembly (1) with (3).
1st gear using hydraulic press.
Difference between synchronizer outer ring
! CAUTION and inner ring “a”
Standard: 0.95 – 1.25 mm (0.0375 – 0.0492 in.)
To avoid gear teeth from damage, support 1st Service limit: 0.5 mm (0.0196 in.)
gear with flat side of bearing puller.
I2RH01520057-01
IAP70A520028-01
2. Center cone
7) Remove 1st gear needle bearing from shaft.
8) In order to remove right bearing (1) from • Each chamfered tooth of gear and synchronizer
countershaft, grind with a grinder (2) one part “a” of ring for abnormal wear and damage
right bearing (1) as illustrated till it becomes thin.
• Gear tooth for abnormal wear and damage
! CAUTION Replace it with new one if necessary.
3) To ensure lubrication of countershaft (1), blow air
Be careful not to grind countershaft (3).
into oil holes (2) as shown in figure and make sure
that they are free from any obstruction.
3 2
1 “a”
3
1 I2RH01520060-01
4) Fit low speed synchronizer sleeve (4) to hub (3),

insert 3 keys (2) in it and then set springs (1) at
I5RW0A520035-01
specified position as shown in figure.
9) Break right bearing (2) at thin point with a chisel (1)
to remove it. NOTE
correct direction. (No direction is specified
1
to each key.)
• Low speed synchronizer keys and springs
are larger than high speed ones in size.
Synchronizer key installation position

“a” = “b”
2
I5RW0A520036-01
Reassembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new one if
necessary.
2) Check the following:
(D): 09924M07710
IAP70A520029-01
[a]: 1st gear side
5) Install right bearing cone (1) to countershaft (2) using

special tools and hydraulic press.
Special tool
(A): 09913M76010
(B): 09924M07720 I8RW0A520007-01
[A]: 1st gear side B: Short flange

A: Key slots

(A)
NOTE
(B)
1 Make sure that taper side of circlip is facing
downwards while the flat side is facing
2 upward.
10) Install needle bearing (2) and apply oil to needle

I5RW0A520038-01 bearing.
6) Install needle bearing (4), apply oil to it, and then 11) Install 2nd gear (6) with synchronizer outer ring (3),
install 1st gear (3). center cone (4) and inner ring (5) as shown in figure.
7) Install synchronizer outer ring (2).
8) 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-
• Check free rotation of 1st gear (3) after
press-fitting sleeve & hub assembly.
IAP70A520031-01
Special tool
(A): 09923M78210 [A]: Section [a] – [a]
(B): 09913M85210
(C): 09940M54910
12) 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
13) Press-fit 4th gear (2) using the same procedure as

step 11).
14) Install left bearing cone (1) 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
(E): 09913M80113
I2RH01520066-01
Gear Shift Shaft Components

AENFL80B5216021
1
7 (a)
5 (b)
IFL80B521011-02
1. Low speed gear shift shaft 5. 5th gear shift fork bolt 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
2. High speed gear shift shaft 6. Reverse gear shift lever 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
3. 5th & reverse gear shift shaft 7. Reverse gear shift lever bolt : Do not reuse.
4. 5th & reverse gear shift fork 8. Reverse gear shift arm
Differential Components
AENFL80B5216024
1 2 3
4
8 (a)
2
10
1
3 9
4
5 7
5
I7V20A522033-01
1. Differential pinion washer 6. Differential case : 100 Nm (10.2 kgf-m, 74.0lbf-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
AENFL80B5216025
Differential Disassembly and Reassembly
Disassembly Differential side gear backlash

1) Remove left bearing (1) using special tool. 0.10 – 0.15 mm (0.0039 – 0.0059 in.)
Special tool b) Differential side gear thrust play [b]

(A): 09913M65135 • Hold differential assembly with soft jawed vise
(B): 09913M85230 and apply measuring tip of dial gauge to side
gear as shown in figure.
• Move side gear up and down by hand and
read dial gauge.
(A)
(B)
0.03 – 0.31 mm (0.001 – 0.012 in.)
1
(A)
[a]
I6RS0E520012-01
2) Remove right bearing in the same manner as step (B)
1).
3) Support differential case (1) with soft jawed vise.
4) Remove final gear bolts and remove final gear.
5) Remove differential pinion shaft pin using special
tool and hammer, and then disassemble
components parts. [b] (A)
Special tool
(A): 09922M85811
(B)
(C)
IAP70A520032-03
2) Install new differential pinion shaft pin from right side

till the depth from differential case surface is about
1.2 mm (0.047 in.).
I6RS0E520013-01
3) Press-fit left bearing (1) using special tool and
2. Differential side gear hydraulic press.
Special tool
Reassembly
(A): 09951M16080
1) Install differential pinion, side gear and pinion shaft
to differential case, and measure backlash and thrust
play of differential side gear using special tools as
follows.
If measured value is out of specification, select
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
• Fixing differential pinion, turn side gear back
and forth and read dial gauge.
I6RS0E520038-01
2. Differential case 3. Differential side left bearing
5) Hold differential assembly with soft jawed vise (3),

I2RH01520074-01 install final gear (2) and then tighten new final gear
2. Differential case bolts (1).
Tightening torque
4) Press-fit right bearing (1) using special tools and Final gear bolt (a): 100 N·m (10.2 kgf-m, 74.0 lbf-
hydraulic press. ft)
Special tool
(A): 09925M15410
(B): 09940M54910
(C): 09913M85230
I5RW0A520049-01
Specifications
AENFL80B5217002
NOTE
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Transaxle oil drain plug 21 2.1 15.5 
Transaxle oil level / filler plug 21 2.1 15.5 
Gear shift guide case No.1 bolt* 23 2.3 17.0 
Gear shift interlock bolt 23 2.3 17.0 
Countershaft nut 100 10.2 74.0 
5th gear shift fork bolt 10 1.0 7.5 
Inputshaft bolt 100 10.2 74.0 
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 /
Reference:
“Gear Shift and Select Shaft Assembly Components”: Petrol and Bi-Fuel CNG Model
“Manual Transaxle Assembly Components”: Petrol and Bi-Fuel CNG Model
“Gear Shift Shaft Components”: Petrol and Bi-Fuel CNG Model
“Differential Components”: Petrol and Bi-Fuel CNG Model

AENFL80B5218003
Grease SUZUKI Super Grease A P/No.: 99000–25011 
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 ////
NOTE
“Gear Shift and Select Shaft Assembly Components”: Petrol and Bi-Fuel CNG Model
“Manual Transaxle Assembly Components”: Petrol and Bi-Fuel CNG Model
“Input Shaft and Countershaft Components”: Petrol and Bi-Fuel CNG Model
“Differential Components”: Petrol and Bi-Fuel CNG Model
Special Tool
AENFL80B5218004
09900M20607 09900M20701
Dial gauge Magnetic stand
 
09912M34510 09913M50121
Case separator Oil seal remover
 
09913M65135 09913M70123
Bearing puller Bearing installer
 /
09913M76010 09913M80113
 //
09913M84510 09913M85210
 /
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 09925M15410
 
09927M76060 09940M54910
Gear holder Front fork oil seal install
driver
/ /
09944M88220 09951M16080
Oil seal installer Bearing installer
 
09952M06010
Dial gauge plate No.1

Manual Transmission/Transaxle: Diesel Model 5B-30
Diesel Model
General Description
Manual Transaxle Construction
AENFL80B5221001
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 devices for high
performance of shifting to 1st and 2nd gears.
For servicing, it is necessary to use genuine sealant or its equivalent on mating surfaces of transaxle case which is
made of aluminum. The case fastening bolts must be tightened to specified torque by means of torque wrench. It is
also important that all parts are thoroughly cleaned with cleaning fluid and air-dried before reassembling.
Further, care must be taken to adjust preload of countershaft taper roller bearings. New synchronizer rings are
inhibited from being lapped with respective gear cones using lapping compound before they are assembled.
20
19
18
17
16
15
14
11
13
2
12
4
5
6
8 7
9
10
IFL80B522011-01
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
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.
5B-31 Manual Transmission/Transaxle: Diesel Model
13
4 6 7
3 8
6
9
11
10
5
12
IFL80B522002-02
1. Gear shift control cable 6. Reverse gear shift lever 11. Low speed gear shift shaft
2. Gear select control cable 7. 5th & reverse gear shift shaft 12. High speed gear shift shaft
3. Select cable lever 8. Gear shift & select shaft assembly 13. Gear shift control lever assembly
4. Shift cable lever 9. Gear shift interlock bolt
5. 5th gear shift fork 10. Gear shift & select lever
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.
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]
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
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 2
lever (1) is blocked by the projection of the reverse

shift limit yoke (2). 1
1 [A] 1 [A]
[C] [B]
2 2
I9P60A521053-01
[C] [B] [C] [B]
[A]: 5th [B]: Reverse [C]: 4th
I9P60A521051-01
[C]: 4th
Repair Instructions
Manual Transaxle Oil Change 3) Remove oil level / filler plug (2).
AENFL80B5226002
4) Remove drain plug (1), and drain oil.
1) Before changing oil, be sure to stop engine and keep
the vehicle horizontal during oil level check. 5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
2) With vehicle hoisted, check leakage.
If leakage exists, correct it.
“A”: Sealant 99000–31260 (SUZUKI Bond Neutral position switch specification

No.1217G) Neutral position: Continuity exists
Other than neutral position: No continuity
Tightening torque
Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m,
15.5 lbf-ft)
6) Add 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-80 gear oil”.
1
Transaxle oil specification
: API GL-4 (For SAE classification, refer to IFL10A520001-01
viscosity chart [A] in figure.)
Transaxle oil capacity (Reference) Manual Transaxle Unit Dismounting and
: 2.6 liters (5.5/4.6 US/Imp. pt.) Remounting
AENFL80B5226010
7) Apply sealant to thread of level / filler plug, and then Dismounting
tighten it to specified torque. 1) Remove engine with transaxle. “Engine Assembly
“A”: Sealant 99000–31260 (SUZUKI Bond Removal and Installation (ISG Model)”: Diesel in
No.1217G) Section 1D (Page 1D-36)
2) Remove left drive shaft assembly and drive
Tightening torque
intermediate shaft assembly.
Transaxle oil level / filler plug (b): 21 N·m (2.1
- Left drive shaft assembly: (Page 3A-3)
kgf-m, 15.5 lbf-ft)
- Intermediate shaft assembly: (Page 3A-9)
3) Remove starting motor. “Starting Motor Removal and
2, (b), “A” Installation”: Diesel in Section 1I (Page 1I-8)
4) Disconnect the following electric wires/connectors
and each clamp.
• Battery ground cable
• Back up light switch
• VSS (Non-ABS model)
• Neutral position switch
1, (a), “A”
5) Remove rear engine mounting bracket (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]
IFL80B522003-02
Neutral Position Switch On-Vehicle Inspection 1

AENFL80B5226026
Check neutral position switch (1) function using I9P60A522010-01
ohmmeter.
6) Remove other attached parts from transaxle, if any.
Replace gear shift & select shaft assembly if switch does
not operate as specified. 7) Remove transaxle-engine bolts.
8) Pull out transaxle from engine so as to disconnect
input shaft from clutch disc.
Remounting • Tighten each bolt to specified torque. 

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

AENFL80B5226011
2 (a)
2 (a)
3 (a)
4 (a)
2 (a)
1 1217G
3 (a)
3 (a)
IFL10A520002-01
1. Gear shift & select shaft assembly 5. Neutral position switch

: Apply sealant 99000-31260 to mating surface.
2. Gear shift guide case No.1 bolt : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: For tightening order, refer to “Gear Shift Control Lever and
Cable Removal and Installation”: Diesel Model in related
manual
3. Gear shift guide case No.2 bolt : Do not reuse.
: For tightening order, refer to “Gear Shift Control Lever and
Cable Removal and Installation”: Diesel Model in related
manual
4. Gear shift interlock bolt
Gear Shift and Select Shaft Assembly Removal 5) Disconnect neutral position switch connector.
and Installation 6) Remove gear shift guide case bolts (4) and gear shift
AENFL80B5226012
& select shaft assembly (2).
Removal
1) Remove coolant reservoir from coolant reservoir
bracket.
2) Remove battery and battery tray. “Battery Removal
and Installation”: Diesel (with ISG) in Section 1J
(Page 1J-24)
3) Disconnect gear shift and gear select control cables
from transaxle.
4) Remove gear shift interlock bolt (1) from transaxle
case.
4) Tighten gear shift guide case No.2 bolt (5) to

2 specified torque.
4 Tightening torque
Gear shift guide case No.2 bolt (d): 23 N·m (2.3
kgf-m, 17.0 lbf-ft)
4
3 1
5,(d)
1
3,(b)
IFL80B522014-01
3. Transaxle side cover
Installation 2,(a)
! CAUTION
4,(c)
1) Clean mating surface of gear shift guide case (1)

and transaxle left case (6), apply sealant to left case
as shown in figure, mate guide case with left case.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for left case
“a”: 1.5 mm (0.059 in.) 6
2) Install gear shift & select shaft assembly in the IFL80B522015-01
following procedure. 5) Connect neutral position switch connector.

a) Hand-tighten new gear shift guide case No.1 6) Connect gear shift and gear select control cables to
bolts (2) and No.2 bolts (3), (5). transaxle.
b) Tighten gear shift guide case No.1 bolt (2) to 7) Install battery tray and battery, and then install
specified torque. coolant reservoir to coolant reservoir bracket.
Tightening torque “Battery Removal and Installation”: Diesel (with ISG)
Gear shift guide case No.1 bolts (a): 23 N·m ( in Section 1J (Page 1J-24)
2.3 kgf-m, 17.0 lbf-ft) 8) Check input shaft for rotation in each gear position.
c) Tighten gear shift guide case No.2 bolt (3) to

specified torque.
Tightening torque
Gear shift guide case No.2 bolt (b): 23 N·m (
2.3 kgf-m, 17.0 lbf-ft)
3) Install new washer and new gear shift interlock bolt
(4), and then tighten it to specified torque.
Tightening torque
Gear shift interlock bolt (c): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)
Manual Transaxle Assembly Components

AENFL80B5226013
10 1217G (a)
1217G 3
6 (e)
[B] [A] 41 42
OIL
37 (g) 7
47 (c)
36 33 A
45
46 2 1217G
OIL
7
35
8 34
14 (b)
40 (f)
5 1217G
34
43
9 1217G (a)
36
44 (c)
21 (d)
20
1 11 (c)
22 (c)
23
13 (c)
OIL
15 18
32
OIL
24
4 17
14 (b)
OIL
16
33 A 25
19 12 (b)
32
31 (b)
OIL
39 28
29
26
30
27 (b)
26
IFL80B522005-02
[A]. Non ABS model 28. Reverse gear shaft

[B]. ABS model 29. Washer
1. Transaxle right case 30. Reverse idler gear
2. Transaxle left case 31. Reverse gear shaft bolt
: Apply sealant 99000-31260 to mating surface of left case and right
case.
3. Gear shift & select shaft assembly 32. Washer
: For details, refer to “Gear Shift and Select Shaft Assembly Removal
and Installation”: Diesel Model (Page 5B-34).
4. Transaxle left case plate 33. Oil seal
: Apply grease 99000-25011 to oil seal lip.
5. Transaxle side cover 34. Outer race
: Apply sealant 99000-31260 to mating surface of side cover and left
case.
6. Back up light switch 35. Shim
7. O-ring 36. Input oil gutter

: Apply transaxle oil to O-ring
8. Differential assembly 37. Vehicle speed sensor bolt
: For details, refer to “Differential Disassembly and Reassembly”:
Diesel Model (Page 5B-52).
9. Oil level / filler plug 38. Vehicle speed sensor
10. Oil drain plug 39. Input shaft & countershaft assembly
: Apply sealant 99000-31260 to threads. : For details, refer to “Input Shaft and Countershaft
Components”: Diesel Model in related manual.
11. Oil gutter bolt 40. Gear shift locating bolt
12. Left case plate bolt 41. Breather plug
13. Side cover bolt 42. Breather hose
14. Transaxle case bolt 43. Breather cover plate
15. 5th speed synchronizer ring 44. Breather cover plate bolt
16. 5th speed synchronizer lever 45. Breather union
17. 5th speed synchronizer sleeve & hub 46. Cap
18. Inputshaft nut 47. Cap bolt
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)
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 : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
26. Reverse gear shift lever : Do not reuse.
27. Reverse gear shift lever bolt : Apply transaxle oil.
Fifth Gear Disassembly and Reassembly

AENFL80B5226014
Disassembly 1
5B-34)
2) Remove side cover bolts and take off transaxle side
cover (1) using special tool.
! CAUTION
Be sure not to distort side cover when it is
removed from transaxle left case. 1
Special tool
(A)
(A): 09921M96510
I9P60A522015-01
3) Unfasten caulking of input shaft nut (3).

4) Arrange a double-gear-engagement shifting both low
shaft (2) in arrow direction, and then remove input
shaft nut (3) and washer.
I9P60A522016-01
3
Reassembly
1) Install countershaft 5th gear (1) to countershaft as
IDAA0A521019-01
shown in figure.
5) Remove 5th gear shift fork bolt (1).
6) Remove 5th gear shift fork (2) and 5th gear all
together. Use gear puller for removal if spline fitting [C]
of hub is tight. [B]
2
1
[A]
I9P60A522045-02
[A]: Countershaft side

[B]: Long flange (Inside)
[C]: Short flange (Outside)
IDAA0A521020-01
7) Unfasten caulking of countershaft nut (2), install 2) Apply transaxle oil to needle bearing (3), and install it
input shaft 5th gear (1) and special tool to stop to input shaft.
rotation of shafts, and then remove countershaft nut 3) Install input shaft 5th gear (1) to input shaft.
(2). 4) Install special tool to stop shaft rotation.
Special tool Special tool
(A): 09927M76060 (A): 09927M76060
5) Tighten new countershaft nut (2) to specified torque,
(A) and caulk nut securely.
Tightening torque
2 Countershaft nut (a): 100 N·m (10.2 kgf-m, 74.0
lbf-ft)
I4RH01520016-01
8) Remove input shaft 5th gear, needle bearing and

then countershaft 5th gear (1). Gear puller (2) is
necessary if spline fitting of countershaft 5th gear is
tight.
1
3
I9P60A522047-01
c) Install 5th speed synchronizer ring (1) to 5th

speed synchronizer hub (2) in specified direction
as shown in figure.
I7V20A522015-01
6) Assemble 5th speed synchronizer sleeve (1), 5th

speed synchronizer hub (2), 5th speed synchronizer
levers (3) and 5th speed synchronizer ring (4) as 2
follows.
I4RH01520055-01
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.
I4RH01520054-01
a) Install 5th speed synchronizer hub (1) to 5th

speed synchronizer sleeve (2) in specified
[B] 1
[A]
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 I3RH0A520080-01
(2). 8) Tighten new 5th gear shift fork bolt (1) to specified
torque.
Tightening torque
5th gear shift fork bolt (a): 10 N·m (1.0 kgf-m, 7.5 1
lbf-ft)
9) Arrange a double-gear-engagement shifting both low “B”
shaft (2) in arrow direction.
10) Install washer and new input shaft nut (4).
11) Tighten input shaft nut to specified torque, and then
caulk nut securely.
(a) (a)
NOTICE
1
• Once input shaft nut is removed, it will no (a)
longer have necessary fastening (a)
performance. (a)
Never reuse the input shaft nut.
• If caulking part of input shaft nut is (a)
cracked while caulking, the nut will spoil
locking performance. Replace the nut with (a) (a)
new one again. (a)
I9P60A522017-01
Tightening torque 13) Install gear shift & select shaft assembly. (Page
Inputshaft bolt (a): 100 N·m (10.2 kgf-m, 74.0 lbf- 5B-34)
ft)
Manual Transaxle Assembly Disassembly and
3 Reassembly
AENFL80B5226015
1, (a)
Disassembly
2
5B-34)
2) Remove input shaft 5th gear and countershaft 5th
gear. (Page 5B-37)
3) Remove left case plate bolts (3).
4, (b)
4) Remove left case plate (1) and bearing set shim (2).
5) Remove snap ring (6) using snap ring pliers (4).
IDAA0A521022-01 3
12) 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 to specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
3
5
“a”: 1.5 mm (0.059 in.)
Tightening torque 1
Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
3
I9P60A522018-02
11) Pull out reverse gear shaft (1) with washer (2), and
2 then take off reverse idler gear (3).
5 4
12) Pull out 5th & reverse gear shift shaft (6).
7
NOTE
When removing 5th & reverse gear shift shaft
(6), push up high speed gear shift shaft and
shift it to 4th to facilitate removal of 5th &
6
reverse shift shaft.
6
I9P60A522019-01
5. Input shaft
7. Input shaft left bearing
6) Remove back up light switch. 

1
7) Remove reverse gear shaft bolt (1) with gasket.
2
4 3
5
I9P60A522021-01 IFL80B522006-02
8) Remove transaxle case bolts (1). 13) Remove countershaft left bearing outer race (1) from
9) Remove transaxle left case (2) from transaxle right transaxle left case (2) using special tool.
case (3) using special tool.
Special tool
Special tool (A): 09913M70123
(A): 09912M34510
2
(A)
2 (A) 1
I9P60A522025-01
1 14) By tapping input shaft end with plastic hammer, push

it out as assembly from case a little, and then
1 remove input shaft assembly (1), countershaft
1
assembly (2), high speed gear shift shaft (3) and low
speed gear shift shaft (4) all together.
1 1
I9P60A522022-03
10) Remove reverse gear shift lever bolts (4) and

reverse gear shift lever (5).
NOTE
1
3
2
I2RH01520035-01
15) Remove differential assembly from transaxle right

case.
Reassembly
IFL80B522009-02
! CAUTION
4) Mate reverse idler gear (1) with reverse gear shift
Be sure to use new bolt with pre-coated lever (2), insert reverse gear shaft (3) and washer (6)
adhesive. Otherwise, bolt may loosen. into case (4) through idler gear and then align bolt
hole (7) on shaft with notch (8) on case.
1) Install differential assembly into transaxle right case.
5) Tighten new reverse gear shift lever bolts (5) to
2) Join input shaft (5), countershaft (4), low speed gear specified torque.
shift shaft (2) and high speed gear shift shaft (3)
assemblies all together, and then install them into Tightening torque
transaxle right case (1). Reverse gear shift lever bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lbf-ft)
NOTE
• Be sure not to damage oil seal by input 7
shaft spline while installing.
• Make sure that countershaft is engaged
with final gear.
3
6
1
4
I2RH01520080-01
5, (a) 2
3) Install 5th & reverse gear shift shaft (1) into transaxle
right case (4). Reverse gear shift arm (3) has to be
joined with reverse gear shift lever (2) at the same
time.
IFL80B522013-01
6) Clean mating surfaces of both transaxle right and left

cases, apply sealant to transaxle left case (2) as
shown in figure, then mate it with transaxle right
case (1).

No.1217G) 2 4
Sealant amount for left case 3

“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 1
lbf-ft)
I7RW01520006-01
2. Input shaft
3. Input shaft left bearing
10) To seat countershaft left bearing outer race (1) to

bearing cone, tap countershaft left bearing outer
race (1) by using special tool and plastic hammer
(3).
Special tool
(A): 09913M70123
3, (a)
3, (a) 3, (a)
1
3, (a) 3, (a)
I9P60A522029-02 1
I9P60A522031-01
8) Install new reverse gear shaft bolt (1), with new
gasket and tighten it to specified torque. 2. Input shaft
Tightening torque 11) Select countershaft 5th gear shim as follows.

Reverse gear shaft bolt (a): 23 N·m (2.3 kgf-m,
a) Push down bearing outer race and measure
17.0 lbf-ft)
clearance “a” between transaxle right case and
bearing outer race using straightedge (1) and
feeler gauge (2).
1,(a)
I9P60A522030-01
9) Install new snap ring (1) using snap ring pliers (4).
1
2
“a”
I9P60A521037-01
b) Select a shim which fits the clearance measured

above.
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.) NOTE
0.58 – 0.62 mm Insert 0.2 mm (0.008 in.) feeler to check
0.80 mm (0.0314 in.)
(0.0228 – 0.0244 in.) whether or not a shim fulfills specification.
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.)
0.73 – 0.77 mm
0.95 mm (0.0374 in.)
(0.0287 – 0.0303 in.)
0.78 – 0.82 mm
1.00 mm (0.0393 in.)
(0.0307 – 0.0322 in.)
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.)
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.)
(0.0385 – 0.0401 in.)
I9P60A521048-02
c) Put the thickest spare part shim on bearing outer
race and install left case plate (2). 12) Install left case plate (2) and then tighten new left
case plate bolts (1) to specified torque.
d) Tighten used bolts (1) to specified torque.
NOTE
Tightening torque
Left case plate bolt (a): 23 N·m (2.3 kgf-m, After tightening bolts, make sure that
17.0 lbf-ft) countershaft (3) can be rotated by hand with
certain load.
e) Turn countershaft (3) 10 times or more.
Tightening torque
1, (a)
Left case plate bolt (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)
1, (a)
1, (a)
1, (a)
1, (a)
IFL80B521026-01 3
4. Input shaft
1, (a)
f) Remove left case plate. IFL80B521027-01
g) Place straightedge (1) over shim (3) and 4. Input shaft

compress it by hand through straightedge, and
measure “a” using feeler gauge (2). 13) Install input shaft 5th gear and countershaft 5th gear.
(Page 5B-37)
14) Install gear shift & select shaft assembly. (Page 5) Remove high speed synchronizer sleeve & hub
5B-34) assembly (2) together with 3rd gear (3) by using
15) Install back up light switch.  puller (4) and hydraulic press.
16) Check input shaft for rotation in each gear position. ! CAUTION
17) Also confirm continuity of back up light switch with
To avoid gear teeth damage, support 3rd gear
gears in reverse position using ohmmeter.
at flat side of bearing puller.
Input Shaft Disassembly and Reassembly

AENFL80B5226019
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.

Reassembly
I4RH01520029-01
2) Remove 5th gear spacer (2), left bearing (3) and 4th any abnormality and replace them with new ones if
gear (4) all together using puller (5) and hydraulic necessary.
press.
2) Check clearance “a” between synchronizer ring (2)
! CAUTION and gear (1), key slot width “b” in synchronizer ring
and replace with new one, if necessary. Also, check
To avoid gear teeth damage, support 4th gear gear teeth for damage.
at flat side of bearing puller.
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.
I5JB0A520054-01
I7RW01520007-01
3) To ensure lubrication of input shaft (1), blow air to oil

holes (2) as shown in figure and make sure that they
are free from any obstruction.
I3RH0A520019-01
6) Install 3rd gear needle bearing (4), apply oil to it, and
I2RH01520049-01 then install 3rd gear (1) and synchronizer ring (2).
4) Fit high speed synchronizer sleeve (4) to hub (3), 7) Install high speed sleeve & hub assembly (3) using
insert 3 keys (2) in it and then set springs (1) at special tool and hydraulic press.
NOTE
NOTE
• Be sure to assemble sleeve and hub in are aligned with keys (5) in sleeve & hub
correct direction. (No direction is specified assembly.
to each key.)
• Check free rotation of 3rd gear after press-
• High speed synchronizer sleeve, hub, keys fitting sleeve & hub assembly.
and springs are smaller in size than low
speed ones.
Synchronizer spring installation position
Special tool
“a” = “b”
(A): 09913M84510
[C]
[B]
[C]
3 [A]
(A)
[C]
[A]
I9P60A522049-02
[A]: 4th gear side

[B]: Short flange side 4 [B] 2
[C]: Projecting end I9P60A522051-01
[A]: 3rd gear side

5) Install right bearing (1) to input shaft (2) using [B]: Key way
special tool and hydraulic press. [C]: Long flange
Special tool
(A): 09913M80113 8) Install new circlip (1) to groove securely.
NOTE
Make sure that taper side of circlip is facing
downwards while the flat side is facing
upward.
9) Install needle bearing (2), apply oil to it and then

install synchronizer ring (3) and 4th gear (4).
I2RH01520054-01
1. Countershaft
2) Apply puller (5) to 2nd gear (4), and remove 3rd &
4th gear spacer (2) and 3rd gear (3) together with
2nd gear by using hydraulic press. Needle bearing
would come out with 2nd gear.
I2RH01520052-01 ! CAUTION
5. Input shaft To avoid gear teeth damage, be sure to
support 2nd gear at flat side of bearing puller.
10) Press-fit left bearing (2) by using special tool and
hydraulic press.
Special tool
(A): 09913M80113
11) Using the same special tool at step 10), install 5th
gear spacer (1).
! 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.
I3RH0A520020-01
Countershaft Disassembly and Reassembly I7RW01520008-01

AENFL80B5226020
2. Low speed synchronizer sleeve
Disassembly
1) Remove left bearing cone (2) with 4th gear (3) by 5) Apply puller (3) to 1st gear (2) and remove low
using puller (4) and hydraulic press. speed synchronizer sleeve & hub assembly (1) with
1st gear by using hydraulic press.
! CAUTION
To avoid gear teeth damage, support 4th gear
(3) at flat side of puller.
! 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
at flat side of bearing puller. in.)
Service limit “b”: 0.5 mm (0.0196 in.)
I2RH01520057-01

7) Remove 1st gear needle bearing from shaft. I2RH01520059-01
8) In order to remove right bearing (1) from 3) To ensure lubrication of countershaft (1), blow air
countershaft, grind with a grinder (2) one part “a” of into oil holes (2) as shown in figure and make sure
right bearing (1) as illustrated till it becomes thin. that they are free from any obstruction.
! CAUTION
Be careful not to grind countershaft (3).
I2RH01520060-01
2
4) Fit low speed synchronizer sleeve (4) to hub (3),
3
insert 3 keys (2) in it and then set springs (1) at
“a”
1
3
1 NOTE
I5RW0A520035-01
correct direction. (No direction is specified
to each key.)
9) Break right bearing (2) at thin point with a chisel (1)
to remove it. • Low speed synchronizer keys and springs
are larger than high speed ones in size.
Synchronizer spring installation position

1
“a” = “b”
2
I5RW0A520036-01
Reassembly
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.
NOTE
• Support shaft with special tool as shown in
figure so that retainer of bearing cone will
be free from compression.
(8) are aligned with keys (5) while press-
• 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
5) Install right bearing cone (1) to countershaft (2) by

B
using special tools and hydraulic press.
Special tool
(A): 09913M76010
(B): 09924M07720
(A)
(B)
1
2
IBP80A522003-01
[A]: Section B – B
B: 1st gear side
I5RW0A520038-01
C: Short flange
6) Install needle bearing (4), apply oil to it, and then
install 1st gear (3).
7) Install synchronizer outer ring (2), center cone (6)
and inner ring (7) together as shown in figure. NOTE
8) Install low speed sleeve & hub assembly (1) by using Make sure that taper side of circlip is facing
special tools and hydraulic press. downwards while the flat side is facing
upward.
10) Install needle bearing (2) and apply oil to needle

bearing.
11) Install 2nd gear (6) with synchronizer outer ring (3),
center cone (4) and inner ring (5) as shown in figure.
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
Gear Shift Shaft Components

AENFL80B5226021
7 (a)
4
5 (b)
3
8
IFL80B522008-01
1. Low speed gear shift shaft 5. 5th gear shift fork bolt Do not reuse.
2. High speed gear shift shaft 6. Reverse gear shift lever 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
3. 5th & reverse gear shift shaft 7. Reverse gear shift lever bolt 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
4. 5th gear shift fork 8. 5th & reverse gear shift yoke
Differential Components
AENFL80B5226024
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 : 100 Nm (10.2 kgf-m, 74.0 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 • Fixing differential pinion, turn side gear back
AENFL80B5226025 and forth and read dial gauge.
Disassembly Differential side gear backlash
1) Remove left bearing (1) using special tool. 0.10 – 0.15 mm (0.0039 – 0.0059 in.)
Special tool b) Differential side gear thrust play [B]

(A): 09913M65135 • Hold differential assembly with soft jawed vise
(B): 09913M85230 and apply measuring tip of dial gauge to side
• Move side gear up and down by hand and
read dial gauge.
(A)
(B)
0.03 – 0.30 mm (0.001 – 0.012 in.)
1
(A)
[A]
I6RS0E520012-01
(B)
2) Remove right bearing in the same manner as step
1).
3) Support differential case (1) with soft jawed vise.
4) Remove final gear bolts and remove final gear.
5) Remove differential pinion shaft pin by using special
tool and hammer, and then disassemble
components parts. [B] (A)
Special tool
(A): 09922M85811
(B)
(C)
I7V20A522045-01
2) Install new differential pinion shaft pin from right side

till the depth from differential case surface is about
1.2 mm (0.047 in.).
I6RS0E520013-01 3) Press-fit left bearing (1) by using special tool and
2. Differential side gear hydraulic press.
Special tool
Reassembly
(A): 09951M16080
1) Install differential pinion, side gear and pinion shaft
to differential case, and measure backlash and thrust
play of differential side gear using special tools as
follows.
If measured value is out of specification, select
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
I6RS0E520038-01
2. Differential case
3. Differential side left bearing
I2RH01520074-01 5) Hold differential assembly with soft jawed vise (3),

2. Differential case install final gear (2) and then tighten new final gear
bolts (1).
4) Press-fit right bearing (1) by using special tools and
! CAUTION
hydraulic press.
Special tool
(A): 09925M15410
(B): 09940M54910
(C): 09913M85230 Tightening torque
Final gear bolt (a): 100 N·m (10.2 kgf-m, 74.0 lbf-
ft)
I5RW0A520049-01
Specifications
AENFL80B5227002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Transaxle oil drain plug 21 2.1 15.5 
Transaxle oil level / filler plug 21 2.1 15.5 
Gear shift guide case No.1 bolts 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 
Countershaft nut 100 10.2 74.0 
5th gear shift fork bolt 10 1.0 7.5 
Inputshaft bolt 100 10.2 74.0 
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 /
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Reference:
“Gear Shift and Select Shaft Assembly Components”: Diesel Model
“Manual Transaxle Assembly Components”: Diesel Model
“Gear Shift Shaft Components”: Diesel Model
“Differential Components”: Diesel Model

AENFL80B5228003
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 ////
NOTE
“Gear Shift and Select Shaft Assembly Components”: Diesel Model
“Manual Transaxle Assembly Components”: Diesel Model
“Differential Components”: Diesel Model
Special Tool
AENFL80B5228004
09900M20607 09900M20701
Dial gauge Magnetic stand
 
09912M34510 09913M65135
Case separator Bearing puller
 
09913M70123 09913M76010
/ 
09913M80113 09913M84510
// 
09913M85210 09913M85230
Bearing installer Bearing remover tool
/ /
09921M96510 09922M85811
Oil pan seal cutter Spring pin remover (4.5 mm)
 
09923M78210 09924M07710
Bearing installer Synchronizer hub installer
// 
09924M07720 09925M15410
Synchronizer hub installer Oil seal installer
 
09927M76060 09940M54910
Gear holder Front fork oil seal install
driver
/ /
09951M16080 09952M06010
Bearing installer Dial gauge plate No.1
 
Clutch: Petrol and Bi-Fuel CNG Model 5C-1
Clutch
Repair Instructions
Removal and Installation (Keyless Push Start
Model)
AENFL80B5316001
Removal
1) Disconnect connector of CPP No.1 switch (1) with
ignition “OFF”.
2) Remove CPP No.1 switch (1) from clutch pedal
bracket.
“a”
(a)
IFL80B531004-01
Tightening torque
CPP No. 1 switch lock nut (a): 7.5 N·m (0.76 kgf-m,
5.5 lbf-ft)
3) Connect connector to CPP No.1 switch securely.

Inspection and Adjustment (Keyless Push Start
IFL80B531003-01 Model)
AENFL80B5316002
Installation Inspection
Measure resistance between terminals under each
1) Install CPP No.1 switch to clutch pedal bracket.
condition below. If check result is not satisfactory,
2) Maintain the clearance between end of thread part of replace switch.
switch and pedal stay as per specification with clutch
pedal pulled up and hold. Tighten the switch to CPP No. 1 switch specification
specified torque. When switch shaft is pushed [a]: No continuity
When switch shaft is free [b]: Continuity
Gap between Switch thread top and pedal stay
“a”: 4.25 to 4.75 mm (0.167 to 0.187 in.)
5C-2 Clutch: Petrol and Bi-Fuel CNG Model
“a”
(a)
IAP70A530002-02

Removal and Installation
AENFL80B5316020
Removal IFL80B531006-01
1) Disconnect connector of CPP No.2 switch (1) with Tightening torque

ignition “OFF”. CPP No.2 switch lock nut (a): 7.5 N·m (0.76 kgf-m,
2) Remove CPP No.2 switch (1) from clutch pedal 5.5 lbf-ft)
bracket.
3) Connect connector to CPP No.2 switch securely.

Inspection and Adjustment
AENFL80B5316021
Inspection
Measure resistance between terminals under each
1 condition below. If check result is not satisfactory,
replace switch.
CPP No. 2 switch specification
When switch shaft is pushed [a]: No continuity
When switch shaft is free [b]: Continuity
IFL80B531005-01
Installation
1) Install CPP No.2 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 (0.056 to 0.074 in.)
Clutch: Petrol and Bi-Fuel CNG Model 5C-3
Clutch Pedal Assembly Components

AENFL80B5316013
b (a)
1
(b)
(c)
(c)
a (a) 6
2 E
3
2
4
7 E
IFL80B531001-02
1. Clutch pedal bracket assembly 7. Clutch pedal spring

: Apply grease 99000-25050 to inside of spring.
2. Pedal boss bushing 8. CPP (Clutch Pedal Position) No.1 switch
: Apply grease 99000-25050 to all surface of bushing.
3. Pedal shaft spacer 9. CPP (Clutch Pedal Position) No.2 switch
4. Clutch pedal : Tightening order: “a” → “b”
5. Pedal pad : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
6. Clutch pedal stop cushion : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
7. Clutch pedal spring : 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)
Specifications
AENFL80B5317002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
CPP No. 1 switch lock nut 7.5 0.76 5.5 
CPP No.2 switch lock nut 7.5 0.76 5.5 
Reference:
“Clutch Pedal Assembly Components”: Petrol and Bi-Fuel CNG Model
“Fastener Caution” in Section 00 in related manual
5C-4 Clutch: Petrol and Bi-Fuel CNG Model

AENFL80B5318003
NOTE
“Clutch Pedal Assembly Components”: Petrol and Bi-Fuel CNG Model
Clutch: Diesel Model 5C-5
Diesel Model
Repair Instructions
CPP (Clutch Pedal Position) No.1 Switch CPP (Clutch Pedal Position) No.2 Switch
Removal and Installation (Keyless Push Start Removal and Installation
AENFL80B5326017
Model) Refer to “CPP (Clutch Pedal Position) No.2 Switch
AENFL80B5326001
Refer to “CPP (Clutch Pedal Position) No.1 Switch Removal and Installation”: Petrol and Bi-Fuel CNG
Removal and Installation (Keyless Push Start Model)”: Model (Page 5C-2)
Petrol and Bi-Fuel CNG Model (Page 5C-1)
CPP (Clutch Pedal Position) No.1 Switch Inspection and Adjustment
AENFL80B5326018
Inspection and Adjustment (Keyless Push Start Refer to “CPP (Clutch Pedal Position) No.2 Switch
Model) Inspection and Adjustment”: Petrol and Bi-Fuel CNG
AENFL80B5326002
Refer to “CPP (Clutch Pedal Position) No.1 Switch Model (Page 5C-2)
Inspection and Adjustment (Keyless Push Start Model)”:
Petrol and Bi-Fuel CNG Model (Page 5C-1)
Clutch Pedal Assembly Components

AENFL80B5326012
b (a)
1
(b)
(c)
(c)
a (a) 6
2 E
3
2
4
7 E
IFL80B531001-02
5C-6 Clutch: Diesel Model
1. Clutch pedal bracket assembly 7. Clutch pedal spring

2. Pedal boss bushing 8. CPP (Clutch Pedal Position) No.1 switch
: Apply grease 99000-25050 to all surface of bushing.
3. Pedal shaft spacer 9. CPP (Clutch Pedal Position) No.2 switch
4. Clutch pedal : Tightening order: “a” → “b”
5. Pedal pad : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
6. Clutch pedal stop cushion : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
7. Clutch pedal spring : 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)
Specifications
AENFL80B5327002
Reference:
“Clutch Pedal Assembly Components”: Diesel Model
“Fastener Caution” in Section 00 in related manual

AENFL80B5328003
NOTE
“Clutch Pedal Assembly Components”: Diesel Model
Section 6
Steering
CONTENTS
NOTE
Precautions .................................................6-1 Power Assisted Steering System........... 6C-1

Precautions............................................................. 6-1 General Description ............................................. 6C-*
Precautions for Steering ....................................... 6-1 P/S System Description ...................................... 6C-*
Steering System Note ............................................ 6-* Description of EPS System Component
Precautions for Diagnosing Trouble....................... 6-* Function ............................................................ 6C-*
OBD System Description .................................... 6C-*
Steering General Diagnosis.....................6A-* Schematic and Routing Diagram ........................6C-1
Precautions........................................................... 6A-* P/S System Diagram...........................................6C-1
Precautions for Steering General Diagnosis ........6A-* Component Location ........................................... 6C-*
Diagnostic Information and Procedures............ 6A-* Power Steering Control System Component
Steering Symptom Diagnosis...............................6A-* Location............................................................. 6C-*
Steering System Inspection .................................6A-* Diagnostic Information and Procedures ............6C-2
P/S System Check .............................................. 6C-*
Steering Wheel and Column................... 6B-1 “P/S” Warning Light Check.................................. 6C-*
General Description .............................................6B-1 DTC Check..........................................................6C-2
Steering Wheel and Column Construction .......... 6B-1 DTC Clearance ...................................................6C-2
Diagnostic Information and Procedures............ 6B-* DTC Table...........................................................6C-3
Checking Steering Column for Accident Fail-Safe Table.................................................... 6C-* 6
Damage .............................................................6B-* Scan Tool Data ................................................... 6C-*
Repair Instructions ..............................................6B-1 Visual Inspection .................................................6C-4
Steering Wheel and Column Components.......... 6B-1 P/S System Symptom Diagnosis ........................ 6C-*
Steering Wheel Removal and Installation ........... 6B-3 “P/S” Warning Light Does Not Come ON with
Contact Coil Assembly Removal and Ignition “ON” before Engine Starts .................... 6C-*
Installation..........................................................6B-* “P/S” Warning Light Remains ON Steady after
Centering of Contact Coil Assembly (With Air Engine Starts..................................................... 6C-*
Bag) ...................................................................6B-* DTC C1111 / C1113 / C1115 / C1116 ................ 6C-*
Contact Coil Assembly Inspection........................6B-* DTC C1141 / C1142 / C1143 / C1145 ................ 6C-*
Steering Column Removal and Installation ......... 6B-3 DTC C1153 / C1155............................................6C-4
Steering Shaft Joint On-Vehicle Inspection .........6B-* DTC C1160 ......................................................... 6C-*
Steering Column Inspection .................................6B-* DTC C1161 / C1162............................................6C-5
Steering Column Lower Shaft Inspection.............6B-* DTC U0073 ......................................................... 6C-*
Steering Lock Removal and Installation.............. 6B-5 DTC U0100 ......................................................... 6C-*
Steering Lock Disassembly and Reassembly ......6B-* DTC U0155 ......................................................... 6C-*
Steering Lock Inspection......................................6B-* DTC U1082 .........................................................6C-6
Auto Steering Lock Inspection (Keyless Push P/S Control Module Power Supply and
Start Model) ...................................................... 6B-7 Ground Circuit Check........................................ 6C-*
Ignition Switch Removal and Installation..............6B-* Inspection of P/S Control Module and Its
Ignition Switch Inspection ....................................6B-* Circuits .............................................................. 6C-*
Steering Lower Shaft Removal and Steering Wheel Play Check ................................ 6C-*
Installation......................................................... 6B-7 Steering Force Check ......................................... 6C-*
Specifications.......................................................6B-8 Repair Instructions ..............................................6C-6
Tightening Torque Specifications........................ 6B-8 Steering Gear Case Assembly Components ...... 6C-*
Special Tools and Equipment .............................6B-8 Tie-Rod End Boot On-Vehicle Inspection ........... 6C-*
Special Tool ........................................................ 6B-8 Tie-Rod End Removal and Installation................ 6C-*
Tie-Rod End Inspection....................................... 6C-* P/S Control Module Removal and Installation..... 6C-*
Steering Gear Case Assembly Removal and Torque Sensor Inspection ...................................6C-6
Installation ......................................................... 6C-* P/S Motor Inspection........................................... 6C-*
Steering Gear Case Bushing Removal and Specifications ....................................................... 6C-*
Installation ......................................................... 6C-* Tightening Torque Specifications........................ 6C-*
Steering Rack Boot Inspection............................ 6C-* Special Tools and Equipment .............................6C-7
Tie-Rod / Rack Boot Removal and Installation .... 6C-* Recommended Service Material ......................... 6C-*
Pinion Shaft Rotation Torque Inspection............. 6C-* Special Tool ........................................................6C-7
Pinion Shaft Rotation Torque Adjustment ........... 6C-*
Precautions: 6-1
Precautions
Steering
Precautions
Precautions for Steering
AENFL80B6000001
General Precautions

Fastener Caution
Air Bag Warning

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 in related
manual.

Precautions for CAN Communication System

Refer to “Precautions for CAN Communication System” in Section 00 in related manual.
6B-1 Steering Wheel and Column:
Steering Wheel and Column

Steering
General Description
Steering Wheel and Column Construction
AENFL80B6201001
• The steering column is of a collapsible tube type. The column contracts in the event of a heavy frontal collision to
absorb impact energy and thus helps reduce injuries to the driver. The steering column also has the following
features:
– The steering column is provided with a tilt adjustment mechanism. This mechanism allows step-less adjustment
of the whole steering column in up-and-down directions.
– The steering column incorporates a steering lock to help prevent theft. On the ignition switch model, the ignition
switch is installed on the steering column together with the steering lock.
When servicing the steering column, it is important that only the specified fasteners 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.
• 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 in related manual
to prevent accidental deployment.
Repair Instructions
Steering Wheel and Column Components
AENFL80B6206001
! WARNING
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-49).
Steering Wheel and Column: 6B-2
[B]
(d)
[A]
4
(d)
18
[B]
13 (b)
8 9
12 (b)
5
10
3
11 (c)
[A] 17
14 7
6
15
(a)
1 16
2
IFL80B620003-01
[A]: Keyless push start model 8. Steering column 17. Steering joint cover
[B]: Ignition switch model 9. Steering lower shaft 18. Steering column reinforcement
1. Driver air bag (inflator) module 10. Steering column assembly : 33 Nm (3.4 kgf-m, 24.5 lbf-ft)
2. Auto steering lock 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-3)
3. Steering wheel 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-7).
4. Steering column upper cover 13. Steering lower shaft joint bolt : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
: For installation, refer to “Steering Lower Shaft
5. Steering column lower cover 14. Ignition switch : Do not reuse.
6. Contact coil assembly 15. Steering lock
:Perform centering. 
7. Steering lock mounting bolt 16. Ignition switch cylinder
: For installation, refer to “Steering Lock
Steering Wheel Removal and Installation

AENFL80B6206002
! 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 in related
manual.
(A)
I9P60A620002-01
NOTICE
• Do not turn the rotor of the contact coil Installation
more than about two and a half turns
NOTICE
clockwise or counterclockwise from the
center position with steering wheel Performing steps 1), 2) and 3) below is
removed, otherwise the coil will break. indispensable for installation of steering
• Be careful not to damage the steering wheel. Neglecting these steps will cause
column with excessive shock. damage to rotation part of contact coil when
steering is turned.
• For diesel engine model, do not remove
steering wheel damper from steering 1) Check that vehicle's front wheels are at straight-
wheel. Remove steering wheel together ahead position.
with steering wheel damper.
2) If contact coil is turned after removing steering
Removal wheel, center contact coil assembly. 
1) Park vehicle on a level surface, apply parking brake, 3) Install steering wheel to steering shaft with 2 grooves
set steering wheel in straight-ahead position and set (1) in contact coil assembly fitted on 2 lugs (2) on
ignition “OFF”. back side of steering wheel aligning matchmarks (3)
on steering wheel and steering shaft.
4) Tighten steering shaft nut (4) to specified torque.
3) Disable air bag system. 
4) Remove driver air bag (inflator) module from Tightening torque
steering wheel.  Steering shaft nut (a): 33 N·m (3.4 kgf-m, 24.5
lbf-ft)
5) Disconnect steering switch connector (if equipped).
6) Remove steering shaft nut and then make alignment 3
marks (1) across steering wheel and shaft for correct
reinstallation.
4,(a)
1
IAP70P620003-01
I4RS0A620005-01
5) Connect steering switch connector (if equipped).
7) Remove steering wheel using special tool. 6) Install driver air bag (inflator) module to steering
wheel. (Page 8B-49)
Special tool
(A): 09944M36011 7) Connect negative (–) cable at battery.
8) Enable air bag system. 
Steering Column Removal and Installation

AENFL80B6206008
! WARNING Ignition switch model
For handling of removed air bag (inflator)

module, refer to “Precautions for Handling 1
and Storage of Air Bag System Components”
in Section 8B in related manual. 4 3
NOTICE 1
• Steering column is designed to absorb 5

impact by deforming itself. Keep the
5
following points in mind when handling
removed steering column. 1
– Dropping steering column assembly on
its end could collapse steering shaft or
loosen capsules that maintain original
6
column length.
– Leaning steering column assembly on 2
wall or anything other could cause it to
IBP80A620012-01
bend or be deformed.
• Any of the damage could impair the Keyless push start model
column’s collapsible arrangement.
• Steering column mounting nuts should not
be loosened with steering shaft joint upper 1
side bolt tightened as this could cause 7
damage to shaft joint bearing.
Removal 1
1) Remove contact coil assembly. 
2) For ignition switch model, remove immobilizer 5
control module from steering lock.  5
3) Remove lighting switch and wiper switch.

1
• Lighting switch: 
• Wiper switch: 
4) Remove steering column hole cover. (Page 9C-24) 6
5) Remove steering joint cover. (Page 6B-1)
6) Remove steering lower shaft. (Page 6B-7) 2
7) Remove combination meter cluster panel. (Page IFL80B620004-01
9C-24) 13) Remove steering column.

8) Detach steering column harness clamps (1).
Installation
9) Disconnect P/S control module connector (2).
10) For ignition switch model, disconnect both key NOTICE
switch connector (3) and ignition switch connector Install steering lower shaft after tightening
(4). steering column mounting nuts. If steering
11) For keyless push start model, disconnect auto lower shaft is installed before tightening the
steering lock connector (7). nuts, steering shaft joint of steering column
12) Remove steering column mounting nuts (5) and may be damaged.
reinforcement nut (6).
1) Check that vehicle’s front wheels are at straight-
ahead position.
2) Install steering column. Then tighten steering column
lower nuts (1) and then steering column upper nuts
(2) to specified torque.
3) Install reinforce nut (3) to specified torque.
NOTE Keyless push start model

• When installing steering column, check
that clearance “a” between bolt (4) and
9
bracket (5) is 0 (zero). 10
• After installing tilt steering column, make
sure that steering column moves upwards
and downwards smoothly and stops when 9 2, (b)
tilt lever is fixed.
2, (b)
Tightening torque
9
Steering column mounting lower nut (a): 14 N·m 1, (a)
(1.4 kgf-m, 10.5 lbf-ft)
Steering column mounting upper nut (b): 14
1, (a)
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) 3, (c)
4) For ignition switch model, connect both key switch 8

connector (6) and ignition switch connector (7). 5
For keyless push start model, connect auto steering
lock connector (10).
5) Connect P/S control module connector (8). “a” “a”
6) Attach steering column harness clamps (9) in place.

4
Ignition switch model IEP80A620002-01
7) Install combination meter cluster panel. (Page 9C-

24)
9
8) Install steering lower shaft. (Page 6B-7)
6
7 9) Install steering joint cover. (Page 6B-1)
10) Install lighting switch and wiper switch.
2, (b)
9 • Lighting switch: 
2, (b) • Wiper switch: 
11) For ignition switch model, install immobilizer control
9
1, (a) module to steering lock. 
12) Install contact coil assembly. 
1, (a) 13) Install steering column hole cover. (Page 9C-24)
14) Enable air bag system. 
3, (c)
Steering Lock Removal and Installation

8 AENFL80B6206012
5
Removal
“a” “a” ! WARNING

The steering lock uses magnesium parts.
4
IBP80A620013-01 Never perform drilling, cutting, filing or other
work which produces sparks on the steering
lock. The magnesium powder is highly
flammable and the sparks may ignite the
magnesium powder, causing a fire.
NOTICE 2) For ignition switch model, install steering lock to

Take the following precautions when steering shaft with key cylinder (1) toward steering
removing and installing the steering column wheel.
and steering lock. For keyless push start model, install auto steering
lock with the column cover mounting screw hole (2)
• Be careful not to damage or apply heavy toward P/S motor side.
impact.
• If dust, dirt, oil or water enters in the [A]
steering column or steering lock, it may 1
causes malfunction. Keep the steering
column and lock away from such [a]
contaminations.
1) Remove steering column. (Page 6B-3)

2) Hold steering column using soft jawed vise.
3) Loosen steering lock bolt(s) (2) using chisel, then
remove auto steering lock (3) or steering lock (4)
[B]
from steering column (1).
[A] [B]
[b]
4
1 1
3
2 IEP80A620004-01
[A]: Ignition switch model [a]: Steering wheel side

2 [B]: Keyless push start model [b]: P/S motor side
IDL10A620011-02
[A]: Ignition switch model 3) Tighten new steering lock bolts (1) until head of each
[B]: Keyless push start model bolt is broken off.
Installation
1) For ignition switch model, align oblong hole (2) in
steering shaft (3) with center of hole (1) in steering
column.
Turn ignition key to “LOCK” position and pull it out,
and then align lug of steering lock with hole in
steering shaft. IBP80A620015-02
4) Install steering column. (Page 6B-3)

5) Set ignition to “ACC” or “ON” and check that steering
shaft rotates smoothly. Then set ignition to “LOCK”
(OFF) (and pull out key for ignition switch model)
and check that steering wheel is locked.
6) For ignition switch model, if ignition switch cylinder
has been replaced, register ignition key transponder
3 code in BCM after completing installation. (Page
10B-34)
2
7) Check steering column and torque sensor after
1
installation. If condition is found faulty, replace
steering column.
• Steering column: 
• Torque sensor: (Page 6C-6)
I9P60A620029-01
Auto Steering Lock Inspection (Keyless Push NOTICE

Start Model) Never turn steering wheel while steering
AENFL80B6206018
lower shaft is removed.
1) Remove steering column lower cover and steering
If it is turned and contact coil assembly gets
column hole cover.
out of centered position, the assembly must
• Steering column lower cover: (Page 6B-1) be centered again. Also, turning steering
• Steering column hole cover: (Page 9C-24) wheel more than about two and a half turns
2) Measure voltage between terminals “1” – “4”, “2” – will break contact coil assembly. (with air
“5”, and “3” – “5”. If check result is not as specified, bag)
check auto steering lock wire harness for open or
short and if auto steering lock wire harness is in Removal
good condition, replace auto steering lock (1). 1) Turn steering wheel so that vehicle’s front wheels
(Page 6B-5) are at straight-ahead position.
2) Set ignition “LOCK” and remove key.
Auto steering lock unit terminal voltage
Normal 3) Remove steering joint cover. (Page 6B-1)
Terminal Condition 4) Make matchmarks (1) on the following parts for
voltage
1 10 – 14 V • Any door opened or closed correct reinstallation.
with ignition “OFF”* • Steering lower shaft (2) and shaft joint of steering
• Ignition “OFF” → “ACC”* column (3)
0–1V Other than above condition • Steering lower shaft (2) and pinion shaft (4)
2 10 – 14 V • Any door opened or closed 5) Remove steering lower shaft joint bolts (5) and
with ignition “OFF”* steering column joint bolt (6).
• Ignition “OFF” → “ACC”* 6) Remove steering lower shaft.
0–1V Other than above condition
3 10 – 14 V • Any door opened or closed
with ignition “OFF”*
• Ignition “OFF” → “ACC”* 3

4 0–1V Ignition is in any mode. 6
5 0–1V Ignition is in any mode. 1
2
NOTE
*: Voltage can be checked only for a short 2
time while locking or releasing auto steering
lock. 1
4 5
1
IBP80A620016-01
Installation
NOTICE
To prevent damage to each lead wire when
installing covers, be careful not to pinch lead
wire between covers.
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;
[A] otherwise joints of steering lower shaft will
be damaged.
[a]
654321
1) Check that vehicle’s front wheels are at straight-
IDL10A620014-01 ahead position.
2) Align flat part “a” on steering lower shaft (1) with bolt
Steering Lower Shaft Removal and Installation hole “b” of steering shaft joint (2) of steering column
AENFL80B6206017 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
2
column joint bolt to specified torque in numerical
order (“1” through “2”) as indicated in figure. “2”, (b) “b”
Tightening torque
Steering lower shaft joint bolt (a): 35 N·m (3.6 3 “a”
kgf-m, 26.0 lbf-ft)
Steering column joint bolt (b): 35 N·m (3.6 kgf- 1
m, 26.0 lbf-ft)
4 “1”, (a)
IBP80A620017-01
5) Install steering joint cover. (Page 6B-1)
Specifications
AENFL80B6207002
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 
Reference:
“Steering Wheel and Column Components”:

Special Tool
AENFL80B6208002
09944M36011
Steering wheel remover

6C-1 Power Assisted Steering System:
Power Assisted Steering System

Steering

P/S System Diagram
AENFL80B6302001
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 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
IFL80B630001-01
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
[A]: P/S control module connector (View: [a]) 1. P/S control module
Power Assisted Steering System: 6C-2
NOTE
For circuit name and terminal voltage, refer to“Inspection of P/S Control Module and Its Circuits” in
related manual.

DTC Check 2) Connect SUZUKI scan tool to DLC (1) located
AENFL80B6304003 around bottom of instrument panel on driver’s seat
1) Set ignition “OFF”. side.
2) Connect SUZUKI scan tool to DLC (1) located
Special tool
around bottom of instrument panel on driver’s seat
side.
Special tool
(A)
(A)
IFL80B180001-01

IFL80B180001-01
SUZUKI scan tool. For details of SUZUKI scan tool,
3) Start engine. refer to its Operator’s Manual.
4) Read DTC according to the instructions displayed on 5) When ignition is “OFF”, disconnect SUZUKI scan
SUZUKI scan tool. For details of SUZUKI scan tool, tool from DLC after completing clearance.
refer to its Operator’s Manual.
NOTE
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
is detected in any control module)
5) Set ignition to “OFF” and disconnect SUZUKI scan

tool from DLC.
DTC Clearance
AENFL80B6304004
1) Confirm that ignition is in “OFF”.
DTC Table
AENFL80B6304005
! CAUTION
Be sure to perform the “P/S System Check” in related manual before starting troubleshooting
corresponding to each DTC.
NOTE
*D/C (Driving Cycle) is a duration from engine start to the following engine shutoff.
• 1 D/C: When a malfunction is detected in 1st driving cycle, DTC is detected as current DTC.
“P/S”
DTC DTC name DTC detecting condition *D/C warning
light
Voltage of torque sensor signal (main) circuit is
C1111 Torque Sensor (Main) higher than specified value (4.5 V) or lower than
1 Light up
 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
 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
 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

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
 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
 Malfunction 1 value by 10 A or more.
C1143 P/S Motor Circuit Current
Measured motor drive current is more than 65 A. 1 Light up
 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
 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-4) 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-4)
Voltage too High
C1160
Assist Map Signal Failure Assist map data is not set in P/S control module. 1 Light up

C1161 CAN Invalid Data from
Invalid data is received from ECM. 1 Off
(Page 6C-5) Vehicle Speed
C1162 CAN Invalid Data from
Invalid data is received from ECM. 1 Light up
(Page 6C-5) Engine Speed
U0073 Control Module Transmitting and receiving error of P/S control
1 Off
 Communication Bus Off module for specified time continuously.
U0100 Lost Communication With CAN communication data from ECM cannot be
1 Light up
 ECM received.
“P/S”
DTC DTC name DTC detecting condition *D/C warning
light
U0155 CAN communication data cannot be received
Instrument Panel Cluster 1 Light up
 from combination meter.
U0182 CAN communication data related to ENG A-STOP
ENG A-STOP Control 1 Light up
(Page 6C-6): cannot be received from ECM.
Module
Visual Inspection
AENFL80B6304008
Visually check the following parts and system.
Battery Petrol and Bi-Fuel CNFG model: 
Level, leakage Diesel (without ISG) model: 
Diesel (with ISG) model: (Page 1J-22)
Connectors of electric wire “Intermittent Connection and Poor Contact Inspection” in
Disconnection, friction
harness Section 00 in related manual
Fuses Blowout
“P/S” warning light Operation ““P/S” Warning Light Check” in related manual
Other parts that can be checked visually
DTC C1153 / C1155

AENFL80B6304014
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

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” in related
manual.
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.  circuit.

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 Petrol and Bi-Fuel CNG
rpm. DTC.  model: (Page 1J-10)
Is voltage between 9 V and 15 V? Diesel (without ISG)
model: (Page 1J-19)
Diesel (with ISG) model:
(Page 1J-29)
DTC C1161 / C1162

AENFL80B6304016
C1161: CAN Invalid Data from Vehicle Speed • CAN communication circuit
Invalid data is received from ECM. • ECM
C1162: CAN Invalid Data from Engine Speed
Invalid data is received from ECM.

DTC C1161
• Refer to Confirmation Procedure for DTC P0500 Vehicle Speed Sensor “A”. Refer to “DTC P0500”: Petrol in
Section 1A (Page 1A-78) / “DTC P0500”: Diesel in Section 1A (Page 1A-253).
DTC C1162
• Refer to Confirmation Procedure for DTC P0335 Crankshaft Position Sensor “A”. Refer to “DTC P0335 / P0336”:
Petrol in Section 1A (Page 1A-64) / “DTC P0335”: Diesel in Section 1A (Page 1A-241).
DTC Troubleshooting
Step Action Yes No
1 Was “P/S System Check” performed? Go to Step 2. Go to “P/S System
Check” in related
manual.
2 DTC Check Go to troubleshooting Substitute a known-
1) Check ECM for DTC. (Page 6C-2) for applicable DTC good P/S control
(ECM-related faulty). module and recheck
Is there any DTC(s) detected? Refer to “DTC Table”: DTC. 
Petrol in Section 1A
(Page 1A-17) / “DTC
Table”: Bi-Fuel CNG in
Section 1A (Page 1A-
134) / “DTC Table”:
Diesel in Section 1A
(Page 1A-182).
DTC U1082
AENFL80B6304024
Refer to “Troubleshooting for Lost Communication”: Petrol and Bi-Fuel CNG Model in Section 10H (Page 10H-12) or
“Troubleshooting for Lost Communication”: Diesel Model in Section 10H (Page 10H-38).
Repair Instructions
Torque Sensor Inspection • steering column hole cover: (Page 9C-24)
AENFL80B6306012
Using SUZUKI Scan Tool • Steering lower shaft: (Page 6B-7)
1) Connect SUZUKI scan tool to DLC (1) located 2) With ignition “ON”, measure voltage between
around bottom of instrument panel on driver’s seat terminals “3” – “5” and “3” – “7” at “E11” connector
side. (1) connected to P/S control module (2). If check
result is not as specified, replace steering column.
Special tool
(A): SUZUKI scan tool (Suzuki SDT-II) Torque sensor voltage
“3” and “5”: Approx. 2.5 V
“3” and “7”: Approx. 2.5 V
4 3 2 1
8 7 6 5
1
1
(A)
IFL80B180001-01
2) With ignition “ON”, check “Sensor (Main) Torque”

and “Sensor (Sub) Torque” in “Data list” mode on
SUZUKI scan tool.
Sensor torque IAP70P630025-01
Main: Approx. –0.8 – 0.8 Nm
Sub: Approx. –0.8 – 0.8 Nm
3) If check result is not as specified, remove steering
wheel and steering lower shaft.
• Steering wheel: (Page 6B-3)
• Steering lower shaft: (Page 6B-7)
4) With ignition “ON”, check “Sensor (Main) Torque”
and “Sensor (Sub) Torque” in “Data list” mode on
SUZUKI scan tool.
If check result is not as specified, replace torque
sensor (steering column assembly).
Sensor torque
Main: Approx. –0.8 – 0.8 Nm
Sub: Approx. –0.8 – 0.8 Nm
Using Voltmeter
1) Remove steering column hole cover and steering
lower shaft.

Special Tool
AENFL80B6308003
SDT-II)
—
//
Section 7
HVAC
CONTENTS
NOTE
Precautions ................................................. 7-* Blower Motor Inspection....................................7B-16

Precautions.............................................................. 7-* Blower Motor Resistor Removal and
Precautions for HVAC ............................................ 7-* Installation ......................................................... 7B-*
A/C System Caution............................................... 7-* Blower Motor Resistor Inspection ....................... 7B-*
Precautions for Servicing A/C System ................... 7-* Evaporator Inspection ......................................... 7B-*
Evaporator Temperature Sensor Removal
HVAC System........................................... 7B-1 and Installation (If Equipped) ............................ 7B-*
Single A/C Type.......................................................7B-1 Evaporator Temperature Sensor Inspection
General Description .............................................7B-1 (If Equipped)...................................................... 7B-*
HVAC System Description .................................. 7B-1 Expansion Valve Removal and Installation ......... 7B-*
Sub-Cool A/C System Description .......................7B-* Expansion Valve Inspection ................................ 7B-*
A/C Operation Description at ECM (Petrol HVAC Control Unit Components......................... 7B-*
Model) ................................................................7B-* HVAC Control Unit Removal and Installation...... 7B-*
A/C Operation Description at ECM (Diesel Blower Speed Selector Inspection ...................... 7B-*
Model) ................................................................7B-* A/C Refrigerant Pressure Sensor and Its
Circuit Inspection............................................... 7B-*
Schematic and Routing Diagram........................7B-3
A/C Refrigerant Pressure Sensor Removal
Manual A/C Electronic Control Input / Output
Block Diagram....................................................7B-*
Air Intake Switch Inspection ................................ 7B-*
Manual A/C System Circuit Diagram................... 7B-3
Air Intake Control Actuator Removal and
Component Location ...........................................7B-5 Installation ......................................................... 7B-*
Manual A/C Control System Component Air Intake Control Actuator Inspection................. 7B-*
Location ............................................................ 7B-5 Actuator Linkage Inspection................................ 7B-* 7
Diagnostic Information and Procedures............7B-5 Center Ventilation Louver Removal and
A/C System Performance Inspection .................. 7B-5 Installation ......................................................... 7B-*
Trouble Diagnosis for Abnormal Pressure ...........7B-* Side Ventilation Louver Removal and
A/C System Symptom Diagnosis ...................... 7B-10 Installation ......................................................... 7B-*
Abnormal Noise Symptom Diagnosis of HVAC Air Filter Removal and Installation .........7B-16
HVAC System ....................................................7B-* HVAC Air Filter Inspection ................................7B-17
Visual Inspection ............................................... 7B-13 A/C Switch Inspection ......................................... 7B-*
Inspection of HVAC Control Unit and Its HVAC System Relay Inspection.......................... 7B-*
Circuit.............................................................. 7B-13 A/C Compressor Drive Belt Inspection and
A/C System Inspection at ECM............................7B-* Adjustment ......................................................7B-17
Repair Instructions ............................................7B-14 Diesel Model (with ISG) ....................................7B-17
Operation Procedure for Refrigerant Charge .......7B-* A/C Compressor Drive Belt Removal and
A/C System Major Components...........................7B-* Installation .......................................................7B-18
Radiator Cooling Fan Removal and A/C Compressor Assembly Removal and
Installation..........................................................7B-* Installation .......................................................7B-18
Radiator Cooling Fan Inspection..........................7B-* A/C Compressor Assembly Components
Condenser Assembly On-Vehicle Inspection.......7B-* (Petrol Model).................................................... 7B-*
Condenser Assembly Removal and A/C Compressor Assembly Components
Installation..........................................................7B-* (Diesel Model) ................................................... 7B-*
HVAC Unit Components ................................... 7B-15 Magnet Clutch Inspection.................................... 7B-*
HVAC Unit Removal and Installation ................ 7B-15 Magnet Clutch Removal and Installation............. 7B-*
Blower Motor Removal and Installation................7B-* Relief Valve Inspection........................................ 7B-*
Relief Valve Removal and Installation (Petrol Evaporator Temperature Sensor Inspection
Model) ............................................................... 7B-* (If Equipped)...................................................... 7B-*
Specifications.....................................................7B-20 Expansion Valve Removal and Installation ......... 7B-*
Tightening Torque Specifications...................... 7B-20 Expansion Valve Inspection ................................ 7B-*
Special Tools and Equipment ...........................7B-20 HVAC Control Unit Components ......................... 7B-*
Recommended Service Material ....................... 7B-20 HVAC Control Unit Removal and Installation...... 7B-*
Special Tool ...................................................... 7B-20 Blower Speed Selector Inspection ...................... 7B-*
Dual A/C Type ........................................................7B-21 A/C Refrigerant Pressure Sensor and Its
Circuit Inspection............................................... 7B-*
General Description ...........................................7B-21
A/C Refrigerant Pressure Sensor Removal
HVAC System Description ................................ 7B-21
Sub-Cool A/C System Description ...................... 7B-*
Air Intake Switch Inspection ................................ 7B-*
A/C Operation Description at ECM (Petrol
Air Intake Control Actuator Removal and
Model) ............................................................... 7B-*
Installation ......................................................... 7B-*
A/C Operation Description at ECM (Diesel
Air Intake Control Actuator Inspection................. 7B-*
Model) ............................................................... 7B-*
Actuator Linkage Inspection................................ 7B-*
Schematic and Routing Diagram......................7B-22
Center Ventilation Louver Removal and
Manual A/C Electronic Control Input / Output
Installation ......................................................... 7B-*
Block Diagram................................................... 7B-*
Side Ventilation Louver Removal and
Manual A/C System Circuit Diagram................. 7B-22
Installation ......................................................... 7B-*
Component Location ........................................... 7B-* A/C Switch Inspection ......................................... 7B-*
Manual A/C Control System Component Rear Defogger Switch Inspection (If
Location ............................................................ 7B-* Equipped).......................................................... 7B-*
Diagnostic Information and Procedures..........7B-25 Rear Cooling Unit Removal and Installation ....... 7B-*
A/C System Performance Inspection .................. 7B-* Rear Cooling Unit Inspection .............................. 7B-*
Trouble Diagnosis for Abnormal Pressure .......... 7B-* Rear Blower Speed Selector Removal and
A/C System Symptom Diagnosis ........................ 7B-* Installation ......................................................... 7B-*
Abnormal Noise Symptom Diagnosis of Rear Blower Speed Selector Inspection ............. 7B-*
HVAC System ................................................... 7B-* Rear Ventilation Louver Removal and
Visual Inspection ................................................. 7B-* Installation ......................................................... 7B-*
Inspection of HVAC Control Unit and Its HVAC System Relay Inspection.......................... 7B-*
Circuit .............................................................. 7B-25 A/C Compressor Drive Belt Inspection and
A/C System Inspection at ECM........................... 7B-* Adjustment ........................................................ 7B-*
Repair Instructions ............................................7B-26 A/C Compressor Drive Belt Removal and
Operation Procedure for Refrigerant Charge ...... 7B-* Installation ......................................................... 7B-*
A/C System Major Components.......................... 7B-* A/C Compressor Assembly Removal and
Radiator Cooling Fan Removal and Installation ......................................................... 7B-*
Installation ......................................................... 7B-* A/C Compressor Assembly Components............ 7B-*
Radiator Cooling Fan Inspection......................... 7B-* Magnet Clutch Inspection.................................... 7B-*
Condenser Assembly On-Vehicle Inspection...... 7B-* Magnet Clutch Removal and Installation............. 7B-*
Condenser Assembly Removal and Relief Valve Inspection........................................ 7B-*
Installation ......................................................... 7B-* Relief Valve Removal and Installation (Petrol
HVAC Unit Components ..................................... 7B-* Model) ............................................................... 7B-*
HVAC Unit Removal and Installation .................. 7B-* HVAC Air Filter Removal and Installation .........7B-26
Blower Motor Removal and Installation............... 7B-* HVAC Air Filter Inspection ................................7B-26
Blower Motor Inspection...................................... 7B-* Specifications ....................................................... 7B-*
Blower Motor Resistor Removal and Tightening Torque Specifications........................ 7B-*
Installation ......................................................... 7B-* Special Tools and Equipment ............................. 7B-*
Blower Motor Resistor Inspection ....................... 7B-* Recommended Service Material ......................... 7B-*
Evaporator Inspection ......................................... 7B-* Special Tool ........................................................ 7B-*
Evaporator Temperature Sensor Removal
and Installation (If Equipped) ............................ 7B-*
HVAC System: Single A/C Type 7B-1
HVAC System
HVAC
Single A/C Type

General Description
HVAC System Description
AENFL80B7211001
• 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 control 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 in related manual or “A/C Operation Description at ECM (Diesel Model)”: Single A/C Type in
related manual 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 in related manual 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. The HVAC unit also incorporates
an air filter.
• Each side ventilator has a shutter mechanism.
• The condenser is of a sub-cool type. It is integral with the receiver/dryer and mounted on the vehicle body in a
floating manner.
• For the electronic control system component location, refer to “Manual A/C Control System Component Location”:
Single A/C Type (Page 7B-5).
For the A/C system component location, refer to “A/C System Major Components”: Single A/C Type in related
manual.
For the A/C electrical control input / output diagram, refer to “Manual A/C Electronic Control Input / Output Block
Diagram”: Single A/C Type in related manual.
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
24
8 6
4
2
7
5
: [A]
3
: [B]
: [C]
IFL80B721001-02
[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 24. HVAC air filter
4. Receiver/dryer 11. Front foot air 18. Temperature control door

Manual A/C System Circuit Diagram
AENFL80B7212002
Petrol Model
1
WHT G155-6
YEL G155-7
G155-1 BLK
9
GRY G155-3
WHT BLK 2
15
BLU YEL RED G155-2
10 11
LT GRN G155-5
3
G154-1 G154-7 WHT
4
YEL G154-11
12
5
BLU G154-5 6
G154-12 BLK
GRN G154-6
13
RED G154-9
WHT/BLK
7
14 LTGRN G154-3 BEG
16
17
19 20 18
GRY E01-19
LT BLU WHT
GRY E01-48
BLU E01-55
BLU E01-56
21
8
YEL PNK E01-49
YEL
E01- 1 RED
18
22 E01- 2 WHT
LT GRN E01-46
GRY RED 26
E01-14 PNK
23
E01-17 GRN
LT BLU 25 BLK
E01-8 GRY
RED
24
RED
C01-50 BLK
WHT
C01-51 BLK
GRN E01-36
IFL80B721006-01
1. HVAC control unit 8. Ignition switch 15. BCM 22. Radiator cooling fan relay No.1
2. Blower speed selector 9. Heater relay 16. Evaporator temperature sensor 23. Radiator cooling fan relay No.2
3. A/C switch 10. Blower motor 17. ECM 24. Radiator cooling fan relay No.3
4. “A/C” indicator light 11. Blower motor resistor 18. CAN driver 25. Radiator cooling fan motor
5. “REC” indicator light 12. Air intake control actuator 19. A/C compressor relay 26. A/C refrigerant pressure sensor
6. Air intake switch 13. Lighting switch 20. A/C compressor
7. Illumination light 14. Combination meter 21. Main relay
Diesel Model
1
WHT G155-6
YEL G155-7
G155-1 BLK
9
GRY G155-3
WHT BLK 2
15
BLU YEL RED G155-2
10 LT GRN G155-5
11
3
G154-1 G154-7 WHT
4
YEL G154-11
12
5
BLU G154-5 6
G154-12 BLK
GRN G154-6
13
RED G154-9
7
14 LT GRN G154-3
16
BLK
18 19 17
LT BLU WHT
GRY E01-77
20
LT GRN E01-7
GRY BLU E01- 64 RED
8 17
21 E01- 40 WHT
BLU/BLK 23 BLK
25
BLU/WHT E01-37 PNK
22
E01-87 GRN
GRN E01-8 E01-10 GRY
GRN E01-4
BLU GRN E01-5
24
WHT BLU GRN E01-6
YEL PNK E01-80
E01-1 BRN
E01-2 BRN
E01-3 BRN
IFL80B721005-01
1. HVAC control unit 8. Ignition switch 15. BCM 22. Radiator cooling fan relay No.3
2. Blower speed selector 9. Heater relay 16. ECM 23. Radiator cooling fan motor
3. A/C switch 10. Blower motor 17. CAN driver 24. Main relay
4. “A/C” indicator light 11. Blower motor resistor 18. A/C compressor relay 25. A/C refrigerant pressure sensor
5. “REC” indicator light 12. Air intake control actuator 19. A/C compressor
6. Air intake switch 13. Lighting switch 20. Radiator cooling fan relay No.1
7. Illumination light 14. Combination meter 21. Radiator cooling fan relay No.2
Component Location
Manual A/C Control System Component Location
AENFL80B7213001
7 15
8
14 12 17 16
11
6
10
[A] 19 20 21 2 18
[B]
13
[B] 19 20 21 2 18
[A]
5
1
4
1
3
IFL80B721007-01
[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. Heater relay 14. Temperature selector

A/C System Performance Inspection 1) Confirm that vehicle and environmental conditions
AENFL80B7214001 are as follows.
• Vehicle is put indoors.
• Ambient temperature is within 25 – 45 °C (77 – 4) Warm up engine to normal operating temperature

113 °F). and keep it at specified idle speed.
• Relative humidity is within 30 – 70%. 5) Turn A/C switch ON, and then set blower speed
• There is no wind indoors. selector to maximum speed position, temperature
selector to maximum cold position, air flow selector
• HVAC unit is normal.
to face position, air intake switch to recirculation
• Blower motor is normal. mode and side ventilation louvers to open position.
• There is no air leakage from air ducts. (Confirm that A/C compressor and radiator cooling
• Condenser fins are clean. fan are working.)
• HVAC air filter is not clogged with dirt and dust. 6) Wait for ten minutes to stabilize A/C operation.
• Battery voltage is about 12 V or more (battery in 7) Open all door windows, front doors and hood.
good condition). 8) Put about 20 mm (0.8 in.) of dry-bulb thermometer
• Radiator cooling fan operates normally. (1) in front of center ventilation louver. Put wet-and-
2) Make sure that high pressure valve (1) and low dry-bulb thermometer (2) near air inlet of HVAC unit.
pressure valve (2) of manifold gauge (A) are firmly
1
closed.
Special tool
(A): 09990M06020
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).
(A)
2
1
3 2
IBP80A721081-01
4
IBL80A721007-01
9) Check for each pressure of low side and high side if it is within shaded range in the following graph. If each gauge
reading is out of specified pressure, correct defective part referring to the following table.
When diagnosing troubles of abnormal pressure on the low side and high side more specifically, refer to “Trouble
Diagnosis for Abnormal Pressure”: Single A/C Type in related manual.
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)
[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 on high pressure gauge [E]: Ambient temperature [G]: Acceptable range
[B]: Diesel model [D]: Pressure on low pressure gauge [F]: Humidity
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: 
- Diesel model: (Page 1F-9)
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

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.
[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
[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

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.
A/C System Symptom Diagnosis

AENFL80B7214003

Blower motor does not Blown fuse Check related fuses, and then check for short
operate circuit to ground.
Faulty fan relay Check fan relay. 
Faulty heater relay Check heater relay. 
Faulty blower motor resistor Check blower motor resistor. 
Faulty blower speed selector Check blower speed selector. 
Faulty wiring or grounding Repair or replace wiring as necessary.
Faulty blower motor Check blower motor. (Page 7B-16)
Foreign material is present Remove foreign material.
Air outlet ports do not Broken or bent air flow control cable Check air flow control cable.
change or do not agree Faulty air flow selector Check air flow selector.
with air flow selector’s Incorrect installation of air flow control Check position of cable and adjust it if
position even if air flow cable necessary.
selector is changed Broken air flow control door assembly Repair air flow control door assembly.
Leaky or clogged air ducts Repair air ducts.
Air intake door does not Blown fuse Check related fuses, and then check for short
change even if air intake circuit to ground.
mode is changed Broken air intake door Repair air intake door.
Faulty air intake control actuator Check air intake control actuator. 
Faulty air intake switch Check air intake switch. 
Warm air does not come Broken or bent temperature control Check temperature control cable.
out or insufficient heating cable
(Faulty temperature Faulty temperature selector Check temperature selector.
control) Incorrect installation of temperature Check position of cable and adjust it if
control cable necessary.
Broken temperature control door Repair or replace temperature control door
assembly assembly.
Clogged air ducts Repair air ducts.
Leaky or clogged heater core Replace heater core.
Leaky or clogged heater hoses Replace heater hoses.
Faulty ECT Sensor Check ECT sensor.
- Petrol model: 
- Diesel model: 
No cool air comes out (A/ No refrigerant Recover refrigerant, evacuate and charge A/C
C compressor does not system. 
operate) Blown fuse Check related fuses, and then check for short
circuit to ground.
Faulty A/C switch Check A/C switch. 
Faulty blower speed selector Check 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 ECM and its circuit Check ECM.
- Petrol model: (Page 1A-107)
- Diesel model: (Page 1A-318)
Faulty magnet clutch Check magnet clutch. 
Loose or broken A/C compressor drive Check A/C compressor drive belt. (Page 7B-
belt (petrol model) 17)
Loose or broken accessory drive belt Check accessory drive belt. 
(diesel model without ISG)
Loosen or broken water pump drive belt Check water pump drive belt. (Page 1F-10)
(diesel model with ISG)
Faulty A/C compressor Check A/C compressor.
Faulty A/C compressor relay Check A/C compressor relay. 
Faulty BCM Check BCM. 

No cool air comes out Blown fuse Check related fuses, and then check for short
(radiator cooling fan circuit to ground.
motor does not operate) Faulty wiring or grounding Repair or replace wiring as necessary.
Faulty radiator cooling fan relay Check radiator cooling fan relay. (Page 10B-
35)
Faulty radiator cooling fan motor Check radiator cooling fan motor.
- Petrol model: (Page 1F-6)
- Diesel model: 
ECM faulty Check ECM. 
Cool air does not come Insufficient or excessive charge of Check amount of refrigerant and system for
out or insufficient cooling refrigerant leaks.
(A/C compressor in Clogged condenser Check condenser. 
normal operation) Clogged or frosted evaporator Check evaporator and evaporator temperature
sensor (If equipped).
- Evaporator: 
- Evaporator temperature sensor: 
Faulty evaporator temperature sensor (if Check evaporator temperature sensor. 
equipped)
Faulty expansion valve Check expansion valve. 
Loose or broken A/C compressor drive Check A/C compressor drive belt. (Page 7B-
belt (petrol model) 17)
Air in A/C system Replace condenser, and then evacuate and
charge A/C system with refrigerant. 
Air leaking from HVAC unit or air duct Repair HVAC unit or air duct as necessary.
Faulty heater and ventilation system Check HVAC unit.
Excessive compressor oil in A/C system Drain excessive compressor oil from A/C
system circuit and A/C compressor.
Cool air does not come Faulty wiring connection Repair or replace wiring as necessary.
out intermittently Faulty evaporator temperature sensor (If Check evaporator temperature sensor. 
equipped)
Faulty expansion valve Check expansion valve. 
Excessive moisture in A/C system Replace condenser, and then evacuate and
charge A/C system. 
Excessive amount of refrigerant Check the amount of refrigerant.
Cool air comes out only at Clogged condenser Check condenser. 
high speed Insufficient charge of refrigerant Check amount of refrigerant and system for
leaks.
Air in A/C system Replace condenser, and then evacuate and
charge A/C system with refrigerant. 
Loose A/C compressor drive belt (petrol Check A/C compressor drive belt. (Page 7B-
model) 17)
Cool air does not come Excessive amount of refrigerant Check amount of refrigerant.
out only at high speed Frosted evaporator Check evaporator and evaporator temperature
- Evaporator: 

Insufficient cool air flow Clogged or frosted evaporator Check evaporator and evaporator temperature
- Evaporator: 
Air leaking from HVAC unit or air duct Repair HVAC unit or air duct as necessary.
Visual Inspection
AENFL80B7214005
Check visually the following parts and systems.
Inspection item Correction
• Battery Fluid level and corrosion of Petrol model: 
terminals Diesel model (without ISG): 
Diesel model (with ISG): (Page 1J-21)
• Connectors of electric wire harness Disconnection and friction “Intermittent Connection and Poor Contact
Inspection” in Section 00 in related manual
• Fuses Blowout “Intermittent Connection and Poor Contact
Inspection” in Section 00 in related manual
• Parts Installation and damage —
• Other parts that can be checked visually
Inspection of HVAC Control Unit and Its Circuit

AENFL80B7214006
HVAC control unit and its circuits can be checked at HVAC control unit 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-15)
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
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 LT GRN Ground for illumination Below 0.5 V —
Normal
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
G154-6 GRN
(Fresh air) from “REC” to “FRE”
10 – 14 V Air intake switch in “REC” position
0–1V selector is at any position other than
G154-7 WHT 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 Illumination switch
10 – 14 V Lighting switch in ON position
0–1V Ignition “OFF”
G154-11 YEL Power supply
10 – 14 V Ignition “ON”
G154-12 BLK 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)
Approx. 6 V Blower speed selector in 1st position
G155-3 GRY 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
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
Repair Instructions
HVAC Unit Components

AENFL80B7216007
10
18
6
15 13
1
13 10
24
15 13
19 2
20
19
22
13
26 5
10
11 24 21
12
17 25
40 28 8
7 23
9
(a)
4
OIL
16 14
10
27
IFL80B721004-01
1. Right Case 9. Expansion valve 17. Shaft 25. Blower motor resistor
2. Left case 10. Packing 18. Airflow control plate 26. Heater core
3. Blower upper case 11. Temperature control door assembly 19. Foot duct 27. Blower motor
4. Blower lower case 12. Evaporator temperature sensor 20. Heater pipe bracket 28. Packing (diesel model)
(petrol model)
5. Air intake case 13. Airflow control door assembly 21. Air intake control : 3.5 Nm (0.36 kgf-m, 2.5
actuator lbf-ft)
6. Fresh air inlet duct 14. Plug 22. Relay bracket : Do not reuse.
7. Evaporator 15. Stopper 23. Air filter
8. Air filter cover 16. O-ring 24. Air duct
: Apply compressor oil
HVAC Unit Removal and Installation Then disconnect heater hoses from HVAC unit.
AENFL80B7216008
5) Remove cowl top garnish from vehicle body. 
Removal 6) Remove battery.
1) Recover refrigerant from A/C system using recovery - Diesel model (without ISG): 
and recycling equipment referring to “Recovery” in - Diesel model (with ISG): (Page 1J-24)
“Operation Procedure for Refrigerant Charge”: 7) Loosen bolt (1), and then remove liquid pipe and
Single A/C Type in related manual. suction hose from expansion valve (2).
3) Disable air bag system (if equipped). 
4) Drain engine coolant.
- Petrol model: 
- Diesel model: 
• Adjust control cables. 

• Enable air bag system (if equipped). 
1
• Evacuate and charge the A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”: Single A/C Type in related
manual.
Blower Motor Inspection

2 AENFL80B7216010
I7V20A720023-01
• Check for continuity between two terminals as shown.
8) Remove instrument panel from vehicle body. If there is no continuity, replace blower motor.
(Page 9C-24)
9) Remove HVAC unit (1) from vehicle body by
removing nuts (2).
NOTE
When removing HVAC unit, be careful not to
spill engine coolant and compressor oil on
vehicle floor.
IBP80A721048-01
• Check for operation and current

a. Put blower motor (1) in a soft-jawed vise.
b. Connect battery to blower motor as shown.
2
c. Check if blower motor operates smoothly without
noise.
d. Check if ammeter indicates the specified current.
If measured current is not as specified, replace
blower motor.
Blower motor specified current at 13.5 V
18.5 A maximum at 20 – 25°C (68 – 77°F)
2
IBL80A721018-01
Installation
• 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 in related manual.
• Install padding (1) to installation hole uniformly.
IBP80A721043-01
HVAC Air Filter Removal and Installation

AENFL80B7216040
1
Removal
1) Remove glove box.
2) Remove HVAC air filter cover (1) from HVAC unit.
3) Remove air filter (2) from HVAC unit.
IBP80A721094-01
• Refill cooling system with coolant.

- Petrol model:
- Diesel model: 
NOTE
1 2 When replacing drive belt, adjust drive belt

tension to the following specifications.
New A/C compressor drive belt tension “a”

: 7 – 8 mm (0.28 – 0.31 in.) /100 N (10 kgf or 22 lb)
Between magnet clutch pulley and crankshaft
pulley
IDAA0A722047-01
Installation
• Position air filter (1) directing its arrow mark (2)
upward. 1
1
2
“a”
3
IBP80A721114-01
2
IDAA0A722048-01
Adjustment
HVAC Air Filter Inspection 1) Loosen tension pulley bolt (1).
AENFL80B7216041 2) Adjust belt tension by tightening or loosening tension
Check that filter is not excessively dirty, damaged or oily. pulley adjusting bolt (2).
Clean filter with compressed air from its air outlet side.
3) Tighten tension pulley bolt (1).
4) Rotate the crankshaft pulley 360°, and then recheck
drive belt (3) tension.
UP
2
1
IDL10A721045-01
A/C Compressor Drive Belt Inspection and

3
Adjustment
AENFL80B7216031
Petrol Model
Inspection
• Check A/C compressor drive belt (1) for wear, cracks, I9P60A722023-08
deformation and contamination. If any defect is found,
replace the belt with new one. (Page 7B-18) Diesel Model (without ISG)
• Check A/C compressor drive belt tension by For inspection and adjustment, refer to “Accessory Drive
measuring how much it deflects when pushed at Belt Tension Inspection”: Diesel (without ISG) in Section
intermediate point between magnet clutch pulley (2) 1J in related manual.
and crankshaft pulley (3) with about 100 N (10 kg)
force after rotating crankshaft pulley 360°. If belt Diesel Model (with ISG)
AENFL80B7216042
tension is out of specification, adjust belt tension For inspection and adjustment, refer to “Water Pump
referring to “Adjustment”. Drive Belt Inspection (ISG Model)”: Diesel in Section 1F
A/C compressor drive belt tension “a” (Page 1F-10)
: 7 – 8 mm (0.28 – 0.31 in.) / 100 N (10 kgf or 22 lb)
Between magnet clutch pulley and crankshaft
pulley
A/C Compressor Drive Belt Removal and 8) Disconnect discharge hose (1) and suction hose (2)
Installation from A/C compressor (3).
AENFL80B7216032
Petrol Model NOTE
Removal Cap open fittings immediately to keep
1) Loosen tension pulley bolt (1). moisture out of the system.
2) Loosen belt tension by loosening tension pulley
adjusting bolt (2). 9) Remove A/C compressor mounting bolts (4), and
then remove A/C compressor (3) from its bracket.
3) Remove A/C compressor drive belt (3).
[A]
2 2 1 3
1
4
4
I9P60A722023-08 [B]
4
Installation
• Adjust belt tension. (Page 7B-17)
Diesel Model (without ISG)

For removal and installation, refer to “Accessory Drive
Belt Tensioner Removal and Installation”: Diesel (without
ISG) in Section 1J in related manual.
Diesel Model (with ISG)

For removal and Installation, refer to “Water Pump Drive
Belt Removal and Installation (ISG Model)”: Diesel in 3 4 2 1 4
IBL80A721025-01
Section 1F (Page 1F-10)
[A]: Petrol model
[B]: Diesel model
A/C Compressor Assembly Removal and
Installation Installation
AENFL80B7216033
Removal Reverse removal procedure, noting the following points.
1) Run engine at idle speed with A/C ON for 10 • If A/C compressor is replaced, replenish A/C system
minutes. with new compressor oil referring to “Replenishing
2) Stop engine. Compressor Oil” in “Operation Procedure for
Refrigerant Charge”: Single A/C Type in related
3) Disconnect negative (–) cable at battery. manual.
4) Recover refrigerant from A/C system using recovery • Apply compressor oil to new O-ring of discharge hose
and recycling equipment referring to “Recovery” in and liquid pipe.
“Operation Procedure for Refrigerant Charge”:
Single A/C Type in related manual. Petrol Model: Compressor oil 95590–58D30
5) Remove right side engine undercover. (Compressor oil (ND-OIL8))
Diesel Model: Compressor oil 99000–990C5–00A
6) Petrol Model: Remove A/C compressor drive belt.
(Compressor oil (SP10))
(Page 7B-17)
Diesel Model (without ISG): Remove accessory drive • Tighten A/C compressor mounting bolts in numerical
belt.  order (“1” through “3”) as shown in the figure.
Diesel Model (with ISG): Remove water pump drive
belt. (Page 1F-10)
7) Disconnect magnet clutch lead wire connector.
[A]
"2" "3"
"1"
[B]
"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 in related
manual.
• Petrol Model: Adjust drive belt tension. (Page 7B-
17)
Diesel Model (without ISG): Adjust accessory drive
belt. 
Diesel Model (with ISG): Adjust water pump drive belt.
(Page 1F-10)
Specifications
AENFL80B7217002
Reference:
“HVAC Unit Components”: Single A/C Type

AENFL80B7218003
Compressor oil Compressor oil (ND-OIL8) P/No.: 95590–58D30 
Compressor oil (SP10) P/No.: 99000–990C5– 
00A
NOTE
“HVAC Unit Components”: Single A/C Type
Special Tool
AENFL80B7218004
09990M06020
Manifold gauge set (R134a)
1. Manifold gauge 2.
Charging hoses 3. Quick
connector 4. Refrigerant
container tap valve 5.
Refrigerant container T joint
6. Packing sets 7. Case
HVAC System: Dual A/C Type 7B-21
Dual A/C Type

General Description
HVAC System Description
AENFL80B7221001
• 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 control 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 in related manual or “A/C Operation Description at ECM (Diesel Model)”: Dual A/C Type in related
manual 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 in related manual 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. The HVAC unit also incorporates
an air filter.
• Each side ventilator has a shutter mechanism.
• The condenser is of a sub-cool type. It is integral with the receiver/dryer and mounted on the vehicle body in a
floating manner.
• 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 component location, refer to “Manual A/C Control System Component Location”:
Dual A/C Type in related manual.
For the A/C system component location, refer to “A/C System Major Components”: Dual A/C Type in related
manual.
For the A/C electrical control input / output diagram, refer to “Manual A/C Electronic Control Input / Output Block
Diagram”: Dual A/C Type in related manual.
7B-22 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
28
25
8
26 27
6
4
2
7
5
24
: [A]
3
: [B]
: [C]
IFL80B722001-02
[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 28. HVAC air filter
5. Discharge hose 13. Demister air 21. Engine

Manual A/C System Circuit Diagram
AENFL80B7222002
Petrol Model
11 1
WHT BLK WHT G155-6
BLU YEL YEL G155-7
G155-1 BLK
16 13 GRY G155-3
2
RED/WHT 24
RED G155-2
15 14
12
LT GRN G155-5
17
3
G154-1 G154-7 WHT
4
YEL G154-11
18 WHT/BLK
5
6 BEG
19 BLU G154-5
25
21 GRN G154-6
20 7
WHT RED G154-2 G154-12 BLK
22 8
RED G154-9
9 G154-8 BRN
23 LT GRN G154-3
BLK/YEL
26
28 29 27
GRY E01-19
LT BLU WHT
GRY E01-48
BLU E01-55
BLU E01-56
30
10 35
YEL PNK E01-49
YEL 27
E01- 1 RED
27
31 E01- 2 WHT
LT GRN E01-46
GRY RED 36
E01-14 PNK
32
E01-17 GRN
LT BLU 34 BLK
E01-8 GRY
RED
33
RED
C01-50 BLK
WHT
C01-51 BLK
GRN E01-36
IFL80B722003-01
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
Diesel Model
11 1
WHT BLK WHT G155-6
BLU YEL YEL G155-7
16 G155-1 BLK
13 GRY G155-3
RED/WHT 2
24
15 14 RED G155-2
17 LT GRN G155-5
12 3
G154-1 G154-7 WHT
4
YEL G154-11
18
5
BLU G154-5 6
19
21 GRN G154-6
20 7
WHT RED G154-2 G154-12 BLK
22 8
RED G154-9
9 G154-8 BRN
23 LT GRN G154-3
BLK/YEL
25
BLK
27 28 26
LT BLU WHT
GRY E01-77
34
29
LT GRN E01-7 26
GRY BLU E01- 64 RED
10 26
30 E01- 40 WHT
BLU/BLK 32 BLK
35
BLU/WHT E01-37 PNK
31
E01-87 GRN
GRN E01-8 E01-10 GRY
GRN E01-4
BLU GRN E01-5
33
WHT BLU GRN E01-6
YEL PNK E01-80
E01-1 BRN
E01-2 BRN
E01-3 BRN
IFL80B722002-01
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

Inspection of HVAC Control Unit and Its Circuit
AENFL80B7224006
HVAC control unit and its circuits can be checked at HVAC control unit 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. 
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
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
10 – 14 V
selector at OFF
Rear defogger OFF (rear defogger
0–1V
Rear defogger indicator (if indicator OFF)
G154-2 RED
equipped) Rear defogger ON (rear defogger
10 – 14 V
indicator ON)
G154-3 LT GRN Ground for illumination Below 0.5 V —
Air intake switch in “REC” position or
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
G154-6 GRN
(Fresh air) from “REC” to “FRE”
10 – 14 V Air intake switch in “REC” position
0–1V selector is at any position other than
G154-7 WHT A/C switch signal
OFF position
10 – 14 V A/C switch at OFF
Rear defogger switch signal (if Ignition Switch Model refer to: (Page 10B-20)
G154-8 BRN
equipped) Keyless Push Start Model refer to: (Page 10B-27)
0–1V Lighting switch in OFF position
G154-9 RED Illumination switch
10 – 14 V Lighting switch in ON position
0–1V Ignition “OFF”
G154-11 YEL Power supply
10 – 14 V Ignition “ON”
G154-12 BKL Ground for HVAC control unit Below 0.5 V —
Normal
Voltage
Ground for blower speed
G155-1 BLK Below 0.5 V —
selector
G155-2 RED Blower speed selector (1st)
G155-3 GRY 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
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
Repair Instructions
HVAC Air Filter Removal and Installation
AENFL80B7226045
Refer to “HVAC Air Filter Removal and Installation”:
Single A/C Type (Page 7B-16)
HVAC Air Filter Inspection

AENFL80B7226046
Refer to “HVAC Air Filter Inspection”: Single A/C Type
(Page 7B-17)
Section 8
Restraint
CONTENTS
NOTE
Precautions ................................................. 8-* Air Bag System Construction ..............................8B-1

Precautions.............................................................. 8-* Schematic and Routing Diagram ........................8B-2
Precautions for Restraint ....................................... 8-* Air Bag System Input / Output Diagram ..............8B-2
Air Bag System Circuit Diagram..........................8B-2
Seat Belts ................................................. 8A-1 Component Location ........................................... 8B-*
Precautions........................................................... 8A-* Air Bag System Component, Wiring and
Precautions for Service and Diagnosis of Seat Connector Location ........................................... 8B-*
Belt.....................................................................8A-* Diagnostic Information and Procedures ............8B-3
General Description ............................................. 8A-* Air Bag Diagnostic System Check ...................... 8B-*
Seat Belt Construction .........................................8A-* Visual Inspection ................................................. 8B-*
Diagnostic Information and Procedures............ 8A-* “AIR BAG” Warning Light Check......................... 8B-*
Repair and Inspection Required after Self Diagnosis Function ...................................... 8B-*
Accident .............................................................8A-* DTC Check..........................................................8B-3
Repair Instructions ..............................................8A-1 DTC Clearance ...................................................8B-4
Front Seat Belt Components................................8A-* DTC Table...........................................................8B-4
Front Seat Belt Assembly Removal and Scan Tool Data ...................................................8B-5
Installation..........................................................8A-* “AIR BAG” Warning Light Comes ON Steady .....8B-6
Front Seat Belt Assembly Inspection ...................8A-* “AIR BAG” Warning Light Does Not Come ON ....8B-7
Front Seat Belt Buckle Inspection ........................8A-* DTC B1011 ......................................................... 8B-*
2nd Row Seat Belt Components ..........................8A-* DTC B1012 ......................................................... 8B-*
2nd Row Seat Belt Assembly Removal and DTC B1013 ......................................................... 8B-*
Installation..........................................................8A-* DTC B1016 ......................................................... 8B-*
2nd Row Center Seat Belt Removal and DTC B1017 ......................................................... 8B-*
Installation..........................................................8A-* DTC B1021 / B1026 ............................................ 8B-*
3rd Row Seat Belt Components.......................... 8A-1 DTC B1031 .........................................................8B-8
3rd Row Seat Belt Assembly Removal and DTC B1032 .......................................................8B-11
Installation..........................................................8A-* DTC B1033 .......................................................8B-14 8
2nd Row and 3rd Row Rear Seat Belt DTC B1034 .......................................................8B-16
Assembly Inspection ..........................................8A-* DTC B1041 .......................................................8B-20
2nd Row and 3rd Row Seat Belt Buckle DTC B1042 .......................................................8B-24
Inspection...........................................................8A-* DTC B1043 .......................................................8B-27
DTC B1044 .......................................................8B-29
Specifications.......................................................8A-2
DTC B1051 / B1055 ..........................................8B-31
Tightening Torque Specifications........................ 8A-2
DTC B1052 / B1056 ..........................................8B-34
Special Tools and Equipment ............................. 8A-*
DTC B1053 / B1057 ..........................................8B-36
Special Tool .........................................................8A-*
DTC B1054 / B1058 ..........................................8B-38
DTC B1071 / B1072 ..........................................8B-41
Air Bag System ........................................ 8B-1
DTC B1073 / B1074 ..........................................8B-42
Precautions........................................................... 8B-* DTC U0073 ......................................................... 8B-*
Precautions for Air Bag System Service ..............8B-* SDM Power Supply and Ground Circuit
Precautions for Handling and Storage of Air Check ................................................................ 8B-*
Bag System Components ..................................8B-* Contact Coil and Its Circuit Check ....................8B-47
Precautions for Disposal of Air Bag and Seat Repair and Inspection Required after
Belt Pretensioner ...............................................8B-* Accident ............................................................ 8B-*
General Description .............................................8B-1 Repair Instructions ............................................8B-49
Disabling Air Bag System.................................... 8B-* Seat Belt Pretensioner Inspection....................... 8B-*
Enabling Air Bag System .................................... 8B-* Forward Impact Sensor Removal and
SDM Removal and Installation............................ 8B-* Installation ......................................................... 8B-*
SDM Inspection................................................... 8B-* Forward Impact Sensor Inspection ..................... 8B-*
Driver Air Bag (Inflator) Module Removal and Air Bag (Inflator) Module and Seat Belt
Installation ....................................................... 8B-49 Pretensioner Disposal ....................................... 8B-*
Driver Air Bag (Inflator) Module Inspection ......... 8B-* Deployed Air Bag (Inflator) Module and
Passenger Air Bag (Inflator) Module Removal Activated Seat Belt Pretensioner Disposal........ 8B-*
and Installation .................................................. 8B-* Specifications ....................................................... 8B-*
Passenger Air Bag (Inflator) Module Tightening Torque Specifications........................ 8B-*
Inspection.......................................................... 8B-* Special Tools and Equipment ...........................8B-51
Seat Belt Pretensioner Components................... 8B-* Use of Special Tools ........................................... 8B-*
Seat Belt Pretensioner Removal and Special Tool ......................................................8B-51
Installation ......................................................... 8B-*
Seat Belts: 8A-1
Seat Belts
Restraint
Repair Instructions
3rd Row Seat Belt Components

AENFL80B8106008
Split Type Seat
“3” (a)
1
1
“2” (b)
“2” (b)
(a)
“1” (a)
“1” (a)
2
“4” (a)
“4” (a)
IFL80B810001-01
8A-2 Seat Belts:
Bench Type Seat
“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)
Specifications
AENFL80B8107002
Reference:
“3rd Row Seat Belt Components”:
Air Bag System: 8B-1
Air Bag System

Restraint
General Description
Air Bag System Construction The air bag system is designed to activate only in severe
AENFL80B8201001 frontal collisions. It is not designed to activate in rear
There are two types of air bag system in this model, 1-
impacts, side impacts, rollovers, or minor frontal
channel air bag system and 4-channel air bag system,
collisions; it would offer no protection in these types of
depending on vehicle specification.
accidents.
Main Components of 1-Channel Air Bag System
• Driver-side air bag (inflator) module
• Forward impact sensor
• SDM
Main Components of 4-Channel Air Bag System

• Driver and passenger air bag (inflator) modules
IBL80A820002-01
• Driver and passenger seat belt pretensioners
• Forward impact sensor
• SDM
To supplement protection offered by seat belts, the air
bag system includes the following air bags: front air bag
for driver seat and front air bag for passenger seat (4-
channel air bag system).
For 4-channel air bag system, in addition to these air
bags, the system also includes 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
(stowed in the center of the steering wheel for the driver
seat and under the top of instrument panel for passenger
seat) are deployed.
The front seat belt pretensioners are activated whenever
a frontal impact exceeding the preset level is detected to
take up the sag in the seat belts.
IBP80A820002-02
1. Driver air bag

2. Passenger air bag (4-channel air bag system)
3. Seat belt pretensioner (4-channel air bag system)
8B-2 Air Bag System:

Air Bag System Input / Output Diagram
AENFL80B8202001
INPUT SDM OUTPUT
Driver air bag

Battery voltage DC / DC converter Safing power driver
Passenger air bag

Front air bag (4-channel air bag system)
Back up capacitor and
seat belt
pretensioner
X-Y G sensor Driver seat belt pretensioner
deployment
(Longitudinal / (4-channel air bag system)
driver
lateral acceleration)
Main CPU Passenger seat belt pretensioner
Forward impact sensor (4-channel air bag system)
BCM
Combination meter
IDL10A820004-01
Air Bag System Circuit Diagram

AENFL80B8202002
9
YEL/BLK YEL/BLK G11-10
G11-6 YEL
11
GRN GRN G11-9
[E40] G11-5 GRY
[E382] [G334] [G347] [S172] [S121] 12
G11-19 YEL YEL
G11-18 PPL PPL

1 [G372] [G373] [G259] 13
2
RED/BLK L04-6 YEL
3 7 [G240] 5
8 L04-5 GRY
10 RED G11-13 [L283] 14
6 6
WHT G11-14 L04-7 YEL
BLK
L04-8 PPL
RED L04-18 [L285]
4 15
L1
L2
L3
L04-23 BLK
: 16
L4
: 17
L5
L6
IFL80B820002-02
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 —

DTC Check NOTE
AENFL80B8204005
and SDM is not possible, perform the
2) Connect SUZUKI scan tool (PC and VCI (2)) to DLC following checks:
(1) located on underside of instrument panel at
PC and VCI using SUZUKI scan tool
Special tool function.
(A): SUZUKI scan tool (Suzuki SDT-II) • Check DLC power circuit and ground
3) Set ignition “ON”. circuit.
4) Read DTC according to instructions displayed on • Check DLC cable. If necessary, check DLC
SUZUKI scan tool and print it or write it down. Refer cable by substituting a known-good DLC
to SUZUKI scan tool operators manual for further cable.
details.
• Check CAN communication system. NOTE

(“Control Module Communication Bus Off” If communication between SUZUKI scan tool
is detected in any control module.) and SDM is not possible, perform the
referring to “Troubleshooting for following checks:
Communication Bus Off”: Petrol and Bi-
Fuel CNG Model in Section 10H (Page 10H-
PC and VCI using SUZUKI scan tool
19) / “Troubleshooting for Communication
function.
Bus Off”: Diesel Model in Section 10H
(Page 10H-45). • Check DLC power circuit and ground
circuit.
• Check SDM power circuit and ground
circuit.  • Check DLC cable. If necessary, check DLC
cable.
referring to “Troubleshooting for
Communication Bus Off”: Petrol and Bi-
Fuel CNG Model in Section 10H (Page 10H-
19) / “Troubleshooting for Communication
1
Bus Off”: Diesel Model in Section 10H
(Page 10H-45).
• Check SDM power circuit and ground
2
circuit. 
(A)
IFL80B450002-04
5) After completing the check, set ignition “OFF”, and

1
DTC Clearance
AENFL80B8204006
1) Set ignition “OFF”. 2
2) Connect SUZUKI scan tool (PC and VCI (2)) to DLC

(1) located on underside of instrument panel at (A)
Special tool
3) Set ignition “ON”. IFL80B450002-04
4) Clear DTC according to instructions displayed on 5) After completing DTC clearance, set ignition “OFF”,
SUZUKI scan tool and print it or write it down. Refer and disconnect SUZUKI scan tool from DLC.
to SUZUKI scan tool operators manual for further
NOTE
details.
If DTC B1013, B1021 or DTC B1026 is stored
in SDM, it is not possible to clear the DTC.
DTC Table
AENFL80B8204007
DTC DTC name DTC detecting condition
— Normal —
B1011  SDM Wrong Assembly SDM has inconsistent ID code.
B1012  Intermittent Connection of SDM Connector Faulty connection of SDM connector.
Malfunctioning SDM internal circuit, G sensor,
B1013  SDM Internal Failure
memory or CPU.

Power supply voltage is more than specified
B1016  Power Source Voltage too High
range.
Power supply voltage is less than specified
B1017  Power Source Voltage too Low
range.
Deployment of front air bag has been recorded
B1021  Front Air Bag Deployment Record
in SDM.
Activation of seat belt pretensioner has been
B1026  Seat Belt Pretensioner Activation Record
recorded in SDM.
Driver air bag (inflator) module circuit resistance
B1031 (Page 8B-8) Driver Air Bag Circuit High Resistance
is more than specified range.
B1032 (Page 8B- Driver air bag (inflator) module circuit resistance
Driver Air Bag Circuit Low Resistance
11) is less than specified range.
B1033 (Page 8B- Driver air bag (inflator) module circuit has been
Driver Air Bag Circuit Shorted to Ground
14) shorted to ground.
B1034 (Page 8B- Driver Air Bag Circuit Shorted to Power Driver air bag (inflator) module circuit has been
16) Supply shorted to power supply.
B1041 (Page 8B- Passenger air bag (inflator) module circuit
Passenger Air Bag Circuit High Resistance
20) resistance is more than specified range.
B1042 (Page 8B- Passenger air bag (inflator) module circuit
Passenger Air Bag Circuit Low Resistance
24) resistance is less than specified range.
B1043 (Page 8B- Passenger Air Bag Circuit Shorted to Passenger air bag (inflator) module circuit has
27) Ground been shorted to ground.
B1044 (Page 8B- Passenger Air Bag Circuit Shorted to Power Passenger air bag (inflator) module circuit has
29) Supply been shorted to power supply.
B1051 (Page 8B- Driver Seat Belt Pretensioner Circuit High Driver seat belt pretensioner circuit resistance is
31) Resistance more than specified range.
B1052 (Page 8B- Driver Seat Belt Pretensioner Circuit Low Driver seat belt pretensioner circuit resistance is
34) Resistance less than specified range.
B1053 (Page 8B- Driver Seat Belt Pretensioner Circuit Shorted Driver seat belt pretensioner circuit has been
36) to Ground shorted to ground.
B1054 (Page 8B- Driver Seat Belt Pretensioner Circuit Shorted Driver seat belt pretensioner circuit has been
38) to Power Supply shorted to power supply.
B1055 (Page 8B- Passenger Seat Belt Pretensioner Circuit Passenger seat belt pretensioner circuit
31) High Resistance resistance is more than specified range.
B1056 (Page 8B- Passenger Seat Belt Pretensioner Circuit Passenger seat belt pretensioner circuit
34) Low Resistance resistance is less than specified range.
B1057 (Page 8B- Passenger Seat Belt Pretensioner Circuit Passenger seat belt pretensioner circuit has
36) Shorted to Ground been shorted to ground.
B1058 (Page 8B- Passenger Seat Belt Pretensioner Circuit Passenger seat belt pretensioner circuit has
38) Shorted to Power Supply been shorted to power supply.
B1071 (Page 8B- Driver Forward Impact Sensor Forward impact sensor has communicated with
41) Communication Data Inconsistent no response or inconsistent ID code.
B1072 (Page 8B- Driver Forward Impact Sensor Forward impact sensor has communicated with
41) Communication Data Invalid invalid data.
B1073 (Page 8B- Driver Forward Impact Sensor Circuit Forward impact sensor circuit has been shorted
42) Shorted to Ground to ground.
B1074 (Page 8B- Forward impact sensor circuit has been shorted
Driver Forward Impact Sensor Circuit Open
42) to power supply or opened.
Transmitting and receiving error of SDM for
U0073  Control Module Communication Bus Off
specified time continuously.
Scan Tool Data Normal Condition /

AENFL80B8204008 Scan Tool Data
Reference Value
Data list of SDM
Driv A/B Ini Res 1.0 – 4.5 ohm
Normal Condition /
Scan Tool Data Pass A/B Ini Res 1.0 – 3.8 ohm
Reference Value
Driv Preten Ini Res 1.0 – 3.8 ohm
System ID 1ch / 4ch
Pass Preten Ini Res 1.0 – 3.8 ohm
Battery Voltage 10 – 14 V
Backup Volt 27.0 – 33.0 V
Scan Tool Data Definition Driv A/B Ini Res (Driver air bag initiator resistance)
System ID (1ch / 4ch) (Ω)
This parameter indicates number of initiator circuits. This parameter indicates resistance of driver air bag
initiator circuit.
Battery Voltage (V)
Power supply voltage is an analog input signal read by Pass A/B Ini Res (Passenger air bag initiator
SDM. resistance) (Ω)
This parameter indicates resistance of passenger air
Backup Volt (V) bag initiator circuit.
This parameter indicates capacity of backup capacitor
installed to maintain ignition current (as much as Driv Preten Ini Res (Driver pretensioner initiator
possible) even when power supply to SDM that ignites resistance) (Ω)
inflator is shut off. This parameter indicates resistance of driver seat belt
pretensioner initiator circuit.
Pass Preten Ini Res (Passenger pretensioner

initiator resistance) (Ω)
This parameter indicates resistance of passenger seat
belt pretensioner initiator circuit.
“AIR BAG” Warning Light Comes ON Steady

AENFL80B8204009
Circuit Diagram
3 6 2
4
1 RED G240-3 7
BLK 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
IFL80B820003-02
[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 SDM connector check Go to Step 2. Connect connector
1) Check for proper connection to SDM connector. securely.

2 DTC Check Go to applicable DTC Go to Step 3.
1) Perform “DTC Check” (Page 8B-3). troubleshooting.

Step Action Yes No

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
circuits.
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.

5 Combination meter check Replace SDM and End.
1) Replace combination meter. (Page 9C-24) recheck DTC. 
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” in related manual to confirm that the trouble has been
solved.
“AIR BAG” Warning Light Does Not Come ON

AENFL80B8204010
Circuit Diagram
3 6 2
4
1 RED G240-3 7
BLK 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
IFL80B820003-02
[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.
Do other indicator lights come ON?

Step Action Yes No

2 DTC check Go to “Troubleshooting Replace SDM and
1) Confirm that ignition is in “OFF”. for Communication Bus recheck DTC. 
Off”:.
2) Connect scan tool to DLC.
4) Check DTC. (Page 8B-3)

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.

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” and “BLK” 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” wire and ground.
Is it 10 – 14 V?
6 Combination meter ground circuit check Replace combination “BLK” circuit open.
1) Measure resistance between “BLK” wire and ground. meter and recheck “AIR
BAG” warning light
Is resistance less than 1 Ω? operation. (Page 9C-
24)
NOTE
corrected.
DTC B1031
AENFL80B8204017
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
YEL G11-6
A2
GRY 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
IFL80B820004-05
[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” in related
manual.
Step Action Yes No

2 Driver air bag (inflator) module check Go to Step 3. Go to Step 4.
3) Disconnect “G347” connector.
4) Connect “STEERING WHEEL” harness (1) of special
tools (A) and (B) to “G347” connector.
Special tool
(A): 09932M78340
(B): 09932M75010
[G347]
1
(A)
(B)
IBP80A820010-01

Is DTC B1031 detected?

Step Action Yes No

3 Instrument panel harness circuit check Replace SDM with new Replace instrument
1) Set ignition “OFF”. one.  panel harness.
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): 09932M76010
[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

4 Contact coil circuit check Replace driver air bag Replace contact coil
1) Check contact coil circuit. (Page 8B-47) (inflator) module. assembly. 
(Page 8B-49)
Is contact coil circuit in good condition?
NOTE
• Clear DTCs, referring to “DTC Clearance” (Page 8B-4) if any DTC is detected.
solved.
DTC B1032
AENFL80B8204018
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
Circuit Diagram
[S121] [S172] [G347]

A1
1 2
YEL G11-6
A2
GRY 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
IFL80B820004-05
ground circuit
DTC Troubleshooting
Step Action Yes No
Diagnostic System
Check” in related
manual.
Step Action Yes No

2 Driver air bag (inflator) module check Go to Step 3. Go to Step 4.
tools (A) and (B) to “G347” connector.
Special tool
(A): 09932M78340
(B): 09932M75010
[G347]
1
(A)
(B)
IBP80A820010-01


Step Action Yes No

3 Instrument panel harness circuit check Replace SDM and Replace instrument
1) Set ignition “OFF”. recheck DTC.  panel harness.
• Resistance between “G11-5” and “G11-6” terminals:
infinity
Special tool
(A): 09932M76010
[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

4 Contact coil circuit check Replace driver air bag Replace contact coil
1) Check contact coil circuit. (Page 8B-47) (inflator) module. assembly. 
(Page 8B-49)
Is contact coil circuit in good condition?
NOTE
solved.
DTC B1033
AENFL80B8204019
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
Circuit Diagram
[S121] [S172] [G347]

A1
1 2
YEL G11-6
A2
GRY 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
IFL80B820004-05
ground circuit
DTC Troubleshooting
Step Action Yes No
Diagnostic System
Check” in related
manual.
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.
Special tool
(A): 09932M76010
(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

Step Action Yes No

3 Contact coil circuit check Replace SDM and Replace contact coil. 
1) Connect “G347” connector. recheck DTC. 
2) Remove driver air bag (inflator) module from steering
column. (Page 8B-49)
• Resistance between each of “A1” and “A2” circuit and
ground: infinity
Special tool
(A): 09932M76010
(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
NOTE
solved.
DTC B1034
AENFL80B8204020
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
Circuit Diagram
[S121] [S172] [G347]

A1
1 2
YEL G11-6
A2
GRY 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
IFL80B820004-05
ground circuit
DTC Troubleshooting
Step Action Yes No
Diagnostic System
Check” in related
manual.
Step Action Yes No

• Voltage between each of “A1” and “A2” circuits and
ground: 0 V
Special tool
(A): 09932M76010
(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

Step Action Yes No

3 Contact coil circuit check Replace SDM and Replace contact coil
1) Confirm that ignition is in “OFF”. recheck DTC.  assembly. 
2) Connect “G347” connector.
3) Remove driver air bag (inflator) module from steering
column. (Page 8B-49)
ground: 0 V
Special tool
(A): 09932M76010
(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
NOTE
solved.
DTC B1041
AENFL80B8204021
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
YEL YEL G11-19

A2 A4
PPL PPL 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
IFL80B820005-04
[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
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
Diagnostic System
Check” in related
manual.
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. 
tool (A), (B) and (C) to “G259” connector.
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75010
(B)
[G259]
(A)
(C)
IBP80A820012-01


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. 
• Resistance between “G11-19” and “G259-1”
terminals: 1 Ω or less
terminals: 1 Ω or less
Special tool
(A): 09932M76010
[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

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.
• Resistance of “A3” and “A4” circuits: 1 Ω or less
Special tool
(A): 09932M76010
[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
NOTE
solved.
DTC B1042
AENFL80B8204022
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
YEL YEL G11-19

A2 A4
PPL PPL 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
IFL80B820005-04
DTC Troubleshooting
Step Action Yes No
Diagnostic System
Check” in related
manual.
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. 
tool (A), (B) and (C) to “G259” connector.
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75010
(B)
[G259]
(A)
(C)
IBP80A820012-01


Step Action Yes No

terminals: infinity
Special tool
(A): 09932M76010
[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

1) Disconnect “G372” connector. bag (inflator) module panel harness.
harness.
• Resistance between “G11-18” and “G11-19” terminal:
infinity
Special tool
(A): 09932M76010
[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

NOTE
solved.
DTC B1043
AENFL80B8204023
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
YEL YEL G11-19

A2 A4
PPL PPL 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
IFL80B820005-04
DTC Troubleshooting
Step Action Yes No
Diagnostic System
Check” in related
manual.
Step Action Yes No

1) Confirm that ignition is in “OFF”. recheck DTC. 
Special tool
(A): 09932M76010
(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

1) Disconnect “G372” connector. bag (inflator) module panel harness.
harness.
Special tool
(A): 09932M76010
(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

NOTE
solved.
DTC B1044
AENFL80B8204024
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
YEL YEL G11-19

A2 A4
PPL PPL 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
IFL80B820005-04
DTC Troubleshooting
Step Action Yes No
Diagnostic System
Check” in related
manual.
Step Action Yes No

ground: 0 V
Special tool
(A): 09932M76010
(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

1) Confirm that ignition is in “OFF”. bag (inflator) module panel harness.
harness.
ground: 0 V
Special tool
(A): 09932M76010
(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

NOTE
corrected.
DTC B1051 / B1055

AENFL80B8204025
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
YEL L04-6
A2
GRY L04-5
[L285]
A3
2
YEL L04-7
A4
PPL 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
IFL80B820006-04
[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
Diagnostic System
Check” in related
manual.
Step Action Yes No

2 Seat belt pretensioner check Go to Step 3. Replace seat belt
1) Confirm that ignition is in “OFF”. pretensioner. 
2) Check for proper connection to “L283” or “L285”
connector.
3) Disconnect “L283” or “L285” connector.
tool (A), (B) and (C) to “L283” or “L285” connector.
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75010
(C)
)A(
(B)
[L283 (L285)]
1
IBP80A820014-01

Is DTC B1051 or DTC B1055 indicated?

Step Action Yes No

3 Floor harness circuit check Replace SDM and Replace floor harness.
2) Check for proper connection to “L04” connector.
3) Disconnect “L04” connector.
• 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): 09932M76010
[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
NOTE
solved.
DTC B1052 / B1056

AENFL80B8204026
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
YEL L04-6
A2
GRY L04-5
[L285]
A3
2
YEL L04-7
A4
PPL 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
IFL80B820006-04
output circuit
ground circuit
output circuit
ground circuit
DTC Troubleshooting
Step Action Yes No
Diagnostic System
Check” in related
manual.
Step Action Yes No

2 Seat belt pretensioner check Go to Step 3. Replace seat belt
1) Confirm that ignition is in “OFF”. pretensioner. 
tool (A), (B) and (C) to “L283” or “L285” connector.
Special tool
(A): 09932M76010
(B): 09932M78310
(C): 09932M75010
(C)
)A(
(B)
[L283 (L285)]
1
IBP80A820014-01

Is DTC B1052 or DTC B1056 indicated?

Step Action Yes No

• 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): 09932M76010
[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
NOTE
solved.
DTC B1053 / B1057

AENFL80B8204027
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.
Circuit Diagram
[L283] 3
1 A1
YEL L04-6
A2
GRY L04-5
[L285]
A3
2
YEL L04-7
A4
PPL 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
IFL80B820006-04
output circuit
ground circuit
output circuit
ground circuit
DTC Troubleshooting
Step Action Yes No
Diagnostic System
Check” in related
manual.
Step Action Yes No

and ground (DTC B1053): infinity
and ground (DTC B1057): infinity
Special tool
(A): 09932M76010
[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
NOTE
solved.
DTC B1054 / B1058

AENFL80B8204028
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.
Circuit Diagram
[L283] 3
1 A1
YEL L04-6
A2
GRY L04-5
[L285]
A3
2
YEL L04-7
A4
PPL 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
IFL80B820006-04
output circuit
ground circuit
output circuit
ground circuit
DTC Troubleshooting
Step Action Yes No
Diagnostic System
Check” in related
manual.
Step Action Yes No

ground (DTC B1054): 0 V
ground (DTC B1058): 0 V
Special tool
(A): 09932M76010
[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
NOTE
solved.
DTC B1071 / B1072

AENFL80B8204029
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
A2 A4
GRN GRN 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
IFL80B820007-02
[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
Diagnostic System
Check” in related
manual.
1) Check if DTC B1073 or B1074 is detected. (Page 8B- troubleshooting.
3)
Is relevant DTC detected?

3 Forward impact sensor check Replace SDM and End.
2) Replace forward impact sensor. 
Is DTC detected?
NOTE
solved.
DTC B1073 / B1074

AENFL80B8204030
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
A2 A4
GRN GRN 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
IFL80B820007-02
[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
Diagnostic System
Check” in related
manual.
Step Action Yes No

Special tool
(A): 09932M76010
[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

1) Check the following point. panel harness.
infinity
Special tool
(A): 09932M76010
[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

Step Action Yes No

1) Check the following point. panel harness.
Special tool
(A): 09932M76010
[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

1) Set ignition “ON”. panel harness.
ground: 0 V
Special tool
(A): 09932M76010
[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

6 Main harness circuit check Go to Step 7. Replace main harness.
Special tool
(A): 09932M76010
[E382]
4 3 2 1
[E40] (A)
1 2
IBP80A820016-01

Step Action Yes No

• Resistance between “E40-1” and “E40-2” terminals:
infinity
Special tool
(A): 09932M76010
[E40]
1 2
(A)
IBP80A820018-01

Special tool
(A): 09932M76010
[E40]
1 2
(A)
IBP80A820019-01

ground: 0 V
Special tool
(A): 09932M76010
[E40]
1 2
(A)
IBP80A820020-01

Step Action Yes No

10 Forward impact sensor check Replace SDM and End.
2) Replace forward impact sensor. 
Is DTC detected?
NOTE
solved.
Contact Coil and Its Circuit Check

AENFL80B8204033
Circuit Diagram
[S121] [S172] [G347]

A1
1 2
YEL G11-6
A2
GRY 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
IFL80B820004-05
ground 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-49) is OK, replace contact
coil assembly. 
infinity
Special tool
(A): 09932M76010
[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

Step Action Yes No

2 Contact coil circuit (driver air bag (inflator) module Go to Step 3. Replace contact coil
circuit) check assembly. 
1) Remove contact coil assembly. 
• Resistance between “S121-1” and “S172-2” terminals:
1 Ω or less
1 Ω or less
Special tool
(A): 09932M76010
[S172]
2 1
(A)
[S121]
1 2
IAP70B820008-01

Step Action Yes No

3 Contact coil circuit (horn circuit) check Go to Step 4. Replace contact coil
1) Check the following point. assembly. 
1 Ω or less
Special tool
(A): 09932M76010
[S61]
6 5 4 3 2 1
(A)
[S171]
6 5 4 3 2 1
IBL80A820012-01
Is check result OK?

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. 
coil and other terminals. condition.
Is each measured resistance infinite?
Repair Instructions
Driver Air Bag (Inflator) Module Removal and • Carefully read “Precautions for Air Bag
Installation System Service” in related manual,
AENFL80B8206005 “Precautions for Handling and Storage of
! WARNING Air Bag System Components” in related
manual and “Precautions for Disposal of
Failure to take proper precautions when
Air Bag and Seat Belt Pretensioner” in
performing service on the driver air bag
related manual and follow all of the
(inflator) module can result in personal injury
instructions provided.
or non-activation of the air bag in the event of
a collision.
NOTICE
• Never disassemble or repair an air bag
(inflator) module. If any abnormal An air bag (inflator) module that has been
condition is found, replace the module dropped may not operate correctly.
with a new one. Never use an air bag (inflator) module that
has been dropped. Replace the module with a
new one.
NOTE • Lock connector for driver air bag (inflator) module

Refer to “Repair and Inspection Required securely.
after Accident” in related manual before • Check that the harness does not get caught or
replacing deployed air bag. protrude.
• Insert two upper pins (1) of driver air bag (inflator)
Removal module first, and then bottom pin (2).
2) Insert a flat-bladed screwdriver (3) into service hole
(2) of steering wheel (1) and push spring pin (4) in 1
arrow direction to release lock.
3
2
IDAA0A820183-01
• Enable air bag system. 
2
2
3
4
4
1 2
ICV00P820016-02
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.
“2” “1”
2 3
1
IDAA0A820126-01
5) Remove driver air bag (inflator) module from

steering wheel.
Installation

Special Tool
AENFL80B8208003
09932M75010 09932M76010
Air bag load tool Connector test adapter set
///// This set includes the
following items. 1.
Connector test adapter kit
(09932-75020), 2.
Connector test adapter &
shorting bar release tool
(09932-76020) /  /  / 
////////
///////
///////
///////

09932M78310 09932M78340
Adapter cable Deployment adapter cable
/// /

SDT-II)
—
/
Section 9
Body, Cab and Accessories

CONTENTS
NOTE
Precautions ................................................. 9-* Charging System Circuit Diagram (Diesel

Precautions.............................................................. 9-* Engine without ISG model) .............................9A-45
Precautions for Body, Cab and Accessories.......... 9-* A-3 Ignition System Circuit Diagram (Petrol
Engine Model) ................................................... 9A-*
Wiring Systems........................................ 9A-1 A-4 Cooling System Circuit Diagram (Bi-fuel
Precautions........................................................... 9A-* CNG Model) ....................................................9A-46
Cautions for Body Electrical System Servicing .....9A-* A-4 Cooling System Circuit Diagram (Diesel
Engine Model) .................................................9A-47
General Description ............................................. 9A-*
A-5 Engine and A/C Control System Circuit
Abbreviations .......................................................9A-*
Diagram (Bi-fuel CNG Model) .........................9A-48
Wire / Connector Color Symbols..........................9A-*
A-5 Engine and A/C Control System Circuit
Symbols and Marks .............................................9A-*
Diagram (Diesel Engine Model) ......................9A-54
How to Read Connector Layout Diagram ............9A-*
A-6 A/T Control System Circuit Diagram...........9A-60
How to Read Connector Codes and Terminal
A-8 Body Control System Circuit Diagram
Nos.....................................................................9A-*
(ignition Switch Model) ....................................9A-62
How to Read Ground Point ..................................9A-*
A-8 Body Control System Circuit Diagram
How to Read Power Supply Diagram...................9A-*
(Keyless Push Start Model).............................9A-66
How to Read System Circuit Diagram..................9A-*
A-9 CAN Circuit Diagram ..................................9A-69
Glossary ...............................................................9A-*
A-10 Security Control System Circuit Diagram
Connector Layout Diagram .................................9A-1
(Without Keyless Push Start Model) ...............9A-70
Connector Layout Diagram ..................................9A-*
A-10 Security Control System Circuit Diagram
Engine Compartment .......................................... 9A-1
(With Keyless Push Start Model) ....................9A-72
Instrument Panel ............................................... 9A-11
A-11 ENG A-STOP System Circuit Diagram.....9A-75
Door, Roof......................................................... 9A-14
B-1 Windshield Wiper and Washer Circuit
Floor .................................................................. 9A-17
Diagram...........................................................9A-78
Rear .................................................................. 9A-19
B-2 Rear Wiper and Washer Circuit Diagram ...9A-79
Ground Point ........................................................ 9A-* B-3 Rear Defogger Circuit Diagram .................... 9A-*
Ground Point ........................................................9A-* B-4 Power Window Circuit Diagram.................... 9A-*
Power Supply Diagram ......................................9A-20 B-5 Power Door Lock Circuit Diagram ..............9A-80
Power Supply Diagram (Petrol Engine Model) .. 9A-20 B-6 Power Mirror Circuit Diagram .....................9A-82
Power Supply Diagram (Diesel Engine Model) .. 9A-24 B-7 Horn Circuit Diagram .................................... 9A-*
Fuses and the Protected Parts ......................... 9A-27 B-9 Parking Sensor System Circuit Diagram ....9A-83 9
J/B Connector / Fuse Layout ............................ 9A-31 C-1 Combination Meter Circuit Diagram ...........9A-84
J/B Inner Circuit (Detail) .................................... 9A-33 D-1 Headlight System Circuit Diagram ............... 9A-*
System Circuit Diagram.....................................9A-40 D-2 Position, Tail and License Plate Light
System Circuit Diagram .................................... 9A-40 System Circuit Diagram ..................................9A-86
A-1 Cranking System Circuit Diagram D-3 Front Fog Light System Circuit Diagram ....9A-87
(Ignition Switch Model).................................... 9A-41 D-4 Illumination Light System Circuit Diagram ..9A-88
A-1 Cranking System Circuit Diagram D-5 Interior Light System Circuit Diagram.........9A-89
(Keyless Push Start Model) ............................ 9A-42 D-6 Turn Signal and Hazard Warning Light
A-2 Charging System Circuit Diagram (Petrol System Circuit Diagram ..................................9A-90
Engine Model) ................................................. 9A-43 D-7 Brake Light System Circuit Diagram ............ 9A-*
A-2 Charging System Circuit Diagram (Diesel D-8 Back-Up Light System Circuit Diagram ........ 9A-*
Engine Model with ISG model) ....................... 9A-44 D-9 Headlight Leveling System Circuit
Diagram...........................................................9A-92
D-10 Rear Fog Light Circuit Diagram.................. 9A-* Headlight Leveling Actuator Inspection ............... 9B-*
E-1 Heater System Circuit Diagram .................. 9A-93 Lighting and Turn Signal Switch Removal and
E-3 Rear A/C System Circuit Diagram .............. 9A-95 Installation ......................................................... 9B-*
F-1 Air Bag System Circuit Diagram ................. 9A-96 Lighting and Turn Signal Switch Inspection ........ 9B-*
F-2 Anti-Lock Brake System Circuit Diagram.... 9A-97 Hazard Warning Switch Removal and
F-4 Power Steering System Circuit Diagram ...... 9A-* Installation ......................................................... 9B-*
G-1 Audio System Circuit Diagram ................... 9A-98 Hazard Warning Switch Inspection ..................... 9B-*
G-2 Accessory Socket System Circuit Front Fog Light Switch Removal and
Diagram ............................................................ 9A-* Installation (If Equipped) ................................... 9B-*
G-3 Navigation System Circuit Diagram .........9A-100 Front Fog Light Switch Inspection (If
List of Connector .............................................9A-102 Equipped).......................................................... 9B-*
List of Connectors ........................................... 9A-102 Headlight Relay / Tail Light Relay / Front Fog
A Connector ........................................................ 9A-* Light Relay Inspection....................................... 9B-*
C Connector .................................................... 9A-102 Headlight Leveling Switch Removal and
D Connector ........................................................ 9A-* Installation ......................................................... 9B-*
E Connector .................................................... 9A-104 Headlight Leveling Switch Inspection.................. 9B-*
G Connector.................................................... 9A-106 Specifications ....................................................... 9B-*
J Connector..................................................... 9A-107 Electric Bulb Capacity ......................................... 9B-*
K Connector .................................................... 9A-108
L Connector..................................................... 9A-108 Instrumentation / Driver Info. / Horn ...... 9C-1
M Connector.................................................... 9A-109 General Description .............................................9C-1
O Connector.................................................... 9A-109 Combination Meter Description ...........................9C-1
R Connector ........................................................ 9A-* Selector Switch Description (Bi-Fuel CNG
S Connector ........................................................ 9A-* Model) ...............................................................9C-4
Reassembling Note for Wiring Harness.........9A-110 Parking Sensor System Description (If
Reassembling Note for Wiring Harness .......... 9A-110 Equipped)..........................................................9C-5
Around Engine .................................................... 9A-* Parking Sensor Description (If Equipped) ...........9C-6
Around Battery ................................................ 9A-111 Schematic and Routing Diagram ........................9C-7
Around Strut .................................................... 9A-114 Parking Sensor Input / Output Block Diagram ....9C-7
Around Instrument Panel ................................ 9A-117 Combination Meter Circuit Diagram ....................9C-8
Around Main Floor........................................... 9A-120 Parking Sensor System Circuit Diagram (If
Around Rear End Door.................................... 9A-124 Equipped)..........................................................9C-9
Around Fuel Tank................................................ 9A-* Component Location .........................................9C-10
Specifications...................................................9A-125 Parking Sensor System Component Location
Tightening Torque Specifications.................... 9A-125 (If Equipped)....................................................9C-10
Diagnostic Information and Procedures ..........9C-10
Lighting Systems .................................... 9B-1 Combination Meter / Parking Sensor System
Component Location ........................................... 9B-* Diagnosis Function Description.......................9C-10
Lighting System Component Location ................ 9B-* Combination Meter / Parking Sensor System
Diagnostic Information and Procedures............ 9B-* Self-Diagnosis Function ..................................9C-11
Lighting System Diagnosis Function ................... 9B-* DTC Table.........................................................9C-11
Lighting System Symptom Diagnosis.................. 9B-* Scan Tool Data .................................................9C-12
Repair Instructions ..............................................9B-1 Scan Tool Active Test .......................................9C-12
Headlight Unit Removal and Installation .............9B-1 DTC B1802 .......................................................9C-13
Headlight Aiming and Light Intensity Check........ 9B-* DTC B1810 .......................................................9C-14
Front Fog Light Removal and Installation (If DTC B1820 .......................................................9C-15
Equipped).......................................................... 9B-* DTC B1840 .......................................................9C-15
Front Fog Light Aiming Adjustment (If DTC B1841 .......................................................9C-15
Equipped).......................................................... 9B-* DTC B1842 .......................................................9C-16
Rear Fog Light Assembly Removal and DTC B1852 .......................................................9C-16
Installation ......................................................... 9B-* DTC B1864 / B1865 / B1866 / B1867 ...............9C-18
Side Turn Signal Light Removal and DTC U0073 / U0100 / U0101 / U0121 / U0140
Installation ......................................................... 9B-* / U0141 / U0151 ..............................................9C-19
License Plate Light Removal and Installation ..... 9B-* Inspection of Combination Meter and Its
Rear Combination Light Removal and Circuits ............................................................9C-19
Installation ......................................................... 9B-* Inspection of Parking Sensor System Control
High Mount Stop Light Removal and Module and Its Circuits (If Equipped) ..............9C-22
Installation ......................................................... 9B-* Combination Meter Diagnosis ...........................9C-24
Dome Light Removal and Installation ................. 9B-* Repair Instructions ............................................9C-24
Instrument Panel Components .........................9C-24 Rear Defogger Component Location .................. 9E-*
Horn Removal and Installation ............................ 9C-* Diagnostic Information and Procedures ............ 9E-*
Horn Inspection ................................................... 9C-* Power Window System Symptom Diagnosis ...... 9E-*
Parking Sensor System Control Module Power Door Mirror Control System Symptom
Removal and Installation (If Equipped) ...........9C-27 Diagnosis (If Equipped)..................................... 9E-*
Parking Sensor Removal and Installation (If Rear Defogger (If Equipped) Symptom
Equipped)........................................................9C-27 Diagnosis .......................................................... 9E-*
Parking Sensor Inspection (If Equipped) ..........9C-27 Inspection of Power Window Main Switch and
Parking Sensor OFF Switch Removal and Its Circuit ........................................................... 9E-*
Installation (If Equipped) .................................9C-27 Repair Instructions ..............................................9E-2
Parking Sensor OFF Switch Inspection (If Windshield Components ..................................... 9E-*
Equipped)........................................................9C-28 Windshield Removal and Installation .................. 9E-*
Parking Sensor Buzzer Removal and Rear End Door Window Glass Components....... 9E-*
Installation (If Equipped) .................................9C-28 Rear End Door Window Glass Removal and
Parking Sensor Buzzer Inspection (If Installation ......................................................... 9E-*
Equipped)........................................................9C-28 Inner Rear View Mirror Removal and
Engine Auto-Stop OFF Switch Removal and Installation ......................................................... 9E-*
Installation (If Equipped) .................................9C-28 Front Door Components...................................... 9E-*
Engine Auto-Stop OFF Switch Inspection (If Front Door Glass Removal and Installation ........ 9E-*
Equipped)........................................................9C-29 Front Window Regulator Assembly Removal
CNG Selector Switch Removal and and Installation .................................................. 9E-*
Installation (Bi-Fuel Model) ............................... 9C-* Front Window Regulator Assembly Inspection .... 9E-*
Selector Switch Inspection (Bi-Fuel CNG Rear Door Components ...................................... 9E-*
Model) ............................................................... 9C-* Rear Door Glass Removal and Installation ......... 9E-*
Specifications.....................................................9C-29 Rear Window Regulator Assembly Removal
Tightening Torque Specifications......................9C-29 and Installation .................................................. 9E-*
Rear Window Regulator Assembly Inspection .... 9E-*
Wipers / Washers......................................9D-* Power Window Main Switch Inspection .............. 9E-*
Component Location ........................................... 9D-* Power Window Sub Switch Inspection................ 9E-*
Wiper and Washer Component Location ............ 9D-* Door Mirror Removal and Installation.................. 9E-*
Diagnostic Information and Procedures............ 9D-* Power Door Mirror Switch Inspection (If
Wiper and Washer Symptom Diagnosis ............. 9D-* Equipped)..........................................................9E-2
Repair Instructions .............................................. 9D-* Rear Window Defogger Relay and Mirror
Washer Tank and Washer Pump Removal Heater Relay (If Equipped) Inspection .............. 9E-*
and Installation.................................................. 9D-* Specifications....................................................... 9E-*
Washer Pump Inspection .................................... 9D-* Tightening Torque Specifications........................ 9E-*
Windshield Wiper Motor Removal and Special Tools and Equipment ............................. 9E-*
Installation......................................................... 9D-* Recommended Service Material ......................... 9E-*
Windshield Wiper Motor Operation Inspection .... 9D-*
Rear Wiper Removal and Installation.................. 9D-* Security and Locks...................................9F-1
Rear Wiper Motor Inspection .............................. 9D-* Precautions............................................................9F-*
Wiper and Washer Switch Removal and Precautions for Replacing Keyless Entry /
Installation......................................................... 9D-* Security Controller..............................................9F-*
Wiper and Washer Switch Inspection ................. 9D-* General Description ............................................. 9F-1
Specifications....................................................... 9D-* Key Code Construction ........................................9F-*
Tightening Torque Specifications........................ 9D-* Power Door Lock System Description................. 9F-1
Keyless Entry / Security Controller General
Glass / Windows / Mirrors....................... 9E-1 Description (If Equipped)....................................9F-*
Precautions............................................................9E-* Keyless Entry System Description (If
Precautions for Working on Glass........................9E-* Equipped)...........................................................9F-*
Precautions for Working on Power Window.........9E-* Emergency Lever of Back Door Description ........9F-*
General Description ..............................................9E-* Security System Description (If Equipped)...........9F-*
Power Window System Description .....................9E-* Back Door Opener System Description (If
Rear End Door Window Defogger (If Equipped)...........................................................9F-*
Equipped) Description........................................9E-* Schematic and Routing Diagram ........................ 9F-2
Component Location ........................................... 9E-1 Power Door Lock System Circuit Diagram.......... 9F-2
Power Window Component Location .................. 9E-1 Keyless Entry / Security Controller Input /
Power Door Mirror Component Location (If Output Diagram (if equipped).............................9F-*
Equipped).......................................................... 9E-2
Keyless Entry / Security Controller Circuit Front Bumper Removal and Installation ..............9H-1
Diagram (If Equipped) ........................................9F-* Front Bumper Member Removal and
Component Location ............................................9F-* Installation ......................................................... 9H-*
Keyless Entry System Component Location ........9F-* Rear Bumper Removal and Installation ..............9H-3
Diagnostic Information and Procedures.............9F-* Cowl Top Garnish Removal and Installation ....... 9H-*
Keyless Entry / Security System Symptom Hood Silencer Removal and Installation ............. 9H-*
Diagnosis ...........................................................9F-* Roof Molding Removal and Installation............... 9H-*
Inspection of Keyless Entry / Security Trim Removal and Installation.............................9H-3
Controller and Its Circuits...................................9F-* Floor Carpet Removal and Installation................ 9H-*
Repair Instructions .............................................. 9F-2 Head Lining Removal and Installation................. 9H-*
Front Door Lock Components ..............................9F-* Center Console Box Removal and Installation ....9H-7
Front Door Lock Assembly Removal and Accessory Socket Removal and Installation ....... 9H-*
Installation ......................................................... 9F-2 Specifications ....................................................... 9H-*
Front Door Lock Assembly Inspection .................9F-* Plastic Part Specifications................................... 9H-*
Rear Door Lock Components...............................9F-*
Rear Door Lock Assembly Removal and Hood / Fenders / Doors ............................9J-1
Installation ..........................................................9F-* Repair Instructions .............................................. 9J-1
Rear Door Lock Assembly Inspection ..................9F-* Hood Removal and Installation ............................ 9J-*
Door Lock Switch and Actuator On-Vehicle Hood Inspection and Adjustment ........................ 9J-1
Inspection (If Equipped) .....................................9F-* Hood Latch Release Cable Components............. 9J-*
Front and Rear Door Switch Inspection ...............9F-* Front Fender Components ................................... 9J-*
Power Door Lock Switch Inspection (If Front Fender Removal and Installation ................ 9J-*
Equipped)...........................................................9F-* Front Door Components....................................... 9J-*
Back Door Lock Components ..............................9F-* Front Door Assembly Removal and
Back Door Latch On-Vehicle Inspection ..............9F-* Installation .......................................................... 9J-*
Back Door Lock Removal and Installation ...........9F-* Rear Door Components ....................................... 9J-*
Request Switch On-Vehicle Inspection ............... 9F-3 Rear Door Assembly Removal and
Ignition Key Registration (Ignition Switch Installation .......................................................... 9J-*
Model) ............................................................... 9F-4 Fuel Filler Door Removal and Installation ............ 9J-*
Replacement of Transmitter Battery (If Fuel Filler Door Opener Cable Removal and
Equipped)...........................................................9F-* Installation .......................................................... 9J-*
Programming Transmitter Code for Keyless Back Door Assembly Components ...................... 9J-*
Entry System..................................................... 9F-4 Back Door Assembly Removal and
Security Controller Removal and Installation Installation .......................................................... 9J-*
(If Equipped) ......................................................9F-* All Latches, Hinges and Locks Inspection............ 9J-*
Valet Switch Inspection (If Equipped) ..................9F-* Specifications ....................................................... 9J-2
Hood Switch Removal and Installation (If Tightening Torque Specifications........................ 9J-2
Equipped)...........................................................9F-* Special Tools and Equipment ..............................9J-*
Hood Switch Inspection (If Equipped) ..................9F-* Recommended Service Material .......................... 9J-*
Siren Removal and Installation (If Equipped).......9F-*
Siren Inspection (If Equipped)..............................9F-* Body Structure......................................... 9K-1
Specifications....................................................... 9F-4 Precautions........................................................... 9K-*
Tightening Torque Specifications........................ 9F-4 Precautions for Body Structure ........................... 9K-*
Special Tools and Equipment ............................. 9F-5 General Description .............................................9K-1
Recommended Service Material ......................... 9F-5 Body Repair Description ..................................... 9K-*
Sheet Metal Description ......................................9K-1
Seats......................................................... 9G-1 Body Structure Description ................................. 9K-*
Repair Instructions ............................................. 9G-1 Checking and Straightening Benches
Front Seat Components ...................................... 9G-* Instruction.......................................................... 9K-*
Front Seat Removal and Installation ................... 9G-* Component Location ........................................... 9K-*
Rear Seat Components....................................... 9G-* Silencer Sheet Installation Area .......................... 9K-*
Rear Seat Removal and Installation.................... 9G-* Diagnostic Information and Procedures ............ 9K-*
3rd Row Seat Components ................................ 9G-1 Inspection for Body Damage............................... 9K-*
3rd Row Seat Removal and Installation ............. 9G-4 Transmission Routes of Impact........................... 9K-*
Specifications...................................................... 9G-4 Panel Clearance.................................................. 9K-*
Tightening Torque Specifications....................... 9G-4 Front Body Dimensions....................................... 9K-*
Rear End Door Dimensions ................................ 9K-*
Exterior Trim / Interior Trim .................... 9H-1 Side Body Outside Dimensions........................... 9K-*
Repair Instructions ..............................................9H-1 Side Body Inside Dimensions ............................. 9K-*
Table of Contents 9-v
Windshield Dimensions........................................9K-* Rear Lamp House Outer Panel and Rear

Underbody Dimensions........................................9K-* Lamp House Inner Lower Panel Removal
Engine Room Dimensions with Mechanical and Installation .................................................. 9K-*
Parts...................................................................9K-* Roof Panel Removal and Installation ................9K-14
Front Underbody Dimensions with Foamed Material Filling Area Repair................... 9K-*
Mechanical Parts ...............................................9K-* Specifications.....................................................9K-17
Front Suspension Frame Dimensions..................9K-* Tightening Torque Specifications......................9K-17
Repair Instructions ............................................9K-11 Special Tools and Equipment ............................. 9K-*
Hood Lock Member and Lamp Support Brace Recommended Service Material ......................... 9K-*
Removal and Installation....................................9K-*
Front Fender Lower Bracket Removal and Paint / Coatings ........................................ 9L-*
Installation..........................................................9K-* Precautions............................................................9L-*
Apron Side Member Removal and Installation .....9K-* Precautions for Working on Air Bag System ........9L-*
Apron Side Member (Partial) Removal and General Description ..............................................9L-*
Installation..........................................................9K-* Anti-Corrosion Treatment.....................................9L-*
Cowl Side Outer Member Removal and Repair Instructions ...............................................9L-*
Installation..........................................................9K-* Sealant Application Areas ....................................9L-*
Dash Side Front Panel, Cowl Side Panel and Undercoating Application Areas...........................9L-*
Front Fender Center Bracket Removal and Anti-Corrosion Compound Application Area ........9L-*
Installation..........................................................9K-*
Fender Apron Panel Removal and Installation .....9K-* Audio Visual / Navigation ....................... 9O-1
Fender Apron Extension Removal and
Schematic and Routing Diagram ....................... 9O-1
Installation..........................................................9K-*
Audio System Circuit Diagram ........................... 9O-1
A-Pillar Outer Panel Removal and Installation .....9K-*
Component Location .......................................... 9O-2
A-Pillar Outer Panel, Front Door Hinge
Audio System Component Location................... 9O-2
Reinforcement and Dash Side Panel
Removal and Installation....................................9K-* Diagnostic Information and Procedures ........... 9O-2
A-Pillar Outer Panel, Front Door Hinge Audio System Inspection.................................... 9O-2
Reinforcement, Dash Side Panel, Front Audio System Symptom Diagnosis .................... 9O-6
Pillar Inner Panel and Front Pillar Upper Repair Instructions ............................................. 9O-7
Reinforcement Removal and Installation ...........9K-* Audio/Navigation Unit Removal and
B-Pillar Outer Panel Removal and Installation .....9K-* Installation (If equipped)................................... 9O-7
B-Pillar Outer Panel, Rear Door Hinge Front Speaker and Rear Speaker Removal
Reinforcement and Center Pillar Inner Panel and Installation .................................................. 9O-*
Removal and Installation....................................9K-* Tweeter Removal and Installation....................... 9O-*
Side Sill Outer Panel Removal and Radio Antenna Removal and Installation ............ 9O-*
Installation..........................................................9K-* Radio Antenna Feeder Cable Inspection ............ 9O-*
Quarter-Pillar Outer Panel Removal and Steering Switch (Audio Control Switch and
Installation..........................................................9K-* Hands-Free Switch) Removal and
Wheel House Outer Panel Removal and Installation (If Equipped) .................................. 9O-7
Installation..........................................................9K-* Steering Switch (Audio Control Switch and
Back Panel Removal and Installation ............... 9K-11 Hands-Free Switch) Inspection (If Equipped) ... 9O-8
Rear Floor Panel and Rear Floor 5th Cross USB / AUX Socket Removal and Installation ...... 9O-*
Member Removal and Installation .....................9K-* GPS Antenna Removal and Installation............. 9O-9
Quarter Inner Lower Panel, Rear Floor Side USB / AUX Socket Inspection ............................. 9O-*
Rear Member (Partial), Rear Floor Side USB Harness Inspection ..................................... 9O-*
Extension and Rear Floor Side Rear Panel AUX Harness Inspection ..................................... 9O-*
(Partial) Removal and Installation ......................9K-* Specifications....................................................... 9O-*
Tightening Torque Specifications........................ 9O-*
9A-1 Wiring Systems:
Wiring Systems
Connector Layout Diagram

Engine Compartment
AENFL80B910A002
A: Battery Cable / C: Engine Harness (Petrol Engine Model) - M/T 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
IFL80B910902-01
A: Battery Cable
No. Color Connective position Remarks
A72 - Battery (–)
C: Engine Harness
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
C91 GRY Fuel injector #1
C101 GRY Ignition coil #1
Wiring Systems: 9A-2

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
C343 N Main harness (To E371)
C371 BLU CMP sensor
A: Battery Cable / C: Engine Harness (Petrol Engine Model) - A/T Model
C 9 1 C192 C93 C195 C38 C48

C06 C07 C 3 6 C92 C196 C123 C94 C371 C 34
W/S
W/S
C
18
C343
C194
(TO E371 )
C01
C101
A72
C282
C31 C283
C133
C143
C44
5 C102 C103 C56

4 19
C141 C162 6 C37 C104 C42 C39 C45 C166
IFL80B910904-02
A: Battery Cable
A72 - Battery (–)
C: Engine Harness
C01 BLK ECM
C06 N TCM A/T model
C07 N TCM A/T model
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
C123 BLK EVAP canister purge valve
C133 BLK OCV
C139 GRY A/T assembly A/T model
C141 BLK A/C compressor
C162 N Engine oil pressure switch
C166 GRY Transmission range sensor A/T model
C194 GRN Generator
C195 BLK Starting motor
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
Without ISG model
C192 C196 C C191
18
C343
(To E371)
C283
C194
C282
C195 20 5 C33 C165

IBL80A910903-03
With ISG model
C201 C196 C C366
18
C343
(To E371)
C283
C202
C282
C365
C195 20 5 C33 C168 C165

IFL80B910903-01
C: Engine Harness
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
C115 BLK Glow plug #1
C122 GRY EGR Valve
C141 GRY A/C compressor
C162 BLK Engine oil pressure switch
C168 BLK Neutral position switch With ISG model
C191 - Battery (–)
C194 GRY Generator
C195 N Starting motor
C201 - ISG (+B) With ISG model
C202 BLK ISG With ISG model
C345 BLK Main harness (To E373)
C365 BLK Battery sensor With ISG model
C374 GRN ECT sensor
D: Glow Plug Control Module Wire

D02 N Glow plug control module
D245 GRY Main harness (To E404)
E: Main Harness (Bi-fuel CNG Model)
E223
E224
E221
E265
E229
E225
E227
E234 E222
E64 E183 E312 E311 E01 32 33 34 W/S

E307 E23
E
E165 ES8
E166
27
E371
35 (To C343)
36 E160
E361
E24
E134
E304 E35
E159 E152
E36
E162
W/S
E69
E161
E151
E68
W/S E65
E34
E164
2
E63
E62
E163
E40 3 E303 E302 E210 E37 E282 E281

IFL80B910907-02
E: Main Harness
E01 BLK ECM
E23 GRY CNG control module Bi-fuel CNG model
E24 BLK ABS control module ABS model
E34 GRY Wheel speed sensor (Front-right) ABS model
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
Electric load current sensor & battery temperature
E58 GRY If equipped
sensor
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)
E134 BRN Regulator shutoff valve Bi-fuel CNG model
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
E225 BLK Starting motor relay
E227 BLK Fuel pump relay
E229 BLK A/C compressor relay
E234 BLK Front fog light relay If equipped
E265 BLK Fuel shutoff valve relay Bi-fuel CNG model
E281 BLK Horn
E282 BLK Horn
E302 BLK Horn HI
E303 BLK Horn HI
E304 GRY Security horn (Siren) If equipped
E307 GRY Outside warning buzzer If equipped
E311 BRN Main fuse box
E312 GRY Main fuse box
E361 BLK Fuel remaining pressure sensor Bi-fuel CNG model
E371 N Engine harness (To C343)
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 E56 E65 E312 E404
(To D245)
IFL80B910908-02
E: Main Harness
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

E40 N Forward impact-sensor
E47 BLK Fuel filter water detection sensor
E56 BLK MAF and IAT sensor
E57 BLK A/F sensor
Electric load current sensor and battery temperature without ISG model
E58 GRY
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)
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
E185 GRY Brake booster switch A/T model
E210 BLK Hood latch switch (Security hood switch)
E221 BLK Main relay
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
E307 GRY Outside warning buzzer 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)
Instrument Panel
AENFL80B910A003
E: Main Harness
E192 E190 E11 E12 E13 31

E484
E191 E181 E266
FWD
E336
E337
E325
E323 E324
E04
E387 E382
(To L371) (To G334)
E05
E384
(To G336) E383
(To G335)
IFL80B910909-03
E: Main Harness
E04 GRY BCM
E05 GRY BCM Keyless push start model
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
E190 N CPP (Clutch pedal position) switch#1 Keyless push start model
E191 BLK APP (Acceleration pedal position) sensor
E192 N CPP (Clutch pedal position) switch#2
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
E366 BLK Brake stroke sensor with ISG model
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)
E484 - BCM Keyless push start model
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 G248 G141 S121 S172 G370 (To K156)
G247 G267 G221 G202 B G50 S G145 G246
G451 G140
W/S
G306
23
24
G38
G151
G152
G194 G115
or
G62 G116
G194 G164
W/S or
G117
G04
or
G05
21
26
G146
22 G 25
G231 S G147
G16 A
G232 G17
G341 G101 G154 G251 G216 G217 G211 S61
G243 or G371 or G346
(To L374) G61 G32 G155 G11 S173 S171
S62
USB / AUX Cable
FWD
Fuse box
G273
A with Navigation model G274
B without Navigation model G275
G342 G336
(To L375) (To E384)
G334
G272 (To E382)
G271 G335
(To E383)
IFL80B910910-01
G: Instrument Panel Harness
G04 GRY BCM Ignition switch model
G05 GRY BCM Keyless push start model
G11 YEL A/B SDM with Air bag
G16 - Keyless start control module Keyless push start model
G17 N Immobilizer control module
G32 N Evaporator temperature sensor
G38 N Shock sensor with Security model
G50 N P/S control module
G61 N Blower motor

G62 GRN Air intake control actuator
G101 N Blower motor resistor
G117 BLU Parking sensor OFF switch If equipped
G140 BLK Engine push start switch Keyless push start model
G141 BLK Combination switch
G144 N Combination switch
G145 N Main switch (key)
G146 N Auto steering lock unit Keyless push start model
G147 N Ignition switch
G151 GRN Front fog light switch If equipped
G152 BLK Headlight leveling switch
G153 N Hazard switch
G154 N HVAC control unit
G155 BRN Blower speed selector
G164 BLU Valet switch / Parking sensor OFF switch If equipped
G194 N Heater relay
G195 N Fan relay without Rear A/C
G211 BLK DLC
G231 GRY Navigation unit (Microphone) with Navigation model
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)
G341 N Floor harness (To L374)
G342 WHT Floor harness (To L375)
G346 N Contact coil (To S171) with Air bag
G347 YEL Contact coil (To S172)
G369 YEL Instrument panel harness (To G370) with Air bag
G371 N Contact coil (To S173) without Air bag
G451 GRY Microphone without Navigation model
G: USB / AUX Cable

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)

G259 ORN Front-passenger air bag (inflator) module with Air bag
G: Instrument Panel Antenna Wire

G267 - Audio

G354 - Roof audio antenna wire (To K154)
S: Contact Coil
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
AENFL80B910A004
J: Front and Rear Door Wire
J87 J81 J85 J153 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 J86 J154
Front door wire (Passenger side)
IFL80B910911-02
J: Front Door Wire (Drive Side)
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
J85 N Door request switch (Driver side) Keyless push start model

J87 N Power mirror switch If equipped
J141 N Front speaker (R)
J153 BLU Driver outside antenna Keyless push start model
J215 N Floor harness (To L379)
J: Front Door Wire (Passenger Side)

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
J86 N Door request switch (Passenger side) Keyless push start model
J142 N Front speaker (L)
J154 BLU Front-passenger outside antenna Keyless push start model
J: Rear Door Wire (R)

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)
J: Rear Door Wire (L)

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)
K: Roof Wire, Roof Audio Antenna Wire
K121 K53 Roof audio K52 K154

antenna wire
K130
(To G354) K
K156
(To G340)
K02 K131
IFL80B910912-01
K: Roof Wire
K02 N Rear A/C unit If equipped
K52 N Spot light with Rear A/C
K53 N Dome light without Rear A/C
K130 N Microphone If equipped
K131 N J/B
K156 N Instrument panel harness (To G340) If equipped
K: Roof Audio Antenna Wire

K121 - Roof audio antenna amplifier
K154 - Instrument panel antenna wire (To G354)
Floor
AENFL80B910A005
L: Floor Harness / R: Fuel Pump Wire
L101 L380
L285 L162 10 L167 (To J216) L10 L04 L170
L374
(To G341)
L393 L382 9 8 40 L266 L381 L161
(To O233) (To J218) (To J217) L01
L21
L02
L03
L
L164
L390
(To O231)
12
11
L134
L103
L177
L379
(To J215)
L32
L292 L293
L392
(TO M151) L135 L133 L294
L262
13 L13 14 15 L31 L163 R101 R L389 38 L283 16 17
R151
L371
(To E387)
L315
L375
(To G342)
L313
L322 L314
L319
L316
FWD
IFL80B910914-03
L: Floor Harness
L01 GRY BCM
L02 BLK BCM Keyless push start model

L03 GRY BCM Keyless push start model
L04 YEL A/B SDM with Air bag
L10 GRY Keyless / security control module If equipped
L13 N Parking sensor control module with Parking sensor
L21 - Keyless push start control module Keyless push start model
L31 BLK Wheel speed sensor (Rear-right) ABS model
L32 BLK Wheel speed sensor (Rear-left) ABS model
L101 N Shift lock selector A/T model
L103 BLK Fuel shutoff valve Bi-fuel CNG 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
L177 N Fuel filler lid switch Bi-fuel CNG model
L262 GRY Rear parking sensor system buzzer with Parking sensor
L266 BLK Security option #2 Option
L283 BLK Pretensioner (Driver side) with Air bag
L285 BLK Pretensioner (Passenger side) with Air bag
L292 BLK Rear outside antenna Keyless push start model
L293 N Rear inside antenna (luggage antenna) Keyless push start model
L294 N Mid inside antenna Keyless push start model
L313 YEL J/B
L314 N J/B
L315 N J/B
L316 - J/B
L319 BLU J/B
L322 GRY J/B
L371 N Main harness (To E387)
L373 N Accessory socket wire (To L388)
L374 N Instrument panel harness (To G341)
L375 N Instrument panel harness (To G342)
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)
L392 N Rear bumper wire (To M151) with Parking sensor
L393 N Rear washer wire (To O233)
R: Fuel Pump Wire

R101 BLK Fuel pump and gauge
R151 GRY Floor harness (To L389)
Rear
AENFL80B910A006
Rear Bumper Wire
M116
M117
M118 M151
M119
(To L392)
Rear bumper wire
IFL80B910956-01
M: Rear Bumper Wire
M116 BLK Rear parking sensor#1 with Parking sensor
M151 N Floor harness (To L392) with Parking sensor
O: Rear End Door Harness, Rear Washer Wire
Rear washer wire

O
O92 O91
O231
(To L390)
O181
O122
O21
O94
O188
O95
B O121
A O121
O233 A with Rear A/C

O123 1 O182 (To L393) B without Rear A/C
IFL80B910913-01
O: Rear End Door Harness
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 or GRN Rear end door lock switch and motor If equipped
O122 N Rear end door request switch with Keyless push start model
O123 N Rear end door lock motor If equipped
O181 BLK Rear defogger (+) If equipped
O182 BLK Rear defogger (–) If equipped
O188 N Rear-view camera with Parking sensor model
O231 N Floor harness (To L390)
O: Rear Washer Wire

O91 N Rear dome light
O233 N Floor harness (To L393)
Power Supply Diagram

Power Supply Diagram (Petrol Engine Model)
AENFL80B910D001
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"
1a
1b
Relay
J/B
4
20A
Relay
box 52 54 55 56
15A 15A 20A 7.5A
LT GRN BRN BLU RED/WHT
52 54 55 56
18 19
IFL80B910968-01
B Keyless push start model
17 31 32 18 13 11 25 2 3 12
15A 10A 20A 10A 10A 10A 7.5A 20A 20A 10A
Blower
Tail motor
Horn light relay
relay relay 23 30
7.5A 15A
B 5
J/B
E324 1
4
3
BLU WHT YEL BLK
Relay box
2 6
53 60 62 48 47 57 50 41 44 46 39 42
25A 7.5A 7.5A 30A 40A 40A 30A 10A 60A 40A 15A 15A
RED RED/WHT BLU LT GRN RED LT BLU GRN WHT/RED YEL

YEL YEL YEL
E221 1 4
W/S Main
53 60 62 41 44 46 39 relay
E225 1 3 3 5
Starting PNK
motor
relay W/S
2 4
BLU BLU BLU
YEL
E227 1 4
YEL
Relay
2 3
48 PNK
42
IFL80B910977-01
A Ignition switch model

C with ABS model
D with Air bag model
B
B
Keyless start
Keyless start Keyless start
control module
control module control module
"A-10"
"A-10" "A-10"
BLU
YEL GRY
L315 19
L315
6 7
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 D C GRN BRN RED/WHT
4
Starting motor
relay
WHT/BLU "A-1"
A
A
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
IFL80B910978-01
Power Supply Diagram (Diesel Engine Model)

AENFL80B910D002
C191
1 72 74 75 76 77
Battery Main fuse box
100A 100A 100A 50A 80A
C282 1 C283 1 E311 1 2 E312 2

BLK/GRY BLK/GRY WHT BLK WHT BLK WHT BLU
Glow
Starting motor Generator Cont. M
"A-1" "A-2"
E323 2
"A-5"
Relay
J/B
4
20A
Relay
box 52 54 55
15A 15A 20A
LT GRN BRN BLU
52 54 55
20 18
IFL80B910979-01
17 31 32 18 13 11 25 2 3 12
15A 10A 20A 10A 10A 10A 7.5A 20A 20A 10A
Blower
Tail motor
Horn light relay
relay relay 23 30
7.5A 15A
B 5
J/B
E324 1
4
3
BLU WHT YEL BLK
Relay box
2 6
53 60 62 48 47 57 50 41 44 46 39 42
25A 7.5A 7.5A 30A 40A 40A 30A 10A 60A 40A 15A 15A
RED RED/WHT BLU LT GRN RED LT BLU GRN WHT/RED YEL

YEL YEL YEL
E221 1 4
W/S Main
53 60 62 41 44 46 39 relay
E225 1 3 3 5
Starting PNK
motor
relay W/S
2 4
BLU BLU BLU
YEL
E227 1 4
YEL
Relay
2 3
48 PNK
42
IFL80B910980-01

C with ABS model
D with Air bag model
B
B
Keyless start
Keyless start Keyless start
control module
control module control module
"A-10"
"A-10" "A-10"
BLU
YEL GRY
L315 19
L315
6 7
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 D C GRN BRN RED/WHT
4
Starting motor
relay
WHT/BLU "A-1"
A
A
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
IFL80B910981-01
Fuses and the Protected Parts

AENFL80B910D003
The chart below describes what parts each fuse protects.
Fuses in Main Fuse Box
NOTE
Refer to “Around Battery” (Page 9A-111) 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

100 A (Petrol engine model), All electric circuit
120 A (Diesel engine without model) Battery
450A (Diesel engine with ISG 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
Individual Circuit Fuse Box No. 1
Diesel engine model 10
69
70
E221
71
1
2
3
58
59
60 E223 E224
61
Petrol engine model
37 47
10
38 E221
48
39
40
41 49
42 E229
E265
50 62
43 51 4
52
E222 E225
53
44 54
55
56 E227
45
46 57 E234 6
10 9 10 8 5
IFL80B910966-01
1. Radiator cooling fan relay #2 4. A/C compressor relay 7. Fuel pump relay 10. BLANK
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. CNG valve relay
No. Fuse Description on the cover Protected circuit

50 A IGN2 Individual circuit fuse box No.2 (In J/B)
ECM (Diesel model)
7.5 A ECM
Main relay (In relay box - Diesel model)
15 A AT/CVT A/T control model (If equipped)
20A FP Fuel pump relay (Diesel model)
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
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)

30A DC DC DC-DC converter
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 Fuel shut-off valve relay
40 A IGN Individual circuit fuse box No.2 (In J/B)
BLANK BLANK BLANK
BLANK BLANK BLANK
7.5 A CNG CNG control module
7.5A WIP SUB Gateway control module
Combination switch
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 fun relay #2 (In relay box)
Radiator cooling fun relay #3 (In relay box)
Boost pressure regulator valve
BLANK BLANK BLANK
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

30 A BELT BLANK
20 A P/W T Power window master switch (If equipped)
20 A STL Keyless start control module
Rear defogger relay (In J/B)
20 A RR DEF Rear defogger
HVAC control unit
20 A S/R BLANK
15 A DEICER BLANK
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 Keyless start control module
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
HVAC control unit
10 A BACK Air intake control actuator
Parking sensor OFF switch
Parking sensor system control module
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 (If equipped)
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
Tail light relay (in J/B)
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
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

BLANK BLANK BLANK
Heater relay
7.5 A BLANK
Rear A/C unit
J/B Connector / Fuse Layout

AENFL80B910D004
Fuse Side
K131
E336 E337
E325 1
G273 G274 G275
E324
G271
E323
G272
IBL80A910919-01
1. Fuse box
Relay Side
1
4
4
6
7
2
L314
L313
L315
L322
L316
L319
IFL80B910967-02
1. Horn relay 3. Accessory relay (Keyless 5. Tail relay (Keyless push 7. IG1 relay (Keyless push
push start model) start model) start model)
2. Rear defogger relay 4. BLANK 6. IG2 relay (keyless push
start model)
J/B Inner Circuit (Detail)

AENFL80B910D005
Abbreviations
Abbreviation Full spelling Abbreviation Full spelling
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
Abbreviation Full spelling Abbreviation Full spelling

F-R Front R R-R Rear R
FR Front RR Rear
INP Instrument panel S/H Seat heater
LEV (Headlight) leveling
Connector No. / Terminal No.

J/B E323 E324 E325 E336 E337 G271 G272 G273 G274 G275 K131 - L314 L315 L316 L319 L322
3
13
IG COIL 15A
5
IG1 relay
12
7
27
IG1 SIG 7.5A
2
6
33
CRUISE 7.5A
6
34
MTR 10A
3
13
19
A/B 10A
4
14
ABS 10A
11
20
BACK 10A
9
10
17
15
ACC 15A
8
16
Accessory
relay 6
10
19
7
9
ACC2 15A
3
1 5
(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

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 6 7 8 9 10 9 10 11 12 13 14 15 16 6 7 8 9 10 11 12 13
L314 L315 L316 L319 L322

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 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 6 7 8 9 10 11 12 13 5 6 7 8 9 10 11 14 15 16 17 18 19 20 21 22 23 24 25
IDL10A910907-02

1
8
4
22
FR WIP 25A
7
IG2 relay
15
6
10
P/W 30A
4
10
35 21
IG2 SIG 7.5A WIP 15A
1
Blower 2
motor relay
8
8
ST SIG 7.5A
2
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

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 6 7 8 9 10 9 10 11 12 13 14 15 16 6 7 8 9 10 11 12 13
L314 L315 L316 L319 L322

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 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 6 7 8 9 10 11 12 13 5 6 7 8 9 10 11 14 15 16 17 18 19 20 21 22 23 24 25
IDL10A910908-01

16
5
4
RR DEF 20A
1
Relay
2
17
HORN 15A
6
4
Horn relay
5
31
TAIL 10A
5
Tail light
relay
4
11
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

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 6 7 8 9 10 9 10 11 12 13 14 15 16 6 7 8 9 10 11 12 13
L314 L315 L316 L319 L322

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 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 6 7 8 9 10 11 12 13 5 6 7 8 9 10 11 14 15 16 17 18 19 20 21 22 23 24 25
IDL10A910909-01

3
11
HAZ 10A
13
15
2
P/W T 20A
1
3
STL 20A
2
12
BCM 7.5A
9
10
12
14
20
12
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

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 6 7 8 9 10 9 10 11 12 13 14 15 16 6 7 8 9 10 11 12 13
L314 L315 L316 L319 L322

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 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 6 7 8 9 10 11 12 13 5 6 7 8 9 10 11 14 15 16 17 18 19 20 21 22 23 24 25
IDL10A910910-01

13
25
1
30
RADIO 15A
1
23
DOME 7.5A
9
11
10
12
11
23
(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

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 6 7 8 9 10 9 10 11 12 13 14 15 16 6 7 8 9 10 11 12 13
L314 L315 L316 L319 L322

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 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 6 7 8 9 10 11 12 13 5 6 7 8 9 10 11 14 15 16 17 18 19 20 21 22 23 24 25
IDL10A910911-01
System Circuit Diagram

System Circuit Diagram
AENFL80B910E001
Refer to “A-1 Cranking System Circuit Diagram (Ignition Switch Model)” (Page 9A-41).
Refer to “A-1 Cranking System Circuit Diagram (Keyless Push Start Model)” (Page 9A-42).
Refer to “A-2 Charging System Circuit Diagram (Petrol Engine Model)” (Page 9A-43).
Refer to “A-2 Charging System Circuit Diagram (Diesel Engine Model with ISG model)” (Page 9A-44).
Refer to “A-3 Ignition System Circuit Diagram (Petrol Engine Model)” in related manual.
Refer to “A-4 Cooling System Circuit Diagram (Bi-fuel CNG Model)” (Page 9A-46).
Refer to “A-4 Cooling System Circuit Diagram (Diesel Engine Model)” (Page 9A-47).
Refer to “A-5 Engine and A/C Control System Circuit Diagram (Bi-fuel CNG Model)” (Page 9A-48).
Refer to “A-5 Engine and A/C Control System Circuit Diagram (Diesel Engine Model)” (Page 9A-54).
Refer to “A-8 Body Control System Circuit Diagram (ignition Switch Model)” (Page 9A-62).
Refer to “A-8 Body Control System Circuit Diagram (Keyless Push Start Model)” (Page 9A-66)
Refer to “A-9 CAN Circuit Diagram” (Page 9A-69).
Refer to “A-10 Security Control System Circuit Diagram (Without Keyless Push Start Model)” (Page 9A-70)
Refer to “A-10 Security Control System Circuit Diagram (With Keyless Push Start Model)” (Page 9A-72)
Refer to “A-11 ENG A-STOP System Circuit Diagram” (Page 9A-75)
Refer to “B-1 Windshield Wiper and Washer Circuit Diagram” (Page 9A-78).
Refer to “B-2 Rear Wiper and Washer Circuit Diagram” (Page 9A-79).
Refer to “B-3 Rear Defogger Circuit Diagram” in related manual.
Refer to “B-4 Power Window Circuit Diagram” in related manual.
Refer to “B-5 Power Door Lock Circuit Diagram” (Page 9A-80).
Refer to “B-6 Power Mirror Circuit Diagram” (Page 9A-82).
Refer to “B-7 Horn Circuit Diagram” in related manual.
Refer to “C-1 Combination Meter Circuit Diagram” (Page 9A-84).
Refer to “D-1 Headlight System Circuit Diagram” in related manual.
Refer to “D-2 Position, Tail and License Plate Light System Circuit Diagram” (Page 9A-86).
Refer to “D-3 Front Fog Light System Circuit Diagram” (Page 9A-87).
Refer to “D-4 Illumination Light System Circuit Diagram” (Page 9A-88).
Refer to “D-5 Interior Light System Circuit Diagram” (Page 9A-89).
Refer to “D-6 Turn Signal and Hazard Warning Light System Circuit Diagram” (Page 9A-90).
Refer to “D-7 Brake Light System Circuit Diagram” in related manual.
Refer to “D-8 Back-Up Light System Circuit Diagram” in related manual.
Refer to “D-9 Headlight Leveling System Circuit Diagram” (Page 9A-92).
Refer to “D-10 Rear Fog Light Circuit Diagram” in related manual.
Refer to “E-1 Heater System Circuit Diagram” (Page 9A-93).
Refer to “E-3 Rear A/C System Circuit Diagram” (Page 9A-95).
Refer to “F-1 Air Bag System Circuit Diagram” (Page 9A-96).
Refer to “F-2 Anti-Lock Brake System Circuit Diagram” (Page 9A-97).
Refer to “F-4 Power Steering System Circuit Diagram” in related manual.
Refer to “G-1 Audio System Circuit Diagram” (Page 9A-98).
Refer to “G-2 Accessory Socket System Circuit Diagram” in related manual.
Refer to “G-3 Navigation System Circuit Diagram” (Page 9A-100).
A-1 Cranking System Circuit Diagram (Ignition Switch Model)

AENFL80B910E039
OUT LOCK
A Petrol engine model Relay 48
box ST
B Diesel engine model ACC
30A
ON
IN
ST
A A72
B C191 G147 2
Main
1 fuse
Battery box
BRN
A
C282 1
G271 8
A B
BLK BLK/GRY
J/B
8 ST SIG
7.5A
E336 2
WHT BLK
RED PNK
or
E225 3 1
1 2 Starting
motor
relay
or
4 2
YEL A/T model M/T model
B
BLK/GRY YEL GRN
Realy 62 ST
Box
7.5A SIG2 YEL GRN GRN
G
E371 12
E371 6 C343 ECM
C343
GRN
"A-5" BLK
LT GRN YEL
C166 4
Lg
or
P L W/S
Transmission
ECM R 2
1 range sensor N D
"A-5"
C196 1 C195 1
5
BLK
BLK
Starting
motor "A-5" "A-5"
M
3 7
IEP80A910978-03
A-1 Cranking System Circuit Diagram (Keyless Push Start Model)

AENFL80B910E002
A Petrol engine model

B Diesel engine model
Relay 48 ST
box
30A
A A72 Battery
B C191 Keyless start
control module
Main "A-10"
1 fuse
box P
A
C282 1
RED PNK
BLK BLK/GRY A B
E225 3 1
Starting
motor relay
WHT BLK
4 2
YEL GRN
or
1 2
GRN GRN
or G G
YEL Keyless start

Y control module ECM
B "A-10"
"A-5"
Relay 62 ST
box SIG2
7.5A
YEL GRN
BLK/GRY LT GRN LT GRN
E371 6 E190 1
C343
Lg Lg CPP
switch
Keyless start YEL #1
ECM control module
"A-10"
"A-5" 2
1 BLK
C196 1 C195 1
W/S
Starting
motor
BLK
M
7
IFL80B910990-02
A-2 Charging System Circuit Diagram (Petrol Engine Model)

AENFL80B910E004
Main
fuse
72 13 IG COIL J/B
box
100A 15A
C283 1 E336 5
BLK WHT
E371 5
C343
BLK
BLU
C192 1 C194 2
Stator
coil
Generator
IC regulator
Field
coil
IFL80B910950-01
A-2 Charging System Circuit Diagram (Diesel Engine Model with ISG model)
AENFL80B910E005
(Diesel Engine without ISG model)
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
Charging System Circuit Diagram (Diesel Engine without ISG model)

AENFL80B910E040
(Diesel Engine with ISG model)
Main
fuse
66
box
120A
C283 1
Gateway
control module
"A-11"
B Lb G
BLK LT BLU GRN
ECM
E493 9 4 20
"A-11","A-5"
P B
WHT BLK LT BLU GRN PPL BRN
E371 14 13 19 10 9
C343
BLK LT BLU GRN PPL BRN
C201 1 C202 1 2 5 3 4
Stator
coil
ISG
Inverter
Rotor
coil
IFL80B910916-01
A-4 Cooling System Circuit Diagram (Bi-fuel CNG Model)

AENFL80B910E007
Relay 45 RDTR
box
30A
Main relay
"A-5"
B
BLU GRY
W/S
BLU GRY GRN GRY GRN
E222 1 4 E223 3 5 E224 1 5
Relay #1 Relay #2 Relay #3
2 3 1 4 3 4
LT GRN RED RED RED BLK
Lg G
ECM ECM
R Lb W
"A-5" "A-5"
RED LT BLU WHT
E65 2 4 3
M
Motor
BLK
33
IFL80B910917-01
A-4 Cooling System Circuit Diagram (Diesel Engine Model)

AENFL80B910E008
Relay 45 RDTR
box
30A
GRY
W/S W/S
BLU BLU GRY BLU GRY BLU
E222 1 4 E223 1 5 E224 3 5
2 3 3 4 1 4
LT GRN GRN GRN BLK
ECM
B Lg "A-5"
ECM ECM
B BB BW
"A-5" "A-5"
BLU BLU/BLK BLU/WHT BLK
E65 1 2 4
M
Motor
BLK
33
IFL80B910918-01
A-5 Engine and A/C Control System Circuit Diagram (Bi-fuel CNG Model)
AENFL80B910E009
41 A/C 42 FI Relay
box
13 IG COIL J/B
10A 15A 15A
E336 12
YEL YEL
E221 1 4
1
Main
relay
3 5
LT BLU PNK BLU
B
W/S W/S W/S W/S
W/S BLU
BLU BLU BLU E371 14
C343
E229 3 1 E227 4 1 BLU
W/S
BLU
Compressor Relay
relay C123 1
4 2 3 2
EVAP
canister
purge
valve
2
WHT PNK GRY YEL WHT BLU BLU BLU
W/S BLU/BLK
E01 48 49 54 6 56 55 C01 40
ECM
E371 19 E387 5 C01 49 19 16 38 52 7 18 37

C343 L371
WHT PNK RED/BLU BLU YEL/BLK GRN/WHT BLU YEL/GRN
L389 2
R151
PNK
R101 3
P
and Gauge BRN YEL RED BLU
4
BLK
C42 3 4 2 1 C56 3 4 2 1
C141 1
BLK
1
BLK BLK HO2S-2 HO2S-1
Compressor
38 13
IFL80B910925-01
45 Relay 18 STOP
RDTR J/B
box 10A
30A
E337 5
GRY
W/S
1 2 PNK
B
E181 3
BLU GRY GRY GRN WHT
E222 1 4 E223 3 5 E224 1 5 Brake
light
switch
2 3 1 4 3 4 1
LT GRN RED GRN RED LT BLU RED BLK GRN
E337 4
RED
Lg R Lb W G J/B
E336 4
GRN G
Motor
"A-4"
E01 46 36 E01 28
ECM
C01 1 13 45 20 25 36 2 39 6 E01 14 17 8
WHT BLK GRY/BLU LT GRN BLK/YEL GRY/BLU GRY/RED RED/BLK GRY/BLU PNK GRN GRY
C39 2 C38 1 C36 1 3 E36 3 2
ECT IAT
sensor sensor Refrigerant
pressure
sensor
C37 1
1 2 2 MAP 1
sensor
Knock 2
sensor
33
IFL80B910926-01
60 CNG
Individual circuit
7.5A fuse box no. 1
BLU RED/WHT
E371 3
C343
RED/WHT
W/S
2 BLU BLU 3
W/S
BLU BLU BLU BLU RED/WHT RED/WHT RED/WHT RED/WHT RED/WHT

C91 1 C92 1 C93 1 C94 1 C81 1 C82 1 C83 1 C84 1
#1 2 #2 2 #3 2 #4 2 #1 2 #2 2 #3 2 #4 2
BLU/YEL BLU/WHT BLU/RED LT GRN/BLK WHT/BLK GRY WHT/BLU BRN/YEL RED/WHT RED/WHT
C12 6 14 5 13 1 10 18 27 E23 1 10
CNG
Cont.M
8 16 7 15 25 33 17 9 26
BR R
(CAN)
BRN/YEL BRN WHT/GRN BLK/RED RED WHT BLK BLK BLK
C01 11 12 10 22 3 15
ECM
E01 2 1 19 C01 41 16 35 34 33 32
(CAN)
WHT RED GRY BLU YEL GRN BLK LT GRN BRN GRN/WHT GRN/YEL
E383 7
46
G335
GRY
W R G G Lg B GW GY
A Blower OCV Starting Ignition Ignition Ignition Ignition
speed motor coil #4 coil #3 coil #2 coil #1
ABS
Cont.M selector relay "A-3" "A-3" "A-3" "A-3"
"E-1" C133 2 "A-1"
"A-9","F-2"
B
5
BCM A with ABS model
B without ABS model
"A-8,9"
IFL80B910927-01
With M/T model
E371 C343 W/S W/S

3 BLK/RED BLK/RED BLK/RED
14
BLU BLU BLU
Relay
box
C31 3 C371 3 C33 3 "A-1"
Lg
CKP CMP
sensor VSS
sensor
1 2 1 2 2 1
GRY PNK GRY RED/YEL BLK PPL LT GRN
C01 31 28 27 52
ECM
C01 50 51
GRY BLK BLK
BLK
6 5
IFL80B910928-01
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
YEL/RED LT GRN RED GRN WHT BLK BLK YEL WHT BRN LT BLU BLU
BLK
C01 54 53 14 26 8 17 37 E01 4 5 20 15 18 21
ECM
E01 10
PPL
E192 1
CPP
switch
2
BLK
W/S
BLK
35
with M/T model

IFL80B910929-01
Individual circuit 56 CNG 13

fuse box No.1 VLV IG COIL J/B
7.5A 15A
(Combination switch)
"D-4”
WHT/BLK E336 5
R
E387 6
L371
WHT/BLK WHT/BLK RED/WHT BLK WHT RED BLK
E134 1 L103 1 E265 4 2 G115 4 6

Fuel
Regulator Fuel CNG
shutoff
shutoff shutoff W/S select
valve
valve valve switch
relay
2 2 3 1 5 7
BLU/BLK WHT/BLK BLK/BLU LT GRN LT GRN/BLK
G335 3
12
Lg
E383
BLU/WHT BLU/BLK "C-1" LT GRN/BLK
E23 26 34 4 E01 6 E23 22
CNG
Cont.M
5 14 13 24 6 15 23 31 30
LT GRN/RED GRY GRY/RED BLU/RED GRN/WHT GRN/BLK
E371 9 8 16 13 E387 7 8
C343 L371
LT GRN/RED GRY GRY/RED BLU/RED RED/BLU RED/BLK RED/YEL GRN/WHT GRN/BLK
C30 3 4 2 E361 1 2 L60 2 3
CNG Fuel
OPEN CLOSE
pressure and remaining
temperature pressure
sensor
sensor
Fuel lid
3 1
switch
1
ECM
BLK BLK BLK
34 16 10 11
IFL80B910930-02
A-5 Engine and A/C Control System Circuit Diagram (Diesel Engine Model)
AENFL80B910E010
Main
J/B 18 STOP 33 CRUISE 71 fuse 13 IG COIL
box J/B
10A 7.5A 80A 15A
E337 5 6 E318 1
E336 5 12
RED
E404 1
D245
PNK LT GRN WHT 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 BLU BLU RED YEL GRN PNK LT BLU BLK WHT
B
E337 4
J/B C115 1 C116 1 C117 1 C118 1
E336 4
GRN
G
E01 20 68 70 74 23
ECM
37 87 10 83 65 35 15 41 32
PNK GRN GRY BRN BLU YEL WHT

LT BLU BLK
E36 1 3 2 E191 2 3 4 1 6 5
open close open close
MAIN SUB
APP sensor
Refrigerant
pressure sensor
BLK
33 29
IFL80B910919-01
A without ISG model

B with ISG model
J/B 13 IG COIL C Keyless push start model
15A
E336 12
WHT
A E41
B E47 3
Fuel filter
water detection
sensor
2 1
BLK RED
E01 90
ECM
E01 61 13 1 2 3 40 64 27
(CAN) C
PPL
YEL BLU BRN BRN BRN WHT RED PPL PPL
E59 6 E190 1
P
Fuel Keyless start

CPP
temperature control module
switch
sensor W R "A-10"
#2
5 ABS 2
Cont.M
"A-9","F-2"
BLK BRN BLK BLK
28 29 28 32 36
IFL80B910920-01
Relay
38 ECM 43 FI 41 A/C 69 INJ DRV 65 F/P box
7.5A 30A 10A 20A 20A
BLU
2
W/S
1
GRN
YEL WHT BLU LT BLU BLU BLU
E221 4 3 E229 1 3 E227 1 4
Main
relay Compressor
relay Relay
1 2 2 4 2 3
YEL PNK BLU GRY WHT GRN GRN GRN YEL PNK
A 77
E01 50 80 B 79 4 5 6 75
ECM
C01 29 54 59 43 4 20
E387 5
E373 5
L371
C345
PNK
GRN PPL/WHT YEL/RED GRY/BLK WHT YEL/BLK YEL
L389 2
C141 2 C69 1 R151
PNK
High R101 3
pressure P
C374 1 C31 1
Compressor pump
and P
1
2 Gauge
BLK
4
ECT CKP BLK
2 2
sensor sensor 7
BLK
1
A without ISG model BLK BLK BLK
B with ISG model
29 17 15
IFL80B910921-01
Relay
64 FI2 45 RDTR box
10A 30A
BLU BLU GRY
2
W/S W/S W/S W/S
1 BLU
B
BLU
E373 2
C345
BLU/RED BLU GRY BLU GRY BLU
E222 1 4 E223 1 5 E224 3 5

BLU BLU/RED BLU/RED
C345 1
A/F sensor E57 6 C122 4 E373
BLU/RED 3
2 3 4 1 4
E135 2
Boost GRN GRN
pressure
EGR 6 control
2 3 1 4 5 valve solenoid
valve
1 BLU BLU/BLK BLU/WHT BLK
YEL/GRN
Lg G B BB BW
3
LT GRN YEL WHT BLK PNK GRY/RED BLU/RED YEL/GRN LT GRN
Motor Motor
E01 44 46 45 47 12 C01 15 5 30 E01 7 8 "A-4" "A-4"
ECM
C01 47 16 49 17 48 31 46 1 E01 84 92
WHT GRY/WHT YEL YEL/BLK GRN WHT/GRN BLU WHT/BLU LT GRN GRN
Lg G
C91 1 C92 1 C93 1 C94 1
Starting CPP
motor relay switch #1
"A-1" "A-1"
#1 2 #2 2 #3 2 #4 2
33
IFL80B910922-02
A without ISG model

B with ISG model
IG DOME
J/B 13 COIL 23
15A 7.5A
E336 5 G275 2
WHT
A E124
B E56 1
Fuel pressure sensor
without ISG model
MAF sensor
Generator
with IAT sensor-1
"A-2"
BY
C50 3 2 1 4 2 3
GRN/YEL YEL/BLK YEL/RED RED YEL BLU BLU/YEL
C01 8 38 6 E01 56 34 62 79
ECM
C01 25 56 21 23 41 24 37 9 E01 66
W
C343 16
E371
PNK PNK/BLK PPL RED/BLK YEL BLK WHT/GRN GRY/YEL GRY GRY PPL
E383 14 6
G335 "A-9","C-1"
GRY PPL W R
P
C32 3 2 1 C51 3 4 1 2
CMP sensor Boost pressure sensor C162 1 BLK WHT WHT RED
with IAT sensor-2 (CAN)
G211 13 12 10 1 3 11
Engine oil W/S
pressure
switch BLK BLK
DLC
3 9 11
IFL80B910923-01
Hood latch EGN A STOP DC / DC

Brake stroke switch OFF switch Converter
sensor
"A-11" "A-11" "A-11" "A-11" "A-11"
"A-11"
G P G G G B Lb P
GRY PPL GRN GRN GRY BLU LT BLU PPL
E01 11 94 38 24 17 9 19 85
BCM
21 26 93 51 59
GRY YEL PNK BRN PPL
G Y P B P
brake booster Neutral position ISG ISG

switch switch
"A-2" "A-2"
"A-11" "A-11"
IFL80B910924-01
A-6 A/T Control System Circuit Diagram

AENFL80B910E045
J/B
20 BACK
10A
E336 9
YEL
E371 18
C343
YEL
2
C166
Transmission
range sensor P L
R N D 2
6 1 9 7 3 8
RED
E371 C343
RED RED BEG BLU GRN/YEL LT GRN/BLK
R 17 R
PNK/BLK RED
J/B
"D-8"
C07 20 1 8 7 19 18
TCM
BCM
21
"A-8" J/B
GRN
W "D-4"
C343 13 R
E371
WHT GRN
G349 8 E387 11
L399 RED
L371
WHT GRN
L101 5 3 4
Select A/T
O/D cut
ILL
lever shift lock

switch
assembly solenoid
10 7 8 9
BLK BLK BLK LT GRN
L399 5
BLK G349
RED/BLK
8 16
RB
Combination meter
"C-1"
IFL80B910991-01
J/B
27 IG1 SIG 39 AT Relay
box
7.5A 15A
E337 2
Input shaft VSS

speed sensor
C44 2 1 C34 2 1
ECM
YEL
"A-5,9"
W R
E371 3
LT GRN C343 WHT BLK PPL GRY
E371 9
C343 YEL/BLK
WHT RED
LT GRN/BLK
(CAN)
C06 24 7 17 6 C07 16 6 14 5
TCM
C06 2 4 3 5 9 22 19 21 16 12 11 23 1
BLK BLK
LT GRN/BLK GRY/RED WHT/BLK WHT/BLU BLK RED BLU/BLK BLK/YEL BRN BEG LT GRN
BLK
C139 11 4 9 3 13 6 12 5 10 7 1
B1 Pressure Lock-up C1 Pressure C2 Pressure Shift A/T fluid

control solenoid control control solenoid temperature
solenoid solenoid solenoid No.1 sensor
Automatic transaxle
4
IFL80B910992-01
A-8 Body Control System Circuit Diagram (ignition Switch Model)

AENFL80B910E011
J/B 23 DOME 11 HAZ 15 ACC

7.5A 10A 15A
E337 9 13 G275 8
E37 2
Outside air
temperature
sensor "A-10"
B G G Y
1
GRY LT GRN BRN WHT GRN BRN GRN GRY YEL
E04 9 2 6 7 G04 32 22 6 23 7
BCM
14 1 10 3 11 4 8
BLU RED GRN YEL WHT RED GRY
(CAN)
B R E183 1 Y W R E337 14
Front turn Front turn Security Gateway

signal light signal light J/B
Brake horn control module
(L) (R) fluid "A-10" "A-9,11"
"D-6" "D-6" level L322 20
switch
BLK BLK
W/S
BLK
6 13
IFL80B910931-01
G32 1
Main
J/B switch (key)
"B-3" Evaporator "A-10"
Y temperature B
sensor
YEL BEG GRN BLU
G04 11 28 29 31
BCM
G04 10 8 32 33 9 14 3 18 2
WHT BRN LT GRN PPL LT GRN WHT PPL WHT RED

(CAN)
W B Lg P Lg W P W R
HVAC HVAC without Navigation P/S

control control Cont.M
unit unit Switch Switch Audio
"E-1" "B-3","E-1" (Security alarm "D-6" "G-1" "A-9","F-4"
"D-6" indicator)
"A-10"
with Navigation
Navigation
"G-3"
IFL80B910932-01
BCM
L01 26 14 15 1 12 25
GRN/BLK GRN BLU RED
BLK GRN/RED GRN/BLK GRN GRN/BLK GRN GRN/BLK GRN GRN/BLK BLU GRN RED BLU
GR GB G GB G GB G GB B G R B
Rear Rear Rear Rear

combination combination
assembly motor light (L) light (R)
motor motor Turn signal Turn signal
"D-6" "D-6" light (R)
(R) (L) light (L)
"B-5" "B-5" "D-6" "D-6"
"B-5" "B-5"
13
IFL80B910933-01
32 34
J/B D/L MTR
20A 10A
L315 20 3
J/B
"D-5"
W
BRN WHT WHT
L01 13 10 18
BCM
L01 20 22 17 4 6 19 21 8 7
YEL LT GRN GRY BLU LT GRN BRN RED BEG YEL

with Navigation
LT GRN
Lg G B Lg B R B Y
L175 1
Navigation Front/Rear Front door Rear end
"G-3" door switch door
switch "A-10" solenoid
Master switch Assembly
Seat "A-10" "B-5"
belt "B-5"
switch
LT GRN
"B-5"
2
BLK
L167 1
W/S
Parking
brake
switch
BLK BLK
15 13
IFL80B910934-01
A-8 Body Control System Circuit Diagram (Keyless Push Start Model)
AENFL80B910E041
E37 2
Outside air
temperature
sensor
GRY LT GRN
E05 8 20
BCM
13 1 18 6 5
BLU RED GRN WHT RED
(CAN)
B R E183 1 W R
Front turn Front turn

Brake Gateway
signal light signal light
fluid control module
(L) (R)
"D-6" "D-6" level "A-9,11"
switch
BLK
W/S
BLK
6
IFL80B910935-01
32
J/B D/L
20A
L315 20
G32 1
"D-2,4" Evaporator
P temperature
sensor
PNK BEG GRN BRN
P
G05 4 6 24 L02 26
BCM
G05 13 14 15 32 1 2 10 L03 19 21
PPL LT GRN WHT PPL WHT RED WHT YEL LT GRN

(CAN)
with Navigation
P Lg W P W R W L175 1
without Navigation P/S HVAC LT GRN
Cont.M control
Switch Audio unit Seat Lg
"D-6" "G-1" "A-9","F-4" "E-1" belt
switch Navigation
"D-6"
"G-3"
with Navigation 2
Navigation
"G-3" BLK LT GRN
L167 1
Parking
brake
switch
15
IFL80B910936-02
J/B 21 WIP 23 DOME 11 HAZ 20 BACK 34 MTR

15A 7.5A 10A 10A 10A
L322 2 23 15 17 L315 3
J/B J/B
"B-3" "D-5"
Y W
YEL WHT BRN WHT YEL WHT WHT
L03 3 10 11 12 25 9 L02 13
BCM
L03 14 15 2 1 L02 14 15 21 22 L03 26 13

GRN/BLK GRN BLU RED
BLK BLK GRN/BLK GRN GRN/BLK GRN/BLK GRN/BLK GRY BLU BLU GRN RED BLU
GRN/RED
GRN GRN
BLK GR GB G GB G GB G GB G B B G R B
Rear Rear Rear Rear

combination combination
assembly motor light (L) light (R)
motor motor Master switch Turn signal Turn signal
"D-6" "D-6" light (R)
(R) (L) light (L)
"B-5" "B-5" "D-6" "D-6"
"B-5" "B-5"
"B-5"
13
IFL80B910937-02
A-9 CAN Circuit Diagram

AENFL80B910E012
Auto A/C model
HVAC
A Keyless push start model
Cont.M B Ignition switch model
CAN
G154 7 8 Keyless push start model

W R
WHT RED Keyless start

control module
A G05 A 10 A 26
B G04 B 10 B 11
CAN
CAN
BCM G16 19 9
W R
WHT RED
(CAN)
A E05 A 6 A 5 A G05 A 1 A 2
B E04 B 11 B 4 B G04 B 26 B 6
W R W R
WHT RED WHT RED
G307 E D
(CAN) (CAN)
G50 5 6
P/S
Cont.M CAN
7 4
WHT RED WHT RED
W R
E493 16 17
Gateway
CAN control
module
G240 9 21 11 25
6 7
ECM
CAN
CAN
12 24 10 22
E01 40 64
W R W R
WHT RED
W R W R
G369 1 2
WHT RED WHT RED G370
(CAN) (CAN)
WHT RED WHT RED
(CAN) (CAN)
E08 15 2 16 3 G11 1 2 G211 3 6
CAN
DLC
CAN
ABS
Cont.M A/B
SDM
with Air bag

IFL80B910938-03
A-10 Security Control System Circuit Diagram (Without Keyless Push Start Model)
AENFL80B910E013
A with Security
B without Security
Keyless / Security control module
L10 24 11 B
26 21 9 22
Security option #1
RED PNK E266 1 2 YEL GRY PPL WHT
YEL WHT/RED
L374 16 7 L371 2 1 L374 17 6
G341 E387 G341
RED PNK YEL GRY PPL WHT
P W
Audio
G164 7 6 E304 2 "G-1"
Switch
"D-6"
Valet
switch Security
horn H
8 5
1
BLK BLK
W/S
BLK
BLK
W/S
BLK
E210 1
Security
hood
switch
25 34
IFL80B910972-01
J/B 23 DOME 34 MTR

7.5A 10A
G275 3 L322 12 L315 3

WHT/RED
G145 2
Main switch
(Key)
1
BLU BLU WHT
G349 4
L399
BLU
L10 10 25 23
Keyless / Security control module
19 7 4 15 20 6 18
GRY BLU BLU BLK RED BEG YEL
BLU
G B
L390 11
Switch O231
YEL
"B-5" O121 2
Rear end
OFF
ON
switch
RED RED 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
IFL80B910973-01
A-10 Security Control System Circuit Diagram (With Keyless Push Start Model)
AENFL80B910E046
J/B 23 57 IGN
37 IGN2
12 BCM
DOME
10A 40A 50A 7.5A
E337 9 Relay E323

box WHT WHT/BLU
1
E324 3
Accessory IG1 IG2

relay relay relay
J/B
15 ACC
34 MTR
35 IG2
15A 10A 7.5A SIG
L315 10 19 1 9 13 7 4 6
L316 L315
Relay Starting
box motor relay
"A-1" "A-1"
Lg G
BRN LT GRN GRN YEL BLK RED GRY BLU YEL WHT BRN
E484 1 6 4 L21 19 20 27 7 8 39 40
OFF
ACC
ON
START
L21 9 29 11 10 30 E484 5 8
BEG PNK PPL BLU YEL
L379 14 L380 14 L379 20 L380 20 L390 10
J215 J216 J215 J216 O231
BEG PNK PPL BLU YEL YEL PNK
J31 6 J32 2 J85 1 J86 1 O122 2 E307 1
Outside
warning P
BLK
buzzer
Starting
motor relay
Door Door
5 3 request
2 2 Back door 1 2
"A-1"
request request
Switch Switch switch switch switch
BLK BLK BLK BLK BLK
BLK
5
W/S W/S
BLK BLK
J215 J216 BLK

17 24
L379 L380 BLK BLK BLK
BLK BLK
13 14 15 15 13 6
IFL80B910974-01
Outside antenna Outside antenna

Rear outside Mid inside Rear inside
antenna antenna antenna
J153 2 1 J154 2 1 L292 1 2 L294 1 2 L293 1 2
J/C
"A-9"
W R GRN BEG RED YEL
J215 17 23 J216 17 23
L379 L380
WHT RED GRN BEG RED YEL WHT BLU BLK GRN LT GRN RED
(CAN)
G16 19 9 L21 4 24 5 25 3 23 1 21 2 22
G16 14 L21 34 15 35 16 36 14 18 13
BLK WHT BLU RED BEG BLK YEL LT GRN BRN
G272 5
Y LG B
J/B
Backdoor lid
opener
L322 20 actuator Assembly
"B-5"
"B-5"
BLK
L164 1 L163 1 L162 1 L161 1
OFF OFF OFF OFF

ON ON ON ON
(L) (R) Front door Front door

Rear door switch switch
switch
13 13
IFL80B910975-01
3 STL
23 DOME J/B
20A 7.5A
G272 2 G274 9 G275 10 2

RED WHT
G153 8 WHT
G140 12
SECURITY
G38 4
Engine IMMOBI Switch
push (Security
PUSH
Shock
start alarm
sensor
switch Push Push indicator)
switch1 switch2
7 J/B
B 2 1 "D-7"
10 8 3 4 6 1 2 7
G
BRN
G341 15
BLU BLU GRN YEL BRN LT GRN BLK LT GRN GRN
L374
BRN GRY
BRN
G16 1 18 13 7 17 6 4 15 16 L21 32 38
E484 2 G16 2 10 5 11 28 33
YEL PPL
L371 2 L371 11
GRY GRY GRN PNK BLU BLK E387 E387
YEL BLK
PPL
Y
G146 5 3 2 1
G E304 2 P
UART
Hood latch
switch ECM
Auto steering CPU Security
lock unit
"A-11" horn H "A-5"
M RELAY
4 1
BLK BLK
W/S W/S W/S
BLK BLK BLK BLK BLK
11 12 6 9 11
IFL80B910976-01
A-11 ENG A-STOP System Circuit Diagram

AENFL80B910E042
Relay
29 28 27 IG1 15 J/B
box 54 DCDC ACC3 RADIO2 SIG ACC
30A 10A 15A 7.5A 15A
E337 16 8 2 G272 1
LT GRN
1
BLU BRN GRN YEL E Blower speed
selector
G335 3 "E-1"
E383 G
LT GRN
BRN
GRY
E213 5 1 6 7 8
G335 7
DC/DC converter
E383
GRY
4 9 10
E374 6
C242
PPL LT BLU
GRY
E01 85 19 D01 39
ECM
24 17 11 94 38
GRY
GRN GRY PPL GRN
GRY GRY
E210 2 3 E366 1 2 3
G
Hood C Brake
latch stroke
switch Keyless start
sensor
control module
"A-10"
1
or
D
BCM
BLK BLK BLK
"A-8,10"
C Keyless push start model

D Ignition switch model
18 7 E Manual A/C model
IFL80B910946-01
and
Relay
Switch 38 ECM box
7.5A
"B-1"
W
YEL
E371 8
WHT C343
YEL BCM
1 ISG
C365 1
"A-2" "A-8,9"
B Lb G
W R
WIP Relay Battery
61 sensor
SUB box
7.5A
2
BLU
LT GRN BLK LT BLU GRN PPL C343 3 WHT RED

E371
BLU
E493 2 13 4 20 5 14 16 17
Gateway control module
12
ECM
E01 21 59 51
PPL BRN
GRY
P B
ISG
E185 1 "A-2"
Brake booster
switch
BLK
7
IFL10A910922-02
C
J/B
"D-4"
16 A-STOP 27 IG1 J/B
SIG or
10A 7.5A D
E336 8 G275 6
ABS "D-4"
Cont.M
LT GRN R
"A-9","F-2"
W R
RED
G116 6 4
ENG A-STOP
ILL
OFF switch
WHT RED WHT

7 5
BLU LT GRN
E493 6 7 10
G334 8
E382 Lg
BLU
"C-1"
E01 9
ECM
26 93
PNK
E371 2
C343
PNK
C168 1
Neutral position
switch
YEL YEL
C343 1
E371
D Ignition switch model
IFL80B910947-02
B-1 Windshield Wiper and Washer Circuit Diagram

AENFL80B910E014
22 21
FR WIP WIP
J/B
25A 15A
G275 15 E325 1 E337 7
YEL
E62 2
M
Motor
1
PPL BLU BLU
E383 2
G335
BLU
G141 3 7
OFF
ON
Switch
Switch
MIST
OFF
INT
LO
HI
INT Unit
2 4 5 6
and
Relay box
RED YEL WHT BLK Switch
"A-11"
W
G335 1 12 11
E383
RED YEL WHT WHT
WHT
E64 3 5 1 2
LO
W/S
HI
M
Motor
BLK BLK
6 9
IFL80B910939-01
B-2 Rear Wiper and Washer Circuit Diagram

AENFL80B910E015
21 WIP
J/B
15A
L319 7 E325 5
YEL
E63 2
M
Motor
1
GRN
E383 5
G335
GRN
G141 8
P T WR +1R EW
ON+WASH
OFF
ON
ON+WASH Switch
9 6
BEG
G341 11
L133
YEL BEG
L390 2
9
O231
YEL BEG BLK
W/S
BLK
O21 2 1
M
Motor
24
IFL80B910949-01
B-5 Power Door Lock Circuit Diagram

AENFL80B910E018

B
Keyless start
control module
"A-10"
Lg B
LT GRN BRN
or
BCM
A 2 Action type
A L01 17 4 6 19 A L01 14
B L03 21 22 B L03 15
LT GRN BRN
GRN/RED 1
GRN 2
G B Lg B GR GB
GRY BLU GRN/RED 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
IFL80B910988-03
J/B 32 D/L J/B 32 D/L

20A 20A
L315 20 L315 20
BLU BLK/RED
L266 1
Security option #2
without Security L01 13
with Security
BCM
2 Action type
A L01 1 15 7A L01 B L03 25

B L03 14 2 1B L02
1 GRN/BLK
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
J32 1 4 J36 1 4 J35 1 4 O121 2 1
Front
M M M M
motor LOCK LOCK LOCK LOCK
Rear Rear Rear end
motor (L) motor (R) solenoid
1 Action type
A L01 1 15
1 GRN/BLK
2
G GB G GB G GB G GB

L380 21 25 L382 4 8 L381 4 8 L390 6 5
J216 J218 J217 O231
Front
J32 1 4 J36 1 4 J35 1 4 O121 2 1
Rear Rear Rear end
motor M M M M
LOCK LOCK LOCK motor (R) LOCK solenoid
motor (L)
IFL80B910989-02
B-6 Power Mirror Circuit Diagram

AENFL80B910E019
15 ACC J/B
15A
L314 6
BLU/WHT
L443 2
J241
BLU/WHT
If equipped
J87 3
UP DOWN RIGHT LEFT SET RTR
Retract
Switch switch
L R
Angle adjustment
switch
13 9 4 10 12 7 8 5
LT GRN YEL PNK
LT GRN BRN/WHT YEL PNK BEG

J241 5 6 12 11 4
L443
BLK LT GRN BRN/WHT YEL PNK BEG LT GRN RED YEL PNK BLU
L444 5 6 12 11 4
J242
LT GRN BRN/WHT YEL PNK BEG
J28 3 5 2 7 8 J27 3 5 2 7 8
RTR RTR
UP M1 DOWN
M L M2 R UP M1 DOWN M L M2 R
SET SET
Assembly Assembly
J215 17
L379
BLK
13
IFL80B910948-01
B-9 Parking Sensor System Circuit Diagram

AENFL80B910E043
20 BACK J/B
10A
L322 17 G275 9
J/C
"D-4"
GRY R
RED
G117 6 4
Parking
sensor
ILL
ILL
YEL OFF
switch
8 7 5
J/B
"D-8"
PNK BRN LT GRN
R
Lg
G343 9 3
J/C
L376 "C-1"
RED
PNK BRN
L13 10 4 8 13
Parking sensor system control module
22 17 16 15 14 11 21
LT GRN RED BEG GRN PPL

BLU
L392 2 6 3 4 1
M151
L262 1
Rear
parking
LT GRN RED LT GRN BEG LT GRN GRN LT GRN PPL sensor
system BLK
buzzer
M116 1 2 M117 1 2 M118 1 2 M119 1 2
2
Rear parking Rear parking Rear parking Rear parking
sensor #1 sensor #2 sensor #3 sensor #4
BLK
BLK
14
IFL80B910970-01
C-1 Combination Meter Circuit Diagram

AENFL80B910E021
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
G273 6
(CAN) (CAN) (CAN) BEG
B
G240 11 23 9 21 12 24 2 3 17
1
C
CAN 2
POSITION LIGHT
SPEED TACHO FUEL TEMP
REAR FOG
METER METER METER METER
TURN (R)
TURN (L)
HI BEAM
Power
IMMOBI
DOOR
ACC
circuit
CPU
LCD
(ODO-TRIP)
Lighting LED
Mode
switch
10 22 15 16 8
ECM RED YEL LT BLU
G349 1 12
"A-5" L399
PW RED YEL R
(CAN) G335 14 L389 3
E383 R151
WHT WHT RED PPL/WHT GRY GRY 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
R151 4
L389
A Petrol engine model

A B
15
25 6 5
IFL80B910986-01

D ABS model
D B C
1
C
2
ENG A- STOP OFF

WATER IN FUEL
CHECK ENGINE
OIL SERVICE
SEAT BELT
Low Battery
PUSH ON
CHARGE
AIRBAG
BRAKE
GLOW
PUSH
FUEL
ABS
DPF
OIL
P/S
CPU
G240 18 20 5
P
HVAC Engine Parking

Steering control A-Stop sensor
Switch Audio switch Switch Switch unit off switch off switch
"D-6" "G-1" "G-1" "D-9" "D-3" "E-1" "A-11" "B-9"
P P P P LG LG LG LG
PPL PPL PPL PPL PPL LT GRN LT GRN LT GRN LT GRN LT GRN BLK
BLK
G274 6
J/B
L322 3
BLK
25 17
IFL80B910987-01
D-2 Position, Tail and License Plate Light System Circuit Diagram
AENFL80B910E023

B Ignition switch model
C with Rear wiper model
D without Rear wiper model
31 Tail light
J/B TAIL relay
10A
B G275 5 A L315 5 G272 6 L319 4 L322 14 E325 3 4

YEL RED
Y R R R R
W L03 9
RED
WHT R R
BCM
L390 C6
G05 4 O231 D 7
PNK
G144 5
RED RED/YEL RED RED RED RED
Head
OFF
Tail
A Light switch
RED/YEL
BLK O94 2 O95 2 L134 3 L133 3 E162 2 E161 2

License License
plate plate
light #1 light #2
1 1 5 (L) (R) 5 1 (L) (R) 1

Tail light Clearance
BLK BLK (Rear combination BLK light BLK
light)
W/S
BLK BLK BLK W/S W/S

BLK
BLK O231 C 5
L390 D 1 BLK BLK
BLK
25 12 1 12 13 34 35
IFL80B910982-01
D-3 Front Fog Light System Circuit Diagram

AENFL80B910E024
55 FR Relay
FOG box
20A
G335 8
E383
GRN BLU
"D-4"
R
E234 2 4
RED
Relay
1 3
R R
BLK
RED RED GRN
G151 7 4 6
Switch
LT GRN LT GRN
8 5
E164 1 E163 1
BLK LT GRN
Lg (L) (R)
2 2
"C-1" BLK BLK
W/S W/S
BLK BLK BLK BLK
22 23 34 35
IFL80B910983-01
D-4 Illumination Light System Circuit Diagram

AENFL80B910E025
31 Tail light
J/B TAIL relay
10A
B G275 5 A L315 5 G272 6 L314 4 L322 14 E325 3 4 G273 8

YEL
Y RED RED RED RED RED RED
W L03 9
WHT
BCM
R RY
Tail light (L),
G05 4 Licence plate
BCM
PNK light
"D-2" "A-8"
G144 5
RED RED
Head R R R
Tail light (R) Front
OFF position
Tail "D-2"
light (R)
(Combination switch) Actuator (R)
Light switch "D-2" "D-9"
A
8 RED RED
R R
B
Front
RED position
light (L)
Actuator (L)
"D-9" "D-2"
RED
BLK
RED RED RED RED RED RED RED RED
R R R R R R R R
HVAC Steering Audio,
control unit switch Navigation
Switch "E-1" "G-1" "G-1"
W/S Switch Switch
"D-9" "D-6" "G-3" "D-3"
BLK

25 B Ignition switch model
IFL80B910984-02
D-5 Interior Light System Circuit Diagram

AENFL80B910E026
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 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
BLK/YEL BLK
4 2
WHT BLK WHT BLK WHT
K131 9 10 L322 5
J/B
L315 15 12
WHT
W
L01 18
BCM
BLK BLK
8 14
IFL80B910940-01
D-6 Turn Signal and Hazard Warning Light System Circuit Diagram
AENFL80B910E027
A with Side turn signal light

B with Power mirror turn signal light
11
HAZ J/B
10A
E337 13
WHT
E04 7
BCM
G04 25 24 14 E04 14 1
BLU RED
A
"D-4"
R
V Lg W GR R Gr R
PPL LT GRN WHT RED GRN/RED RED GRY RED
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
BLK BLK PPL BLK BLK BLK BLK
W/S V W/S
W/S
BLK BLK BLK BLK BLK

"C-1"
INST INST INST MAIN MAIN

GND GND GND GND GND
DR#1 CTR#1 AS#1 FL#2 FR#1
IFL80B910951-01
A with Side turn signal light

B with Power mirror turn signal light
BCM
L01 12 25
BLU RED
B
B R L RB
BLU RED BLU RED/BLU
L380 14 L379 14
J216 J215
BLU 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 26
L380 26
BLK BLK BLK BLK
BLK BLK BLK BLK
L390 5
O231
BLK BLK BLK
FLR FLR FLR FLR FLR FLR FLR FLR

GND GND GND GND GND GND GND GND
RL#2 RL#2 RR#1 FL#1 FL#1 RL#1 FR#2 FR#2
IFL80B910952-01
D-9 Headlight Leveling System Circuit Diagram

AENFL80B910E030
31
TAIL
10A
J/B
Tail light
B relay
A
G275 5 L315 5 G272 6 E325 3 4

YEL R R R
Y
W L02 9
WHT
BCM RED RED RED
G05 4
PNK
E69 3 E68 3
G144 5
Head
Actuator (L) M Control circuit M Control circuit
Actuator (R)
OFF Lighting
Tail switch (Combination switch)
2 1 2 1
8 B GRN GRN
RED
A
GRN
E383 16
G335
R
BLK BLK
RED
BLK
W/S
GRN
RED RED
G152 6 5 3
BLK
R1 P0
R2
P1
W/S
R3 P2
ILL
R4 P3
switch
R5
BLK R6 P4
2 4
PPL BLK
15
V
INST BLK
GND
DR#1 BLK
"C-1"
B Ignition switch model
INST INST
GND GND
DR#2 LTR#3
IFL80B910953-01
E-1 Heater System Circuit Diagram

AENFL80B910E032
J/B
20 BACK
10A
G274 5
YEL
BCM BCM
J/B
"B-3" "A-8","B-3" "D-4" "A-8"
R W R W
RED WHT RED YEL YEL WHT
G63 5
M Air intake
control
actuator 1
1 2
GRN BLU LT GRN
G154 2 8 9 6 5 11 7 1
REAR
DEF
A/C
HARF REC
CIRCUIT
HVAC control
unit
FRE
REC
3 12
LT GRN BLK
Lg
"C-1" BLK
17 25
IFL80B910941-01
Relay 47 35
BLW IG2 J/B
box
SIG
40A 7.5A
BLU G274 8
E384 1
WHT
G336
BLU
G194 2 1
Heater
relay
3 4
YEL
G61 2
Blower
motor M
Blower motor resister

Petrol engine model
1
ECM
"A-5"
G
G101 2 1 4 3
GRY WHT GRY WHT
LT GRN RED YEL GRY WHT

G155 5 2 7 3 6
Blower speed
selector
FAN
BLK BLK BLK
22 21 10
IFL80B910942-01
E-3 Rear A/C System Circuit Diagram

AENFL80B910E033
Relay 47 35
BLW IG2 J/B
box
SIG
40A 7.5A
BLU G274 8
E384 1
WHT
G336
BLU
G194 2 1
Heater
relay
3 4
YEL
Y
Fuse 66 RR A/C
box
7.5A
RED
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 BLK BLK
8 14 21 10
IFL80B910943-01
F-1 Air Bag System Circuit Diagram

AENFL80B910E034
19 J/B
A/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 YEL/BLK GRN

Check terminal
L04 18 G11 G11 G11 14 13 10 9
A/B
SDM
23 G11 6 5 19 18 L04 6 5 7 8
Check terminal
YEL PPL
G372 1 2
G373
BLK YEL GRY YEL PPL YEL GRY YEL PPL 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
IFL80B910944-01
F-2 Anti-Lock Brake System Circuit Diagram

AENFL80B910E035
53 49 Relay
14
ABS ABS box ABS J/B
25A 40A 10A
SOL MOT
E325 11
Wheel speed sensor Wheel speed sensor Wheel speed sensor Wheel speed sensor
(Rear-left) (Rear-right) (Front-left) (Front-right)
L32 1 2 L31 1 2 E35 1 2 E34 1 2
RED GRN BEG BRN YEL LT BLU PNK GRN BLK GRN BEG
L371 3 9 4 10
E387
BRN YEL LT BLU PNK
E08 1 26 4 7 19 18 5 20 33 17 29
ABS
Cont.M
14 38 16 3 15 2
BLK BLK WHT RED WHT RED
(CAN) (CAN)
W R W R
Gateway
ECM
control module
"A-5, 9" "A-9,11"

W/S
BLK
6
IFL80B910945-01
G-1 Audio System Circuit Diagram

AENFL80B910E037
If equipped
30 RADIO 15 ACC J/B
Steering switch (Remote audio control switch)
15A 15A
G273 1 G275 16
A S62
A 9 A 3 A 7 A 8 A 11
B S61
B 5 B 6 B 4 B 3 B 2
Contact
coil
A S173 A 9 A 3 A 7 A 8 A 11
G371 B 5 B 6 B 4 B 3 B 2
B S171
GRY LT GRN G346 PPL GRN PNK YEL
J/C J/C
"D-4" "D-4" P
R R J/C
"C-1"
RED RED
G248 1 9 2 19 20 8
Audio unit
3 13 12 G221 G248 4 14
PPL
G216
WHT BLU P RED YEL
If equipped
J/C
G312 A C "C-1" USB connector B D
J/C
A C A C B D B D
WHT BLU RED YEL
G343 10 16 G341 5 15
L376 L374
WHT BLU RED YEL
L380 3 4 L443 16 22
J216 J241
WHT BLU WHT BLU RED YEL RED YEL
J142 2 1 G247 1 2 J141 2 1 G246 1 2
Front speaker (L) Tweeter (L) Front speaker (R) Tweeter (R)
A With cruise control

B Without cruise control
IFL80B910954-01
BCM
"A-8"
P
Antenna
PPL
Antenna amplifier
G311 A
K121 1 2
J/C
BLK
A 1
PPL K154 2
G354
P
BLK
G248 18 G267 1 2
Audio unit
If equipped
G248 5 15 6 16 11 G231 2 3 4 1 G232 1 3 4 2 5
PNK BLU YEL BLU
7 8 6 BLK RED WHT GRY

G340
K156
GRN BRN PPL LT BLU BLK PNK BLU YEL G343 8 15 9 14 6
L376
G343 11 17 G341 6 16
K130 3 2 1
L376 L374
GRN BRN PPL LT BLU BLK RED WHT GRY
Microphone unit
L382 7 1 L381 7 1 L390 14 12 13 11 10

J218 J217 O231
BLK
GRN BRN PPL LT BLU BLK RED WHT
J146 2 1 J145 2 1 O188 4 1 2 3
Rearview camera unit
Rear speaker (L) Rear speaker (R)
13
IFL80B910955-02
G-3 Navigation System Circuit Diagram

AENFL80B910E044
If equipped
30 RADIO 15 ACC J/B
Steering switch (Remote audio control switch)
15A 15A
G273 1 G275 16
A S62
A 9 A 3 A 7 A 8 A 11
B S61
B 5 B 6 B 4 B 3 B 2
Contact
coil
A S173 A 9 A 3 A 7 A 8 A 11
G371 B 5 B 6 B 4 B 3 B 2
B S171
GRY LT GRN G346 PPL GRN PNK YEL
J/C J/C
"D-4" "D-4" P
R R J/C
"C-1"
RED RED
G248 1 9 2 19 20 8
Navigation unit
3 13 12 G221 G248 4 14
PPL
G216
WHT BLU P RED YEL
If equipped
J/C
G312 A C "C-1" USB connector B D
J/C
A C A C B D B D
WHT BLU RED YEL
G343 10 16 G341 5 15
L376 L374
WHT BLU RED YEL
L380 3 4 L443 16 22
J216 J241
WHT BLU WHT BLU RED YEL RED YEL
J142 2 1 G247 1 2 J141 2 1 G246 1 2
Front speaker (L) Tweeter (L) Front speaker (R) Tweeter (R)
A With cruise control

B Without cruise control
IEAD0A910988-02
Parking brake BCM

J/B switch
"D-8" "A-8" "A-8"
R Lg P
Antenna
LT GRN PPL
GPS
G311 A Antenna amplifier antenna
J/C K121 1 2
L376 4 BLK
A A
G343
LT GRN K154 1 2
RED PPL PPL
P P
G354
BLK
G243 2 1 3 G248 18 G267 1 2

No internal
connection
Navigation unit
If equipped
G248 5 15 6 16 11 G231 2 3 4 1 G232 1 3 4 2 5
PNK BLU YEL BLU
7 8 6 BLK RED WHT GRY

G340
K156
GRN BRN PPL LT BLU BLK PNK BLU YEL G343 8 15 9 14 6
L376
G343 11 17 G341 6 16
K130 3 2 1
L376 L374
GRN BRN PPL LT BLU BLK RED WHT GRY
Microphone unit
L382 7 1 L381 7 1 L390 14 12 13 11 10

J218 J217 O231
BLK
GRN BRN PPL LT BLU BLK RED WHT
J146 2 1 J145 2 1 O188 4 1 2 3
Rearview camera unit
Rear speaker (L) Rear speaker (R)
13
IEAD0A910989-01
List of Connector
List of Connectors
AENFL80B910F001
Refer to “A Connector” in related manual.
Refer to “C Connector” (Page 9A-102).
Refer to “D Connector” in related manual.
Refer to “E Connector” (Page 9A-104).
Refer to “G Connector” (Page 9A-106).
Refer to “J Connector” (Page 9A-107).
Refer to “K Connector” (Page 9A-108).
Refer to “L Connector” (Page 9A-108).
Refer to “M Connector” (Page 9A-109).
Refer to “O Connector” (Page 9A-109).
Refer to “R Connector” in related manual.
Refer to “S Connector” in related manual.
C Connector
AENFL80B910F003
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
C06 C07 C12
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 1 2 3 4 5 6 10 11 12 13 14 15 16 17
7 8 9 10 11 12 13 14 15 16 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
17 18 19 20 21 22 23 24 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
MCONF240020-01 MCONF260020-01 MCONF340013-01
A/T model A/T model Bi-fuel CNG model
C13 C30 C31 C31 C32 C33
1 2 3 4 5 6 1 2 3 4 1 2 3 1 2 1 2 3 1 2 3
MCONF060113-01 MCONF040110-01 MCONF030103-02 MCONF030103-02
MCONF020377-01 MCONF030163-01
Diesel engine Bi-fuel CNG Petrol engine Diesel engine Diesel engine
model model model model model
C36 C37 C38 C39 C42 C48
1 2
1 2 3 1 2 1 2 1 2 1 2 3 4 5 6
MCONF030085-01 MCONF020150-01 MCONF020293-01 3 4 MCONF060068-01
MCONF020156-01
MCONF040092-01
Petrol engine Petrol engine Petrol engine Petrol engine Petrol engine Petrol engine
model model model model model model
C50 C51 C56 C69 C81 C82
1 2
1 2 3 1 2 3 4 1 2 1 2 1 2
3 4 MCONF020366-01 MCONF020366-01
MCONF040081-01
Diesel engine Diesel engine Petrol engine Diesel engine Bi-fuel CNG Bi-fuel CNG
C83 C84 C91 C91 C92 C92
1 1
1 2 1 2 1 2 1 2
2 2
MCONF020328-01 MCONF020328-01
Bi-fuel CNG Bi-fuel CNG Petrol engine Diesel engine Petrol engine Diesel engine
C93 C93 C94 C94 C101 C102
1 1
1 2 1 2 1 2 3 1 2 3
2 2
MCONF020328-01 MCONF020328-01
Petrol engine Diesel engine Petrol engine Diesel engine Petrol engine Petrol engine
C103 C104 C115 C116 C117 C118
1 2 3 1 2 3 1 1 1 1
MCONF030103-02 MCONF030103-02 MCONF010135-01 MCONF010135-01 MCONF010135-01 MCONF010135-01
Petrol engine Petrol engine Diesel engine Diesel engine Diesel engine Diesel engine
C122 C123 C133 C139 C141 C141
1 2 3 4 5 6
1 2 1 2 1 1 2
1 2 7 8 9 10 11 12 13
MCONF020156-01
MCONF020379-01
MCONF130039-02
Diesel engine Petrol engine Petrol engine Petrol engine Diesel engine
A/T model
model model model model model
C162 C162 C165 C166 C168 C191
1 2 3 4 1
1 1 2
1 1 2
5 6 7 8 9
MCONF090017-01 MCONF010134-01
Petrol engine Diesel engine Diesel with ISG Diesel engine
A/T model
model model model model
C192 C194 C194 C195 C195 C196
1 1 1 2 1 1 1
MCONF010046-01
MCONF010057-03 MCONF010145-01 MCONF020194-01 MCONF010021-01 MCONF010138-01
Petrol engine Petrol engine Diesel engine Petrol engine Diesel engine Petrol engine
C196 C201 C202 C282 C283 C343 (To E371)
1 2 3 4
5 6 7 8 9 10
1 1 1 2 3 4 5 1 1
11 12 13 14
MCONF010078-01
MCONF010072-03 MCONF010072-03 MCONF050072-01 MCONF010082-01 15 16 17 18 19 20
MCONF200011-01
Diesel engine Diesel with ISG Diesel with ISG
model model model
C345 (To E373) C365 C366 C371 C374
2 1
5 4 3 1 2 1 1 2 3 1 2
7 MCONF020407-01
6
MCONM070008-01
Diesel engine Diesel engine Petrol engine Diesel engine
E Connector
AENFL80B910F005
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 E05 E07 E11
1 2 3 4 5 6 7 1 3 4 5 6 7 8 9 10 11 12 2 1 2 3 4
1 2 3 4 5
8 9 10 11 12 13 14 13 15 16 17 18 19 20 21 22 23 24 14 5 6 7 8
MCONF050068-01
Diesel engine
model
E12 E13 E24 E34 E35
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 1
15 16 17 18 19 20 21 22 23 24 25 1 2 1 2
2 2 26 38
27 28 29 30 31 32 33 34 35 36 37 MCONF020315-01 MCONF020315-01
MCONF020185-01 MCONF020185-01
MCONF380002-01
ABS model ABS model ABS model
E36 E36 E37 E40 E47 E56
1 2 3 1 2 1 2 1 2 1 2 3 1 2 3 4
MCONF030083-01 3 MCONF020200-01 MCONF030115-01 MCONF040110-01
MCONF020191-01
MCONF030097-01
Petrol engine Diesel engine Diesel engine Diesel W/o ISG
If equipped ABS model
E56 E57 E58 E59 E62 E63
1 2 3 1 2 1 1
1 2 3 4 1 2 3 4 5 6
4 5 6 3 4 2 2
MCONF060068-01
MCONF040197-01
MCONF040170-01
Diesel with ISG Diesel engine Diesel without ISG Diesel engine
If equipped
E64 E65 E68 E69 E135 E151
1 2 1 2 1
1 2 3 1 2
1 2 2 3
4 5 3 4 3 3
MCONF020382-01
Diesel engine
model
E152 E159 E160 E161 E162 E163
1
2 3 1 2 1 2 1 2 1 2 1 2
MCONF030166-01
If equipped
E164 E165 E166 E181 E181 E183
1 2 1 2 1
1 2 1 2 1 2 3 4 3 4
MCONF020162-01
MCONF020084-01 MCONF020084-01
MCONF040009-01
2
MCONF040135-01 MCONF020182-01
Petrol engine Diesel engine
If equipped If equipped If equipped
model model
E190 E191 E192 E210 E210
1 2 1 2 3 4 5 6 1 2 1 1 2 3
with Keyless push
without ISG model with ISG model
start model
E213 E221 E221 E222 E223
1 2 3 1 1 2 1 2 3
1 2 3
4 2 3 3 4
4 5 6 7 8 9 10
5 4 4 5
MCONF040086-01
Petrol engine Diesel engine
Diesel with ISG model
model model
E224 E225 E227 E229 E234 E266
1 2 3 1 2 1 2 1 2 1 2
1
4 3 3 3 3
5 4 4 4 4 2
MCONF050044-01 MCONF040131-01 MCONF040131-01 MCONF040131-01 MCONF040131-01 MCONF020008-01
If equipped Option
E281 E282 E302 E303 E304 E311
1
1 1 1 1 1 2
MCONF010130-01 MCONF010130-01 MCONF010130-01 MCONF010130-01 2
MCONF020277-01
MCONF020169-01
If equipped
E312 E323 E324 E325
1 1 2 1 2 3 4
1 2
2 3 4 5 6 7 8 9 10 11
MCONF020202-01
E336 E337 E366 E371 (To C343)

4 3 2 1
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 10 9 8 7 6 5
1 2 3 4 5
8 9 10 11 12 13 14 9 10 11 12 13 14 15 16 14 13 12 11
MCONF050050-01 20 19 18 17 16 15
MCONF140037-01 MCONF160065-01
MCONM200005-01
with ISG model
E373 (To C345) E382 (To G334) E383 (To G335) E384 (To G336) E387 (To L371)
1 2
10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6
3 4 5 4 3 2 1 2 1
18 17 16 15 14 13 12 11 7 8 9 10 11 12
MCONM040047-01 MCONM020026-01
6 7 MCONF120072-01
MCONM180010-01
MCONF070022-01
Diesel engine
model
E404 (To D245) E493 E383 (To G335)
1 1 2 3 4 5 6 7 8 9 10 10 9 8 7 6 5 4 3 2 1
11 12 13 14 15 16 17 18 19 20 18 17 16 15 14 13 12 11
MCONF010097-01 MCONF200029-01
MCONM180010-01
Diesel engine
Diesel with ISG model
model
G Connector
AENFL80B910F006
G04 G05
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 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 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
MCONF320022-01 MCONF320022-01
G11 G16 G17
1 2 3 4 5 6 7 8
2 3 4 5 6 7 8 9 10
9 10 11 12 13 14 1 11 1 2 3 4 5 6 7 8
12 13 14 15 16 17 18 19 20
15 16 17 18 19 20 21 MCONF080040-01
MCONF200038-01
MCONF210002-01
with Air bag Keyless push start model
G32 G38 G50 G61 G62 G101
1 1 2 3 1 2
1 2 3 4 1 2 3 4 5 6 7
4 5 6 7 8 1 2
2 3 4
with Security
model
G117 G140 G141 G144
1 2 3 1 2 3 4
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10
4 5 6 7 8 5 6 7 8 9 10 11 12 13
7 8 9 10 11 12 MCONF100038-01
MCONF080022-01 MCONF130010-01
MCONF120052-01
with Parking Keyless push start
sensor model
G145 G146 G147 G151 G152
1 2 3 1 2 3 1 2
1 2 1 2 3 4 5 6 4 5 6 7 8 3 4 5 6
MCONF060080-02
4 5 6
MCONF020274-01
Keyless push start model If equipped

G153 G154 G155 G164 G195 G202
1
1 2 3 4 1 2 3 1 2 3
1 2 3 4 5 6 2 3 1 2 3 4 5 6
5 6 7 8 9 10 4 5 6 7 4 5 6 7 8
7 8 9 10 11 12 7 8 9 10 11 12
MCONF070016-01 MCONF080050-01 4
MCONF040086-01
If equipped If equipped
G211 G216 G217 G221 G231
1 2 3 4 5 6 7 8 1 2
1 2 3 4 1 2 3 4 1 2 3 4
9 10 11 12 13 14 15 16 3 4
MCONF160023-01 MCONF040183-01
If equipped If equipped If equipped Navigation model

G240 G246 G247 G248
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10
1 2 1 2
13 14 15 16 17 18 19 20 21 22 23 24 11 12 13 14 15 16 17 18 19 20
MCONF020159-01 MCONF020159-01
MCONF240014-01 MCONF200012-01
If equipped If equipped
G251 G259 G267 G271 G272 G273
1 2 1 2 3 4 1 2 3 4 5 6
1 1 2 3 4
1 2
5 6 7 8 5 6 7 8 9 10 7 8 9 10 11 12
2 MCONF020305-01
MCONF020235-01 MCONF120073-01
with Air bag
G274 G275 G306 G334 (To E382)
A B B D D
A A B C C C D D
1 2 3 4 5 1 2 3 4 5 6 7 8
1 2 3 4
6 7 8
MCONF100108-01
9 10 9 10 11 12 13 14 15 16
MCONF160065-01 ( MCONF130038-01
) MCONF040180-01
If equipped
G335 (To E383) G336 (To E384) G340 (To K156) G346 (To S171)
1 2 3 4 5 6 7 8 9 10
1 2 4 3 2 1 1 2 3 4 5 6
11 12 13 14 15 16 17 18 MCONF020114-01 MCONF060080-02
MCONM040047-01
MCONF180028-01
with Air bag
G347 (To S172) G341 (To L374) G354 (To K154) G369 (To G370) G370 (To G369)
11 10 9 8 7 6 5 4 3 2 1
1 2 1 2 4 3 2 1 1 2 3 4
MCONF020212-01 20 19 18 17 16 15 14 13 12 MCONF020305-01 MCONF040180-01
MCONM040047-01
MCONM200011-01
with Air bag with Air bag
G371 (To S173) G372 (To G373) G373 (To G372) G451
1 1 2 2 1 1 2 3 4
MCONM020065-01
without Air bag with Air bag with Air bag without Navigation
J Connector
AENFL80B910F007
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 J85 J86
1 2 3 1 2 3 1 2 3 2 1 2 1
4 5 6 7 8 4 5 6 7 8 4 5 6 7 8
MCONM020034-01 MCONM020034-01
Keyless push start Keyless push start
If equipped If equipped If equipped
model model
J87 J141 J142 J145 J146
1 2 3 4 5 1 1 1 1
6 7 8 9 10 11 12 13 2 2 2 2
If equipped
J153 J154 J215 (To L379) J216 (To L380) J217 (To L381) J218 (To L382)
22 14 22 14
21 13 21 13
28 20 12 6 28 20 12 6
27 19 11 5 27 19 11 5
2 1 2 1 26 4 26 4 1 2 3 4 1 2 3 4
25 3 25 3 5 6 7 8 5 6 7 8
MCONM020018-01 MCONM020018-01
24 18 10 2 24 18 10 2 MCONF080035-01 MCONF080035-01
23 17 9 1 23 17 9 1
16 8 16 8
15 7 15 7
MCONM280004-01 MCONM280004-01
Keyless push start Keyless push start
model model
K Connector
AENFL80B910F008
K02 K52 K53 K121 K130 K154 (To G354)
1 2 1 2 3 1 2 3 1 2 1
MCONF010046-01
1 2 3
MCONF020268-01 MCONF030134-01 MCONF030134-01 MCONF030165-01 MCONM020067-01
If equipped with Rear A/C without Rear A/C

K156 (To G340) K131
1 2 3 4 5
1 2 3 4
6 7 8 9 10 11 12 13
MCONF040180-01
MCONF130017-01
If equipped
L Connector
AENFL80B910F009
L01 L02 L03
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 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 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
Keyless push start model Keyless push start model
L10 L13
1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9
14 15 16 17 18 19 20 21 22 23 24 25 26 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
MCONF260026-01 MCONF240015-01
with Parking Sensor

L21 L31 L32 L101
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5
1 2 1 2
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 6 7 8 9 10
MCONF020315-01 MCONF020315-01
MCONF400001-01 MCONF100076-02
Keyless push start model ABS model ABS model A/T model
L103 L133 L134 L135 L161 L162
1 2 3 1 2 3
1 2 2 1 1 1
MCONF020217-02
4 5 6 4 5 6 MCONF010100-01 MCONF010100-01
MCONM020066-01
MCONF060075-01 MCONF060075-01
Bi-fuel CNG
If equipped
model
L163 L164 L167 L170 L177 L266
1
1 1 1 1 2 1 2 3 4
MCONF010021-01 MCONF040098-01
2
MCONF020008-01
Bi-fuel CNG
If equipped If equipped Option
model
L283 L285 L292 L293 L294 L313
1 2 1 2
1 2 1 2 1 2 1 2
MCONF020207-01 MCONF020207-01
Keyless push start Keyless push start Keyless push start
with Air bag with Air bag
switch switch switch
L314 L315 L319
1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 1 2 3 4
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8 9 10 11
MCONF110016-01
MCONF100090-01 MCONF200021-01
L322 L371 (To E387) L373 L374 (To G341)
1 2 3 4 5 6 7 8 9 10 11 12 13 6 5 4 3 2 1 2 1 1 2 3 4 5 6 7 8 9 10 11
MCONM020062-02
14 15 16 17 18 19 20 21 22 23 24 25 12 11 10 9 8 7 12 13 14 15 16 17 18 19 20
MCONF250004-01 MCONM120010-01 MCONF200039-01
L379 (To J215) L380 (To J216) L381 (To J217) L382 (To J218) L389 (To R151) L390 (To O231)
14 22 14 22
13 21 13 21
6 12 20 28 6 12 20 28
5 11 19 27 5 11 19 27 2 1
4 26 4 26 4 3 2 1 4 3 2 1 2 1
7 6 5 4 3
3 25 3 25 4 3
8 7 6 5 8 7 6 5 11 10 9 8
2 10 18 24 2 10 18 24
MCONM080018-01 MCONM080018-01 MCONM040048-01 MCONM110006-01
1 9 17 23 1 9 17 23
8 16 8 16
7 15 7 15
MCONF280006-01 MCONF280006-01
Ignition switch
model
L390 (To O231) L392 (To M151) L393 (To O233) L374 (To G341)
5 4 3 2 1 2 1
1 2 3 4 5 6 7 8 9 10 11
9 8 7 6 4 3 4 3 2 1
17 16 15 14 13 12 11 10 6 5 12 13 14 15 16 17 18 19 20
MCONM040044-01
MCONF200039-01
MCONM170002-01 MCONM060042-01
with Parking
Sensor
M Connector
AENFL80B910F013
M116 M117 M118 M119 M151 (To L392)
1 2
1 2 1 2 1 2 1 2 3 4
MCONF020367-01 MCONF020367-01 MCONF020367-01 MCONF020367-01 5 6
MCONF060108-01
with Parking with Parking with Parking with Parking with Parking
sensor sensor sensor sensor sensor
O Connector
AENFL80B910F010
O21 O91 O92 O94 O95 O121
1 1
1 2 1 2 3 1 2 1 2
2 2
MCONF020013-01 MCONF020013-01
If equipped with Rear A/C
O121 O122 O123 O181 O182 O188
1 2 1 2
2 1 1 2 1 1
3 4 3 4
MCONM020045-01 MCONF020224-02 MCONM010034-01 MCONM010034-01
MCONF040143-01 MCONF040112-01
Keyless push start with Parking
without Rear A/C If equipped If equipped If equipped
model sensor
O231 (To L390) O231 (To L390) O233 (To L393)
1 2 3 4 5 1 2
6 7 8 9 3 4 5 6 7 1 2 3 4
10 11 12 13 14 15 16 17 8 9 10 11 MCONF040033-01
MCONF170009-01 MCONF110014-01
Ignition switch
model

AENFL80B910H001
Refer to “Around Engine” in related manual.
Refer to “Around Battery” (Page 9A-111).
Refer to “Around Strut” (Page 9A-114).
Refer to “Around Instrument Panel” (Page 9A-117).
Refer to “Around Main Floor” (Page 9A-120).
Refer to “Around Fuel Tank” in related manual.
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.
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 Battery
AENFL80B910H003
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)
[C] [C]
[E] [E]
3
3 [H]
[G]
[f]
[a]
[a] [C]
[C]
2
1 1
[B]
[g]
[D]
2
[b]
[F]
4 (a)
[A] [G]
5
(a)
IFL80B910957-03
[A]: Detail [a] [E]: Leftward 1. Clamp 5. GND bolt

: Set into the body hole.
[B]: Detail [b] [F]: Rightward 2. Battery cable 6. GND bolt
[C]: Forward [G]: Petrol model 3. Battery (–) : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
[D]: Upward [H]: CNG model 4. GND bolt
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.
Around Strut
AENFL80B910H004
Right Side
[b]
10
3 16 1
[a] 17
7
14
[C]
1
6
4
1
18 2
15
[B]
[A]
5
1
8 1
11 12
20
1
13
1
19 13
1 9
IFL80B910959-01
[A]: View [a] 6. Headlight (R) 13. Washer hose

[B]: Detail [b] 7. Headlight leveling actuator (R) 14. GND bolt
: Set the terminal to hole, and tighten bolt.
[C]: Forward 8. Grommet 15. A/C refrigerant pressure sensor
1. Clamp 9. Brake fluid level switch 16. Security horn
2. Main harness 10. ABS control module (ABS model) 17. Boost pressure regulator (Diesel engine model)
3. Front turn signal light (R) 11. Side turn signal light (R) 18. Hood opener cable
4. Front position light (R) 11. Side turn signal light (R) 19. Brake oil switch
5. Windshield wiper motor 12. Hood release cable 20. Rear parking sensor system buzzer
[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
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
[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
Around Instrument Panel

AENFL80B910H005
On Dash Panel
[c]
2 [a]
[f] 1
1
1 1 1
3
1
1
[B] [A]
6
[E]
5 4 7
4 8 10
4 9 7
8
9
[b]
“a”
[C] [D] [F]

12
12
[e]
15
18
1
17
1
19 1 16
4
[d]
4 1
13
14
IFL80B910958-01
[A Detail [a] 2. Main harness 9. To instrument panel harness (Connector color: GRY) 16. BCM (Connector color: N)
]:
[B View [b] 3. Grommet 10. BCM (Connector color: GRY) 17. Glow controller (Connector
]: color: BLK)
[C Detail [c] 4. J/B (Connector color: N) 11. CPP switch 18. DC-DC converter (Connector
]: color: GRY)
[D View [d] 5. J/B (Connector color: BLU) 12. P/S control module 19. Brake stroke sensor
]:
[E Detail [e] 6. To floor harness (Connector 13. Brake light switch 20. CPP switch 2
]: color: N)
[F] Detail [f] 7. To instrument panel harness 14. APP sensor “a”. ±45°
: (Connector color: N)
1. Clamp 8. To instrument panel harness 15. GND bolt
(Connector color: YEL)
Inside Instrument Panel (Right Side)
[a]
3 [C]
4
16 9 10 11
13
2 [D] 17 18
[B]
1 (a)
15 8
[b] 1
6
12
7
8 1
8
IFL80B910963-01
[A]: Detail [a] (Front view) 5. To roof wire 13. A/B connector
[B]: View [b] 6. BCM (Connector color: GRY) 14. J/C
[C]: Around option switch (Back view) 7. J/B 15. Fuse box
[D]: Forward 8. GND bolt 16. SCR switch (Connector color: BLU)
1. Clamp 9. Valet switch (Connector color: BLU) 17. Shock controller unit (Connector color: WHT)
2. Instrument panel harness 10. Front fog light switch (Connector color: GRN) 18. Push start switch (Connector color: BLK)
3. Combination meter 11. Headlight leveling switch (Connector color: : 8.8 Nm (0.9 kgf-m, 6.5 lbf-ft)
BLK)
4. P/S control module 12. Tweeter (R)
Inside Instrument Panel (Left Side)
[c]
[A]
1 2
1 [a]
1 1
1
1
3
1 13
2
1
1 7
1
10 1 11
[C] [b]
15
4 9
12
6 6
IFL80B910962-01
[A]: Detail [a] 3. Front-passenger air bag (inflator) module 9. Blower motor resistor
[B]: View [b] 4. Tweeter (L) 10. Evaporator temperature sensor
[C]: Detail [c] 5. To floor harness (Connector color: N) 11. Main harness
[D]: Forward 6. GND bolt 12. Floor harness
1. Clamp 7. Fan relay 13. To instrument panel harness (Connector color: WHT)
2. Instrument panel harness 8. Blower motor
Around Main Floor

AENFL80B910H006
Front Part
10 [D]
2 [b]
1 [c]
[a]
1
1
[e]
1
3 1
4 1
9 1
[B] [C]
5 5
[E]
[A]
1
3
[D]
6 (a)
IFL80B910961-01
[A]: Detail [a] 1. Clamp 5. GND bolt 8. ACC socket

[B]: Detail [b] 2. Floor harness 6. Nut 9. Antenna
[C]: Detail [c] 3. Seat belt switch 7. A/B SDM (with Air bag) 10. Selector AT
[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
IBL80A910996-01
[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.
[B] [A]
[C]
9 1
8
1
11
5
1
10
2 6
1 7
1
5 4
[a]
3
1 2 [D]
[b] 1
1
[d]
2 1 1
1 1
12
IFL80B910960-01
[A]: Detail [a] 2. Grommet 6. GND bolt 10. Rear sonar buzzer
[B]: Detail [b] (Outside view) 3. Floor harness 7. Rear combination light (R) 11. Sonar ECU
[C]: Forward 4. Rear washer wire 8. Wheel speed sensor (Rear-right) (ABS model) 12. Antenna (LF)
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
IBL80A910997-01
[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 2
1 [C]
1
[C]
1 8
1 1
7
1 [D]
9
3 11
1
[a]
1 5
[d] 1
10
[b] 1
IFL80B910965-01
[A]: Detail [a] 2. Grommet 7. Rear combination light (L)

[B]: Detail [b] (Outside view) 3. Floor harness 8. Wheel speed sensor (Rear-left) (ABS model)
: Pass the harness outside of the cable.
[C]: Forward 4. Rear end door harness 9. To rear end door harness
[D]: Detail [d] 5. Rear door switch (L) 10. CNG tank valve
1. Clamp 6. GND bolt 12. Fuel filler lid switch
Around Rear End Door

AENFL80B910H007
4
3
12 1
5 2
1 8
1 1 1 1
1
1 7 11
1 [a]
[b]
[A] [B]
6
“a”
9
10
IFL80B910964-01
[A]: Detail [a] 4. Rear defogger (–) 10. GND bolt

: Harness should not pressed between “Rear end door trim”
and “Rear end door panel”.
[B]: Detail [b] (Electric latch) 5. Rear wiper motor 11. Rear-view camera
[C]: Detail [c] (Manual latch) 6. Rear end door opener switch 12. Back door request
switch
1. Clamp 7. License plate light #1 “a”. ±45°
2. Rear end door harness 8. License plate light #2
Rear defogger (+) 9. Rear end door solenoid
3. : Harness should not pressed between
“Rear end door trim” and “Rear end door
panel”.
Specifications
AENFL80B910S002
Reference:
“Around Battery”:
“Around Strut”:
“Around Instrument Panel”:
“Around Main Floor”:
Lighting Systems: 9B-1
Lighting Systems
Repair Instructions
Headlight Unit Removal and Installation • Install screws (2, “1” – 2, “5”) according to numerical
AENFL80B9206001 order as shown in figure.
! WARNING
Headlight bulbs may be extremely hot. There 2
1, “2”
is risk of burn if you touch them carelessly.
1, “3”
! CAUTION
Do not touch glass surface of bulb with bare
hands. Bulb surface with dirt deteriorates
1, “4”
and becomes unclear when bulb lights up.
NOTE
• Bulb(s) can be replaced with headlight unit
installed on vehicle.
• After replacing headlight unit and/or
headlight bulb(s), check and adjust 1, “1”
headlight. 
1, “5”
Removal
1) Disconnect negative (–) cable at battery. IFL80B920004-02
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).
2
1
IFL80B920003-03
5) Remove bulbs, if necessary.
Installation
• Install headlight unit clip (1).
9C-1 Instrumentation / Driver Info. / Horn:
Instrumentation / Driver Info. / Horn

General Description
Combination Meter Description
AENFL80B9301001
• 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]
IFL80B930001-02
Information Display
The information display indicates various items of information including odometer, trip meter, outside air temperature,
instantaneous fuel consumption, average fuel consumption and brightness of instrument panel.
User customization function

When vehicle is stationary and the ignition is set to “ON”, pushing and holding the indicator selector knob at the
combination meter for more than 3 seconds activates the customization function. While this function is active,
parameters including door lock setting, light setting, security system function setting and default setting can be
configured by turning the indicator selector knob.
Door lock setting

• Door lock setting can be made in 3 setting modes; Power door lock setting mode, power door unlock setting mode
and siren setting mode.
• In power door lock setting mode, the function mode of power door lock can be selected from vehicle-speed-linked
mode or unlinked mode.
• In power door unlock setting menu, the function mode of power door unlock can be selected from vehicle-speed-
linked mode or unlinked mode.
• In siren setting mode, siren sound (answer-back) can be set to ON or OFF.
Instrumentation / Driver Info. / Horn: 9C-2
[D]
[E] [H]
[I]
[O]
[F] [H]
[K]
[O]
[G] [M]
[N]
[O]
[A] :
[B] :
[O]
[C] :
IFL80B930021-01
[A]: Push indicator selector knob [H]: Unlinked

[B]: Turn indicator selector knob [I]: Vehicle-speed-linked
[C]: Automatic transition [K]: IG-linked
[D]: Door lock setting [O]: Back
[E]: Power door lock setting [M]: ON
[F]: Power door unlock setting [N]: OFF
[G]: Siren setting
Light setting
• In light setting, additional flashes of turn signal light after turn signal switch is turned off can either be set to ON or
OFF.
• For more information on setting of additional number of flashes, refer to “Scan Tool Utility Table” in Section 10B
(Page 10B-15).
[D] [E]
[F] [G]
[I]
[H]
[J]
[F]
[A] :
[B] :
[F]
[C] :
IDL10A930048-02
[A]: Push indicator selector knob [E]: Flashing setting of turn signal light [I]: Success
[B]: Turn indicator selector knob [F]: Back [J]: Failure
[C]: Automatic transition [G]: ON
[D]: Light setting [H]: OFF
Security system function setting

• Security system function setting can be made in 4 setting modes; security alarm mode selection mode, shock
sensor mode selection mode, shock sensor pre-warn sensitivity level selection mode and shock sensor full blast
sensitivity level selection mode.
• For more information on security alarm mode selection, refer to “Security Alarm Mode Selection Procedure” in
Section 10E (Page 10E-53) (ignition switch model) or “Security Alarm Mode Selection Procedure” in Section 10B in
related manual (keyless push start model).
• For more information on Shock Sensor Mode Selection, refer to “Security Alarm Mode Selection Procedure” in
Section 10E (Page 10E-53) (ignition switch model) or “Security Alarm Mode Selection Procedure” in Section 10B in
related manual (keyless push start model).
• For more information on Shock Sensor Pre-warn Sensitivity Level Selection, refer to “Security Alarm Mode
Selection Procedure” in Section 10E (Page 10E-53) (ignition switch model) or “Security Alarm Mode Selection
Procedure” in Section 10B in related manual (keyless push start model).
• For more information on shock sensor full blast sensitivity level selection, refer to “Security Alarm Mode Selection
Procedure” in Section 10E (Page 10E-53) (ignition switch model) or “Security Alarm Mode Selection Procedure” in
Section 10B in related manual (keyless push start model).
[D] [E] [I]

[N]
[J]
[O]
[M]
[F] [I]
[J]
[M]
[G] [K]
[L]
[M]
[H] [K]
[L]
[M]
[A] :
[B] :
[M]
[C] :
IDL10A930049-01
[A]: Push indicator selector knob [F]: Shock sensor mode selection [K]: Shock sensor sensitivity level (OFF)
[B]: Turn indicator selector knob [G]: Shock sensor Pre-warn sensitivity level selection [L]: Shock sensor sensitivity level (Level 1 to Level 15)
[C]: Automatic transition [H]: Shock sensor Full Blast sensitivity level selection [M]: Back
[D]: Security system function [I]: ON [N]: Success
[E]: Security alarm mode selection [J]: OFF [O]: Failure
Default setting
All the settings can be reset to default settings.
[D] [E]
[G]
[H]
[A] :
[F]
[B] :
[C] :
IDL10A930050-01
[A]: Push indicator selector knob [D]: Default setting [G]: Success
[B]: Turn indicator selector knob [E]: Yes [H]: Failure
[C]: Automatic transition [F]: No
Selector Switch Description (Bi-Fuel CNG Model)

AENFL80B9301004
IDL80A930003-02
1: Select Switch
CNG level Indicator

When the ignition switch is in the “ON” position, this gauge gives an approximate indication of the quantity of CNG
in the CNG cylinder. “F” stands for full and “E” stands for empty. The mark (1) indicates that the fuel filler lid is located
on the left side of the vehicle.
IDL80A930004-01
Fuel Mode Selection

• Operating mode can be switched between “Petrol MODE” and “AUTO MODE” at every push of changeover switch
when ignition switch is turned to “ON” position with engine stopped, or when engine is running.
• “Forced CNG MODE” can be selected by pushing and holding changeover switch for more than 8 sec. when ignition
switch is on with engine stopped.
• If ignition switch is turned to OFF position and then turned to ON position again under “Forced CNG MODE”,
operating mode is switched to “AUTO MODE”.
AUTO MODE PETROL MODE FORCED CNG MODE
[A] [B] [C]
IDL80A930005-02
[A] [B] [C]

Auto Mode Petrol Mode Forced CNG Mode
Selector Switch Indications

Petrol MODE
In this mode vehicle starts in petrol and continue running in petrol mode. In this mode, petrol indication is continuously
displayed and CNG indicator will remain “OFF”.
Forced CNG MODE

In this mode vehicle starts in CNG mode and continues running in CNG mode. With ignition “ON” and engine not
running, press and hold the changeover switch till only CNG indicator is displayed. In this mode CNG indicator is
displayed and petrol indicator remains off.
AUTO MODE
In this mode engine starts in petrol mode and then automatically changes to CNG after reaching programmed
warming up condition. With ignition switch on and vehicle started in “AUTO MODE”, CNG indicator blinks on the
display and petrol indicator is displayed. After changeover to CNG, CNG indicator will be displayed and Petrol
indicator will switch off automatically.
Abnormal Condition
Petrol indicator and CNG indicator blink alternately when communication error between selector switch and CNG
control module occurs.
Parking Sensor System Description (If Equipped)

AENFL80B9301002
• The parking sensor system consists of the parking sensor system control module, combination meter (information
display), rear parking sensors, parking sensor rear buzzer, parking sensor OFF switch, and back up light switch.
• The parking sensor system activates when the parking sensor OFF switch is in ON position (Indicator ON) and:
– The shift position is in “R” range.
• The parking sensor system works when the gear position is in reverse.
• If the parking sensors located on the rear bumpers detect an obstacle, the parking sensor system control module
causes a symbol representing the direction of and distance to the obstacle to be indicated on the information
display, in addition to causing the parking sensor buzzer to sound.
• The parking sensor control module communicates with the combination meter via the LIN communication system.
(For LIN communication, refer to “Communication System Description”: Petrol and Bi-Fuel CNG Model in Section
10H (Page 10H-1) or “Communication System Description”: Petrol and Bi-Fuel CNG Model in Section 10H (Page
10H-1).)
• DTC for parking sensor control system can be checked by selecting the “Combination Meter/M&A” on SUZUKI scan
tool.
Information Display Indications and Buzzer Sounding Patterns

Obstacle detection by center-left / center-right parking sensor (Figures below represent indications when center-right
parking sensor detects obstacle.)
Information
display Rear
indication
IAW101930005-01 IAW101930004-02 IAW101930006-02
Detection
distance About 600 – 1,500 About 450– 600 About 350 – 450 About 350 or less
Rear
(reference) mm (23.6 – 59.1) (17.7 – 23.6) (13.8 – 17.7) (13.8)
(in.)
Buzzer sounding pattern [A] [B] [C] [D]
Obstacle detection by left / right parking sensor (Figures below represent indications when right parking sensor
detects obstacle.)
Information
Rear
display indication
IAW101930007-01 IAW101930008-01 IAW101930009-01
Detection distance (reference) About 450 – 600 About 350 – 450 About 350 or less
mm (in.) (17.7 – 23.6) (13.8 – 17.7) (13.8)
Buzzer sounding pattern [B] [C] [D]
[A] ON [C] ON
OFF OFF
450ms
50ms 50ms
[B] ON [D] ON
OFF OFF
150ms
50ms
IDL10A930002-01
Parking Sensor Description (If Equipped)

AENFL80B9301003
• The parking sensors are ultrasonic sensors* that are located at 4 positions, i.e., left corner, center-left, center-right,
and right corner positions on the rear bumpers.
• UART (Universal Asynchronous Receiver/Transmitter) is used for communications between the parking sensors
and parking sensor system control module.
*: Sound waves of 20,000 Hz or higher frequencies, which are not audible to human ears.

Parking Sensor Input / Output Block Diagram
AENFL80B9302002
Input Parking sensor system Output

control module
Combination meter
Back up light switch
Obstacle detection indication
Reverse position Parking sensor system control
Buzzer sounding
Parking sensor system

Display request
malfunction/fault indication
Parking sensor
Obstacle detection Parking sensor buzzer

Buzzer sounding request
Buzzer sounding
Indicator ON request
Parking sensor OFF switch Parking sensor OFF switch
Switch position Indicator ON/OFF
LIN communication
IEAD0A930025-01
Combination Meter Circuit Diagram

AENFL80B9302001
Circuit Diagram
BLK G240-5
1 3 6
2 4
WHT G240-2 7
9
3
RED G240-3
10
11
12
14
G240-15 RED
G240-16 YEL
[E]
G240-9 WHT
[E] 15
G240-21 RED
[E] G240-10 WHT

13 16
G240-22 RED
G240-11 WHT
17
G240-23 RED
5 G240-12 WHT
18
G240-24 RED
[E]
G240-8 LT BLU
19
20
G240-17 BEG
[B] G240-20 LT GRN 21
[B]
[D]
G240-18 PPL 22
[C]
IFL80B930002-01
[A]: D13A model 5. CPU 14. Fuel level sensor

[B]: A-STOP model 6. Speedometer 15. EPS
[C]: A/T model 7. Tachometer (if equipped) 16. DLC
[D]: SHVS model 8. Fuel meter 17. Auto A/C
[E]: Keyless Push Start model 9. Temperature meter 18. SDM
1. “DOME” fuse 10. LCD 19. Dimmer switch
2. “MTR” fuse 11. Trip switch 20. Rear fog light switch
3. Buzzer 12. Mode switch 21. Bulb illumination signal
4. Voltage regulator circuit 13. CAN driver 22. LED illumination signal
Parking Sensor System Circuit Diagram (If Equipped)

AENFL80B9302003
6
[B]
4 10
7
2 12
8
[A] L13-11 BLU

5
BRN L13-8
L13-14 PPL
3 17 L13-15 GRN
PNK L13-4 13
11 L13-16 BEG
L13-17 RED 14
15
16
YEL L13-10
L13-22 LT GRN
9 RED L13-13
BLK L13-21
IDL10A930005-03
[A]: Ignition switch model 6. Parking sensor OFF switch 13. Parking sensor No. 4
[B]: Keyless push start model 7. Illumination light 14. Parking sensor No. 3
1. J/B 8. Combination Meter 15. Parking sensor No. 2
2. “TAIL” fuse 9. Back up light switch 16. Parking sensor No. 1
3. “BACK” fuse 10. Parking sensor system control module 17. Indicator light
4. Tail light relay 11. CPU
5. Lighting and turn signal switch 12. Parking sensor buzzer
Component Location
Parking Sensor System Component Location (If Equipped)
AENFL80B9303002
[A] [B]
2 4
IFL80B930003-01
[A]: 5 M/T model 3. Rear parking sensor

[B]: 6 M/T model 4. Back up light switch
1. Parking sensor system control module 5. Parking sensor OFF switch
2. Parking sensor buzzer

Combination Meter / Parking Sensor System Diagnosis Function Description
AENFL80B9304024
SUZUKI scan tool provides the following functions about the combination meter / parking sensor system.
• DTC check: (Page 10B-10)
• DTC clearance: (Page 10B-10)
• DTC list display: (Page 9C-11)
• Parameter display: (Page 9C-12)
• Active tests: (Page 9C-12)
Combination Meter / Parking Sensor System

[A]
Self-Diagnosis Function
AENFL80B9304023
Self-Diagnosis Function
Combination meter and parking sensor system control
module have self-diagnosis function that stores content
(DTC) of a detected error.
A recorded DTC will be retained until it is cleared.
Warning Function
In case any malfunction is found in the parking sensor
1
system, if the parking sensor OFF switch is not pressed
(the parking sensor system is active), the parking sensor
[B]
symbol (1) on information display flashes and the
parking sensor buzzer sounds to warn the driver of the
malfunction.
IFL80B930004-03
[A] With Tachometer

[B] Without Tachometer
Fail-Safe Function
Fail-safe function inhibits operation of parking sensor
system when malfunction occurs in the system.
DTC Table
AENFL80B9304001
DTC DTC name DTC detecting condition Fail-safe
B1802 (Page Power Source Voltage too Voltage across “MTR” fuse is less than lower limit
—
9C-13) Low (8.0 V) for specified or longer time.
B1810 (Page Fuel Level Sensor Circuit / Fuel level signal has not been input for specified or
—
9C-14) Open longer time.
B1820 (Page Internal Control Module Memory in combination meter is faulty.
—
9C-15) EEPROM Error
B1852 (Page Rear Parking Sensor Combination meter cannot send / receive Stop of part of
9C-16) Communication Bus Error communication data to / from rear parking sensor. parking sensor
operation
B1864 (Page Rear-Left Parking Sensor • Parking sensor system control module detected
9C-18) fault in inner part of parking sensor (rear-left). Stop of part of
parking sensor
• Fault is detected in circuit for communication with operation
parking sensor (rear-left).
B1865 (Page Rear-Center-Left Parking • Parking sensor system control module detected
9C-18) Sensor fault in inner part of parking sensor (rear-center- Stop of part of
left). parking sensor
parking sensor (rear-center-left).
B1866 (Page Rear-Center-Right • Parking sensor system control module detected
9C-18) Parking Sensor fault in inner part of parking sensor (rear-center- Stop of part of
right). parking sensor
parking sensor (rear-center-right).
B1867 (Page Rear-Right Parking • Parking sensor system control module detected
9C-18) Sensor fault in inner part of parking sensor (rear-right). Stop of part of
parking sensor
parking sensor (rear-right).
DTC DTC name DTC detecting condition Fail-safe

U0073 (Page Control Module
—
9C-19) Communication Bus Off
U0100(Page Lost Communication With
—
9C-19) ECM
U0101(Page Lost Communication With
Stop of part of
9C-19) TCM Refer to “CAN DTC (Lost Communication and parking sensor
U0121 (Page Lost Communication With Communication Bus Off) Table” in Section 10H. operation
9C-19) ABS Control Module
• K14B model: (Page 10H-10)
U0140 (Page Lost Communication With
• D13A model: (Page 10H-10) —
9C-19) Body Control Module
9C-19) Keyless Start Control —
Module
—
9C-19) Restraints Control Module
Scan Tool Data

AENFL80B9304022
NOTE
If communication between SUZUKI scan tool and combination meter is not possible, perform the
following checks:
• Check communication condition between PC and VCI using SUZUKI scan tool function.
• Check DLC power circuit and ground circuit.
• Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
• Check CAN communication system. (“Control Module Communication Bus Off” is detected in any
control module.)
– K14B model:(Page 10H-19)
– D13A model: (Page 10H-45)
• Check combination meter power circuit and ground circuit. (Page 9C-19)
Normal condition
Scan tool data Condition
/ Reference value
Battery voltage 10 – 14 V Engine: Running
RR parking Detect Rear-Right side parking sensor is in abnormal condition.
sensor fault Not detect Rear-Right side parking sensor is in normal condition.
RCR parking Detect Rear-Center-Right side parking sensor is in abnormal condition.
sensor fault Not detect Rear-Center-Right side parking sensor is in normal condition.
RCL parking Detect Rear-Center-Left side parking sensor is in abnormal condition.
sensor fault Not detect Rear-Center-Left side parking sensor is in normal condition.
RL parking Detect Rear-Left side parking sensor is in abnormal condition.
sensor fault Not detect Rear-Left side parking sensor is in normal condition.
Parking sensor Equipped Parking sensor system is installed.
system Unequipped Parking sensor system is not installed.
Scan Tool Active Test

AENFL80B9304021
Active control is possible for the following items using active test function of SUZUKI scan tool.
! CAUTION
• Set the parking brake and block the wheels. After confirming the safe conditions, execute this active
test.
• This active test can be executed in the following conditions.
– Vehicle: stop– Engine: stop
Test item Test content

ECT Meter (Sweep) Water temperature meter is forcedly operated from MIN to MAX.
Test item Test content

Fuel Meter (Sweep) Fuel meter is forcedly operated from MIN to MAX.
Tachometer (Sweep) Tachometer is forcedly operated from MIN to MAX.
Speedometer (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.
Tachometer (Direct) Tachometer is forcedly operated to specified level.
Speedometer (Direct) Speedometer is forcedly operated to specified level.
Information Display Dot In “Display dot” mode, all-dot pattern is shown on the information-display.
Warning Buzzer Buzzer in combination meter is forcedly operated.
DTC B1802
AENFL80B9304025
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
BLK G240-5
[a]
1 5
WHT G240-2
[A] G240
3
12 11 10 9 8 7 6 5 4 3 2 1
G240-3
2 24 23 22 21 20 19 18 17 16 15 14 13
RED
PPL G240-18
IFL80B930005-04
[A]: Combination meter connector (View: [a]) 3. “MTR” fuse 6. CPU

1. “DOME” fuse 4. Combination meter
2. “RADIO 2” fuse 5. Voltage regulator circuit
DTC Troubleshooting
Step Action Yes No
1) Clear DTC. trouble. 
4) Check DTC.
Is DTC B1802 still detected?

2 Combination meter power supply and ground circuit Go to Step 3. Repair defective wire
check harness.
1) Check combination meter power supply and ground
circuits. (Page 9C-19)
Is check result OK?

Step Action Yes No

3 Combination meter power supply voltage check Replace combination Check charging system.
1) Check power supply voltage with engine speed at 3,000 meter and recheck • K14B model (Page
rpm. DTC. (Page 9C-24) 1J-3)
Is voltage 10 – 15 V? • D13A model without
ISG (Page 1J-13)
• D13A model with ISG
(Page 1J-23)
DTC B1810
AENFL80B9304026
B1810: Fuel Level Sensor Circuit / Open • Combination meter
Fuel level signal has not been input for specified or longer time. • Fuel level sensor
• Fuel level sensor circuit
Circuit Diagram
1
[a]
3
G240-15 RED
2 [A] G240
G240-16 YEL
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
IFL80B930006-03
[A]: Combination meter connector (View: [a]) 2. CPU

1. Combination meter 3. Fuel level sensor
DTC Troubleshooting
Step Action Yes No
1) Clear DTC. trouble. 
4) Check DTC.

2 Fuel level sensor check Go to Step 3. Replace fuel level
1) Check fuel level sensor sensor and recheck
DTC.
• K14B model:
• D13A model: (Page 1G-26) • K14B model: or 
• D13A model: 
Is check result OK?
Step Action Yes No

3 Fuel level sensor circuit check Replace combination Repair defective wire
1) Check that ignition is “OFF”. meter and recheck harness and recheck
DTC. (Page 9C-24) 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.
Is check result OK?
DTC B1820
AENFL80B9304027
B1820: Internal Control Module EEPROM Error • Combination meter
Memory in combination meter is faulty. • Parking sensor system control module
DTC Troubleshooting
Step Action Yes No
1 DTC check Replace combination Check for intermittent
1) Clear DTC. meter and recheck trouble. 
DTC. (Page 9C-24)
4) Check DTC.
DTC B1840
AENFL80B9304028
B1840: Vehicle Speed Invalid Data • Wheel speed sensor
Combination meter received abnormal vehicle speed data from ECM. • ABS control module
• ECM
DTC Troubleshooting
Step Action Yes No
1) Check DTC in ABS control module. for applicable DTC.
• ABS model: (Page 4E-3)

2 DTC check Go to troubleshooting Replace combination
1) Check DTC in ECM. for applicable DTC. meter and recheck
DTC.(Page 9C-24)
• K14B model: (Page 1A-16) or (Page 1A-133)
• D13A model: (Page 1A-181)
DTC B1841
AENFL80B9304029

B1841: Outside Air Temperature Invalid Data • Outside air temperature sensor
Combination meter received abnormal outside air • BCM
temperature data from BCM.
DTC Troubleshooting
Step Action Yes No
1) Check DTC in BCM. (Page 10B-10) for applicable DTC. meter and recheck
DTC B1842
AENFL80B9304030
B1842: Fuel Consumption Invalid Data • ECM
Combination meter received abnormal fuel consumption data from ECM. • Combination meter
DTC Troubleshooting
Step Action Yes No
1) Check DTC in ECM. for applicable DTC. meter and recheck
• K14B model: (Page 1A-16) or (Page 1A-133)
• D13A model: (Page 1A-181)
DTC B1852
AENFL80B9304031
B1852: Rear Parking Sensor Communication Bus Error • Parking sensor system control module
Combination meter cannot send / receive communication data • Parking sensor
to / from rear parking sensor.
• Communication circuit
Circuit Diagram
5
L13-14 PPL
4
L13-15 GRN
3
L13-16 BEG
2
L13-17 RED
6
L13-22 LT GRN
L13-21 BLK
[A] L13
[a]
9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10
IFL80B930008-05
[A]: Parking sensor system control module connector (View: [a]) 4. Parking sensor (Rear-center-right)
1. Parking sensor system control module 5. Parking sensor (Rear-right)
2. Parking sensor (Rear-left) 6. Communication driver
3. Parking sensor (Rear-center-left)
DTC Troubleshooting
Step Action Yes No
1 Circuit check Go to Step 2. Repair defective wire
1) Check that ignition is “OFF”. harness.
2) Disconnect parking sensor system control module
connectors and all parking sensor connectors.
3) Check for proper connection parking sensor system
control module connector and all parking sensor
connectors.
4) If connections are OK, check circuits between parking
sensor system control module connector and all parking
sensor connectors for open circuit, short to ground or
short to power supply.
Is check result OK?

2 Parking sensor (rear-left) check Go to Step 3. End.
1) Connect parking sensor system control module
connector and all parking sensor connectors.
2) Replace parking sensor (rear-left). (Page 9C-27)
4) Check DTC.

3 Parking sensor (rear-center-left) check Go to Step 4. End.
1) Replace parking sensor (rear-center-left). (Page 9C-
27)
3) Check DTC.

Step Action Yes No

4 Parking sensor (rear-center-right) check Go to Step 5. End.
1) Replace parking sensor (rear-center-right). (Page 9C-
27)
3) Check DTC.

5 Parking sensor (rear-right) check Replace parking sensor End.
1) Replace parking sensor (rear-right). (Page 9C-27) system control module.
(Page 9C-27)
3) Check DTC.
DTC B1864 / B1865 / B1866 / B1867

AENFL80B9304032
B1864: Rear-Left Parking Sensor • Parking sensor
• Parking sensor system control module detected fault in inner part of parking • Parking sensor system control
sensor (rear-left). module
• Fault is detected in circuit for communication with parking sensor (rear-left). • Communication circuit
B1865: Rear-Center-Left Parking Sensor
• Parking sensor system control module detected fault in inner part of parking
sensor (rear-center-left).
• Fault is detected in circuit for communication with parking sensor (rear-
center-left).
B1866: Rear-Center-Right Parking Sensor
sensor (rear-center-right).
• Fault is detected in circuit for communication with parking sensor (rear-
center-right).
B1867: Rear-Right Parking Sensor
sensor (rear-right).
• Fault is detected in circuit for communication with parking sensor (rear-right).
Circuit Diagram
5
L13-14 PPL
4
L13-15 GRN
3
L13-16 BEG
2
L13-17 RED
6
L13-22 LT GRN
L13-21 BLK
[A] L13
[a]
9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10
IFL80B930008-05
[A]: Parking sensor system control module connector (View: [a]) 4. Parking sensor (Rear-center-right)
1. Parking sensor system control module 5. Parking sensor (Rear-right)
2. Parking sensor (Rear-left) 6. Communication driver
3. Parking sensor (Rear-center-left)
DTC Troubleshooting
NOTE
The following procedure describes how to check DTC B1864. Follow the same procedure for DTC
B1865, B1866 and B1867.
Step Action Yes No

1 DTC check Go to “DTC B1852” Go to Step 2.
(Page 9C-16).
2 Parking sensor check Replace parking sensor Replace parking sensor
1) Replace parking sensor with normal one and recheck system control module. (rear-left).
DTC. (Page 9C-27) (Page 9C-27)
DTC U0073 / U0100 / U0101 / U0121 / U0140 / U0141 / U0151

AENFL80B9304033
Refer to “CAN DTC (Lost Communication and Communication Bus Off) Table” in Section 10H.
• K14B model:(Page 10H-10)
• D13A model: (Page 10H-36)
Inspection of Combination Meter and Its Circuits

AENFL80B9304034
Voltage and Signal Check
1) Remove combination meter (with connectors connected). (Page 9C-24)
2) Check voltage and/or pulse signal using voltmeter and oscilloscope.
NOTE
• Check that battery voltage is 12 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
Terminal Normal
No. voltage
Approx.
2 WHT Backup power supply Ignition: “OFF”, “ACC” or “ON”
12.0 V
Approx.
Ignition: “ON”
3 RED Power supply 12.0 V
0V Ignition: All
5 BLK GND 0V Ignition: All
Approx. Lighting and turn signal switch:
Lighting and turn signal switch signal 12.0 V Other than high beam position
8 LT BLU
(High Beam) Lighting and turn signal switch:
0V
High beam position
9* WHT CAN communication signal (low) to EPS
10* WHT CAN communication signal (low) to DLC Refer to reference waveform.
11* WHT CAN communication signal (low) to KLS “CAN communication signal” (Page 9C-21)
12* WHT CAN communication signal (low) to SDM
G240
15* RED Fuel level sensor signal (power supply)
“Fuel level sensor signal” (Page 9C-21)
16 YEL Fuel level sensor signal (GND) 0V Ignition: All
18* PPL LED illumination signal
“Illumination control signal” (Page 9C-22)
20* LT GRN Bulb illumination signal
“Illumination control signal” (Page 9C-22)
CAN communication signal (high) to
21* RED
EPS
22* RED Refer to reference waveform.
DLC
“CAN communication signal” (Page 9C-21)
23* RED CAN communication signal (high) to KLS
24* RED
SDM
Reference Waveform
Oscilloscope display
Shown below is typical waveform display provided by
oscilloscope.
NOTE
• Display includes the following types of
data:
IAW101A20014-01
1. CAN communication signal (high)

2. CAN communication signal (low)
IAW101970026-01
[a]: Waveform of channel 1 [c]: VOLT/DIV of each channel

Fuel level sensor signal
[b]: Ground level of each channel [d]: TIME/DIV Channel Probe Terminal No.
+ G240-15
1
• Waveform varies depending on – G240-16
CAN communication signal • Ignition: “ON”
• Fuel: Full
CAN communication signal (High)
G240-21
G240-22
+
1 G240-23
G240-24
– G240-5
CAN communication signal (Low)

G240-9
G240-10
+ I9R90A930005-01
2 G240-11
1. Fuel level sensor signal
G240-12
– G240-5
Measurement condition • Fuel: Empty
I9R90A930006-01
1. Fuel level sensor signal

Illumination control signal

1
G240-18
+
1 G240-20
– G240-5
• Lighting switch: Other than OFF position
• Illumination control: 7th position (Brightest)
I9P60A930013-01
1. Illumination control signal
1
• Illumination control: 1st position (Dimmest)
I9P60A930012-01
• Illumination control: 4th position
I9P60A930038-01
Inspection of Parking Sensor System Control Module and Its Circuits (If Equipped)
AENFL80B9304035
1) Remove parking sensor system control module (with connectors connected). (Page 9C-27)
2) Check voltage and/or pulse signal using voltage and oscilloscope.
NOTE
[A] L13
[a] 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10
I9P60A930015-03
[A]: Parking sensor system control module connector (View: [a])

Terminal
Wire color Circuit Normal voltage Condition
No.
Approx. 12 V
Parking sensor OFF switch indicator:
Parking sensor OFF switch OFF
4 PNK
indicator signal Approx. 0 V Parking sensor OFF switch indicator:
ON
Approx. 12 V Parking sensor OFF switch indicator:
In position
8 BRN Parking sensor OFF switch signal
Approx. 0 V Parking sensor OFF switch indicator:
Out position
Parking sensor system control Approx. 12 V Ignition: “ON”
10 YEL
module power supply Approx. 0 V Ignition: “OFF” or “ACC”
11* BLU Parking sensor buzzer signal
“Parking sensor buzzer signal” (Page 9C-23)
L13 Approx. 12 V • Ignition: “ON”
13 RED Back-up light signal • Gear shift lever: “Reverse” position
14* PPL Parking sensor signal (Rear-right)
Parking sensor signal (Rear-center
15* GRN
right) Refer to reference waveform.
Parking sensor signal (Rear- “Parking sensor signal” (Page 9C-24)
16* BEG
center-left)
17* RED Parking sensor signal (Rear-left)
Parking sensor system control Approx. 0 V Ignition: “OFF”, “ACC” or “ON”
21 BLK
module ground
22 LT GRN Rear parking sensor ground Approx. 0 V Ignition: “OFF”, “ACC” or “ON”
Reference Waveform • Waveform varies depending on

Oscilloscope display measurement condition and vehicle spec.
oscilloscope. Parking sensor buzzer signal
NOTE Channel Probe Terminal No.
+ L13-11
• Display includes the following types of 1
– L13-21
data:
• Rear parking sensor system: operated
IAW101970026-01

[b]: Ground level of each channel [d]: TIME/DIV IAW101930046-03
1. Buzzer sounds 2. Buzzer does not sound

Parking sensor signal

L13-14
L13-15
+
1 L13-16
L13-17
– L13-21
• Rear parking sensor system: operated
IDL10A930010-01
Combination Meter Diagnosis

AENFL80B9304036
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-19)
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), check 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 in related manual.
model) Circuit (including relays and fuses) —
Repair Instructions
Instrument Panel Components
AENFL80B9306001
NOTE
• To remove instrument panel, remove parts (1) through (12) and disconnect instrumental panel
harness connector beforehand.
A A
A A A
A A
AA A
A A A
A A A
A A
A A AA
11 A
A A A
14
A A 14
A A
A
A
A
A
6
A A 11(a) 25
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 23 2 21
A A 24
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
IFL80B930020-01
[A]: Release the locks 9. Audio unit (if equipped) 17. Engine switch bezel
1. Steering column hole cover 10. Radio hole cover (if equipped) 18. Ornament
2. Front fog light switch (if equipped) 11. Airbag cover (with Passenger airbag) (if equipped) 19. Switch bezel
3. Floor console side cover 11a. Airbag cover (without Passenger airbag) 20. Instrument panel top silencer
(if equipped)
4. Support member lower brace 12. HVAC control unit (manual A/C model) 21. Headlight leveling switch

5. Glove box 13. Auto A/C panel (auto A/C model) 22. Front fog light switch (if equipped)
6. Combination meter cluster panel 14. Side ventilation louver 23. Eng A-Stop OFF switch (if equipped)
7. Combination meter 15. Glove box upper cover 24. Parking sensor OFF switch (If equipped)
8. Center ventilation louver 16. Center side cover 25. SLDA (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)
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
Parking Sensor System Control Module • Front: (Page 9H-1)

Removal and Installation (If Equipped) • Rear: (Page 9H-3)
AENFL80B9306005
Removal 2) Disconnect parking sensor connector.
1) Remove right side rear quarter inner lower trim. 3) Remove parking sensor (1) from bumper.
(Page 9H-3)
2) Disconnect parking sensor system control module
connector (1).
3) Remove screws (2) and remove parking sensor
system control module (3).
3 1
IDAA0A930028-01
Installation
1 Reverse removal procedure.
Parking Sensor Inspection (If Equipped)

AENFL80B9306007
• Check parking sensor for damage.
• Check parking sensor connector for damage.
IDAA0A930027-01
• Check parking sensor connector terminal for bend,
Installation rust or corrosion.
Reverse removal procedure. If any defect is found, replace parking sensor.
Parking Sensor Removal and Installation (If Parking Sensor OFF Switch Removal and
Equipped) Installation (If Equipped)
AENFL80B9306008
AENFL80B9306006
Removal Removal
1) Remove bumper. 1) Remove switch bezel. (Page 9C-24)
2) Disconnect parking sensor OFF switch connector.

3) Remove parking sensor OFF switch (1) from switch
bezel.
IEAD0A930019-01 IDAA0A930033-01
Installation Installation
Reverse removal procedure. Reverse removal procedure.
Parking Sensor OFF Switch Inspection (If Parking Sensor Buzzer Inspection (If Equipped)
AENFL80B9306011
Equipped)
AENFL80B9306009 1) Connect parking sensor buzzer (1) to positive (+)
Check parking sensor OFF switch for continuity between and negative (–) terminals as shown in figure.
terminals at each switch position. If check result is not as Replace parking sensor buzzer if it does not sound.
specified, replace parking sensor OFF switch.
1
6 4
3 2
8 7 6 5 4
2 1
1
8 7 5
IEAD0A930020-02
Parking sensor OFF switch continuity
Terminal
Switch 6 7 IFL80B930016-01
position
Released
Engine Auto-Stop OFF Switch Removal and
Installation (If Equipped)
AENFL80B9306004
Pushed Removal
IEAD0A930021-01 1) Remove switch bezel. (Page 9C-24)
2) Disconnect Auto-stop OFF switch connector.
Parking Sensor Buzzer Removal and 3) Remove Auto-stop OFF switch (1) from switch bezel.
Installation (If Equipped)
AENFL80B9306010
Removal
1) Remove right side rear quarter inner lower trim.
(Page 9H-3)
2) Disconnect parking sensor rear buzzer connector
(1).
3) Remove parking sensor rear buzzer (2).
Check parking sensor OFF switch for continuity between

terminals at each switch position. If check result is not as
specified, replace parking sensor OFF switch.
6 4
1 2
4 5 6 7 8
1
3
7 5
IFL80B930019-01
IFL80B930018-01
Engine Auto-Stop OFF Switch Inspection
Installation
Reverse removal procedure. Terminal
Switch 6 7
position
Engine Auto-Stop OFF Switch Inspection (If Released

Equipped)
AENFL80B9306012
Pushed
IEAD0A930021-01
Specifications
AENFL80B9307002
Reference:
“Instrument Panel Components”:
Glass / Windows / Mirrors: 9E-1
Glass / Windows / Mirrors

Component Location
Power Window Component Location
AENFL80B9503001
3
3
6
6 4
2
6
1
1
2
5
8 7
IFL80B950001-01
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-2 Glass / Windows / Mirrors:
Power Door Mirror Component Location (If Equipped)

AENFL80B9503002
1 6
4 5
IFL80B950002-01
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 6. Outside rear view mirror retractable switch
Repair Instructions
Power door mirror switch continuity
Power Door Mirror Switch Inspection (If [A]
Equipped) [B] 3 4 5 6 7 8 9 10 11 12 13
AENFL80B9506017 [C] [D]
Check continuity between terminals at each switch
[H]
position.
If check result is not as specified, replace switch. [I]
[E]
[J]
[E] [D]
[K]
[H]
[H] [I]
1 [F]
[C] [F]
[J]
[G]
[K]
[A] IDL10A950052-02
3
[B]
2
5 4 3 2 1
13 12 11 10 9 8 7 6
IAP70B950008-01
Glass / Windows / Mirrors: 9E-3
Retract switch continuity

[A]
[B] 3 4 5 6 7 8 9 10 11 12 13
[G]
[L]
[M]
IDL10A950055-01
[A]: Terminal [H]: Up

[B]: Switch Position [I]: Down
[C]: R/L Switch [J]: Right
[D]: Angle Switch [K]: Left
[E]: L [L]: Set
[F]: R [M]: Retract
[G]: Retract switch (if equipped)
9F-1 Security and Locks:
Security and Locks

General Description
Power Door Lock System Description
AENFL80B9601007
• Power door lock system consists of keyless start control module (1) (keyless push start models), BCM (2), door lock
actuators (3), power door lock switch (4) and door request switches (5).
• Power door lock system is controlled by the BCM on ignition switch models and, by the keyless start control module
and the BCM on keyless push start models.
• The door lock actuators are integrated into door lock assembly. The front door lock assembly also incorporates the
door lock switch.
• The door lock actuators are all covered for antitheft purpose.
• In the power door lock system on ignition switch models, BCM locks or unlocks doors upon receipt of lock or unlock
command from registered keyless transmitter (6), driver’s door key cylinder, or power door lock switch.
• In the power door lock system on keyless push start models, keyless start control module and BCM lock or unlock
doors upon receipt of lock or unlock command from registered remote controller (7), door request switch for driver’s
door or passenger’s door, or power door lock switch.
• Power door lock system operates in 4 modes, vehicle-speed-linked door lock mode, ignition-linked door unlock
mode, door lock disabled mode and door unlock disabled mode.
• In the vehicle-speed-linked door lock mode with any of doors unlocked, ignition set to “ON” and all the doors closed,
all unlocked doors will be automatically locked when the vehicle speed exceeds 15 km/h for more than 2 seconds.
• In the ignition-linked door unlock mode on ignition switch models with any of doors locked and all the doors closed,
all locked doors will be automatically unlocked when the ignition key is removed from the ignition key cylinder.
• In the ignition-linked door unlock mode on keyless push start models with any of doors locked and all the doors
closed, all locked doors will be automatically unlocked when engine switch is pressed and the ignition is set to
“OFF” from “ON”.
• In the door lock disabled mode, vehicle-speed-linked door lock function is disabled.
• In the door unlock disabled mode, ignition-linked door unlock function is disabled.
• Power door lock system can be configured using user customization function.
Security and Locks: 9F-2
5
4
6
5
5 3 3
IFL80B960001-01

Power Door Lock System Circuit Diagram
AENFL80B9602003
• Ignition switch model: Refer to “Body Electrical Control System Circuit Diagram” in Section 10B (Page 10B-4).
• Keyless push start model: Refer to “Body Electrical Control System Circuit Diagram” in Section 10B (Page 10B-4)
and “Keyless Start System Electric Circuit Diagram” in Section 10E (Page 10E-10).
Repair Instructions
Front Door Lock Assembly Removal and NOTE
Installation Perform this work with front window fully
AENFL80B9606002
closed.
Removal
2) For keyless push start model, disconnect harness
1) Remove door trim and sealing cover referring to clamp (1) from front door rear sash.
Step 2) to 8) of “Front Door Glass Removal and
3) For keyless push start model, disconnect driver door
Installation” in Section 9E in related manual.
request switch connectors (2).
4) Remove inside door handle (6) by moving it in arrow
directions “3” and “4”.
5) Remove inside door handle wire clip (8).
6) Remove lock (1) in arrow direction “1” and then • Apply grease to sliding parts and rotation parts of door
move door lock open rod (2) in arrow direction “2” to lock assembly.
remove it from outside door handle (3).
: Grease 99000–25011 (SUZUKI Super Grease A)
7) For power door lock model, disconnect door lock
connector (4) from front door lock assembly (5). • Tighten each screw to specified torque referring to
“Front Door Lock Components” in related manual.
8) Remove door lock screws (7).
• Move door latch striker (2) up or down to align its
9) Remove inside door handle and door lock assembly
center with the center of groove (3) on door lock
as a unit.
assembly (1) as shown in figure.
“4”
6 2 3 1
“3”
I9W10P960004-01
8 • Move door latch striker (1) to adjust front door panel

surface (2) flat with rear door panel surface (3) as
4 6 shown in figure.
5
Tightening torque
Door latch striker screw: 10 N·m (1.0 kgf-m, 7.5
lbf-ft)
2 3
7
1
3
“1”
“2”
1
2 I9W10P960005-01
Request Switch On-Vehicle Inspection

AENFL80B9606022
I9P60A960005-01 1) Detach request switch harness clamp (1) from trunk
10) Remove door lock wires (1) from inside door handle lid (2).
(2) by pulling them in arrow direction. 2) Disconnect request switch connector (3).
3) Check continuity between terminals at each switch
2
position.
If check result is not as specified, replace trunk lid
request switch.
1
IAW101960011-02
Installation
Security and Locks: 9F-4
1) Confirm that all doors are closed and ignition key is

out of ignition key cylinder.
2 1
2) Open driver side door.
4 3
3) Turn ignition switch to ON position, and then take out
2 1
ignition key from ignition key cylinder within 10
seconds after that.
4) Push and release driver side door switch (1) 3 times
by hand within 20 seconds after removing ignition
key from ignition key cylinder.
5) Turn ignition switch to ON position, and then remove
ignition key from ignition key cylinder within 10
seconds after that. All doors automatically lock and
unlock once.
This indicates that the system is in registration
IFL80B960002-01 mode.
6) Push “LOCK” / “UNLOCK” button (2) on transmitter
Trunk lid request switch continuity (3) within 10 seconds after Step 5) for “N” times,
[A]
where “N” indicates the number of transmitter
2 4 registered. All doors automatically lock and unlock
[B]
once.
[C]
This indicates that code registration is completed.
[D]
IEP80A960017-01
[A]: Terminal [C]: Pushed

[B]: Switch position [D]: Released
Ignition Key Registration (Ignition Switch

1
Model) 2
AENFL80B9606013 3
Refer to “Ignition Key Registration (Ignition Switch
Programming Transmitter Code for Keyless

Entry System IBP80A960018-01
AENFL80B9606015
NOTE 7) If an additional transmitter needs to be programed,
repeat the procedure step (3) and step (6) within 10
• Perform ignition key registration before seconds of registering the previous transmitter.
programming transmitter code. Refer to
“Ignition Key Registration (Ignition Switch
Model)” in Section 10B (Page 10B-34)
• Four transmitter codes can be registered.
• When four transmitters are registered and
then new transmitter code is registered,
the oldest one will be cleared.
If transmitter or Security controller is replaced or

additional transmitter(s) is required, program transmitter
code(s).
Specifications
AENFL80B9607002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Door latch striker screw 10 1.0 7.5 
Reference:

AENFL80B9608002
Grease SUZUKI Super Grease A P/No.: 99000–25011 
Seats: 9G-1
Seats
Repair Instructions
3rd Row Seat Components

AENFL80B9706005
9G-2 Seats:
Bench Type
5
4
9 (a)
8
(a)
11
(b) 7 8 9
(a)
11 (b)
6
(a)
7
10
10
IFL80B970002-01
1. Rear back lock band 6. 3rd seat cushion pad 11. Cushion fixed stay bush
2. 3rd seatback trim 7. 3rd seat cushion frame : 43 Nm (4.38 kgf-m, 32 lbf-ft)
3. 3rd seatback pad 8. 3rd seat hinge : 8.35 Nm (0.85 kgf-m, 6 lbf-ft)
4. 3rd seatback frame 9. 3rd seat hinge outside cover
5. 3rd seat cushion trim 10. 3rd seat mounting cover
Seats: 9G-3
Split Type
4
5
10, “2” (a)

10, “1” (a)
10, “3” (a)
10
6 (b)
11
6 (b)
10, “5” (a) 8
10, “4” (a)
9
IFL80B970001-01
1. Headrest 5. 3rd seatback trim 9. Cover, mounting outer

2. Headrest guide 6. 3rd seat hinge outside cover 10. 3rd seat mounting bolts:
Tighten bolts in the order “1”-”5”
3. 3rd seatback frame 7. 3rd seat cushion frame 43 Nm (4.38 kgf-m, 32 lbf-ft)
4. 3rd seatback pad 8. 3rd seat center trim 8.35 Nm (0.85 kgf-m, 6 lbf-ft)
9G-4 Seats:
3rd Row Seat Removal and Installation

AENFL80B9706006
Removal
1) For split type seat remove the tail end trim.(Page 9H-3)
2) Remove seat assembly by removing 3rd seat mounting bolts. (Page 9G-1)
3) Remove seat cushion assembly. (Page 9G-1)
4) Disassemble and repair seat if necessary. (Page 9G-1)
Installation
• Refer to “3rd Row Seat Components” (Page 9G-1) for tightening torque.
Specifications
AENFL80B9707002
Reference:
“3rd Row Seat Components”:
Exterior Trim / Interior Trim: 9H-1
Exterior Trim / Interior Trim

Repair Instructions
Front Bumper Removal and Installation
AENFL80B9806001
NOTE
The asterisk “*” mark in the figure represents that the same part is available symmetrically on the
other side.
Remove and install parts referring to figure.
4
10*
[A] [B]
1
IFL80B980013-01
9H-2 Exterior Trim / Interior Trim:
[a]
[e]
[a] [d]
[c]
6 7
[b]
[b]
8*
[e]
3
[d]
[c] A
A A
A 9*
A
A
IFL80B980010-01
[A]: With front fog light 3. Front bumper 7. Front bumper side holder
[B]: Without front fog light 4. Radiator upper grille 8. Fender lining
1. Front bumper cap 5. Radiator lower grille 9. Mud flap
2. License plate nuts 6. Front bumper front holder 10. Radiator upper grille bracket
Rear Bumper Removal and Installation

AENFL80B9806003
4
4
[b]
[c] [d]
[a]
3
[d]
[b] [c]
[a]
5
5*
A
A
A
IFL80B980011-01
1. Rear bumper 3. Rear bumper rear holder 5. Mud flap

2. Rear fender lining 4. Rear bumper side holder
Trim Removal and Installation

AENFL80B9806007
Removal
Front pillar trim
• Remove front pillar trim (1) pulling it in arrow direction.
A B
A
IBP80A980017-01
Dash side trim and front side sill scuff

• Remove front side sill scuff (1) and then remove dash side trim (2) pulling them in arrow directions.
A B
A
A
C
A
B
A 2
IFL80B980008-02
A B
A
A
C
C
2
B 1
A
A
B A
IBL80A980008-01
Rear side sill scuff Seat belt with shoulder adjuster

• Remove rear side sill scuff (1) pulling it in arrow
A
direction.
2
3
4
1 A
A IEP80A980008-02
A
A
Seat belt without shoulder adjuster
A
2
IBL80A980009-01
3
Center pillar trims

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). 1 A
4) Remove upper trim (2) pulling them in arrow
directions.
4
4
I9P60A980017-03
Tail end trim Installation

• Remove clips and then remove tail end trim (1) pulling
it in arrow direction. Reverse removal procedure noting the following points.
• Tighten front seat belt anchor plate bolt to specified
A
torque. 
• Tighten rear seat hinge bolt to specified torque. 
A
A
IBL80A980010-01
Quarter inner trims

1) Remove tail end trim (2).
2) Remove rear seat. 
3) Remove clips and then remove rear quarter inner
lower trim (3) pulling it in arrow direction.
4) Remove rear quarter inner upper trim (4) pulling it in
arrow direction.
A B 4
2
B A
B
3
B
IBL80A980011-01
Center Console Box Removal and Installation

AENFL80B9806010
1 5
7 B
A B
A “1”
B
8
“2”
IFL80B980007-01
1. Floor console box front garnish 4. Cup holder 7. Floor console box front bracket
2. Floor console front box 5. Floor console front cover 8. Floor console box rear bracket
3. Floor console rear box 6. Floor console front cover bracket
9J-1 Hood / Fenders / Doors:
Hood / Fenders / Doors

Repair Instructions
Hood Inspection and Adjustment
AENFL80B9A06002
Inspection
• Check that hood opens and closes smoothly and
properly. Lubricate it if necessary. 1
• 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.
Hood Latch Switch Check IBL80A9A0001-01
1) Remove front bumper.“Front Bumper Removal and • Turn hood cushion (2) if there is a step between hood
Installation” in Section 9H (Page 9H-1) and front fender.
2) Disconnect hood latch switch connector (2).
3) Check continuity between terminals of hood latch
switch connector (2) when latch (1) is operated. If
check result is not as specified, replace hood latch. 2
[A]
1 2 3
[B]
[C]
[D]
IFL10A9A0002-01
[A]: Terminal [C]: Fully latched IBL80A9A0002-01

[B]: Lock position [D]: Latch released
Hood latch position adjustment

1) Loosen hood latch bolts (1) and adjust height of
1 hood latch (2).
2) Tighten hood latch bolts to specified torque.
Tightening torque
Hood latch bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
3 2 1
IFL80B9A0004-01
Adjustment
Horizontal adjustment of hood 1,(a)
IFL80B9A0003-01
Loosen hood hinge bolts and adjust installation position
of hood.  3) Make sure hood is locked smoothly and securely.
Vertical adjustment of hood

• Turn hood cushion (1) if there is a step between hood
and front fender.
Hood / Fenders / Doors: 9J-2
Specifications
AENFL80B9A07002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Hood latch bolt 10 1.0 7.5 
Reference:
9K-1 Body Structure:
Body Structure
General Description
Sheet Metal Description
AENFL80B9B01002
This section contains information for body repair (welding) work.
NOTE
All the numbered panels in figure are supplied available as spare parts.
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-2
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 crossmember (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 crossmember (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)

Thickness
(mm (in.))
73 Dash upper crossmember 1
73-1 Dash upper crossmember 1.0 (0.039)
73-2 Dash upper side crossmember (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)
Floor
109-2
109-1
103-3 109-2
103
103-2 89
102 108 109
106 109-3
103-1
105 90
104 106 103-3
105
103-2
87
103
103-1
107
97 92 88
101 104
96
96 113
95-2 92 135-3
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
131-1
91
131 131-2
122
121
IFL80B9B0007-01

Thickness
(mm (in.))
87 Third seat inner bracket, R (Split seat) 1 2.0 (0.079)
88 Third seat inner bracket, L (Split seat) 1 2.0 (0.079)
89 Third seat bracket inner rear, R (Split seat) 1 2.0 (0.079)
90 Third seat bracket inner rear, L (Split seat) 1 2.0 (0.079)
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 crossmember (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 crossmember extension (R) 1.4 (0.055)
111-4 Trailing arm outside bracket (R) 1.4 (0.055)
111-5 Rear floor 2nd crossmember 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 crossmember extension (L) 1.4 (0.055)
121-4 Trailing arm outside bracket (L) 1.4 (0.055)
121-5 Rear floor 2nd crossmember 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 crossmember 1
131-1 Rear floor front crossmember 440 1.0 (0.039)
131-2 Floor side member cap 0.8 (0.031)
132 Rear floor 2nd crossmember 1
132-1 Rear floor 2nd crossmember 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)

Thickness
(mm (in.))
133 Rear floor 3rd crossmember 1 1.2 (0.047)
134 Rear floor 4th crossmember 1
134-1 Rear floor 4th crossmember 1.2 (0.047)
134-2 3rd seat belt reinforcement 1.4 (0.055)
134-3 Rear floor 4th crossmember extension 2.0 (0.079)
135 Rear floor 5th crossmember 1
135-1 Rear floor 5th crossmember 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)
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
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

Thickness
(mm (in.))
R: 1
141 Front pillar inner panel (R, L)
L: 1
141-1 Roof side inner rail (R, L) 590 1.0 (0.039)
R: 1.2
R: 1 R: 780 (0.047)
142 Front pillar inner panel (R, L)
L: 1 L: 590 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) 1 780 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) 590 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)

Thickness
(mm (in.))
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
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
IFL80B9B0001-01

Thickness
(mm (in.))
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)
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
Repair Instructions
Back Panel Removal and Installation

AENFL80B9B06017
NOTE
The figure below shows condition where the following parts are removed.
• Front fender 
IBL80A9B0252-01
Removal
1) Unscrew 4 bolts.
2) Drill out welding spots and remove back panel.
[A] [A]
[B] [B]
(2) 2
(1) 3 (1) 2 (1) 2 (1) 3
(1) (1) (1) (1) (1) (1)

[A] [A]
(2) (2)
[B] [B]
(3) (9) (1) (1) (5) (3)

(1) (1)
(4)
(1) (1)
(1) (1) (3) (1) (6) (4) (2) (2) (5) (1) (3) (1) (1)
(2) (2)
(2)
IFL80B9B0002-01
[A] [B]
(2) (2) 1
(3)
(1)
IBL80A9B0254-01
1: This symbol indicates that back panel and rear lamp house outer panel are replaced at the same time.
2: This symbol indicates that back panel and rear floor panel are replaced at the same time.
3: This symbol indicates that back panel and rear floor side rear member are replaced at the same time.
4: When heating around adhesive application portion to detach adhesive, be sure that temperature of said portion does not reach 170 °C (338 °F).
Installation
NOTE
• Before conducting any weld, check installation position and condition for installation part(s). 
• Proceed repair while taking into consideration installation of parts that affect appearance. 
1) Apply adhesive.
2) Install back panel, tighten 4 bolts temporarily and adjust position relative to adjoining parts.
3) Conduct resistance spot weld and plug weld.
4) Tighten 4 bolts to specified torque.
[A] [A]
(2) 1 (2) 1
[B] [B]
(2) 2
(1) 4 (1) 4
(1) 3 (1) 2 (1) 2 (1) 3
(2) 2
(1) (1) (1) (1) (1) (1)

[A] [A]
(2) (2)
[B] [B]
(3) (9) (1) (1) (5) (3)

(1) (1)
(4)
(1) (1)
(1) (1) (3) (1) (6) (4) (2) (5) (1) (3) (1) (1)
(2)
(2) (2)
(2)
IFL80B9B0003-01
[A] [B]
(2) (2) 1
(3)
(a)
(1)
IBL80A9B0256-01
1: This symbol indicates that back panel and rear lamp house inner lower panel are replaced at the same time.
2: This symbol indicates that back panel and rear floor panel are replaced at the same time.
3: This symbol indicates that back panel and rear floor side rear member are replaced at the same time.
4: This symbol indicates that back panel and rear floor side extension are replaced at the same time.
: 8.8 Nm (0.90 kgf-m, 6.5 lbf-ft)
Roof Panel Removal and Installation

AENFL80B9B06021
NOTE
The figure below shows condition where the following parts are removed.
• Front fender 
IBL80A9B0282-01
Removal
1) Drill out welding spots and remove roof panel.
(5)
(5) (4) (2) (12)
(8)
(2)
[A]
(17)
(2)
(8)
(4) (2) (12)
(5)
(5)
IFL80B9B0005-01
[A]
[B]
(6)
(3) (6) (6) (3)
(4) (4)
(9)
IBL80A9B0284-01
[B]: Vehicle forward

1. If equipped
: When heating around sealer application portion to detach body sealer, be sure that temperature of said portion does not reach 170 °C (338 °F).
Installation
NOTE
Before conducting any weld, check installation position and condition for installation part(s).  / 
1) Conduct tack welding to roof panel center No. 2 member, roof panel center No. 3 member, roof panel center No. 4
member and roof panel center No. 5 member.
2) Apply body sealer.
IFL80B9B0006-01
1. If equipped
3) Install roof panel.

4) Conduct resistance spot weld and plug weld.
(1) (1) (3)

(4) (2) (2) (4) (2) (3) (2) (5) (2) (5) (1) (1)
(2)
(1)
[A]
(11)
(1)
(2)
(2) (5) (1) (1)
(2) (2) (3) (2) (5)
(2) (4)
(4)
(1) (1) (3)
IBL80A9B0286-01
[A]
[B]
(1) (4)
(1)
(3) (5) (5) (3)
(1) (3) (2) (2) (3) (1)

(7)
IBL80A9B0287-01
[B]: Vehicle forward

: Conduct resistance spot weld as three panel thickness.
Specifications
AENFL80B9B07002
Reference:
“Back Panel Removal and Installation”:
Audio Visual / Navigation: 9O-1
Audio Visual / Navigation


Audio System Circuit Diagram
AENFL80B9F02001
2
1
3
GRY G248-4 RED RED +
G248-1 G248-14 YEL YEL - 15
4 LT BLU G248-9
RED +
- 16
YEL
7 G267-1
BLK G267-2
[A]
22 WHT +
BLU - 18
23 RED G243-2
G248-3 PNK WHT +
PPL G243-3 17
G248-13 BLU BLU -
9 PPL G248-18
G248-6 RED PPL +
10 19
RED G248-2 G248-16 GRY LT BLU -
11 PPL G248-12
G248-5 LT GRN GRN +
GRN - 20
G248-15 BRN
12
ORN G248-19 G231-2 PNK
13
PNK G248-20 G231-3 BLU 5
G231-4 YEL
PPL
[A] G231-3 LT BLU
RED G231-1 LT BLU
14 G221-1
YEL G248-8 G221-2
G221-3
G221-4
[B]
BLK BLK BLK G232-1 G248-11 BLK

RED RED RED G232-3 6
21
WHT WHT WHT G232-4
G202-1 BLK
G232-2 G202-2 BLK
BLK GRY GRY G232-5 G202-5 GRN
G202-6 WHT
G202-7 RED
IFL80B9F0004-01
[A]: For navigation Unit 8. Radio antenna 17. Front speaker (L)
[B]: With rear view camera 9. To BCM 18. Front tweeter (L) (if equipped)
1. Audio unit (if equipped) 10. To tail light relay 19. Rear speaker (R) (if equipped)
2. Junction block 11. Combination meter 20. Rear speaker (L) (if equipped)
3. “RADIO” fuse 12. Contact coil 21. Rear view camera
4. “ACC” fuse 13. Steering switch (audio control switch) (if equipped) 22. GPS antenna
5. Microphone (if equipped) 14. Steering switch (hands free switch) (if equipped) 23. To back up light switch (M/T model)
6. AUX (if equipped) 15. Front speaker (R)
7. Radio antenna amplifier 16. Front tweeter (R) (if equipped)
9O-2 Audio Visual / Navigation:
Component Location
Audio System Component Location
AENFL80B9F03001
3
4
12 3
6 7
1 8
9
10
11
IFL80B9F0003-02
1. Front speaker 5. Radio antenna feeder cable (roof) 9. Steering switch (audio control switch)
2. Rear speaker 6. Radio antenna feeder cable (instrument panel) 10. Steering switch (Hands-free switch)
3. Tweeter 7. Audio/Navigation unit 11. Rear-view camera
4. Radio antenna 8. USB / AUX socket 12. GPS antenna

Audio System Inspection
AENFL80B9F04001
1) Remove audio unit (with connector connected). (Page 9O-7)
2) Check voltage using circuit tester and oscilloscope.
NOTE
[A] [B] [C] [D]
[a] 10 9 8 7 6 5 4 3 2 1
2 1 5 4 3 2 1
4 3 2 1 20 19 18 17 16 15 14 13 12 11 3
[F]
[E]
5 4 3 2 1 4 3 2 1
8 7 6 5
IEAD0A9F0005-01
[A]: “G231” connector (microphone (if equipped)) (View: [a]) [D]: “G232” connector (rear-view camera (if equipped)) (View: [a])
[B]: “G248” connector (audio / navigation unit) (View: [a]) [E]: “G243” connector (navigation unit) (View: [a])
[C]: “G267” connector (radio antenna feeder) (View: [a]) [F]: “G202” connector (AUX) (View: [a])
[A] “G231” connector (Microphone in audio unit without navigation (if equipped))
Terminal Normal
No. voltage
— Audio: “ON”
2* PNK Microphone signal Refer to reference waveform.
“Speaker / microphone wave” (Page 9O-6)
Ignition: “OFF”, “ACC” or
3 BLU Ground for microphone Approx. 0 V
“ON”
4 YEL Power source for microphone Approx. 5 V Ignition: “ACC” or “ON”
[A] “G231” connector (Microphone with audio unit with navigation (If equipped))
Terminal Normal
No. voltage
1 LT BLU Ground for microphone Approx. 0 V
“ON”
— Audio: “ON”
2* PNK Microphone signal Refer to reference waveform.
3 LT BLU Ground for microphone Approx. 0 V
“ON”
4 YEL Power source for microphone Approx. 5 V Ignition: “ACC” or “ON”
[B] G248 connector (Audio unit without navigation)

Terminal Normal
No. voltage
1 WHT Power source Approx. 12 V
“ON”
Approx. 12 V When clearance light is on
2 RED Power source (illumination)
— Audio: “ON”
3* PNK Front speaker (L) (+), tweeter (L) (+) Refer to reference waveform.
— Audio: “ON”
4* RED Front speaker (R) (+), tweeter (R) (+) Refer to reference waveform.
— Audio: “ON”
5* LT GRN Rear speaker (L) (+) Refer to reference waveform.
— Audio: “ON”
6* RED Rear speaker (R) (+) Refer to reference waveform.
8 YEL Steering switch (Hands-free switch) Approx. 3.3 V Ignition: “ACC” or “ON”
9 LT BLU Power source (ACC) Approx. 12 V Ignition: “ACC” or “ON”
Terminal Normal
No. voltage
11 BLU Ground for audio unit Approx. 0 V
“ON”
Refer to “Inspection of Combination Meter
12 PPL Illumination signal
and Its Circuits” in Section 9C (Page 9C-19)
— Audio: “ON”
13* BLU Front speaker (L) (–), tweeter (L) (–) Refer to reference waveform.
— Audio: “ON”
14* YEL Front speaker (R) (–), tweeter (R) (–) Refer to reference waveform.
— Audio: “ON”
15* GRN Rear speaker (L) (–) Refer to reference waveform.
— Audio: “ON”
16* GRY Rear speaker (R) (–) Refer to reference waveform.
Refer to “Inspection of BCM and Its Circuits”
18* PPL Vehicle speed signal in Section 10B.
• Ignition switch model: (Page 10B-20)
19 ORN Steering switch (audio control switch) Approx. 3.3 V Ignition: “ACC” or “ON”
20 PNK Ground for steering switch Approx. 0 V
“ON”
[B] G248 connector (Navigation Unit)

Terminal Normal
No. voltage
1 WHT Power source Approx. 12 V
“ON”
Approx. 12 V When clearance light is on
2 RED Power source (illumination)
— Audio: “ON”
3* PNK Front speaker (L) (+), tweeter (L) (+) Refer to reference waveform.
— Audio: “ON”
4* RED Front speaker (R) (+), tweeter (R) (+) Refer to reference waveform.
— Audio: “ON”
5* LT GRN Rear speaker (L) (+) Refer to reference waveform.
— Audio: “ON”
6* RED Rear speaker (R) (+) Refer to reference waveform.
8 YEL Steering switch (Hands-free switch) Approx. 3.3 V Ignition: “ACC” or “ON”
9 LT BLU Power source (ACC) Approx. 12 V Ignition: “ACC” or “ON”
11 BLU Ground for audio unit Approx. 0 V
“ON”
Refer to “Inspection of Combination Meter
12 PPL Illumination signal
and Its Circuits” in Section 9C (Page 9C-19)
— Audio: “ON”
13* BLU Front speaker (L) (–), tweeter (L) (–) Refer to reference waveform.
— Audio: “ON”
14* YEL Front speaker (R) (–), tweeter (R) (–) Refer to reference waveform.
— Audio: “ON”
15* GRN Rear speaker (L) (–) Refer to reference waveform.
Terminal Normal
No. voltage
— Audio: “ON”
16* GRY Rear speaker (R) (–) Refer to reference waveform.
Refer to “Inspection of BCM and Its Circuits”
in Section 10B.
18* PPL Vehicle speed signal • Ignition switch model: (Page 10B-20)
• Keyless push start system:(Page 10B-
27)
19 GRN Steering switch (audio control switch) Approx. 3.3 V Ignition: “ACC” or “ON”
20 PNK Ground for steering switch Approx. 0 V
“ON”
[C] G267 connector (radio antenna feeder)

Terminal Normal
No. voltage
1 BLK Power source for radio antenna amplifier Approx. 12 V Audio: “ACC” or “ON”
2 BLK Radio antenna amplifier signal — —
Radio antenna amplifier shield ground Ignition: “OFF”, “ACC” or
3 — Approx. 0 V
circuit “ON”
[D] “G232” connector (Rear-view camera (If equipped))

Terminal Normal
No. voltage
1 BLK Ground for rear-view camera Approx. 0 V
“ON”
2 WHT Ground for rear-view camera Approx. 0 V
“ON”
Audio: “ON”
—
Shift lever: reverse position
3* RED Rear-view image signal input
“Rear view image signal” (Page 9O-6)
Audio: “ON”
4 BLK Power source for rear-view camera Approx. 6 V
5 BLK Ground for rear-view camera Approx. 0 V
“ON”
[E] “G243” connector (Navigation unit)

Terminal Normal
No. voltage
Audio: “ON”
1 LT GRN Parking switch Approx. 6 V
Ignition: “ON”
Approx. 0 V
2 RED Back up light switch Shift lever: reverse position
Refer to “Inspection of BCM and Its Circuits
(Ignition Switch Model)” in Section 10B (Page
3* PPL Vehicle speed signal 10B-20)“Inspection of BCM and Its Circuits
(Keyless Push Start Model)” in Section 10B
(Page 10B-27).
[F] “G202” connector (AUX if equipped)

Terminal Wire color Circuit Normal Condition
No. voltage
1 BLK AUX L-channel input Approx. 1 V→ Ignition: “ACC” or “ON”
0V
Approx. 0 V Ignition: “OFF”
2 BLK Ground for AUX Ignition: “OFF”, “ACC” or “ON”
5 GRN AUX R-channel input Approx. 1 V→

Ignition: “ACC” or “ON”
0V
6 WHT AUX GND Approx. 0 V Ignition: “OFF” “ACC” or “ON”
7 RED AUX-DET Approx. 1 V→ Ignition: “ACC” or “ON”
0V
Reference Waveform Rear view image signal

Oscilloscope display Channel Probe Terminal No.
Shown below is typical waveform display provided by + G232-3
1
oscilloscope. – G232-5
NOTE Speaker signal
• Display includes the following types of Channel Probe Terminal No.
data: Front speaker (L): G248-3
Front speaker (R): G248-4
+
Rear speaker (L): G248-5
Rear speaker (R): G248-6
1
Front speaker (L): G248-13
Front speaker (R): G248-14
–
Rear speaker (L): G248-15
Rear speaker (R): G248-16
• Audio: ON
I8T201111007-03

[b]: Ground level of each channel [d]: TIME/DIV

Speaker / microphone wave IAW1019F0005-02
NOTE 1. Speaker / microphone signal
Voltage changes depending on sound

volume and quality.
Microphone signal
+ G231-2
1
– G231-3
Audio System Symptom Diagnosis

AENFL80B9F04002
Before performing the following troubleshooting, check if the symptom is not caused by incorrect handling while
referring to owner’s manual.
If the cause cannot be identified by the following troubleshooting, replace audio unit with a known-good one. If the
symptom is cleared, audio unit is the cause.
Audio unit cannot turn ON Faulty audio connector Check audio connectors for connection.
Faulty audio power supply and ground Refer to “Audio System Circuit Diagram” (Page
circuit (including fuse) 9O-1) and “Audio System Inspection” (Page
9O-2).

Poor radio reception Faulty radio antenna connector Check radio antenna connectors for
connection.
Faulty radio antenna Substitute a known-good radio antenna and
recheck reception.
Faulty radio antenna feeder cable Refer to “Radio Antenna Feeder Cable
Inspection” in related manual.
Faulty radio antenna power supply Refer to “Audio System Circuit Diagram” (Page
circuit 9O-1) and “Audio System Inspection” (Page
9O-2).
No sound from speaker Faulty speaker connector Check speaker connectors for connection.
Faulty speaker circuit Refer to “Audio System Circuit Diagram” (Page
9O-1) and “Audio System Inspection” (Page
9O-2).
Light mode does not Faulty illumination power supply and Refer to “Audio System Circuit Diagram” (Page
change when lighting ground circuit (including fuse) 9O-1) and “Audio System Inspection” (Page
switch is turned on 9O-2).
Audio system is Faulty audio control switch connector Check steering switch connectors for
operative, but audio connection.
control switch does not Faulty audio control switch Refer to “Steering Switch (Audio Control
control audio system Switch and Hands-Free Switch) Removal and
Installation (If Equipped)” (Page 9O-7).
Faulty audio control switch circuit Refer to “Audio System Circuit Diagram” (Page
9O-1).
Repair Instructions
Audio/Navigation Unit Removal and Installation Navigation Unit (If equipped)
(If equipped)
AENFL80B9F06001
Removal
2) Remove center ventilation louver. (Page 9C-24)
3) Remove audio unit or the navigation unit (1) from
instrument panel by removing two mounting screws
(2).
4) Disconnect audio unit connectors (3).
Audio Unit (if equipped)
3
A
2
1 A
A A
2
2
IFL80B9F0002-02
A
A
Installation
Reverse removal procedure.
A A
A
1 Steering Switch (Audio Control Switch and
Hands-Free Switch) Removal and Installation (If
I9P60A9F0004-03
Equipped)
AENFL80B9F06013
Removal
1) Remove steering wheel referring to “Steering Wheel
Removal and Installation” in Section 6B (Page 6B-3).
2) Remove screws and disconnect connector (1).

3) Remove steering wheel cover (2) and hands-free [A]
[2]
switch (3) (if equipped) from steering wheel. [1]
6 5 4 3 2 1
4) Remove audio control switch (4) and cruise control 11 12 10 4
12 11 10 9 8 7
switch (5) (if equipped) from steering wheel.
[d]
[a]
[e]
[b]
[B]
2 [f]
4 [c]
5
14 13
16 15
[A] [3]
3 12
1 [a] [b] [c] [d] [e] [f]
[B]
11
15
IDAA0A9F0012-01
16
Installation 4 13
Reverse removal procedure. 10
8 14
I9P60A9F0023-01
Steering Switch (Audio Control Switch and
Hands-Free Switch) Inspection (If Equipped) [A]: Steering switch connector (to contact coil)
AENFL80B9F06012 [B]: Steering switch connector (to hands-free switch)
1) Remove driver air bag (inflator) module. (Page 8B- [1]: Without cruise control switch and hands-free switch
49) [3]: Audio control switch
2) Disconnect steering switch connector.

Audio control switch resistance
3) Measure resistance between the following terminals
Terminal
under each condition in the table. Resistance Measurement condition
position
4) Check for continuity between the following terminals. 12 – 11 56 ± 0.6 Ω Mute switch [a]: ON
• For vehicles not equipped with hands-free switch: 131 ± 1.3 Ω Volume switch [b]: ON
between terminals “4” and “10” 241 ± 2.4 Ω Volume switch [c]: ON
• For vehicles equipped with hands-free switch: 421 ± 4.2 Ω Mode switch [d]: ON
between connectors [A] and [B] 751 ± 7.5 Ω Seek switch [e]: ON
1571 ± 15.7 Ω Seek switch [f]: ON
NOTE 5171 ± 51.7 Ω Except above
Set tester at diode range when measuring
between terminals 4 and 10, 4 and 13, 10 and 6) Measure resistance between the following terminals
16, 13 and 16. under each condition in the table.
7) Check for continuity between terminals “2” and “3”.
5) If check result is not as specified, replace audio
control switch. NOTE
Set tester at diode range when measuring
between terminals 2 and 3.
8) If check result is not as specified, replace hands-free

switch.
[A]
1
2 1
4 3
[a] [b] [c]

[1]
3 2
4
[a] [b] [c]
1
IDAA0A9F0013-01
I9P60A9F0024-01
[A]: Hands-free switch connector [1]: Hands-free switch Installation

Hands-free switch resistance
Terminal
Resistance Measurement condition
position
56 ± 0.6 Ω Talk switch [a]: ON
241 ± 2.4 Ω Off hook switch [b]: ON
1–4
751 ± 7.5 Ω On hook switch [c]: ON
5151 ± 51.7 Ω Except above
GPS Antenna Removal and Installation

AENFL80B9F06011
Removal
2) Remove navigation unit. (Page 9O-7)
3) Remove combination meter cluster panel. (Page
9C-24)
4) Remove screw (3) and then remove GPS antenna
(1) from the instrument panel (2)
IFL80B9F0001-02
Section 10
Control Systems
CONTENTS
NOTE
Precautions ...............................................10-1 DTC U0100 ....................................................... 10B-*

Precautions........................................................... 10-1 DTC U0101 .....................................................10B-20
Precautions for Control Systems......................... 10-1 DTC U0141 .....................................................10B-20
DTC U0151 ....................................................... 10B-*
Body Electrical Control System ........... 10B-1 DTC U0155 .....................................................10B-20
Precautions......................................................... 10B-* DTC U0164 ....................................................... 10B-*
Precautions for Diagnosing Trouble...................10B-* DTC U1082 .....................................................10B-20
Precautions for Replacing Ignition Key Inspection of BCM and Its Circuits (Ignition
(Ignition Switch Model).....................................10B-* Switch Model)................................................10B-20
Precautions for Transmitter Disposal (Ignition Inspection of BCM and Its Circuits (Keyless
Switch Model) ..................................................10B-* Push Start Model) .........................................10B-27
Precautions for Replacing BCM (Ignition Repair Instructions ..........................................10B-34
Switch Model) ..................................................10B-* Ignition Key Registration (Ignition Switch
General Description ...........................................10B-1 Model) ...........................................................10B-34
BCM General Description ................................. 10B-1 BCM Registration (Ignition Switch Model).......10B-34
Security System Description (Ignition Switch BCM Removal and Installation (Ignition
Model) ..............................................................10B-* Switch Model).................................................. 10B-*
CAN Communication System Description..........10B-* BCM Removal and Installation (Keyless Push
Start Model)...................................................10B-34
Schematic and Routing Diagram......................10B-2
Outside Air Temperature Sensor Removal
BCM Input / Output Diagram............................. 10B-2
and Installation ................................................ 10B-*
Body Electrical Control System Circuit
Outside Air Temperature Sensor Inspection ..... 10B-*
Diagram .......................................................... 10B-4
Transmitter Battery Replacement (Ignition
Component Location .........................................10B-8
Switch Model).................................................. 10B-*
BCM and Related System Component
Hood Latch Switch Removal and Installation.... 10B-*
Location .......................................................... 10B-8
Hood Latch Switch Inspection........................... 10B-*
Control Relay Component Location .................. 10B-8
Siren Removal and Installation ......................... 10B-*
Diagnostic Information and Procedures........10B-10 Siren Inspection ................................................ 10B-*
Body Electrical Control System Check...............10B-* Security Alarm Mode Selection Procedure ....... 10B-*
BCM Self-Diagnosis Function ............................10B-* Shock Sensor Mode Selection Procedure ........ 10B-*
DTC Check ..................................................... 10B-10 Shock Sensor Full Blast Sensitivity Level
DTC Clearance ............................................... 10B-10 Selection Procedure........................................ 10B-*
DTC Table....................................................... 10B-11 Shock Sensor Pre-Warn Sensitivity Level
Fail-Safe Table................................................ 10B-12 Selection Procedure........................................ 10B-*
Scan Tool Data ............................................... 10B-12 Shock Sensor Removal and Installation ........... 10B-*
Scan Tool Active Test Table ........................... 10B-14 Control Relay Inspection .................................10B-35 10
Scan Tool Utility Table .................................... 10B-15
Specifications...................................................10B-36
DTC B1120 / B1132 ........................................ 10B-15
Tightening Torque Specifications....................10B-36
DTC B1122 ..................................................... 10B-16
Special Tools and Equipment .........................10B-36
DTC B1133 ..................................................... 10B-17
Special Tool ....................................................10B-36
DTC B1141 / B1142 ........................................ 10B-17
DTC B1145 / B1146 ........................................ 10B-19 Immobilizer Control System ................. 10C-1
DTC B1157 ..................................................... 10B-20
Ignition Switch Model ...........................................10C-1
DTC B1158 / B1159 ...........................................10B-*
DTC U0073 ........................................................10B-* Precautions......................................................... 10C-*
Precautions for Diagnosing Trouble.................. 10C-*
Precautions for Immobilizer System.................. 10C-* DTC P1611 .......................................................10C-7

General Description ........................................... 10C-* DTC P1622 .......................................................10C-8
Immobilizer Control System Introduction .......... 10C-* DTC P1642 / P1646 ..........................................10C-8
CAN Communication System Description......... 10C-* DTC P1644 .......................................................10C-9
Schematic and Routing Diagram...................... 10C-* DTC B1167 .....................................................10C-10
Immobilizer Control System Circuit Diagram .... 10C-* DTC B1168 .....................................................10C-11
Component Location ......................................... 10C-* DTC B1169 .....................................................10C-11
Immobilizer Control System Component DTC B1173 .....................................................10C-12
Location .......................................................... 10C-* DTC B1175 .....................................................10C-12
DTC B1176 .....................................................10C-13
Diagnostic Information and Procedures..........10C-1
DTC B1189 .....................................................10C-13
Immobilizer Control System Check ................... 10C-*
Immobilizer Control System Self-Diagnosis Repair Instructions ..........................................10C-14
Function .......................................................... 10C-* Engine Switch Removal and Installation .........10C-14
DTC Check........................................................ 10C-* Remote Controller Registration .......................10C-14
DTC Clearance ................................................. 10C-* ECM Registration ............................................10C-14
DTC Table......................................................... 10C-* Keyless Start Control Module Registration .....10C-14
DTC P1610 ....................................................... 10C-*
Keyless Start System ............................ 10E-1
DTC P1611 ....................................................... 10C-*
DTC P1622 ....................................................... 10C-* Precautions.........................................................10E-1
DTC P1642 / P1646 .......................................... 10C-* Precautions for Diagnosing Trouble..................10E-1
DTC P1644 ....................................................... 10C-* Precautions for Replacing Remote Controller ...10E-1
DTC B1167 ....................................................... 10C-* Precautions for Remote Controller Disposal .....10E-1
DTC B1168 ....................................................... 10C-* Precautions for Replacing Keyless Start
DTC B1169 ....................................................... 10C-* Control Module................................................10E-1
DTC B1170 ....................................................... 10C-* General Description ...........................................10E-1
DTC B1173 ....................................................... 10C-* Security System Description (Keyless Push
DTC B1175 ....................................................... 10C-* Start Model).....................................................10E-1
DTC B1176 ....................................................... 10C-* Keyless Start System (Keyless Push Start
DTC B1188 ....................................................... 10C-* System) Description ........................................10E-1
DTC B1189 .......................................................10C-1 Description of Keyless Start System Parts
DTC B1190 ....................................................... 10C-* and Functions..................................................10E-2
Repair Instructions ............................................ 10C-* Description of Keyless Start System Door
Immobilizer Control Module Removal and Lock Function..................................................10E-3
Installation ....................................................... 10C-* Description of Keyless Engine Start Function ...10E-5
Ignition Key Registration ................................... 10C-* Description of Keyless Start System Alarm
ECM Registration .............................................. 10C-* Function ..........................................................10E-7
BCM Registration .............................................. 10C-* CAN Communication System Description.........10E-8
Keyless Push Start Model ....................................10C-3 Schematic and Routing Diagram ......................10E-9
Keyless Start Control Module Input / Output
Precautions.........................................................10C-3
Diagram...........................................................10E-9
Precautions for Diagnosing Trouble..................10C-3
Keyless Start System Electric Circuit Diagram 10E-10
General Description ...........................................10C-3
Component Location .......................................10E-12
Immobilizer Control System Introduction ..........10C-3
Keyless Start System Component Location ....10E-12
Description of Ignition Mode Switching
Procedure .......................................................10C-3 Diagnostic Information and Procedures ........10E-14
Description of Engine Starting Procedure .........10C-3 Keyless Start System Check...........................10E-14
CAN Communication System Description.........10C-4 Keyless Start Control Module Self-Diagnosis
Function ........................................................10E-14
Schematic and Routing Diagram......................10C-4
DTC Check......................................................10E-14
Immobilizer Control System Circuit Diagram ....10C-4
DTC Clearance ...............................................10E-15
Component Location .........................................10C-4
DTC Table.......................................................10E-16
Immobilizer Control System Component
Fail-Safe Table................................................10E-18
Location ..........................................................10C-4
Scan Tool Data ...............................................10E-19
Diagnostic Information and Procedures..........10C-6 Scan Tool Active Test Table ...........................10E-20
Immobilizer Control System Check ...................10C-6 Scan Tool Utility Table ....................................10E-21
Immobilizer Control System Self-Diagnosis DTC B1102 / B1103 / B1105 / B1106 / B1107 10E-21
Function ..........................................................10C-6 DTC B1120 / B1170 ........................................10E-23
DTC Check........................................................10C-6 DTC B1122 .....................................................10E-23
DTC Clearance .................................................10C-6 DTC B1123 .....................................................10E-24
DTC Table.........................................................10C-6 DTC B1134 .....................................................10E-24
DTC P1610 .......................................................10C-7
DTC B1158 / B1159 ........................................ 10E-25 Special Tools and Equipment .........................10E-56
DTC B1160 ..................................................... 10E-26 Special Tool ....................................................10E-56
DTC B1161 / B1163 ........................................ 10E-28
DTC B1162 ..................................................... 10E-29 Communication System........................ 10H-1
DTC B1180 / B1181 / B1182 .......................... 10E-31 Petrol and Bi-Fuel CNG Model .............................10H-1
DTC B1190 ..................................................... 10E-32 Precautions.........................................................10H-1
DTC B1191 ..................................................... 10E-34 Precautions for Diagnosing Trouble..................10H-1
DTC B1192 ..................................................... 10E-36 General Description ...........................................10H-1
DTC B1193 ..................................................... 10E-38 Communication System Description .................10H-1
DTC B1194 ..................................................... 10E-40 CAN Communication System Diagnosis
DTC B1461 ..................................................... 10E-41 General Description ........................................10H-2
DTC U0073 ..................................................... 10E-42 CAN Communication System Transmitting
DTC U0100 ..................................................... 10E-42 and Receiving Data Table...............................10H-4
DTC U0101 ..................................................... 10E-42 Schematic and Routing Diagram ......................10H-7
DTC U0121 ..................................................... 10E-42 CAN Communication System Circuit Diagram ..10H-7
DTC U0140 ..................................................... 10E-42
Component Location .........................................10H-9
DTC U0155 ..................................................... 10E-42
CAN Communication System Component
Inspection of Keyless Start Control Module
Location...........................................................10H-9
and Its Circuits .............................................. 10E-43
Diagnostic Information and Procedures ........10H-10
Repair Instructions .......................................... 10E-49
CAN Communication Check ...........................10H-10
Remote Controller Registration....................... 10E-49
CAN DTC (Lost Communication and
Switching Procedure for Disabling / Enabling
Communication Bus Off) Table .....................10H-10
Keyless Start System .................................... 10E-50
Troubleshooting for Lost Communication .......10H-12
Keyless Start Control Module Registration ..... 10E-50
Troubleshooting for Communication Bus Off ..10H-19
Keyless Start Control Module Removal and
Installation..................................................... 10E-50 Special Tools and Equipment .........................10H-26
Driver Side / Passenger Side Outside Special Tool ....................................................10H-26
Antenna and Door Request Switch Removal Diesel Model ........................................................10H-27
and Installation.............................................. 10E-50 Precautions.......................................................10H-27
Rear End Door Request Switch Removal and Precautions for Diagnosing Trouble................10H-27
Installation..................................................... 10E-51 General Description .........................................10H-27
Rear Outside Antenna Removal and Communication System Description ...............10H-27
Installation..................................................... 10E-51 CAN Communication System Diagnosis
Mid Inside Antenna Removal and Installation . 10E-51 General Description ......................................10H-29
Rear Inside Antenna Removal and Installation 10E-51 CAN Communication System Transmitting
Request Switch Inspection.............................. 10E-52 and Receiving Data Table.............................10H-31
Antenna Inspection ......................................... 10E-52 Schematic and Routing Diagram ....................10H-33
Driver / Passenger Door Lock Switch CAN Communication System Circuit Diagram 10H-33
Removal and Installation............................... 10E-53 Component Location .......................................10H-35
Driver / Passenger Door Lock Switch CAN Communication System Component
Inspection...................................................... 10E-53 Location.........................................................10H-35
Engine Switch Removal and Installation ......... 10E-53 Diagnostic Information and Procedures ........10H-36
Engine Switch Inspection ................................ 10E-53 CAN Communication Check ...........................10H-36
Hood Latch Switch Removal and Installation.. 10E-53 CAN DTC (Lost Communication and
Hood Latch Switch Inspection......................... 10E-53 Communication Bus Off) Table .....................10H-36
Siren Removal and Installation ....................... 10E-53 Troubleshooting for Lost Communication .......10H-38
Siren Inspection .............................................. 10E-53 Troubleshooting for Communication Bus Off ..10H-45
Security Alarm Mode Selection Procedure ..... 10E-53 Communication Check ....................................10H-50
Shock Sensor Mode Selection Procedure ...... 10E-54 Judgment of Communication Bus Check ........10H-51
Shock Sensor Full Blast Sensitivity Level
Special Tools and Equipment .........................10H-51
Selection Procedure...................................... 10E-54
Special Tool ....................................................10H-51
Shock Sensor Pre-Warn Sensitivity Level
Selection Procedure...................................... 10E-54 Engine Auto Stop Start System .............10I-1
Shock Sensor Removal and Installation ......... 10E-54
Precautions.......................................................... 10I-1
Outside Warning Buzzer Removal and
Precautions for Diagnosing Trouble................... 10I-1
Installation..................................................... 10E-54
Precautions for Replacing ECM ......................... 10I-1
Outside Warning Buzzer Inspection................ 10E-55
Remote Controller Battery Replacement ........ 10E-55 General Description ............................................ 10I-1
ENG A-STOP System Description ..................... 10I-1
Specifications................................................... 10E-56
Tightening Torque Specifications.................... 10E-56
Description of ENG A-STOP System Inspection of ECM and Its Circuits ................... 10I-13
Components..................................................... 10I-2 Inspection of Gateway Control Module and Its
Description of ENG A-STOP System Alarm Circuits ........................................................... 10I-13
Function ........................................................... 10I-3 Inspection of DC/DC Converter and Its
CAN Communication System Description.......... 10I-3 Circuits ........................................................... 10I-14
LIN Communication System Description............ 10I-3 Repair Instructions ........................................... 10I-15
Schematic and Routing Diagram....................... 10I-4 ECM Removal and Installation ......................... 10I-15
ENG A-STOP System Input / Output Diagram ... 10I-4 DC/DC Converter Removal and Installation..... 10I-15
ENG A-STOP System Electric Circuit ISG Removal and Installation........................... 10I-15
Diagram ........................................................... 10I-5 Starting Motor Inspection ................................. 10I-15
Component Location .......................................... 10I-6 Neutral Position Switch Inspection................... 10I-15
ENG A-STOP System Component Location...... 10I-6 CPP No.1 Switch Removal and Installation ..... 10I-15
Diagnostic Information and Procedures........... 10I-8 CPP No.1 Switch Inspection ............................ 10I-15
ENG A-STOP System Check............................. 10I-8 CPP No.2 Switch Removal and Installation ..... 10I-15
ENG A-STOP System Self-Diagnosis CPP No.2 Switch Inspection ............................ 10I-15
Function ......................................................... 10I-10 Brake Stroke Sensor Removal and
ENG A-STOP Warning Light Check................. 10I-10 Installation ...................................................... 10I-15
DTC Check....................................................... 10I-10 Brake Stroke Sensor Inspection....................... 10I-15
DTC Clearance ................................................ 10I-11 Brake Stroke Sensor Calibration ...................... 10I-15
DTC Table........................................................ 10I-11 Brake Booster Switch Inspection ..................... 10I-15
Fail-Safe Table................................................. 10I-11 Hood Latch Switch Removal and Installation... 10I-15
Scan Tool Data ................................................ 10I-11 Hood Latch Switch Inspection.......................... 10I-15
ENG A-STOP System Symptom Diagnosis ..... 10I-11 Battery Sensor Inspection ................................ 10I-15
ENG A-STOP Warning Light Does Not Come ENG A-STOP OFF Switch Removal and
ON with Ignition “ON” and Engine Stopped Installation ...................................................... 10I-15
(but Engine Can Be Started) .......................... 10I-13 ENG A-STOP OFF Switch Inspection.............. 10I-16
ENG A-STOP Warning Light Remains ON or Special Tools and Equipment .......................... 10I-16
Blinking with Ignition “ON”.............................. 10I-13 Special Tool ..................................................... 10I-16
Precautions: 10-1
Precautions
Control Systems
Precautions
Precautions for Control Systems
AENFL80BA000001
General Precautions

Fastener Caution
Precautions for Replacing ECM

Refer to “Precautions for Replacing ECM” in “Precautions for Engine (K14B)” in Section 1 in related manual /
“Precautions for Engine (D13A)” in Section 1 in related manual.
Air Bag Warning


10B-1 Body Electrical Control System:
Body Electrical Control System

Control Systems
General Description
BCM General Description Rear Defogger Control
AENFL80BA201001 When a rear defogger switch ON or OFF signal is sent
The BCM incorporates relays and controllers which
from the HVAC control module to the BCM, it controls
constitute the following control systems.
the rear defogger relay to turn on or off the rear end door
• Turn signal light control window defogger and indicator.
• Warning buzzer control
• Door lock control (if equipped) Dome Light Control
When the dome light switch is in the door position, the
• Seat belt reminder control
BCM turns on or off the dome light as follows:
• Rear defogger control (if equipped)
• Dome light control Light ON control
• Shift lock control (A/T model) When any of the following conditions is met, the BCM
turns on the dome light.
Turn Signal Light Control • An ON signal by opening a door is sent from any one
When the turn signal switch lever is turned up or down, a of door switches to the BCM
signal is sent from the switch to the BCM. Accordingly, • Door lock actuator is unlocked by unlock signal from
the BCM operates flashing of the turn signal light. When keyless entry transmitter
turning the switch on and off momentarily in situations
• All door switches are turned off by closing all doors
such as lane changes, the BCM flashes the turn signal
and an OFF signal from the key reminder switch by
lights for a pre-set number of times.
removing ignition key from the ignition key cylinder is
sent to the BCM
Warning Buzzer Control
When any of “Key reminder function”, “Lights ON • All door switches are turned off by closing all doors
reminder function” and “Parking brake reminder function” and power door lock switch in the door is pressed in
is at work, the BCM transmits the buzzer request signal unlock direction with the ignition key removed from
to the combination meter through CAN communication. the ignition key cylinder
For details, refer to “Combination Meter Description” in
Section 9C (Page 9C-1). Light OFF control
When any of the following conditions is met, the BCM
Door Lock Control turns off the dome light.
Power door lock control • 15 seconds have elapsed from the time that after all
When a lock/unlock signal is sent from the key cylinder door switches are turned off by closing all doors
switch or power door lock switch to the BCM, the door • The door lock actuator is locked by the lock signal
lock actuator relay in the BCM is controlled to activate from the keyless entry transmitter
each door lock actuator so that each door is locked/ • All door switches are turned off by closing all doors
unlocked. and an ON signal is sent from the key reminder switch
with the ignition key remained in the ignition key
Door lock cancel control cylinder
When an air bag deployment signal is sent from the
• The battery running down protection function is
SDM to the BCM, the door lock actuator relay in the
working
BCM is controlled to unlock all door lock actuators.
• All door switches are turned off by closing all doors
Seat Belt Reminder Control and power door lock switch in the door is pressed in
The BCM judges whether the driver wears the seat belt lock direction with the ignition key removed from the
or not when vehicle is running. If the driver is not wearing ignition key cylinder
the seat belt under the specified conditions, the BCM
turns on the seat belt reminder and make the siren Battery running down protection function
sound to warn the driver. To protect the battery from unnecessary discharging, the
For details, refer to “Seat Belt Construction” in Section BCM turns off the dome light and open door warning
8A in related manual. light in the combination meter when any door is left open
for longer than 15 minutes.
Body Electrical Control System: 10B-2

BCM Input / Output Diagram
AENFL80BA202001
Input BCM Output

Outside air temperature sensor Driver, passenger, rear (R), rear (L)
(if equipped) and rear end doors lock actuators
Turn signal switch

Shift lock solenoid (A/T model)
Hazard warning switch
Driver, passenger, rear (R), rear (L) All turn signal lights
and rear end doors switch signal
Key reminder switch Turn signal light

control Rear defogger relay
Lighting switch Warning buzzer
control
Evaporator temperature sensor
Door lock control
Generator (charging switch) Seat belt reminder Vehicle speed signal (audio unit)
(D13A (without ISG) model) control
Oil pressure switch (K14B model)

Rear defogger
control
Parking brake switch Dome light Dome light
control
Brake fluid level switch
Vehicle speed
Driver seat belt buckle switch pulse output
Door key cylinder switch (if equipped) Indicator light Immobilizer control module
control
Power door lock switch (if equipped) CAN communication
Self-diagnosis
Rear defogger switch (if equipped)
ECM
A/C switch
Ignition switch signal

Combination meter
Battery
ECM
SDM
CAN communication
TCM
IFL80BA20001-03
Input BCM Output
Power door lock switch Door lock control Each door lock actuator
Lighting switch
Dome light
Turn signal switch Interior light
control
Each turn signal light
Driver seat belt buckle switch
Exterior light
Brake fluid level switch control
Rear defogger relay
Parking brake switch
Evaporator temperature sensor Rear defogger

Vehicle speed signal
control
Outside air temperature sensor
Ignition signal
Seat belt reminder
Battery control
Rear defogger switch

Indicator light
Generator (charging switch) control
(D13A (without ISG) model)
Oil pressure switch (K14B model) Warning buzzer

control
A/C switch
ECM ECM
CAN communication
ABS control module ABS control module
Combination meter Self-diagnosis Combination meter
P/S control module P/S control module
SDM Keyless start control module

CAN communication
IFL80BA20002-02
Body Electrical Control System Circuit Diagram

AENFL80BA202002
2 55
LTGRN
PPL E04-2 D G04-13 WHT
GRY E04-9
A [A]
3 L01-1 GRN
PPL G04-25 B B
LTGRN G04-24 C 27 28 29 30 31
4
WHT G04-14 L01-15 GRN/BLK
[A] 5
C
E04-1 RED
BEG L01-8 RED
32 L01-25
RED L01-21 E04-14 BLU
YEL L01-7 L01-12 BLU 33 34 35 36 37 38
6 7 8 9 10
39
11 G04-12 YEL
BLU G04-31
12 40
RED G04-30 5 [A]
13
14
GRN G04-29 G04-3 PPL 41 42
BEG G04-28 OFF
D
DOOR
15 L01-18 WHT
GRN E04-12
ON
16 A 54
G04-7 YEL
BLU E04-3 A G04-23 GRY
17 43
G04-6 GRN
LT GRN L01-22
18 A G04-22 BRN
GRN E04-10 E04-4 RED
19 A 44 E04-11 WHT
G04-2 RED 45
YEL L01-20
G04-18 WHT
[A] 47
C 46 E04-7 WHT
20 LOCK LTGRN L01-6
UNLOCK 48
BRN L01-19 E04-6 BRN
C
21 LOCK BLU L01-4 C [A]
UNLOCK 49
GRY L01-17 B L01-13 BLK/RED
50
5 G04-32 GRN
52
D D ACC
51
L01-10 WHT
22 ON
BRN G04-11
25 A
26
D L01-26 BLK
23 E04-8 GRY 53
24 WHT G04-10
:12V :5V
IFL80BA20003-01
[A]: Power door lock model 19. Driver seat belt buckle switch 38. Side turn signal light (R)
1. BCM 20. Door key cylinder switch 39. Rear defogger relay (if equipped)
2. Outside air temperature sensor (if 21. Power door lock switch 40. Rear defogger (if equipped)
equipped)
3. Turn signal switch 22. Rear defogger switch 41. Audio unit
4. Hazard warning switch 23. A/C switch 42. Dome light
5. Security controller (if equipped) 24. Blower speed selector 43. Immobilizer control module
6. Driver door switch 25. Blower motor 44. CAN driver
7. Passenger door switch 26. HVAC control unit 45. All control modules:
• K14B model: (Page 10H-7)
• D13A model: (Page 10H-33)
8. Rear door switch (R) 27. Driver door lock actuator 46. Power supply circuit
9. Rear door switch (L) 28. Passenger door lock actuator 47. “HAZ” fuse
10. Rear end door switch 29. Rear door lock actuator (R) 48. “DOME” fuse
11. Key reminder switch 30. Rear door lock actuator (L) 49. “D/L” fuse
12. Lighting switch 31. Rear end door lock actuator 50. “ACC” fuse
13. Tail light 32. Turn signal circuit 51. “MTR” fuse
14. Evaporator temperature sensor 33. Rear turn signal light (L) 52. Ignition switch
15. Generator (charging switch) (D13A 34. Front turn signal light (L) 53. Battery
(without ISG) model)
16. Oil pressure switch (K14B model) 35. Side turn signal light (L) 54. CPU
17. Parking brake switch 36. Rear turn signal light (R) 55. Shift lock solenoid (A/T model)
18. Brake fluid level switch 37. Front turn signal light (R)
2
LOCK
BLU L03-22
UNLOCK
GRY L03-21
3
PPL G05-13
L02-1 GRN
A 45 A 17 18 19 20 21
LT GRN G05-14
4 L02-2 GRN/BLK
WHT G05-15
5
PNK G05-4
8
YEL L03-9 22
9 L02-3 YEL
23
G05-32 PPL 24
BEG G05-6
10
GRN G05-24 G05-2 RED
46 25
G05-1 WHT
E05-5 RED
E05-6 WHT 26
11
BLU E05-19
51
12
PPL E05-20
LT GRN G05-19
OFF
DOOR 28
GRY E05-8 L03-13 WHT
ON
13
YEL L02-19 29
6 L02-11 BRN
35
14 37
GRN E05-18 30
L02-9 WHT
15 31
LT GRN L02-21 L02-25 YEL
36
32 37
L02-10 WHT
33
49 A L03-26 BLK/RED
50
34
L02-12 WHT
16
48 WHT G05-10
E05-1 RED
L02-13 RED
27 7
E05-13 BLU
BRN G05-26 L02-26 BLU
38 39 40 41 42 43
47
GRN E05-7 L02-14 BLK 44
L02-15 BLK
12V 5V
IFL80BA20004-01
1. BCM 18. Rear left door lock actuator 35. IG1 relay
2. Power door lock switch 19. Passenger door lock actuator 36. IG2 relay
3. Turn signal switch 20. Driver door lock actuator 37. Keyless start control module
4. Hazard warning switch 21. Rear end door lock actuator 38. Rear left turn signal light
5. Lighting switch 22. Rear defogger relay 39. Door mirror left turn signal light
6. Power supply circuit 23. Rear defogger 40. Front left turn signal light
7. Turn signal circuit 24. Audio unit 41. Rear right turn signal light
8. Tail light relay 25. P/S control module 42. Door mirror right turn signal light
9. Tail light 26. Control module: 43. Front right turn signal light
• ABS control module (Non ISG model)
• Gateway control module (ISG model)
10. Evaporator temperature sensor 27. Rear defogger switch 44. Battery
11. Oil pressure switch (K14B model) 28. Dome light 45. Door lock actuator relay
12. Outside air temperature sensor 29. “DOME” fuse 46. CAN driver
13. Driver seat belt buckle switch 30. “MTR” fuse 47. Generator (charging switch) (D13A (without
ISG model))
14. Brake fluid level switch 31. “BACK” fuse 48. Blower speed selector
15. Parking brake switch 32. “WIP” fuse 49. Blower motor
16. A/C switch 33. “D/L” fuse 50 HVAC control unit
17. Rear right door lock actuator 34. “HAZ” fuse 51 CPU
Component Location
BCM and Related System Component Location
AENFL80BA203001
2 [A] [A]
4 5
1
3
[B] 12
10
[A] 13
8
[C] 12
11
6
9
7
24
22
[A]
14
23 25
15
20 21
17
19
18 16
IFL80BA20011-02
[A]: Power door lock model 8. Individual circuit fuse box No.1 18. Parking brake switch
[B]: Door mirror turn signal light model 9. Rear turn signal light 19. Driver seat belt buckle switch
[C]: Without door mirror turn signal light model 10. Generator (D13A model) 20. A/C switch
1. Dome light 11. Front turn signal light 21. Rear defogger switch
2. Oil pressure switch (K14B model) 12. Side turn signal light 22. Evaporator temperature sensor
3. Brake fluid level switch 13. Door switch (ignition switch model) 23. Shift lock solenoid (A/T model)
4. Front door lock actuator (driver side: 14. Power door lock switch 24. Lighting switch (included in turn signal switch)
Incorporated in key cylinder switch)
5. Rear door lock actuator 15. BCM 25. Key reminder switch (included in ignition switch)
6. Rear end door lock switch and actuator 16. J/B
7. Outside air temperature sensor (if 17. Hazard warning switch
equipped)
Control Relay Component Location

AENFL80BA203002
[A] [B]
1
1 2
6 3
3
6 2 4 5 4
7 5
7
8
17 8
16
15
11
10
13 14 12
9
IFL80BA20014-02
[A]: K14B model 6. Radiator cooling fan relay No.2 13. IG1 relay
[B]: D13A model 7. Radiator cooling fan relay No.1 14. IG2 relay
1. Radiator cooling fan relay No.3 8. Front fog light relay (if equipped) 15. Tail light relay
2. Main relay 9. Heater relay (if equipped) 16. J/B
3. A/C compressor relay 10. ACC relay 17. Individual circuit fuse box No. 1
4. Starting motor relay 11. Horn relay
5. Fuel pump relay 12. Rear defogger relay (if equipped)

DTC Check DTC Clearance
AENFL80BA204003 AENFL80BA204004
1) Set ignition “OFF”. 1) Set ignition “OFF”.
2) Connect SUZUKI scan tool to DLC (1). 2) Connect SUZUKI scan tool to DLC (1).
Special tool Special tool
(A): SUZUKI scan tool (Suzuki SDT-II) (A): SUZUKI scan tool (Suzuki SDT-II)
3) Set ignition “ON”. 3) Set ignition “ON”.
4) Read DTC according to instructions displayed on 4) Clear DTC according to instructions displayed on
SUZUKI scan tool and print it or write it down. Refer SUZUKI scan tool. Refer to Operator's Manual of
to Operator's Manual of SUZUKI scan tool for further SUZUKI scan tool for further details.
details.
NOTE
NOTE If communication between SUZUKI scan tool
If communication between SUZUKI scan tool and BCM is not possible, perform the
and BCM is not possible, perform the following checks:
following checks: • Check communication condition between
• Check communication condition between PC and VCI (2) using SUZUKI scan tool
PC and VCI (2) using SUZUKI scan tool function.
function. • Check DLC power circuit and ground
circuit. • Check DLC cable. If necessary, check DLC
• Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC
cable by substituting a known-good DLC cable.
cable. • Check CAN communication system.
• Check CAN communication system. (“Control Module Communication Bus Off”
(“Control Module Communication Bus Off” is detected in any control module.) (Page
is detected in any control module.) (Page 10H-45)
10H-45) • Check BCM power circuit and ground
• Check BCM power circuit and ground circuit.
circuit. – Ignition switch model: (Page 10B-20)
– Ignition switch model: (Page 10B-20) – Keyless push start model: (Page 10B-
– Keyless push start model: (Page 10B- 27)
27)
1
1
(A)
(A)
IFL80B450002-04
IFL80B450002-04 5) After completing DTC clearance, set ignition “OFF”

5) After completing the check, set ignition “OFF” and and disconnect SUZUKI scan tool from DLC.
DTC Table
AENFL80BA204005
NOTE
• History DTC of the DTC with “*1” is not memorized.
• *2: Applicable to ignition switch model.
• *3: Applicable to keyless push start model.
• *4: Applicable to A/T model.

B1120 (*1, *3)
BCM Internal Defect BCM internal failure.
(Page 10B-15)
B1122 (*2) Measured voltage of backup power supply circuit is
BCM Backup Power Supply Malfunction
(Page 10B-16) lower than specified value for specified time.
B1132 (*3)
5V System Voltage too Low BCM internal failure.
(Page 10B-15)
Backup power supply circuit voltage from “DOME”
B1133 (Page
Battery Voltage too High fuse is continuously higher than 16.0 V for specified
10B-17)
time.
B1141 (Page Outside Air Temperature (Ambient Outside air temperature sensor signal circuit voltage is
10B-17) Temperature) Sensor Circuit Open higher than 4.85 V for specified time continuously.
Outside Air Temperature (Ambient
B1142 (Page Outside air temperature sensor signal circuit voltage is
Temperature) Sensor Circuit Short to
10B-17) lower than 0.15 V for specified time continuously.
Ground
B1145 (Page A/C Evaporator Temperature Sensor Evaporator temperature sensor signal circuit voltage is
10B-19) Circuit High higher than 4.85 V for specified time continuously.
B1146 (Page A/C Evaporator Temperature Sensor Evaporator temperature sensor signal circuit voltage is
10B-19) Circuit Low lower than 0.15 V for specified time continuously.
B1157 (Page
Air Bag Impact Signal Input Air bag deployment signal is fed from SDM to BCM.
10B-20)
B1167 (*2) Immobilizer Information Mismatched
B1168 (*2) Password Mismatched
B1169 (*2) Registration Failure
B1173 (*2) Transponder Unregistered Refer to “DTC Table”: Ignition Switch Model in Section
B1175 (*2) Immobilizer Information Unregistered 10C in related manual.
B1176 (*2) Specification Information Unregistered
B1188 (*2) Transponder Communication Error
B1189 (*2) Immobilizer Antenna Communication Error
B1190 (*2) Engine Switch Malfunction Refer to “DTC Table” in Section 10E (Page 10E-16).
BCM fails to transmit and receive the data via CAN for
U0073  Control Module Communication Bus Off
Receiving error of the data from ECM via CAN for
U0100  Lost Communication With ECM
U0101 (*4) Receiving error of the data from TCM via CAN for
Lost Communication With TCM
(Page 10B-20) specified time continuously.
U0141 (*3) Lost Communication With Keyless Start Receiving error of the data from keyless start control
(Page 10B-20) Control Module module via CAN for specified time continuously.
Lost Communication With Restraints Receiving error of the data from SDM via CAN for
U0151 
Control Module specified time continuously.
U0155 (*3) Lost Communication With Instrument Receiving error of the data from combination meter via
(Page 10B-20) Panel Cluster (IPC) Control Module CAN for specified time continuously.
Lost Communication With HVAC Control Receiving error of the data from HVAC control module
U0164 
Module via CAN for specified time continuously.
Receiving error of the data related to ENG A-STOP
U1082 (Page Lost Communication With ENG A-STOP
system from ECM via CAN for specified time
10B-20) Control Module
continuously.
Fail-Safe Table
AENFL80BA204006
When DTC is detected, BCM enters fail-safe mode as long as malfunction continues to exist but that mode is canceled
when BCM recovers normal condition.
B1120 (Page
BCM Internal Defect —
10B-15)
B1122 (Page
BCM Backup Power Supply Malfunction —
10B-16)
B1132 (Page
5V System Voltage too Low —
10B-15)
B1133 (Page
Battery Voltage too High —
10B-17)
B1141 (Page Outside Air Temperature (Ambient
BCM outputs outside air temperature –40 °C (–40 °F).
10B-17) Temperature) Sensor Circuit Open
Outside Air Temperature (Ambient
B1142 (Page
Temperature) Sensor Circuit Short to BCM outputs outside air temperature 87.5 °C (189.5 °F).
10B-17)
Ground
B1145 (Page A/C Evaporator Temperature Sensor
BCM outputs evaporator temperature –40 °C (–40 °F).
10B-19) Circuit High
B1146 (Page A/C Evaporator Temperature Sensor
BCM outputs evaporator temperature 60 °C (140 °F).
10B-19) Circuit Low
B1157 (Page BCM stops lock operation at power door lock switch until
Air Bag Impact Signal Input
10B-20) ignition is set to “OFF”.
U0073  Control Module Communication Bus Off BCM performs controls with default values.
U0100  Lost Communication With ECM BCM performs controls with default values.
U0101 (Page
Lost Communication With TCM BCM performs controls with default values.
10B-20)
U0141 (Page Lost Communication With Keyless Start
BCM performs controls with default values.
Lost Communication With Restraints
U0151  BCM performs controls with default values.
Control Module
U0155 (Page Lost Communication With Instrument
10B-20) Panel Cluster (IPC) Control Module
Lost Communication With HVAC Control
U0164  BCM performs controls with default values.
Module
U1082 (Page Lost Communication With ENG A-STOP
Scan Tool Data

AENFL80BA204007
NOTE
• If communication between SUZUKI scan tool and BCM is not possible, perform the following
checks:
– Check communication condition between PC and VCI using SUZUKI scan tool function.
– Check DLC power circuit and ground circuit.
– Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
– Check CAN communication system. (“Control Module Communication Bus Off” is detected in any
control module.) (Page 10H-45)
– Check BCM power circuit and ground circuit.
– Ignition switch model: (Page 10B-20)
– Keyless push start model: (Page 10B-27)
• *1: Applicable to ignition switch model.
• *2: Applicable to keyless push start model.
• *3: Data with asterisk 3 (*3) in the table below may either be applicable or not applicable depending
on the model.
Normal condition /
Reference value
The same value as
Outside Air Temp Measured environmental temperature at front bumper
outside air temperature
Battery Voltage 10 – 14 V Engine: Running
A/C compressor: ON
A/C Evaporator Temp 0 – 5 °C (32 – 41 °F) Temperature selector: Maximum cool position
Blower speed selector: Low
Almost the same as
Vehicle Speed In driving
speedometer reading
Engine Speed 760 – 850 rpm Engine: Idle speed with no load applied after warming up
Passive Auto drive lock setting: Disabled mode
Auto Drive Lock Mode Vehicle Speed Auto drive lock setting: Vehicle speed mode
Shift Position (*3) Auto drive lock setting: Shift position mode
Passive Auto drive unlock setting: Disabled mode
Auto Drive Unlock
Ignition Key Auto drive unlock setting: Ignition Key mode
Mode
Shift Position (*3) Auto drive unlock setting: Shift position mode
ON Driver door: Opened
Driv Door SW
OFF Other than above condition
ON Passenger door: Opened
Pass Door SW
ON Rear end door: Opened
Back Door/Trunk SW
Rear Right Door SW ON Right rear door: Opened
(*2) OFF Other than above condition
Rear Left Door SW ON Left rear door: Opened
ON Rear defogger switch: Pushed
Rear Defogger SW
Door Key SW (Lock) ON Driver key cylinder switch: “Lock” position
Door Key SW ON Driver key cylinder switch: “Unlock” position
(Unlock) (*3) OFF Other than above condition
Power door lock SW ON Power door lock switch: “Lock” position
Power door Unlock ON Power door lock switch: “Unlock” position
SW (*3) OFF Other than above condition
KeyIn (*1) Ignition key: Inserted in ignition key cylinder
Key Reminder SW Pulled (*1) Other than above condition
— (*2, *3) —
Headlight SW (*3) — —
ON Lighting switch: “CLEARANCE” or “HEAD” position
Tail Light SW
Headlight HI SW (*3) — —
Turn Signal Light R ON Turn signal switch (R): ON
SW OFF Other than above condition
Turn Signal Light L ON Turn signal switch (L): ON
SW OFF Other than above condition
ON Hazard warning switch: ON
Hazard SW
Fasten Driver seat belt: Fasten
Driv Seatbelt SW
Unfasten Other than above condition
Low Brake fluid level switch: ON (brake fluid level lower than MIN level)
Brake Fluid Level Brake fluid level switch: OFF (brake fluid level at MIN level or
Normal
higher)
ON Parking brake lever: Pull
Parking Brake SW
OFF Parking brake lever: Release
OFF Engine: Running
Charge Light (*3)
ON Other than above condition
Normal condition /
Reference value
OFF Engine: Running
Oil Pressure SW (*3)
Auto A/C model:
“AUTO” switch: ON
Manual A/C model:
ON
A/C SW Ignition: “ON”
Blower speed selector: Other than OFF position
A/C switch: ON
ON Ignition: “ON”
Ignition 1 Switch
Ignition 2 Switch (*2)
ON Ignition: “ACC” or “ON”
ACC Switch
0 Flashing setting of turn signal light: 0
+1 Flashing setting of turn signal light: +1
Turn Signal Light
Scan Tool Active Test Table

AENFL80BA204008
SUZUKI scan tool includes output test function which can force operation of the following actuators and relays of
systems controlled by BCM. When a malfunction is found in system controlled by BCM, execute output test to facilitate
judgment of whether the malfunction is on the input or output side of BCM. For details of SUZUKI scan tool, refer to its
Operator's Manual.
NOTE
*1: Applicable to ignition switch model.
*2: Applicable to keyless push start model.
*3: Applicable to A/T model.
Parking/Tail Light (*2) Interior (Dome) Light Rear Defogger

Hazard Warning Light Door Shift Lock Solenoid (*3)
Scan Tool Utility Table

AENFL80BA204009
SUZUKI scan tool has setting change function of BCM as follows. For details of SUZUKI scan tool, refer to its
Operator's Manual.
NOTE
*1: Applicable to ignition switch model.
*2: Data with asterisk 2 (*2) in the table below can also be selected by customized menu of
combination meter, refer to “Information Display” under “Combination Meter Description” in Section
9C (Page 9C-1).
*3: Data with asterisk 3 (*3) in the table below is applicable to A/T model.
Item Setting Description

For situations such as lane changes, it is possible to set the number of
times the turn signal lights flash when turn signal switch is momentarily
switched on and off.
• 0: Turn signal lights flash once when turn signal switch is turned on 1
time.
Turn Signal Light 0 / +1 / +2 / +3 • +1: Turn signal lights flash 2 times when turn signal switch is turned
on 1 time. (+1 time on and off for 1 time switching on)
• +2: Turn signal lights flash 3 times when turn signal switch is turned
• +3: Turn signal lights flash 4 times when turn signal switch is turned
Auto drive unlock condition can be changed.
• Disabled: OFF
Auto Drive Unlock Disabled / Ignition Key / • Ignition Key: linked with ignition is “ON” / “ACC” to “OFF” when each
(*2) Shift Position (*3) door is locked.
• Shift Position: linked with shift position when select lever is shifted to
“P” position from other position (A/T model).
Auto drive lock condition can be changed.
• Disabled: OFF
Auto Drive Lock Disabled / Vehicle Speed • Vehicle Speed: linked with vehicle speed when each door is
(*2) / Shift Position (*3) unlocked.
• Shift Position: linked with shift position when select lever is shifted to
other position from “P” position (A/T model).
Door Unlock (*2) 1 Action / 2 Action Setting of door unlock function (1 Action / 2 Action) can be changed.
DTC B1120 / B1132

AENFL80BA204010
B1120: BCM Internal Defect BCM
BCM internal failure.
B1132: 5V System Voltage Too Low
BCM internal failure.

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Replace BCM and End.
1) Disconnect negative (–) cable at battery. recheck DTC. (Page
10B-34)
3) Perform “DTC Confirmation Procedure” (Page 10B-15)
and then recheck DTC.
Is DTC B1120 or B1132 still detected?
DTC B1122
AENFL80BA204011
B1122: BCM Backup Power Supply Malfunction • “DOME” fuse
Measured voltage of backup power supply circuit is lower than • “HAZ” fuse
specified value for specified time.
• BCM backup power supply circuit
• BCM
Circuit Diagram
A1 2 A3 5
3
YEL E324-1 E337-9 BRN E04-6
4
WHT E323-2 E337-13 WHT E04-7
1 A2 A4
[A] E04 [B] E323 E324 E337

2 1 21 8 7 6 5 4 3 2 1
[a] 7 6 5 4 3 2 1 4 3 16 15 14 13 12 11 10 9
14 13 12 11 10 9 8
IFL80BA20015-01
[A]: BCM connector (View: [a]) A3: Backup power supply No.1 circuit (BCM) 3. “DOME” fuse
[B]: J/B connector (View: [a]) A4: Backup power supply No.2 circuit (BCM) 4. “HAZ” fuse
A1: Backup power supply No.1 circuit (J/B) 1. Main fuse box 5. BCM
A2: Backup power supply No.2 circuit (J/B) 2. J/B

DTC Troubleshooting
Step Action Yes No
1 Parameter check End. (Intermittent Go to Step 2.
1) Connect SUZUKI scan tool to DLC when ignition is trouble)
“OFF”.
3) Check “Battery Voltage”, “Ignition 1 Switch” and “ACC
Switch” displayed on SUZUKI scan tool. (Page 10B-
12)

2 Circuit fuse check Go to Step 3. Replace circuit fuse(s).
1) Set ignition “OFF”, and then remove “DOME” fuse and
“HAZ” fuse from J/B.
2) Check “DOME” fuse and “HAZ” fuse.

Step Action Yes No

3 BCM backup power supply circuit check Go to Step 4. Check “A1” and/or “A2”
1) Disconnect “E323” and “E324” connectors from J/B. circuit(s) for open or
short to ground.
2) Check for proper terminal connection to “E323” and
• Voltage of “A1” circuit and ground: Battery voltage

4 BCM backup power supply circuit check Replace BCM and Check “A3” and/or “A4”
1) Disconnect “E04” connector from BCM. recheck DTC.  circuit(s) for open or
short to ground.
DTC B1133
AENFL80BA204012
B1133: Battery Voltage Too High • Charging system
Backup power supply circuit voltage from “DOME” fuse is • BCM
continuously higher than 16.0 V for specified time.

1) Start engine, if possible.
DTC Troubleshooting
Step Action Yes No
1 Charging system check Replace BCM and Repair charging system.
1) Check charging system. recheck DTC.
• K14B model: (Page 1J-3) • Ignition switch model:
• D13A model (with ISG): (Page 1J-23) 
• D13A model (without ISG): (Page 1J-13) • Keyless push start
model: (Page 10B-
Is check result OK? 34)
DTC B1141 / B1142

AENFL80BA204013
B1141: Outside Air Temperature (Ambient Temperature) • Outside air temperature sensor circuit / connector
Sensor Circuit Open • Outside air temperature sensor
Outside air temperature sensor signal circuit voltage is
• BCM
higher than 4.85 V for specified time continuously.
B1142: Outside Air Temperature (Ambient Temperature)
Sensor Circuit Short to Ground
Outside air temperature sensor signal circuit voltage is
lower than 0.15 V for specified time continuously.
Circuit Diagram
1 5V
A1 [A]:E04-2
LT GRN [B]:E05-20
GRY [A]:E04-9
A2 [B]:E05-8
[C] E04 [D] E05
[a] 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
14 13 12 11 10 9 8 24 23 22 21 20 19 18 17 16 15 14 13
IFL80BA20012-01
[A]: Ignition switch model [D]: BCM connector (keyless push start model) (View: [a]) 1. Outside air temperature sensor
[B]: Keyless push start model A1: Outside air temperature sensor signal circuit 2. BCM
[C]: BCM connector (ignition switch model) (View: [a]) A2: Outside air temperature sensor ground circuit

DTC Troubleshooting
Step Action Yes No
1 Outside air temperature sensor circuit check Go to Step 2. Repair or replace
1) Check that ignition is “OFF”. defective wire harness.
2) Disconnect outside air temperature sensor and the
following connectors.
• Ignition switch model: “E04” connector
• Keyless push start model: “E05” connector
3) Check for proper terminal connection to outside air
temperature sensor and the following connectors.
• Ignition switch model: “E04” connector
• Keyless push start model: “E05” connector
• Resistance between “A1” and “A2” circuit terminals at
outside air temperature sensor connector: infinity
Is check result OK?

2 Outside air temperature sensor check Replace BCM and Replace outside air
1) Check outside air temperature sensor.  recheck DTC. temperature sensor. 
• Ignition switch model:
Is check result OK?

• Keyless push start
34)
DTC B1145 / B1146

AENFL80BA204014
B1145: A/C Evaporator Temperature Sensor Circuit High • Evaporator temperature sensor circuit / connector
Evaporator temperature sensor signal circuit voltage is • Evaporator temperature sensor
higher than 4.85 V for specified time continuously.
• BCM
B1146: A/C Evaporator Temperature Sensor Circuit Low
Evaporator temperature sensor signal circuit voltage is lower
than 0.15 V for specified time continuously.
Circuit Diagram
1 5V
A1 [A]:G04-29
GRN [B]:G05-24
BEG [A]:G04-28
A2 [B]:G05-6
[C] G04
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
[a]
[D] G05
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
IFL80BA20013-01
[A]: Ignition switch model [D]: BCM connector (keyless push start model) (View: [a]) 1. Evaporator temperature sensor
[B]: Keyless push start model A1: Evaporator temperature sensor signal circuit 2. BCM
[C]: BCM connector (ignition switch model) (View: [a]) A2: Evaporator temperature sensor ground circuit

DTC Troubleshooting
Step Action Yes No
1 Evaporator temperature sensor circuit check Go to Step 2. Repair or replace
2) Disconnect evaporator temperature sensor and the
• Ignition switch model: “G04” connector
• Keyless push start model: “G05” connector
3) Check for proper terminal connection to evaporator
temperature sensor and the following connectors.
• Ignition switch model: “G04” connector
• Keyless push start model: “G05” connector
evaporator temperature sensor connector: infinity
Is check result OK?

Step Action Yes No

2 Evaporator temperature sensor check Replace BCM and Replace evaporator
1) Check evaporator temperature sensor. recheck DTC. temperature sensor.
• Single A/C type:  • Ignition switch model: • Single A/C type: 
• Dual A/C type:   • Dual A/C type: 
Is check result OK? model: (Page 10B-
34)
DTC B1157
AENFL80BA204015
B1157: Air Bag Impact Signal Input • SDM
Air bag deployment signal is fed from SDM to BCM. • BCM

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Go to Step 2. End. (Air bag has
1) Clear DTC. (Page 10B-10) deployed in past. (DTC
is not cleared))
2) Perform “DTC Confirmation Procedure” (Page 10B-20)

2 DTC recheck Replace BCM and End. (SDM was faulty)
1) Replace SDM.  recheck DTC.
2) Perform “DTC Confirmation Procedure” (Page 10B-20) • Ignition switch model:
and then recheck DTC. 
34)
DTC U0101 DTC U0155

Refer to “Troubleshooting for Lost Communication”: Refer to “Troubleshooting for Lost Communication”:
Diesel Model in Section 10H (Page 10H-38). Diesel Model in Section 10H (Page 10H-38).
DTC U0141 DTC U1082

Refer to “Troubleshooting for Lost Communication”: Refer to “Troubleshooting for Lost Communication”:
Diesel Model in Section 10H (Page 10H-38). Diesel Model in Section 10H (Page 10H-38).
Inspection of BCM and Its Circuits (Ignition Switch Model)

AENFL80BA204024
Check voltage and/or pulse signal of BCM (1) using voltmeter (2) and oscilloscope (3).
NOTE
• The voltage of terminal with asterisk (*) cannot be measured by voltmeter because it is pulse signal.
Check it with oscilloscope if necessary.
2
E04
G04
L01
[A] G04 [A] E04 [A] L01

[a]
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 7 6 5 4 3 2 1
13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 14 13 12 11 10 9 8
26 25 24 23 22 21 20 19 18 17 16 15 14
IBL80AA20009-01
[A]: BCM connector (View: [a])
Terminal Wire color Circuit Normal voltage Condition

Front and side turn signal Right turn signal light:
E04-1 RED 0 ← → 14 V
light signal (R) Blinking
Ignition: “ON”
About 2.7 V Outside air temperature: 0
Outside air temperature
°C (32 °F)
E04-2 LT GRN sensor signal (if
Ignition: “ON”
equipped)
About 1.6 V Outside air temperature: 20
°C (68 °F)
Refer to “Oil pressure switch signal” (Page 10B-24).
Oil pressure switch signal
E04-3* BLU Ignition: “ON”
(K14B model) Approx. 0 V
Engine: Stopped
CAN communication line Refer to “CAN communication signal” (Page 10B-
E04-4* RED
(high) 25).
E04-5 — — — —
E04-6 BRN Backup power supply 10 to 14 V —
Power supply for turn
E04-7 WHT 10 to 14 V —
signal light
E04-8 GRY Ground for BCM Approx. 0 V —
Ground for outside air
E04-9 GRY temperature sensor (if Approx. 0 V —
equipped)
Refer to “Brake fluid level switch signal, rear
defogger switch signal, power door lock switch
signal (Unlock), driver key cylinder switch signal and
Brake fluid level switch
E04-10* GRN driver seat belt buckle switch signal” (Page 10B-25).
signal
Ignition: “ON”
Approx. 0 V Brake fluid level: Lower than
MIN level
CAN communication line Refer to “CAN communication signal” (Page 10B-
E04-11* WHT
(low) 25).
Generator “L” terminal 10 to 14 V Engine: Running
E04-12 GRN (D13A (without ISG)
model)

E04-13 — — — —
Front and side turn signal
E04-14 BLU 0 ← → 14 V Left turn signal light: Blinking
light signal (L)

G04-1 — — — —
CAN communication
G04-2* RED Refer to “CAN communication signal” (Page 10B-25).
line (high)
G04-3* PPL Vehicle speed signal Refer to “Vehicle speed signal” (Page 10B-26).
G04-4 — — — —
G04-5 — — — —
Immobilizer control
G04-6 GRN — —
module
Immobilizer control
G04-7 YEL — —
module
G04-8 — — — —
G04-9 — — — —
Ignition: “ON”
10 to 14 V Blower speed selector: OFF
A/C switch: Released
G04-10 WHT A/C switch signal Ignition: “ON”
Blower speed selector: Other than
Approx. 0 V
OFF position
A/C switch: Pushed
Refer to “Brake fluid level switch signal, rear defogger
Rear defogger switch switch signal, power door lock switch signal (Unlock),
G04-11* BRN
signal driver key cylinder switch signal and driver seat belt
buckle switch signal” (Page 10B-25).
Engine: Running
Rear defogger relay Approx. 0 V
G04-12 YEL Rear defogger switch: ON
control (if equipped)
10 to 14 V Other than above condition
Ignition: “ON” Select lever: “P” range
Shift lock solenoid 10 to 14 V
G04-13 WHT Brake pedal: Depressed
control (A/T model)
Refer to “Hazard warning switch signal and turn signal
G04-14* WHT switch signal” (Page 10B-26).
signal
Approx. 0 V Hazard warning switch: ON
G04-15 — — — —
G04-16 — — — —
G04-17 — — — —
CAN communication
G04-18* WHT Refer to “CAN communication signal” (Page 10B-25).
line (low)
G04-19 — — — —
G04-20 — — — —
G04-21 — — — —
Immobilizer control
G04-22 BRN — —
module
Immobilizer control
G04-23 GRY — —
module
Turn signal switch switch signal” (Page 10B-26).
G04-24* LT GRN
signal (R) Ignition: “ON”
Approx. 0 V
Turn signal switch (R): ON
Turn signal switch switch signal” (Page 10B-26).
G04-25* PPL
signal (L) Ignition: “ON”
Approx. 0 V
Turn signal switch (L): ON
G04-26 — — — —
G04-27 — — — —

Ground for evaporator
G04-28 BEG Approx. 0 V —
temperature sensor
Ignition: “ON”
About 3.2 V A/C outlet port temperature: 0 °C (32
Evaporator temperature °F)
G04-29 GRN
sensor signal Ignition: “ON”
About 1.8 V A/C outlet port temperature: 25 °C
(77 °F)
Lighting switch: “CLEARANCE”
Lighting switch signal 10 to 14 V
G04-30 RED position or “HEAD” position
(CLEARANCE)
Approx. 0 V Lighting switch: OFF
Ignition key: Inserted to ignition key
10 to 14 V
Key reminder switch cylinder
G04-31 BLU
signal Ignition key: Pulled out from ignition
Approx. 0 V
key cylinder
10 to 14 V Ignition: “ACC” or “ON”
G04-32 GRN Power source (ACC)

Door lock actuator Unlock signal is output for all door
10 to 14 V
L01-1 GRN control (Unlock) (if lock actuator
equipped) Approx. 0 V Other than above condition
L01-2 — — — —
L01-3 — — — —
Refer to “Power door lock switch signal (Lock), rear end
Power door lock switch door switch signal, driver door switch signal and other than
L01-4* BLU signal (Lock) (if driver door switch signal” (Page 10B-26).
equipped) Power door lock switch: “Lock”
Approx. 0 V
position
L01-5 — — — —
switch signal, power door lock switch signal (Unlock),
Driver door key cylinder
driver key cylinder switch signal and driver seat belt buckle
L01-6* LT GRN switch signal (Lock) (if
switch signal” (Page 10B-25).
equipped)
Driver door key cylinder switch:
Approx. 0 V
“Lock” position
Rear end door switch door switch signal, driver door switch signal and other than
L01-7* YEL
signal driver door switch signal” (Page 10B-26).
Approx. 0 V Rear end door: Opened
Driver door switch door switch signal, driver door switch signal and other than
L01-8* BEG
signal driver door switch signal” (Page 10B-26).
Approx. 0 V Driver door: Opened
L01-9 — — — —
L01-10 WHT Power source (IG)
L01-11 — — — —
Rear turn signal light
L01-12 BLU 0 ← → 14 V Left turn signal light: Blinking
signal (L)
Power supply for door
L01-13 BLK/RED lock actuator (if 10 to 14 V —
equipped)
L01-14 — — — —
Door lock actuator Lock signal is output for all door lock
10 to 14 V
L01-15 GRN/BLK control (Lock) (if actuator
equipped) Approx. 0 V Other than above condition
L01-16 — — — —

Power door lock switch
L01-17* GRY signal (Unlock) (if
switch signal” (Page 10B-25)
equipped)
Power door lock switch: “Unlock”
Approx. 0 V
position
Dome light switch: “DOOR” position
10 to 14 V
L01-18 WHT Dome light control Dome light: Not light up
Driver door key cylinder
L01-19* BRN switch signal (Unlock)
(if equipped)
Driver door key cylinder switch:
Approx. 0 V
“Unlock” position
Driver seat belt buckle driver key cylinder switch signal and driver seat belt buckle
L01-20* YEL
switch signal switch signal” (Page 10B-25).
Ignition: “ON”
Approx. 0 V
Driver seat belt: Unfastened
Other than driver door
L01-21* RED driver key cylinder switch signal and driver seat belt buckle
switch signal
Approx. 0 V Other than driver door: Opened
Refer to “Parking brake switch signal” (Page 10B-26).
Parking brake switch
L01-22* LT GRN Ignition: “ON”
signal Approx. 0 V
Parking brake lever: Pulled up
L01-23 — — — —
L01-24 — — — —
Rear turn signal light
L01-25 RED 0 ← → 14 V Right turn signal light: Blinking
signal (R)
L01-26 BLK Ground for BCM Approx. 0 V —
Reference Waveform • Waveforms may vary with measurement

Oscilloscope display conditions and vehicle specifications.
oscilloscope. Oil pressure switch signal
NOTE Channel Probe Terminal No.
+ E04-3
• Display includes following types of data: 1
– E04-8
• Engine: Running
IAW101970026-01

• Brake fluid level switch: OFF (brake fluid level: higher

than MIN level)
Rear defogger switch signal:

+ G04-11
1
– E04-8
• Rear defogger switch: Released
Driver door key cylinder switch signal (Lock):

IAW101A20018-01
+ L01-6
1
CAN communication signal – E04-8
CAN communication signal (high) (1): Measurement condition

Channel Probe Terminal No. • Driver door key cylinder switch (Lock): OFF
E04-4
+ Power door lock switch signal (Unlock):
1 G04-2
– E04-8 Channel Probe Terminal No.
+ L01-17
1
CAN Communication signal (low) (2): – E04-8
E04-11 Measurement condition
+
2 G04-18 • Power door lock switch (Unlock): OFF
– E04-8
Driver door key cylinder switch signal (Unlock):
Measurement condition Channel Probe Terminal No.
• Ignition: “ON” + L01-19
1
– E04-8
• Driver door key cylinder switch (Unlock): OFF
Driver seat belt buckle switch signal:

+ L01-20
1
– E04-8
• Driver seat belt: Fastened
IAW101A20014-01
Brake fluid level switch signal, rear defogger switch

signal, power door lock switch signal (Unlock),
driver key cylinder switch signal and driver seat belt
buckle switch signal
Brake fluid level switch signal:

+ E04-10
1
– E04-8
Turn signal switch signal (L):

+ G04-25
1
– E04-8
• Turn signal switch (L): OFF
I9W10PA20015-01

+ G04-3
1
– E04-8
• Vehicle speed: 40 km/h (25 mph) I9P60AA20022-01
Parking brake switch signal
Parking brake switch signal:

+ L01-22
1
– E04-8
• Parking brake lever: Released
IAW101A20021-01
Hazard warning switch signal and turn signal switch

signal
Hazard warning switch signal:

+ G04-14
1
– E04-8
• Hazard warning switch: OFF
IAW101A20015-01
Turn signal switch signal (R): Power door lock switch signal (Lock), rear end door
Channel Probe Terminal No. switch signal, driver door switch signal and other
+ G04-24 than driver door switch signal
1
– E04-8
Power door lock switch signal (Lock):
Measurement condition Channel Probe Terminal No.
• Ignition: “ON” + L01-4
1
• Turn signal switch (R): OFF – E04-8

• Power door lock switch (Lock): OFF • Other than driver door: Closed
Rear end door switch signal:

+ L01-7
1
– E04-8
• Rear end door: Closed
Driver door switch signal:

+ L01-8
1
– E04-8
• Driver door: Closed
IBP80AA20013-01
Other than driver door switch signal:
+ L01-21
1
– E04-8
Inspection of BCM and Its Circuits (Keyless Push Start Model)

AENFL80BA204025
Check voltage and/or pulse signal of BCM (1) using voltmeter (2) and oscilloscope (3).
NOTE
• The voltage of terminal with asterisk (*) cannot be measured by voltmeter because it is pulse signal.
2
L02
E05
L03
G05
3
[A] L02 [A] E05
13 12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 24 23 22 21 20 19 18 17 16 15 14 13
[a]
[A] L03 [A] G05
13 12 11 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
IDL10AA20016-01
[A]: BCM connector (View: [a])
Normal
Terminal Wire color Circuit Condition
voltage
Front and door mirror right turn signal
E05-1 RED 0 ←→ 14 V Right turn signal light: Blink
light signal
E05-2 — — — —
E05-3 — — — —
E05-4 — — — —
E05-5* RED CAN communication line (high)
Refer to “CAN communication signal” (Page 10B-31).
E05-6* WHT CAN communication line (low)
Generator “L” terminal (D13A 10 to 14 V Engine: Running
E05-7 GRN
(without ISG) model) Approx. 0 V Other than above condition
Ground for outside air temperature
E05-8 GRN Approx. 0 V —
sensor
E05-9 — — — —
E05-10 — — — —
E05-11 — — — —
E05-12 — — — —
Front and door mirror left turn signal
E05-13 BLU 0 ←→ 14 V Left turn signal light: Blink
light signal
E05-14 — — — —
E05-15 — — — —
E05-16 — — — —
E05-17 — — — —
switch signal and power door lock switch signal” (Page
E05-18* GRN Brake fluid level switch signal 10B-33).
Ignition: “ON”
Approx. 0 V
Brake fluid level: Lower than MIN level
Normal
voltage
Refer to “Oil pressure switch signal” (Page 10B-32).
Oil pressure switch signal (K14B
E05-19 BLU Ignition: “ON”
model) Approx. 0 V
Engine: Stopped
Ignition: “ON”
Approx. 2.7 V
Outside air temperature sensor Outside air temperature: 0 °C (32 °F)
E05-20 LT GRN
signal Ignition: “ON”
Approx. 1.6 V
Outside air temperature: 25 °C (77 °F)
E05-21 — — — —
E05-22 — — — —
E05-23 — — — —
E05-24 — — — —
Normal
voltage
G05-1* WHT CAN communication line (low)
Refer to “CAN communication signal” (Page 10B-31).
G05-2* RED CAN communication line (high)
G05-3 — — — —
10 – 14 V Lighting switch: OFF
G05-4 PNK Lighting switch signal (CLEARANCE) Lighting switch: “CLEARANCE” position
Approx. 0 V
or “HEAD” position.
G05-5 — — — —
Ground for evaporator temperature
G05-6 BEG Approx. 0 V —
sensor
G05-7 — — — —
G05-8 — — — —
G05-9 — — — —
Ignition: “ON”
10 to 14 V Blower speed selector: OFF
A/C switch: Released
G05-10 WHT A/C switch signal Ignition: “ON”
Blower speed selector: Other than OFF
Approx. 0 V
position
A/C switch: Pushed
G05-11 — — — —
G05-12 — — — —
Refer to “Turn signal switch signal” (Page 10B-32).
G05-13* PPL Turn signal switch signal (L) Ignition: “ON”
Approx. 0 V
Turn signal switch (L): ON
Refer to “Turn signal switch signal” (Page 10B-32).
G05-14* LT GRN Turn signal switch signal (R) Ignition: “ON”
Approx. 0 V
Turn signal switch (R): ON
Refer to “Driver seat belt buckle switch signal and hazard
G05-15* WHT Hazard warning switch signal warning switch signal” (Page 10B-33).
Approx. 0 V Hazard warning switch: ON
G05-16 — — — —
G05-17 — — — —
G05-18 — — — —
G05-19 — — — —
G05-20 — — — —
G05-21 — — — —
G05-22 — — — —
G05-23 — — — —
Ignition: “ON”
Approx. 3.2 V
A/C outlet port temperature: 0 °C (32 °F)
Evaporator temperature sensor
G05-24 GRN Ignition: “ON”
signal
Approx. 1.8 V A/C outlet port temperature: 25 °C (77
°F)
G05-25 — — — —
Normal
voltage
G05-26 BRN Rear defogger switch signal switch signal and power door lock switch signal” (Page
10B-33).
G05-27 — — — —
G05-28 — — — —
G05-29 — — — —
G05-30 — — — —
G05-31 — — — —
G05-32* PPL Vehicle speed signal Refer to “Vehicle speed signal” (Page 10B-33).
Normal
voltage
Unlock signal is output to rear door lock
10 – 14 V
L02-1 GRN Door lock actuator control (Unlock) actuator
Lock signal is output to all door lock
10 – 14 V
L02-2 BLK Door lock actuator control (Lock) actuators
Ignition: “ON”
10 – 14 V
Rear defogger switch: OFF
L02-3 YEL Rear defogger relay control
Ignition: “ON”
Approx. 0 V
Rear defogger switch: ON
L02-4 — — — —
L02-5 — — — —
L02-6 — — — —
L02-7 — — — —
L02-8 — — — —
10 – 14 V Ignition: “ON”
L02-9 WHT Power source (IG1)
L02-10 WHT Power source (IG2)
L02-11 BRN Power supply 10 – 14 V —
L02-12 WHT Power supply for turn signal light 10 – 14 V —
L02-13 RED Rear right turn signal light signal 0 ←→ 14 V Right turn signal light: Blink
L02-16 — — — —
L02-17 — — — —
L02-18 — — — —
Refer to “Driver seat belt buckle switch signal and hazard
warning switch signal” (Page 10B-33).
L02-19* YEL Driver seat belt buckle switch signal
Ignition: “ON”
Approx. 0 V
Driver seat belt: Unfasten
L02-20 — — — —
Refer to “Parking brake switch signal” (Page 10B-32).
L02-21* LT GRN Parking brake switch signal Ignition: “ON”
Approx. 0 V
Parking brake lever: Pulled up
L02-22 — — — —
L02-23 WHT Shift lock solenoid control — —
L02-24 — — — —
L02-25 YEL Backup power supply — —
L02-26 BLU Rear left turn signal light signal 0 ←→ 14 V Left turn signal light: Blink
Normal
voltage
L03-1 — — — —
L03-2 — — — —
L03-3 — — — —
Normal
voltage
L03-4 — — — —
L03-5* — — — —
L03-6 — — — —
L03-7 — — — —
L03-8 — — — —
10 – 14 V Other than above condition
L03-9 YEL Tail light relay control
Approx. 0 V Tail light: Light up
L03-10 — — — —
L03-11 — — — —
L03-12 — — — —
Refer to “Dome light control (DOOR)” (Page 10B-32).
L03-13* WHT Dome light control (DOOR) Dome light switch: “DOOR” position
10 – 14 V
Dome light: Not light up
L03-14 — — — —
L03-15 — — — —
L03-16 — — — —
L03-17 — — — —
L03-18 — — — —
L03-19 — — — —
L03-20 — — — —
Power door lock switch signal switch signal and power door lock switch signal” (Page
L03-21* BLU
(Unlock) 10B-33).
Approx. 0 V Power door lock switch: “Unlock” position
switch signal and power door lock switch signal” (Page
L03-22* GRN Power door lock switch signal (Lock)
10B-33).
Approx. 0 V Power door lock switch: “Lock” position
L03-23 — — — —
L03-24 — — — —
L03-25 — — — —
L03-26 BLK/RED Power supply for door lock actuator 10 – 14 V —

oscilloscope. CAN communication signal
NOTE
CAN communication signal (high) (1):
• How to read waveforms is shown below. Channel Probe Terminal No.
E05-5
+
1 G05-2
– L02-14
CAN communication signal (low) (2):

E05-6
+
2 G05-1
– L02-14
IAW101970026-01

IAW101A20014-01 IAW101A20015-01
Oil pressure switch signal Dome light control (DOOR)

+ E05-19 Dome light control (DOOR) signal:
1
– L02-14 Channel Probe Terminal No.
+ L03-13
1
Measurement condition – L02-14
• Engine: Running
• Dome light switch: “DOOR” position
• Any one of the door: Close ↔ Open
IAW101A20018-01
Parking brake switch signal

IDL10AA20013-01
+ L02-21
1 2. Door: Close 3. Door: Open
– L02-14
Measurement condition Turn signal switch signal

Turn signal switch signal (L):
• Parking brake lever: Released Channel Probe Terminal No.
+ G05-13
1
– L02-14
• Turn signal switch (L): OFF
Turn signal switch signal (R):

+ G05-14
1
– L02-14

• Ignition: “ON” • Vehicle speed: 40 km/h (25 mph)
• Turn signal switch (R): OFF
IAW101A20021-01
I9P60AA20022-01
Brake fluid level switch signal, rear defogger switch
Driver seat belt buckle switch signal and hazard signal and power door lock switch signal
warning switch signal
Brake fluid level switch signal:
Driver seat belt buckle switch signal: Channel Probe Terminal No.
Channel Probe Terminal No. + E05-18
1
+ L02-19 – L02-14
1
– L02-14
Measurement condition • Ignition: “ON”
• Ignition: “ON” • Brake fluid level switch: OFF (brake fluid level: higher
• Driver seat belt: Fasten than MIN level)
Hazard warning switch signal: Rear defogger switch signal:

+ G05-15 + G05-26
1 1
– L02-14 – L02-14

• Hazard warning switch: OFF • Ignition: “ON”
• Rear defogger switch: Released
Power door lock switch signal (Unlock):

+ L03-21
1
– L02-14
• Power door lock switch (Unlock): OFF
Power door lock switch signal (Lock):

+ L03-22
1
– L02-14
IDL10AA20017-01

+ G05-32
1
– L02-14
• Power door lock switch (Lock): OFF
I9P60AA20015-01
Repair Instructions
Ignition Key Registration (Ignition Switch NOTE
Model) When ECM and BCM are replaced with new
AENFL80BA206001
NOTE ones at the same time, perform “Immobilizer
Key Registration” instead of “ECM
Refer to Operator’s Manual of SUZUKI scan Registration” using SUZUKI scan tool and
tool immobilizer system for the immobilizer security device. Refer to Operator’s Manual
registration. of SUZUKI scan tool immobilizer system for
the immobilizer registration.
• Register ignition key ID code using “Immobilizer Key
Registration” function in SUZUKI scan tool.
• Remote controller registration is performed through BCM Removal and Installation (Keyless Push
“Immobilizer Key Registration”, and this registers the Start Model)
AENFL80BA206004
immobilizer transponder code.
Removal
• Performing “Immobilizer Key Registration” clears all of
the ID codes already registered. Prepare all of the
ignition keys. 2) Disconnect negative (–) cable at battery.
• It is possible to register 4 ignition keys in BCM. 3) Remove steering column hole cover. (Page 9C-24)
• If the BCM is replaced, register all of the ignition keys. 4) Remove dash side trim. (Page 9H-3)
5) Remove hood lock release lever (1), and then
BCM Registration (Ignition Switch Model) disconnect clamp (2).
AENFL80BA206002 6) Disconnect connectors (3) and clamps from J/B (4).
After BCM is replaced with new one, register ignition key
ID code in BCM using SUZUKI scan tool and security 7) Remove nuts (5) and pull J/B out to access back
device. side.
1) Prepare all of ignition keys ready for registration.
5
2) Perform “Immobilizer Key Registration” in 3
“Immobilizer” menu on SUZUKI scan tool. Refer to
Operator’s Manual of SUZUKI scan tool immobilizer
system.
3
4 1
2 5
IBP80AA20008-02
8) At back side of J/B (1), disconnect connectors (2).
2
3
1
2
IBP80AA20009-01
9) Disconnect connectors (1) from BCM (2).

10) Remove nuts (3), and then remove BCM.
3
IDL10AA20020-01
Installation
• Tighten BCM nuts to specified torque.
Tightening torque
BCM nut: 13 N·m (1.3 kgf-m, 9.5 lbf-ft)
• Enable air bag system. 
Control Relay Inspection

AENFL80BA206017
1) Disconnect relay(s) to be checked. (Page 10B-8)
2) Check that there is no continuity between terminals “3” and “4”.
If there is faulty condition, replace relay.
3) Measure resistance between terminals “1” and “2” of relay.
If check result is not as specified, replace relay.
Relay resistance between terminal “1” and “2”
Main relay (D13A model): Approx. 80 Ω at 20 °C (68 °F)
Stating motor relay, A/C compressor relay, fan relay and heater relay: Approx. 170 Ω at 20 °C (68 °F)
Other than above relay: Approx. 90 Ω at 20 °C (68 °F)
4) Connect battery positive (+) terminal and negative (–) terminal to relay as shown in figure, and check for continuity
between terminals “3” and “4”.
If there is no continuity when relay is connected to the battery, replace relay.
[A] [B]
“1” “4”
“3”
“2”
“2”
“4”
“3” “1”
[C]
“2”
“1” “2”
“4”
“3” “3” “4”
“1”
IBL80AA20011-01
[A]: Other than [B] and [C] [B]: Main relay (D13A Non-ISG) and IG2 relay [C]: Heater relay and Main relay (ISG)
Specifications
AENFL80BA207002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
BCM nut 13 1.3 9.5 
Reference:

Special Tool
AENFL80BA208002
SDT-II)
—
/
10C-1 Immobilizer Control System: Ignition Switch Model
Immobilizer Control System

Control Systems
Ignition Switch Model

DTC B1189
AENFL80BA314019
B1189: Immobilizer Antenna Communication Error • Immobilizer control module circuit / connector
Communication error with immobilizer control module (built-in • Immobilizer control module
immobilizer coil antenna).
• BCM
Circuit Diagram
1 2
A1
G17-4 GRY G04-23
A2
G17-1 BRN G04-22
A3
G17-3 GRN G04-6
A4
G17-6 YEL G04-7
[A] G17 [B] G04
[a] 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
IFL80BA31002-01
[A]: Immobilizer control module connector (View: [a]) A2: Immobilizer control module signal circuit 2 1. Immobilizer control module (including
immobilizer coil antenna)
[B]: BCM connector (View: [a]) A3: Immobilizer control module signal circuit 3 2. BCM
A1: Immobilizer control module signal circuit 1 A4: Immobilizer control module signal circuit 4

1) Set ignition “ON” for 10 seconds.
DTC Troubleshooting
Step Action Yes No
1 Immobilizer control module signal circuit check Go to Step 2. Repair or replace
3) Check for proper terminal connection to “G17” and “G04”
connectors.
• Resistance of “A1”, “A2”, “A3” and “A4” circuits: less
than 1 Ω
• Resistance between each of “A1”, “A2”, “A3” and “A4”
• Resistance between circuit terminal and other
terminals at “G17” connector: infinity
Is check result OK?

Immobilizer Control System: Ignition Switch Model 10C-2
Step Action Yes No

2 DTC check Replace BCM and End. (Immobilizer
1) Replace immobilizer control module.  recheck DTC.  control module was
faulty)
2) Perform “DTC Confirmation Procedure”: Ignition Switch
Model (Page 10C-1) and then recheck DTC.

10C-3 Immobilizer Control System: Keyless Push Start Model
Keyless Push Start Model

Precautions
Precautions for Diagnosing Trouble
AENFL80BA320001
• Immobilizer control system is controlled by keyless start control module and ECM. Before diagnosing troubles, refer
to “Precautions for Diagnosing Trouble” in Section 10E (Page 10E-1).
• Before using scan tool, read its Operator’s Manual to know how to use it.
• Clear all DTCs after completing troubleshooting.
General Description
Immobilizer Control System Introduction
AENFL80BA321001
• The engine can be started only when the remote controller ID code corresponds with the registered code in keyless
start control module.
• In the case that remote controller battery is flat, there is system trouble, and/or the keyless push start system has
brought functioning to a stop, touching remote controller to engine switch enables changing of ignition mode to “ON”
and “Engine Starting”.
Description of Ignition Mode Switching Procedure

AENFL80BA321002
Push the engine switch without depressing clutch pedal, and in about 10 seconds period in which the PUSH indicator
light on combination meter stays blinking, place remote controller on the engine switch for about 2 seconds. Through
this process, the keyless start control module checks remote controller ID code, and keyless start control module
permits switching of ignition mode according to operational state of the engine switch only when code corresponds
with the registered code.
Description of Engine Starting Procedure

AENFL80BA321003
In the case that remote controller battery is flat, there is system trouble, and/or the keyless push start system is
disabled, engine starting procedure is as follows.
1) When depressing clutch pedal, the keyless start control module outputs a PUSH indicator light signal through CAN
communication.
2) Push engine switch.
3) Keyless start control module outputs an immobilizer indicator light signal and a PUSH indicator light signal through
CAN communication.
4) Place remote controller on the engine switch for about 2 seconds while combination meter blinks PUSH indicator
light.
5) Keyless start control module reads transponder code of remote controller through immobilizer coil antenna
equipped in engine switch.
6) The starting motor control relay turns ON and the starting motor starts, a steering lock release request is output to
the steering lock unit through serial communication, and a message is sent to the ECM to permit engine starting
only when transponder code corresponds with the registered code.
7) When transponder code does not correspond with the registered code, keyless start control module does not turn
on the starting motor control relay to inhibit the starting motor operation.
Immobilizer Control System: Keyless Push Start Model 10C-4
Combination meter
(1) (3)
PUSH Immobilizer
indicator light indicator light
CAN communication
Serial communication
Starting motor
control relay
(1) (3)
ON Starting motor
PUSH Immobilizer
OFF indicator light indicator light
signal signal
Engine switch
(Including immobilizer coil antenna)
(7) Inhibit
engine Transponder
starting Not OK Transponder code
code
(6) (5)
verification
OK
Permit (4) Touch
(6) engine
Fuel injector ECM starting
(2) Push Remote controller

(6) Steering lock
Steering lock unit release
request

IFL80BA32003-01
CAN Communication System Description

AENFL80BA321004
ECM and keyless start control module uses CAN communication to communicate with other control modules. For
more detail of CAN communication, refer to “Communication System Description”: Petrol and Bi-Fuel CNG Model in
Section 10H (Page 10H-1) / “Communication System Description”: Diesel Model in Section 10H (Page 10H-27).

Immobilizer Control System Circuit Diagram
AENFL80BA322001
Refer to “Keyless Start System Electric Circuit Diagram” in Section 10E (Page 10E-10).
Component Location
Immobilizer Control System Component Location
AENFL80BA323001
[B] 2
1 [A]
5 6 4
16
10
13 14
15
11 12 9
IFL80BA32004-01
[A]: K14B model 5. PUSH indicator light 11. IG1 relay

[B]: D13A model 6. Immobilizer indicator light 12. IG2 relay
1. Remote controller 7. Engine switch 13. CPP No.1 switch
2. ECM 8. Keyless start control module 14. Brake light switch
3. Starting motor control relay 9. J/B (back side) 15. Steering lock unit
4. Combination meter 10. ACC relay 16. Transmission range sensor

Immobilizer Control System Check
AENFL80BA324001
Step Action Yes No

1 Engine start check Immobilizer control Go to Step 2.
1) Start engine. system is in good
condition.
Does engine start?
2 DTC check Go to troubleshooting Go to “Engine Basic
1) Check DTC. (Page 10C-6) for applicable DTC. Inspection”: Diesel in
Is there any DTC detected? 210).
Immobilizer Control System Self-Diagnosis DTC Check

AENFL80BA324003
Function
AENFL80BA324002 • ECM: Refer to “DTC Check”: Petrol in Section 1A
ECM and keyless start control module monitor each of (Page 1A-16) / “DTC Check”: Diesel in Section 1A
the input and output signals of the immobilizer system, (Page 1A-181).
and they are equipped with a self-diagnosis function • Keyless start control module: Refer to “DTC Check” in
which displays DTC when an abnormal condition is Section 10E (Page 10E-14).
detected.
Also, when an abnormal condition is detected,
immobilizer indicator light blinks or lights up to warn the DTC Clearance
AENFL80BA324004
driver. • ECM: Refer to “DTC Clearance”: Petrol in Section 1A
Conditions vary depending on the details of the (Page 1A-16) / “DTC Clearance”: Diesel in Section 1A
abnormal condition, but the basic lighting patterns are as (Page 1A-182).
follows.
• Keyless start control module: Refer to “DTC
• Lighting: Engine can be started Clearance” in Section 10E (Page 10E-15).
• Blinking: Engine cannot be started
DTC Table
AENFL80BA324005
NOTE
• When immobilizer DTC is detected on ECM, troubleshoot DTC item first and check whether the
same DTC is indicated on the keyless start control module.
• *1: Whether immobilizer indicator light comes on or not depends on the trouble condition.
ECM
Immobilizer
indicator light
P1610
Immobilizer ID and/or Password Not
(Page Immobilizer ID code is not registered. Blinking
Registered
10C-7)
P1611
(Page Password Not Matched Stored password is incorrect. Off
10C-7)
P1622
(Page EEPROM Reading / Writing Error EEPROM in ECM is corrupted. Blinking *1
10C-8)
P1642
Immobilizer Communication Line Communication error with keyless start control
(Page Blinking
Error module.
10C-8)
P1644
Verification error between ECM and keyless start
(Page Immobilizer ID Mismatched Blinking
control module.
10C-9)
P1646
(Page ID Code Incorrectness CAN Communication error. Blinking
10C-8)

Immobilizer
indicator light
B1167 (Page Immobilizer Information Verification error between keyless start control
Off
10C-10) Mismatched module and ECM.
B1168 (Page
Password Mismatched Wrong password is inputted. Off
10C-11)
B1169 (Page
Registration Failure Registration failure of ECM or remote controller. Off
10C-11)
B1173 (Page Transponder code in the transponder built in
Transponder Unregistered Lighting
10C-12) remote controller is not registered.
B1175 (Page Immobilizer Information Immobilizer ID code is not registered in keyless
Lighting
10C-12) Unregistered start control module.
B1176 (Page Specification Information Vehicle specification is not registered in keyless
Lighting
10C-13) Unregistered start control module.
B1189 (Page Immobilizer Antenna Communication error with engine switch
Lighting
10C-13) Communication Error (incorporating immobilizer coil antenna).
DTC P1610
AENFL80BA324006
P1610: Immobilizer ID and/or Password Not • ECM ID code is not registered in keyless start control module
Registered • ECM
Immobilizer ID code is not registered.
• CAN communication circuit / connector
• Control module connected with CAN communication line
DTC Troubleshooting
Step Action Yes No
1 ECM registration Go to Step 2. End. (ECM was not
1) Perform “ECM Registration”: Keyless Push Start Model registered)
(Page 10C-14).
2) Recheck DTC.

1) Check DTC in keyless start control module. (Page for applicable DTC.
10C-6)
Is DTC B1173, B1175 or B1176 detected?

1) Check DTC related to CAN communication. for applicable DTC. recheck DTC.
DTC P1611
AENFL80BA324007
P1611: Password Not Matched • Keyless start control module or ECM which was used in
Stored password is incorrect. another vehicle has been installed
• ECM
• Keyless start control module
DTC Troubleshooting
Step Action Yes No
1 ECM registration Replace ECM and End. (ECM was not
1) Perform “ECM Registration”: Keyless Push Start Model recheck DTC. If DTC registered)
(Page 10C-14). P1611 is still detected,
replace keyless start
2) Recheck DTC.
control module and
Is DTC P1611 still detected? recheck DTC.
• ECM: 
• Keyless start control
module: (Page
10E-50)
DTC P1622
AENFL80BA324008
P1622: EEPROM Reading / Writing Error ECM
EEPROM in ECM is corrupted.
DTC Troubleshooting
Step Action Yes No
1 DTC check Replace ECM and End. (Intermittent
1) Check that ignition is “OFF”. recheck DTC.  trouble)
3) Recheck DTC.
DTC P1642 / P1646

AENFL80BA324009
P1642: Immobilizer Communication Line Error • CAN communication circuit / connector
Communication error with keyless start control module. • Control module connected with CAN communication line
P1646: ID Code Incorrectness
• ECM
CAN Communication error.
DTC Troubleshooting
Step Action Yes No
1 DTC check Go to Step 2. End. (Intermittent
1) Set ignition “OFF” and leave ignition “OFF” for 5 seconds trouble)
or more.
3) Recheck DTC.
Is current DTC P1642 or P1646 detected?

1) Check DTC related to CAN communication. for applicable DTC.

Step Action Yes No

3 CAN communication circuit check Replace ECM and Repair or replace
1) Check CAN communication circuit referring to recheck DTC. If DTC defective wire harness.
“Troubleshooting for Communication Bus Off”: Petrol P1642 or P1646 is still
and Bi-Fuel CNG Model in Section 10H (Page 10H-19) / detected, replace
“Troubleshooting for Communication Bus Off”: Diesel keyless start control
Model in Section 10H (Page 10H-45). module and recheck
DTC.
Is check result OK?
• ECM:
– Petrol and Bi-fuel
CNG model: 
– Diesel model: 
• Keyless start control
module: (Page
10E-50)
DTC P1644
AENFL80BA324010
P1644: Immobilizer ID Mismatched • Remote controller
Verification error between ECM and keyless start • ECM ID code is not registered in keyless start control module
control module.
• Remote controller is not registered
• Engine switch circuit / connector
• Engine switch
• Keyless start control module power supply / ground circuit
• ECM
DTC Troubleshooting
NOTE
If keyless start control module is used in another vehicle before, remote controller cannot be
registered. Always install new keyless start control module whenever replacement is necessary.
Step Action Yes No

or more.
3) Recheck DTC.
Is current DTC P1644 detected?

2 DTC check Go to “DTC B1189”: Go to Step 3.
1) Check DTC in keyless start control module. Keyless Push Start
Model (Page 10C-13).
3 DTC recheck Go to Step 4. End. (A possibility of
1) Check remote controller is in keyless engine start taking out remote
function operation area. controller to outside of
the operation area)
4) Recheck DTC.

Step Action Yes No

4 Keyless start control module power supply and ground Go to Step 5. Repair or replace
1) Check keyless start control module power supply and
ground circuits. (Page 10E-43)
Is check result OK?

5 ECM registration Go to Step 6. End. (ECM was not
(Page 10C-14).
4) Recheck DTC.

6 Remote controller registration Replace ECM and End. (Remote controller
1) Perform “Immobilizer Key Registration”. (Page 10C- recheck DTC. If DTC was not registered)
14) P1644 is still detected,
replace keyless start
control module and
3) Set ignition “ON”. recheck DTC.
4) Recheck DTC. • ECM: 
Is DTC P1644 still detected? • Keyless start control
module: (Page
10E-50)
DTC B1167
AENFL80BA324011
B1167: Immobilizer Information Mismatched • ECM ID code is not registered in keyless start control module
Verification error between keyless start control • Remote controller is not registered
module and ECM.
• ECM
DTC Troubleshooting
NOTE
If keyless start control module is used in another vehicle before, remote controller cannot be
registered. Always install new keyless start control module whenever replacement is necessary.
Step Action Yes No

or more.
3) Recheck DTC.
Is current DTC B1167 detected?

1) Check DTC in ECM. for applicable DTC.
• Petrol model: (Page 1A-16)
• Diesel model: (Page 1A-181)
Is there any DTC detected?

Step Action Yes No

3 DTC recheck Go to Step 4. End. (ECM was not
(Page 10C-14).
4) Recheck DTC.

4 Remote controller registration Replace keyless start End. (Remote controller
1) Perform “Immobilizer Key Registration”. (Page 10C- control module and was not registered)
14) recheck DTC. If DTC
B1167 is still detected,
replace ECM and
3) Set ignition “ON”. recheck DTC.
4) Recheck DTC. • Keyless start control
Is DTC B1167 still detected? module: (Page
10E-50)
• ECM:
– Petrol and Bi-fuel
CNG model: 
– Diesel model: 
DTC B1168
AENFL80BA324012
B1168: Password Mismatched Wrong password is inputted
Wrong password is inputted.
DTC Troubleshooting
Step Action Yes No
1 Immobilizer password input Recheck immobilizer End. (Wrong password
1) Input immobilizer password again. password. is inputted)
4) Recheck DTC.
DTC B1169
AENFL80BA324013
B1169: Registration Failure • Power supply circuit / connector
Registration failure of ECM or remote controller. • CAN communication circuit / connector
• ECM
DTC Troubleshooting
Step Action Yes No
for applicable DTC.
Is there any DTC(s) other than B1169 detected?
Step Action Yes No

2 ECM registration Replace ECM and Replace keyless start
1) Perform “ECM Registration”: Keyless Push Start Model recheck DTC. control module and
(Page 10C-14). • Petrol and Bi-fuel recheck DTC. (Page
CNG model:  10E-50)
3) Set ignition “ON”. • Diesel model: 
4) Recheck DTC.
DTC B1173
AENFL80BA324014
B1173: Transponder Unregistered • Remote controller is not registered
Transponder code in the transponder built in the remote • Keyless start control module
controller is not registered.
DTC Troubleshooting
NOTE
An inability to register the immobilizer normally may be caused by remote controller malfunction.
Step Action Yes No

14) recheck DTC. (Page
10E-50)
4) Recheck DTC.
DTC B1175
AENFL80BA324015
B1175: Immobilizer Information Unregistered • Remote controller is not registered
Immobilizer ID code is not registered in keyless start control module. • Keyless start control module
DTC Troubleshooting
NOTE
If immobilizer registration is not performed normally, check whether or not ECM suits the specification
or CAN communication DTC is not shown. Further, check remote controller itself.
Step Action Yes No

10E-50)
4) Recheck DTC.

DTC B1176
AENFL80BA324016
B1176: Specification Information Unregistered • Remote controller is not registered
Vehicle specification is not registered in keyless start control • Keyless start control module
module.
DTC Troubleshooting
Step Action Yes No
10E-50)
4) Recheck DTC.
DTC B1189
AENFL80BA324018
B1189: Immobilizer Antenna Communication Error • Engine switch circuit / connector
Communication error with engine switch (incorporating • Engine switch
immobilizer coil antenna).
Circuit Diagram
1 2
A1
G140-4 GRY G16-17
A2
G140-8 BRN G16-13
A3
G140-3 GRN G16-7
A4
G140-6 YEL G16-6
[A] G140 [B] G16
[a] 10 9 8 7 6 5 4 3 2
6 5 4 3 2 1
11 20 19 18 17 16 15 14 13 12 1
12 11 10 9 8 7
IDL10AA32003-01
[A]: Engine switch connector (View: [a]) A2: Engine switch signal circuit 2 1. Engine switch (including immobilizer coil antenna)
[B]: Keyless start control module connector (View: [a]) A3: Engine switch signal circuit 3 2. Keyless start control module
A1: Engine switch signal circuit 1 A4: Engine switch signal circuit 4

1) Remove remote controller battery. (Page 10E-55)
2) Touch remote controller to engine switch and set ignition “ON”.
DTC Troubleshooting
Step Action Yes No
1 Engine switch signal circuit check Go to Step 2. Repair or replace
3) Check for proper terminal connection to “G140” and
“G16” connectors.
• Resistance of “A1”, “A2”, “A3” and “A4” circuits: less
than 1 Ω
• Resistance between each of “A1”, “A2”, “A3” and “A4”
• Resistance between circuit terminal and other
terminals at “G140” connector: infinity
Is check result OK?

2 DTC check Replace keyless start End. (Engine switch
1) Replace engine switch. (Page 10E-53) control module and was faulty)
2) Perform “DTC Confirmation Procedure”: Keyless Push
10E-50)
Start Model (Page 10C-13) and then recheck DTC.
Repair Instructions
Engine Switch Removal and Installation NOTE
AENFL80BA326001
Refer to “Engine Switch Removal and Installation” in • When ECM is replaced with new one, refer
Section 10E (Page 10E-53). to “Procedure after ECM Replacement”:
Petrol and Bi-Fuel CNG in Section 1C in
Remote Controller Registration related manual / “Registration for ECM
AENFL80BA326002 Replacement”: Diesel in Section 1C in
Refer to “Remote Controller Registration” in Section 10E related manual.
(Page 10E-49).
• When ECM and keyless start control
module are replaced with new ones at the
ECM Registration same time, perform “Immobilizer Key
AENFL80BA326003
After ECM is replaced with new one, register keyless Registration” instead of “ECM
start control module information to the ECM using Registration” using SUZUKI scan tool and
SUZUKI scan tool and security device. security device. Refer to Operator’s
Manual of SUZUKI scan tool for the
• Perform “ECM Registration” in “Immobilizer” menu on
immobilizer registration.
SUZUKI scan tool.
Refer to Operator’s Manual of SUZUKI scan tool for
further details. Keyless Start Control Module Registration
AENFL80BA326004
Refer to “Keyless Start Control Module Registration” in
Section 10E (Page 10E-50).
10E-1 Keyless Start System:
Keyless Start System

Control Systems
Precautions
Precautions for Diagnosing Trouble • Clear all DTCs after completing troubleshooting.
AENFL80BA500001
• Before using scan tool, read its Operator’s Manual to Precautions for Replacing Remote Controller
know how to use it. AENFL80BA500002
• Keyless start system executes data transmission / Remote controller incorporates the transponder.
reception by means of the radio wave. Therefore, Therefore, register the transponder code when remote
proper operation may not be obtained if door lock controller is replaced or added. (Page 10E-49)
function and engine start function of keyless start
system are attempted to be used near the place Precautions for Remote Controller Disposal
AENFL80BA500003
where strong radio wave is emitted (TV and radio
broadcasting stations, etc.). • To prevent theft, break remote controller before
disposing of it.
• Keyless start control module controls the following
systems. Refer to the following sections for • Dispose of the used battery properly according to
maintenance and diagnosis. applicable rules or regulations. Do not dispose of
lithium batteries with ordinary household trash.
– Immobilizer control system (refer to Section 10C)
– Keyless start system
Precautions for Replacing Keyless Start Control
• If voltage of vehicle battery is very low, the following Module
symptom may occur. Check power supply / ground AENFL80BA500004
circuit of keyless start control module or battery • When replacing the keyless start control module,
voltage, etc. replace it with new one.
– Ignition mode cannot be changed from “ON” to • After keyless start control module is replaced with
“OFF”. (Pressing engine switch for about 2 seconds new one, perform “Immobilizer Key Registration”
or 3 times continuously can change the mode to using SUZUKI scan tool. (Page 10E-49)
“ACC”.) • When keyless start control module and ECM are
– Ignition mode repeats “ON” and “OFF”. replaced at the same time, refer to “ECM
• When disconnecting keyless start control module Registration”: Keyless Push Start Model in Section
connector, disconnect negative (–) cable at battery 10C (Page 10C-14) for their registration.
beforehand. • All of remote controllers must be ready for the
registration.
General Description
Security System Description (Keyless Push • Door is opened by some way other than using
Start Model) registered remote controller.
AENFL80BA501001
• Battery negative (–) cable has been disconnected /
Security system consists of a keyless start control
reconnected.
module, shock sensor, hood latch switch, theft deterrent
light, siren, each door switch, rear end door switch and • Shock sensor detects a shock to the body of the
each door lock actuator (door lock assemblies). vehicle.
The keyless start control module monitors vehicle
conditions through the signals from shock sensor and Keyless Start System (Keyless Push Start
switches (hood latch, door and rear end door). System) Description
Security system operates when door is locked by AENFL80BA501002
pushing the lock button of registered remote controller or Keyless start system (keyless push start system) has
pushing the door request switch incorporated in the four functions as described below.
outside handle of door while carrying remote controller. • Door lock function:
The keyless start control module also activates the theft Door can be locked or unlocked by pushing the door
deterrent light, the hazard warning light and the siren to request switch incorporated in the outside handle of
provide a warning of an abnormal condition to those who door while carrying remote controller.
are around when any of the following conditions is • Rear end door opener function:
present while security system is in operation. Rear end door can be opened by pushing rear end
door request switch while carrying remote controller.
Keyless Start System: 10E-2
• Keyless entry system function: If there is a malfunction in CAN communication line,

Door can be locked or unlocked by pushing the lock or ECM, or the keyless start control module, etc., ignition
unlock button of remote controller. mode cannot be changed to “OFF” due to fail-safe
• Keyless engine start function: operation. Follow the following procedure to stop engine.
Ignition mode can be switched and engine can be Check that engine is not started until malfunction has
started / stopped by depressing clutch pedal and been repaired.
pushing engine switch while carrying the remote 1) Push and hold engine switch for approximately 2
controller. seconds or repeat push and release engine switch 3
If the remote controller battery has run down or a system times with clutch pedal released to stop engine.
malfunction has occurred, doors can be locked or Ignition mode switches to “ACC” in this case.
unlocked with the emergency key built into remote 2) Disconnect negative (–) cable at battery until
controller and the engine can be started by touching the malfunction has been repaired to prevent battery
remote controller to the engine switch. from going flat.
Description of Keyless Start System Parts and Functions

AENFL80BA501003
Part Construction / Function
Installed on underside of instrument panel at passenger side. Transmits information
through CAN communication between ECM, BCM, and combination meter, etc.
Keyless start control module Monitors status of each request switch, door switch and engine switch. Makes
requests for locking and unlocking doors, starting engine, and releasing steering
lock.
Receives request signal from each antenna. Transmits ID code and request signal to
keyless entry receiver. Also includes the following equipment and functions.
• Operation indicator light
• When ignition mode is “ON”, if battery voltage falls, transmits signal to keyless
start control module to indicate remote controller battery is running down to light up
Remote controller
the remote controller battery consumption warning light in combination meter to
alert driver to replace battery.
• Emergency key to lock or unlock doors when keyless start system does not
operate because of run-down battery, etc.
• Lock / unlock buttons to lock or unlock doors using keyless entry system function.
Located on instrument panel at driver side. Includes push switch that detects
Engine switch
operation status.
Driver side outside antenna
Included in outside door handle. Transmits request signals to remote controller
Passenger side outside
outside vehicle.
antenna
Located in back side of back panel. Transmits request signals to remote controller
Rear outside antenna
outside vehicle.
Located in center console box. Transmits request signals to remote controller inside
Mid inside antenna
vehicle.
Located in the luggage compartment. Transmits request signals to remote controller
Rear inside antenna
inside vehicle.
Driver door request switch Located on each outside door handle. Transmits ON/OFF information from each door
Passenger door request switch request switch to keyless start control module.
Located on rear end door. Transmits ON/OFF information from rear end door request
Rear end door request switch
switch to keyless start control module.
Each door switch Transmits open / close information from each door to keyless start control module.
Included in rear end door latch. Transmits open / close information from rear end
Rear end door switch
door to keyless start control module.
Located in steering column. Releases or locks steering lock.
Steering lock unit Includes unlock detection switch and lock detection switch which detect steering lock
status. Outputs status to keyless start control module through serial communication.
Located in combination meter. Goes out if ID code of remote controller matches
when engine switch is pushed. Lights up if remote controller cannot be detected
Immobilizer indicator light
when engine switch is pushed.
Lights up or blinks when system malfunction has occurred.
Located in hazard warning switch. Lights up or blinks when security alarm is set or
Theft deterrent light
system malfunction has occurred.
Part Construction / Function

ACC relay
IG1 relay Located in J/B. Switch ignition mode under control by keyless start control module.
IG2 relay
Located in relay box. Turns ON and supplies power to starting motor when keyless
Starting motor control relay
start control module determines that engine starting is possible.
Located on clutch pedal. Transmits operation information from clutch pedal to
CPP switch
keyless start control module.
Located in hood latch in ISG model and separately under the hood in non-ISG model.
Hood switch
Transmits open / close information from hood latch to keyless start control module.
ACC indicator light Located in combination meter. Lights up when ignition mode is “ACC”.
Located in combination meter. Lights up when ignition mode is “ON” with engine
ON indicator light
stationary.
Located in combination meter.
Lights up when depressing clutch pedal.
PUSH indicator light
Blinks if ID code of remote controller is not a registered one when engine switch is
pushed.
Located in instrument panel at driver’s seat side. When an abnormality in the vehicle
Shock sensor
occurs, shock sensor transmits signal to keyless start control module.
Located on right fender apron panel. Sounds when door lock / unlock or security
Siren
system function operates.
Located on outside of cowl side outer member on the driver side. Sounds when alarm
Outside warning buzzer
or warning function operates.
Driver / passenger door lock Included in both front door lock actuators. Transmits lock / unlock information from
switch driver / passenger door to keyless start control module.
Included in driver door lock actuator. Transmits lock / unlock information from door
Key cylinder switch
key cylinder to keyless start control module.
Description of Keyless Start System Door Lock Function

AENFL80BA501004
Door lock function consists of 3 types of lock / unlock methods: using request switch, using keyless entry system, and
using key cylinder operation.
Lock / Unlock Using Door Request Switch

Lock / unlock the doors using door request switch as shown below.
1) Push door request switch incorporated in the outside handle of driver or passenger door or rear end door.
2) Keyless start control module (1) activates mid inside antenna (2) and rear inside antenna (3) to transmit request
signal within the vehicle compartment.
3) When keyless start control module determines that remote controller (4) is not in vehicle compartment, it activates
the outside antenna of door at which door request switch was pushed and sends request signal to remote
controller.
4) The remote controller that receives request signal sends ID code to keyless start control module.
5) Keyless start control module compares ID code sent from remote controller with ID code registered in keyless start
control module. If ID codes match, keyless start control module outputs door lock / unlock request signal
(depending on door lock switch state) to BCM (5) through CAN communication.
6) BCM activates door lock actuator.
4 6
10 “3” “1”
“6”
5
9
“2”
“5”
“2”
3
“4” 2
8
[A]: “1” - “6” 7
IFL80BA50025-01
[A]: Signal flow “1” – “6” linked with Step 1) – 6) 7. Passenger door request switch 9. Driver side outside antenna
6. Driver door request switch 8. Passenger side outside antenna 10. Each door lock actuator
Operation area NOTE

Distance between remote controller and each door
antenna should be within approximately 80 cm (31.5 in, • Door lock function may not operate if
2.6 ft) (1), to ensure operation of door lock function. Also, remote controller is placed too close to
locking and unlocking are possible only when remote vehicle, near to the ground, or too high up.
controller is within operation area where request switch • Door lock function may not operate if the
has been pushed. (For example: When driver door same type of vehicles equipped with
request switch has been pushed, remote controller keyless start system are placed next to
should be within operation area of driver side outside each other, and both keyless start systems
antenna.) operate at the same time.
• Door lock function may not operate if a
registered remote controller and an
unregistered remote controller are carried
at the same time.
IFL80BA50005-01
2. Passenger side outside antenna 3. Driver side outside antenna
Safety function
Doors cannot be locked with door request switch when
any of the following conditions is present.
• Ignition is “ACC” or “ON”. Lock / Unlock with Keyless Entry System

• One of the doors is open. When all of the following conditions are met and the lock
or unlock signal from remote controller is inputted into
• Keyless start control module determines that remote
keyless start control module, keyless start control
controller is in vehicle compartment.
module outputs door lock / unlock request signal
(depending on the door lock switch state) to BCM
Remote controller lock-in vehicle prevention
through CAN communication. When BCM receives
function
signal, it activates each door lock actuator.
This function prevents driver from locking doors and
leaving vehicle with remote controller left behind in • Ignition mode in “OFF”.
vehicle compartment. • All doors are closed. (When locking doors)
When mid inside antenna (1) or rear inside antenna (2)
detects remote controller (i.e., remote controller is in the Lock / Unlock with Key Cylinder
vehicle compartment) and following activity is carried When the lock or unlock signal from key cylinder switch
out, keyless start control module outputs an unlock is inputted into keyless start control module, keyless
doors request to BCM through CAN communication. start control module outputs door lock / unlock request
• Doors are locked with key cylinder (emergency key) signal (depending on the door lock switch state) to BCM
or door lock knob with one of the doors open. through CAN communication. When BCM receives
signal, it activates each door lock actuator.
NOTE
Timer Lock Function
• Remote controller lock-in vehicle
This function automatically locks doors again if doors are
prevention function may not operate when
unlocked with door request switch or keyless entry
remote controller is on instrument panel,
system and no door is opened within approximately 30
in one of the storage boxes, around the
seconds.
foot area of driver side or passenger side,
or in door pocket, etc.
• When keyless start system function is off,
remote controller lock-in vehicle
prevention function does not operate.
3 4
1 2
IFL80BA50006-01
3. Mid inside antenna detection area

4. Rear inside antenna detection area
Description of Keyless Engine Start Function

AENFL80BA501006
Changing Ignition Mode
• When engine switch is pushed with remote controller inside cabin and clutch pedal released, keyless start control
module compares the ID code sent by remote controller with the ID code registered in keyless start control module.
When these ID codes match, keyless start control module controls ON/OFF of the ACC, IG1, and IG2 relays
according to engine switch operation for switching ignition mode from “OFF” → “ACC” → “ON” (engine not running)
→ “OFF”. When ignition mode is “ACC”, ACC indicator light lights on the combination meter. When mode is “ON”
(engine not running), ON indicator light lights up in combination meter.
• Table below shows transition of ignition mode according to engine switch operation. One arrow indicates transition
by pressing engine switch once.
NOTE
Except in emergency situations, do not stop engine while driving.
1 hour elapsed
Starting motor
Ignition mode
control relay
Engine switch: Pushed
ACC relay
IG1 relay
IG2 relay
Engine Clutch pedal Clutch pedal
: Released : Depressed
OFF OFF OFF OFF OFF Stop
ACC ON OFF OFF OFF Stop
ON ON ON ON OFF Stop
ON ON ON ON OFF Running
: [A]
: [B]
: [C]
START OFF ON OFF ON Cranking
: [D]
IDL10AA50006-01
[A]: Always shift [C]: Shift only while the vehicle is stopped
[B]: Shift only when the ID code sent from the remote controller matches [D]: While driving (shift when holding the engine switch down longer)
Starting Engine
The method of starting engine is as follows.
1) When clutch pedal is depressed, keyless start control module (1) sends request signal to combination meter (2)
through CAN communication to light up push indicator light in combination meter.
2) Push engine switch (3) with remote controller (4) being carried.
3) Keyless start control module activates mid inside antenna (5) or rear inside antenna (6) to send request signal to
remote controller.
4) Remote controller receives request signal and then sends ID code to keyless start control module.
5) Keyless start control module compares ID code sent from remote controller with ID code registered in keyless start
control module. If ID codes match, keyless start control module outputs a steering lock release request signal to
steering lock unit (6). At the same time, it outputs engine start signal to ECM (7) and turns the starting motor
control relay ON to activate the starting motor (8). This enables the steering lock to be released and the engine to
be started.
“2”
“5”
6
4
“5”
8 2
“4” “3” 5 “3” 6

[B]
[C] 7
7
“1”
“5”
1
[A]: “1” - “5”

IFL80BA50009-01
[A]: Signal flow “1” – “5” linked with Step 1) – 5)

[B]: Diesel model
[C]: Petrol model
Operation area Engine Cannot Be Started

Engine can be started when remote controller is within • When remote controller is not in vehicle compartment
detection area (1) of mid inside antenna or detection or there is only an unregistered one in vehicle
area (2) of rear inside antenna. compartment, keyless start control module sends
immobilizer indicator light request signal, push
NOTE
indicator light request signal, and warning buzzer
Keyless engine start function may not request signal to combination meter through CAN
operate when remote controller is on communication to warn driver. At the same time, it
instrument panel, in one of the storage turns ACC, IG1, IG2 and starting motor control relays
boxes, around foot area of driver side or OFF to inhibit ignition mode from switching and the
passenger side or in door pocket etc. starting motor from activating.
• If remote controller battery has run down or system
1 2 malfunction has occurred, engine can be started by
placing remote controller on the engine switch as an
emergency measure. (Page 10C-3)
3 4
IFL80BA50010-01
3. Mid inside antenna

4. Rear inside antenna
Description of Keyless Start System Alarm Function

AENFL80BA501007
This function warns driver using outside warning buzzer, warning buzzer built in combination meter, immobilizer
indicator light, remote controller battery consumption warning light and theft deterrent light.
NOTE
• *1: Mode (active / inactive) can be switched. (Page 10E-21)
• *2: Alarm may operate even when remote controller battery has run down.
Immobilizer
Warning
Outside indicator light
buzzer (in
Alarm function Condition warning / Display on
combination
buzzer information
meter)
display
Ignition mode un- Ignition mode in “ACC” while driver door is
— Intermittent —
returned alarm opened.
One of door request switches is pushed while
Ignition mode
ignition mode in “ACC” or “ON”, remote controller Once (2 sec.) — —
alarm
is outside the vehicle, and all doors are closed.
One of door request switches is pushed while one
Door ajar alarm 1
of doors is opened and ignition mode is “OFF”.
Doors are locked with keyless entry system while Once (2 sec.) — —
Door ajar alarm 2 one of doors is opened and ignition mode is
“OFF”.
Remote controller One of door request switches is pushed while
lock-in prevention ignition mode in “OFF”, remote controller is in Once (2 sec.) — —
alarm 1 vehicle compartment and all doors are closed.
Immobilizer
Warning
Outside indicator light
buzzer (in
Alarm function Condition warning / Display on
combination
buzzer information
meter)
display
Remote controller “Lock” button of remote controller is pushed while
lock-in prevention ignition mode in “OFF”, remote controller is in
Once (2 sec.) — —
alarm 2 (if vehicle compartment and the driver and
equipped) passenger doors are closed.
• Remote
controller
Remote controller Remote controller transmits remote controller battery
battery run down battery run down signal to keyless start control — — consumption
alarm *1 module while ignition mode in “ON”. warning light
lights up (15
sec.)
• Immobilizer
indicator light
Remote controller No registered remote controller is in vehicle lights up (5
out of detection compartment when engine switch is pushed while — *1 sec.)
area alarm *2 ignition mode in “OFF”. • PUSH
indicator light
blinks
Steering lock Driver door is opened with steering lock not • Immobilizer
abnormal locked while ignition mode in “ACC” or has — Intermittent indicator light
condition alarm switched from “ON” to “OFF”. lights up
Remote controller is carried out of vehicle, one of • Immobilizer
doors is opened, and then all doors are closed indicator light
Remote controller while ignition mode in “ON” or “ACC”. blinks
5 times 5 times
carried-out alarm Remote controller is carried out of vehicle and • PUSH
engine switch is pushed with clutch pedal indicator light
depressed while ignition mode in “ON” or “ACC”. blinks
• Immobilizer
indicator light
System Malfunction has been detected in keyless start lights up
— —
malfunction alarm system. • Theft
deterrent
light blinks

AENFL80BA501008
Keyless start control module uses CAN communication to communicate with other control module. For more detail of
CAN communication, refer to “Communication System Description”: Petrol and Bi-Fuel CNG Model in Section 10H
(Page 10H-1) / “Communication System Description”: Diesel Model in Section 10H (Page 10H-27).

Keyless Start Control Module Input / Output Diagram
AENFL80BA502001
Input Keyless start control Output

module
ID code
Battery run Antenna
down signal Each outside antenna
Lock / unlock
Keyless entry Each inside antenna

system function
Individual door switch
IG1 relay
Driver / passenger Door lock function
door lock switch
IG2 relay
Door key cylinder switch IG1 relay control
ACC relay
Each request switch
IG2 relay control
Rear end door request switch Starting motor control relay
ACC relay control
Rear end door switch
Steering lock unit
Engine switch Keyless engine
start function
Brake light switch Siren
Engine switch
Hood latch switch
illumination control Theft deterrent light
CPP No.1 switch
Security alarm
CPP No.2 switch function Outside warning buzzer
Starting motor control relay

Warning buzzer
signal
control ECM
Shock sensor
BCM
Self-diagnosis
ECM function Combination meter
BCM
: LIN communication
CAN communication
ABS control module : CAN communication
: Serial communication
IFL80BA50011-01
Keyless Start System Electric Circuit Diagram

AENFL80BA502002
1
20
12V 5V
21
G16-18 BLU
2
G16-17 GRY
LOCK
LT GRN L21-18 G16-13 BRN
UNLOCK
BRN L21-13 G16-6 YEL
3 G16-7 GRN
GRY E484-2 22
G16-4 BRN
23
G16-15 LT GRN
4 G16-2 GRY
PPL L21-33 G16-5 PNK
G16-10 GRN 24
5
PPL L21-11 G16-11 BLU
6
BLU L21-10 L21-1 BLK
25
L21-21 GRN
7 L21-2 LT GRN
26
YEL L21-30 L21-22 RED
49 L21-3 WHT
27
L21-23 BLU
YEL L21-14 L21-4 GRN
9 28
BEG L21-16 L21-24 BEG
10 RED L21-35 L21-5 RED
11 29
WHT L21-34 L21-25 YEL
12 BLU L21-15 8
13 L21-32 BRN 30
L21-28 YEL 31
32
14
L21-38 GRN
GRY L21-9
33
15 G16-1 BLU
34
PNK L21-29
L21-20 RED
35
50 E484-1 BRN
36 41
16 L21-27 GRY
YEL E484-5 L21-19 YEL
37
42
L21-7 BLU
17 L21-39 WHT
LT GRN G16-16 38
43
L21-8 YEL
L21-40 BRN
39
RED G16-9 46
19 18
WHT G16-19 E484-4 GRN 44
E484-8 PNK
E484-6 LT GRN
40
45
46
G16-14 BLK 47
L21-36 BLK 48
IFL80BA50012-01
1. Keyless start control module 18. CAN driver 35. “BCM” fuse
2. Door key cylinder switch 19. Each control module 36. “DOME” fuse
: Refer to “CAN Communication System Circuit Diagram”: Petrol and
Bi-Fuel CNG Model in Section 10H (Page 10H-7) / “CAN
Communication System Circuit Diagram”: Diesel Model in Section
10H (Page 10H-33).
3. Hood latch switch 20. Engine switch 37. “ACC” fuse
4. CPP No.2 switch 21. Engine switch illumination 38. “MTR” fuse
5. Driver door request switch 22. Push switch 1 39. “IG2 SIG” fuse
6. Passenger door request switch 23. Push switch 2 40. “ST SIG2” fuse
7. Rear end door request switch 24. Steering lock unit 41. ACC relay
8. CPU 25. Mid inside antenna 42. IG1 relay
9. Rear end door switch 26. Rear inside antenna 43. IG2 relay
10. Driver door switch 27. Rear outside antenna 44. CPP No.1 switch
11. Passenger door switch 28. Driver side outside antenna 45. Starting motor control relay
12. Rear left door switch 29. Passenger side outside antenna 46. ECM
13. Rear right door switch 30. Shock sensor 47. Battery
14. Driver door lock switch 31. Siren 48. Starting motor
15. Passenger door lock switch 32. Brake light switch 49. Antenna circuit
16. Outside warning buzzer 33. Brake light 50. Power supply circuit
17. Theft deterrent light 34. “STL” fuse
Terminal Arrangement of Keyless Start Control Module Connector
NOTE
For circuit name and terminal voltage, refer to “Inspection of Keyless Start Control Module and Its
Circuits” (Page 10E-43).
[a]
[A]
G16 E484
L21
10 9 8 7 6 5 4 3 2 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 4 3 2 1
11 20 19 18 17 16 15 14 13 12 1 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 8 7 6 5
IDAA0AA50032-01
[A]: Keyless start control module connector (View: [a])

Component Location
Keyless Start System Component Location
AENFL80BA503001
5
3 4
1
9
[B] 6
14
10
11 8
12 [A]
14
6
1
15
13
16 17 18 21 22 10
19 20
23
28
24
25 26 27
29 30 31
35
33
32
36
34 37
IFL80BA50004-01
[A]: K14B model 13. Siren 27. Brake light switch

[B]: D13A model 14. Hood latch switch (ISG model) 28. ACC relay
1. Rear inside antenna 15. Starting motor control relay 29. IG1 relay
2. Driver door lock actuator (included in door key cylinder 16. ACC indicator light 30. IG2 relay
switch and door lock switch)
3. Door request switch 17. ON indicator light 31. J/B
4. Driver side outside antenna / Passenger side outside 18. PUSH indicator light 32. Keyless start control module
antenna
5. Outside warning buzzer 19. Remote controller battery consumption 33. Mid inside antenna
warning light
6. ECM 20. Immobilizer indicator light 34. Steering lock unit
7. Rear end door request switch 21. Combination meter 35. Operation indicator light
8. Door switch 22. Engine switch 36. Remote controller
9. Passenger door lock actuator (included in door lock 23. Shock sensor 37. Emergency key
switch)
10. Individual circuit fuse box No. 1 24. Theft deterrent light 38. Hood switch (without ISG model)
11. Rear end door actuator assembly (incorporating rear end 25. CPP No.2 switch
door switch)
12. Rear outside antenna 26. CPP No.1 switch

Keyless Start System Check • For details of operations of theft deterrent light and
AENFL80BA504001 immobilizer indicator light as the warning function,
Refer to “Body Electrical Control System Check” in
refer to the following items.
Section 10B in related manual.
– Immobilizer control system: (Page 10C-6)
Keyless Start Control Module Self-Diagnosis – Keyless start system: (Page 10E-16)
Function
AENFL80BA504002 Fail-Safe Control
Description Keyless start control module performs fail-safe control
Keyless start control module monitors conditions of the when an abnormal condition related to keyless start
system components and its circuit. When an abnormal system is detected and stops all controls to protect
condition in the system occurs, keyless start control system. Details of fail-safe control vary depending on the
module performs control as follows. detected DTC. (Page 10E-18)
Self-Diagnosis Function NOTE

Keyless start control module is equipped with self- When a malfunction of immobilizer control
diagnosis function that stores DTC for abnormalities system is detected, keyless start control
detected in keyless start system and immobilizer control module does not perform fail-safe control.
system. Stored DTC is saved until abnormal condition is
corrected.
DTC Check
AENFL80BA504003
Warning Function
• When a malfunction of keyless start system and
immobilizer control system is detected, keyless start
control module makes theft deterrent light, Special tool
immobilizer indicator light and/or remote controller (A): SUZUKI scan tool (Suzuki SDT-II)
battery consumption warning light turn on to warn the
driver.
NOTE SUZUKI scan tool and print it or write it down. Refer
When DTC B1194 is detected, immobilizer to Operator's Manual of SUZUKI scan tool for further
indicator light stays on until normal details.
condition is detected at least twice
consecutively.
• After detecting a malfunction, theft deterrent light and

immobilizer indicator light are turned on. However
they are turned off when normal condition is detected.
NOTE NOTE
If communication between SUZUKI scan tool If communication between SUZUKI scan tool
and keyless start control module is not and keyless start control module is not
possible, perform the following checks: possible, perform the following checks:
• Check communication condition between • Check communication condition between
PC and VCI (2) using SUZUKI scan tool PC and VCI (2) using SUZUKI scan tool
function. function.
• Check DLC power circuit and ground • Check DLC power circuit and ground
circuit. circuit.
• Check DLC cable. If necessary, check DLC • Check DLC cable. If necessary, check DLC
cable by substituting a known-good DLC cable by substituting a known-good DLC
cable. cable.
• Check CAN communication system. • Check CAN communication system.
(“Control Module Communication Bus Off” (“Control Module Communication Bus Off”
is detected in any control module.) (Page is detected in any control module.) (Page
10H-45) 10H-45)
• Check keyless start control module power • Check keyless start control module power
circuit and ground circuit. (Page 10E-43) circuit and ground circuit. (Page 10E-43)
1 1
2 2
(A) (A)
IFL80B450002-04 IFL80B450002-04
5) After completing the check, set ignition “OFF” and 5) After completing DTC clearance, set ignition “OFF”
disconnect SUZUKI scan tool from DLC. and disconnect SUZUKI scan tool from DLC.
DTC Clearance
AENFL80BA504004
Special tool
SUZUKI scan tool. Refer to Operator's Manual of
DTC Table
AENFL80BA504005
NOTE
• *1: Theft deterrent light blinks.
• *2: Remote controller battery consumption warning light lights up. (15 seconds)
• *3: Immobilizer indicator light lights up or blinks.
• *4: Immobilizer indicator light lights up when relay is turned on.
• *5: Immobilizer indicator light lights up. (5 seconds)
• *6: Immobilizer indicator light lights up. (It stays on for 15 minutes when steering lock fails, and for 5
seconds when steering unlock fails and ignition is in other than “ON”. It stays on continuously
when ignition is “ON”.)
• *7: A/T model
DTC DTC name DTC detecting condition Warning

B1102
Mid inside antenna does not operate, even if mid
(Page Mid Inside Antenna Circuit *1
inside antenna is ON.
10E-21)
B1103
Rear inside antenna does not operate, even if rear
(Page Rear Inside Antenna Circuit *1
inside antenna is ON.
10E-21)
B1105
Driver side outside antenna does not operate, even
(Page Driver Side Outside Antenna Circuit *1
if driver side outside antenna is ON.
10E-21)
B1106
Passenger side outside antenna does not operate,
(Page Passenger Side Outside Antenna Circuit *1
even if passenger side outside antenna is ON.
10E-21)
B1107
Rear outside antenna does not operate, even if
(Page Rear Outside Antenna Circuit *1
rear outside antenna is ON.
10E-21)
B1120
Keyless Start Control Module Internal
(Page Keyless start control module internal failure. *3
Defect
10E-23)
B1122
Backup power supply circuit voltage from “BCM”
(Page Backup Power Supply Malfunction *1
fuse is lower than specified value.
10E-23)
B1123
Backup power supply circuit voltage from “DOME”
(Page Backup Power Supply Malfunction *1
fuse is lower than specified value.
10E-24)
B1134
Remote controller battery run down signal is
(Page Remote Controller Battery Low *2
received from remote controller.
10E-24)
B1158
Receiving error of LIN communication data from
(Page LIN Communication Error *1
shock sensor for specified time continuously.
10E-25)
B1159
Malfunction of LIN communication data from shock
(Page Shock Sensor Circuit *1
sensor is detected.
10E-25)
B1160
No communication is available between keyless
(Page Steering Lock Unit Communication Error *6
start control module and steering lock unit.
10E-26)
B1161
Steering Lock Unit Information Verification error between keyless start control
(Page *5
Mismatched module and steering lock unit.
10E-28)
B1162 • Steering lock unit internal failure.
(Page Steering Lock Unit Internal Defect *6
10E-29) • Lock / Unlock operation failure.

B1163
(Page Steering Lock Unit Unregistered No registration of steering lock unit Off
10E-28)
B1167 Immobilizer Information Mismatched
Refer to “DTC Table”: Keyless Push Start Model in Section 10C
B1168 Password Mismatched
(Page 10C-6).
B1169 Registration Failure
B1170
Keyless start control module internal failure.
(Page EEPROM Access Error *3
(EEPROM error)
10E-23)
B1173 Transponder Unregistered
Refer to “DTC Table”: Keyless Push Start Model in Section 10C
B1175 Immobilizer Information Unregistered
(Page 10C-6).
B1176 Specification Information Unregistered
B1180
Driver Side Door Request Switch Driver door request switch signal voltage is lower
(Page *1
Malfunction than specified value for specified time.
10E-31)
B1181
Passenger Side Door Request Switch Passenger door request switch signal voltage is
(Page *1
Malfunction lower than specified value for specified time.
10E-31)
B1182
(Page
10E-31)
B1188 Transponder Communication Error Refer to “DTC Table”: Keyless Push Start Model in Section 10C
B1189 Immobilizer Antenna Communication Error (Page 10C-6).
B1190 Push switch 1 signal voltage and/or push switch 2
(Page Engine Switch Malfunction signal voltage is not as specified for longer than *3
10E-32) specified time.
B1191 Inconsistency between input voltage via “ACC”
(Page Accessory Relay Malfunction fuse and ACC relay control condition continuously *4
10E-34) for longer than specified time.
B1192 Inconsistency between input voltage via “MTR”
(Page Ignition1 Relay Malfunction fuse and IG1 relay control condition continuously *4
B1193 Inconsistency between input voltage via “IG2 SIG”
(Page Ignition2 Relay Malfunction fuse and IG2 relay control condition continuously *4
Inconsistency between starting motor control relay
B1194
monitor input voltage and starting motor control
(Page Starting Motor Relay Malfunction *3
relay ON condition is continued for longer than
10E-40)
specified time.
B1461
(Page Vehicle Speed Signal Inconsistency Vehicle speed is not input by CAN communication. Off
10E-41)
U0073 Keyless start control module fails to transmit and
(Page Control Module Communication Bus Off receive data via CAN for specified time Off
10E-42) continuously.
U0100
Receiving error of data from ECM via CAN for
(Page Lost Communication With ECM Off
10E-42)
U0101
Receiving error of data from TCM via CAN for
(Page Lost Communication With TCM Off
10E-42)
U0121
Lost Communication With ABS / ESP® Receiving error of the data from ABS control
(Page Off
Control Module module via CAN for specified time continuously.
10E-42)
U0140
Lost Communication With Body Control Receiving error of data from BCM via CAN for
(Page Off
Module specified time continuously.
10E-42)

U0155
Lost Communication With Instrument Receiving error of data from combination meter via
(Page Off
Panel Cluster (IPC) Control Module CAN for specified time continuously.
10E-42)
Fail-Safe Table
AENFL80BA504006
When DTC is detected, keyless start control module enters fail-safe mode as long as malfunction continues to exist
but that mode is canceled when keyless start control module recovers normal condition.
B1102 (Page
Mid Inside Antenna Circuit —
10E-21)
B1103 (Page
Rear Inside Antenna Circuit —
10E-21)
B1105 (Page
Driver Side Outside Antenna Circuit —
10E-21)
B1106 (Page Passenger Side Outside Antenna
—
10E-21) Circuit
B1107 (Page
Rear Outside Antenna Circuit —
10E-21)
B1120 (Page Keyless Start Control Module Internal
—
10E-23) Defect
B1122 (Page
Backup Power Supply Malfunction —
10E-23)
B1123 (Page
Backup Power Supply Malfunction —
10E-24)
B1134 (Page
Remote Controller Battery Low —
10E-24)
B1158 (Page
LIN Communication Error —
10E-25)
B1159 (Page
Shock Sensor Circuit —
10E-25)
B1160 (Page Steering Lock Unit Communication
—
10E-26) Error
B1161 (Page Steering Lock Unit Information
—
10E-28) Mismatched
B1162 (Page
Steering Lock Unit Internal Defect —
10E-29)
B1163 (Page
Steering Lock Unit Unregistered —
10E-28)
B1170 (Page Keyless start control module performs controls with default
EEPROM Access Error
10E-23) values.
B1180 (Page Driver Side Door Request Switch Keyless start control module assumes that driver door request
10E-31) Malfunction switch signal is OFF.
B1181 (Page Passenger Side Door Request Switch Keyless start control module assumes that passenger door
10E-31) Malfunction request switch signal is OFF.
B1182 (Page
10E-31)
• Control performed by normally operating side switch when
B1190 (Page one side brakes down.
Engine Switch Malfunction
10E-32) • When both sides brake down, engine start / stop and
ignition mode changes are inhibited.
B1191 (Page
Accessory Relay Malfunction —
10E-34)
B1192 (Page
Ignition1 Relay Malfunction —
10E-36)
B1193 (Page
Ignition2 Relay Malfunction —
10E-38)
B1194 (Page Starting motor control relay is kept ON when engine switch is
Starting Motor Relay Malfunction
10E-40) pressed continuously.

B1461 (Page
Vehicle Speed Signal Inconsistency —
10E-41)
Scan Tool Data

AENFL80BA504007
NOTE
If communication between SUZUKI scan tool and keyless start control module is not possible, perform
the following checks:
• Check communication condition between PC and VCI using SUZUKI scan tool function.
• Check DLC cable. If necessary, check DLC cable by substituting a known-good DLC cable.
• Check CAN communication system. (“Control Module Communication Bus Off” is detected in any
control module.) (Page 10H-45)
• Data with asterisk (*) in the table below is not applicable.
• Check keyless start control module power circuit and ground circuit. (Page 10E-43)
Normal condition /
Reference value
Battery Voltage 10 – 14 V Engine: Running
Almost the same as
Vehicle Speed In driving
speedometer reading
Engine Speed 760 – 850 rpm Engine: Idle speed with no load applied after warming up
IG OFF Ignition: “OFF”
ACC Ignition: “ACC”
Ignition Position IG ON Ignition: “ON”
Cranking Engine: Cranking
Unclear Other than above condition
Open Driver door: Opened
Driv Door SW
Close Other than above condition
Open Other than driver door: Opened
Pass Door SW
Close Other than above condition
Rear End Door Opener* — —
ON Rear end door: Opened
Back Door/Trunk SW
ON Ignition “ON” or engine at cranking
Ignition 1 Relay
Ignition 2 Relay
ON Ignition: “ACC” and “ON”
Accessory Relay
ON Engine: Cranking
Starting Motor Relay (Com)
0 – 5,000 times Steering lock operation times: 0 – 5,000
5,001 – 7,000 times Steering lock operation times: 5,001 – 7,000
Steering Lock Counter 10,001 – 15,000 times Steering lock operation times: 10,001 – 15,000
Over 200,000 times Steering lock operation times: Over 200,000
ON Driver key cylinder: Lock position
Door Key SW (Lock)
ON Driver key cylinder: Unlock position
Door Key SW (Unlock)
ON Driver door request switch: ON
Driver Request SW
Normal condition /
Reference value
ON Passenger door request switch: ON
Passenger Request SW
ON Rear end door request switch: ON
Rear door/trunk requ SW
ON Hood: Opened
Hood Switch
ON Clutch pedal: Depressed
P Position / CPP 2 Switch
ON Engine: Cranking
Starting Motor Relay (Mon)
ON Clutch pedal: Depressed
Clutch / Shift Switch
ON Brake pedal: Depressed
Brake light Switch
Steering Unlock Condition
ON Set ignition “OFF” and open a door
Steering Lock Condition
Driver Door Lock SW
OFF Driver door lock: Lock position
Passenger Door Lock SW
OFF Passenger door lock: Lock position
Active Answer-back (siren) setting: Active mode
Answer- back (Siren)
Disabled Answer-back (siren) setting: Disabled mode
Ignition Switch1
Ignition Switch2
Accessory Switch
ON Engine switch: Pushed
Push Switch1
ON Engine switch: Pushed
Push Switch2
ON Keyless start control system: Active
Keyless Start System
OFF Keyless start control system: Disabled
Active Remote controller battery warning setting: Active mode
Remote Cont Bat Warning
Disabled Remote controller battery warning setting: Disabled mode
Active Security alarm setting: Active mode
Security Alarm
Disabled Security alarm setting: Disabled mode
Answer-back* — —
Active Remote controller area warning setting: Active mode
Remote Cont Area Warning
Disabled Remote controller area warning setting: Disabled mode
OFF Shock sensor pre-warn sensitivity setting: Disabled mode
Pre-warn Sensitivity Shock sensor pre-warn sensitivity setting: Level 1 to Level
Level 1 to Level 15
15
OFF Shock sensor full blast sensitivity setting: Disabled mode
Full Blast Sensitivity Shock sensor full blast sensitivity setting: Level 1 to Level
Level 1 to Level 15
15
Scan Tool Active Test Table

AENFL80BA504008
SUZUKI scan tool has output test function which can force operation of the following actuators and relays of the
system controlled by keyless start control module. When a malfunction is found in the system controlled by keyless
start control module, execute output test which facilitates judgment whether malfunction is on input side or output side
of keyless start control module. For details of SUZUKI scan tool, refer to its Operator's Manual.
NOTE
Data with asterisk (*) in the table below is not applicable.
Engine Switch Light Warning Buzzer (Outside) Keyless Start Antenna

Alarm Indicator Siren Immobilizer Antenna
Warning Buzzer (Inside) Horn*
Scan Tool Utility Table

AENFL80BA504009
SUZUKI scan tool has setting change function of keyless start control module as follows. For details of SUZUKI scan
tool, refer to its Operator's Manual.
NOTE
*1: Data with asterisk 1 (*1) in the table below is not applicable.
*2: Data with asterisk 2 (*2) in the table below can also be selected by customized menu of
combination meter, refer to “Information Display” under “Combination Meter Description” in Section
9C (Page 9C-1).
Item Setting Description

Keyless Start Setting of each inside and outside antenna (radio wave
ON / OFF
System transmission allowed / not allowed) can be changed.
Answer-back
(Outside buzzer) — —
(*1)
Setting (active / disabled) for warning buzzer (in combination
Remote Controller
ON / OFF meter) during remote controller out of detection area alarm
Area Warning
can be changed.
Answer-back (Siren) Setting (active / disabled) for siren during answer-back can
ON / OFF
(*2) be changed.
Configuration Remote Controller Setting (active / disabled) for remote controller battery run
ON / OFF
Battery Warning down warning can be changed.
Setting (active / disabled) for security alarm mode can be
Security Alarm (*2) ON / OFF
changed.
Setting of shock sensor function on sensitivity alarm (ON /
Shock Sensor (*2) ON / OFF
OFF) can be changed.
Answer-back (*1) — —
Shock Sensor Pre- OFF / Level 1 Setting (OFF, Level 1 to Level 15) for shock sensor pre-warn
warn Sensitivity (*2) to Level 15 sensitivity can be changed.
Shock Sensor Full OFF / Level 1 Setting (OFF, Level 1 to Level 15) for shock sensor full blast
Blast Sensitivity (*2) to Level 15 sensitivity can be changed.
DTC B1102 / B1103 / B1105 / B1106 / B1107

AENFL80BA504010
B1102: Mid Inside Antenna Circuit • Each outside antenna circuit / connector
Mid inside antenna does not operate, even if mid inside antenna is ON. • Each outside antenna
B1103: Rear Inside Antenna Circuit
• Each inside antenna circuit / connector
Rear inside antenna does not operate, even if rear inside antenna is
ON. • Each inside antenna
B1105: Driver Side Outside Antenna Circuit • Keyless start control module
Driver side outside antenna does not operate, even if driver side
outside antenna is ON.
B1106: Passenger Side Outside Antenna Circuit
Passenger side outside antenna does not operate, even if passenger
side outside antenna is ON.
B1107: Rear Outside Antenna Circuit
Rear outside antenna does not operate, even if rear outside antenna is
ON.
Circuit Diagram
7 A1
L21-1 BLK
A2 1
L21-21 GRN
B1
L21-2 LT GRN
B2 2
L21-22 RED
C1
L21-4 GRN
C2 3
L21-24 BEG
D1
L21-5 RED
D2 4
L21-25 YEL
E1
L21-3 WHT
E2 5
L21-23 BLU
[A] L21
[a] 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
IFL80BA50013-01
[A]: Keyless start control module connector C2: Diver side outside antenna signal circuit 2 2. Rear inside antenna
(View: [a])
A1: Mid inside antenna signal circuit 1 D1: Passenger side outside antenna signal circuit 1 3. Driver side outside antenna
A2: Mid inside antenna signal circuit 2 D2: Passenger side outside antenna signal circuit 2 4. Passenger side outside antenna
B1: Rear inside antenna signal circuit 1 E1: Rear outside antenna signal circuit 1 5. Rear outside antenna
B2: Rear inside antenna signal circuit 2 E2: Rear outside antenna signal circuit 2 6. Keyless start control module
C1: Diver side outside antenna signal circuit 1 1. Mid inside antenna 7. Antenna circuit

2) Close all doors.
3) Open a door for more than 4 seconds.
DTC Troubleshooting
Step Action Yes No
1 Antenna check Go to Step 2. Replace defective
1) Check the antenna for which DTC has appeared. antenna.
(Page 10E-52) • Driver side /
passenger side
Is check result OK?
outside antenna:
(Page 10E-50)
• Rear outside
antenna: (Page
10E-51)
• Mid inside antenna:
(Page 10E-51)
• Rear inside antenna:
(Page 10E-51)
Step Action Yes No

2 Antenna circuit check Replace keyless start Repair or replace
1) Check that ignition is “OFF”. control module and defective wire harness.
2) Disconnect related antenna and keyless start control
10E-50)
module connectors.
3) Check for proper terminal connection to antenna and
keyless start control module connectors.
• Resistance of “A1” and “A2”, “B1” and “B2”, “C1” and
“C2”, “D1” and “D2” or “E1” and “E2” circuits: less than
1Ω
• Resistance between each of “A1” and “A2”, “B1” and
“B2”, “C1” and “C2”, “D1” and “D2” or “E1” and “E2”
mid inside antenna connector: infinity
• Resistance between “B1” and “B2” circuit terminals at
rear inside antenna connector: infinity
• Resistance between “C1” and “C2” circuit terminals at
driver side outside antenna connector: infinity
• Resistance between “D1” and “D2” circuit terminals at
passenger side outside antenna connector: infinity
• Resistance between “E1” and “E2” circuit terminals at
rear outside antenna connector: infinity
• Voltage of “A1” and “A2”, “B1” and “B2”, “C1” and
“C2”, “D1” and “D2” or “E1” and “E2” circuits: approx.
0 V (When ignition is “ON”)
DTC B1120 / B1170

AENFL80BA504011
B1120: Keyless Start Control Module Internal Defect Keyless start control module
Keyless start control module internal failure.
B1170: EEPROM Access Error
Keyless start control module internal failure. (EEPROM error)

DTC Troubleshooting
Step Action Yes No
1 DTC recheck Replace keyless start End.
1) Clear DTC. (Page 10E-15) control module and
10E-50)
3) Perform “DTC Confirmation Procedure” (Page 10E-23)
DTC B1122
AENFL80BA504012

B1122: Backup Power Supply Malfunction • “BCM” fuse
Backup power supply circuit voltage from “BCM” fuse is lower than specified value. • Keyless start control module

DTC Troubleshooting
Step Action Yes No
1 Fuse check Replace keyless start Replace “BCM” fuse
1) Check that ignition is “OFF”. control module and and go to Step 2.
2) Check “BCM” fuse.
10E-50)
Is check result OK?
2 DTC check Replace “BCM” fuse End.
1) Set ignition “ON”. and keyless start control
module, and recheck
2) Check DTC. (Page 10E-14)
DTC. (Page 10E-50)
DTC B1123
AENFL80BA504013
B1123: Backup Power Supply Malfunction • “DOME” fuse
Backup power supply circuit voltage from “DOME” fuse is lower than • Each system connected to “DOME” fuse
specified value.

DTC Troubleshooting
Step Action Yes No
1 Fuse check Replace keyless start Replace “DOME” fuse
1) Check that ignition is “OFF”. control module and and go to Step 2.
2) Check “DOME” fuse.
10E-50)
Is check result OK?
2 DTC check Go to Step 3. End.

3 Each system check connected to “DOME” fuse Replace “DOME” fuse Repair or replace
1) Check each system connected to “DOME” fuse, except and keyless start control defective part and/or
keyless start control module. module, and recheck wire harness, and then
DTC. (Page 10E-50) replace “DOME” fuse
Is check result OK? and recheck DTC.
DTC B1134
AENFL80BA504015
B1134: Remote Controller Battery Low • Remote controller battery
Remote controller battery run down signal is received from remote controller. • Remote controller
NOTE
Prepare all registered remote controllers before performing DTC confirmation procedure.

2) Check that “Remote Controller Battery Warning” setting is “Active” mode. (Page 10E-21)
3) Place remote controller within the keyless engine start operation area and open and close door more than 2 times.
4) Repeat Step 3) 6 times.
5) Perform Step 3) – 4) with all of registered remote controllers.
DTC Troubleshooting
Step Action Yes No
1 Remote controller check Go to Step 2. End. (Remote controller
1) Prepare all registered remote controllers. battery run down signal
was detected in the
2) Set ignition “ON” with remote controller carried with
past. (DTC is not
oneself.
cleared))
3) Check whether remote controller battery consumption
warning light lights up in combination meter.
5) Perform Step 2) – 4) for all remote controllers.
Does remote controller battery consumption warning light

lights up in combination meter?
2 Remote controller battery check Replace remote End.
1) Replace battery of corresponding remote controller with controller and recheck
new one. (Page 10E-55) DTC.
2) Clear DTC. (Page 10E-15)
DTC B1158 / B1159

AENFL80BA504017
B1158: LIN Communication Error • LIN communication line / connector
Receiving error of LIN communication data from shock sensor for specified • Keyless start control module
time continuously.
• Shock sensor
B1159: Shock Sensor Circuit
Malfunction of LIN communication data from shock sensor is detected. • Shock sensor power supply circuit
Circuit Diagram
12V 1 2
A1 A2
WHT BRN L21-32
A3
BLK
[A] L21
[a] 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
IDL10AA50015-01
[A]: Keyless start control module connector (View: [a]) A2: Shock sensor signal circuit 1. Shock sensor
A1: Shock sensor power supply circuit A3: Shock sensor ground circuit 2. Keyless start control module

DTC Troubleshooting
Step Action Yes No
1 Shock sensor power supply circuit check Go to Step 3. Go to Step 2.
2) Disconnect shock sensor connector.
3) Check for proper terminal connection to shock sensor
connector.
4) If connection is OK, set ignition “ON”.
battery voltage.
Is check result OK?

2 Shock sensor ground circuit check Repair “A3” circuit. Repair “A1” circuit.
battery voltage.
Is check result OK?

3 Shock sensor signal circuit check Go to Step 4. Repair or replace
3) Check for proper terminal connection to “L21” connector.
4) If connections are OK, check following points.
“ON”)
Is check result OK?

4 DTC check Replace keyless start End.
1) Replace shock sensor. (Page 10E-54) control module and
10E-50)
DTC B1160
AENFL80BA504018
B1160: Steering Lock Unit Communication Error • Steering lock unit circuit / connector
No communication is available between keyless start control module • Steering lock unit
and steering lock unit.
Circuit Diagram
1 2
A1
G146-1 BLU G16-11
A2
G146-2 PNK G16-5
B1
G146-3 GRN G16-10
C1
G146-5 GRY G16-2
C2
G146-4 BLK
[B] G146 [A] G16
[b] [a] 10 9 8 7 6 5 4 3 2
1 2 3 4 5 6
11 20 19 18 17 16 15 14 13 12 1
IDL10AA50016-01
[A]: Keyless start control module connector (View: [a]) A2: Steering lock unit power supply circuit 2 C2: Steering lock unit ground circuit 2
[B]: Steering lock unit connector (View: [b]) B1: Steering lock unit signal circuit 1. Steering lock unit
A1: Steering lock unit power supply circuit 1 C1: Steering lock unit ground circuit 1 2. Keyless start control module

1) Repeat lock / unlock operation of steering lock unit several times.
• Lock: Change ignition “ON” to “OFF” and open a door.
• Unlock: Set ignition “ON” at steering lock conditions.
DTC Troubleshooting
NOTE
This DTC might be detected when battery is run down or the voltage is very low.
Step Action Yes No

1 Steering lock unit operation check Intermittent trouble. Go to Step 2.
3) Repeat Step 1) – 2) several times.
4) Check that steering lock is locked / unlocked according
to change of ignition.
Is check result OK?

2 Steering lock unit power supply circuit check Go to Step 5. Go to Step 3.
2) Disconnect steering lock unit connector.
3) Check for proper terminal connection to steering lock
unit connector.
4) If connections are OK, check that voltage between “A2”
and “C1” circuits is battery voltage when ignition is
switched from “OFF” to “ON”.
Is check result OK?

3 Steering lock unit ground circuit check Repair or replace “C1” Go to Step 4.
1) Check that voltage between “A2” circuit and ground is circuit.
battery voltage when ignition is switched from “OFF” to
“ON”.
Is check result OK?

Step Action Yes No

4 Steering lock unit power supply circuit check Replace keyless start Repair or replace
1) Set ignition “OFF”. control module and defective wire harness.
10E-50)
3) Check for proper terminal connection to “G16”
connector.
terminal at steering lock unit connector: infinity
Is check result OK?

5 Steering lock unit signal circuit check Go to Step 6. Repair or replace
connector.
terminal at steering lock unit connector: infinity
Is check result OK?

6 DTC check Replace keyless start End. (Steering lock unit
1) Replace steering lock unit. (Page 6B-5) control module and was faulty)
10E-50)
DTC B1161 / B1163

AENFL80BA504019
B1161: Steering Lock Unit Information Mismatched • Steering lock unit circuit / connector
Verification error between keyless start control module and steering lock unit. • Steering lock unit
B1163: Steering Lock Unit Unregistered
No registration of steering lock unit.

DTC Troubleshooting
Step Action Yes No
1 DTC check Go to Step 2. Intermittent trouble.

Step Action Yes No

10E-50)
DTC B1162
AENFL80BA504020
B1162: Steering Lock Unit Internal Defect • Steering lock unit circuit / connector
• Steering lock unit internal failure. • Steering lock unit
• Lock / Unlock operation failure. • Keyless start control module
Circuit Diagram
1 2
A1
G146-1 BLU G16-11
A2
G146-2 PNK G16-5
B1
G146-3 GRN G16-10
C1
G146-5 GRY G16-2
C2
G146-4 BLK
[B] G146 [A] G16
[b] [a] 10 9 8 7 6 5 4 3 2
1 2 3 4 5 6
11 20 19 18 17 16 15 14 13 12 1
IDL10AA50016-01
[A]: Keyless start control module connector (View: [a]) A2: Steering lock unit power supply circuit 2 C2: Steering lock unit ground circuit 2
[B]: Steering lock unit connector (View: [b]) B1: Steering lock unit signal circuit 1. Steering lock unit
A1: Steering lock unit power supply circuit 1 C1: Steering lock unit ground circuit 1 2. Keyless start control module

1) Set steering wheel in straight ahead position.
DTC Troubleshooting
NOTE
• This DTC might be detected when battery is run down or the voltage is very low.
• If ignition is set “OFF” with force applied to steering wheel, there may be a case that B1162 is
detected because steering lock unit cannot be unlocked. This is a temporary malfunction and not a
permanent defect.
Step Action Yes No

1 Battery voltage check Go to Step 2. Check battery and
1) Check that battery terminal voltage is 12 V or more. generator.
• Battery: (Page 1J-
Is check result OK?
22)
– Petrol model: 
– Diesel (without
ISG) model: 
– Diesel (with ISG)
model: (Page
1J-22)
• Generator:
– Petrol model:
(Page 1J-3)
– Diesel (without
ISG) model:
(Page 1J-13)
– Diesel (with ISG)
model: (Page
1J-23)
2 DTC check Go to Step 4. Go to Step 3.

3 DTC recheck Go to Step 4. End. (Intermittent
1) Clear DTC. (Page 10E-15) trouble)
3) Set steering wheel in straight ahead position.
5) Open driver door.

4 Steering lock unit operation check Intermittent trouble. Go to Step 5.
5) Check that steering lock does lock / unlock according to
change of ignition.
Is check result OK?

Step Action Yes No

5 Steering lock unit power supply circuit check Clear DTC, and then go Clear DTC, and then go
1) Set ignition “OFF”. to Step 8. (Page 10E- to Step 6. (Page 10E-
15) 15)
2) Disconnect steering lock unit connector.
3) Check for proper terminal connection to steering lock
unit connector.
• Voltage between “A1” and “C2” is battery voltage
when ignition is switched from “OFF” to “ON”.
• Voltage between “A2” and “C1” is battery voltage
when ignition is switched from “OFF” to “ON”.
Is check result OK?

6 Steering lock unit ground circuit check Repair or replace “C1” Go to Step 7.
1) Check that voltage between each of “A1” and “A2” and “C2” circuits.
circuits and ground is battery voltage when ignition is
switched from “OFF” to “ON”.
Is check result OK?

7 Steering lock unit power supply circuit check Replace keyless start Repair or replace
10E-50)
connector.
• Resistance between each of “A1” and “A2” circuit
terminals and each terminal at steering lock unit
connector: infinity
Is check result OK?

10E-50)
DTC B1180 / B1181 / B1182

AENFL80BA504022
B1180: Driver Side Door Request Switch Malfunction • Each request switch circuit /
Driver door request switch signal voltage is lower than specified value for specified connector
time. • Each request switch
B1181: Passenger Side Door Request Switch Malfunction
Passenger door request switch signal voltage is lower than specified value for
specified time.
B1182: Rear End Door / Trunk Lid Request Switch Malfunction
Rear end door request switch signal voltage is lower than specified value for
specified time.
Circuit Diagram
12V
1
A1
BLK PPL L21-11
12V
2
A2
BLK BLU L21-10
12V
3
A3
BLK YEL L21-30
[A] L21
[a] 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
IFL80BA50016-01
[A]: Keyless start control module connector (View: [a]) A3: Rear end door request switch signal circuit 3. Rear end door request switch
A1: Driver door request switch signal circuit 1. Driver door request switch 4. Keyless start control module
A2: Passenger door request switch signal circuit 2. Passenger door request switch

2) Push request switch related to DTC.
3) Release request switch.
4) Keep ignition “ON” for 10 minutes or more.
DTC Troubleshooting
Step Action Yes No
1 Request switch signal circuit check Go to Step 2. Repair or replace
2) Disconnect request switch and “L21” connectors.
3) Check for proper terminal connection to request switch
and “L21” connectors.
4) If connections are OK, check that resistance between
each of “A1”, “A2” and “A3” circuits and ground is infinity.
Is check result OK?

2 Request switch check Replace keyless start Replace request switch.
1) Check request switch. (Page 10E-52) control module and
Is check result OK? 10E-50)
DTC B1190
AENFL80BA504023
B1190: Engine Switch Malfunction • Engine switch circuit / connector
Push switch 1 signal voltage and/or push switch 2 signal voltage is not as • Engine switch
specified for longer than specified time.
Circuit Diagram
4
1
12V
2
A1
BRN G16-4
3
B1 A2
BLK LT GRN G16-15
[A] G16
[a] 10 9 8 7 6 5 4 3 2
11 20 19 18 17 16 15 14 13 12 1
IDL10AA50019-02
[A]: Keyless start control module connector (View: [a]) B1: Push switch ground circuit 3. Push switch 2
A1: Push switch 1 signal circuit 1. Engine switch 4. Keyless start control module
A2: Push switch 2 signal circuit 2. Push switch 1

DTC Troubleshooting
Step Action Yes No
1 Push switch signal circuit and push switch ground Go to Step 2. Repair or replace
2) Disconnect engine switch and “G16” connectors.
3) Check for proper terminal connection to engine switch
and “G16” connectors.
• Resistance of “A1”, “A2” and “B1” circuits: less than 1
Ω
• Resistance between each of “A1” and “A2” circuit
terminals and each terminal at engine switch
connector: infinity
terminal at engine switch connector: infinity
Is check result OK?

2 Engine switch check Replace keyless start Replace engine switch.
1) Check engine switch. (Page 10E-53) control module and (Page 10E-53)
DTC B1191
AENFL80BA504024
B1191: Accessory Relay Malfunction • ACC relay circuit / connector
Inconsistency between input voltage via “ACC” fuse and ACC relay control • ACC relay
condition continuously for longer than specified time.
• “IGN” fuse
• “ACC” fuse
Circuit Diagram
9
12V
3 C1
GRY L21-27
A1 4
YEL L21-19
B1
12V
5 C2
BLU L21-7
A2 12V
1 6
WHT WHT L21-39
B2
12V
7 C3
YEL L21-8
2 A3 8
BLU BRN L21-40
B3
[A] L21
[a] 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
IDL10AA50020-02
[A]: Keyless start control module connector (View: [a]) C1: ACC relay power supply circuit (coil side) 5. IG1 relay
A1: ACC relay power supply circuit (switch side) C2: IG1 relay power supply circuit (coil side) 6. “MTR” fuse
A2: IG1 relay power supply circuit (switch side) C3: IG2 relay power supply circuit (coil side) 7. IG2 relay
A3: IG2 relay power supply circuit (switch side) 1. “IGN” fuse 8. “IG2 SIG” fuse
B1: ACC relay signal circuit 2. “IGN2” fuse 9. Keyless start control module
B2: IG1 relay signal circuit 3. ACC relay
B3: IG2 relay signal circuit 4. “ACC” fuse

2) Set ignition “ACC”.
DTC Troubleshooting
NOTE
• This DTC might be detected when battery is run down or the voltage is very low.
• Before performing troubleshooting, remove aftermarket devices connected to the line via “ACC”
fuse and devices that have a backup power supply function located in their accessory socket (non-
genuine devices, optional parts, audio, etc.). Voltage from these devices may cause this DTC to be
detected during diagnosis.
Step Action Yes No

1 ACC relay power supply circuit (switch side) check Go to Step 2. Repair or replace
1) Check that ignition is “OFF”. defective wire harness
and “IGN” fuse.
2) Remove ACC relay.
battery voltage.
Is check result OK?

2 Fuse check Go to Step 4. Go to Step 3.
1) Check “ACC” fuse.
Is check result OK?

3 ACC relay signal circuit check Replace “ACC” fuse and Repair or replace
1) Set ignition “OFF”. keyless start control defective wire harness,
module and recheck and then replace “ACC”
DTC. (Page 10E-50) fuse.
terminal at ACC relay connector: infinity
Is check result OK?

4 ACC relay signal circuit check Go to Step 5. Repair or replace
“ON”)
Is check result OK?

5 ACC relay power supply circuit (coil side) check Go to Step 6. Repair or replace
“ON”)
Is check result OK?

Step Action Yes No

6 ACC relay check Replace keyless start Replace ACC relay.
1) Check ACC relay. (Page 10B-35) control module and
DTC B1192
AENFL80BA504025
B1192: Ignition 1 Relay Malfunction • IG1 relay circuit / connector
Inconsistency between input voltage via “MTR” fuse and IG1 relay control • IG1 relay
• “IGN” fuse
• “MTR” fuse
Circuit Diagram
9
12V
3 C1
GRY L21-27
A1 4
YEL L21-19
B1
12V
5 C2
BLU L21-7
A2 12V
1 6
WHT WHT L21-39
B2
12V
7 C3
YEL L21-8
2 A3 8
BLU BRN L21-40
B3
[A] L21
[a] 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
IDL10AA50020-02

DTC Troubleshooting
NOTE
Step Action Yes No

1 IG1 relay power supply circuit (switch side) check Go to Step 2. Repair or replace
and “IGN” fuse.
2) Remove IG1 relay.
3) Check that voltage between “A2” circuit terminal of IG1
relay connector and ground is battery voltage.
Is check result OK?

1) Check “MTR” fuse.
Is check result OK?

3 IG1 relay signal circuit check Replace “MTR” fuse Repair or replace
1) Set ignition “OFF”. and keyless start control defective wire harness,
module and recheck and then replace “MTR”
DTC. (Page 10E-50) fuse.
terminal at IG1 relay connector: infinity
Is check result OK?

4 IG1 relay signal circuit check Go to Step 5. Repair or replace
“ON”)
Is check result OK?

5 IG1 relay power supply circuit (coil side) check Go to Step 6. Repair or replace
“ON”)
Is check result OK?

6 IG1 relay check Replace keyless start Replace IG1 relay.
1) Check IG1 relay. (Page 10B-35) control module and
DTC B1193
AENFL80BA504026
B1193: Ignition 2 Relay Malfunction • IG2 relay circuit / connector
Inconsistency between input voltage via “IG2 SIG” fuse and IG2 relay control • IG2 relay
• “IGN2” fuse
• “IG2 SIG” fuse
Circuit Diagram
9
12V
3 C1
GRY L21-27
A1 4
YEL L21-19
B1
12V
5 C2
BLU L21-7
A2 12V
1 6
WHT WHT L21-39
B2
12V
7 C3
YEL L21-8
2 A3 8
BLU BRN L21-40
B3
[A] L21
[a] 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
IDL10AA50020-02

DTC Troubleshooting
NOTE
Step Action Yes No

1 IG2 relay power supply circuit (switch side) check Go to Step 2. Repair or replace
and “IGN2” fuse.
2) Remove IG2 relay.
battery voltage.
Is check result OK?

1) Check “IG2 SIG” fuse.
Is check result OK?

3 IG2 relay signal circuit check Replace “IG2 SIG” fuse Repair or replace
1) Set ignition “OFF”. and keyless start control defective wire harness,
module and recheck and then replace “IG2
DTC. (Page 10E-50) SIG” fuse.
Is check result OK?

4 IG2 relay signal circuit check Go to Step 5. Repair or replace
“ON”)
Is check result OK?

5 IG2 relay power supply circuit (coil side) check Go to Step 6. Repair or replace
“ON”)
Is check result OK?

6 IG2 relay check Replace keyless start Replace IG2 relay.
1) Check IG2 relay. (Page 10B-35) control module and
DTC B1194
AENFL80BA504027
B1194: Starting Motor Relay Malfunction • Starting motor control relay circuit / connector
Inconsistency between starting motor control relay • Starting motor control relay
monitor input voltage and starting motor control relay
• “ST” fuse
ON condition is continued for longer than specified
time. • “ST SIG2” fuse
• CPP No.1 switch circuit / connector
• CPP No.1 switch
Circuit Diagram
3 12V
4
PNK E484-8
1 A1 A2
RED YEL LT GRN E484-6
6
7
YEL LT GRN [D]: E01-84
[C]: E01-52
[C]: E01-16
2 GRN [D]: E01-92
M
[A] E484 [B]
[D] E01 C01

4 3 2 1
8 7 6 5
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 4 1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
5 2
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
[a]
94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 6 3 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
[C] C01 E01
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
IFL80BA50017-01
[A]: Keyless start control module connector (View: [a]) 1. “ST” fuse 5. Keyless start control module
[B]: ECM connector (View: [a]) 2. Starting motor 6. ECM
A1: Starting motor control relay signal circuit No.1 3. CPP No.1 switch 7. “ST SIG2” fuse
A2: Starting motor control relay signal circuit No.2 4. Starting motor control relay

1) Start engine.
2) Stop engine.
3) Repeat Step 1) – 2) once.
DTC Troubleshooting
NOTE
Step Action Yes No

for applicable DTC.
2 Fuse check Go to Step 3. Replace “ST” and/or
1) Check “ST” and “ST SIG2” fuses. “ST SIG2” fuse.
Is check result OK?

3 Starting motor control relay check Go to Step 4. Replace starting motor
1) Check starting motor control relay. (Page 10B-35) control relay.
Is check result OK?

4 Starting motor control relay signal circuit check Replace keyless start Repair or replace
2) Disconnect “E01”, “E484” and starting motor connectors.
10E-50)
3) Check for proper terminal connection to “E01”, “E484”
and starting motor connectors.
terminal at starting motor control relay connector:
infinity
Is check result OK?
DTC B1461
AENFL80BA504028
B1461: Vehicle Speed Signal Inconsistency • CAN communication line
Vehicle speed is not input by CAN communication. • Wheel speed sensor
• ABS control module
• ECM
! WARNING
accident can occur.
1) Drive vehicle at 60 km/h (37 mile/h) or more for 1 minute.

DTC Troubleshooting
Step Action Yes No
1 DTC check Go to troubleshooting in Go to Step 2.
1) Check DTC. (Page 10E-14) “DTC U0100” (Page
10E-42).
2 DTC check Go to troubleshooting in Go to Step 3.
1) Check ECM for DTC. “DTC P0500”: Petrol in
• Petrol model: (Page 1A-16)
78) for petrol model /
• Diesel model: (Page 1A-181) “DTC P0500”: Diesel in
Is DTC P0500 detected? Section 1A (Page 1A-
253) for diesel model.
3 DTC check Go to troubleshooting Replace ABS control
1) Check DTC for ABS control module. (Page 4E-3) for applicable DTC. module and recheck
DTC. 
Is DTC(s) related to wheel speed sensor detected?
DTC U0073
AENFL80BA504029
Refer to “Troubleshooting for Communication Bus Off”:
Diesel Model in Section 10H (Page 10H-45).
DTC U0100
AENFL80BA504030
DTC U0101
AENFL80BA504035
DTC U0121
AENFL80BA504031
DTC U0140
AENFL80BA504032
DTC U0155
AENFL80BA504033
Inspection of Keyless Start Control Module and Its Circuits

AENFL80BA504034
Check voltage and/or pulse signal of keyless start control module (3) using voltmeter (1) and oscilloscope (2).
NOTE
• Voltage of terminal with asterisk (*) cannot be measured by voltmeter because it is pulse signal.
3
1
2
[a]
[A]
G16 E484
L21
10 9 8 7 6 5 4 3 2 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 4 3 2 1
11 20 19 18 17 16 15 14 13 12 1 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 8 7 6 5
IFL80BA50023-01
[A]: Keyless start control module connector (View: [a])
Normal
voltage
E484-1 BRN Backup power supply 10 – 14 V —
Refer to “Door key cylinder switch signal, door lock
switch signal, rear end door switch signal, door
E484-2* GRY Hood latch switch signal switch signal and hood latch switch signal” (Page
10E-48).
Approx. 0 V Hood: Opened
E484-3 — — — —
Approx. 0 V Clutch pedal: Depressed
Refer to “CPP No.1 switch signal and power
E484-4* GRN CPP No.1 switch signal
supply for starting motor control relay” (Page 10E-
49).
E484-5 YEL Outside warning buzzer 0 ←→ 14 V Outside warning buzzer: Sounding
10 – 14 V Engine: Cranking
E484-6 LT GRN Starting motor control relay signal
E484-7 — — — —
10 – 14 V Engine: Cranking
Power supply for starting motor Refer to “CPP No.1 switch signal and power
E484-8* PNK
control relay supply for starting motor control relay” (Page 10E-
49).
Normal
voltage
G16-1 BLU Power supply for steering lock unit 10 – 14 V —
G16-2 GRY Steering lock unit — —
G16-3 — — — —
Approx. 0 V Engine switch: Pushed
G16-4 BRN Push switch 1 signal
Normal
voltage
G16-5 PNK Steering lock unit — —
G16-6 YEL Engine switch — —
G16-7 GRN Engine switch — —
G16-8 — — — —
CAN communication line (high) Refer to “CAN communication signal” (Page 10E-
G16-9* RED
46).
G16-10 GRN Steering lock unit — —
G16-11 BLU Steering lock unit — —
G16-12 — — — —
G16-13 BRN Engine switch — —
Ground for keyless start control
G16-14 BLK Approx. 0 V —
module
Approx. 0 V Engine switch: Pushed
G16-15 LT GRN Push switch 2 signal
0 ←→ 14 V Theft deterrent light: Blinking
G16-16 LT GRN Theft deterrent light signal
G16-17 GRY Engine switch — —
Approx. 0 V Engine switch illumination: Lit
G16-18 BLU Engine switch illumination signal
10 – 14 V Engine switch illumination: Not lit
CAN communication line (low) Refer to “CAN communication signal” (Page 10E-
G16-19* WHT
46).
G16-20 — — — —
Normal
voltage
Refer to “Mid inside antenna signal” (Page 10E-
L21-1* BLK Mid inside antenna (+) signal
47).
Refer to “Rear inside antenna signal” (Page 10E-
L21-2* LT GRN Rear inside antenna (+) signal
47).
Refer to “Rear outside antenna signal” (Page 10E-
L21-3* WHT Rear outside antenna (+) signal
47).
Refer to “Driver side outside antenna signal and
L21-4* GRN Driver side outside antenna (+) signal passenger side outside antenna signal” (Page
10E-48).
Passenger side outside antenna (+)
L21-5* RED passenger side outside antenna signal” (Page
signal
10E-48).
L21-6 — — — —
L21-7 BLU Power supply for IG1 relay
L21-8 YEL Power supply for IG2 relay
switch signal and hood latch switch signal” (Page
L21-9* GRY Driver door lock switch signal
10E-48).
Driver door lock switch: “Unlock”
Approx. 0 V
position
Passenger door request switch:
Approx. 0 V
L21-10 BLU Passenger door request switch signal Pushed
Approx. 0 V Driver door request switch: Pushed
L21-11 PPL Driver door request switch signal
L21-12 — — — —
Normal
voltage
Door key cylinder switch signal switch signal and hood latch switch signal” (Page
L21-13* BRN
(Unlock) 10E-48).
Door key cylinder switch: “Unlock”
Approx. 0 V
position
L21-14* YEL Rear end door switch signal switch signal and hood latch switch signal” (Page
10E-48).
Approx. 0 V rear end door: Opened
L21-15* BLU Rear right door switch signal switch signal and hood latch switch signal” (Page
10E-48).
Approx. 0 V Rear right door: Opened
L21-16* BEG Driver door switch signal switch signal and hood latch switch signal” (Page
10E-48).
Approx. 0 V Driver door: Opened
L21-17 — — — —
L21-18* LT GRN Door key cylinder switch signal (Lock)
10E-48).
Door key cylinder switch: “Lock”
Approx. 0 V
position
10 – 14 V Ignition: “ACC” or “ON”
L21-19 YEL ACC relay signal
L21-20 RED Backup power supply 10 – 14 V —
Refer to “Mid inside antenna signal” (Page 10E-
L21-21* GRN Mid inside antenna (–) signal
47).
Refer to “Rear inside antenna signal” (Page 10E-
L21-22* RED Rear inside antenna (–) signal
47).
Refer to “Rear outside antenna signal” (Page 10E-
L21-23* BLU Rear outside antenna (–) signal
47).
L21-24* BEG Driver side outside antenna (–) signal passenger side outside antenna signal” (Page
10E-48).
Passenger side outside antenna (–)
L21-25* YEL passenger side outside antenna signal” (Page
signal
10E-48).
L21-26 — — — —
L21-27 GRY Power supply for ACC relay
10 – 14 V Siren: Sounding
L21-28 YEL Siren control
L21-29* PNK Passenger door lock switch signal
10E-48).
Passenger door lock switch: “Unlock”
Approx. 0 V
position
Rear end door request switch:
Approx. 0 V
L21-30 YEL Rear end door request switch signal Pushed
L21-31 — — — —
Normal
voltage
Refer to “Shock sensor signal” (Page 10E-49).
L21-32* BRN Shock sensor signal
Ignition: “ON”
Approx. 0 V
Clutch pedal: Depressed
L21-33 PPL CPP No.2 switch signal
Ignition: “ON”
10 – 14 V
L21-34* WHT Rear left door switch signal switch signal and hood latch switch signal” (Page
10E-48).
Approx. 0 V Rear left door: Opened
L21-35* RED Passenger door switch signal switch signal and hood latch switch signal” (Page
10E-48).
Approx. 0 V Passenger door: Opened
Ground for keyless start control
L21-36 BLK Approx. 0 V —
module
L21-37 — — — —
Approx. 0 V Brake pedal: Released
L21-38 GRN Brake light switch signal
10 – 14 V Brake pedal: Depressed
L21-39 WHT IG1 relay signal
L21-40 BRN IG2 relay signal

oscilloscope. CAN communication signal
NOTE
CAN communication signal (high) (1):
• How to read waveforms is shown below. Channel Probe Terminal No.
+ G16-9
1
– G16-14
CAN communication signal (low) (2):

+ G16-19
2
– G16-14
IAW101970026-01

Rear inside antenna (–) signal (2):

+ L21-22
2
– G16-14
• Remote controller: Within rear inside antenna
detection range
• Door request switch: ON
IAW101A50023-01
Mid inside antenna signal
Mid inside antenna (+) signal (1):

+ L21-1
1
– G16-14
Mid inside antenna (–) signal (2):

Channel Probe Terminal No. IDL10AA50024-01
+ L21-21 3. Unlock 4. Lock
2
– G16-14
Rear outside antenna signal
• Remote controller: Within mid inside antenna Rear outside antenna (+) signal (1):
detection range Channel Probe Terminal No.
• Door request switch: ON + L21-3
1
– G16-14
Rear outside antenna (–) signal (2):

+ L21-23
2
– G16-14
• Remote controller: Within rear outside antenna
detection range
• Rear end door request switch: ON
IDL10AA50023-01
3. Unlock 4. Lock
Rear inside antenna signal
Rear inside antenna (+) signal (1):

+ L21-2
1
– G16-14
IDL10AA50025-01
Driver side outside antenna signal and passenger • Door key cylinder switch (Unlock): OFF
side outside antenna signal
Door key cylinder switch (Lock) signal:
Driver side outside antenna (+) signal (1): Channel Probe Terminal No.
Channel Probe Terminal No. + L21-18
1
+ L21-4 – G16-14
1
– G16-14
Driver side outside antenna (–) signal (2): • Door key cylinder switch (Lock): OFF
+ L21-24 Driver door lock switch signal:
2
– G16-14 Channel Probe Terminal No.
+ L21-9
Measurement condition 1
– G16-14
• Remote controller: Within driver side outside antenna
detection range Measurement condition
• Driver door request switch: ON • Driver door lock switch: Locked
Passenger side outside antenna (+) signal (1): Rear end door switch signal:
+ L21-5 + L21-14
1 1
– G16-14 – G16-14
Passenger side outside antenna (–) signal (2): Measurement condition

Channel Probe Terminal No. • Rear end door: Closed
+ L21-25
2
– G16-14 Rear right door switch signal:
Measurement condition + L21-15
1
• Remote controller: Within passenger side outside – G16-14
antenna detection range
• Passenger door request switch: ON Measurement condition
• Rear right door: Closed
Driver door switch signal:

+ L21-16
1
– G16-14
• Driver door: Closed
Passenger door lock switch signal:

+ L21-29
1
– G16-14
IDL10AA50026-01
3. Unlock 4. Lock Measurement condition

• Passenger door lock switch: Locked
Door key cylinder switch signal, door lock switch
signal, rear end door switch signal, door switch Rear left door switch signal:
signal and hood latch switch signal Channel Probe Terminal No.
+ L21-34
1
Door key cylinder switch (Unlock) signal: – G16-14
+ L21-13 Measurement condition
1
– G16-14 • Rear left door: Closed
Passenger door switch signal: Measurement condition

Channel Probe Terminal No. • Ignition: “OFF”
+ L21-35
1
– G16-14
• Passenger door: Closed
Hood latch switch signal:

+ E484-2
1
– G16-14
• Hood: Closed
IDL10AA50027-01
Shock sensor signal

+ L21-32
1
– G16-14
• Security alarm: ON ↔ OFF
I9P60AA20015-01
CPP No.1 switch signal and power supply for

starting motor control relay
CPP No.1 switch signal:

+ E484-4
1
– G16-14
• Ignition: “OFF” IDL10AA50028-01
• Clutch pedal: Released 2. Security alarm: OFF 3. Security alarm: ON
Power supply for starting motor control relay signal:

+ E484-8
1
– G16-14
Repair Instructions
Remote Controller Registration • Remote controller registration is performed through
AENFL80BA506001 “Immobilizer Key Registration”, and this registers the
NOTE
immobilizer transponder code.
Refer to Operator’s Manual of SUZUKI scan • Performing “Immobilizer Key Registration” clears all of
tool for the immobilizer registration. the ID codes already registered. Prepare all of the
remote controllers.
• Register remote controller ID code using “Immobilizer
Key Registration” function in SUZUKI scan tool.
• It is possible to register 4 remote controllers in keyless 3) For ISG model, Remove gateway control module.
start control module. (Page 11A-53)
• If the keyless start control module is replaced, register 4) For ISG model, Remove DC/DC converter. (Page
all of the remote controllers. 10I-15)
• If all of the remote controllers are lost, register remote 5) Disconnect keyless start control module connectors
controllers after replacing keyless start control (1).
module. 6) Remove nuts (2), and then remove keyless start
control module (3).
Switching Procedure for Disabling / Enabling
Keyless Start System 2
AENFL80BA506002
Select “Keyless Start System” in “Configuration” under 3
“Utility” mode in “Keyless start control module” on
SUZUKI scan tool. (Page 10E-21)
NOTE
• When the keyless start system function is
disabled, the following functions are
inactive. 1
– Keyless engine start function
– Door lock function with door request
switches
– Remote controller lock-in vehicle
prevention function
• When the keyless start system function is
disabled, touching remote controller to
engine switch can start engine and change
ignition mode.
Keyless Start Control Module Registration

AENFL80BA506003
After keyless start control module is replaced with new
one, register remote controller ID code in keyless start
control module using SUZUKI scan tool and security 2
IFL80BA50024-01
device.
1) Prepare all of remote controllers ready for Installation
registration. Reverse removal procedure noting the following points.
2) Perform “Immobilizer Key Registration” in • Tighten keyless start control module nuts to specified
“Immobilizer” menu on SUZUKI scan tool. Refer to torque.
Operator’s Manual of SUZUKI scan tool for further
details. Tightening torque
Keyless start control module nut: 13 N·m (1.3
NOTE kgf-m, 9.5 lbf-ft)
When ECM and keyless start control module • If keyless start control module is replaced, perform
are replaced with new ones at the same time, “Keyless Start Control Module Registration” (Page
perform “Immobilizer Key Registration” 10E-50).
instead of “ECM Registration” using SUZUKI
scan tool and security device. Refer to Driver Side / Passenger Side Outside Antenna
Operator’s Manual of SUZUKI scan tool for
and Door Request Switch Removal and
the immobilizer registration.
Installation
AENFL80BA506005
Driver side and/or passenger side outside antenna and
Keyless Start Control Module Removal and
request switch cannot be removed from outside door
Installation handle.
AENFL80BA506004
Removal Remove and install antenna and request switch referring
1) Disconnect negative (–) cable at battery. to “Front Door Lock Components” in Section 9F in
related manual.
2) Remove glove box.
Rear End Door Request Switch Removal and Rear Outside Antenna Removal and Installation
AENFL80BA506007
Installation Removal
AENFL80BA506006
Refer to “Request Switch On-Vehicle Inspection” in 1) Disconnect negative (–) cable at battery.
Section 9F (Page 9F-3). 2) Remove rear bumper. (Page 9H-3)
3) Disconnect connector (1), and then remove rear
outside antenna (2).
IFL80BA50018-01
Installation
Mid Inside Antenna Removal and Installation

AENFL80BA506008
Removal
2) Remove center console box. (Page 9H-7)
3) Disconnect connector (1), and then remove mid
inside antenna (2).
1
IFL80BA50019-01
Installation
Rear Inside Antenna Removal and Installation

AENFL80BA506009
Removal
2) Remove luggage box. (Page 9H-3)
3) Disconnect rear inside antenna connector (1), and
then remove rear inside antenna (2).
[A]
1
1 2
IFL80BA50020-01
Installation
Reverse removal procedure. [B]
Request Switch Inspection

AENFL80BA506010
1) Remove door trim.
2 1
• Driver and passenger door trim:  1
• Rear end door trim: 

2) Disconnect request switch connector (1).
IFL80BA50022-01
3) Check request switch for continuity between
[A]: Front door [D]: PUSH
terminals at each switch position.
[B]: Rear end door [E]: Switch position
If check result is not as specified, replace request
[C]: FREE [F]: Terminal
switch.
Antenna Inspection
[F] 1 2 AENFL80BA506011
[E]
Using SUZUKI Scan Tool
[D]
1) Connect SUZUKI scan tool to DLC with ignition
“OFF”.
[C]
IFL80BA50021-01
3) Select “Keyless Start Antenna” function in “Active
Test” mode.
4) Check that each antenna operates.
If check result is not as specified, check applicable
circuit for open or short. (Page 10E-43)
If check result is as specified, replace applicable
antenna.
• Driver / Passenger side outside antenna: (Page
10E-50)
• Rear outside antenna: (Page 10E-51)
• Mid inside antenna: (Page 10E-51)
• Rear inside antenna: (Page 10E-51)
Not Using SUZUKI Scan Tool

Referring to the following table, check the function by
exchanging each antenna.
Trouble antenna Exchanging antenna
Driver side outside antenna Passenger side outside
antenna
Passenger side outside Driver side outside antenna
antenna
Rear outside antenna —
Mid inside antenna Rear inside antenna
Rear inside antenna Mid inside antenna
If check result is not as specified, check applicable NOTE

circuit for open or short. Use diode range of circuit tester when
checking terminals “12” and “10”.
Driver / Passenger Door Lock Switch Removal
and Installation
AENFL80BA506012
[F]
Refer to “Front Door Lock Assembly Removal and 1 2 7 12 10
[E]
Installation” in Section 9F (Page 9F-2).
[D]
Driver / Passenger Door Lock Switch Inspection
AENFL80BA506013
[C]
Refer to “Door Lock Switch and Actuator On-Vehicle
Inspection (If Equipped)” in Section 9F in related
manual.
[A]
Engine Switch Removal and Installation 1

AENFL80BA506014
[B]
Removal
6 5 4 3 2 1
1) Disconnect negative (–) cable at battery. 2
12 11 10 9 8 7
2) Remove steering column hole cover. (Page 9C-24) 7
3) Remove instrument panel driver outside garnish. 12

(Page 9C-24)
10
4) Remove engine switch from instrument panel driver
IDL10AA50036-01
outside garnish.
[A]: Push switch 1 [D]: PUSH
Installation [B]: Push switch 2 [E]: Switch position
[C]: FREE [F]: Terminal
Engine Switch Inspection Hood Latch Switch Removal and Installation

AENFL80BA506016
AENFL80BA506015
Check engine switch for continuity between terminals at Refer to “Hood Latch Switch Removal and Installation” in
each switch position. Section 10I (Page 10I-15).
If check result is not as specified, replace engine switch.
Hood Latch Switch Inspection
AENFL80BA506017
Refer to “Hood Latch Switch Inspection” in Section 10I
(Page 10I-15).
Siren Removal and Installation

AENFL80BA506018
Refer to “Siren Removal and Installation” in Section 10B
in related manual.
Siren Inspection
AENFL80BA506019
Refer to “Siren Inspection” in Section 10B in related
manual.
Security Alarm Mode Selection Procedure

AENFL80BA506020
Security alarm mode can be selected by performing the
following procedure.
NOTE NOTE
Security alarm mode can also be selected by This procedure can also be selected by
setting change function, refer to “Scan Tool customized menu of combination meter, refer
Utility Table” (Page 10E-21) or “Information to “Information Display” under “Combination
Display” under “Combination Meter Meter Description” in Section 9C (Page 9C-1).
Description” in Section 9C (Page 9C-1).
1) Check that all doors are closed, all doors are Shock Sensor Full Blast Sensitivity Level
unlocked and lighting switch is “OFF” position. Selection Procedure
AENFL80BA506022
2) Set ignition “ON”. Setting of shock sensor full blast sensitivity can be
3) Perform the following steps within 15 seconds. changed in 16 levels (OFF, Level 1 to Level 15). The
a) Turn lighting switch to “CLEARANCE” position. level with bigger number can detect weaker shock.
Select “Shock Sensor Full Blast Sensitivity” refer to
b) Turn lighting switch to “OFF” position. “Scan Tool Utility Table” (Page 10E-21).
c) Repeat Step a) - b) 3 times.
NOTE
d) Operate driver door lock switch (1) to “LOCK”
position. This procedure can also be selected by
e) Operate driver door lock switch to “UNLOCK” customized menu of combination meter, refer
position. to “Information Display” under “Combination
Meter Description” in Section 9C (Page 9C-1).
f) Repeat Step d) and e) once.
g) Operate driver door lock switch to “LOCK”
position. Shock Sensor Pre-Warn Sensitivity Level
Selection Procedure
AENFL80BA506023
Lock
Setting of shock sensor pre-warn sensitivity can be
Unlock
changed in 16 levels (OFF, Level 1 to Level 15). The
level with bigger number can detect weaker shock.
Select “Shock Sensor Pre-warn Sensitivity” refer to
“Scan Tool Utility Table” (Page 10E-21).
NOTE
1 This procedure can also be selected by
customized menu of combination meter, refer
to “Information Display” under “Combination
Meter Description” in Section 9C (Page 9C-1).
Shock Sensor Removal and Installation

AENFL80BA506024
Refer to “Shock Sensor Removal and Installation” in
Section 10B in related manual.
Outside Warning Buzzer Removal and

IDL10AA50038-01
Installation
AENFL80BA506025
4) Warning buzzer (in combination meter) sounds by Removal
the specified number for each mode as follows. 1) Disconnect negative (–) cable at battery.
• Changed from “Passive” mode to “Active” mode: 2) Remove driver side front fender lining. 
Buzzer sounds 4 times.
3) Disconnect connector (1), and then remove outside
• Changed from “Active” mode to “Passive” mode: warning buzzer (2).
Buzzer sounds once.
Shock Sensor Mode Selection Procedure

AENFL80BA506021
Setting of shock sensor function in security alarm can be
changed in “ON” mode or “OFF” mode. Select “Shock
Sensor” refer to “Scan Tool Utility Table” (Page 10E-21).
4) Remove battery (2) using a flat-bladed screwdriver

(1) as shown in figure.
2
2
3
IFL80BA50026-01
1
3. Shop rag
5) Place battery (lithium disc-type CR 2032 or

IDL10AA50037-01 equivalent) (1) so its “–” terminal faces “–” mark of
the printed circuit board (2).
Installation
Outside Warning Buzzer Inspection

AENFL80BA506026 1
1) Connect SUZUKI scan tool to DLC with ignition
“OFF”. 2
IFL80BA50027-01
3) Select “Warning buzzer (Outside)” function in “Active
Test” mode. 6) Install printed circuit board to lower case and then fit
upper case securely.
4) Check that outside warning buzzer sounds.
If check result is not as specified, check applicable
circuit for open or short. If circuit is normal, replace
outside warning buzzer and recheck it.
Remote Controller Battery Replacement

AENFL80BA506027
1) Remove emergency key (4).
2) Remove upper case (1) using a flat-bladed
screwdriver as shown in figure.
3) Remove printed circuit board (2) from lower case (3).
4
3
IAW101A50043-01
5. Shop rag
NOTE
• Insert the battery all the way into the
printed circuit board.
• Do not touch any electrical components of
the remote controller.
• Be careful not to get any oil or foreign
material on the remote controller or
battery.
• Do not replace the battery with wet hands.
• Dispose of the used battery properly
according to applicable rules or
regulations. Do not dispose of lithium
batteries with ordinary household trash.
Specifications
AENFL80BA507002
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Keyless start control module nut 13 1.3 9.5 
Reference:

Special Tool
AENFL80BA508002
SDT-II)
—
/
10H-1 Communication System: Petrol and Bi-Fuel CNG Model
Communication System
Control Systems

Precautions
AENFL80BA810001
• Before using SUZUKI scan tool, read its “Operator’s (Instructions) Manual” to know how to use it.
• Diagnosing target control module / sensor only is not enough in order to accurately diagnose any trouble of CAN
communication system. Check communication conditions of overall system (including control modules and sensor
related to CAN communication) and diagnose trouble by putting those information together.
• It is possible that CAN system has trouble because of blown fuse or low battery voltage. Before troubleshooting,
confirm that fuse, battery voltage and charging system condition are normal.
• CAN communication error is detected if connector of control modules or sensor being connected to CAN
communication line or applicable fuse is connected / disconnected when ignition is “ON”.
• Confirm that no equipment or option other than original parts is connected onto CAN bus. If any of those items are
connected, disconnect it before troubleshooting.
• If any DTCs together with “Lost Communication” (Reception error) and/or “Communication Bus Off” are displayed,
start troubleshooting of CAN communication first.
• Before diagnosing trouble, be sure to check equipment of vehicle being serviced as well as control modules and
sensor connected to CAN communication line.
• Be sure to clear all DTCs after completing troubleshooting.
General Description
Communication System Description
AENFL80BA811001
System Description
Communication between each control module and device is established through continuous input / output of ON/OFF
signals with various data items. Transmitting / receiving these data is called as serial communication interface.
Several types of serial communication interface protocols (a communication standard) such as UART, CAN and LIN
have been adopted for in-car communication system.
UART is used for communication between keyless start control module and steering lock unit.
LIN is used for communication between shock sensor and BCM (ignition switch model) or keyless start control module
In addition, BCM, keyless start control module (keyless push start model), ECM, combination meter, P/S control
module, ABS control module (ABS model), TCM (A/T model), CNG control module (Bi-fuel CNG model) and SDM
transmit / receive data through a twist pair of two communication lines (CAN High and CAN Low) connected through
CAN communication. Data obtained by a specific control module can be shared with every control module.
UART and LIN Communication Signal

UART and LIN communication system is a serial communication system capable of transmitting multiple types of
information using a single communication line.
Each block of data transmitted via the serial communication system is called a frame.
A frame contains multiple bytes, and each byte consists of a start bit, data bits, and a stop bit.
The data bit stream consists of 8 data bits that are transmitted in series, and each bit is assigned to a specific
information item.
Switching between High and Low in each bit enables transmission of multiple types of information via a single
communication line.
When multiple devices are connected, 1 transmission cycle includes more than 1 frame and the frame length varies
depending on the protocol used.
Communication System: Petrol and Bi-Fuel CNG Model 10H-2
1 Byte
Start bit Data bit Stop bit

High (Approx. 12 V)
Low (Approx. 0 V)
1 2 3 4 5 6 7 8
bit bit bit bit bit bit bit bit
No.1 frame No.2 frame No.1 frame
High (Approx. 12 V)
Low (Approx. 0 V)
Present transmission cycle Next transmission cycle
IDL10AA80008-02
CAN Communication Signal

CAN communication system is a serial communication system for transmitting multiple data items (values from
sensors, control data and control signals) as ON/OFF signals through communication lines. This system uses two
lines (CAN High and CAN Low) for the communication circuit to maintain high reliability even when used for high-
speed serial communication.
Serial communication is established as shown below with 2.5 V as the reference level for both CAN High signal (1)
and CAN Low signal (2). The range of CAN High signal is from 2.5 V to about 3.5 V and that of CAN Low signal is from
2.5 V to about 1.5 V. When both are at 2.5 V, signal is judged as OFF. When CAN High signal is 3.5 V and CAN Low
signal is 1.5 V (that is, when the difference between High voltage and Low voltage is more than about 2 V), signal is
judged as ON. For this reason, a feature of CAN communication signal is that the signal waveform between CAN High
and CAN Low signals is symmetrical with respect to 2.5 V level. CAN communication fails when the symmetrical
signal form collapses.
1
3.5 V
2.5 V
2.5 V
1.5 V
2
I7V10AA81002-01
CAN Communication System Diagnosis General Description

AENFL80BA811002
SUZUKI scan tool is used for diagnosis in this section. Communication method between SUZUKI scan tool and each
control module and sensor is shown below.
Special tool
1
3
4 9
5
[B]
6 10
[C]
7
: [A]
IFL80BA81004-01
[A]: CAN communication line [B]: With ABS [C]: Without ABS
Control module / sensor Communication with scan tool Monitor of CAN-DTC Bus check function
1 Combination meter CAN Available Available
2 DLC — — —
3 SDM CAN Available Available
4 Keyless start control module CAN Available Available
5 CNG control module (Bi-fuel CAN Available Available
CNG model)
6 ECM CAN Available Available
7 TCM (A/T model) CAN Available Available
8 P/S control module CAN Available Available
9 BCM CAN Available Available
10 ABS control module CAN Available Available
CAN Communication System Transmitting and Receiving Data Table

AENFL80BA811003
NOTE
• T (Transmitting): When two or more control modules start transmission at the same time, control
module transmitting the highest priority information enters data transmission mode and all other
control modules enter reception mode.
• R (Receiving): All control modules connected with CAN communication lines receive all information
on CAN communication line. Each control module selects only the necessary information for
performing its control.
• ECM calculates and determines vehicle speed based on VSS signal and transmits the information to
other control modules through CAN.
• *1: ABS model
Bi-fuel CNG Model
CNG control module *4
ABS control module

Combination meter
P/S control module

BCM
ECM
SDM
EPI fail safe control T R
Engine torque signal T R
Engine speed signal T R R R R
MIL control signal T R
Engine coolant temperature signal T R R
Engine oil information signal T R
Immobilizer indicator light control signal T T R
Vehicle speed signal T R R R R
Fuel consumption signal T R
Brake light switch signal T R R
Charging system signal T T R
CNG service lamp indication ON T R
CNG mode indication status T R
Petrol mode indication status T R
Auto mode indication status T R
Gas fuel temperature R T R
Gas fuel pressure R T R
CNG remaining fuel pressure R T
Illumination ON signal T R
Brake fluid level switch signal T R
Oil pressure switch signal R T
A/C ON signal R T
Parking brake switch signal T R R
A/C switch status R T
Electric load signal R T R
Turn signal switch signal T R
Buzzer request signal T R
Driver seat belt switch signal T R
Door switch status T R
A/C evaporator temperature signal R T
Outside air temperature signal R T R
Fuel level signal R T
Mileage information signal R T
P/S warning light signal R T
Wheel speed signal R T
CNG control module *4
ABS control module

Combination meter
P/S control module

BCM
ECM
SDM
Warning light signal (ABS / EBD) R T
Air bag deployment signal R T
Air bag indication light signal R T
NOTE
• *1: Ignition switch model
• *2: Keyless push start model
• *3: A/T model
• *4: M/T model
• *5: ABS model
Petrol (Non-CNG) Model

Keyl
ess
Com P/S ABS
start
binat cont cont
TCM BCM BCM cont
ECM ion rol rol SDM
*3 *1 *2 rol
mete mod mod
mod
r ule ule
ule
*2
Engine torque signal T R R
Accelerator position signal T R
Engine speed signal T R R R R R R R
Throttle position signal T R
Engine coolant temperature signal T R R R R
Immobilizer indicator light control signal T T T R
Vehicle speed signal T R R R R R
Brake light switch signal T R R R R R*1 R
Charging system signal T T T R
Transmission warning light signal R T R
Transmission shift position signal R T R R R R
O/D off switch signal T R
Illumination ON signal T T R
Brake fluid level switch signal T T R
Oil pressure switch signal R T T
Parking brake switch signal T T R R
A/C switch status R T T
Electric load signal R T T R R
Turn signal switch status T T R
T T R
Buzzer request signal
R T R
Driver seat belt switch signal T T R
T T R
Door switch status
R T
Door lock status T R
A/C evaporator temperature signal R T T
Keyl
ess
Com P/S ABS
start
binat cont cont
TCM BCM BCM cont
ECM ion rol rol SDM
*3 *1 *2 rol
mete mod mod
mod
r ule ule
ule
*2
Outside air temperature signal R T T R
Light switch status T R
Key lock / unlock switch status R T
Door lock / unlock request signal R T
Rear end door opener request signal R T
Answer back request signal R T
Power mode status R T R
Electric load signal (High beam) R R T
Illumination signal R R T
Fuel level signal R T
Mileage information signal R T*2
Wheel speed signal R*4 R T
Air bag deployment signal R R T
Air bag indication light signal R T

CAN Communication System Circuit Diagram
AENFL80BA812001
1
[b]
G240-21 RED G50-4
11 11
5
G240-9 WHT G50-7
2 G50-5 G50-6
[a]
G240-22 RED G211-6 [c]
G240-10 WHT G211-14
RED WHT
3
[i]
G240-24 RED G11-13
11
G240-12 WHT G11-14
G369 G370
[C]:G04-2 [C]:G04-18
[D]:G05-2 [D]:G05-1
[D]
4
11 6
[h]
G240-23 RED G16-9
11 [C]:E04-4 [C]:E04-11
G240-11 WHT G16-19
[D]:E05-5 [D]:E05-6
9 [E]
C12-33 RED WHT

11
C12-25 [g]
[d]
[A]
WHT
RED
E24-2 E24-15
C01-3 C01-15
[e]
E01-1 RED RED E24-3 7
8 11 11
E01-2 WHT WHT E24-16
C01-3 C01-15
[B]
10 RED WHT
C06-17 [j]
11 [f] RED WHT
C06-7
[F]
IFL80BA81001-01
C01 E01
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
[k]
13 14 15 16 17 18 19 20 21 22 23 24 13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 25 26 27 28 29 30 31 32 33 34 35 36
37 38 39 40 41 42 43 44 45 46 47 48 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 49 50 51 52 53 54 55 56
G50 G11
[C] E04 1 2 3 1 2 3 4 5 6 7 8
G04
4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
15 16 17 18 19 20 21
8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
[D]
E05 G05 G16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 2 3 4 5 6 7 8 9 10
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 11
13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20
G240 G211 E24
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
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 15 16 15 16 17 18 19 20 21 22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38
C12 C06
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17
1 2 3 4 5 6
18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
IFL80BA81002-01
[A]: ABS model [k]: Connector view 7. ABS control module

[B]: Non-ABS model 1. Combination meter 8. ECM
[C]: Ignition switch model 2. DLC 9. CNG control module
[D]: Keyless push start model 3. SDM 10. TCM
[E]: Bi-Fuel CNG model 4. Keyless start control module 11. CAN driver
[F]: A/T model 5. P/S control module
[a] to [j]: CAN communication line (linked with diagnosis flows [a] to [j] of 6. BCM
“Diagnosis Flow Selection Table”)
Component Location
CAN Communication System Component Location
AENFL80BA813001
3 6
10
4
5
IFL80BA81003-01
1. ABS control module (ABS model) 5. BCM 9. Keyless start control module (Keyless push start model)
2. ECM 6. Combination meter 10. TCM (A/T model)
3. P/S control module 7. DLC
4. SDM 8. CNG control module (Bi-Fuel CNG model)

CAN Communication Check
AENFL80BA814001
Using SUZUKI scan tool, execute “Communication Malfunction DTC” under “Bus check” and check DTCs of all control
modules connected to CAN Communication Bus.
Condition Action Reference
Check the following:
1. Disconnect and connect all control
module and sensor connectors connected
to the CAN communication line.
2. Check all control module power sources
Only history DTC is detected in either of (including fuses) connected to the CAN
communication line. —
system
3. Start the engine and check DTC while
idling.
If the detected DTC is a history DTC,
there may be a temporary malfunction
due to poor connection at the connector
or faulty power supply.
“Control Module Bus Off” is detected in either Perform “Troubleshooting for Communication
(Page 10H-19)
of system (current DTC) Bus Off”.
Only “Lost Communication” is detected in Perform “Troubleshooting for Lost
(Page 10H-12)
either of system (current DTC) Communication”.
Check if SUZUKI scan tool is communicable
—
No display on SUZUKI scan tool (It is not by connecting it to another vehicle.
possible to communicate with any systems.) Perform “Troubleshooting for Lost
(Page 10H-12)
Communication”.
CAN DTC (Lost Communication and Communication Bus Off) Table

AENFL80BA814002
DTC DTC name Detecting condition
ECM
Control Module Communication ECM fails to transmit and receive the data via CAN
U0073 (Page 10H-19)
Bus Off for specified time continuously.
Receiving error of the data from TCM control
U0101 (Page 10H-12) Lost Communication With TCM
module via CAN for specified time continuously.
Lost Communication With Receiving error of the data from CNG control
U0108 (Page 10H-12)
Alternative Fuel Control Module module via CAN for specified time continuously.
Lost Communication With ABS / Receiving error of the data from ABS control module
U0121 (Page 10H-12)
ESP® Control Module via CAN for specified time continuously.
Lost Communication With Power Receiving error of the data from P/S control module
U0131 (Page 10H-12)
Steering Control Module via CAN for specified time continuously.
Lost Communication With Body Receiving error of the data from BCM via CAN for
U0140 (Page 10H-12)
Lost Communication With Keyless Receiving error of the data from BCM via CAN for
U0141 (Page 10H-12)
Start Control Module specified time continuously.
Receiving error of the data from combination meter
U0155 (Page 10H-12) Instrument Panel Cluster (IPC)
via CAN for specified time continuously.
Control Module
ABS control module
Control Module Communication ABS control module fails to transmit and receive the
U0073 (Page 10H-19)
Bus Off data via CAN for specified time continuously.
U0100 (Page 10H-12) Lost Communication With ECM
TCM (A/T model)
U0073 (Page 10H-19)

CNG control module (Bi-fuel CNG model)
U0073 (Page 10H-19)
BCM (ignition switch model)
Control Module Communication BCM fails to transmit and receive the data via CAN
U0073 (Page 10H-19)
Lost Communication With Receiving error of the data from SDM via CAN for
U0151 (Page 10H-12)
Restraints Control Module specified time continuously.
BCM (keyless push start model)
U0073 (Page 10H-19)
Lost Communication With Keyless Receiving error of the data from keyless start control
U0141 (Page 10H-12)
Start Control Module module via CAN for specified time continuously.
U0151 (Page 10H-12)
Control Module
P/S control module
Control Module Communication P/S control module fails to transmit and receive the
U0073 (Page 10H-19)
Control Module
Combination meter
Control Module Communication Combination meter fails to transmit and receive the
U0073 (Page 10H-19)
Receiving error of the data from TCM via CAN for
U0121 (Page 10H-12)
U0140 (Page 10H-12)
U0141 (Page 10H-12)
U0151 (Page 10H-12)
Keyless start control module (keyless push start model)
Keyless start control module fails to transmit and
Control Module Communication
U0073 (Page 10H-19) receive the data via CAN for specified time
Bus Off
continuously.
Receiving error of the data from TCM via CAN for
U0121 (Page 10H-12)
U0140 (Page 10H-12)

Control Module
SDM
Control Module Communication SDM fails to transmit and receive the data via CAN
U0073 (Page 10H-19)
Troubleshooting for Lost Communication

AENFL80BA814003
Circuit Diagram
1
[b]
G240-21 RED G50-4
11 11
5
G240-9 WHT G50-7
2 G50-5 G50-6
[a]
G240-22 RED G211-6 [c]
G240-10 WHT G211-14
RED WHT
3
[i]
G240-24 RED G11-13
11
G240-12 WHT G11-14
G369 G370
[C]:G04-2 [C]:G04-18
[D]:G05-2 [D]:G05-1
[D]
4
11 6
[h]
G240-23 RED G16-9
11 [C]:E04-4 [C]:E04-11
G240-11 WHT G16-19
[D]:E05-5 [D]:E05-6
9 [E]
C12-33 RED WHT

11
C12-25 [g]
[d]
[A]
WHT
RED
E24-2 E24-15
C01-3 C01-15
[e]
E01-1 RED RED E24-3 7
8 11 11
C01-3 C01-15
[B]
10 RED WHT
C06-17 [j]
11 [f] RED WHT
C06-7
[F]
IFL80BA81001-01
C01 E01
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
[k]
13 14 15 16 17 18 19 20 21 22 23 24 13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 25 26 27 28 29 30 31 32 33 34 35 36
37 38 39 40 41 42 43 44 45 46 47 48 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 49 50 51 52 53 54 55 56
G50 G11
[C] E04 1 2 3 1 2 3 4 5 6 7 8
G04
4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
15 16 17 18 19 20 21
8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
[D]
E05 G05 G16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 2 3 4 5 6 7 8 9 10
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 11
13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20
G240 G211 E24
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
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 15 16 15 16 17 18 19 20 21 22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38
C12 C06
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17
1 2 3 4 5 6
18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
IFL80BA81002-01

Diagnosis Procedure
NOTE
• Perform “CAN Communication Check”: Petrol and Bi-Fuel CNG Model (Page 10H-10) before
performing this flow.
• Occurrence of multiple troubles is not included in the scope of this trouble diagnosis.
When “Lost Communication” is detected in any control module, perform diagnosis according to the following
procedure.
1) Connect SUZUKI scan tool to DLC.
3) Select “Communication Bus Check” under “Bus Check” menu of SUZUKI scan tool and check for communication-
disabled control module (it is not displayed).
4) Based on above check results, select applicable diagnosis flow ([a] to [j]) from “Diagnosis Flow Selection Table”:
Petrol and Bi-Fuel CNG Model (Page 10H-14).
5) Perform troubleshooting according to selected diagnosis flow.
Diagnosis Flow Selection Table
NOTE
• If an individual control module fails to communicate, check whether power circuit or ground circuit
of control module is in good condition, referring to system circuit diagram, etc. before diagnosing
trouble with flow chart.
• If it is not possible to select suitable diagnosis flow from “Diagnosis Flow Selection Table” or “two
or more diagnosis flows are selectable”, perform “Troubleshooting for Communication Bus Off”:
• Diagnosis flows [a] to [j] linked with CAN communication lines [a] to [j] of “Circuit Diagram”: Petrol
and Bi-Fuel CNG Model (Page 10H-12).
ABS model
Communication-disabled control module Diagnosis flow
All control modules communicating by CAN [a] (Page 10H-14)
P/S control module, BCM, ABS control module, ECM,
[b] (Page 10H-15)
CNG control module and TCM
BCM, ABS control module, ECM, CNG control module
[c] (Page 10H-15)
and TCM
ABS control module, ECM, CNG control module and
[d] (Page 10H-16)
TCM
ECM, CNG control module and TCM [e] (Page 10H-16)
CNG control module [g] (Page 10H-18)
Keyless start control module [h] (Page 10H-18)
SDM [i] (Page 10H-18)
TCM [j] (Page 10H-18)
Without ABS model

Communication-disabled control module / sensor Diagnosis flow
P/S control module, BCM and ECM [b] (Page 10H-15)
BCM and ECM [c] (Page 10H-15)
ECM [f] (Page 10H-17)
Troubleshooting
Diagnosis flow: [a]
Step Action Yes No
1) Disconnect negative (–) cable at battery. defective wire harness.
2) Disconnect combination meter connector.
3) Check for proper connection to DLC and combination
meter connector.
4) If connections are OK, check CAN communication circuit
[a] between DLC and combination meter connector for
open circuit.
Is check result OK?

Step Action Yes No

2 Combination meter terminating resistance check Go to “Troubleshooting Replace combination
1) Connect combination meter connector. for Communication Bus meter and recheck
Off”: Petrol and Bi-Fuel DTC. (Page 9C-24)
2) Disconnect ECM connector “E01”.
CNG Model (Page 10H-
3) Measure resistance between “G211-6” and “G211-14” 19).
terminals of DLC.
Is resistance 114 to 134 Ω?
Diagnosis flow: [b]

Step Action Yes No
2) Disconnect combination meter connector and P/S
control module connector “G50”.
connector.
[b] between combination meter connector and P/S
control module connector for open circuit.
Is check result OK?

2 CAN communication circuit resistance check Replace P/S control Replace combination
1) Connect combination meter connector. module and recheck meter and recheck
DTC.  DTC. (Page 9C-24)
2) Measure resistance between “G50-4” and “G50-7”
terminals of P/S control module connector.
Diagnosis flow: [c]

Step Action Yes No
2) Disconnect P/S control module connector “G50” and
following BCM connector.
• Ignition switch model: “G04”
• Keyless push start model: “G05”
3) Check for proper connection to P/S control module
connector and BCM connector.
[c] between P/S control module connector and BCM
connector for open circuit.
Is check result OK?

2 CAN communication circuit resistance check Replace BCM and Replace P/S control
1) Connect P/S control module connector. recheck DTC. module and recheck
DTC. 
2) Measure resistance between following terminals of BCM • Ignition switch model:
connector. 
• Ignition switch model: “G04-2” and “G04-18” • Keyless push start
• Keyless push start model: “G05-2” and “G05-1” model: (Page 10B-
34)
Diagnosis flow: [d]

Step Action Yes No
2) Disconnect BCM connector “E04” (ignition switch model)
/ “E05” (keyless push start model) and ABS control
module connector.
3) Check for proper connection to BCM connector and ABS
control module connector.
[d] between BCM connector and ABS control module
Is check result OK?

2 CAN communication circuit resistance check Replace ABS control Replace BCM and
1) Connect BCM connector “E04” (ignition switch model) / module and recheck recheck DTC.
“E05” (keyless push start model). DTC.  • Ignition switch model:
2) Measure resistance between “E24-2” and “E24-15” 
terminals of ABS control module connector. • Keyless push start
34)
Diagnosis flow: [e]

Step Action Yes No
2) Disconnect ABS control module connector and ECM
connector “E01”.
3) Check for proper connection to ABS control module
connector and ECM connector “E01”.
[e] between ABS control module connector and ECM
Is check result OK?

2 CAN communication circuit resistance check Replace ABS control Replace ECM and
1) Connect ECM connector “E01”. module and recheck recheck DTC. 
DTC. 
2) Measure resistance between “E24-3” and “E24-16”
terminals of ABS control module connector.

Diagnosis flow: [f]

Step Action Yes No
2) Disconnect BCM connector “E04” (ignition switch model)
/ “E05” (keyless push start model) and ECM connector
“E01”.
3) Check for proper connection to BCM connector “E04”
(ignition switch model) / “E05” (keyless push start model)
and ECM connector “E01”.
[f] between BCM connector and ECM connector for open
circuit.
Is check result OK?

2 ECM terminating resistance check Replace BCM and Replace ECM and
1) Connect ECM connector “E01”. recheck DTC. recheck DTC. 
2) Measure resistance between following terminals of BCM • Ignition switch model:
connector. 
• Ignition switch model: “E04-4” and “E04-11” • Keyless push start
• Keyless push start model: “E05-5” and “E05-6” model: (Page 10B-
34)
Diagnosis flow: [g]

Step Action Yes No
2) Disconnect CNG control module connector “C12”and
ECM connectors “C01” and “E01”.
3) Check for proper connection to CNG control module
connector and ECM connector “C01”.
[g] between CNG control module connector and ECM
Is check result OK?

2 CAN communication circuit resistance check Replace CNG control Replace ECM and
1) Connect CNG control module connector “C12”. module and recheck recheck DTC. 
DTC. 
2) Measure resistance between “C12-25” and “C12-33”
terminals of CNG control module connector.

Diagnosis flow: [h]

Step Action Yes No
2) Disconnect combination meter connector and keyless
start control module connector “G16”.
connector and keyless start control module connector
“G16”.
[h] between combination meter connector and keyless
start control module connector for open circuit.
Is check result OK?

2 CAN communication circuit resistance check Replace keyless start Replace combination
1) Connect combination meter connector. control module and meter and recheck
recheck DTC. (Page DTC. (Page 9C-24)
10E-50)
terminals of keyless start control module connector.
Diagnosis flow: [i]

Step Action Yes No
1 CAN communication circuit check Go to Step 2. Repair or replace the
1) Disconnect negative (–) cable at battery. following defective part.
2) Disconnect combination meter connector and SDM • CAN communication
connector “G11”. circuit [i] is faulty
3) Check for proper connection to combination meter between combination
connector and SDM connector “G11”. meter and SDM.
4) If connections are OK, check CAN communication circuit • Poor connection of

[i] between combination meter connector and SDM “G369” and “G370”
connector for open circuit. connectors.
Is check result OK?

2 CAN communication circuit resistance check Replace SDM and Replace combination
1) Connect combination meter connector. recheck DTC.  meter and recheck
terminals of SDM connector.
Diagnosis flow: [j]

Step Action Yes No
2) Disconnect TCM connector “C06” and ECM connectors
“C01” and “E01”.
3) Check for proper connection to TCM connector and
ECM connector “C01”.
[j] between TCM connector and ECM connector for open
circuit.
Is check result OK?

Step Action Yes No

2 CAN communication circuit resistance check Replace TCM and Replace ECM and
1) Connect TCM connector “C06”. recheck DTC. (Page recheck DTC. 
5A-121)
2) Measure resistance between “C06-7” and “C06-17”
terminals of CNG control module connector.
Troubleshooting for Communication Bus Off

AENFL80BA814004
NOTE
Be sure to perform “CAN Communication Check”: Petrol and Bi-Fuel CNG Model (Page 10H-10) before
performing this flow.
Circuit Diagram
1
[b]
G240-21 RED G50-4
11 11
5
G240-9 WHT G50-7
2 G50-5 G50-6
[a]
G240-22 RED G211-6 [c]
G240-10 WHT G211-14
RED WHT
3
[i]
G240-24 RED G11-13
11
G240-12 WHT G11-14
G369 G370
[C]:G04-2 [C]:G04-18
[D]:G05-2 [D]:G05-1
[D]
4
11 6
[h]
G240-23 RED G16-9
11 [C]:E04-4 [C]:E04-11
G240-11 WHT G16-19
[D]:E05-5 [D]:E05-6
9 [E]
C12-33 RED WHT

11
C12-25 [g]
[d]
[A]
WHT
RED
E24-2 E24-15
C01-3 C01-15
[e]
E01-1 RED RED E24-3 7
8 11 11
C01-3 C01-15
[B]
10 RED WHT
C06-17 [j]
11 [f] RED WHT
C06-7
[F]
IFL80BA81001-01
C01 E01
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
[k]
13 14 15 16 17 18 19 20 21 22 23 24 13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 25 26 27 28 29 30 31 32 33 34 35 36
37 38 39 40 41 42 43 44 45 46 47 48 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 49 50 51 52 53 54 55 56
G50 G11
[C] E04 1 2 3 1 2 3 4 5 6 7 8
G04
4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
15 16 17 18 19 20 21
8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
[D]
E05 G05 G16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 2 3 4 5 6 7 8 9 10
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 11
13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20
G240 G211 E24
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
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 15 16 15 16 17 18 19 20 21 22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38
C12 C06
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17
1 2 3 4 5 6
18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
IFL80BA81002-01

Diagnosis Procedure
When “CAN Communication Bus Off” is detected in any control modules, or when it is not possible to communicate
with any control modules with CAN using SUZUKI scan tool, perform the following procedure.
1) Connect oscilloscope to DLC when ignition is “OFF”.
2) Using oscilloscope, observe waveform in the following condition when ignition is “ON”.
+ G211-6 (Page 10H-20)
1
– Ground
+ G211-14 (Page 10H-20)
2
– Ground
3) Compare observed signal waveform and waveforms given as “Reference Waveform”. Find the most similar signal
waveform and identify the system in trouble and cause of trouble. (Page 10H-25)
4) Perform troubleshooting. (Page 10H-24)
Reference Waveform
NOTE
Waveforms in “Examples of abnormal waveforms” are selected examples of CAN communication
waveforms seen when an abnormal condition occurs. However, these waveforms may not be exactly
the same in appearance as observed waveforms. Therefore, to identify an abnormal condition, select
the waveform that is most similar to the observed waveform from “Examples of abnormal waveforms”:
Normal waveform
Normal waveform Description
Reference voltages for both
[D] CAN High signal and CAN
Low signal are 2.5 V.
Waveform of CAN High
signal is 2.5 – 3.5 V and that
of CAN Low signal is 2.5 –
1.5 V.
[E]
[A]
[B] [C]
IDAA0AA82009-01
[A]: Ground level of each channel [D]: Waveform of channel 1 (CAN High signal)
[B]: VOLT/DIV of each channel [E]: Waveform of channel 2 (CAN Low signal)
[C]: TIME/DIV of each channel
Examples of abnormal waveforms

Characteristic waveform
Possible cause Description
CAN High signal CAN Low signal
Shorted to ground In case CAN High signal
wire is shorted to ground
circuit
Both of CAN High signal
and CAN Low signal are
fixed to GND level (0 V).
In case CAN Low signal
circuit
IDAA0AA82011-01
IDAA0AA82010-01 of CAN High signal and
CAN Low signal are GND
level (0 V) and CAN High
signal waveform oscillates
irregularly.
• CAN High signal:
Between 0 V and 3.5 V
• CAN Low signal: Fixed to
0V
Opened In case CAN High signal
wire is open
CAN High signal and CAN
Low signal are 2.5 V and
these waveforms oscillate
irregularly.
Between 4.0 V and 1.0 V
IDAA0AA82012-01 IDAA0AA82013-01 • CAN Low signal:
wire is open
of CAN High signal and
CAN Low signal are 2.5 V
and these waveforms
oscillate irregularly.
• CAN Low signal:
Shorted to power In case CAN High signal
supply circuit (12 V) wire is shorted to power
supply circuit (12 V)
CAN High signal is fixed to
12 V and CAN Low signal is
fixed to 11 V.
wire is shorted to power
IDAA0AA82014-01 IDAA0AA82015-01
fixed to 12 V.
irregularly.
IDAA0AA82017-01
IDAA0AA82016-01
• CAN Low signal:
Reference voltage is 4.5 V
and phase is the same for
both CAN High signal and
CAN Low signal, and
waveforms oscillate
irregularly between 6.0 V
and 1.0 V.
CAN High signal and Both of CAN High signal
CAN Low signal and CAN Low signal are
wires are shorted to fixed to near 2.5 V.
each other
IDAA0AA82018-01
Troubleshooting
NOTE
• Before diagnosing trouble, be sure to check equipment of vehicle being serviced as well as control
modules and sensor connected to CAN communication line.
• When performing “Communication Bus Check” using SUZUKI scan tool in this troubleshooting,
refer to “Judgment of Communication Bus Check”: Petrol and Bi-Fuel CNG Model (Page 10H-26).
Step Action Yes No

2) Disconnect connectors from all the control modules
communicating by CAN. (Page 10H-20)
3) Check for proper connection to each CAN
communication circuit at all control modules
(communicating by CAN) connectors and DLC.
4) If connections are OK, check the following points of each
CAN communication circuit based on results found in
Steps 3) of “Diagnosis Procedure”: Petrol and Bi-Fuel
CNG Model (Page 10H-21).
• Open circuit
• Short to power circuit
• Short to ground circuit
• Short to CAN communication wire with each other
Is check result OK?

2 ECM communication check Go to Step 3. Replace ECM and
1) Connect “E01” connector to ECM. recheck DTC. 
2) Measure resistance between the following terminals.
• Without ABS: “E04-4” and “E04-11” terminals of BCM
connector
• With ABS: “E24-3” and “24-16” terminals of ABS
control module connector

Step Action Yes No

3 ABS control module (ABS model) communication check Go to Step 4. Replace ABS control
1) Connect ABS control module connector to ABS control module and recheck
module. DTC. 
2) Measure resistance between following terminals of BCM
connector.
• Ignition switch model: “E04-4” and “E04-11”
• Keyless push start model: “E05-5” and “E05-6”
Is resistance 114 – 134 Ω?

4 BCM communication check Go to Step 5. Replace BCM and
1) Connect “G04” (ignition switch model) / “G05” (keyless recheck DTC.
push start model) and “E04” (ignition switch model) / • Ignition switch model:
“E05” (keyless push start model) connectors to BCM. 
2) Measure resistance between “G50-5” and “G50-6” • Keyless push start
terminals of P/S control module connector. model: (Page 10B-
34)
5 P/S control module communication check Go to Step 6. Replace P/S control
1) Connect P/S control module connector “G50”. module and recheck
DTC. 
terminals of combination meter connector.

6 Combination meter communication check Perform Replace combination
1) Connect “G240” connector to combination meter. “Communication meter and recheck
Check”: Petrol and Bi- DTC. (Page 9C-24)
Fuel CNG Model (Page
“G211-6” and “G211-14” terminals of DLC.
10H-25).
• “G211-6” and “G211-14” terminals of DLC connector.
• “G11-13” and “G11-14” terminals of SDM connector.
• “G16-9” and “G16-19” terminals of keyless start
control module connector.
Communication Check
Keyless Start Control Module (Keyless Push Start Model)
2) Connect “G16” connector to keyless start control module.
4) Select “Communication Bus Check” menu of SUZUKI scan tool.
5) Check the CAN communication to check that control modules and keyless start control module which have been
already connected are in normal condition. (Page 10H-26)
6) If any malfunction is found, replace keyless start control module and recheck DTC. (Page 10E-50)
SDM
2) Connect “G11” connector to SDM.
5) Check the CAN communication to check that control modules and SDM which have been already connected are in
normal condition. (Page 10H-26)
6) If any malfunction is found, replace SDM and recheck DTC. 
CNG control module (Bi-fuel CNG Model)

2) Connect “C12” connector to CNG control module.
5) Check the CAN communication to check that control modules and CNG control module which have been already
connected are in normal condition. (Page 10H-26)
6) If any malfunction is found, replace CNG control module and recheck DTC. 
TCM (A/T Model)

2) Connect “C06” connector to TCM.
4) Select “Communication Bus Check” of SUZUKI scan tool.
5) Check the CAN communication to check that control modules and TCM which have been already connected are in
normal condition. (Page 10H-26)
6) If any malfunction is found, replace TCM and recheck DTC. (Page 5A-121)
Judgment of Communication Bus Check

When performing “Communication Bus Check” using SUZUKI scan tool, refer to the following table for judgment.
Judgment Display of Communication Bus Check
All connected control modules (communicating by CAN) are displayed in “Controller” and
Normal
“Found” is displayed in “Connection to CAN Bus”.
Abnormal Some or all of connected control modules (communicating by CAN) is not displayed.

Special Tool
AENFL80BA818002
SDT-II)
—

10H-27 Communication System: Diesel Model
Diesel Model
Precautions
AENFL80BA820001
• Diagnosing target control module / sensor only is not enough to accurately diagnose any trouble of CAN
communication system. Check communication conditions of overall system (including control modules and sensors
related to CAN communication) and diagnose trouble by putting those information together.
• It is possible that CAN system has trouble because of blown fuse or low battery voltage. Before troubleshooting,
check that fuse, battery voltage and charging system condition are normal.
• CAN communication error is detected if connector of control modules or sensors being connected to CAN
communication line or applicable fuse is connected / disconnected when ignition is “ON”.
• Check that no equipment or option other than original parts is connected onto CAN bus. If any of those items are
connected, disconnect it before troubleshooting.
• If any DTCs together with “Lost Communication” (Reception error) and/or “Communication Bus Off” are displayed,
start troubleshooting of CAN communication first.
• Before diagnosing trouble, check equipment of vehicle being serviced as well as control modules and sensors
connected to CAN communication line.
General Description
Communication System Description
AENFL80BA821001
System Description
Communication between each control module and device is established through continuous input / output of ON/OFF
digital signals to exchange various data items. Transmitting / receiving these data is called as serial communication
interface.
Types of serial communication interface with protocols (communication standards) such as UART, CAN and LIN have
been adopted for in-car communication system.
UART is used for communication between keyless start control module and steering lock unit.
LIN is used for communication between shock sensor and keyless start control module (keyless push start model), for
communication between ISG and gateway control module, and for communication between battery sensor and
gateway control module.
In addition, combination meter, P/S control module, keyless start control module (keyless push start model), SDM (air
bag model), BCM, ABS control module, ECM and gateway control module are transmitted / received data through a
twist pair of two communication lines (CAN High and CAN Low) connected through CAN communication. Data
obtained by a specific control module can be shared with every control module.
Communication System: Diesel Model 10H-28
3 7
1
4 [A] [B] 8
12 9
13
10
5 11
: 14
: 15
: 16
IFL80BA82001-01
[A]: Non-ISG model 5. ECM 11. ABS control module

[B]: ISG model 6. P/S control module 12. Shock sensor
1. Combination meter 7. BCM 13. Steering lock unit
2. DLC 8. Gateway control module 14. CAN communication line
3. SDM 9. ISG 15. LIN communication line
4. Keyless start control module (keyless push start model) 10. Battery sensor 16. UART communication line
UART and LIN Communication Signal

UART and LIN communication system is a serial communication system capable of transmitting multiple types of
information using a single communication line.
Each block of data transmitted via the serial communication system is called a frame.
A frame contains multiple bytes, and each byte consists of a start bit, data bits, and a stop bit.
The data bit stream consists of 8 data bits that are transmitted in series, and each bit is assigned to a specific
information item.
Switching between High and Low in each bit enables transmission of multiple types of information via a single
communication line.
When multiple devices are connected, 1 transmission cycle includes more than 1 frame and the frame length varies
depending on the protocol used.
1 Byte
Start bit Data bit Stop bit

High (Approx. 12 V)
Low (Approx. 0 V)
1 2 3 4 5 6 7 8
bit bit bit bit bit bit bit bit
No.1 frame No.2 frame No.1 frame
High (Approx. 12 V)
Low (Approx. 0 V)
Present transmission cycle Next transmission cycle
IDL10AA80008-02
CAN Communication Signal

CAN communication system is a serial communication system for transmitting multiple data items (values from
sensors, control data and control signals) as ON-OFF digital signals through communication lines. This system uses
two lines (CAN High and CAN Low) for the communication circuit to maintain high reliability even when used for high-
speed serial communication.
Serial communication is established as shown below with 2.5 V as the reference level for both CAN High signal (1)
and CAN Low signal (2). The range of CAN High signal is from 2.5 V to about 3.5 V and that of CAN Low signal is from
2.5 V to about 1.5 V. When both are at 2.5 V, signal is judged as OFF. When CAN High signal is 3.5 V and CAN Low
signal is 1.5 V (that is, when the difference between High voltage and Low voltage is more than about 2 V), signal is
judged as ON. For this reason, a feature of CAN communication signal is that the signal waveform between CAN High
and CAN Low signals is symmetrical with respect to 2.5 V level. CAN communication fails when the symmetrical
signal form collapses.
1
3.5 V
2.5 V
2.5 V
1.5 V
2
I7V10AA81002-01
CAN Communication System Diagnosis General Description

AENFL80BA821002
SUZUKI scan tool is used for diagnosis in this section. Communication method between SUZUKI scan tool and each
control module and sensor is shown below.
Special tool
3 7
1 2
4 [B] 8 [A]
: [C]
IFL80BA82002-01
[A]: Non-ABS model [B]: ABS model [C]: CAN communication line
Control module / sensor Communication with scan tool Monitor of CAN-DTC Bus check function
1 Combination meter CAN Available Available
2 DLC — — —
3 SDM CAN Available Available
4 Keyless start control module CAN Available Available
5 ECM K-line Available Available
6 P/S control module CAN Available Available
7 BCM CAN Available Available
8 Gateway control module CAN Available —
9 ABS control module CAN Available Available
CAN Communication System Transmitting and Receiving Data Table

AENFL80BA821003
NOTE
• T (Transmitting): When two or more control modules start transmission at the same time, control
module transmitting the highest priority information enters transmission mode and all other control
modules enter reception mode.
• R (Receiving): All control modules connected with CAN communication lines receive all information
on CAN communication line. Each control module selects only the necessary information for
performing its control.
• ECM using wheel speed signal transmitted from ABS control module calculates and determines
vehicle speed and transmits that information to each control module.
• Gateway control module exchanges information on ISG and battery sensor with other control
modules. For detail, refer to “Description of SHVS System Components” in Section 11A (Page 11A-
5).
• *1: Ignition switch model
• *2: Keyless push start model
• *3: ISG model
Keyless start control module *2
Gateway control module *3

ABS control module
Combination meter
P/S control module

BCM *1
BCM *2
ECM
SDM
Engine torque signal T R

Engine speed signal T R R R R R R
T R R R R
ENG A-STOP status
T R
ISG control request signal T R
Engine coolant temperature signal T R R R
Water in fuel filter indicator signal T R
Push start system / Immobilizer indicator light control signal T T T R
Vehicle speed signal T R R R R R
Brake light switch signal T R R R R*1 R
T R
Charging system signal
T T R
Keyless start control module *2
Gateway control module *3

ABS control module
Combination meter
P/S control module

BCM *1
BCM *2
ECM
SDM
Shift indication signal T R
Illumination ON signal T T R
Glow indicator light signal T R R
SHVS indicator light signal T R
T T T R
Buzzer request signal
R T R
ENG A-STOP indicator light signal T R
ENG A-STOP warning light signal T R
T T R
Illumination signal
R R T
Brake fluid level switch signal T T R
Parking brake switch signal T T R R
A/C switch status R T T
Electric load signal R T T R R
Turn signal switch status T T R
Driver seat belt switch signal R T T R
R T T R
Door switch status
R T
Door lock status T T R
Outside air temperature signal T T R
Light switch status T R
Key lock / unlock switch status R T
Door lock / unlock request signal R T
Rear end door opener request signal R T
Answer back request signal R T
Power mode status R R T R*2
Electric load signal (High beam) R T
ABS equipped signal T
Wheel speed signal R R T
Air bag deployment signal R R T
Air bag warning light signal R T
ISG signal R T
Battery sensor signal R T

CAN Communication System Circuit Diagram
AENFL80BA822001
1
[b]
G240-21 RED G50-4
10 10
5
G240-9 WHT G50-7
2 G50-5 G50-6
[a] [c]
G240-22 RED G211-6
RED WHT
G240-10 WHT G211-14
[C]:G04-2 [C]:G04-18
[D]:G05-2 [D]:G05-1
3
[i]
G240-24 RED G11-13 10 6
10
G240-12 WHT G11-14 [C]:E04-4 [C]:E04-11
G369 G370 [D]:E05-5 [D]:E05-6
4
RED WHT
[h]
G240-23 RED G16-9 [B] [A] [d]
10
G240-11 WHT G16-19 E493-17 E493-16
[f]
10 7
RED WHT
E493-7 E493-6
[e]
RED WHT
9
E24-2 E24-15
[g]
E01-64 RED RED E24-3 8
10 10
E01-40 WHT WHT E24-16
IFL80BA82003-01
E01
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
[j]
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
5 6
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
E24
E493
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10
15 16 17 18 19 20 21 22 23 24 25
11 12 13 14 15 16 17 18 19 20
26 27 28 29 30 31 32 33 34 35 36 37 38
[C] E04
G04
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
[D]
E05 G05 G16
1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
2 3 4 5 6 7 8 9 10 11 12 2 3 4 5 6 7 8 9 10
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 11
13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20
G50 G11 G240 G211
1 2 3 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8
4 5 6 7 8 9 10 11 12 13 14 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12 13 14 15 16
15 16 17 18 19 20 21
IFL80BA82004-01
[a] to [i]: CAN communication line (linked with diagnosis 1. Combination meter 7. Gateway control module
flows [a] to [i] of “Diagnosis Flow Selection Table”)
[j]: Connector view 2. DLC 8. ABS control module
[A]: ISG model 3. SDM 9. ECM
[B]: Non-ISG model 4. Keyless start control module (keyless push start 10. CAN driver
model)
[C]: Ignition switch model 5. P/S control module
[D]: Keyless push start model 6. BCM
Component Location
CAN Communication System Component Location
AENFL80BA823001
7 8
5
6
IFL80BA82005-01
1. ECM 4. Keyless start control module (keyless push start model) 7. P/S control module
2. ABS control module 5. SDM 8. Combination meter
3. Gateway control module 6. BCM 9. DLC

CAN Communication Check
AENFL80BA824001
Using SUZUKI scan tool, execute “Communication Bus Check” and check DTCs of all control modules connected to
CAN Communication Bus.
NOTE
Gateway control module is not shown on the result screen of “Communication Bus Check” even when
its communication is properly established.
Select “Vehicle Health” on SUZUKI scan tool to check the DTCs of gateway control module.
Condition Action Reference

Perform the following steps.
1. Disconnect and connect all control
module and sensor connectors connected
to the CAN communication line.
2. Check all control module power sources
Only history DTC is detected in either of (including fuses) connected to the CAN
communication line. —
system
3. Start the engine and check DTC while
idling.
If the detected DTC is a history DTC,
there may be a temporary malfunction
due to poor connection at the connector
or faulty power supply.
“Control Module Bus Off” is detected in either Perform “Troubleshooting for Communication
(Page 10H-45)
of system (current DTC) Bus Off”.
Only “Lost Communication” is detected in Perform “Troubleshooting for Lost
(Page 10H-38)
either of system (current DTC) Communication”.
Check if SUZUKI scan tool is communicable
—
No display on SUZUKI scan tool (It is not by connecting to another vehicle.
possible to communicate with any systems.) Perform “Troubleshooting for Communication
(Page 10H-45)
Bus Off”.
CAN DTC (Lost Communication and Communication Bus Off) Table

AENFL80BA824002
ECM
Control Module Communication ECM fails to transmit and receive the data via CAN
U0073 (Page 10H-45)
U0121 (Page 10H-38)
Lost Communication With Power Receiving error of the data from P/S control module
U0131 (Page 10H-38)
Steering Control Module via CAN for specified time continuously.
U0140 (Page 10H-38)
U0141 (Page 10H-38)
Control Module
Receiving error of the data related to ISG from
U2006 (Page 10H-38) LIN Lost Communication With ISG gateway control module via CAN for specified time
continuously.
Receiving error of the data related to battery sensor
LIN Lost Communication With
U2007 (Page 10H-38) from gateway control module via CAN for specified
Battery Sensor
time continuously.
ABS control module

U0073 (Page 10H-45)
BCM (ignition switch model)
U0073 (Page 10H-45)
U0151 (Page 10H-38)
Lost Communication With ENG A-
U1082 (Page 10H-38) system from ECM via CAN for specified time
STOP Control Module
continuously.
BCM (keyless push start model)
U0073 (Page 10H-45)
U0141 (Page 10H-38)
U0151 (Page 10H-38)
Control Module
STOP Control Module
continuously.
Keyless start control module (keyless push start model)
Keyless start control module fails to transmit and
Bus Off
continuously.
U0121 (Page 10H-38)
U0140 (Page 10H-38)
Control Module
Combination meter
Control Module Communication Combination meter fails to transmit and receive the
U0073 (Page 10H-45)
U0121 (Page 10H-38)
U0140 (Page 10H-38)
U0141 (Page 10H-38)
P/S control module
Control Module Communication P/S control module fails to transmit and receive the
U0073 (Page 10H-45)

Control Module
STOP Control Module
continuously.
SDM
Control Module Communication SDM fails to transmit and receive the data via CAN
U0073 (Page 10H-45)
Gateway control module fails to transmit and
Bus Off
continuously.
Troubleshooting for Lost Communication

AENFL80BA824003
Circuit Diagram
1
[b]
G240-21 RED G50-4
10 10
5
G240-9 WHT G50-7
2 G50-5 G50-6
[a] [c]
G240-22 RED G211-6
RED WHT
G240-10 WHT G211-14
[C]:G04-2 [C]:G04-18
[D]:G05-2 [D]:G05-1
3
[i]
G240-24 RED G11-13 10 6
10
G240-12 WHT G11-14 [C]:E04-4 [C]:E04-11
G369 G370 [D]:E05-5 [D]:E05-6
4
RED WHT
[h]
G240-23 RED G16-9 [B] [A] [d]
10
G240-11 WHT G16-19 E493-17 E493-16
[f]
10 7
RED WHT
E493-7 E493-6
[e]
RED WHT
9
E24-2 E24-15
[g]
E01-64 RED RED E24-3 8
10 10
E01-40 WHT WHT E24-16
IFL80BA82003-01
E01
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
[j]
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
5 6
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
E24
E493
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10
15 16 17 18 19 20 21 22 23 24 25
11 12 13 14 15 16 17 18 19 20
26 27 28 29 30 31 32 33 34 35 36 37 38
[C] E04
G04
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
[D]
E05 G05 G16
1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
2 3 4 5 6 7 8 9 10 11 12 2 3 4 5 6 7 8 9 10
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 11
13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20
G50 G11 G240 G211
1 2 3 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8
4 5 6 7 8 9 10 11 12 13 14 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12 13 14 15 16
15 16 17 18 19 20 21
IFL80BA82004-01
model)
Diagnosis Procedure
NOTE
• Perform “CAN Communication Check”: Diesel Model (Page 10H-36) before performing this flow.
• Occurrence of multiple troubles is not included in the scope of this trouble diagnosis.
• When ECM detects DTC U2006 or U2007, check CAN communication between ECM and gateway
control module. If its communication is in good condition, check DTC in gateway control module.
(Page 11A-11)
If gateway control module detects DTC U2006 or U2007, go to troubleshooting for “DTC U2006” in
Section 11A (Page 11A-49) or “DTC U2007” in Section 11A (Page 11A-50).
When “Lost Communication” is detected in any control module / sensor, perform diagnosis according to the following
procedure.
1) Connect SUZUKI scan tool to DLC.
3) Select “Communication Bus Check” menu of SUZUKI scan tool and check for communication-disabled control
module / sensor (it is not displayed).
NOTE
Check that “Status” is shown as “Found” in “Vehicle Health” on SUZUKI scan tool to check that
communication of gateway control module is in normal condition.
4) Based on above check results, select applicable diagnosis flow ([a] to [i]) from “Diagnosis Flow Selection Table”:
Diesel Model (Page 10H-40).
5) Perform troubleshooting according to selected diagnosis flow.
Diagnosis Flow Selection Table
NOTE
• If an individual control module or sensor fails to communicate, check whether power circuit or
ground circuit of control module or sensor is in good condition, referring to system circuit diagram,
etc. before diagnosing trouble with flow chart.
• If it is not possible to select suitable diagnosis flow from “Diagnosis Flow Selection Table” or “two
or more diagnosis flows are selectable”, perform “Troubleshooting for Communication Bus Off”:
• Diagnosis flows [a] to [k] link with CAN communication lines [a] to [i] of “Circuit Diagram”: Diesel
Model (Page 10H-38).
Communication-disabled control module / sensor Diagnosis flow

P/S control module, BCM, gateway control module (ISG model), ABS control
[b] (Page 10H-41)
module and ECM
BCM, gateway control module (ISG model), ABS control module and ECM [c] (Page 10H-41)
ISG model
[d] (Page 10H-42)
Gateway control module, ABS control module and ECM
ISG model
[e] (Page 10H-42)
ABS control module and ECM
Non-ISG model
[f] (Page 10H-43)
ABS control module and ECM
ECM [g] (Page 10H-43)
Keyless start control module (keyless push start model) [h] (Page 10H-44)
Troubleshooting
Diagnosis flow: [a]
Step Action Yes No
2) Disconnect combination meter connector “G240”.
3) Check for proper connection to DLC and combination
meter connector.
[a] between DLC and combination meter connector for
open circuit.
Is check result OK?

Step Action Yes No

2 Combination meter terminating resistance check Go to “Troubleshooting Replace combination
1) Connect combination meter connector. for Communication Bus meter and recheck
Off”: Diesel Model DTC. (Page 9C-24)
2) Disconnect P/S control module connector “G50”.
(Page 10H-45).
terminals of DLC.
Diagnosis flow: [b]

Step Action Yes No
2) Disconnect combination meter connector “G240” and P/
S control module connector “G50”.
connector.
[b] between combination meter connector and P/S
Is check result OK?

2 Combination meter terminating resistance check Replace combination Replace P/S control
1) Connect P/S control module connector. meter and recheck module and recheck
DTC. (Page 9C-24) DTC. 
Diagnosis flow: [c]

Step Action Yes No
2) Disconnect P/S control module connector “G50” and the
• Ignition switch model: BCM connector “G04”
• Keyless push start model: BCM connector “G05”
3) Check for proper connection to P/S control module
[c] between P/S control module connector and BCM
Is check result OK?

2 CAN communication circuit resistance check Replace BCM and Replace P/S control
1) Connect P/S control module connector. recheck DTC. module and recheck
2) Measure resistance between the following terminals of • Ignition switch model: DTC. 
BCM connector. 
• Ignition switch model: “G04-2” and “G04-18” terminals • Keyless push start
• Keyless push start model: “G05-2” and “G05-1” model: (Page 10B-
terminals 34)

Diagnosis flow: [d]

Step Action Yes No
2) Disconnect gateway control module connector “E493”
and the following connectors.
• Ignition switch model: BCM connector “E04”
• Keyless push start model: BCM connector “E05”
3) Check for proper connection to gateway control module
[d] between gateway control module connector and BCM
Is check result OK?

2 CAN communication circuit resistance check Replace gateway Replace BCM and
1) Connect BCM connector. control module and recheck DTC.
recheck DTC. (Page • Ignition switch model:
11A-53) 
terminals of gateway control module connector.
34)
Diagnosis flow: [e]

Step Action Yes No
2) Disconnect ABS control module connector “E24” and
gateway control module connector “E493”.
3) Check for proper connection to gateway control module
connector and ABS control module connector.
[e] between gateway control module connector and ABS
Is check result OK?

2 CAN communication circuit resistance check Replace ABS control Replace gateway
1) Connect gateway control module connector. module and recheck control module and
DTC.  recheck DTC. (Page
11A-53)

Diagnosis flow: [f]

Step Action Yes No
• Keyless push start model: BCM connector “E05”
3) Check for proper connection to ABS module connector
and BCM connector.
[f] between ABS module connector and BCM connector
for open circuit.
Is check result OK?

2 CAN communication circuit resistance check Replace ABS control Replace BCM and
1) Connect following connectors. module connector and recheck DTC.
recheck DTC.  • Ignition switch model:
• Keyless push start model: BCM connector “E05” 
2) Measure resistance between “E24-2” and “E24-15” • Keyless push start
terminals of ABS control module connector. model: (Page 10B-
34)
Diagnosis flow: [g]

Step Action Yes No
ECM connector “E01”.
3) Check for proper connection to ABS control module
connector and ECM connector.
[g] between ABS control module connector and ECM
Is check result OK?

2 CAN communication circuit resistance check Replace ECM and Replace ABS control
1) Connect ABS control module connector. recheck DTC.  module and recheck
DTC. 
terminals of ECM connector.

Diagnosis flow: [h]

Step Action Yes No
2) Disconnect combination meter connector and keyless
start control module connector “G16”.
connector and keyless start control module connector
“G16”.
[h] between combination meter connector and keyless
start control module connector for open circuit.
Is check result OK?

2 CAN communication circuit resistance check Replace keyless start Replace combination
1) Connect combination meter connector. control module and meter and recheck
recheck DTC. (Page DTC. (Page 9C-24)
10E-50)
terminals of keyless start control module connector.
Diagnosis flow: [i]

Step Action Yes No
1 CAN communication circuit check Go to Step 2. Repair or replace the
1) Disconnect negative (–) cable at battery. following defective part.
2) Disconnect combination meter connector and SDM • CAN communication
connector “G11”. circuit [i] is faulty
3) Check for proper connection to combination meter between combination
connector and SDM connector “G11”. meter and SDM.
4) If connections are OK, check CAN communication circuit • Poor connection of

[i] between combination meter connector and SDM “G369” and “G370”
connector for open circuit. connectors.
Is check result OK?

2 CAN communication circuit resistance check Replace SDM and Replace combination
1) Connect combination meter connector. recheck DTC.  meter and recheck
terminals of SDM connector.

Troubleshooting for Communication Bus Off

AENFL80BA824004
NOTE
Perform “CAN Communication Check”: Diesel Model (Page 10H-36) before performing this flow.
Circuit Diagram
1
[b]
G240-21 RED G50-4
10 10
5
G240-9 WHT G50-7
2 G50-5 G50-6
[a] [c]
G240-22 RED G211-6
RED WHT
G240-10 WHT G211-14
[C]:G04-2 [C]:G04-18
[D]:G05-2 [D]:G05-1
3
[i]
G240-24 RED G11-13 10 6
10
G240-12 WHT G11-14 [C]:E04-4 [C]:E04-11
G369 G370 [D]:E05-5 [D]:E05-6
4
RED WHT
[h]
G240-23 RED G16-9 [B] [A] [d]
10
G240-11 WHT G16-19 E493-17 E493-16
[f]
10 7
RED WHT
E493-7 E493-6
[e]
RED WHT
9
E24-2 E24-15
[g]
E01-64 RED RED E24-3 8
10 10
E01-40 WHT WHT E24-16
IFL80BA82003-01
E01
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
[j]
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
5 6
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
E24
E493
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10
15 16 17 18 19 20 21 22 23 24 25
11 12 13 14 15 16 17 18 19 20
26 27 28 29 30 31 32 33 34 35 36 37 38
[C] E04
G04
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
[D]
E05 G05 G16
1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
2 3 4 5 6 7 8 9 10 11 12 2 3 4 5 6 7 8 9 10
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 11
13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20
G50 G11 G240 G211
1 2 3 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8
4 5 6 7 8 9 10 11 12 13 14 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12 13 14 15 16
15 16 17 18 19 20 21
IFL80BA82004-01
model)
Diagnosis Procedure
When “CAN Communication Bus Off” is detected in any control modules, or when it is not possible to communicate
with any control modules / sensors with CAN using SUZUKI scan tool, perform the following procedure.
1) Connect oscilloscope to DLC when ignition is “OFF”.
2) Using oscilloscope, observe waveform in the following condition when ignition is “ON”.
+ G211-6 (Page 10H-33)
1
– Ground
+ G211-14 (Page 10H-33)
2
– Ground
3) Compare observed signal waveform with waveforms given as “Reference Waveform:”. Find the most similar signal
waveform and identify the system in trouble and cause of trouble. (Page 10H-47)
4) Perform troubleshooting. (Page 10H-49)
Reference Waveform
NOTE
Waveforms in “Examples of abnormal waveforms” are selected examples of CAN communication
waveforms seen when an abnormal condition occurs. However, these waveforms may not be exactly
the same in appearance as observed waveforms. Therefore, to identify an abnormal condition, select
the waveform that is most similar to the observed waveform from “Examples of abnormal waveforms”:
Normal waveform
Normal waveform Description
[D] CAN High signal and CAN
Low signal are 2.5 V.
Waveform of CAN High
signal is 2.5 – 3.5 V and that
of CAN Low signal is 2.5 –
1.5 V.
[E]
[A]
[B] [C]
IDAA0AA82009-01
[A]: Ground level of each channel [D]: Waveform of channel 1 (CAN High signal)
[B]: VOLT/DIV of each channel [E]: Waveform of channel 2 (CAN Low signal)
[C]: TIME/DIV of each channel
Examples of abnormal waveforms

Shorted to ground In case CAN High signal
circuit
Both of CAN High signal
and CAN Low signal are
fixed to GND level (0 V).
circuit
IDAA0AA82011-01
IDAA0AA82010-01 of CAN High signal and
CAN Low signal are GND
level (0 V) and CAN High
signal waveform oscillates
irregularly.
Between 0 V and 3.5 V
• CAN Low signal: Fixed to
0V
Opened In case CAN High signal
wire is open
irregularly.
IDAA0AA82012-01 IDAA0AA82013-01 • CAN Low signal:
wire is open
of CAN High signal and
CAN Low signal are 2.5 V
and these waveforms
oscillate irregularly.
• CAN Low signal:
fixed to 11 V.
IDAA0AA82014-01 IDAA0AA82015-01
fixed to 12 V.
irregularly.
IDAA0AA82017-01
IDAA0AA82016-01
• CAN Low signal:
Reference voltage is 4.5 V
and phase is the same for
both CAN High signal and
CAN Low signal, and
waveforms oscillate
irregularly between 6.0 V
and 1.0 V.
CAN High signal and Both of CAN High signal
CAN Low signal and CAN Low signal are
wires are shorted to fixed to near 2.5 V.
each other
IDAA0AA82018-01
Troubleshooting
NOTE
• Before diagnosing trouble, check equipment of vehicle being serviced as well as control modules
and sensors connected to CAN communication line.
• When performing “Communication Bus Check” using SUZUKI scan tool in this troubleshooting,
refer to “Judgment of Communication Bus Check”: Diesel Model (Page 10H-51).
Step Action Yes No

2) Disconnect connectors from all the control modules and
sensors communicating by CAN. (Page 10H-33)
3) Check for proper connection to each CAN
communication circuit at all control modules / sensors
(communicating by CAN) connectors and DLC.
4) If connections are OK, check the following points of each
CAN communication circuit based on results found in
Step 3) of “Diagnosis Procedure”: Diesel Model (Page
10H-46).
• Open circuit
• Short to power circuit
• Short to ground circuit
• Short to CAN communication wire with each other
Is check result OK?

2 ECM communication check Go to Step 3. Replace ECM and
1) Connect “E01” connector to ECM. recheck DTC. 

Step Action Yes No

3 ABS control module communication check • ISG model: Go to Replace ABS control
1) Connect “E24” connector to ABS control module. Step 4. module and recheck
• Non-ISG model: Go DTC. 
2) Measure resistance between following terminals.
• ISG model: “E493-7” and “E493-6” terminals of to Step 5.
gateway control module connector
• Non-ISG model:
– Ignition switch model: “E04-4” and “E04-11”
terminals of BCM connector
– Keyless push start model: “E05-5” and “E05-6”
terminals of BCM connector

4 Gateway control module communication check Go to Step 6. Replace gateway
1) Connect “E493” connector to gateway control module. control module and
2) Measure resistance between the following terminals of
11A-53)
BCM connector.
• Ignition switch model: Between “E04-4” and “E04-11”
terminals
• Keyless push start model: Between “E05-5” and “E05-
6” terminals

5 BCM communication check Go to Step 7. Replace BCM and
1) Connect the following connectors to BCM. recheck DTC.
• Ignition switch model: “G04” and “E04” connectors • Ignition switch model:
• Keyless push start model: “G05” and “E05” 
connectors • Keyless push start
2) Measure resistance between “G50-6” and “G50-5” model: (Page 10B-
terminals of P/S control module connector. 34)

6 P/S control module communication check Go to Step 8. Replace P/S control
1) Connect “G50” connector to P/S control module. module and recheck
DTC. 

7 Combination meter communication check Perform Replace combination
1) Connect “G240” connector to combination meter. “Communication meter and recheck
Check”: Diesel Model DTC. (Page 9C-24)
(Page 10H-50).
• Between “G11-13” and “G11-14” terminals of SDM
connector.
• Between “G16-9” and “G16-19” terminals of keyless
start control module (keyless push start model).
• Between “G211-6” and “G211-14” terminals of DLC
Communication Check
AENFL80BA824005
NOTE
Keyless Start Control Module (Keyless Push Start Model)

2) Connect “G16” connector to keyless start control module.
5) Check the CAN communication to check that control modules, sensors and keyless start control module which
have been already connected are in normal condition. (Page 10H-51)
6) If any malfunction is found, replace keyless start control module and recheck DTC. (Page 10E-50)
SDM
2) Connect “G11” connector to SDM.
5) Check the CAN communication to check that control modules, sensors and SDM which have been already
connected are in normal condition. (Page 10H-51)
6) If any malfunction is found, replace SDM and recheck DTC. 
Judgment of Communication Bus Check

AENFL80BA824006
When performing “Communication Bus Check” using SUZUKI scan tool, refer to the following table for judgment.
NOTE
Judgment Display of Communication Bus Check

All connected control modules / sensors (communicating by CAN) are displayed in “Controller”
Normal
and “Found” is displayed in “Connection to CAN Bus”.
Abnormal Some or all of connected control modules / sensors (communicating by CAN) is not displayed.

Special Tool
AENFL80BA828002
SDT-II)
—

Engine Auto Stop Start System: 10I-1
Engine Auto Stop Start System

Control Systems
Precautions
Precautions for Diagnosing Trouble • Before diagnosing troubles, refer to “Precautions for
AENFL80BA900001 Diagnosing Trouble” under “Precautions for Engine
• Before using scan tool, read its Operator’s Manual to (D13A)” in Section 1 in related manual.
know how to use it.
• ENG A-STOP system is controlled by ECM. However,
DTCs related to ENG A-STOP system are detected Precautions for Replacing ECM
by ECM and gateway control module. AENFL80BA900002
Refer to “Precautions for Replacing ECM” under
“Precautions for Engine (D13A)” in Section 1 in related
manual.
General Description
ENG A-STOP System Description • Hood is closed.
AENFL80BA901001
The ISG fitted on the ENG A-STOP system serves as a • Driver’s door is closed.
starter which automatically restarts the engine. • Driver’s seat belt is fastened.
The ENG A-STOP system performs the following • Clutch pedal is released.
controls to reduce emissions, fuel consumption, noise • Gear is shifted to “Neutral”.
during engine restarts, and idling noise during vehicle
stops. The system monitors the vehicle condition • Vehicle speed is 3 km/h (2 mile/h) or below.
depending on signals from the relevant sensors and • Vehicle speed of higher than 4 km/h (2.5 mile/h) was
switches. recorded after starting off.
• Engine auto stop control • ABS is not in operation.
• Engine auto start control • No DTCs related to ENG A-STOP system are
The system informs the driver of the status of these detected.
controls by lighting the ENG A-STOP indicator light and • ISG status does not meet inhibit conditions of engine
SHVS indicator light located in the combination meter. auto start control.
When the engine is being stopped by auto stop control, • DC/DC converter is functioning properly.
the ENG A-STOP indicator light comes on, and when the When the engine auto stop control is activated, an ENG
engine is being restarted by ISG, the SHVS indicator A-STOP indicator light signal is sent to the combination
light comes on. meter via the CAN communication line. The ENG A-
STOP indicator light then lights up.
Engine Auto Stop Control
When all of the following conditions are met, the ECM NOTE
stops the engine. If engine is started while the hood is open in
• Battery charging status is satisfactory. case of jump starting, etc., or battery voltage
• Battery temperature is between 5 °C (41 °F) and 68 is lower than threshold, “engine auto stop
°C (154 °F). control” is suspended until ignition is set to
• Atmospheric pressure is the specified value or higher. “OFF”.
• Engine coolant temperature is between 20 °C (68 °F)
and 108 °C (226 °F).
• Accelerator pedal is not depressed.
• ENG A-STOP OFF switch is OFF.
10I-2 Engine Auto Stop Start System:
Engine Auto Start Control Engine Auto Start Inhibit Control

When the gear is in neutral and one or more of the If any of the following conditions is met during the
following conditions are met, the ECM sends an engine “engine auto stop control”, the ECM suspends the
restart request signal to the gateway control module via “engine auto start control”.
the CAN communication line, and then the gateway • ECM or gateway control module have detected
control module sends this signal to the ISG via the LIN specific DTC(s). This is an engine start inhibition by
communication line. fail-safe mode. For details, refer to “Fail-Safe Table”
And then, the ISG drives the belt first, and then the (Page 10I-11).
crankshaft pulley to restart the engine.
• Hood is open.
• Battery charging status is not satisfactory. (*1)
• Driver’s door is open and driver’s seat belt is
• Battery temperature is 4 °C (39 °F) or less. (*1) unfastened.
• Battery temperature is 68 °C (154 °F) or higher.
NOTE
• Engine coolant temperature is 17 °C (62 °F) or less.
(*1) Once the “engine auto start control” is
inhibited, driver’s operation is needed to
• Engine coolant temperature is 110 °C (230 °F) or
restart the engine.
higher.
• Vacuum in brake booster is lower than the specified
level. (*1) Engine Restart Control after Engine Stall
While driving vehicle, if the engine stalled due to a clutch
• ENG A-STOP OFF switch is ON.
operation error, etc., the engine can be restarted by
• At least 3 minutes have passed after activation of depressing the clutch pedal without turning the ignition
automatic stop of the engine. (*1) key to “START” (ignition switch model) or without
• Initial depression of clutch pedal pushing the engine switch (keyless push start model)
• Vehicle speed is 4 km/h (2.5 mile/h) or higher. (*1) when the following conditions are met.
• ECM has detected malfunctions in battery sensor. (*1) • ISG status meets conditions for activating engine auto
When the engine auto start control is activated, SHVS start control.
indicator light signal is sent to the combination meter via • Clutch pedal is depressed fully.
the CAN communication line. The SHVS indicator light • Gear is shifted to “Neutral”.
then lights up.
NOTE
*1: The ENG A-STOP indicator light then
blinks 5 times.
Description of ENG A-STOP System Components

AENFL80BA901002
The ENG A-STOP system consists of the following components.
Component Description
ECM Refer to “Description of SHVS System Components” in Section 11A (Page 11A-5).
Gateway control module Refer to “Description of SHVS System Components” in Section 11A (Page 11A-5).
ISG Refer to “Description of SHVS System Components” in Section 11A (Page 11A-5).
Battery sensor Refer to “Description of SHVS System Components” in Section 11A (Page 11A-5).
CPP No.1 switch
Refer to “Description of SHVS System Components” in Section 11A (Page 11A-5).
CPP No.2 switch
The DC/DC converter is located inside the instrument panel on the passenger side.
The converter stabilizes the electric power to the combination meter, audio unit and
DC/DC converter auto A/C panel (auto A/C model) when the engine auto start control is activated.
When the DC/DC converter detects malfunctions such as overheat or faulty contact,
the malfunction signal is sent to the ECM.
This switch is installed on the hood latch. The ECM identifies the open / closed state
Hood latch switch
of the hood according to the signal from this switch.
The ENG A-STOP OFF switch is installed in the switch bezel at the instrument panel.
Setting this switch to the operating position enables the driver to cancel the engine
ENG A-STOP OFF switch auto stop control.
When the ENG A-STOP OFF switch is in the pushed position, the indicator inside the
switch is lit.
Component Description
The ENG A-STOP indicator light is located in the combination meter. This indicator
light lights up during the engine auto stop control.
ENG A-STOP indicator light
When ignition is changed to “ON” with engine off, turn on the ENG A-STOP indicator
light for two seconds to check operation of indicator light.
This warning light is located in the combination meter. The light blinks when there is a
problem in the system. The light lights up when the ENG A-STOP OFF switch is
ENG A-STOP warning light pushed and the ECM stops the engine auto stop control.
When ignition is changed to “ON” with engine off, turn on the ENG A-STOP warning
light for two seconds to check operation of warning light.
SHVS indicator light Refer to “Description of SHVS System Components” in Section 11A (Page 11A-5).
This buzzer is located in the combination meter. The buzzer sounds when any of the
Buzzer
conditions for inhibiting the engine auto start control is met.
Description of ENG A-STOP System Alarm Function

AENFL80BA901003
The ENG A-STOP alarm function works when the ECM detects any of the following conditions during the “engine auto
stop control”. The function provides warning by sounding the buzzer inside the combination meter according to the
condition detected.
Alarm Condition Warning buzzer
Gear shift alarm The gear shift lever is moved to a position other than
Sounds.
“Neutral” without depressing the clutch pedal.
Driver’s seat belt unfastened and driver’s The driver’s seat belt is not fastened and driver’s door
Sounds 5 times.
door open alarm is open.
Hood open alarm The hood is open. Sounds 5 times.
ENG A-STOP system malfunction alarm A problem related to the engine auto start control
Sounds 5 times.
occurs in the ENG A-STOP system.

AENFL80BA901004
ECM is using CAN communication to communicate with other control module. For more detail of CAN communication,
refer to “Communication System Description”: Diesel Model in Section 10H (Page 10H-27).
LIN Communication System Description

AENFL80BA901005
Gateway control module is using LIN communication to communicate with ISG and battery sensor. For more detail of
LIN communication, refer to “Communication System Description”: Diesel Model in Section 10H (Page 10H-27).

ENG A-STOP System Input / Output Diagram
AENFL80BA902001
Input Gateway control Output

module
CAN communication
Battery sensor LIN communication ISG
Self-diagnosis
function
ECM
Engine auto stop

ECT sensor control
APP sensor Engine auto start

control
Brake stroke sensor
Indicator light control
Brake light switch
Warning light control
Brake booster switch
Warning buzzer
ENG A-STOP OFF switch
control
Hood latch switch
Self-diagnosis
CPP No.1 switch function
CPP No.2 switch CAN communication
Neutral position switch
Ignition signal *1
DC/DC converter
Ignition switch *2
ABS control module Combination meter

ENG A-STOP indicator light
BCM ENG A-STOP warning light
SHVS indicator light
Warning buzzer
*1: Keyless push start model : CAN communication

*2: Ignition switch model : LIN communication
IFL80BA90001-02
ENG A-STOP System Electric Circuit Diagram

AENFL80BA902002
NOTE
The ENG A-STOP system is controlled by ECM. For connection of ECM, refer to “Electronic Control
System Circuit Diagram”: Diesel in Section 1A (Page 1A-178).
: 12 V :5V
1
2 3
RED E493-7
21 21 21 E493-20 GRN PPL 2
WHT E493-6
20 E493-4 LT BLU 9
4 E493-13 BLK BRN 2
RED E493-17
21
WHT E493-16 10
+B GRN E213-6
YEL E213-7
6 15
BLU E493-14 11 13 E213-1 BRN ACC
5 20
16
E213-5 BLU +B
12 14
8 E213-10 LT BLU
7 WHT PPL E493-5 2
E213-9 PPL
E213-4 BLK
LT GRN E213-8
17
E493-2 LT GRN 19
18
E493-10 WHT +B
E493-12 BLK
IFL80BA90002-01
1. Gateway control module 8. “WIP SUB” fuse 15. “ACC” fuse

2. ECM 9. ISG 16. “DCDC” fuse
3. ABS control module 10. DC/DC converter 17. “IG1 SIG” fuse
4. BCM 11. “ACC3” fuse 18. “A-STOP” fuse
5. Battery sensor 12. To audio unit 19. To ignition switch (ignition switch model) or IG1
relay (keyless push start model)
6. “ECM” fuse 13. “RADIO2” fuse 20. LIN driver
7. Wiper and washer switch 14. To audio unit and combination meter 21. CAN driver
Terminal Arrangement of Gateway Control Module and DC/DC Converter Connector
NOTE
For circuit name and terminal voltage, refer to “Inspection of Gateway Control Module and Its Circuits”
in Section 11A (Page 11A-51) and “Inspection of DC/DC Converter and Its Circuits” (Page 10I-14).
[A] E493 [B] E213
10 9 8 7 6 5 4 3 2 1 [a]
3 2 1
20 19 18 17 16 15 14 13 12 11 7 6 5 4
10 9 8
IFL10AA90010-01
[A]: Gateway control module connector (View: [a]) [B]: DC/DC converter connector (View: [a])
Component Location
ENG A-STOP System Component Location
AENFL80BA903001
1
3 2
8
10
7
9
12
15
13
11 14
22
16
23
20
19
17
18
21
IFL80BA90004-03
1. ABS control module 9. ECT sensor 17. Accelerator pedal assembly (incorporating APP sensor)
2. Brake booster switch 10. Hood latch switch (included in hood latch) 18. Brake light switch
3. ISG 11. Combination meter 19. Brake stroke sensor
4. ECM 12. ENG A-STOP indicator light 20. CPP No.1 switch
5. Driver door switch 13. ENG A-STOP warning light 21. CPP No.2 switch
6. Driver seat belt buckle switch 14. SHVS indicator 22. Gateway control module
7. Battery sensor 15. ENG A-STOP OFF switch 23. DC/DC converter
8. Neutral position switch 16. BCM

ENG A-STOP System Check
AENFL80BA904001
Step Action Yes No

1 Customer complaint analysis Go to Step 2. Perform customer
1) Perform “Step 1. Customer Complaint Analysis” (Page complaint analysis.
10I-9).
Was customer complaint analysis performed?

2 DTC check, record and clearance Print DTC or write it Go to Step 3.
1) Check for DTC. (Page 10I-9) down and clear it
referring to “DTC
Is there any DTC(s)? Clearance” (Page 10I-
11). Then go to Step 3.
3 Trouble symptom confirmation Go to Step 4. Go to Step 5.
1) Check trouble symptom. (Page 10I-9)
Is trouble symptom identified?

4 Rechecking and recording DTC Go to Step 6. Go to Step 7.
1) Recheck for DTC. (Page 10I-9)

5 ENG A-STOP symptom diagnosis Go to Step 8. Check and repair
1) Perform “Step 5. ENG A-STOP System Symptom defective part, and then
Diagnosis” (Page 10I-9). go to Step 8.
Are check and repair completed?

6 Troubleshooting for DTC Go to Step 8. Check and repair
1) Perform troubleshooting for applicable DTC. (Page defective part, and then
10I-9) go to Step 8.
Are check and repair completed?

7 Intermittent problem check Repair or replace Go to Step 8.
1) Check for intermittent problem. (Page 10I-9) defective part, and then
go to Step 8.
8 Final confirmation test Go to Step 4. End.
1) Perform “Step 8. Final Confirmation Test” (Page 10I-10).
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, such a questionnaire form shown below will facilitate collecting information for proper analysis and
diagnosis.
NOTE
The form is a standard sample. It should be modified according to characteristics of each market.
Customer questionnaire form (Example)
Customer s name: Model: VIN:
Date of issue: Date Reg: Date of problem: Mileage:
Engine auto start does not operate

Engine auto stop does not operate
Problem Symptoms
Engine auto stop operates under conditions other
than those specified
Other
Frequency of Occurrence Continuous / Intermittent ( times a day, a month)

/ Other
Weather:
Environmental Condition Fine / Cloudy / Rain / Snow / Other
Temperature: ( F)
DTC No DTC / DTC ( )

IFL10AA90004-01
Step 2. DTC Check, Record and Clearance Step 5. ENG A-STOP System Symptom Diagnosis
First, check for DTCs. (Page 10I-10) Perform “ENG A-STOP System Symptom Diagnosis”
If DTCs are indicated, print DTC or write them down and (Page 10I-11) based on symptom found in vehicle,
then clear them. (Page 10I-11) checking the following items.
• Customer complaint analysis
Step 3. Trouble Symptom Confirmation
• Trouble symptom confirmation
If there is no DTC in Step 2:
Based on information obtained in “Step 1. Customer Step 6. Troubleshooting for DTC
Complaint Analysis” (Page 10I-9) and “Step 2. DTC Perform troubleshooting for applicable DTC and repair
Check, Record and Clearance” (Page 10I-9), check or replace faulty parts.
trouble symptoms.
Step 7. Intermittent Problem Check
If there is any DTC in Step 2:
If there is no DTC in Step 2:
Recheck DTC according to “DTC Confirmation
Check for intermittent problem. 
Procedure” described in each DTC troubleshooting.
If there is any DTC in Step 2:
Step 4. Rechecking and Recording DTC
Check parts related to detected DTC (e.g. wire harness,
Refer to “DTC Check” (Page 10I-10) for checking
connector, etc.).
procedure.
Step 8. Final Confirmation Test

Check that the problem symptom does not recur and the 1
vehicle is free from any abnormal conditions. If what has
been repaired is related to DTC, clear DTC once,
perform DTC confirmation procedure and check that no
DTC is indicated.
ENG A-STOP System Self-Diagnosis Function

AENFL80BA904002
Description
The ECM and gateway control module monitor the
IFL10AA90011-02
conditions of the system components and circuits. When
an abnormal condition in the system occurs, the ECM
performs necessary controls as follows. DTC Check
AENFL80BA904004
Self-Diagnosis Function 1) Set ignition “OFF”.

The ECM and gateway control module have self- 2) Connect SUZUKI scan tool to DLC (1).
diagnosis function that stores DTCs for abnormalities Special tool
detected in the ENG A-STOP system. The stored DTCs (A): SUZUKI scan tool (Suzuki SDT-II)
remain in the memory of ECM and gateway control
module unless they are cleared. 3) Set ignition “ON”.
Warning Function SUZUKI scan tool and print it or write it down. Refer
When a malfunction is detected in the ECM, the ECM to Operator's Manual of SUZUKI scan tool for further
turns on the ENG A-STOP warning light (1) and causes details.
it to blink to warn the driver. The warning light is turned
off when the normal condition is detected. NOTE
1 and ECM or gateway control module is not
possible, perform the following checks:
PC and VCI (2) using SUZUKI scan tool
function.
circuit.
IFL10AA90011-02
cable.
Fail-Safe Control • Check CAN communication system.
The ECM and gateway control module perform a fail- (“Control Module Communication Bus Off”
safe control when an abnormal condition related to the is detected in any control module.) (Page
ENG A-STOP system is detected and stop all the 10H-45)
controls to protect the system. • Check ECM power supply circuit and
The operation of fail-safe control varies depending on ground circuit. (Page 1A-299)
the detected DTC. (Page 10I-11) • Check gateway control module power
supply circuit and ground circuit. (Page
ENG A-STOP Warning Light Check 11A-51)
AENFL80BA904003
2) Check that ENG A-STOP warning light (1) lights for
about 2 sec. and then goes OFF. If anything faulty is
found, refer to “ENG A-STOP Warning Light Does
Not Come ON with Ignition “ON” and Engine
Stopped (but Engine Can Be Started)” (Page 10I-13)
or “ENG A-STOP Warning Light Remains ON or
Blinking with Ignition “ON”” (Page 10I-13).

cable.
is detected in any control module.) (Page
10H-45)
• Check ECM power supply circuit and
ground circuit. (Page 1A-299)
1
• Check gateway control module power
supply circuit and ground circuit. (Page
2 11A-51)
(A)
IFL80B450002-04

1
DTC Clearance
AENFL80BA904005
2
(A)
Special tool
4) Clear DTC according to instructions displayed on IFL80B450002-04
SUZUKI scan tool. Refer to Operator's Manual of
5) After completing DTC clearance, set ignition “OFF”
and disconnect SUZUKI scan tool from DLC.
NOTE
If communication between SUZUKI scan tool DTC Table
AENFL80BA904006
and ECM or gateway control module is not Refer to “DTC Table” in Section 11A (Page 11A-12).
possible, perform the following checks:
• Check communication condition between Fail-Safe Table
PC and VCI (2) using SUZUKI scan tool AENFL80BA904007
function. Refer to “Fail-Safe Table” in Section 11A (Page 11A-15).
circuit. Scan Tool Data
AENFL80BA904008
Refer to “Scan Tool Data” in Section 11A (Page 11A-18).
ENG A-STOP System Symptom Diagnosis

AENFL80BA904009
NOTE
• Perform ENG A-STOP system check referring to “ENG A-STOP System Check” (Page 10I-8) before
performing this ENG A-STOP System Symptom Diagnosis.
• ECM monitors the battery condition through input signals from the battery sensor and performs the
ENG A-STOP control only when it judges that the battery is in a fully charged condition.
• In case the battery discharge is suspected (e.g. when the vehicle has not been used for a long time.),
disconnect the negative (–) cable at the battery and recharge the battery.
When recharging the battery without disconnecting the negative (–) cable at the battery, it will be
necessary to drive the vehicle for maximum 3 hours before the ECM judges that the battery is fully
charged, during which the ENG A-STOP system does not operate.

Engine auto start control Faulty battery sensor “Battery Sensor On-Vehicle Inspection” in
does not operate Section 11A (Page 11A-53)
Faulty battery Check battery. (Page 1J-22)
Faulty ECT sensor “ECT Sensor Inspection”: Diesel in Section 1C
in related manual
Faulty brake booster switch “Brake Booster Switch Inspection” (Page 10I-
15)
Faulty ENG A-STOP OFF switch “ENG A-STOP OFF Switch Inspection” (Page
10I-16)
Faulty CPP switch Check CPP switch.
• CPP No.1 switch: (Page 10I-15)
Faulty ECM Check ECM and its circuit. (Page 1A-318)
Faulty gateway control module Check gateway control module and its circuit.
(Page 11A-51)
Faulty hood latch switch “Hood Latch Switch Inspection” (Page 10I-15)
Faulty driver door switch “Front and Rear Door Switch Inspection” in
Section 9F in related manual
Faulty seat belt buckle switch “Front Seat Belt Buckle Inspection” in Section
8A in related manual
Engine auto stop control Faulty battery sensor “Battery Sensor On-Vehicle Inspection” in
does not operate Section 11A (Page 11A-53)
in related manual
Faulty APP sensor “APP Sensor Assembly Inspection”: Diesel in
Section 1C in related manual
Faulty brake light switch “Brake Light Switch Inspection” in Section 4A
in related manual
Faulty ENG A-STOP OFF switch “ENG A-STOP OFF Switch Inspection” (Page
10I-16)
Faulty parking brake switch “Parking Brake Switch Inspection” in Section
4D in related manual
Faulty hood latch switch “Hood Latch Switch Inspection” (Page 10I-15)
Faulty CPP switch Check CPP switch.
Faulty neutral position switch “Neutral Position Switch Inspection” (Page 10I-
15)
Faulty ISG “Generator Test”: Diesel (with ISG) in Section
1J (Page 1J-23)
Faulty DC/DC converter “Inspection of DC/DC Converter and Its
Circuits” (Page 10I-14)

Engine auto stop control Faulty parking brake switch “Parking Brake Switch Inspection” in Section
operates under 4D in related manual
conditions other than Faulty hood latch switch “Hood Latch Switch Inspection” (Page 10I-15)
those specified. Faulty ENG A-STOP OFF switch “ENG A-STOP OFF Switch Inspection” (Page
10I-16)
in related manual
Faulty brake booster switch “Brake Booster Switch Inspection” (Page 10I-
15)
Faulty APP sensor “APP Sensor Assembly Inspection”: Diesel in
Section 1C in related manual
Faulty ISG “Generator Test”: Diesel (with ISG) in Section
1J (Page 1J-23)
ENG A-STOP Warning Light Does Not Come ON with Ignition “ON” and Engine Stopped (but Engine
Can Be Started)
AENFL80BA904010
Troubleshooting
Step Action Yes No
1) Check for DTC related to CAN communication. for applicable DTC.
Is there any CAN related DTC(s) detected?

1) Check for DTC related to combination meter. for applicable DTC. recheck for DTC.
(Page 10I-15)
Is there any combination meter related DTC(s) detected?
ENG A-STOP Warning Light Remains ON or Blinking with Ignition “ON”

AENFL80BA904011
Troubleshooting
Step Action Yes No
1 ENG A-STOP OFF switch check Go to Step 2. Replace ENG A-STOP
1) Check ENG A-STOP OFF switch. (Page 10I-16) OFF switch. (Page
10I-15)
Is check result OK?
1) Set ignition “OFF”. for applicable DTC. meter and recheck for
If ENG A-STOP warning
3) Check for DTC related to ENG A-STOP system. (Page
light still remains ON or
10I-10)
blinking, replace ECM
Is there any DTC(s) detected? and recheck for DTC.
(Page 10I-15)

AENFL80BA904012
Refer to “Inspection of ECM and Its Circuits”: Diesel in Section 1A (Page 1A-318).
Inspection of Gateway Control Module and Its Circuits

AENFL80BA904013
Refer to “Inspection of Gateway Control Module and Its Circuits” in Section 11A (Page 11A-51).
Inspection of DC/DC Converter and Its Circuits

AENFL80BA904014
1) Remove DC/DC converter. (Page 10I-15)
2) Connect DC/DC converter connector.
3) Check voltage of DC/DC converter (1) using voltmeter (2).
NOTE
Check that battery voltage is 12 V or more.
[A] E213
[a]
3 2 1
10 9 8 7 6 5 4
IFL80BA90006-01
[A]: DC/DC Converter connector (View: [a])
Normal
voltage
E213-1 BRN ACC “ON” signal circuit
E213-2 — — — —
E213-3 — — — —
E213-4 BLK DC/DC converter ground circuit Approx. 0 V —
E213-5 BLU Backup power supply circuit 10 – 14 V —
E213-6 GRN Audio unit power supply circuit
Audio unit, auto A/C panel (auto A/
E213-7 YEL C model) and combination meter 10 – 14 V —
E213-8 LT GRN Ignition “ON” signal circuit
DC/DC converter activation signal 10 – 14 V During engine auto start control
E213-9 PPL
circuit Approx. 0 V Other than above condition
Ignition: “ACC” or within 2 sec. after
DC/DC converter diagnosis output 10 – 14 V
E213-10 LT BLU setting ignition “OFF”
signal
Repair Instructions
ECM Removal and Installation CPP No.2 Switch Removal and Installation
Refer to “ECM Removal and Installation”: Diesel in Refer to “CPP (Clutch Pedal Position) No.2 Switch
Section 1C in related manual. Removal and Installation”: Diesel Model in Section 5C
(Page 5C-5).
DC/DC Converter Removal and Installation
AENFL80BA906002
CPP No.2 Switch Inspection
Removal AENFL80BA906009
1) Remove passenger side instrument panel Refer to “CPP (Clutch Pedal Position) No.2 Switch
undercover and glove box. Inspection and Adjustment”: Diesel Model in Section 5C
(Page 5C-5).
2) Remove nuts (1), and then remove DC/DC converter
(2) from DC/DC converter bracket.
Brake Stroke Sensor Removal and Installation
3) Disconnect connector (3) from DC/DC converter. AENFL80BA906010
Refer to “Brake Stroke Sensor Removal and
1 Installation”: Diesel in Section 1C (Page 1C-5).
Brake Stroke Sensor Inspection

AENFL80BA906011
Refer to “Brake Stroke Sensor Inspection and
Adjustment”: Diesel in Section 1C (Page 1C-6).
2
Brake Stroke Sensor Calibration

AENFL80BA906012
Refer to “Brake Stroke Sensor Zero Point Reset”: Diesel
in Section 1C (Page 1C-7).
3
Brake Booster Switch Inspection
AENFL80BA906013
1 Refer to “Brake Booster Switch Inspection (ISG Model)”
IFL10AA90008-01 in Section 4A (Page 4A-9).
Installation
Hood Latch Switch Removal and Installation
Reverse removal procedure. AENFL80BA906014
Refer to “Hood Latch Release Cable Components” in
ISG Removal and Installation Section 9J in related manual.
AENFL80BA906003
Refer to “ISG Removal and Installation”: Diesel (with
Hood Latch Switch Inspection
ISG) in Section 1J (Page 1J-27). AENFL80BA906015
Refer to “Hood Inspection and Adjustment” in Section 9J
Starting Motor Inspection (Page 9J-1).
AENFL80BA906004
Refer to .
Battery Sensor Inspection
AENFL80BA906016
Neutral Position Switch Inspection Refer to “Brake Stroke Sensor On-Vehicle Inspection” in
AENFL80BA906005 Section 11A (Page 11A-54).
Refer to “Neutral Position Switch On-Vehicle Inspection”:
Diesel Model in Section 5B (Page 5B-33).
ENG A-STOP OFF Switch Removal and
Installation
CPP No.1 Switch Removal and Installation AENFL80BA906017
AENFL80BA906006 Removal
Refer to “CPP (Clutch Pedal Position) No.1 Switch
Removal and Installation (Keyless Push Start Model)”: 1) Remove switch bezel. (Page 9C-24)
Diesel Model in Section 5C (Page 5C-5). 2) Disconnect ENG A-STOP OFF switch connector.
3) Remove ENG A-STOP OFF switch (1) from switch
CPP No.1 Switch Inspection bezel.
AENFL80BA906007
Refer to “CPP (Clutch Pedal Position) No.1 Switch
Inspection and Adjustment (Keyless Push Start Model)”:
Diesel Model in Section 5C (Page 5C-5).
Installation
ENG A-STOP OFF Switch Inspection

AENFL80BA906018
Check continuity between terminals at each switch
1
position. If check result is not as specified, replace ENG
A-STOP OFF switch.
1 2 3 4 5
Terminal
2 3 4 5
Switch position
Release
IFL80BA90003-01 Push
IDAA0AA90013-01

Special Tool
AENFL80BA908002
SDT-II)
—
/
Section 11
Electric Power Train

CONTENTS
Precautions ...............................................11-1 DTC P13A0 .....................................................11A-31

Precautions........................................................... 11-1 DTC P13B0 .....................................................11A-32
Precautions for SHVS System ............................ 11-1 DTC P13B8 .....................................................11A-33

2015 AT SHVS Ertiga-V3-V3

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00

Volume 1 HVAC System ........................................................7B-1

Precautions ...............................................00-1 Wheel and Brake Caution ....................................00-*

• Before disconnecting the negative (–) cable at the

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

Precautions for CNG Vehicles

• Make sure to relieve CNG pressure

Special Tools and Equipment

Ignition Modes and Ignition Switch Positions

Maintenance and Lubrication

Accelerator Pedal Operation • Brake pedal has proper travel.

DTC P2135 ..................................................... 1A-100 Engine Symptom Diagnosis ................................ 1A-*

Repair Instructions ..............................................1C-1 MAF Sensor Data Initialization ............................ 1C-*

Throttle Body On-Vehicle Inspection .................. 1D-* Specifications.....................................................1D-24

Recommended Service Material ........................... 1I-* Generator Test .................................................. 1J-14

Tightening Torque Specifications........................ 1K-3 Exhaust Manifold Components ........................... 1K-*

Engine General Information and Diagnosis

[A] Without tachometer

3 Driving Cycle Detection Logic NOTE

EVAP Canist Prg Duty DTC P0118

Priority of freeze frame data:

Frame 0 Frame 1 Frame 2 Frame 3

Freeze frame data clearance:

System Readiness Test

Monitoring item of system readiness test table

2. B + (Continuous battery power)

Generator Control System Description

6. Battery 10. Combination meter 11. CAN driver

Electronic Control System Description

Engine and Emission Control Input / Output Table

Function Output Input

Function Output Input

Function Output Input

Schematic and Routing Diagram

Exhaust gas Fuel

Electric throttle body

EVAP canister ECT

*ABS control module CPP switch APP sensor

Vehicle speed Blower speed

Electronic Control System Circuit Diagram

[A]. M/T model 22. Blower speed selector 51. Generator

Terminal Arrangement of ECM Connector

[A] C01 E01

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

Information sensors Control devices Others

Diagnostic Information and Procedures

3) Set ignition “ON” and confirm that MIL lights up.

[A]: Without tachometer [B]: With tachometer

DTC DTC name Fail-safe operation

DTC DTC name Fail-safe operation

DTC DTC name Fail-safe operation

DTC DTC name Fail-safe operation

Scan Tool Data

Scan Tool Data Definitions Engine Speed (rpm):

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

Inspection Item Referring section

DTC P0010 / P2088 / P2089

[A] C01 E01

DTC Confirmation Procedure

1) Run engine at idle speed for 10 sec.

Is check result OK?

Is check result OK?

Is check result OK?